Escolar Documentos
Profissional Documentos
Cultura Documentos
Table of Contents
Overview
Product Documentation, IRB 940 Tricept
Chapter 1: Safety, service
Introduction
Safety, service - General
Section A: References
Limitation of Liability
Applicable Safety Standards
Related information
Section B: Safety risks
Pre-installation procedure
Working range, IRB 940 Tricept
Risk of tipping/Stability
Section B: On-site installation
3HAC 16638-1
1
3
5
5
6
7
7
7
8
9
9
9
9
10
10
11
13
13
13
14
14
15
15
15
17
17
18
20
21
21
22
22
26
27
28
28
Table of Contents
C - 1: Signal/Power cables
Connecting the manipulator to the control cabinet, S4Cplus cabling
Connectors on control cabinet, S4Cplus
Connectors on distributed drive unit, DDU
Connection of mains power to control cabinet, S4Cplus
C - 2: Signal connections
Signal Classes
Selecting Cables
Interference elimination
Connection types
Connections to screw terminals
Connections to connectors
C - 3: Customer connections on controller
The MOTORS ON/MOTORS OFF circuit
External customer connections on panel X1 - X4
Connection of external safety relay
ii
31
35
39
40
44
46
47
47
49
52
53
53
54
54
56
56
57
58
59
64
68
68
68
70
71
72
74
74
75
77
79
80
81
81
81
91
94
3HAC 16638-1
Table of Contents
C - 4: Supplies
External 24V supply
24V I/O supply
115/230 VAC supply
C - 5: Buses
Connection of the CAN bus
Interbus-S, slave DSQC 351
Profibus-DP, slave DSQC 352
C - 6: I/O units
Distributed I/O units
Distributed I/O, digital sensors
Distributed I/O, digital I/O DSQC 328 (option)
AD Combi I/O, DSQC 327 (optional)
Analog I/O, DSQC 355 (optional)
Encoder interface unit, DSQC 354 (optional)
Relay I/O, DSQC 332 (optional)
Digital I/O (120 VAC), DSQC 320 (optional)
C - 7: Communication
Communication concept, Allen-Bradley
RIO, remote I/O for Allen-Bradley PLC DSQC 350
Communication, serial links
Communication, Ethernet
External operators panel
Section D: Start-up
BootImage
Start window
Reboot Window
Boot Disk Window
3HAC 16638-1
96
96
98
99
99
99
104
110
114
114
115
116
120
124
130
136
140
144
144
146
149
154
157
159
159
160
162
162
164
166
168
173
175
180
182
184
184
185
187
188
iii
Table of Contents
189
190
192
193
194
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200
iv
200
201
202
203
204
207
207
208
208
210
211
211
215
216
219
222
222
224
231
231
3HAC 16638-1
Overview
About This
Manual
Usage
This manual should be used during installation, from lifting the manipulator to its
work site through installing application software in the robot controller, making
the robot ready for operation.
Prerequisites
Organization of
Chapters
Chapter
3HAC 16638-1
Contents
1.
Safety, service
2.
Reference Information
3.
Manipulator
4.
Controller
5.
Calibration
References
Reference
Document Id
Revisions
Revision
Description
First edition
3HAC 16638-1
General
Overview,
Installation and
Commissioning
Manual
The Installation and Commissioning Manual contains the following main chapters:
Overview, Repair
Manual
Overview,
Maintenance
Manual
3HAC 16638-1
Safety, Service
Reference Information
Unpacking
On-site Installation
Electrical connections
Start-up
Robot controller
Calibration
Safety, Service
Reference Information
Safety, Service
Reference Information
Maintenance schedules
Maintenance activities
Disposal
The chapters for the maintenance activities include instructions for all the maintenance activities specified in the maintenance schedule.
3HAC 16638-1
Safety, service
Definitions
This chapter details safety information for service personnel i.e. personnel performing installation, repair and maintenance work.
