3HAC021395 001RevB

Application manual
Additional axes
RobotWare-OS 5.0
Document ID: 3HAC 021 395-001

Status: Draft
Revision: A p4
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, and contents thereof must not be imparted to a third party nor be used for
any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
© Copyright 2004 ABB All right reserved.

ABB Automation Technologies AB
Robotics
SE-721 68 Västerås
Sweden
7DEOHRI&RQWHQWV
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
,QWURGXFWLRQ
1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
+DUG:DUH
2.1 Configuration of the drive system, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.3 Rectifier and capacitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.4 Single Drive Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.5 Main Drive Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.6 Measurement System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.7 Serial Measurement Link examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.8 Easy to use kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.9 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.10 Resolvers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.11 Serial measurement cables and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6RIW:DUH
3.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.2 Standard additional axis (Option selected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.3 Template files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.4 Serial measurement system configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
$[HV&RQILJXUDWLRQ
4.1 Minimal Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.2 Minimal configuration of servo gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.3 Disconnect a servo motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.4 Servo Tool Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.5 Defining Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.6 Defining Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.7 Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.8 Independent joint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.9 Soft servo. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.10 Activate force gain control for an additional axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.11 Activate notch filter for an additional axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.12 Defining kinematic parameters for general kinematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.13 Coordination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3HAC 021 395-001 Revision: A 3

7DEOHRI&RQWHQWV
7XQLQJRI$[HV
5.1 Tuning the commutation offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7XQLQJ
5.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.2.2 Defining signals in Test Signal Viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.2.3 Tuning of axes, complete procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.2.4 Initial tuning of Kv, Kp and Ti . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.2.5 Specifying the inertia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.2.6 Tuning of bandwidth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.2.7 Tuning of resonance frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.2.8 Tuning of Nominal Acceleration and Nominal Deceleration . . . . . . . . . . . . . . . . . . 102
5.2.9 Final tuning of Kp, Kv and Ti . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.2.10 Tuning of the soft servo parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
$GGLWLRQDOWXQLQJIRUVHUYRJXQV
5.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.3.2 Protecting the gun. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.3.3 Position Interpolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.3.4 Tuning ramp times for force ramping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.3.5 Speed versus force repeatability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.3.6 Tuning the speed limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
5.3.7 Improving the results for poor programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
5.3.8 Tuning the calibration routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5.3.9 Force ready detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6\VWHP3DUDPHWHUV
6.1 System Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4 3HAC 021 395-001 Revision: A

Overview
2YHUYLHZ
$ERXW7KLV0DQXDO
This manual details the setup of the Additional axes option.
8VDJH
This manual can be used either as a brief description to find out if an option is the right choice
for solving a problem, or to describe how to use an option. Detailed information regarding
syntax for RAPID routines, and similar, is not described here, but can be found in the
respective reference manual.
:KR6KRXOG5HDG7KLV0DQXDO"
This manual is primarily intended for advanced user’s and robot programmers.
3UHUHTXLVLWHV
The reader should...
• be familiar with industrial robots and their terminology
• be familiar with the RAPID programming language
• be familiar with system parameters and how to configure them.
2UJDQL]DWLRQRI&KDSWHUV
The manual is organized in the following chapters:
&KDSWHU &RQWHQWV
1. Introduction Additional Axes Overview
2. HardWare Describes the hardware e.g. Drive System and Measurement
System.
3. SoftWare Describes the installation and setup.
4. Axes Configuration Describes how to design the configuration files.
5. Tuning of Axes Describes how to tune the axes.
6. System Parameters Describes the System Parameters
5HIHUHQFHV
3HAC 021 395-001 Revision: A Draft 5

Overview
5HIHUHQFH 'RFXPHQW,G
RAPID Overview 3HAC 16580-1
RAPID reference manual part 1 3HAC 16581-1 part 1
RAPID reference manual part 2 3HAC 16581-1 part 2
Operating manual - IRC5 with graphical teach 3HAC 16590-1
pendant unit
System parameter reference manual 3HAC 17076-1
5HYLVLRQV
5HYLVLRQ 'HVFULSWLRQ
- First edition
A Tuning commutation offset, tuning of the soft servo parameters and Additional
tuning for servo guns has been added to the chapter Tuning of Axes.
6 Draft 3HAC 021 395-001 Revision: A

Product documentation, M2004
3URGXFWGRFXPHQWDWLRQ0
*HQHUDO
The robot documentation may be divided into a number of categories. This listing is based on
the type of information contained within the documents, regardless of whether the products
are standard or optional. This means that any given delivery of robot products ZLOOQRWFRQWDLQ
DOO documents listed, only the ones pertaining to the equipment delivered.
However, all documents listed may be ordered from ABB. The documents listed are valid for
M2004 robot systems.
+DUGZDUHPDQXDOV
All hardware, robots and controller cabinets, will be delivered with a 3URGXFWPDQXDO which
is divided into two parts:
3URGXFWPDQXDOSURFHGXUHV
• Safety information
• Installation and commissioning (descriptions of mechanical installation, electrical
connections and loading system software)
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
• Repair (descriptions of all recommended repair procedures including spare parts)
• Additional procedures, if any (calibration, decommissioning)
3URGXFWPDQXDOUHIHUHQFHLQIRUPDWLRQ
• Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
• Part list
• Foldouts or exploded views
• Circuit diagrams
5RERW:DUHPDQXDOV
The following manuals describe the robot software in general and contain relevant reference
information:
• 5$3,'2YHUYLHZ: An overview of the RAPID programming language.

Product documentation, M2004
• 5$3,'UHIHUHQFHPDQXDOSDUW: Description of all RAPID instructions.

• 5$3,'UHIHUHQFHPDQXDOSDUW: Description of all RAPID functions and data types.
• 7HFKQLFDOUHIHUHQFHPDQXDO6\VWHPSDUDPHWHUV: Description of system
parameters and configuration workflows.
$SSOLFDWLRQPDQXDOV
Specific applications (e.g. software or hardware options) are described in $SSOLFDWLRQ
PDQXDOV. 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 (e.g. cables, I/O boards, RAPID instructions, system parameters)
• How to use the application
• Examples of how to use the application
2SHUDWRU¶VPDQXDOV
This group of manuals is aimed at those having first hand operational contact with the robot,
i.e. production cell operators, programmers and trouble shooters. The group of manuals
include:
• 2SHUDWRU¶VPDQXDO,5&ZLWK)OH[3HQGDQW
• 2SHUDWRU¶VPDQXDO5RERW6WXGLR2QOLQH
• 7URXEOHVKRRWLQJPDQXDO for the controller and robot

Safety
6DIHW\
6DIHW\RISHUVRQQHO
A robot is heavy and extremely powerful regardless of its speed. A pause or long stop in
movement can be followed by a fast hazardous movement. Even if a pattern of movement
is predicted, a change in operation can be triggered by an external signal resulting in an
unexpected movement.
Therefore, it is important that all safety regulations are followed when entering safeguarded
space.
6DIHW\UHJXODWLRQV
Before beginning work with the robot, make sure you are familiar with the safety regulations
described in 2SHUDWRU
VPDQXDO,5&ZLWK)OH[3HQGDQW.

Safety

,QWURGXFWLRQ
1.1. Overview
,QWURGXFWLRQ
2YHUYLHZ
3XUSRVH
The option Additional axes is selected in the Specification Form and is normally preinstalled
at ABB.
Additional axes makes it possible for the system to control extra axes beside the robot axes.
The axes are synchronized and, if desired, coordinated with the movement of the robot, which
results in high speed and high accuracy.
'HVFULSWLRQ
Due to the fact that the additional axes consume more power the drive system must be
changed, i.e a more powerful transformer, rectifier and capacitor must be installed. In
addition to that, the suitable drive units must be installed into the controller. The hardware
set-up must also be configure with software to make system functional.
%DVLFDSSURDFK
This is the general approach for setting up/using Additional axes. For a more detailed
description of how this is done, see the respective section.
• Hardware placement and measurement system.
• Software installation and configuration files.
• Configuration of the axes.
• Tuning of the axes.

,QWURGXFWLRQ
1.1. Overview

+DUG:DUH
2.1. Configuration of the drive system, IRC5
+DUG:DUH
&RQILJXUDWLRQRIWKHGULYHV\VWHP,5&
*HQHUDO
The IRC5 drive module contains a number of drive units, rectifiers and filters. Any allowed
combination of these, depending on the robot type, is specified below.
The robot system may also be equipped with up to three additional drive modules, which are
described in section ,QVWDOODWLRQRIDGGLWLRQDOGULYHPRGXOH,5& of the 3URGXFWPDQXDO
SURFHGXUHV,5&.
/RFDWLRQ
The servo drive units, rectifiers and capacitor units are located in the drive module as shown
below.

+DUG:DUH
xx0400000997
A Control panel
B Capacitor
C Rectifier
D Axis computer
E Drive units
'&EXVEDUV
Between the units are fitted DC-busbars, which are specified below:
'HVFULSWLRQ $UWQR 1RWH

DC-bus bar 3HAC17281-1 DC_L6: long busbar with six connector groups
DC-bus bar 3HAC17281-3 DC_S2: short busbar with two connector groups
Servo drive dummy 3HAC 17282-1 -
,5%

+DUG:DUH
The figures show the drive unit ZLWKDQGZLWKRXWDGGLWLRQDOD[HV respectively. The table
specifies which units may be fitted in which positions.
xx0200000121
xx0200000120
3RVLQ
,GHQWLILFDWLRQ 'HVFULSWLRQ $UWQR 1RWH
ILJXUH
1 DSQC 620_C2 Capacitor unit 3HAC 14551-1 Only in system
with two external
axes, size U

+DUG:DUH
3RVLQ
ILJXUH
with two external
axes, size U
Z2 DSQC 618_RC1 Rectifier 3HAC 14549-1 In systems
ZLWKRXW external
axes only!
Z2 DSQC 618_R2 Rectifier 3HAC 14549-2 In systems ZLWK
external axes
only!
Z3, Y3, DSQC 617_3B3A Main Drive unit 3HAC 14546-1 Z3 - X3 is ONE
X3 unit!
Z4, Y4, DSQC 619 Optional drive 3HAC 14550-1 Size: 1C
X4 units for 3HAC 14550-2 Size: 1T
additional axes 3HAC 14550-3 Size: 1U
,5%
xx0200000121

+DUG:DUH
xx0200000120
3RVLQ
ILJXUH
1 DSQC 620_C2 Capacitor unit 3HAC 14551-1 In systems ZLWK
external axes
only!
with two external
axes, size U
ZLWKRXW external
axes only!
external axes
only!
Z3, Y3, X3 DSQC 617_3B3A Main Drive unit 3HAC 14546-1 Z3 - X3 is ONE
unit!
Z4, Y4, X4 DSQC 619 Optional drive 3HAC 14550-1 Size: 1C
units for 3HAC 14550-2 Size: 1T

+DUG:DUH
,5%
xx0200000121
xx0200000120
3RVLQ
ILJXUH
1 DSQC 620_C4 Capacitor unit 3HAC 14551-3 Only in system with
two external axes, size
U

+DUG:DUH
3RVLQ
ILJXUH
1 DSQC 620_C4 Capacitor unit 3HAC 14551-3 Only in system with
two external axes, size
U
Z2 DSQC 618_RC1 Rectifier 3HAC 14549-1 In systems ZLWKRXW
external axes only!
external axes only!
Z3, Y3, DSQC 617_3B3A Main Drive unit 3HAC 14546-1 Z3 - X3 is ONE unit!
X3
Z4, Y4, DSQC 619 Optional drive 3HAC 14550-1 Size: 1C
X4 units for 3HAC 14550-2 Size: 1T
,5%
xx0200000121

+DUG:DUH
xx0200000120
3RVLQILJXUH ,GHQWLILFDWLRQ 'HVFULSWLRQ $UWQR 1RWH

with two
external axes,
size U
with two
external axes,
size U
ZLWKRXW
external axes
only!
Z2 DSQC 618_R2 Rectifier 3HAC 14549-2 In systems
ZLWK external
axes only!
Z3, Y3, X3 DSQC 617_2E2C2B Main Drive unit 3HAC 14546-2 Z3 - X3 is
ONE unit!
Z4, Y4, X4 DSQC 619 Optional drive 3HAC 14550-1 Size: 1C

+DUG:DUH
,5%
X Y Z
1
Rectifier: Z2
Capacitor: 1
Main drive unit: Z4 - X3
Single drive unit: 7=Y2/8=X2
xx0300000184
3RVLQ
ILJXUH
1 DSQC 620_ C4 Capacitor unit 3HAC 14551-3
1 DSQC 620_ C4 Capacitor unit 3HAC 14551-3
Z2 DSQC 618_R2 Rectifier 3HAC 14549-2
Y2, X2 DSQC 619 Optional drive 3HAC 14550-1 Size: 1C
Z4, Y4, X4, Z3, DSQC Main Drive unit 3HAC 14546-4 Z4 - X3 is ONE
Y3, X3 617_3G3T unit!
,5%

+DUG:DUH
X Y Z
1
Rectifier: Z2
Capacitor: 1
Main drive unit: Z4 - X3
Single drive unit: 7=Y2/8=X2
xx0300000184
3RVLQ
ILJXUH
1 DSQC 620_C3 Capacitor unit 3HAC 14551-2
Z2 DSQC 618_R3 Rectifier 3HAC 14549-3
Y2, X2 DSQC 619 Optional drive units 3HAC 14550-4 Size: 1W
for external axes
Z4, Y4, X4, DSQC 617_3V3W Main Drive unit 3HAC 14546-6 Z4 - X3 is
Z3, Y3, X3 ONE unit!
'ULYHXQLW1RGH
The placement of the power stages in a main drive unit is specified in column Drive Unit
Node.

+DUG:DUH
0DLQGULYHXQLW 'ULYH8QLW1RGH $[LV

DSQC 617_3B3A • Node 1 - Unit Type B M1
• Node 2 - Unit Type B M2
• Node 3 - Unit Type A M4
DSQC 617_2E2C2B • Node 1 - Unit Type E M1
• Node 2 - Unit Type E M2
• Node 3 - Unit Type C M4
DSQC 617_3E1C • Node 1 - Unit Type E M2
• Node 3 - Unit Type - -
• Node 4 - Unit Type - -
DSQC 617_3G3T • Node 1 - Unit Type T M1
• Node 2 - Unit TypeG M4
• Node 3 - Unit Type T M2
• Node 4 - Unit Type G M5
• Node 5 - Unit Type T M3
• Node 6 - Unit Type G M6
DSQC 617_3V3W • Node 1 - Unit Type W M1
• Node 2 - Unit Type V M4
• Node 3 - Unit Type W M2
• Node 5 - Unit Type W M3
For details about the connection pins, see circuit diagram 3HAC020538-002 in the 3URGXFW
PDQXDOUHIHUHQFHLQIRUPDWLRQ,5&.

+DUG:DUH
2.2. Transformers
7UDQVIRUPHUV
2YHUYLHZ
The transformer is used to transform the incoming voltage to the voltage used in the cabinet.
The selection of transformer depends on the selection of primary voltage and drive units.
9ROWDJHDOWHUQDWLYH
The transformers are reversible to following primary voltage alternatives.
• 200 V
• 220 V
• 400 V
• 440 V
• 480 V
• 500 V
• 600 V
7HFKQLFDOGDWD
The following table details the standard option transformers.
5RERWW\SH 3ULPDU\YROWDJH9 (IIHFWN9$

140, 1400 200-600 V 8.5 kVA
140, 1400 + Add.ax 200-600 V 8.5 kVA
2400, 340 200-600 V 8.5 kVA
2400, 340 + Add.ax 200-600 V 8.5 kVA
4400 200-600 V 8.5 kVA
4400 + Add.ax
6600 < 400 V 13 kVA
6600 + Add.ax 400-480 V 1.8 kVA, for electronics
> 480 V 13 kVA
7600 < 400 V 13 kVA
7600 + Add.ax 480 V 1.8 kVA, for electronics
> 480 V 13 kVA

+DUG:DUH
2.3. Rectifier and capacitor
5HFWLILHUDQGFDSDFLWRU
2YHUYLHZ
The rectifier transforms the electric current from alternating current (AC) to continuous
current (DC). There are different sizes of rectifiers, and they are selected based upon the drive
unit current consumption of the attached motor.
127(
Capacitor C1 is included in Rectifier DSQC 618_RC1. Rectifier R2 can be combined with
two different types of capacitors.
7HFKQLFDOGDWD
The following table details the standard option rectifier and capacitor.
0D[
5DWHG 0D[
5HFWLILHU &DSDFLWRU EOHHGHU 5DWHGEOHHGHU 5DWHGGF
FXUUHQW FXUUHQW
XQLW LGHQWLW\ SRZHU SRZHUN: YROWDJH9
$ $
N:
DSQC 7 25 8.1 0.48 Min, 280
618_RC1 Max, 450
DSQC DSQC 32 103 34.7 1.8 Min, 280
618_R2 620_C2 Max, 450
DSQC DSQC 32 103 34.7 1.8 Min, 280
618_R2 620_C4 Max, 450
DSQC DSQC 32 98 51 4 Min, 450
618_R3 620_C3 Max, 800

+DUG:DUH
2.4. Single Drive Units
6LQJOH'ULYH8QLWV
2YHUYLHZ
The single drive unit contains a power stage and is selectable in a number of sizes, depending
on the power consumption. The single drive unit contains no axis computer, and therefor
cannot be used without a main drive unit.
7HFKQLFDOGDWD
The following table details the technical data for additional drive units.
5DWHG
'ULYHXQLW
'ULYHXQLW RXWSXW 'ULYHXQLWPD[ 5HFRPPHQGHG
UDWHGFXUUHQW
LGHQWLW\ YROWDJH FXUUHQW$ UPV PRWRUW\SH$7$:
$ UPV
9
DSQC 800 30 55 MU 10, 20, 30
619_W
DSQC 400 36 55 MU 10, 20, 30
619_U
DSQC 400 25 38 MU 10, 20, 30
619_T
DSQC 400 9 12 MU 10
619_C

+DUG:DUH
2.5. Main Drive Units
0DLQ'ULYH8QLWV
2YHUYLHZ
An MDU (Main Drive Unit) consists of 4 or 6 power stages.
'ULYH8QLWYROWDJH
The following details the input voltage and the Dc-bus voltage for the different drive units.
5DWHGGFEXVYROWDJH9
'ULYH8QLW7\SH
DSQC 617_3B3A 400 V • min 280 V

• max 450 V
DSQC 617_2E2C2B 400 V • min 280 V
• max 450 V
DSQC 617_3E1C 400 V • min 280 V
• max 450 V
DSQC 617_3G3T 400 V • min 280 V
• max 450 V
DSQC 617_3V3W 800 V • min 453 V
• max 800 V
'ULYH8QLW&XUUHQW
The following details the current for the different drive units.
3RZHUVWDJH7\SH 5DWHGFXUUHQW$ UPV 0D[FXUUHQW$ UPV

A 2 3.34
B 5.5 6.7
C 9 12
E 12 19
G 16.5 26
T 25 38
V 14.5 25

+DUG:DUH
2.5. Main Drive Units
3RZHUVWDJH7\SH 5DWHGFXUUHQW$ UPV 0D[FXUUHQW$ UPV

W 30 55

+DUG:DUH
2.6. Measurement System
0HDVXUHPHQW6\VWHP
2YHUYLHZ
This system can control up to nine axes at the same time, and measure another five axes.
$[HV&RPSXWHU%RDUG
The drive module is equipped with one axes computer board which is connected to a
connector in the front of the cabinet.
6HULDOPHDVXUHPHQWOLQNV
Each drive module has two serial measurement links for measurement boards. The
connectors in the front of the drive module are marked, 0HDVXUHPHQWV\VWHP and
0HDVXUHPHQWV\VWHP. These serial links are ring circuits, which means that if there is more
than one board on the same link, the output from 6HULDO0HDVXUHPHQW%RDUG is connected
to the input on 6HULDO0HDVXUHPHQW%RDUG. See VHFWLRQ6HULDOPHDVXUHPHQW/LQN
H[DPSOHV.
6HULDO0HDVXUHPHQW%RDUG
The standard SMB has seven resolver inputs, These inputs can be used as seven different
nodes where the node number is equal to the axis number e.g. axis 1 to node 1.
%DFNXSEDWWHU\
A back-up battery supplies the SMB with power during power failure. If an axis is moved
during power off, the system is ready for operation, and no synchronization is needed after
power on.
)HDWXUHV
Specifications for the measurement system:
• Each drive module can handle up to four SMBs divided on two serial links.
• Each serial link can handle up to seven axes.
• Each node 1 - 7 may only be used once on each link.

