Robots are dangerous, use this test plug information entirely at your own risk!
These are specifications for a test plug, or shorting plug for ABB IRB 1500 robots with S3 or S3E (compact) cabinet. The 1500 has a single chain safety circuit which may not meet with local legislation. If in doubt please check with the local authority in charge of health and safety issues. By putting in place an overiding safety circuit that is "double chain" that governs the robot the problem may be overcome.
The 1500 typically has been used for welding and so almost by default has a weld interface board, this is below the computer and I/O cards mounted on a plate on the back wall of the cabinet. The safety circuit is routed through this interface board. The connector for safety is a 37 way D type connector. This is the connector into which the shorting plug has to be connected. There are also alternate connections on some 1500 cabinets. If in doubt double check continuity at this point (connector X1) as described below.
Please note that this should only be used for test purposes. Under no circumstances should a robot be run in Automatic mode without proper safety systems that comply with local legislation. This will almost certainly include guarding, safety interlocks etc. Please also consider that the robot may over balance and fall if it is not bolted down securely.
Parts required:
1 x 37 way D type male (plug) connector, this can be any type but to avoid the use of tooling use the solder bucket type. RS part number 446-490 which is unfortunately only available in packs of 5.
7 x short lengths of connecting wire of approx 0.5mm2 or 20 AWG.
Tools required:
Wire cutters,
Wire strippers,
Soldering iron
Connections to be made:
|
Pins to Connect |
|
1 to 2 |
|
9 to 10 |
|
11 to 26 |
|
17 to 35 |
|
20 to 21 |
|
31 to 34 |
|
36 to 37 |
Some 1500's will have not been used for MIG welding and so will not have a Weld Interface card. These may require a different safety plug that must be made to connect the following on the B12.X1 plug:
| Pins to connect | Circuit |
| 7 to 10 | Work hold |
| 8 to 9 | Extra enabling devices |
| 11 to 12 | Safety Hold |
| 22 to 23 | Customer E stop |
| 19 to 20 | Ext. drive units POWER OK |
| 40 to 41 | Motor PTC axis 7 * |
| 38 to 39 | 7th (-12th) * |
These connections allow programming in teach.
contact us.