Sections
B. Safety risks lists dangers relevant when servicing the robot system.
The dangers are split into different categories:
Safety risks related to end effector
Safety risks related to tools/workpieces
Safety risks related to pneumatic/hydraulic systems
Safety risks during operational disturbances
Safety risks during installation and service
Risks associated with live electric parts
3HAC 16638-1
Safety, service
Validity and
responsibility
The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment, which can influence the safety
of the total system. To protect personnel, the complete system must be designed
and installed in accordance with the safety requirements set forth in the standards
and regulations of the country where the robot is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable
safety laws and regulations in the country concerned are observed and that the
safety devices necessary to protect people working with the robot system have
been designed and installed correctly. Personnel working with robots must be
familiar with the operation and handling of the industrial robot, described in the
applicable documents, e.g. Users Guide and Product Manual.
Connection of
external safety
devices
Apart from the built-in safety functions, the robot is also supplied with an interface for the connection of external safety devices. Via this interface, an external
safety function can interact with other machines and peripheral equipment. This
means that control signals can act on safety signals received from the peripheral
equipment as well as from the robot.
In the Product Manual - Installation and Commissioning, instructions are provided for connecting safety devices between the robot and the peripheral equipment.
3HAC 16638-1
Safety, service
References
Section A: References
Limitation of Liability
General
Any information given in this information product regarding safety, must not be
construed as a warranty by ABB Robotics that the industrial robot will not cause
injury or damage even if all safety instructions have been complied with.
Standards
3HAC 16638-1
Safety, service
References
Related information
General
Documents
Type of information
Detailed in document
Users Guide
Section
Start-up
3HAC 16638-1
Safety, service
Safety risks
Safe handling
It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure
that guards remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
General
Residual energy
Safe design
3HAC 16638-1
Residual energy may be present in these systems so, after shutdown, particular care must be taken.
Gravity may cause any parts or objects held by these systems to drop.
Shot bolts should be used to prevent tools, etc., from falling due to gravity.
Safety, service
Safety risks
General
Qualified
personnel
Extraordinary
risks
The industrial robot is a flexible tool which can be used in many different
industrial applications.
All work must be carried out professionally and in accordance with the
applicable safety regulations.
Remedial action must only be carried out by qualified personnel who are
familiar with the entire installation as well as the special risks associated
with its different parts.
If the working process is interrupted, extra care must be taken due to risks other
than those associated with regular operation. Such an interruption may have to be
rectified manually.
Nation/region
specific regulations
10
Those in charge of operations must make sure that safety instructions are
available for the installation in question.
Those who install the robot must have the appropriate training for the robot
system in question and in any safety matters associated with it.
To prevent injuries and damage during the installation, lifting and transport of the
robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with.
3HAC 16638-1
Safety, service
Safety risks
Non-voltage
related risks
To be observed
by the supplier of
the complete system
Turntables or the like should be used to keep the operator out of the
robot's working space.
The axes are affected by the force of gravity when the brakes are released
or when the motors or other components are removed.
Never use the robot as a ladder, i.e. do not climb on the robot motors or
other parts during service work. There is a serious risk of slipping because
of the high temperature of the motors or oil spills that can occur on the
robot.
The supplier of the complete system must ensure that all circuits used in
the safety function are interlocked in accordance with the applicable standards for that function.
The supplier of the complete system must ensure that all circuits used in
the emergency stop function are interlocked in a safe manner, in accordance with the applicable standards for the emergency stop function.
Voltage related
risks, general
3HAC 16638-1
The mains supply to the robot must be connected in such a way that it can
be turned off outside the robots working space.
11
Safety, service
Safety risks
Voltage related
risks, controller,
S4Cplus
Units inside the controller, e.g. I/O modules, can be supplied with power
from an external source.
The power supply unit for the computer system (230 VAC)
The rectifier unit (400-480 VAC and 700 VDC. N.B.: Capacitors!)
The power supply unit for tools, or special power supply units for the
machining process
The external voltage connected to the control cabinet remains live even
when the robot is disconnected from the mains.
Additional connections
Voltage related
risks, manipulator, IRB 940 Tricept
Voltage related
risks, tools, material handling
devices, etc.
Tools, material handling devices, etc., may be live even if the robot system is in
the OFF position. Power supply cables which are in motion during the working
process may be damaged.