+DUG:DUH
2.7. Serial Measurement Link examples
6HULDO0HDVXUHPHQW/LQNH[DPSOHV
$GGLWLRQDOD[HV
The following is an example of a setup with one Drive Module, three serial measurement
boards on two measurement links, e.g 7UDFNPRWLRQ.
en0400000680
A Main Computer
B Drive Module
C Axis Computer
D Serial Measurement Link 1 connector XS.2
E Serial Measurement Link 2 connector XS.41
F Serial Mesurement Link 1
G Serial Mesurement Link 2
H Serial Measurement Board
J Six axes Robot system
K Trackmotion
L Axes 8-9
R Resolvers

+DUG:DUH
$GGLWLRQDOD[HV
The following is an example of a setup with one Drive Module, two serial measurement
boards on two measurement links, e.g 6HUYR*XQ or 7UDFNPRWLRQ. If both Servo Gun and
Trackmotion are to be used, the Trackmotion is connected to seriel measurement link 2 and
resolver node 5.
en0400000681
A Main Computer
B Drive Module
C Axis Computer
K Servo Gun
L Axes 8-9
R Resolvers
7KUHH$GGLWLRQDOD[HV

+DUG:DUH
The following is an example of a setup with one Drive Module, two serial measurement
boards on two measurement links, e.g $[HV3RVLWLRQHU.
en0400000682
A Main Computer
B Drive Module
C Axis Computer
K Three axes Positioner
R Resolvers

+DUG:DUH
2.8. Easy to use kits
(DV\WRXVHNLWV
2YHUYLHZ
A number of “easy to use kits” are available from ABB. These kits contain all the parts
needed to install and operate additional axes.
,OOXVWUDWLRQ
xx0500001412
3DUWV
For more information, and technical specification for the motors, see Motor Unit
specification.
3DUW 'HVFULSWLRQ 6SHFLILFDWLRQV

Motor unit All the available motor units Available motor units
include brake and resolver • MU10,
• MU20,
• MU30,

+DUG:DUH
2.8. Easy to use kits
3DUW 'HVFULSWLRQ 6SHFLILFDWLRQV

Connection box The connection box contains:
• serial measurement
board
• manual brake release
• terminal block for limit
switches
Cables and connectors
Configuration file
Documentation

+DUG:DUH
2.9. Motors
0RWRUV
2YHUYLHZ
The motor units sold by ABB are specially designed for ABB’s robots and can be used for
peripherals requiring power-steered motors that are synchronized with the robot movements.
The motor units are designed for optimal performance and to facilitate installation and
application.
127(
When using a non ABB motor, contact ABB to order the document
'LPHQVLRQLQJ +$&. This contains information on how to calculate the
correct motor data.
0RWRUGHVFULSWLRQ
Motor shall be a permanent magnet servo-motor of synchronous type intended for three-
phase sinusoidal AC voltage, coupled in star (Y) connection.
• the motor should preferably be winded as class F according to IEC 85.
• dielectric strength minimum 1600 V. For low voltage motors (IRB 140 - 4400)
connected to DM. For high voltage motors (IRB 6600 and 7600) connected to DM,
see 5HTXLUHPHQWVIRUKLJKYROWDJHPRWRUV on page 35
• Measurement signal cables must be separated from power cables and cables from
temperature sensor and brake.
5HTXLUHPHQWVIRUKLJKYROWDJHPRWRUV
Third party driveline components used as external equipment on the IRB x6xx products must
withstand the voltage stress levels as described in the following.
These data are valid for high voltage motors connected to the drive units:
• Main Drive Unit DSQC617_3V3W
• Single Drive Unit DSQC619_W
The maximum allowed cable length is 30m. Rise time is expressed as an indicative value at
motor terminals.
&RQYHUWHUVSHFLILFV

+DUG:DUH
2.9. Motors
Voltage (Pulse-Width Modulated) 400-480 VAC

DC link maximum voltage 825 VDC
Switching frequency 4 kHz
6\VWHPVSHFLILFV
Rise time / dU/dt (indicative value) 0.2 microsec (as defined in IEC 60034-25) / 9
kV/microsec
5HTXLUHPHQWIRUGULYHOLQHFRPSRQHQWV
Insulation strength According to IEC 60034 (i.e. >2000 V)
Voltage stress withstand capability Above withstand level B according to IEC
(including PD deterioration effects) 60034-25, Figure 17 Chapter 7
7KHUPDOSURWHFWLRQ
The temperature sensor normally used is of type PTC resistor. A high resistance or open
circuit indicates that the temperature of the motor exceeds the rated level. If temperature
sensor not used, the circuit must be strapped. If more than one motor is used, all PTC resistors
are connected in series.
The system input characteristics is:

• High temperature >3500 Ù
• Low temperature <3500 Ù
127(
For F class winding with maximum temperature of 155 C, Siemens B59135- M155_A70 can
be used.
0RWRUFRQQHFWLRQ
Positive electric rotation R ->S ->T -> (U, V, W) results in positive mechanical rotation
defined as FORFNZLVH direction, seen from the drive shaft side. See illustration below. For
connection and cabling for the motor to the controller, see 3URGXFWPDQXDO,5&, M2004

+DUG:DUH
2.9. Motors
xx0400001171
%UDNH
Select a brake with minimum brake torque, sufficiently large to handle emergency stop when
axis is moving downwards with maximum gravity. Check that maximum brake torque does
not exceed allowed mechanical stress levels.
• Brake release voltage: 24 VDC +/- 10%.
127(
Check brake release voltage at maximum brake (motor) temperature and maximum allowed
wear out for the brake.
0RWRUW\SHV
For more information about the recommended motor types from ABB, see section (DV\WR
XVHNLWV.

+DUG:DUH
2.10. Resolvers
5HVROYHUV
2YHUYLHZ
The resolver is integrated in the motors from ABB. The resolver must be approved by ABB
for reliable operation.
$SSURYHGUHVROYHUV
The following resolvers are approved by ABB
0DQXIDFWXUHU $UWLFOHQXPEHUV
LTN Servotechnik GmbH LTN RE-21-1-V02, size 21
LTN RE-15-1-V16, size 15
AG V23401-U2117-C333, size 21
Tamagawa Seiki Co TS 2640N141E172, size 21
&RQVLGHUDWLRQV
The following technical information must be considered before the installation:
• A maximum resolver cable length of 30 m (X, Y for each resolver).
• A maximum resolver cable length of 70 m for EXC signals.
• Use a Shilded, AWG 24, max 55pF/m cable.
,OOXVWUDWLRQ
Each resolver contains two stator and one rotor windings, these are connected as show in the
figure.

+DUG:DUH
2.10. Resolvers
en0400000645
127(
See section, 6HULDOPHDVXUHPHQWFDEOHVDQGFRQQHFWLRQV on page 426HULDOPHDVXUHPHQW
FDEOHVDQGFRQQHFWLRQV on page 42for a description of connections to the SMB.
5HVROYHUFRQQHFWLRQ
xx0400001172
A Resolver
B 9 pin D-sub
Normally in ABB motors, resolvers are connected to the internal cable in robot by a 9 pin D-
sub connector, with pins at the resolver side.
When the motor rotates in a positive direction, the resolver rotates mechanically in a negative
direction, as the resolver is mounted at the opposite side of the drive shat side.

+DUG:DUH
2.10. Resolvers
To deliver electrically positive rotation the y-winding connection S2 and S4 has changed
place.
SLQ'VXE 60%LQSXW 5HVROYHUFRQQHFWLRQ &RORUUHVROYHUZLUHV

6 X S1 Red
1 X 0V S3 Black
7 Y S4 Blue
2 Y 0V S2 Yellow
3 EXC R1 Red/White
8 EXC 0V R2 Yellow/White
127(
For cable type, length and routing, see the motor drawing. If not specified in motor drawing:
• If cable well spaced from motor cables (>40 mm) and not too long cables are used
(<10 cm) no shielding is necessary.
5HVROYHUGLUHFWLRQ
0RWRUDQJOH ;6 <6
0 Max. in phase with feed 0
+ 90 0 Max. in phase with feed
&RPPXWDWLRQ
Commutation can be done in several ways. The following method is one of the possible
methods.
6WHS $FWLRQ ,QIR,OOXVWUDWLRQ

1. Turn the motor to commutation by feeding The number of different positions
positive current into power winding S with T that the motor can turn to is the
connected to ground (R is not connected). same as the number of pole pairs.
For detailed description, follow the first part of
the procedure in 7XQLQJWKHFRPPXWDWLRQRIIVHW
on page 79.

+DUG:DUH
2.10. Resolvers

2. Select a resolver position enabling the resolver
cables to be routed in the best possible way.
3. Feed a 4 kHz sinus signal to the EXC (R1) input
of the resolver.
4. Connect an oscilloscope to EXC (R1), X (S1)
and Y (S4).
5. Adjust the commutation position to +90 degrees The Y (S4) signal should be at max
+/-0.5 degres by tuning the resolver. output and with the same phase as
the EXC (R1) feeding signal.
The X (S1) signal should be 0.00 V
xx0500001401

+DUG:DUH
2.11. Serial measurement cables and connections
6HULDOPHDVXUHPHQWFDEOHVDQGFRQQHFWLRQV
2YHUYLHZ
This section details the cables and connection between the resolver and the serial
measurement board.
6LJQDO&ODVVHV
The cabling must comply with a valid signal class "measurement signals" see 3URGXFWPDQXDO
IRUFRQWUROOHU,5&VHFWLRQ6LJQDO&ODVVHV. The enclosure for external serial measurement
board/boards must comply with enclosure class IP54, in accordance with IEC 144 and IEC
529.
127(
It is very important that the noise level on the measurement signals from the additional axes
is kept as low as possible, to prevent bad performance, NHHSPRWRUDQGUHVROYHUFDEOHV
DSDUW. Correct shielding and ground connections of cables, measurement boards and
resolvers is essential.
&RQVLGHUDWLRQV
The ;, <, 9; and 9<:
• Signals are used to connect resolvers to a serial measurement board.
The (;& and 9(;&:
• are used for common supply for all resolvers, parallel connected.
Resolver:
• 1 - 3, should always be connected to EXC 1.
• 4 - 7, should always be connected to EXC 2.
,OOXVWUDWLRQ

+DUG:DUH
en0400000684
A R2.SMB 1-2 (D-sub 15 socket)

B R2.SMB 1-4 (D-sub 25 pin)
C R2.SMB 3-6 (D-sub 25 socket)
D R2.G
E R2.SMB (D-sub 9 pin)
&RQQHFWLRQVWR60%'64&
&RQWDFW
5* 560% 560% 560% 560%
SRLQW
1 +BAT GND GND GND GND
2 0V BAT - 0V EXC2 X1 X4
3 0V 0V EXC1 Y1 Y4
4 SDO-N Y7 X2 X5
5 SDI-N X7 Y2 Y5
6 - Y1 0V EXC1 0V EXC2

+DUG:DUH
&RQWDFW
5* 560% 560% 560% 560%
SRLQW
7 +24V X1 0V EXC1 0V EXC2
8 SDO - 0V EXC1 0V EXC2
9 SDI EXC2 X3 X6
10 EXC1 Y3 Y6
11 0V Y7 X4 X3
12 0V X7 Y4 Y3
13 0V Y1 0V EXC2 0V EXC1
14 0V X1 0V X1 0VX4
15 0V Y1 0V Y4
16 0V X2 0V X5
17 0V Y2 0V Y5
18 EXC1 EXC2
19 EXC1 EXC2
20 EXC1 EXC2
21 0V X3 0V X6
22 0V Y3 0V Y6
23 0V X4 0V X3
24 0V Y4 0V Y3
25 EXC2 EXC1
([SODQDWLRQ
7HUP 'HVFULSWLRQ
SDO serial communication output
SDI serial communication input
+BAT Battery +
0V BAT Battery 0V
BATLD Not to be used
BATSUP Not to be used
EXC1 excitation power to resolver 1, 2, 3

+DUG:DUH
7HUP 'HVFULSWLRQ
EXC2 excitation power to resolver 4, 5, 6, (7)
+24V 24 V power
0V 0 V power
X1 Input x-stator node 1
Y1 Input y-stator node 1
,OOXVWUDWLRQ
The connection point on the resolver corresponds to the connection table above.
en0400000645
([DPSOH
To connect from resolver to SMB, use input 7 (i.e. node 7). Connect to contact R2.SMB 1-2.
6LJQDOV &RQWDFWSRLQW60% &RQWDFWSRLQW5HVROYHU

EXC 2 9 3
EXC 2, 0 V 2 8
X7 5 6
X7, 0 V 12 1
Y7 4 7
Y7, 0 V 11 2

+DUG:DUH

6RIW:DUH
3.1. Installation
6RIW:DUH
,QVWDOODWLRQ
2YHUYLHZ
Normally the option Additional axes is preloaded at ABB, and does not need to be re-
installed. For more information on how to add options to the system, see 2SHUDWRUV0DQXDO
5RERW6WXGLR,QVWDOO.
,QVWDOODWLRQ
When installing additional axes it is important to design installations, so a combination of
existing files can be used.
/RJLFDOD[HV
Logical axis is used as the axis number in a RAPID instruction and for the teach pendent.
Normally the robot uses axes 1-6 and the additional axes 7-9. The user can change the logical
axis number to fit the new application. Only axes with unique axis numbers may be active at
the same time.

6RIW:DUH
3.2. Standard additional axis (Option selected)
6WDQGDUGDGGLWLRQDOD[LV2SWLRQVHOHFWHG
2YHUYLHZ
Normally all necessary configuration parameters regarding drive unit, rectifiers and
transformers are pre-loaded at ABB, and does not need to be re-installed. For more
information on how to add options to the system, see 2SHUDWRU¶V0DQXDO5RERW6WXGLR,QVWDOO
'ULYHV\VWHP
The following table details the option number regarding the drive system.
3RZHU $GGD[ /RJLFDO 'ULYHXQLW

2SWLRQ 5RERW 3RVLWLRQ
VWDJH SRVLWLRQ D[LV QXPEHU
140, 340, C Z4 1 7 2
1400, 2400
140, 340, T Z4 1 7 2
1400, 2400
140, 340, U Z4 1 7 2
1400, 2400
140, 340, C Y4 2 8 3
1400, 2400
140, 340, T Y4 2 8 3
1400, 2400
140, 340, U Y4 2 8 3
1400, 2400
140, 340, C X4 3 9 4
1400, 2400
140, 340, T X4 3 9 4
1400, 2400
140, 340, U X4 3 9 4
1400, 2400
4400, 940 C Y2 1 7 2
4400, 940 T Y2 1 7 2
4400, 940 U Y2 1 7 2
6600, 7600 W Y2 1 7 2
4400, 940 C X2 2 8 3

6RIW:DUH
3.2. Standard additional axis (Option selected)
3RZHU $GGD[ /RJLFDO 'ULYHXQLW

2SWLRQ 5RERW 3RVLWLRQ
VWDJH SRVLWLRQ D[LV QXPEHU
4400, 940 T X2 2 8 3
4400, 940 U X2 2 8 3
6600, 7600 W X2 2 8 3
0HDVXUHPHQWV\VWHP
The following table details the option number regarding the measurement system. There is
one or more template file for each option, depending on the measurement set-up.
0HDVXUHPHQW %RDUG 60% 60%

2SWLRQ 7HPSODWHILOH
OLQN SRVLWLRQ QRGH QRGH
1 1 7 M7L1B1_DM1.cfg
3HULSKHUDOHTXLSPHQW
If the supplier of Track Motion or other peripheral equipment supplies configuration files,
then those files must be used insted of the standard files. See enclosed documentation.

