1. © Reference - 1 - 01-04-06 - New safety system for Arc Welding products and systems.

2. APM 01085A J. Nilsson 2002.02.21 - 2 New safety system. Why? Some facts. Increased flexibility User friendly, status information on the teach pendant Simplified local engineering Required for the new positioners and the next generation of robot controller Easier assembly and less wiring The new safety system is reqiured for the new positioner program. It is not backward compatible with the present system. The B* and D* positioners still use the current safety system. New Safety System * New version ready Q3 2002

3. APM 01085A J. Nilsson 2002.02.21 - 3 New Safety System Market input is received from the following MC`s. USA Canada Italy France Germany Great Britain The System Unit

4. APM 01085A J. Nilsson 2002.02.21 - 4 Function Present systemNew system Gate supervision. X X External gate reset. X X Station supervision, two stations. X X Supervision of motor contactors. X X 2-level light beams. X X Manual reset of safety system X X Home position X X Programming from the load area (Activation unit) X X Designed for the new station interchange units. X Designed for the 4-station index positioner X New Safety System Blue = Required for the new positioners

5. APM 01085A J. Nilsson 2002.02.21 - 5 Function Present systemNew system Transport position X Tooling interlock X Status information X Visualisation of functions X Prepared for hatch or roll door. X Prepared for different signals from light beams(Four variants) X Output from safety system X Service position X New Safety System Green = New functionality Require the GPP (Ready Q2) Require S5 and the new teach pendant

6. APM 01085A J. Nilsson 2002.02.21 - 6 New Safety System The safety interface Casing Base PCB Optional PCB´s Terminals Relays Dimensions: L x W x H: 240 x 180 x 120 mm

7. APM 01085A J. Nilsson 2002.02.21 - 7 New Safety System The safety interface C/R/K/E/F B/D** C x 3 C x 4 S/L/A/T 2x(S/L/A/T) Positioner Base board incl. CAN DeviceNet. Optional board 1 Optional board 2 Pre reset External gate reset Home position Transport position ** Ready Q3 2002

8. APM 01085A J. Nilsson 2002.02.21 - 8 New Safety System New type of light beam SICK MSL - series The following products will be equipped with this light beam: All Function Packages with the new positioners. The FlexArc´s

9. APM 01085A J. Nilsson 2002.02.21 - 9 New Safety System New Operators Panel The new operators panel is made for the new safety system and the new positioner range. It is compatible with GPP and is not interchangeable with the current type. The following products will be equipped with the new panel. All Function Packages with the new positioners. The FlexArc The FlexArcCompact (Q3 2002)

10. APM 01085A J. Nilsson 2002.02.21 - 10 New Safety System New Operators Panel Indicator: Entrance Permitted Emergency Stop Push-button: Operator ready / Reset Push-button: Program Start Push-button Program Stop Push-button: Menu Indicator: Error This variant is for stations with one load area e.g. one fixed table, L, T, A and positioners with a station interchange unit.

11. APM 01085A J. Nilsson 2002.02.21 - 11 New Safety System New Operators Panel Indicator: Entrance Permitted Emergency Stop Push-button: Operator ready / Reset Push-button: Program Start Push-button Program Stop Push-button: Menu Indicator: Error This variant is for stations with two load areas e.g. two fixed tables, L, T and A positioners.

12. APM 01085A J. Nilsson 2002.02.21 - 12 New Safety System Designed for the new station interchange units. Software supervision performed by the robot control system. Hardware supervision (position switch) performed by the safety interface. Interchange supervision

13. APM 01085A J. Nilsson 2002.02.21 - 13 New Safety System Designed for the 4-station index positioner.

14. APM 01085A J. Nilsson 2002.02.21 - 14 New Safety System Tooling interlock Prevent automatic clamping of the work piece while the operator is within the load area. Signals from the light beams / roll door* and station indication switches* are distributed to the tooling control system. Valves for clamping devices on tooling Tooling control system Safety interface SIB5 * *

15. APM 01085A J. Nilsson 2002.02.21 - 15 New Safety System Status information. Program Stop Service door open Please close the door and reset the system. Information from the safety system in plain language. Ready Q2 2002.

16. APM 01085A J. Nilsson 2002.02.21 - 16 New Safety System Prepared for roll door and hatch. Roll door open Roll door closed Safety interface SIB5 A timer in the safety interface resets the safety system from the moment the operator has pressed the operator ready until the door/hatch is closed. The time is set on the teach pendant. Roll door control system

17. APM 01085A J. Nilsson 2002.02.21 - 17 New Safety System Prepared for signals from different brands of light beams. Configuration of output from the light beam Relay 2 x NO Relay 1 x NO 1 x NC Transistor 1 x PNP 1 x NPN Transistor 1 x PNP Transistor 1 x PNP 1 x PNP INV Activated Not activated Activated Not activated Activated Not activated PNP +24V NPN 0V PNP ---- NPN ---- PNP +24V PNP ---- PNP +24V PNP INV ---- PNP --- PNP INV +24V Activated = Light beam is broken

18. APM 01085A J. Nilsson 2002.02.21 - 18 New Safety System Output from safety system When the safety system is activated a dedicated output signal is set. Can be used for alarm signals etc. Digital I/O CAN-bus

19. APM 01085A J. Nilsson 2002.02.21 - 19 New Safety System Station Indication for two working areas and one service position Part number: Safety interface: 504773-880 Station indication for IRB1400: 504960-880 or Station indication for IRB2400: 504962-880 The operator can enter both areas when the robot is in the service position. Area 1 Area 2 Service position Note! Operator panel, door interlock and pre-reset unit are not shown.

20. APM 01085A J. Nilsson 2002.02.21 - 20 New Safety System Home position for stations with one working area. Part number: Safety interface: 504773-880 Home position switch for IRB 1400: 504964-880 or Home position switch for IRB 2400: 504966-880 Home position The operator can enter the load area when the robot is in the home position. Note! Operator panel, door interlock and pre-reset unit are not shown.

21. APM 01085A J. Nilsson 2002.02.21 - 21 New Safety System Station Indication for two working areas with RTT Part number: Safety interface: 504773-880 Station indication for IRB1400: 504960-880 or Station indication for IRB2400: 504962-880 Area 1 Area 2 Area 1 Service position Please see next page. Note! Operator panel, door interlock and pre-reset unit are not shown.

22. APM 01085A J. Nilsson 2002.02.21 - 22 New Safety System Station Indication for two working areas and transport position with RTT. Part number: Safety interface: 504773-880 Station indication for IRB1400: 504960-880 Home position switch for IRB 1400: 504964-880 or Station indication for IRB2400: 504962-880 Home position switch for IRB 2400: 504966-880 Area 1 Area 2 The operator can enter both areas when the robot is in the transport position. Transport position Note! Operator panel, door interlock and pre-reset unit are not shown.

23. APM 01085A J. Nilsson 2002.02.21 - 23