12
The user connections for tools or other parts of the installation (max. 230V
AC, see Product Manual - Installation and Commissioning)
3HAC 16638-1
Safety, service
Safety actions
General
Install a safety cell around the robot to ensure safe robot installation and operation.
Dimensioning the
fence or enclosure
- withstand any impact from a tool failure. Due to the high kinetic energy
associated with HSM (High Speed Machining), a tool failure poses a serious risk as any debris can cause serious personal injury. Both walls and
ceilings must be designed and dimensioned so that they can withstand any
projectiles that they may be subjected to. Windows must be made of suitable safety glass. Study the planned process to determine the forces
involved and appropriate materials.
- isolate gases and mist generated by the machining process and spray
mist lubrication. Study the planned process to determine the fumes
involved and appropriate ventilation/filtering system.
Fire extinguishing
Use a CARBON DIOXIDE (CO 2 ) extinguisher in the event of a fire in the robot
(manipulator or controller)!
3HAC 16638-1
13
Safety, service
Safety actions
Description
In an emergency situation, any of the manipulators axes may be released manually by pushing the brake release buttons on the distribution box for the manipulator. How to release the brakes is detailed in section "Manually releasing the
brakes" in the Installation Manual.
The manipulator arms may be moved manually when the brakes has been
released.
Increased injury
Before releasing the brakes, make sure that the weight of the arms does not
increase the pressure on the trapped person, further increasing any injury!
Brake testing
When to test
During operation the holding brakes of each axis motor wear normally. A test may
be performed to determine whether the brake can still perform its function.
How to test
The function of each axis motor holding brakes may be checked as detailed
below:
1. Run each manipulator axis to a position where the combined weight of
the manipulator arm and any load is maximized (max. static load).
2. Switch the motor to the MOTORS OFF position with the Operating
mode selector on the controller.
3. Check that the axis maintains its position.
If the manipulator does not change position as the motors are switched off, then
the brake function is adequate.
14
3HAC 16638-1
Safety, service
Safety actions
3HAC 16638-1
15
Safety, service
Safety actions
16
3HAC 16638-1
Reference Information
General
3HAC 16638-1
This chapter presents generic pieces of information, complementing the more specific information in the following chapters.
17
Reference Information
Screw joints
General
This section details how to tighten the various types of screw joints in the manipulator as well as the controller.
The instructions and torque values are valid for screw joints comprising metallic
materials and do not apply to soft or brittle materials.
Any instructions given in the repair, maintenance or installation procedure
description override any value or procedure given here, i.e. these instruction are
only valid for standard type screw joints.
Tightening torque
Screws with
slotted or cross
recess head
Screws with
hexagon socket
head
18
The tightening torque values for different types of screw joint are specified in the
tables below:
Dimension
M2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
Dimension
Tightening
torque (Nm)
Class 8.8 "dry"
Tightening
torque (Nm)
Class 10.9
Tightening
torque (Nm)
Class 12.9
M5
M6
10
17
M8
24
28
40
M10
47
55
70
M12
82
95
120
3HAC 16638-1
Reference Information
3HAC 16638-1
Dimension
Tightening
torque (Nm)
Class 8.8 "dry"
Tightening
torque (Nm)
Class 10.9
Tightening
torque (Nm)
Class 12.9
M16
200
235
300
19
Reference Information
Weight specifications
Definition
In all repair and maintenance instructions, weights of the components handled are
sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in
this way.
ABB recommends handling all components with a weight exceeding 22 kg using
lifting equipment to avoid inflicting injury.
Example
20
3HAC 16638-1
Manipulator
Chapter 3:Manipulator
Introduction
Definitions
3HAC 16638-1
This chapter contains necessary information for installing the manipulator to the
working site.
21
Manipulator
Unpacking
Section A: Unpacking
Pre-installation procedure
General
This instruction is primarily intended for use when unpacking and installing the
manipulator (mechanical robot) for the first time. It also contains information useful during later re-installation of the manipulator.
The checklist below details what must be observed before proceeding with the
actual installation of the manipulator:
1. Make sure only qualified installation personnel, conforming to all
national and local codes, are allowed to perform the installation.
2. Make sure the manipulator has not been damaged, by visually inspecting the manipulator and control cabinet exterior.
3. Make sure the lifting device to be used is dimensioned to handle the
weight of the manipulator as stated in Weight, manipulator.