6RIW:DUH
3.3. Template files
7HPSODWHILOHV
2YHUYLHZ
The following sections detail the template files for respective hardware. Normally you only
need to change the motor data in these files. For more information on how to change these
files, see 8VHU
V0DQXDO5RERW6WXGLR,QVWDOO. The files are stored in the directory:
0HGLDSRRO?5RERW:DUHB;;;;;;?8WLOLW\?$GGLWLRQDO$[LV
127(
No place 9 on large robots, (IRB 4400, 6600, 6650 and 7600).
127(
These files are not downloaded by default, or selected by the option selection.
0RWRUV
There are template files used to connect the drive system to the measurement system.
Listed below are files for motors connected to drive module 1 (located in
0HGLDSRRO?5RERW:DUHB;;;;;;?8WLOLW\?$GGLWLRQDO$[LV?'0?*HQHUDO). Similar template
files exist for drive modules 2-4. These files are adjusted for additional axes on the same drive
unit as a robot.
0HDVXUHPHQW
)LOHQDPH 0HDVXUHPHQWOLQN %RDUGSRVLWLRQ
QRGH
M7L1B1_DM1.cfg 1 1 7
There are also common template files, fore more general purpose. These files exist for drive
module 1-4 (but are rarely used for drive module 1 since axes 1-6 for drive module 1 are
usually used by the robot). Listed below are these files for drive module 2 (located in
0HGLDSRRO?5RERW:DUHB;;;;;;?XWLOLW\?$GGLWLRQDO$[LV?'0?,5&B8).

6RIW:DUH
3.3. Template files
)LOHQDPH 0HDVXUHPHQWOLQN %RDUGSRVLWLRQ 0HDVXUHPHQWQRGH

M1_DM2 1 1 1
M2_DM2 1 1 2
M3_DM2 1 1 3
M4_DM2 1 1 4
M5_DM2 1 1 5
M6_DM2 1 1 6
6HUYR*XQ7UDFNPRWLRQ
The template files for Servo Gun and Track motion are all prepared for drive module 1-4. The
files contain default data for Servo Gun and Track motion. Motor data etc. for selected motor
must be changed. Listed below are the template files for drive module 1.
0HDVXUHPHQW
)LOHQDPH 0HDVXUHPHQWOLQN %RDUGSRVLWLRQ
QRGH
M7L1B1S_DM1.cfg 1 1 7
M7L1B1T_DM1.cfg 1 1 7
M8L2B1T_DM1.cfg 2 1 5
5HFRPPHQGHGFRPELQDWLRQV
The following combination of configuration files for motor 7, 8 and 9 are the recommended
combinations in one Drive module.
0RWRU 0RWRU 0RWRU

M7L1B1_DM1.cfg M8L2B1_DM1.cfg M9L2B1_DM1.cfg

6RIW:DUH
3.3. Template files
127(
See examples in 6HULDO0HDVXUHPHQW/LQNH[DPSOHV on page 30
([SODQDWLRQ
An explanation of some parameters in the configuration file, and the name of the motor
configuration file:
3DUDPHWHU)LOHQDPH 'HVFULSWLRQ
unit_position main drive unit control board (always 1)
node position in drive module (additional axis
always 1)
ext_axis_pos additional axis connection on control board
drive_unit_number user-defined position (used for primarily for
diagnostics)
MXLXBX_DMX M=Motor, L=Serial measurement link, B=
Board (SMB), DM= Drive module

6RIW:DUH
3.4. Serial measurement system configuration
6HULDOPHDVXUHPHQWV\VWHPFRQILJXUDWLRQ
2YHUYLHZ
The following procedures detail how to select the measurement link.
3URFHGXUHV
The parameters in this procedure cannot be changed via RobotStudioOnline or the FlexPendant.
Edit the parameters in the file MOC.cfg and load this file to the controller. For information
about how to load a cfg file, see 2SHUDWRU
V0DQXDO5RERW6WXGLR2QOLQH.

1. Select the serial measurement link by changing the selectable values: 1 or 2
value of the parameter PHDVXUHPHQWBOLQN, in the type
0($685(0(17B&+$11(/.
2. Select the SMB placement by changing the value of selectable values: 1 or 2
the parameter ERDUGBSRVLWLRQ, in the type
0($685(0(17B&+$11(/.
3. Select the measurement node by changing the value selectable values: 1 to 7
of the parameter PHDVXUHPHQWBQRGH, in the type
0($685(0(17B&+$11(/.
127(
Each node (1 to 7) must not be used more than once on each serial measurement link.

6RIW:DUH
3.4. Serial measurement system configuration

$[HV&RQILJXUDWLRQ
4.1. Minimal Configuration
$[HV&RQILJXUDWLRQ
0LQLPDO&RQILJXUDWLRQ
2YHUYLHZ
This section describes how to make a minimal configuration of a standard additional axes.
&$87,21
Incorrect definition of the system parameters for brakes or additional axes may cause damage
to the robot or personal injury.
/RDG3DUDPHWHUV
Use RobotStudioOnline to perform the following instructions. 6HH2SHUDWRU
V0DQXDO
5RERW6WXGLR2QOLQH.
6WHS $FWLRQ
1. Right click on configuration icon in the system view, and select: /RDG3DUDPHWHUV.
2. Select: /RDGSDUDPHWHUVLIQRGXSOLFDWHV and click: 2SHQ.
3. Browse to the directory:
0HGLDSRRO?5RERW:DUHB;;;;;;?XWLOLW\?$GGLWLRQDO$[LV?'0?*HQHUDO
4. Select the configuration file for required axes and click: 2SHQ.
5. Restart the system from the FlexPendant.
&RQILJXUH3DUDPHWHUV
Use RobotStudioOnline to perform the following instructions. See 2SHUDWRU
V0DQXDO
5RERW6WXGLR2QOLQH.
For parameter description, see 6\VWHP3DUDPHWHUV on page 127.

1. Select the topic 0RWLRQand type 0HFKDQLFDO8QLW and • 1DPH
define the following in the parameter. • 6WDQGE\6WDWH
• $FWLYDWHDW6WDUW8S
• 'HDFWLYDWLRQ
)RUELGGHQ

$[HV&RQILJXUDWLRQ

2. Select the topic 0RWLRQ and type 6LQJOH7\SH and Example of values of the
specify the specify the type of additional axis in the parameter 0HFKDQLFV:
parameter 0HFKDQLFV. • TRACK
• FREE_ROT
• EXT_POS
• TOOL_ROT
3. Select the topic 0RWLRQand type -RLQWV and specify Example: Logical axis 10 will
the logical axis number under parameter /RJLFDO$[LV. then correspond to the field
eax_d in the data type
robtarget.
4. Select the topic 0RWLRQ and type $UP and specify the • 8SSHU-RLQW%RXQG
arm characteristics for the axis. • /RZHU-RLQW%RXQG
5. Select the topic 0RWLRQand type $FFHOHUDWLRQ'DWD • 1RPLQDO$FFHOHUDWLRQ
and specify the arm performance for the axis. • 1RPLQDO
'HFHOHUDWLRQ
6. Select the topic 0RWLRQand type 7UDQVPLVVLRQ and • 7UDQVPLVVLRQ*HDU
specify the following. 5DWLR
• 5RWDWLQJ0RYH
• 7UDQVPLVVLRQ+LJK
*HDU
• 7UDQVPLVVLRQ/RZ
*HDU
7. Select the topic 0RWLRQand type 0RWRU7\SH and • 3ROHSDLUV
specify the following. • NH3KDVHWR3KDVH
9VUDG
• 0D[FXUUHQW$UPV
• 3KDVHUHFLVWDQFH
RKP
• 3KDVHLQGXFWDQFH+
8. Select the topic 0RWLRQ and type 0RWRU&DOLEUDWLRQ • &DOLEUDWLRQ2IIVHW
and define the calibration and commutation offsets. • &RPPXWDWRU2IIVHW
9. Select the topic 0RWLRQ and type 6WUHVV'XW\&\FOH • 7RUTXH$EVROXWH0D[
and define the calibration and commutation offsets. • 6SHHG$EVROXWH0D[

$[HV&RQILJXUDWLRQ
127(
1RWH
If 7RUTXH$EVROXWH0D[ is to high it may result in a configuration error at restart.
/LPLWDWLRQ
If 7RUTXH$EVROXWH0D[is to high it may result in a configuration error at restart. To avoid
error do not set 7RUTXH$EVROXWH0D[ higher than:
7RUTXH$EVROXWH0D[3 x NH3KDVHWR3KDVH9VUDG x 0D[&XUUHQW
0D[&XUUHQW, belonging to the type 0RWRU7\SH, is the maximum current of the used drive
module.
NH3KDVHWR3KDVH9VUDG, belonging to the type 0RWRU7\SH, is a voltage constant.

$[HV&RQILJXUDWLRQ
4.2. Minimal configuration of servo gun
0LQLPDOFRQILJXUDWLRQRIVHUYRJXQ
2YHUYLHZ
This chapter describes how to configure a servo gun and the usage of important parameters,
some of them servo gun specific, that need to be set up. This chapter replaces the previous
chapter, Minimal configuration. However, most of the following configuration chapters
(Relays, Brake and Supervision) are also completely valid for servo guns
&$87,21
Incorrect defenition of the system parameters for brakes or additional axes may cause damage
to the robot or personal injury.
/RDG3DUDPHWHUV
Use RobotStudioOnline to perform the following instructions. 6HH2SHUDWRU
V0DQXDO
5RERW6WXGLR2QOLQH.
6WHS $FWLRQ
1. Right click on configuration icon in the system view, and select: /RDG3DUDPHWHUV.
2. Select: /RDGSDUDPHWHUVLIQRGXSOLFDWHV and click: 2SHQ .
3. Browse to the directory:
0HGLDSRRO?5RERW:DUHB;;;;;;?XWLOLW\?$GGLWLRQDO$[LV?'0?6HUYR*XQ
4. Select the configuration file for required axes and click: 2SHQ.
&RQILJXUH3DUDPHWHUV
V0DQXDO
5RERW6WXGLR2QOLQH.

1. Select the topic 0RWLRQand type 0HFKDQLFDO8QLW and • 1DPH
define the following in the parameter.

$[HV&RQILJXUDWLRQ

2. Select the topic 0RWLRQand type -RLQWV and specify Example: Logical axis 10 will
the logical axis number under parameter /RJLFDO then correspond to the field
$[LV. HD[BG in a data of the type
UREWDUJHW.
3. Select the topic 0RWLRQ and type $UP and specify the • 8SSHU-RLQW%RXQG
arm characteristics for the axis. • /RZHU-RLQW%RXQG
/RZHU-RLQW%RXQG should be
set to zero or a small
negative value (e.g. -0.005
m) in order to protect the gun
from collisions. The limit is
not active during force control
of the gun. For force control
there is another positional
limit, 0D[)RUFH&RQWURO
3RVLWLRQ(UURU, in the type
6XSHUYLVLRQ.
4. Select the topic 0RWLRQ and type $FFHOHUDWLRQ'DWD • 1RPLQDO$FFHOHUDWLRQ
and specify the arm performance for the axis. • 1RPLQDO'HFHOHUDWLRQ
5. Select the topic 0RWLRQand type 7UDQVPLVVLRQ and • 7UDQVPLVVLRQ*HDU
specify the following. 5DWLR
6. Select the topic 0RWLRQand type 0RWRU7\SH and • 3ROH3DLUV
specify the following. • NH3KDVHWR3KDVH
9VUDG
• 0D[&XUUHQW$UPV
• 3KDVH5HVLVWDQFH
RKP
• 3KDVH,QGXFWDQFH+
7. Select the topic 0RWLRQand type 0RWRU&DOLEUDWLRQ • &DOLEUDWLRQ2IIVHW
and define the calibration and commutation offsets. • &RPPXWDWLRQ2IIVHW
8. Select the topic 0RWLRQand type 6WUHVV'XW\&\FOH • 7RUTXH$EVROXWH0D[
and define the calibration and commutation offsets. • 6SHHG$EVROXWH0D[
7XQLQJ
After configuration of the parameters, the general additional axis tuning can be performed.
6HHFKDSWHU7XQLQJRI$[HV for tuning of the controller parameters.

$[HV&RQILJXUDWLRQ
&RQILJXUH6HUYRJXQSDUDPHWHUV
After tuning of the controller parameters, the servo gun specific parameters can be defined.

1. Select the topic 0RWLRQ and type 6XSHUYLVLRQ7\SH to • 0D[)RUFH&RQWURO
define the supervision limits during force control. 3RVLWLRQ(UURU
• 0D[)RUFH&RQWURO
6SHHG/LPLW
2. Select the topic 0RWLRQ and type 6*3URFHVV to • 6\QFFKHFNRII
define the process parameters that are specific for a • &ORVH7LPH$GMXVW
servo gun. • )RUFH5HDG\'HOD\
• 0D[)RUFH&RQWURO
0RWRU7RUTXH
• 3RVWV\QFKURQL]DWLRQ
7LPH
• &DOLEUDWLRQ0RGH
• &DOLEUDWLRQ)RUFH
+LJK
• &DOLEUDWLRQ)RUFH
/RZ
• &DOLEUDWLRQ7LPH
7LSIRUFH
The relationship between the programmed Tip force and the resulting motor torque is set up
in the following parameters. The torques may be negative due to the sign of the gear ratio
while the forces must always be positive. Before setting up this table, the parameters in the
Force Master should be tuned. See section $GGLWLRQDOWXQLQJIRUVHUYRJXQV on page 111.
The easiest way to set up the table is by using a RAPID force calibration service routine.
3DUDPHWHU 'HVFULSWLRQ
1XPEHURI6WRUHG)RUFHV Number of stored forces in the force vs motor
torque table. The minimum value allowed is 2.
7LS)RUFH Gun tip force 1 (N)
0RWRU7RUTXH Motor torque 1 (Nm)

$[HV&RQILJXUDWLRQ

$[HV&RQILJXUDWLRQ
4.3. Disconnect a servo motor
'LVFRQQHFWDVHUYRPRWRU
2YHUYLHZ
It is possible to disconnect and reconnect the motor of a deactivated axis if a certain
deactivation mode is setup.
127(
1RWH
If the axis is moved when disconnected, the position of the axis might be wrong after
reconnecting, and this will not be detected by the controller. The position after reconnection
will be correct if the axis not is moved, or if the movement is less than 0.5 motor revolutions.
For servo guns, there is a RAPID calibration method available (the ToolChange calibration)
that will adjust any positional error caused by gun movement during disconnection.
&RQILJXUHSDUDPHWHU
V0DQXDO
5RERW6WXGLR2QOLQH
For parameter description, see chapter 6\VWHP3DUDPHWHUV on page 127.

1. Select the topic 0RWLRQ and type 0HDVXUHPHQW • 'LVFRQQHFWDW
FKDQQHO and define the following in the parameter. 'HDFWLYH

$[HV&RQILJXUDWLRQ
4.4. Servo Tool Change
6HUYR7RRO&KDQJH
2YHUYLHZ
With the option 630-1, Servo Tool Change, it is possible to disconnect the resolver and power
cables from the motor of one external axis and connect them to the motor of another
additional axis.
For details about Servo Tool Change, see $SSOLFDWLRQPDQXDO6HUYRPRWRUFRQWURO.
:$51,1*
It is important that no other mechanical units used with one tool changer, are activated but the
one corresponding to the currently connected servo gun! An activation of wrong mechanical
unit may cause unexpected movements which could cause personal injury. See 'HILQLQJ
5HOD\V.
&RQVLGHUDWLRQV
The section below specifies some special considerations when switching motors.
• The two (or more) additional axes sharing the same motor cables, are configured as
separate mechanical units.
• The additional axes are configured to use the same measurement node and drive unit
node.
• If two servo guns are used with a tool changer, the template file 0/%6B'0FIJ
can be used for configuration of both guns.
• A motor switch can be done only if all sharing axes are deactivated.
• The reconnected motor is activated and this activation will restore the position of the
axis to latest position.
• A new motor switch can not be performed until this axis is deactivated.
• Always use the tool change tip calibration after activation.
&RQQHFWLRQ5HOD\
To make sure that the correct mechanical unit is active, some tool changers support I/O
signals that specifies which gun is currently connected.
It is also possible to lock unconnected mechanical units from activation by specifying a
connection relay and connect it to a digital input (DI).

$[HV&RQILJXUDWLRQ
4.4. Servo Tool Change
'HILQLQJDFRQQHFWLRQUHOD\
V0DQXDO
5RERW6WXGLR2QOLQH.
6WHS $FWLRQ 3DUDPHWHU

1. Select the topic 0RWLRQand type 0HFKDQLFDO8QLW and • 8VH&RQQHFWLRQ
define the name of the relay, or check the name if this 5HOD\
is already defined.
2. Select the topic 0RWLRQand type 5HOD\ and select the
named relay, if this is defined.
3. If the named connection relay not is defined, a new
relay must be created.
4. Change the name of the newly created relay to the • 1DPH
same as the 8VH&RQQHFWLRQ5HOD\ parameter. • 2XWSXW6LJQDO
Define an activation lock signal. • ,QSXW6LJQDO

$[HV&RQILJXUDWLRQ
4.5. Defining Relays
'HILQLQJ5HOD\V
2YHUYLHZ
The additional drive unit can be activated via signals from the robot. When a module is
activated, e.g. by choosing the module in the Jogging window on the FlexPendant, the output
signal is automatically set. A check is made later that the corresponding input signal from the
relay is set.
'HILQHDFWLYDWLQJUHOD\V
Define the input and output signals for all connected relays. Use RobotStudioOnline to perform
the following instructions. See 2SHUDWRU
V0DQXDO5RERW6WXGLR2QOLQH. For parameter
description, see 6\VWHP3DUDPHWHUV on page 127.
6WHS $FWLRQ 3DUDPHWHUV

1. Restart the controller to check that the additional axes
can be activated from the I/O window on the
FlexPendant.
2. Select the topic 0RWLRQ and type 5HOD\ and define the • 1DPH
following parameters. • 2XWSXW6LJQDO
• ,QSXW6LJQDO
3. Select the topic 0RWLRQand type 0HFKDQLFDO8QLW and • 8VH$FWLYDWLRQ5HOD\
specify the name of the activation relay.
4. Restart the system.
'HILQHEUDNHUHOD\V
If the additional mechanical units are equipped with brakes, these will be automatically
activated when the unit is deactivated or when the robot system assumes the MOTORS OFF
state. They will also be activated when the axes have been stationary for a certain time in the
MOTORS ON state.
'HILQLQJWKHLQSXWDQGRXWSXWVLJQDOV
Define the input and output signals for all connected relays. Use RobotStudioOnline to perform

$[HV&RQILJXUDWLRQ
4.5. Defining Relays

1. Restart the controller to check that the brakes can be
activated from the I/O window on the FlexPendant.
2. Select the topic 0RWLRQ and type 5HOD\V and define • 1DPH
the following parameters. • 2XWSXW6LJQDO
• ,QSXW6LJQDO
3. Select the topic 0RWLRQ and type 0HFKDQLFDO8QLW and • 8VH%UDNH5HOD\
specify the name of the brake relay.