4. If the manipulator is not to be installed directly, it must be stored as in
Storage conditions, manipulator.
5. Make sure the appointed operating environment of the manipulator
conforms to the specifications as in Operating conditions, manipulator.
6. Before taking the manipulator to its installation site, make sure the site
conforms to Loads on flange, manipulator and Protection classes.
7. Before moving the manipulator, please observe Risk of tipping/Stability
regarding risk of tipping!
8. When these prerequisites have been met, the manipulator may be
taken to its installation site as in Lifting manipulator in a horizontal/vertical orientation.
22
3HAC 16638-1
Manipulator
Unpacking
Weight,
manipulator
3HAC 16638-1
Manipulator model
Weight
570 kg
Distribution box
31 kg
23
Manipulator
Unpacking
Loads on flange,
manipulator
The table below shows the maximum forces and torques working on the manipulator during operation.
NOTE! These forces and torques are extreme values that are rarely encountered
during operation. The values also never reach their maximum simultaneously!
Tz
xx0200000362
24
Force
Force xy
51 kN
Force z
68 kN
Torque xy
14 kNm
Torque z
45 kNm
3HAC 16638-1
Manipulator
Unpacking
Storage
conditions,
manipulator
Operating
conditions,
manipulator
The table below shows the allowed storage conditions for the manipulator and the
distribution box:
Parameter
Value
-25C
+55C
+55C
The table below shows the allowed operating conditions for the manipulator and
the distribution box:
Parameter
Value
+5C
+45C
Note! The robot must not be operated until the internal temperature of the robot is
stabilized within the prescribed operational temperature range!
Protection
classes
3HAC 16638-1
The table below shows the protection class of the main parts of the robot system:
Equipment
Protection class
Manipulator
IP 66
Distribution box
IP 67
Overpressure unit
IP 67
25
Manipulator
Unpacking
Illustration
The illustration below shows the unrestricted working range of IRB 940 Tricept:
400
0
400
800
800
1200
800
400
400
800
1200
1200
800
400
400
800
1200
(mm)
(mm)
xx0200000356
26
3HAC 16638-1
Manipulator
Unpacking
Risk of tipping/Stability
General
The section below details how to make sure the manipulator does not tip over
before it has not been safely secured to the foundation.
Stability
The figure below shows the robot in its shipping position which also is the most
stable.
The robot must be placed on a spacer, at least 100mm in height, in order to avoid
the risk of collision with the axis 2 servomotor.
B
xx0200000357
The table below specifies the most stable position of each axis of the manipulator.
Axis
Position
Note
1, 2, 3
26 mm
4, 6
-90
1. DO NOT change the manipulator position before securing it to its foundation. The shipping position is the most stable.
3HAC 16638-1
27
Manipulator
On-site installation
General
The section below details how to lift the manipulator in a horizontal orientation
from a transportation pallet to a stand.
Required equipment
Equipment
Note
Crane or hoist
1 strap, length 2 m
2 straps, length 1 m
M16
2 shackles
The section below details how to lift and move the manipulator from the transportation pallet, horizontally, using the lifting equipment specified above.
The IRB 940 manipulator weighs 570 kg! All lifting equipment used must be dimensioned accordingly!
Failure to attach the straps correctly can cause the suspended load to tilt suddenly
and cause both personal injury and severe damage to the load.
28
3HAC 16638-1
Manipulator
On-site installation
Step Action
Note
1.
2.
xx0200000317
3.
4.
xx0200000318
3HAC 16638-1
29
Manipulator
On-site installation
Step Action
5.
Note
C
xx0200000319
30
6.
7.
A: Strap, 1 m (2 pcs)
B: Shackle (2 pcs)
C: Eyebolt (2 pcs)
3HAC 16638-1
Manipulator
On-site installation
General
The section below details how to lift the manipulator from a transportation pallet
to a stand, after turning it into a vertical orientation.
Notice that there are two different ways of turning the manipulator into a vertical
orientation. The section below details a method using a trolley or a machine skate,
that is used to wheel the front of the manipulator towards the centre of the lift as
the manipulator is hoisted.