$[HV&RQILJXUDWLRQ
4.6. Defining Brakes
'HILQLQJ%UDNHV
2YHUYLHZ
The following parameters that control the brake behavior can be changed.
'HILQLQJEUDNHSDUDPHWHU
Define the following parameters to define the time delay and speed. Use RobotStudioOnline to
perform the following instructions. See 2SHUDWRU
V0DQXDO5RERW6WXGLR2QOLQH. For
parameter description, see 6\VWHP3DUDPHWHUV on page 127.

1. Select the topic 0RWLRQand type %UDNH and define • &RQWURO2II'HOD\
the following parameters. • &RQWURO2II6SHHG
/LPLW

$[HV&RQILJXUDWLRQ
4.7. Supervision
6XSHUYLVLRQ
2YHUYLHZ
Supervision is used to avoid overload on the motors. To prevent misleading supervision errors
due to influence forces, all axes with mutual influences shall be configured to the same
influence group.
'HVFULSWLRQ
If a manipulator mounted on a "Trackmotion" accelerates, the reaction (influence) forces
affect the "Trackmotion". In the same way, if the "Trackmotion" accelerates, the manipulator
is affected. Up to 10 different influence groups can be used (1-10). By default the manipulator
belongs to the influence group no. 1.
'HILQHLQIOXHQFHJURXSV
Define the parameter for supervision on the additional axes. Use RobotStudioOnline to perform
description, see 6\VWHP3DUDPHWHUV on page 127

1. Select the topic 0RWLRQand type 6XSHUYLVLRQ7\SH.
2. Select the additional axes to be grouped.
3. Press: (QWHU
4. Select the parameter,QIOXHQFH*URXS and change
the value. Default value: .
5. Press: 2. to confirm.

$[HV&RQILJXUDWLRQ
4.8. Independent joint
,QGHSHQGHQWMRLQW
2YHUYLHZ
With the options 610-1, Independent Axes, an additional axis (linear or rotating) can run
independently of the other axes in the robot system.
'HVFULSWLRQ
An axis is set in independent mode by executing an independent move instruction. Use the
independent reset instruction to return to normal mode. Independent reset instruction can also
be used in normal mode in order to change the logical position of the axis.
For more information about Independent Axes, see $SSOLFDWLRQPDQXDO0RWLRQIXQFWLRQV
DQGHYHQWV.
$FWLYDWH,QGHSHQGHQW-RLQW
the following instructions. See2SHUDWRU
description see section, 6\VWHP3DUDPHWHUV on page 127

1. Select the topic 0RWLRQ and type $UP.
2. Double click the axis to be activated
3. Select the parameter ,QGHSHQGHQW-RLQW in the
appearing list.
4. Set the Independent Joint to value 2Q
• ,QGHSHQGHQW-RLQW
• ,QGHSHQGHQW8SSHU-RLQW
%RXQG
• ,QGHSHQGHQW/RZHU-RLQW
%RXQG
'HILQLQJ7UDQVPLVVLRQUDWLR

$[HV&RQILJXUDWLRQ
4.8. Independent joint
For external axes, the transmission ratio must be defined as normal with the parameter
7UDQVPLVVLRQ*HDU5DWLR but also with its nominator and denominator values in order to get
exact value (no rounding off). Use RobotStudioOnline to perform the following instructions.
See2SHUDWRU
V0DQXDO5RERW6WXGLR2QOLQH. For parameter description see section, 6\VWHP
3DUDPHWHUV on page 127.

1. Select the topic 0RWLRQ and type 7UDQVPLVVLRQ.
2. Specify the following parameters.
• 7UDQVPLVVLRQ+LJK
*HDU
• 7UDQVPLVVLRQ/RZ
*HDU

$[HV&RQILJXUDWLRQ
4.9. Soft servo
6RIWVHUYR
2YHUYLHZ
Soft servo can be activated for additional axes which are configured with /DJ&RQWURO0DVWHU
. The behaviour of movements with the soft servo activated is described in the 5$3,'
UHIHUHQFHPDQXDO5$3,'2YHUYLHZ .
'HVFULSWLRQ
There are four system parameters to consider when the soft servo is used for an additional
axis. The parameter are set to default values.
6HWVRIWVHUYRSDUDPHWHUV
Define the parameter for soft servo on the additional axes. Use RobotStudioOnline to perform

1. Select the topic 0RWLRQ and type /DJ&RQWURO
0DVWHU.
2. Select the lag control master corresponding to the
exernal axis.
3. Select the desired parameter and change its value.
• .6RIW0D[)DFWRU
• .6RIW0LQ)DFWRU
• .S.Y5DWLR)DFWRU
• 5DPS7LPH

$[HV&RQILJXUDWLRQ
4.10. Activate force gain control for an additional axis
$FWLYDWHIRUFHJDLQFRQWUROIRUDQDGGLWLRQDOD[LV
2YHUYLHZ
Force gain control is used in cases when heavy load, high friction and low speed makes it
difficult for an additional axis to reach its end point.
All the axes that affect force gain control must be within a certain position range from the end
point before the forced gain control is enabled. This position range is also specified in
Supervision.
'HVFULSWLRQ
When activating forced gain control for an additional axis, two types under 0RWLRQ must be
considered. Decide which axes should have forced gain control in /DJ&RQWURO0DVWHU, and
decide which axes should affect forced gain control in 6XSHUYLVLRQ.
6HWIRUFHJDLQFRQWUROSDUDPHWHUV
Define the parameter for forced gain control on the additional axes. Use RobotStudioOnline to
perform the following instructions. See2SHUDWRU
description see section, 6\VWHP3DUDPHWHUV on page 1276\VWHP3DUDPHWHUV on page
1276\VWHP3DUDPHWHUV on page 127

0DVWHU.
2. Select the lag control master corresponding to
the additional axis.
3. Select the parameter to be changed. • )RUFHG&RQWURO$FWLYH
• )RUFHG)DFWRUIRU.S
• )RUFHG)DFWRUIRU.L
• 5LVH7LPHIRU.S
6HWVXSHUYLVLRQSDUDPHWHUV

$[HV&RQILJXUDWLRQ
4.10. Activate force gain control for an additional axis
&$87,21
Do not change supervision for the robot axes. Changes on these values could affect the service
interval cycles and impair its performance.

1. Select the topic0RWLRQ and type 6XSHUYLVLRQ.
2. Select the lag control master corresponding to
the axis that should or should not affect forced
gain control.
3. Select the parameter to be changed. • $IIHFWV)RUFHG&RQWURO
• )RUFHGRQ3RVLWLRQ/LPLW
• )RUFHGRII3RVLWLRQ/LPLW

$[HV&RQILJXUDWLRQ
4.11. Activate notch filter for an additional axis
$FWLYDWHQRWFKILOWHUIRUDQDGGLWLRQDOD[LV
2YHUYLHZ
The notch filter is used to prevent the additional axis from oscillating at the weave motion
frequency.
The notch filter is used only in arc welding applications when a variation in additional axis
speed affects the welding process. This problem occurs when both coordinated interpolation
and weaving are used. The frequency of the speed variation is typically 2 times the weaving
frequency.
'HVFULSWLRQ
There are two ways to use the notch filter:
• Lock the notch filter to one specific frequency specified in the parameter 1RWFK)LOWHU
)UHTXHQF\
• Activate 1RWFK$XWR0RGH, which means that the notch filter will automatically adjust
to the current weave frequency.
127(
A notch filter should not be used together with Rapid Weave. In 1RWFK$XWR0RGH this is
handled automatically and as if there was no weaving at all.
$FWLYDWHQRWFKILOWHU
To activate notch filter for an additional axis. Use RobotStudioOnline to perform the following
instructions. See2SHUDWRU
V0DQXDO5RERW6WXGLR2QOLQH. For parameter description see
section,6\VWHP3DUDPHWHUV on page 127

0DVWHU.
2. Select the lag control master corresponding to the
additional axis.

$[HV&RQILJXUDWLRQ
4.11. Activate notch filter for an additional axis

3. Select the desired parameter and change its
value. • 1RWFK)LOWHU$FWLYDWHG
• 1RWFK)LOWHU)UHTXHQF\
• 1RWFK)LOWHU:LGWK
• 1RWFK$XWR0RGH
• $XWR1R:HDYH
)UHTXHQF\
• $XWR0LQ)UHTXHQF\
• $XWR0D[5HODWLYH
&KDQJH
4. Press 2. to confirm.

$[HV&RQILJXUDWLRQ
4.12. Defining kinematic parameters for general kinematics
'HILQLQJNLQHPDWLFSDUDPHWHUVIRUJHQHUDONLQHPDWLFV
2YHUYLHZ
It is possible to use general kinematic for all robots and positioners. There are no standard
configuration files for positioners available.
127(
Definition is not possible via the FlexPendant, PC editing of the MOC.cfg file is necessary.
3RVLWLRQHUV
The following needs to be defined.
7\SH 'HVFULSWLRQ
ROBOT_TYPE • base_pose_rot_u0, base_pose_rot_u1, base_pose_rot_u2,
base_pose_rot_u3 (Rotation between user defined robot base
and internal base according to Denavit - Hartenberg definition).
• no_of_joints = highest joint number
• type *(1B.,1
ARM For each arm of the additional robot in question.
• URWDWLQJBPRYH if rotating axes, exclude otherwise
ARM_TYPE For each arm of the external robot in question.
• OHQJWK (a according to Craigh´s definition)
• RIIVHWB[ = 0
• RIIVHWB\ = 0
• WKHWDBKRPHBSRVLWLRQ (theta according to Craigh´s definition)
• RIIVHWB] (d according to Craigh´s definition)
• DWWLWXGH (alpha according to Craigh´s definition)

$[HV&RQILJXUDWLRQ
4.13. Coordination
&RRUGLQDWLRQ
2YHUYLHZ
It is possible to define additional manipulators with more than one axis.
'HVFULSWLRQ
To achieve the best possible performance from an external manipulator, a set of data,
describing its kinematic and dynamic properties (among other things), must be defined.
This data cannot be defined in the system parameters, but must be read from a parameter file.
If no file was supplied with the manipulator, the manipulator cannot be coordinated with the
robot. It can, however, be defined as a number of separate external axes.
'HILQLQJDGGLWLRQDOPDQLSXODWRUV
Defining additional manipulators with more than one axis. Use RobotStudioOnline to perform
6WHS $FWLRQ 1RWH

1. Read the files that define the manipulator.
2. Add new parameters.
3. Define the calibration offset, name of the mechanical see, 0LQLPDO&RQILJXUDWLRQ
unit, etc. on page 55
4. Define the base coordinate system. see, 2SHUDWRUVPDQXDO
'HILQLQJDQDGGLWLRQDOPHFKDQLFDOXQLW
Defining additional mechanical units with more than one axis. Use RobotStudioOnline to
perform the following instructions. See 2SHUDWRU
V0DQXDO5RERW6WXGLR2QOLQH. For
parameter description, see 6\VWHP3DUDPHWHUV on page 127.
6WHS $FWLRQ 1RWH

1. Define the axis. see, 0LQLPDO&RQILJXUDWLRQ
on page 55
2. Define the base coordinate system. see, 2SHUDWRUVPDQXDO
3. Select the topic 0RWLRQ and type 0HFKDQLFDO8QLW.

$[HV&RQILJXUDWLRQ
4.13. Coordination
6WHS $FWLRQ 1RWH

4. Select the mechanical unit that moves the work
object.
5. Set the parameter $OORZ0RYHRI8VHU)UDPH to Yes
for this mechanical unit.

7XQLQJRI$[HV
5.1. Tuning the commutation offset
7XQLQJRI$[HV
7XQLQJWKHFRPPXWDWLRQRIIVHW
*HQHUDO
Before using an additional axis, you must tune the motors commutation offset. This requires
that you connect a DC power source between two nodes and then measure the position of the
motor.
127(
ABB motors are precommutated with the commutation value 1.5708. Therefor, an ABB
motor does not require tuning of the commutation offset.
3UHUHTXLVLWHV
The motor must comply with the specifications in 0RWRUV on page 35. The resolver must
comply with the specifications in 5HVROYHUV on page 38.
5HTXLUHGPDWHULDO
This is a list of what you need to perform the tuning:
0DWHULDO 'HVFULSWLRQ
PC with Test Signal Viewer The software Test Signal Viewer is delivered on the
RobotWare CD.
Power supply 24 V (DC).
The power supply should be equipped with a relay that trips
at short circuit. Otherwise a fuse will burn every time the
power is applied.
Check the motor data to see the current required from the
power supply.
2 cable sets Cables to brake release and motor phase.
Each cable set includes one plus and one minus cable.
Motor documentation Motor data sheet and electrical connection drawing.
0HDVXULQJSURFHGXUH
This procedure describes how to measure the commutation position of a motor.

7XQLQJRI$[HV
5.1. Tuning the commutation offset
6WHS $FWLRQ
1. Deactivate the axis whose motor you want to tune.
2. Switch off the controller.
3. Disconnect the power cable to the motor.
4. Disconnect the motor from the gear (or in some other way make sure the motor is
not affected by external torque and friction).
5. If the motor is using a brake, release it by connecting the power supply to the contact
pins for the brake release.
See motor specifications for max brake current, which contact are for the brake
release and the polarity of the contacts (if any).
6. Ensure that the brake is released by manually turning the motor.
7. Connect the power supply with the plus cable to the phase S (V) and the minus cable
(0 V) to the to the phase T (W).
A short pulse is enough to move the motor to its commutation position. Disconnect
the power after the voltage pulse.
8. Connect the power to give another voltage pulse to the motor. If the motor is already
in its commutation position it should not move this time.
9. Disconnect the power supply from the brake release, so that the motor brake is on.
10. Reconnect the power cable from the drive module to the motor.
11. Activate the axis.
Do not move any mechanical unit.
12. Start the controller.
13. Configure Test Signal Viewer, selecting mechanical unit and the signal
Resolver_angle.
Zoom in on the signal so you can read at least 2 decimals.
Note that the number of commutation positions are equal to the number of pole pairs.
E.g. a motor with 2 pole pairs have 2 possible values for this measurement. It does
not matter which of the commutation points you are measuring.
14. Set the measured value to the parameter &RPPXWDWRU2IIVHW in the type 0RWRU
&DOLEUDWLRQ.

7XQLQJRI$[HV
5.2.1. Introduction
7XQLQJ
,QWURGXFWLRQ
2YHUYLHZ
The servo control parameters can be adjusted (tuned) to achieve the best possible motion
performance.
This section contains a complete description of how to tune the axes and is divided into the
following sections:
• 7XQLQJRID[HVFRPSOHWHSURFHGXUH on page 84. Details the complete procedure of
tuning the axes, including necessary preparations and references to more detailed
instructions of setting tuned values for the different parameters.
• Separate procedures that detail how to set the tuning parameters respectively.

7XQLQJRI$[HV
5.2.2. Defining signals in Test Signal Viewer
'HILQLQJVLJQDOVLQ7HVW6LJQDO9LHZHU
'HILQLQJWHVWVLJQDOV
The Test Signal Viewer is used during tuning of the parameters. This section shows the
signals that may be used, and how these are defined from the menu Commands - Define Test
Signal.
6LJQDOLGHQWLILHU
Some of the signals may be defined from a drop down list as shown in the figure below:
en0400000763
- speed
- torque_ref
6LJQDOLGHQWLILHUPDQXDO
Some of the signals may be defined manually by entering numbers as shown in the figure
below:

7XQLQJRI$[HV
5.2.2. Defining signals in Test Signal Viewer
en0400000764
6 speed
9 torque_ref
55 positive torque_limit
56 negative torque_limit
57 torque feed forward

7XQLQJRI$[HV
5.2.3. Tuning of axes, complete procedure
7XQLQJRID[HVFRPSOHWHSURFHGXUH
*HQHUDO
This section contains the complete procedure for tuning the axes.
:$51,1*
The system is unstable and therefore dangerous during the tuning process, since bad
parameters or parameter combinations may be used! The safety procedures of the robot
system must be carefully followed throughout the tuning process.
+RZWRVHWWKHSDUDPHWHUYDOXHV
When tuning the axes, the affected parameters are preferably set in RobotStudioOnline. The
parameters may also be edited directly in the configuration file, with a text editor. System
parameters are listed in the section 6\VWHP3DUDPHWHUV on page 127. More information,
including the parameter names in the configuration files, are found in 7HFKQLFDOUHIHUHQFH
PDQXDO6\VWHPSDUDPHWHUV.
3UHSDUDWLRQV
The following preparations must be made before tuning a servomotor axis:
. Set up the Test Signal Viewer software according to the instructions in the pdf-file 7HVW
6LJQDO9LHZHU, enclosed with the program.
. Make sure that the additional axis is commutated and calibrated. Any position may be
defined as the calibration position.
. Select or use default tuning parameters so the axis may be jogged without stopping due to
speed or torque supervision.
7XQLQJFDOLEUDWHGD[HVRYHUYLHZ
Tuning a calibrated axis means setting values for several parameters in the data group /DJ
&RQWURO0DVWHU. The procedure below is an overview of the complete tuning procedure and
includes references to more detailed instructions of how to actually set each parameter.
6WHS $FWLRQ
1. Make the 3UHSDUDWLRQV.
2. Select the topic 0RWLRQ and the type /DJ&RQWURO0DVWHU.

7XQLQJRI$[HV
6WHS $FWLRQ
3. Set initially tuned values for the parameters Kv, Kp and Ti. This is further detailed in
the section ,QLWLDOWXQLQJRI.Y.SDQG7L.
4. Set a value for the parameter )):0RGH (feedforward mode) by choosing one of
following modes:
• No: This is the easiest configuration with no adjustments of the position lag.
(this mode is called in the configuration file)
• 6SG: This is the recommended configuration. In this configuration the
controller receives information about the desired speed of the axis. As a
result, the position lag is greatly reduced compared to the 1R configuration.
(this mode is called in the configuration file)
• 7UT: In this configuration the controller uses the desired speed and
acceleration of the axis to calculate the desired motor torque. This requires
knowledge of the mass moment of inertia of the axis, which must be supplied
by the user. For this reason this configuration is more difficult to tune,
specially for the axes affected by gravity. It is only recommended for
experienced users. (this mode is called in the configuration file)
The controller is driven by the position lag. This is the offset in time from the point of
given command til the point of actual performance of the command. The lag may be
adjusted with the different modes in the parameter )):0RGH.
Depending on which mode is chosen for the )):0RGH, different parameters and
values can further on be set.
5. Set a value for the parameter ,QHUWLD, depending on chosen mode for the )):0RGH:
• )):0RGH = 1R: set ,QHUWLD to 0
• )):0RGH = 6ST: set ,QHUWLD to 0
• )):0RGH = 7UT: calculate and set ,QHUWLD according to the section
6SHFLI\LQJWKHLQHUWLD.
6. If parameter )):0RGH is set to 6SG, the following parameters are also available:
• %DQGZLWK, should be left at its default value
• 'HOD\, should be left at its default value.

7XQLQJRI$[HV
6WHS $FWLRQ
7. If parameter )):0RGH is set to 7UT, the following parameters are also available:
• %DQGZLWK, should be left at its default value. Adjustment is detailed in the
section 7XQLQJRIEDQGZLWK.
• 'HOD\, should be left at its default value (0.004). In rare cases, increasing the
value may reduce the speed overshot.
• 5HVRQDQFHIUHTXHQF\IOH[LELOLW\FRPSHQVDWLRQILOWHU, should initially be left at
its default value. May be adjusted once the other parameters are set, if the
WRUTXHBUHI signal is oscillatory due to mechancial resonance. How to tune this
parameter is detailed in the section 7XQLQJRIUHVRQDQFHIUHTXHQF\ on page
101.
• 5HVRQDQFHGDPSLQJIOH[LELOLW\FRPSHQVDWLRQILOWHU, should be left at its
default value (0.01).
8. In the type $FFHOHUDWLRQ'DWD, set tuned values for 1RPLQDO$FFHOHUDWLRQ and
1RPLQDO'HFHOHUDWLRQas detailed in the section 7XQLQJRI1RPLQDO$FFHOHUDWLRQDQG
1RPLQDO'HFHOHUDWLRQ on page 102.
9. In /DJ&RQWURO0DVWHU, set finally tuned values for the parameters:
• .Y*DLQ6SHHG/RRS
• .S*DLQ3RVLWLRQ/RRS
• 7L,QWHJUDWLRQ7LPH6SHHG/RRS.
This is further detailed in the section )LQDOWXQLQJRI.S.YDQG7L on page 105.
7XQLQJXQFDOLEUDWHGD[HVRYHUYLHZ
Tuning an uncalibrated axis means setting values for several parameters in the data group
8QFDOLEUDWHG&RQWURO0DVWHU. The procedure below is an overview of the complete tuning
procedure and includes references to more detailed instructions of how to actually set each
parameter.
6WHS $FWLRQ
1. Make the 3UHSDUDWLRQV.
2. Set the initial tuning values of .Y*DLQ6SHHG/RRS, .S*DLQ3RVLWLRQ/RRS and 7L
,QWHJUDWLRQ7LPH6SHHG/RRS. Use tuned values, set during tuning of a calibrated
axis. Use the values so that the axis is movable no matter of the position.
3. Set the tuning value of 6SHHG0D[8QFDOLEUDWHG. Maximum speed for uncalibrated
axis (rad/s on motor side).

7XQLQJRI$[HV
6WHS $FWLRQ
4. Set the tuning value of 'HFHOHUDWLRQ0D[8QFDOLEUDWHG. Maximum deceleration for
uncalibrated axis (rad/s2 on motor side). Recommended value: 1RPLQDO
'HFHOHUDWLRQ * 7UDQVPLVVLRQ*HDU5DWLR. How to set the value for the nominal
deceleration is detailed in the section 7XQLQJRI1RPLQDO$FFHOHUDWLRQDQG1RPLQDO
'HFHOHUDWLRQ on page 102.
5. Set the tuning value of $FFHOHUDWLRQ0D[8QFDOLEUDWHG. Maximum acceleration for
uncalibrated axis (rad/s2 on motor side). Recommended value: nominal acceleration
* transm gear ratio. How to set the value for the nominal acceleration is detailed in
the section 7XQLQJRI1RPLQDO$FFHOHUDWLRQDQG1RPLQDO'HFHOHUDWLRQ on page 102.
6. Set the final tuning values of .Y*DLQ6SHHG/RRS, .S*DLQ3RVLWLRQ/RRSand 7L
,QWHJUDWLRQ7LPH6SHHG/RRS, as detailed in the section )LQDOWXQLQJRI.S.YDQG
7L on page 105.

7XQLQJRI$[HV
5.2.4. Initial tuning of Kv, Kp and Ti
,QLWLDOWXQLQJRI.Y.SDQG7L
*HQHUDO
This section details how to make the initial tuning of the parameters .Y*DLQ6SHHG/RRS,
.S*DLQ3RVLWLRQ/RRS and 7L,QWHJUDWLRQ7LPH6SHHG/RRS.
The general strategy is to tune Kv first while keeping Kp constant and without integral effect
(Ti is set to a high value, e.g. 10), then tune Kp to its maximum value without vibration/
oscillation; finally tune Ti and other parameters.
127(
1RWH
Check that the additonal axes motor file contains the correct motor data.
3DUDPHWHUGHVFULSWLRQ
The parameters .Y*DLQ6SHHG/RRS, .S*DLQ3RVLWLRQ/RRS and 7L,QWHJUDWLRQ7LPH6SHHG
/RRS belongs to the type /DJ&RQWURO0DVWHU and are further described in the section 6\VWHP
5$3,'SURJUDP
Program a back-and-forth motion of the axis. For the final tuning of the control parameters
of the axis it is convenient to use the TuneServo command. Each procedure below includes
an example of a RAPID program that can be used.
,QLWLDOWXQLQJRI.Y
The procedure below details how to make the initial tuning of the parameter .Y*DLQ6SHHG
/RRS.
:$51,1*
6WHS $FWLRQ
1. Set the parameter )):0RGH to No.

7XQLQJRI$[HV
6WHS $FWLRQ
2. Make following changes in the type /DJ&RQWURO0DVWHU:
• set the value of parameter .S*DLQ3RVLWLRQ/RRS to 5
• set the value of parameter 7L,QWHJUDWLRQ7LPH6SHHG/RRS to 10 (a big value
in order to eliminate integral portion).
Restart the controller for the changes to take effect.

7XQLQJRI$[HV
6WHS $FWLRQ
3. Increase the Kv value by 10% in each motion loop, until the axis starts to vibrate/
oscillate or a clear vibration can be heard from the axis, either during motion or when
stationary. The axis velocity supervision may also indicate speed failure.
The following RAPID program can be used to increase Kv by 10% of the default
value set in the loaded configuration file:
MODULE Kv_tune
PROC main()
VAR num i;
VAR num per_Kv;
VAR num Kv;
TuneReset;
FOR i FROM 0 TO 40 DO
per_Kv:=100+10*i;
Kv:=1*per_Kv/100;
TPErase;
TPWrite "per_Kv = "\Num:=per_Kv;
TPWrite "Kv = "\Num:=Kv;
TuneServo STN1,1,100\Type:=TUNE_KP;
TuneServo STN1,1,100\Type:=TUNE_TI;
TuneServo STN1,1,per_Kv\Type:=TUNE_KV;
MoveJ p1,v1000,z50,tool0;
WaitTime 1;
ENDFOR
ENDPROC
ENDMODULE
1RWH The velocity data and test positions may be modified depending on the type
of robot and axis to be tuned.
The RAPID instructions are described in the 5$3,'5HIHUHQFHPDQXDOSDUW
,QVWUXFWLRQV$=.
The 7RUTXHBUHI signal in the Test Signal Viewer may be used to evaluate the degree
of vibration/oscillation. A typical plot of the signal is shown in the figure ,OOXVWUDWLRQ
WRUTXHBUHISORW on page 91.
4. Once an unstable point is reached, divide the current value of Kv by 2.
5. Enter the new value in the parameter .Y*DLQ6SHHG/RRS.

7XQLQJRI$[HV
,OOXVWUDWLRQWRUTXHBUHISORW
How to choose the torque_ref signal in the Test Signal Viewer is detailed in section 'HILQLQJ
VLJQDOVLQ7HVW6LJQDO9LHZHU.
xx0400000644
A Normal plot
B Unstable plot
,QLWLDOWXQLQJRI.S
The procedure below details how to make the initial tuning of the parameter .S*DLQ
3RVLWLRQ/RRS.

7XQLQJRI$[HV
:$51,1*
6WHS $FWLRQ
1. Leave the initially tuned value of the parameter .Y*DLQ6SHHG/RRS and the earlier
set default values of .S*DLQ3RVLWLRQ/RRS and 7L,QWHJUDWLRQ7LPH6SHHG/RRS
unchanged.

7XQLQJRI$[HV
6WHS $FWLRQ
2. Increase the Kp value by 10% in each motion loop, until the first signs of
overshooting are observed in the velocity plot.
The following RAPID program may be used to increase Kp by 10% of the default
value set in the loaded configuration file:
MODULE kp_tune
PROC main()
VAR num i;
VAR num per_Kp;
VAR num Kp;
TuneReset;
per_Kp:=100+10*i;
Kp:=5*per_Kp/100;
TPErase;
TPWrite "per_Kp = "\Num:=per_Kp;
TPWrite "Kp = "\Num:=Kp;
TuneServo STN1,1,100\Type:=TUNE_KV;
TuneServo STN1,1,100\Type:=TUNE_TI;
TuneServo STN1,1,per_Kp\Type:=TUNE_KP;
WaitTime 1;
ENDFOR
ENDPROC
ENDMODULE
,QVWUXFWLRQV$= .
A typical plot with speed overshot in the Test Signal Viewer is shown in the figure
,OOXVWUDWLRQVSHHGSORW on page 94.
3. Once an overshot is observed, subtract 1 from the current value of Kp.
If an overshooting is observed at a later time, the Kp must be reduced to an even
lower value.
4. Enter this new value in the parameter .S*DLQ3RVLWLRQ/RRS.

7XQLQJRI$[HV
,OOXVWUDWLRQVSHHGSORW
How to choose the speed signal in the Test Signal Viewer is detailed in section 'HILQLQJ
VLJQDOVLQ7HVW6LJQDO9LHZHU.
xx0400000648
A Normal plot
B Overshoot
,QLWLDOWXQLQJRI7L
The procedure below details how to make the initial tuning of the parameter 7L,QWHJUDWLRQ
7LPH6SHHG/RRS.

7XQLQJRI$[HV
:$51,1*
6WHS $FWLRQ
1. Leave the initially tuned values of parameters .Y*DLQ6SHHG/RRS and .S*DLQ
3RVLWLRQ/RRS unchanged.
2. Set the value of 7L,QWHJUDWLRQ7LPH6SHHG/RRS to 1.0 as default.

7XQLQJRI$[HV
6WHS $FWLRQ
3. Reduce the Ti value by 10% in each motion loop, until an overshot is observed on
the velocity profile in the Test Signal Viewer.
Looking at the WRUTXHBUHI signal can also help to determine the critical value of Ti.
The following RAPID program may be ued to reduce the Ti value by 10% of the
default value set in the loaded configuration file:
MODULE ti_tune
PROC main()
VAR num i;
VAR num per_Ti;
VAR num Ti;
TuneReset;
per_Ti:=100-10*i;
Ti:=1*per_Ti/100;
TPErase;
TPWrite "per_Ti = "\Num:=per_Ti;
TPWrite "Ti = "\Num:=Ti;
TuneServo STN1,1,200\Type:=TUNE_KV;
TuneServo STN1,1,250\Type:=TUNE_KP;
TuneServo STN1,1,per_Ti\Type:=TUNE_TI;
WaitTime 1;
ENDFOR
ENDPROC
ENDMODULE
,QVWUXFWLRQV$=.
4. Once an overshot is observed, stop reducing and instead increase the tuned value
by 5-10%, in order to remove the effect.
5. When the effect is removed, enter the new value in 7L,QWHJUDWLRQ7LPH6SHHG/RRS.

7XQLQJRI$[HV
5HVXOW
/RRS are now initially tuned. Continue with the tuning process as described in next section.
The complete tunig procedure is detailed in section 7XQLQJRID[HVFRPSOHWHSURFHGXUH on
page 84.

7XQLQJRI$[HV
5.2.5. Specifying the inertia
6SHFLI\LQJWKHLQHUWLD
*HQHUDO
This section details how to specify the mass moment of inertia. (only recommended for
experienced users)
3UHUHTXLVLWH
The parameter )):0RGH (in the type /DJ&RQWURO0DVWHU must be set to Trq, in order to
have use of ,QHUWLD. If )):0RGH is set to No or Spd, the parameter ,QHUWLD is not used, but
should be set to 0 anyway.
6SHFLI\LQJWKHLQHUWLD
The procedure below details how to calculate the mass moment of inertia and how to enter
this value.
6WHS $FWLRQ
1. The inertia is given by:
Inertia = Inertiaaxis / (Transm gear ratio)2 + Inertiamotor + Inertia brake
2. Enter this value for the parameter ,QHUWLD in the type /DJ&RQWURO0DVWHU.
5HVXOW
The parameter ,QHUWLD is now tuned. Continue with the tuning procedure.

7XQLQJRI$[HV
5.2.6. Tuning of bandwidth
7XQLQJRIEDQGZLGWK
*HQHUDO
This section details how to set the tuned value for the parameter %DQGZLGWK.
The parameter %DQGZLGWK is found in the data group /DJ&RQWURO0DVWHU and is further
detailed in the section /DJ&RQWURO0DVWHU on page 130.
,OOXVWUDWLRQVSHHGRYHUVKRWEDQGZLGWKWXQLQJ
The figure below shows a typical plot in the Test Signal Viewer when tuning the parameter
%DQGZLGWK.
xx0400000652

7XQLQJRI$[HV
5.2.6. Tuning of bandwidth
7XQLQJRIEDQGZLGWK
The procedure below details how to tune the parameter %DQGZLGWK.
6WHS $FWLRQ
1. Use properly tuned values for the parameters .Y*DLQ6SHHG/RRS, .S*DLQ
3RVLWLRQ/RRS and 7L,QWHJUDWLRQ7LPH6SHHG/RRS.
2. Use the default value (25) for the parameter %DQGZLGWK.
3. In order to verify and tune the default %DQGZLGWK value, run a motion program to see
if the speed overshot occurs. If the overshoot is out of the tolerance, reduce the
value of %DQGZLGWK under the system resonance frequency.
The system resonance frequency may not always be identified. Therefore the value
may be varying several times and it may be necessary to perform a check of the
speed overshoot and of the following error between command position and actual
position. Normally, the bigger the %DQGZLGWK value, the smaller the following error.
A typical speed overshoot plot is shown in the figure ,OOXVWUDWLRQVSHHGRYHUVKRW
EDQGZLGWKWXQLQJ on page 99.
5HVXOW
The parameter %DQGZLGWK is now initially tuned. Continue with the tuning process described
in the next section, and in section 7XQLQJRID[HVFRPSOHWHSURFHGXUH on page 84.

7XQLQJRI$[HV
5.2.7. Tuning of resonance frequency
7XQLQJRIUHVRQDQFHIUHTXHQF\
*HQHUDO
This section details how to set the value of the parameter 'I (resonance frequency).
The parameter 'I is found in the data group /DJ&RQWURO0DVWHU and is further detailed in
the section /DJ&RQWURO0DVWHU on page 130.
7XQLQJRIUHVRQDQFHIUHTXHQF\
The procedure below details how to tune the resonance frequenc).
:$51,1*
6WHS $FWLRQ
1. Measure the distance between the resonance peaks (in points) on the plot of the
WRUTXHBUHI signal. Divide the sampling frequency with this value:
resonance frequency = sampling frequency / distance between resonance peaks
This calculation gives a rough estimate (in 1/s).
1RWH The sampling frequency of the logged data depends on the sampling interval
that has been selected in the configuration of the Test Signal Viewer.
2. The value of the resonance frequency should be in the range 3 to 25 (default 100).
To tune the resonance frequency, program a short back-and-forth motion of the axis
at maximum speed. The axis should not be allowed to reach full speed before
deceleration. Use the TUNE_DF argument of the TuneServo command to adjust the
resonance frequency and examine the WRUTXHBUHI signal.
Adjust the resonance frequency until the oscillations in the WRUTXHBUHI signal are
damped out.
3. Enter the tuned value of the resonance frequency to the parameter 'I.
5HVXOW
The parameter 'I is now tuned. Continue with the tuning procedure as described in the next
section, and in section 7XQLQJRID[HVFRPSOHWHSURFHGXUH on page 84.