Required equipment
Lifting in vertical
orientation, using
a trolley
Equipment
Note
Crane or hoist
2 straps, length 2 m
M16
2 shackles
The section below details how to lift and move the manipulator from the transportation pallet, vertically, using the lifting equipment specified above.
The IRB 940 manipulator weighs 570 kg! All lifting equipment used must be dimensioned accordingly!
3HAC 16638-1
31
Manipulator
On-site installation
Failure to attach the straps correctly can cause the suspended load to tilt suddenly
and cause both personal injury and severe damage to the load.
- Ensure that the area around the manipulator is clear as the machine can swing
round as it leaves the pallet!
- Ensure that the trolley has free movement while lifting. If the trolley gets stuck, the
manipulator is likely to fall off and can cause personal injury and damage to the
manipulator!
Step Action
Note
1.
2.
C
xx0200000320
3.
32
A: Strap, 2 m (2 pcs)
B: Shackle (2 pcs)
C: Eyebolt (2 pcs)
3HAC 16638-1
Manipulator
On-site installation
Step Action
4.
Note
A
B
C
E
xx0200000321
5.
3HAC 16638-1
A: Strap, 2 m (2 pcs)
B: Wrist unit
C: Trolley
D: 125 mm
E: 400 mm
xx0200000322
33
Manipulator
On-site installation
Step Action
Note
6.
As the manipulator is
lifted off the pallet, carefully remove the pallet
to allow free movement
of the trolley towards
the centre of the lift, as
shown in the adjacent
figure.
7.
8.
xx0200000323
xx0200000324
34
3HAC 16638-1
Manipulator
On-site installation
General
The section below details how to lift the manipulator from a transportation pallet
to a stand, after turning it into a vertical orientation.
Notice that there are two different ways of turning the manipulator into a vertical
orientation. The section below details a method using a lifting jack.
Required equipment
Lifting in vertical
orientation, using
a lifting jack
Equipment
Note
Crane or hoist
2 straps, length 2 m
1 strap, length 1 m
M16
2 shackles
Lifting jack
The section below details how to lift and move the manipulator from the transportation pallet, vertically, using the lifting equipment specified above.
The IRB 940 manipulator weighs 570 kg! All lifting equipment used must be dimensioned accordingly!
Failure to attach the straps correctly can cause the suspended load to tilt suddenly
and cause both personal injury and severe damage to the load.
3HAC 16638-1
35
Manipulator
On-site installation
Step Action
Note
1.
2.
C
xx0200000320
3.
36
A: Strap, 2 m (2 pcs)
B: Shackle (2 pcs)
C: Eyebolt (2 pcs)
3HAC 16638-1
Manipulator
On-site installation
Step Action
4.
Note
xx0200000317
5.
xx0200000325
6.
3HAC 16638-1
B: Crane
37
Manipulator
On-site installation
Step Action
7.
Note
xx0200000326
8.
38
3HAC 16638-1
Manipulator
On-site installation
General
The section below details how to release the holding brakes of each axis motor.
This may be done by:
Supplying power on the wrong pin may cause all brakes on the manipulator to be
released!
Internal brake
release unit
This section details how to release the holding brakes using the internal brake
release unit.
When releasing the holding brakes, the manipulator axes may move very quickly
and sometimes in unexpected ways! Make sure no personnel is near the manipulator arm!
Step Action
3HAC 16638-1
Info/Illustration
1.
The push-button unit is equipped with six but- The push-button unit is
tons for controlling the axis brakes. The but- located on the outside of
tons are numbered with the axes numbers.
the distribution box.
2.
39
Manipulator
On-site installation
General
This section details how to orient and secure the manipulator at the stand in order
to run the robot safely.
The cable harness should be installed in the stand before the manipulator is
mounted to it. Installation of the cabling is described in chapter "Electrical connections".
Attachment
screws
The table below specifies the type of securing screws and washers to be used for
securing the manipulator to the foundation. Securing screws are included in the
delivery of the manipulator.
MC6S, M16 x 55
Quality
Quality 8.8
Suitable washer
Thickness: 4 mm
Tightening torque
200 Nm
A locating pin may be used in the mounting flange, when necessary. The dimension for the attachment hole is detailed in part "Hole configuration, mounting
flange".