7XQLQJRI$[HV
5.2.8. Tuning of Nominal Acceleration and Nominal Deceleration
7XQLQJRI1RPLQDO$FFHOHUDWLRQDQG1RPLQDO'HFHOHUDWLRQ
*HQHUDO
This section details how to make the tuning of the parameters 1RPLQDO$FFHOHUDWLRQ and
1RPLQDO'HFHOHUDWLRQ.
The parameters 1RPLQDO$FFHOHUDWLRQ and 1RPLQDO'HFHOHUDWLRQbelongs to the type
$FFHOHUDWLRQ'DWD and are further described in the section $FFHOHUDWLRQ'DWD on page 127.
3UHSDUDWLRQV
The following preparations must be made before performing the tuning:
. If an axis has a varying moment of inertia, 1RPLQDO$FFHOHUDWLRQand 1RPLQDO
'HFHOHUDWLRQshould be tuned with the maximum moment of inertia. For a description of
how to specify the inertia see 6SHFLI\LQJWKHLQHUWLD on page 98.
. If gravity has an influence on the axis, then 1RPLQDO$FFHOHUDWLRQshould be tuned with a
motion accelerating upwards gravity. 1RPLQDO'HFHOHUDWLRQshould be tuned with a
stopping motion (deceleration) while moving downwards in gravity direction.
. Program two test points for acceleration and two test points for deceleration with the
following requirements:
• Velocity: choose a velocity that is approximately 50% of the maximum speed of the
additional axis.
• Distance: the distance should be chosen to ensure that the axis stabilises at the
programmed velocity before deceleration starts.
7XQLQJRI1RPLQDO$FFHOHUDWLRQDQG1RPLQDO'HFHOHUDWLRQ
The procedure below details how to make the tuning of the parameters 1RPLQDO
$FFHOHUDWLRQand 1RPLQDO'HFHOHUDWLRQ.
Before beginning the tuning, observe the following warnings:
:$51,1*

7XQLQJRI$[HV
:$51,1*
Kp can affect the torque level (torque_ref). Therefore, acceleration/deceleration tuning
should be verified again if Kp is changed more than 10%.
:$51,1*
For low values of Kp (e.g. <5) the axis might never reach the acceleration/deceleration value
and these values can be tuned to unrealistically high values without reaching the torque limit.
This can cause problems during an emergency stop if brake_control_on_delay is >0 (motors
used at emergency stop). Do not continue to increase acceleration/deceleration if the effect
on WRUTXHBUHI is small. Always verify WRUTXHBUHI level at emergency stop.
6WHS $FWLRQ 1RWH

1. Use the Test Signal Viewer software to record the How to define these signals
values of SRVLWLYHQHJDWLYHWRUTXHBOLPLWand is detailed in section
WRUTXHBUHI for the axis. 'HILQLQJVLJQDOVLQ7HVW
6LJQDO9LHZHU.
2. Use test positions for 1RPLQDO$FFHOHUDWLRQand do the
following:
1. Run the motion and check the value of
WRUTXHBUHI for the SRVLWLYHQHJDWLYH
WRUTXHBOLPLW.
2. Adjust the value of 1RPLQDO$FFHOHUDWLRQ
upwards or downwards in increments of 0.5
until the WRUTXHBUHI signal shows that the axis
approaches, but does not reach, the torque
limit.
3. Reduce the final value by 10% to allow for
variations in the mechanical system over a
period of time.

7XQLQJRI$[HV
6WHS $FWLRQ 1RWH

3. Use test positions for 1RPLQDO'HFHOHUDWLRQand do
the following:
1. Run the motion and check the value of
WRUTXHBUHI for the SRVLWLYHQHJDWLYH
WRUTXHBOLPLW.
2. Adjust the value of 1RPLQDO'HFHOHUDWLRQ
upwards or downwards in increments of 0.5
until the WRUTXHBUHI signal shows that the axis
approaches, but does not reach, the torque
limit.
3. Reduce the final value by 10% to allow for
variations in the mechanical system over a
period of time.
5HVXOW
The parameters 1RPLQDO$FFHOHUDWLRQand 1RPLQDO'HFHOHUDWLRQare now tuned. Continue
with the tuning process as described in next section. The complete tuning procedure is
detailed in section 7XQLQJRID[HVFRPSOHWHSURFHGXUH on page 84.

7XQLQJRI$[HV
5.2.9. Final tuning of Kp, Kv and Ti
)LQDOWXQLQJRI.S.YDQG7L
*HQHUDO
This section details how to make the final tuning of the parameters .Y*DLQ6SHHG/RRS, .S
*DLQ3RVLWLRQ/RRS and 7L,QWHJUDWLRQ7LPH6SHHG/RRS.
/RRS belongs to the type /DJ&RQWURO0DVWHU and are further described in the section 6\VWHP
3UHSDUDWLRQV
The following preparations must be made before performing the final tuning:
. The parameters must be initially tuned as detailed in the section ,QLWLDOWXQLQJRI.Y.S
DQG7L on page 88.
. If the axis has a varifying moment of inertia, Kv, Kp and Ti should be tuned with the
maximum value for the moment of inertia.
. Program two test points with the following requirements:
• Velocity: choose a velocity that is approximately 25% of the maximum speed of the
additional axis. The speed must be low enough to guarantee that the axis does not
encounter the torque limit but high enough to prevent friction from affecting the result.
• Distance: choose a distance that ensures that the axis stabilises at the programmed
velocity before deceleration starts.
5$3,'SURJUDP
The following RAPID program can be used during the final tuning of the parameters .Y*DLQ
6SHHG/RRS, .S*DLQ3RVLWLRQ/RRS and 7L,QWHJUDWLRQ7LPH6SHHG/RRS:
PROC main()
ActUnit STN1;
TuneServo STN1,1,TuneValue\Type:=TUNE_KP;
TuneServo STN1,1,TuneValue\Type:=TUNE_KV;
TuneServo STN1,1,TuneValue\Type:=TUNE_TI;

7XQLQJRI$[HV
MoveJ p1,v_tune,fine,tool0;
ENDFOR
DeactUnit STN1;
ENDPROC
The argument TuneValue is a percentage (1-500) of the set value in the loaded configuration
file. 100% is the normal value.
Further descriptions of the RAPID instructions and arguments are found in 5$3,'5HIHUHQFH
PDQXDOSDUW,QVWUXFWLRQV$=.
,OOXVWUDWLRQILQDOWXQLQJRI.S
The figure below shows the desired profiles of VSHHG and WRUTXHBUHI when making the final
tuning of the parameter .S*DLQ3RVLWLRQ/RRS.
xx0400000649
)LQDOWXQLQJ

7XQLQJRI$[HV
The procedure below details how to make the final tuning of the parameters .Y*DLQ6SHHG
/RRS, .S*DLQ3RVLWLRQ/RRS and 7L,QWHJUDWLRQ7LPH6SHHG/RRS.
:$51,1*
6WHS $FWLRQ
1. Make the preparations detailed in the section 3UHSDUDWLRQV on page 105before
performing the final tuning.
2. Use the initially tuned values of the parameters .Y*DLQ6SHHG/RRS, .S*DLQ
3RVLWLRQ/RRS and 7L,QWHJUDWLRQ7LPH6SHHG/RRS as default values in the type /DJ
&RQWURO0DVWHU.
3. Make a final tuning of Kv by using the 5$3,'SURJUDP on page 105with the following
values:
• Increase the TuneValue for Kv in steps of 5% and observe the WRUTXHBUHI in
the Test Signal Viewer. Stop when the axis starts to vibrate/oscillate.
• Divide the TuneValue by 2 and run the axis again, while observing the
WRUTXHBUHI. There should be at most one or two damped oscillations after the
acceleration stage. If WRUTXHBUHI oscillates more than this, decrease its value
somewhat.
Kv is a critical parameter. A large value will result in a stiff axis and a fast response.
If Kv is too small, Kp will also be limited, resulting in an under-utilised axis.
4. Make a final tuning of Kp by using the 5$3,'SURJUDP on page 105and the following
information:
• Increase the TuneValue for Kp slowly until the desired VSHHG and WRUTXHBUHI
profiles are achieved as shown in the figure ,OOXVWUDWLRQILQDOWXQLQJRI.S on
page 106. The position error (lag) is inversely proportional to Kp thus a large
value for Kp is desirable.
5. Make a final tuning of Ti by using the 5$3,'SURJUDP on page 105with the following
values:
• Reduce the TuneValue for Ti in steps of 5% until the effect can be seen on
the plot of VSHHG as an increased overshoot.
• Increase the TuneValue for Ti by 5-10% until the effect is removed.
6. Calculate the final values of Kv, Kp and Ti by multiplying the initially tuned value in
the configuration file (that was used as the default value) by the given TuneValue
divided by 100.
Default value * (TuneValue / 100)

7XQLQJRI$[HV
6WHS $FWLRQ
7. Enter these new values to the parameters .Y*DLQ6SHHG/RRS, .S*DLQ3RVLWLRQ
/RRS and 7L,QWHJUDWLRQ7LPH6SHHG/RRS in the type /DJ&RQWURO0DVWHU.
5HVXOW
/RRS are now finally tuned.

7XQLQJRI$[HV
5.2.10. Tuning of the soft servo parameters
7XQLQJRIWKHVRIWVHUYRSDUDPHWHUV
*HQHUDO
This section details how to tune the following parameters in the type/DJ&RQWURO0DVWHU:
• .6RIW0LQ)DFWRU
• .6RIW0D[)DFWRU
• .S.Y5DWLR)DFWRU
• 5DPS7LPH
7,3
In most applications these parameters do not have to be trimmed and can be left at their
default values.
7XQLQJRI.6RIW0LQ)DFWRU
The procedure below details how to make the initial tuning of the parameter .6RIW0LQ
)DFWRU.
7,3
The movements in this trim procedure should be done close to the point where the soft servo
is activated, to minimize the risk of an axis collapsing.
6WHS $FWLRQ
1. Determine a maximum axis movement for which the axis should not move, when the
softness is 100%. Such a movement can be 0.1 rad for a rotating axis.
2. Determine a minimum axis movement for which the axis should move, when the
softness is 100%. Such a movement can be 0.2 rad for a rotating axis.
3. Activate the soft servo with softness 100% and perform the two movements.
4. If the axis moves for both movements, the axis is too stiff and .6RIW0LQ)DFWRU
should be reduced. If the axis does not move for any movement, the axis is too soft
and .6RIW0LQ)DFWRU should be increased.
5. Repeat step 3 and 4 until the axis does not move for the smaller movement but does
move for the bigger movement.
7XQLQJRI.6RIW0D[)DFWRU
In most cases, .6RIW0D[)DFWRU can be left at its default value (1.0).

7XQLQJRI$[HV
5.2.10. Tuning of the soft servo parameters
If the axis is too stiff at 0% softness, reduce .6RIW0D[)DFWRU. If the axis is too soft at 0%
softness, increase .6RIW0D[)DFWRU. The tuning can be made in a similar way as for .6RIW
0LQ)DFWRU, but with smaller movements.
.S.Y5DWLR)DFWRU
.S.Y5DWLR)DFWRU determines the stability margin for the axis. A value less than 1.0
increases the stability. It not possible to set this parameter to a value larger than 1.0 since the
stability of the axis would be jeopardized.
5DPS7LPH
If 5DPS7LPH is changed, the duration of the activation and deactivation phase will change.
A short ramp time can result in a twitch of the axis at activation.

7XQLQJRI$[HV
5.3.1. Introduction
$GGLWLRQDOWXQLQJIRUVHUYRJXQV
,QWURGXFWLRQ
$ERXWWXQLQJRIVHUYRJXQV
For a servo gun there are some additional parameters that need tuning. These parameters
belong types )RUFH0DVWHUand )RUFH0DVWHU&RQWURO.
127(
This tuning must be done before setting up the torque/ force table described in 7LSIRUFH on
page 60.
7,3
To simplify the tuning the STTune instruction should be used.
$ERXWWKH677XQHLQVWUXFWLRQ
The STTune instruction is a RAPID instruction used to modify parameter values without
having to do a warm start. The argument of the instruction specifies which parameter that
should be tuned and the new parameter value. For more information about STTune, see
5$3,'UHIHUHQFHPDQXDOSDUW,QVWUXFWLRQV$=.
Example
This instruction will tune the parameter 5DPSZKHQ,QFUHDVLQJ)RUFH to the value 100 Nm/s.
STTune M7C1B1_S, 100, RampTorqRefClose;
Parameter argument
Below is a list of the values of the parameter argument used in this chapter, and which system
parameters they correlate to:
$UJXPHQWYDOXHVLQ677XQH 3DUDPHWHUQDPH
RampTorqRefClose 5DPSZKHQ,QFUHDVLQJ)RUFH or 5DPS7LPH
KV .Y to .Y
SpeedLimit 6SHHG/LPLW to 6SHHG/LPLW
CollAlarmTorq &ROOLVLRQ$ODUP7RUTXH
CollContactPos &ROOLVLRQ'HOWD3RVLWLRQP

7XQLQJRI$[HV
5.3.1. Introduction
$UJXPHQWYDOXHVLQ677XQH 3DUDPHWHUQDPH
CollisionSpeed &ROOLVLRQ6SHHGPV
SyncCheckOff 6\QFFKHFNRII

7XQLQJRI$[HV
5.3.2. Protecting the gun
3URWHFWLQJWKHJXQ
*HQHUDO
To protect the gun from too high forces two parameters should be set. They are:
• 7RUTXH$EVROXWH0D[, belonging to the type 6WUHVV'XW\&\FOH
• 0D[)RUFH&RQWURO0RWRU7RUTXH, belonging to the type 6*3URFHVV
3UHUHTXLVLWHV
To set these values one need to know maximum allowed motor torque for the motor and
maximum allowed tip force, specified by the gun manufacturer. Some sort of force sensor is
also needed.
3UHSDUDWLRQV
Before starting, make sure that the gun is calibrated. Jog the tips to contact and calibrate the
axis.
Perform a service calibration (from the program editor on the FlexPendant, tap on 'HEXJ,
then &DOO6HUYLFH5RX and select 0DQ6HUYLFH&DOLE).
If you are using the option Servo Tool Control, you need to set the parameter 6\QFFKHFNRII
(this is done automatically by the ManServiceCalib if you have the option Spot Servo).
Setting 6\QFFKHFNRII will allow you to close the gun without having performed a tip
acalibration. To temporarily set 6\QFFKHFNRII, use the STTune instruction:
STTune M7C1B1_S, 1, SyncCheckOff;
5$3,'SURJUDP
Create a RAPID program containing the STClose instruction. The argument TipForce
should be set to 1N and Thickness set to the thickness of the force sensor.
tip_force:=1;
STClose M7C1B1_S, tip_force, sensor_thickness;
WaitTime 1;
STOpen M7C1B1_S;
7,3
If you have any of the RobotWare - Spot options, you can replace the three instructions
STClose, WaitTime and STOpen with the instruction SetForce.

7XQLQJRI$[HV
5.3.2. Protecting the gun
3URFHGXUH
This procedure describes how to tune the parameters 7RUTXH$EVROXWH0D[ and 0D[)RUFH
&RQWURO0RWRU7RUTXH, used to protect the gun from too high forces.
6WHS $FWLRQ
1. Start by setting the force-torque relationship to unity (See 7LSIRUFH on page 60).
Ordered force 1N should give a motor torque of 1 Nm. Note that if the gear ratio, in
the type 7UDQVPLVVLRQ, is positive the torque values should be negative.
It is enough to define 2 force-torque relationships. In the type 6*3URFHVV, set
1XPEHURI6WRUHG)RUFHV to 2, 7LS)RUFH to 1, 7LS)RUFH to 2, 0RWRU7RUTXH to
1 and 0RWRU7RUTXH to 2 if gear ratio is negative ( -1 and -2 if gear ratio is positive).
2. In the type 6WUHVV'XW\&\FOH, set 7RUTXH$EVROXWH0D[ to the value found in the
motor specifications.
3. Make a warm start of the controller for the new parameter values to take effect.
4. Execute the program and record the tip force. Increase the ordered tip force while
measuring the actual tip force until the actual tip force is close to the specified
maximum tip force. For future use also find a torque value corresponding to a typical
tip force used during welding.
5. Because the force-torque relation was set to unity the value in forcedata giving
maximum allowed tip force corresponds to the maximum allowed motor torque. Set
the values of 7RUTXH$EVROXWH0D[ and 0D[)RUFH&RQWURO0RWRU7RUTXH to this
value.
The new value of 7RUTXH$EVROXWH0D[ may be a reduction from the value found
earlier (see previous chapters). If that is the case, the values of 1RPLQDO
$FFHOHUDWLRQ and 1RPLQDO'HFHOHUDWLRQ (in the type$FFHOHUDWLRQ'DWD) may have to
be lowered because the torque available for acceleration has decreased.

7XQLQJRI$[HV
5.3.3. Position Interpolation
3RVLWLRQ,QWHUSRODWLRQ
$ERXW5HIHUHQFHV%DQGZLGWK
The parameter 5HIHUHQFHV%DQGZLGWK belongs to the type )RUFH0DVWHU and decides the
bandwidth of the position references generated to reach the contact position before switching
to force control.
3URFHGXUH
Leave 5HIHUHQFHV%DQGZLGWK at its default value (25Hz). If there are some problems with
oscillations in torque or speed the bandwidth may be reduced.

7XQLQJRI$[HV
5.3.4. Tuning ramp times for force ramping
7XQLQJUDPSWLPHVIRUIRUFHUDPSLQJ
7ZRZD\VWRFRQILJXUHWKHUDPS
There are two different ways to configure how fast the force is increased to its ordered value.
The first method is by deciding how fast the motor torque should increase per second. The
corresponding parameter that needs tuning is 5DPSZKHQ,QFUHDVLQJ)RUFH. The second
method is by specifying how long time the ramp should take. This approach means that the
ramping will be steeper for high forces, something that increases the linearity between force
and torque and thereby reduces the calibration effort. The corresponding parameter in this
case is 5DPS7LPH. To choose between these two approaches a parameter, 8VH5DPS7LPH, is
used. By setting this parameter to TRUE the second method is used.
3UHUHTXLVLWHV
Depending on the type of gun different parameter values might be optimal. For tuning of the
parameters, a force sensor that can read the force during the whole closing procedure would
be optimal. If that is not available, use the Test Signal Viewer and log position (Signal no. 18),
motor speed (VSHHG) and motor torque (WRUTXHBUHI).
5$3,'SURJUDP
Make a RAPID program containing a STClose instruction with ordered force chosen so the
tip force will be a force typically used. The program should also include a STTune instruction
with the argumnet value RampTorqRefClose. If the parameter 8VH5DPS7LPH is set to
TRUE this tune instruction modifies the value of 5DPS7LPH else it modifies 5DPSZKHQ
,QFUHDVLQJ)RUFH.
In case 8VH5DPS7LPH is set to FALSE the program may look like the one below. To be sure
that the speed limitation does not affect the result, include a tune instruction setting the speed
limit to a high value.
STTune M7C1B1_S, 200, SpeedLimit;
FOR i FROM 20 TO 220 STEP 40
STTune M7C1B1_S, i, RampTorqRefClose;
STClose M7C1B1_S, tip_force, thickness;
WaitTime 1;
STOpen M7C1B1_S;
ENDFOR

7XQLQJRI$[HV
5.3.4. Tuning ramp times for force ramping
STTuneReset M7C1B1_S;
In case Use ramp time is set to TRUE the values tested should be in milliseconds. A
reasonable choice is to modify the FOR loop as below:
FOR i FROM 0.020 TO 0.100 STEP 0.01
7,3
If you have any of the RobotWare - Spot options, you can replace the three instructions
3URFHGXUH
This procedure describes how to tune the force ramping. What we want is to have as fast rise
time as possible without getting any other unwanted effects like overshoot in the force. A
large overshoot in the force signal is usually also seen in the position and the speed signals.
Make sure the calibration of the gun and ordered contact position is correct. Incorrect
calibration will usually show as an overshoot of the force signal.
6WHS $FWLRQ
1. Run the RAPID program shown above.
2. If a force sensor is available, look at the overshoot of the force signal. Choose a
ramp value that does not give a large overshoot.
3. After deciding a value of 5DPSZKHQ,QFUHDVLQJ)RUFH or 5DPS7LPH, let the RAPID
program run in continuous mode for a while and study the test signals to make sure
that no unexpected effects show.

7XQLQJRI$[HV
5.3.5. Speed versus force repeatability
6SHHGYHUVXVIRUFHUHSHDWDELOLW\
'HOD\5DPS
Quite often there is a trade-off between short cycle times and good force repeatability. To get
better force repeatability there exist a possibility to have a delay before the ramping starts
after contact has been reached. This delay is controlled by a parameter 'HOD\5DPS,
belonging to the type )RUFH&RQWURO. The value is given in seconds. To minimize the cycle
time set the value of this parameter to zero. For better force repeatability try setting it to a
value between 0 and 0.05 seconds.

7XQLQJRI$[HV
5.3.6. Tuning the speed limitation
7XQLQJWKHVSHHGOLPLWDWLRQ
*HQHUDO
The speed limitation is a functionality to limit the impact speed if the real thickness is smaller
than expected or the contact position just badly programmed. In those cases the limitation will
make a major improvement of force accuracy. It will have no effect for contact positions that
are accurately programmed. The parameters that need tuning are found under type )RUFH
0DVWHU&RQWURO. More information about configuring the speed limits can be found in the
description of )RUFH0DVWHU&RQWURO in 7HFKQLFDOUHIHUHQFHPDQXDO6\VWHPSDUDPHWHUV.
The idea is to find the maximum speed when the contact position is accurately programmed.
This will then be used in the controller to reduce speed when the user has made an error in
defining the contact position.
What needs to be defined in the system parameters are corresponding values of speed
limitation and gain in the speed loop (Kv) for a number of different motor torques. The
parameter 1RRI6SHHG/LPLWV gives the number of limitations used. This value can be
between 1 and 6, depending on how careful the tuning is done.
3DUDPHWHUV
The torque values are 7RUTXH -7RUTXH. If 1RRI6SHHG/LPLWV are chosen to, for example,
3 only 7RUTXH- 7RUTXH need to get values. The unit of these values are torque on the motor
side (Nm). Note that the torque values may be either positive or negative depending on the
gear ratio.
The speed values are 6SHHG/LPLW - 6SHHG/LPLW. If 1RRI6SHHG/LPLWV are chosen to, for
example, 3 only Speed /LPLW- 6SHHG/LPLW need to get values. The unit of these values is
speed on the motor side (rad/s). Note that the speed values may be either positive or negative
depending on the gear ratio.
The Kv values are .Y - .Y. If 1RRI6SHHG/LPLWV are chosen to, for example, 3 only .Y
- .Y need to get values. These values must always be positive.
5$3,'SURJUDP
Note that the gun must be calibrated before running the program.
Create a RAPID program containing the STClose instruction. The argument TipForce
should be between 1N and maximum allowed force. No plates are needed, and the
argument Thickness should be set to 0.

7XQLQJRI$[HV
tip_force:=1;
STClose M7C1B1_S, tip_force, 0;
WaitTime 1;
STOpen M7C1B1_S;
7,3
If you have any of the RobotWare -Spot options, you can replace the three instructions
3URFHGXUHIRUWXQLQJVSHHGOLPLWV
This procedure describes how to tune the speed limitation.
6WHS $FWLRQ
1. Set the force-torque relationship to unity. See 3URWHFWLQJWKHJXQ on page 113.
2. Make sure the speed limitation does not affect the gun closing. Use the STTune
instruction to set the speed limitation to a high value.
STTune M7C1B1_S, 200, SpeedLimit;
3. Make sure the gun is calibrated before running the program.
4. Run the RAPID program shown above.
Check that the position shown on the teach pendant when the tips are in contact is 0.
5. Use the Test Signal Viewer and log motor speed (VSHHG) during the closing of the
gun at different ordered forces. For each ordered force find the maximum speed
during force control.
The speed seen in the Test Signal Viewer will have two maximum values. The first
one is usually the largest one and corresponds to the speed when moving to contact
position. The speed we need for the tuning is the second top, which corresponds to
the speed when the gun tips are in contact.
([DPSOH
At the ordered force 1, corresponding to motor torque equal to 1 Nm, the maximum speed
was recorded to 50 rad/s.
Set 7RUTXH to 1 and 6SHHG/LPLW to 50. If the gear ratio was positive the speed and the
torque values will have negative sign. .Y may be set to 1 while tuning the speed limits.
.Y

7XQLQJRI$[HV
Large Kv values will mean a larger speed reduction which will make the gun slower. The
effect of changing the Kv values may be studied after the speed limitation has been entered
in the system parameters. This can be done by making a program containing a STClose (or
SetForce) instruction and a STTune instruction for tuning of Kv. By studying the effect of
changing the programmed contact position and tuning the value of Kv an optimal value can
be chosen.

7XQLQJRI$[HV
5.3.7. Improving the results for poor programming
,PSURYLQJWKHUHVXOWVIRUSRRUSURJUDPPLQJ
&ORVH3RVLWLRQ$GMXVW
Thanks to the speed limitation, the force accuracy is usually good even for the cases when the
tips are not in contact with the object when the force ramping starts. This will be the case if
the object is thinner than expected or the user has programmed a too large tip distance.
The opposite case, i.e. when the object is thicker than expected is usually not as good.
However, this may be improved by using the parameter &ORVH3RVLWLRQ$GMXVW, in the type 6*
3URFHVV. The parameter value is set in meters and a typical value would be around 0.0005m.
Activating &ORVH3RVLWLRQ$GMXVW usually gives a large improvement for the latter case but
might have a small negative effect on the results for the first case.

7XQLQJRI$[HV
5.3.8. Tuning the calibration routine
7XQLQJWKHFDOLEUDWLRQURXWLQH
*HQHUDO
The RAPID instruction used to find and calibrate the contact position of the gun is called
Calibrate. To improve the accuracy of the calibration, two parameters must normally be
tuned. They are &ROOLVLRQ$ODUP7RUTXH and &ROOLVLRQ'HOWD3RVLWLRQP, belonging to the
type )RUFH0DVWHU
Additional parameters that in some cases may improve the result are &ROOLVLRQ6SHHGPV
and &ROOLVLRQ/3%DQGZLGWK. To begin with these parameters should be left at their default
values.
7XQLQJSURFHGXUH
This procedure describes how to tune the parameters &ROOLVLRQ$ODUP7RUTXH and &ROOLVLRQ
'HOWD3RVLWLRQP.
6WHS $FWLRQ
1. Order a movement with programmed speed equal to the default value of &ROOLVLRQ
6SHHGPV, in the type )RUFH0DVWHU. You need to create your own speeddata
where v_leax is set to the default value of &ROOLVLRQ6SHHGPV. The value in the
system parameters is given in m/s while the value of v_leax should be set in mm/s.
2. Use the Test Signal Viewer and log motor torque (torque_ref) to measure the
maximum torque during the movement. In the Test Signal Viewer, define a low pass
filter with bandwidth equal to the default value of &ROOLVLRQ/3%DQGZLGWK., in the type
)RUFH0DVWHU.

7XQLQJRI$[HV
5.3.8. Tuning the calibration routine
6WHS $FWLRQ
3. Make a RAPID program containing a tune of &ROOLVLRQ$ODUP7RUTXH to a torque-
value two times the absolute value of the maximum torque found in step 2. The
program should also contain a tune of &ROOLVLRQ'HOWD3RVLWLRQ. The initial tune factor
for &ROOLVLRQ'HOWD3RVLWLRQ should be 5mm. The program should also include a
Calibrate instruction and a move to zero position after the calibration. See
example below:
STTune M7C1B1_S , 1.6, CollAlarmTorq;
STTune M7C1B1_S , 0.005, CollContactPos;
! Move to a point about 3cm from contact position
MoveJ p10,speed10,fine,gun1;
Calibrate M7C1B1_S, \TipChg
! Move to zero position of the gun
MoveJ p10,speed10,fine,gun1
STTuneReset M7C1B1_S;
7LSIf you do not have any of the RobotWare - Spot options, but have the option
Servo Tool Control, you can replace the instruction Calibrate with the instruction
STCalib.
4. Execute the RAPID program. Use a thickness gauge to measure the gap between
the tips.
5. Repeat step 4, only changing the tune factor for &ROOLVLRQ'HOWD3RVLWLRQ in step 3
until the calibration works satisfactorily (i.e. the gap is zero). One repetition may be
enough. The new tune factor is calculated by subtracting the gap between the tips
form the last tune factor.
6HWWLQJSDUDPHWHUYDOXHV
When the calibration works satisfactorily (the gap between the tips is zero), enter the new
values of the parameters &ROOLVLRQ'HOWD3RVLWLRQ and &ROOLVLRQ$ODUP7RUTXH in the type
)RUFH0DVWHU. The new values should be equal to the values in the tune instructions.
Make a warm start and test that the calibration works. (Note, if you use the same program then
remove the lines containing the tune.)
6SHHGDQGEDQGZLGWK
Tuning &ROOLVLRQ'HOWD3RVLWLRQand &ROOLVLRQ$ODUP7RUTXH should be enough in most
normal cases. If the calibration is not satisfactory, try to lower the values of &ROOLVLRQ6SHHG
PV or &ROOLVLRQ/3%DQGZLGWK and repeat the tuning procedure.

7XQLQJRI$[HV
5.3.9. Force ready detection
)RUFHUHDG\GHWHFWLRQ
'HILQLQJZKHQRUGHUHGIRUFHKDVEHHQUHDFKHG
The parameters )RUFH'HWHFWLRQ%DQGZLGWK and )RUFH'HWHFWLRQ6SHHG, in the type )RUFH
0DVWHU are involved in deciding when the ordered force has been reached. They should be
left at default values. The effect of increasing the value of any of these two parameters will
be that the system believes ordered force has been reached at an earlier time.

7XQLQJRI$[HV
5.3.9. Force ready detection

6\VWHP3DUDPHWHUV
6.1. System Parameters
6\VWHP3DUDPHWHUV
6\VWHP3DUDPHWHUV
2YHUYLHZ
This section describes the system parameters in a general matter. For more information about
the parameters, see 7HFKQLFDOUHIHUHQFHPDQXDO6\VWHPSDUDPHWHUV.
$FFHOHUDWLRQ'DWD
These parameters belong to the topic 0RWLRQ and the type $FFHOHUDWLRQ'DWD
Nominal Acceleration Axis acceleration in radians/s2. If the value specified is too
high, the motor will reach the torque limit and result in bad path
performance.
Nominal Deceleration Axis deceleration in radians/s2. If the value specified is too
high, the motor will reach the torque limit and the axis will over
shoot in fine points.
$UP
These parameters belong to the topic 0RWLRQ and the type $UP
Upper Joint Bound Upper bound for the axis work area (in radians or meters). The
axis cannot be moved beyond this limit during jogging or
program execution.
Lower Joint Bound Lower bound for the axis work area (in radians or meters). The
axis cannot be moved beyond this limit during jogging or
program execution.
Independent Joint Set parameter to value on in order to activate the possibility to
use independent joint instructions. Default value is off.
Independent Upper Joint Upper bound for the axis work area when operating in
Bound independent mode (in radians or meters).

6\VWHP3DUDPHWHUV
Independent Lower Joint Lower bound for the axis work area when operating in
Bound independent mode (in radians or meters).
%UDNH
These parameters belong to the topic 0RWLRQ and the type %UDNH
Control Off Delay Time delay, used for control off when the speed is less than
Control Off Speed Limit. Motor torque is turned off after the
delay time has expired.
Control Off Speed Limit Speed (ratio of max. speed) at which the time delay starts..
)RUFH0DVWHU
These parameters belong to the topic 0RWLRQ and the type )RUFH0DVWHU.
)RUFH0DVWHU is used to define how a servo gun behaves during force control. The parameters
only affect the servo gun when it is in force control mode.
References Bandwidth The frequency limit for the low pass filter for reference values.
Use ramp time Determines if the ramping of the tip force should use a constant
time or a constant gradient.
Ramp when Increase Determines how fast force is built up while closing the tool when
Force 8VHUDPSWLPH is set to No.
Ramp time Determines how fast force is built up while closing the tool when
8VHUDPSWLPH is set to Yes.
Collision LP Bandwidth Frequency limit for the low pass filter used for tip wear calibration.
Collision Alarm Torque Determines how hard the tool tips will be pressed together during
the first gun closing of new tips calibrations and tool change
calibrations.
Collision Speed Determines the servo gun speed during the first gun closing of new
tips calibrations and tool change calibrations.
Collision Delta Position Defines the distance the servo tool has gone beyond the contact
position when the motor torque has reached the value specified in
&ROOLVLRQ$ODUP7RUTXH.

6\VWHP3DUDPHWHUV
Force Detection The feedback motor speed is filtered through a LP filter with this
Bandwidth bandwidth. This is to avoid that variations in the speed trigger the
force detection too early.
Force Detection Speed When the feedback motor speed is below this value, it is
considered that the ordered force is reached.
Delay ramp Delays the starting of torque ramp when force control is started.
)RUFH0DVWHU&RQWURO
These parameters belong to the topic 0RWLRQ and the type )RUFH0DVWHU&RQWURO.
)RUFH0DVWHU&RQWURO is used to set the speed limit and speed loop gain as functions of the
torque.
No. of speed limits The number of points used to define speed limit and speed loop gain as
functions of the torque. Up to 6 points can be defined.
torque 1 - torque 6 The torque levels, corresponding to the ordered tip force, for which the
speed limit and speed loop gain values are defined.
Speed Limit 1 - 6 6SHHG/LPLW to 6SHHG/LPLW are used to define the maximum speed
depending on the ordered tip force.
Kv 1 - 6 .Y to .Y are used to define the speed loop gain for reducing the
speed when the speed limit is exceeded.
-RLQW
These parameters belong to the topic 0RWLRQ and the type -RLQW.
Logical Axis Used by RAPID programs to identify individual axes. Robots
from ABB normally use the values 1-6, while additional axes
use 7-12.
E.g. the value 7 of /RJLFDO$[LV corresponds to eax_a in the
data type robtarget.

6\VWHP3DUDPHWHUV
/DJ&RQWURO0DVWHU
These parameters belong to the topic 0RWLRQ and the type /DJ&RQWURO0DVWHU. The type
/DJ&RQWURO0DVWHU is normally used for regulation of axes without any dynamicmodel.
Kp, Gain Position Loop The amplification of the position control, e.g. 15. A high value
will give a stiff axis that quickly assumes its new position. The
value should be large without inducing overshoot in the
position or oscillations of the axis.
Kv, Gain Speed Loop The amplification of the velocity control, e.g. 2. A high value
gives better high frequency stiffness, better response speed
and low overshoot. If the value is too high the axis will vibrate.
Ti Integration Time Speed Integration time in the speed regulation loop. The lower the
Loop value of 7L,QWHJUDWLRQ7LPH6SHHG/RRS, the better tracking
and disturbance rejection. Too low value may case oscillation
or noise.
Forced Control Active Determines whether forced gain control is active for this joint.
If set to Yes, $IIHFWV)RUFHG&RQWURO in Supervision should
normally also be set to Yes for this joint (see below).
Forced Factor for Kp The forced factor for .S, if forced gain control is active.
Forced Factor for Ki The forced factor for .L, if forced gain control is active.
Rise Time for Kp The rise time for forced .S
Notch Filter Active Yes (if activated), No (otherwise)
Notch Filter Frequency Frequency of speed variation. Used when 1RWFK$XWR0RGH
is set to No.
Typical value: 2 x Weld speed/Weave length
Notch Filter Width Width of notch filter. A higher value increases the width but can
also have a negative effect on the performance (response) of
the external axis.
Recommended value: 0.2.
Notch Auto Mode If Yes, the notch filter frequency will automatically adjust to the
weave frequency according to the formula.
Typical value: 2 x Weld speed/Weave length

6\VWHP3DUDPHWHUV
Auto No Weave Frequency This frequency is used in the notch filter when 1RWFK$XWR
0RGH is set to Yes, but weaving is not being used or Rapid
Weave is being used.
1RWH: The default value should only be changed by advanced
programmers.
Auto Min Frequency The minimum notch filter frequency when1RWFK$XWR0RGH
is set to Yes.
Auto Max Relative Change Factor that sets the maximum instant change in the notch filter
when 1RWFK$XWR0RGH is set to Yes.
1RWH: The default value should only be changed by advanced
programmers.
FFW Mode Feed forward mode. Possible options are No, Spd or Trq.
Each one corresponds to a different mode of the controller as
described below:
1R: This is the simplest configuration. The controller is driven
by the position error (lag). Because a relatively large lag is
needed to move the axis, the position error can be large.
6SG: In this configuration the controller receives information
about the desired speed of the axis. As a result, the position
lag is greatly reduced compared to the No configuration. For
this reason, Spd is the recommended configuration.
7UT: In this configuration the controller uses the desired speed
and acceleration of the axis to calculate the desired motor
torque.
This requires knowledge of the mass moment of inertia of the
axis, which must be supplied by the user. For this reason this
configuration is more difficult to tune, specially for axes
affected by gravity. It is only recommended for experienced
users.
Bandwidth This parameter should be left at its default value.
Delay This parameter should be left at its default value.
Df Dynamic factor. This parameter is only available in the Trq
configuration. It can be used to damp oscillations of the axis
due to mechanical resonance. Initially Df should be left at its
default value. It can be adjusted once the other controller
parameters have been fixed.
Dw This parameter should be left at its default value.
Inertia Total mass moment of inertia at motor side.

6\VWHP3DUDPHWHUV
K Soft Max Factor Determines the value of the product .S .Y when the soft
servo is used with softness 0%. .6RIW0D[)DFWRUshould be
in the range 0.1 - 2.0 (default 1.0). When the soft servo is
activated with 0% softness, the control parameters .S and .Y
will be tuned such that .S .Y .S .YQRUPDO .6RIW0D[
)DFWRU, where .S .YQRUPDO is the product of .S and .Y
during normal operation
K Soft Min Factor Determines the value of the product .S .Y if the soft servo is
used with softness 100%. .6RIW0LQ)DFWRU should be in the
range 0.001 - 0.1 (default 0.01). When the soft servo is
activated with 100% softness, the control parameters .S and
.Y are tuned such that .S .Y .S .YQRUPDO .6RIW0LQ
)DFWRU.
Kp/Kv Ratio Factor Factor used to alter the .S.Y ratio during soft servo. .S.Y
5DWLR)DFWRU should be in the range 0.1 - 1.0 (default 1.0). In
soft servo mode, .S and .Y are tuned such that .S.Y .S
.YQRUPDO * .S.Y5DWLR)DFWRU.
Ramp Time Default time for activation of the soft servo. The default value
is 0.5 s.
0HDVXUHPHQW&KDQQHO
These parameters belong to the topic 0RWLRQ and the type 0HDVXUHPHQWFKDQQHO
Disconnect at Deactive The measurement channel for a deactivated motor can be
disconnected (Yes/No).
:$51,1*
If the axis is moved when disconnected, the position of the
axis might be wrong after reconnecting, and this will not be
detected by the controller. The position after reconnection will
be correct if the axis not is moved, or if the movement is less
than 0.5 motor revolutions. For servo guns, there is a RAPID
calibration method available (the ToolChange calibration) that
will adjust any positional error caused by gun movement
during disconnection.

6\VWHP3DUDPHWHUV
0HFKDQLFDO8QLW
These parameters belong to the topic 0RWLRQ and the type 0HFKDQLFDO8QLW.
Name Change name of the unit. This name will be used later in the
Jogging window and in the program, e.g. when a unit is
activated.
Use Activation Relay Points out a relay that will be activated or deactivated when
the mechanical unit is activated or deactivated.
Use Brake Relay Points out which brake relay will be activated or deactivated
when the mechanical unit goes to state control on or control
off.
Use Connection Relay Points out a relay that must be activated when the mechanical
unit is activated.
Allow Move of User Frame Unit can move a user frame, e.g. a work object.
Standby State The unit is controlled and the brakes are not released until the
first movement instruction is executed or until it is moved
manually.
Activate at Start Up Unit is automatically activated when starting.
Deactivation Forbidden Unit must not be deactivated.
0RWRU&DOLEUDWLRQ
These parameters belong to the topic 0RWLRQ and the type 0RWRUFDOLEUDWLRQ
Commutator Offset The motor angle when voltage is applied between the phases
S and T.
For ABB motors &RPPXWDWRU2IIVHW should always be 1.5708.
Calibration Offset Can be updated by moving the axes to their calibration
positions and then fine-calibrating from the Service window.

6\VWHP3DUDPHWHUV
0RWRU7\SH
These parameters belong to the topic 0RWLRQ and the type 0RWRUW\SH
Polepairs Number of pole pairs for the motor, typically 2 or 3.
ke Phase to Phase (Vs/rad) Nominal voltage constant, induced voltage phase to phase
(1V/1000rpm <=> 0.00955 Vs/rad).
Max current (A rms) Max. current without irreversible demagnetization.
Phase resistance (Ohm) Stator phase resistance (half the resistance value measured
between incoming phases).
Phase inductance (H) Stator phase inductance (half the resistance value measured
between incoming phases).
5HOD\
These parameters belong to the topic 0RWLRQ and the type 5HOD\V
Name Name of the relay, (max. 16 characters), must be the same as
the Use connection relay parameter defined in Types:
Mechanical Unit.
Output signal Denotes the logical name of the output signal to the relay. The
name must be identical (including upper and lower case
letters) to the name used for the signal definition.
Input signal Denotes the logical name of the input signal to the relay. The
name must be identical (including upper and lower case
letters) to the name used for the signal definition.

6\VWHP3DUDPHWHUV
6*3URFHVV
These parameters belong to the topic 0RWLRQ and the type 6*3URFHVV
Sync check off By setting this parameter to ‘Yes’, it will be possible to close
the gun without having done a tip calibration. This is useful
during the tuning procedure of a servo gun or if running an
application where tip calibrations not are used. When running
the gun in production, it is recommended to always have the
sync check active in order to prevent possible damage caused
by closing an unsynchronized pair of gun tips
Close Time Adjust Constant time adjustment (s), positive or negative, of the
moment when the gun tips reaches contact during a gun
closure. This value is normally zero. May be used to delay the
closing slightly when the synchronized pre closing is used for
welding.
Close Position Adjust When the tool tips reach the position (plate thickness) ordered
by the close instruction, the force control starts. This tool tip
position can be adjusted with &ORVH3RVLWLRQ$GMXVW to make
the force control start earlier.
Force Ready Delay Constant time delay (s) before sending the weld ready signal
after reaching the programmed force.
Max Force Control Motor Maximum allowed motor torque (Nm) during force control. The
Torque parameter will protect the gun from too high programmed
force, by reducing the resulting motor torque to this upper
level. A warning will be logged whenever this happens. The
value must not be set higher than the Torque abs. max (types:
Stress duty cycle) which defines the maximum output of motor
torque during both force and position control.
Post-synchronization Time Release time anticipation (s) of the next robot movement after
a weld. This parameter can be tuned to synchronize the gun
opening with the next robot movement. The synchronization
may fail if the parameters is set too high.
Calibration Mode The number of closings performed during a Tipwear
calibration. Normally 2 closings will be ok. An increase may
improve the accuracy of thickness detection for some servo
guns.
Calibration Force High The maximum tip force (N) used during a TipWear calibration.
For best result of the thickness detection, it is recommended
to use the max programmed weld force.

6\VWHP3DUDPHWHUV
Calibration Force Low The minimum tip force (N) used during a TipWear calibration.
For best result of the thickness detection, it is recommended
to use the minimum programmed weld force.
Calibration Time The wait time (s) during a calibration before the positional gun
tip correction is done. Recommended value ca: 0.5 s.
Number of Stored Forces Number of stored forces in the force VS motor torque table.
The minimum value allowed is 2.
Tip Force 1 - 10 Gun tip force 1 (N)..........Gun tip force 10 (N)
Motor Torque 1 - 10 Motor torque 1 (Nm).........Motor torque 10 (Nm)
6LQJOH7\SH
These parameters belong to the topic 0RWLRQ and the type 6LQJOH7\SH.
Mechanics • TRACK - Linear track motion
• FREE_ROT - Rotating additional axis
• EXT_POS - Used internally
• TOOL_ROT - Used internally
• SG_LIN - Linear servo gun motion
6WUHVV'XW\&\FOH
These parameters belong to the topic 0RWLRQ and the type 6WUHVV'XW\&\FOH
Torque Absolute Max Max. allowed torque (Nm).
Speed Absolute Max Max allowed motor rotation speed (radians/s).
6XSHUYLVLRQ
These parameters belong to the topic 0RWLRQ and the type 6XSHUYLVLRQ
Affects Forced Control Determines whether this joint affects forced gain control.
Forced on Position Limit The upper position limit for forced gain control.

6\VWHP3DUDPHWHUV
Forced off Position Limit The lower position limit for forced gain control.
6XSHUYLVLRQ7\SH
These parameters belong to the topic 0RWLRQ and the type 6XSHUYLVLRQ7\SH
Max Force Control Position Maximum allowed movement of the gun arm (m) during force
Error control from expected close position (= programmed plate
thickness).
1RWH a small positional movement is natural, depending on
the flexibility of the gun arm. The program will be stopped if
this limit is exceeded. The limit may be exceeded if for
instance a tip is lost or if the programmed plate thickness is too
high.
Max Force Control Speed Maximum override of the gun speed limit during force control.
Limit ([DPSOH 0D[)RUFH&RQWURO6SHHG/LPLW = 1.2 will supervise
the gun speed in order to not exceed the speed limit (defined
in type )RUFH0DVWHU&RQWURO).
Influence Group Influence Group is set to the same value for all mechanical
units whose movements affect each other.
A mechanical unit that has no influence on other mechanical
units has ,QIOXHQFH*URXS set to 0. The default ,QIOXHQFH
*URXS for the robot is 1.
([DPSOH A track motion with a robot on it should have
,QIOXHQFH*URXS set to 1.
7UDQVPLVVLRQ
These parameters belong to the topic 0RWLRQ and the type 7UDQVPLVVLRQ
Transmission Gear Ratio Gear ratio between motor and axis.
For linear axis gear ratio is specified as motor rotation in
radians per meter linear move (21.43 denotes that when the
motor rotates 21.43 radians - the axis moves 1 m).
Rotating Move Denotes whether the axis is of the rotating type <HV or linear
type 1R.

6\VWHP3DUDPHWHUV
Transmission High Gear The integer value of the numerator of the transmission gear
ratio. Only used for independent joints.
Transmission Low Gear The integer value of the denominators of the transmission
gear ratio. Only used for independent joints.
([DPSOH For a rotating axis with high gear 100 and low gear
30, has a transmission gear ratio of 100/30=3.333333.
8QFDOLEUDWHG&RQWURO0DVWHU
These parameters belong to the topic 0RWLRQ and the type 8QFDOLEUDWHG&RQWURO0DVWHU.
The type 8QFDOLEUDWHG&RQWURO0DVWHU is used to regulate uncalibrated axes.
Kp, Gain Position Loop The amplification of the position control, e.g. 15. A high value
will give a stiff axis that quickly assumes its new position. The
value should be large without inducing overshoot in the
position or oscillations of the axis.
Kv, Gain Speed Loop The amplification of the velocity control, e.g. 2. A high value
gives better high frequency stiffness, better response speed
and low overshoot. If the value is too high the axis will vibrate.
Ti Integration Time Speed Integration time in the speed regulation loop. The lower the
Loop value of 7L,QWHJUDWLRQ7LPH6SHHG/RRS, the better tracking
and disturbance rejection. Too low value may case oscillation
or noise.
Speed Max Uncalibrated Max speed for uncalibrated axis(rad/s on motor side).
Acceleration Max Max acceleration for uncalibrated axis (rad/s2 on motor side)
Uncalibrated Recommended value: Nominal Acceleration * Transmission
Gear Ratio.
Deceleration Max Max deceleration for uncalibrated axis (rad/s2 on motor side)
Uncalibrated Recommended value: Nominal Deceleration * Transmission
Gear Ratio.

,QGH[
&
capacitor 13
Collision Alarm Torque 128
Collision Delta Position 128
Collision LP Bandwidth 128
Collision Speed 128
Configuration of the drive system 13
'
Delay ramp 129
Drive unit Node 22
drive units 13
)
filters 13
Force Detection Bandwidth 129
Force Detection Speed 129
Force Master 128
Force Master Control 129
.
Kv 1 - 6 129
1
No. of speed limits 129
5
Ramp time 128
Ramp when Increase Force 128
rectifiers 13
References Bandwidth 128
6
servo drive units 13
Speed Limit 1 - 6 129
7
torque 1 - torque 6 129
8
Use ramp time 128
3HAC 021 395-001 Revision: A 139

3HAC021395 001RevB

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

3HAC021395 001RevB

Uploaded by

Copyright:

Available Formats

Application manual

Document ID: 3HAC 021 395-001

© Copyright 2004 ABB All right reserved.

3HAC 021 395-001 Revision: A 3

4 3HAC 021 395-001 Revision: A

3HAC 021 395-001 Revision: A Draft 5

6 Draft 3HAC 021 395-001 Revision: A

3HAC 021 395-001 Revision: A Draft 7

• 5$3,'UHIHUHQFHPDQXDOSDUW: Description of all RAPID instructions.

8 Draft 3HAC 021 395-001 Revision: A

3HAC 021 395-001 Revision: A Draft 9

10 Draft 3HAC 021 395-001 Revision: A

3HAC 021 395-001 Revision: A Draft 11

12 Draft 3HAC 021 395-001 Revision: A

3HAC 021 395-001 Revision: A Draft 13

'HVFULSWLRQ $UWQR 1RWH

14 Draft 3HAC 021 395-001 Revision: A

3HAC 021 395-001 Revision: A Draft 15

16 Draft 3HAC 021 395-001 Revision: A

3HAC 021 395-001 Revision: A Draft 17

18 Draft 3HAC 021 395-001 Revision: A

3HAC 021 395-001 Revision: A Draft 19

3RVLQILJXUH ,GHQWLILFDWLRQ 'HVFULSWLRQ $UWQR 1RWH

20 Draft 3HAC 021 395-001 Revision: A

3HAC 021 395-001 Revision: A Draft 21

22 Draft 3HAC 021 395-001 Revision: A

0DLQGULYHXQLW 'ULYH8QLW1RGH $[LV

3HAC 021 395-001 Revision: A Draft 23

5RERWW\SH 3ULPDU\YROWDJH 9 (IIHFW N9$

24 Draft 3HAC 021 395-001 Revision: A

3HAC 021 395-001 Revision: A Draft 25

26 Draft 3HAC 021 395-001 Revision: A

DSQC 617_3B3A 400 V • min 280 V

3RZHUVWDJH7\SH 5DWHGFXUUHQW $ UPV 0D[FXUUHQW $ UPV

3HAC 021 395-001 Revision: A Draft 27

3RZHUVWDJH7\SH 5DWHGFXUUHQW $ UPV 0D[FXUUHQW $ UPV

28 Draft 3HAC 021 395-001 Revision: A

3HAC 021 395-001 Revision: A Draft 29

30 Draft 3HAC 021 395-001 Revision: A

3HAC 021 395-001 Revision: A Draft 31

32 Draft 3HAC 021 395-001 Revision: A

3DUW 'HVFULSWLRQ 6SHFLILFDWLRQV

3HAC 021 395-001 Revision: A Draft 33

3DUW 'HVFULSWLRQ 6SHFLILFDWLRQV

34 Draft 3HAC 021 395-001 Revision: A

3HAC 021 395-001 Revision: A Draft 35

Voltage (Pulse-Width Modulated) 400-480 VAC

The system input characteristics is:

36 Draft 3HAC 021 395-001 Revision: A

3HAC 021 395-001 Revision: A Draft 37

38 Draft 3HAC 021 395-001 Revision: A

3HAC 021 395-001 Revision: A Draft 39

SLQ'VXE 60%LQSXW 5HVROYHUFRQQHFWLRQ &RORUUHVROYHUZLUHV

6WHS $FWLRQ ,QIR,OOXVWUDWLRQ

40 Draft 3HAC 021 395-001 Revision: A

6WHS $FWLRQ ,QIR,OOXVWUDWLRQ

3HAC 021 395-001 Revision: A Draft 41

42 Draft 3HAC 021 395-001 Revision: A

A R2.SMB 1-2 (D-sub 15 socket)

3HAC 021 395-001 Revision: A Draft 43

44 Draft 3HAC 021 395-001 Revision: A

6LJQDOV &RQWDFWSRLQW60% &RQWDFWSRLQW5HVROYHU

3HAC 021 395-001 Revision: A Draft 45

• 5$3,'UHIHUHQFHPDQXDOSDUW: Description of all RAPID instructions.

'HVFULSWLRQ $UWQR 1RWH

3RVLQILJXUH ,GHQWLILFDWLRQ 'HVFULSWLRQ $UWQR 1RWH

5RERWW\SH 3ULPDU\YROWDJH9 (IIHFWN9$

3RZHUVWDJH7\SH 5DWHGFXUUHQW$ UPV 0D[FXUUHQW$ UPV

3RZHUVWDJH7\SH 5DWHGFXUUHQW$ UPV 0D[FXUUHQW$ UPV

SLQ'VXE 60%LQSXW 5HVROYHUFRQQHFWLRQ &RORUUHVROYHUZLUHV

6WHS $FWLRQ ,QIR,OOXVWUDWLRQ

6WHS $FWLRQ ,QIR,OOXVWUDWLRQ

3RZHU $GGD[ /RJLFDO 'ULYHXQLW

3RZHU $GGD[ /RJLFDO 'ULYHXQLW

0HDVXUHPHQW %RDUG 60% 60%

0RWRU 0RWRU 0RWRU

6WHS $FWLRQ ,QIR,OOXVWUDWLRQ

6WHS $FWLRQ ,QIR,OOXVWUDWLRQ

6WHS $FWLRQ ,QIR,OOXVWUDWLRQ

6WHS $FWLRQ ,QIR,OOXVWUDWLRQ

6WHS $FWLRQ ,QIR,OOXVWUDWLRQ

6WHS $FWLRQ ,QIR,OOXVWUDWLRQ

6WHS $FWLRQ ,QIR,OOXVWUDWLRQ