40
3HAC 16638-1
Manipulator
On-site installation
Illustration,
securing manipulator at stand
The figure below shows how to mount the manipulator to a stand. The figure
shows prepared cabling in the stand.
xx0200000348
3HAC 16638-1
Centering ring
Mounting flange
41
Manipulator
On-site installation
Securing the
manipulator
This section details how to secure the manipulator to the stand in a vertical position, after fitting the stand to the foundation.
Step
42
Action
Info/Illustration
1.
Lift and turn the manipulator to vertical orien- Detailed in "Lifting the
tation.
manipulator in a vertical
orientation, using a trolley/lifting jack".
2.
3.
4.
5.
Specified in "Attachment
screws".
Shown in figure above!
Note! Lightly lubricate the
bolts before assembly!
6.
3HAC 16638-1
Manipulator
On-site installation
The illustration below shows the hole configuration used when securing the
manipulator. Note that the holes are not equally spaced on the flange.
A-A
(400)
350
53
86.5
C-C
18 Through
8x)
3
10 H8 Through
87.5
xx0200000358
3HAC 16638-1
43
Manipulator
On-site installation
General
Illustration, fitting
of extra equipment on upper
platform
The illustration below shows the mounting holes available for fitting extra equipment on the upper platform.
309.5
x M8x12 Deep
xx0200000360
44
3HAC 16638-1
Manipulator
On-site installation
Illustration, fitting
on mounting
flange
The illustration below shows the mounting holes available for fitting equipment
on the mounting flange.
xx0200000359
Fastener quality
When fitting tools on the mounting flange (see the figure above), use only screws
with quality 12.9. When fitting other equipment, standard screws with quality 8.8
can be used.
A guiding pin may be used when fitting equipment on to the tool flange. Attach
the pin to the extra equipment using a press fit, in order to make sure that the pin
remains in the equipment when removing it from the flange.
3HAC 16638-1
45
Manipulator
On-site installation
Loads
General
Any loads mounted on the manipulator must be defined correctly and carefully
(with regard to the position of centre of gravity and inertia factor) in order to avoid
jolting movements and overloading the motors. If this is not done correctly operational stops may result.
References
Load diagrams, permitted extra loads (equipment) and their positions are specified in the Product Specification. The loads must also be defined in the software
as detailed in the Users Guide.
Brake performance
Manipulator motor brake performance depends on any loads attached. For further
information about brake performance, please contact ABB Robotics.
46
3HAC 16638-1
Manipulator
Electrical connections
General
The manipulator is connected to the control cabinet via a distribution box, after
mounting it on the stand.
The section below describes how to install the cabling on board the manipulator.
All the necessary cabling is included in the delivery of the robot but must be connected both to the manipulator and to the distribution box.
All cabling is specified in the part "Connecting the manipulator to the control
cabinet, manipulator (/controller) cabling"
The figure below shows how the cabling is installed to the manipulator.
xx0200000349
3HAC 16638-1
47
Manipulator
Electrical connections
Installation of
cabling on board
the manipulator
Step
Action
Note/Illustration
1.
2.
Connect the cables, axes 1-2-3, Connection points detailed in "Conto the motors of axes 1-2-3. Fit the necting the manipulator to the concables to the brackets mounted
trol cabinet, manipulator cabling".
nearby the motors and secure
with straps.
3.
4.
5.
Connection points detailed in "Connecting the manipulator to the control cabinet, manipulator cabling".
4x
4x
xx0200000428
48
3HAC 16638-1
Manipulator
Electrical connections
General
Description
Manipulator cables
The cables between the distribution box and the manipulator motors are specially manufactured with extra
strong screening. The cabling for each motor consists
of two separate cables, one power cable and one signal
cable. The cabling contains conductors for:
The power cable contains conductors for:
Motor phases
Earth connection
Motor brake
3HAC 16638-1
Handles power supply to and control of the manipulator's motors as well as feedback from the serial measurement board.
49
Manipulator
Electrical connections
Manipulator
cables
The manipulator cables are included in the standard delivery. They are completely
pre-manufactured and ready to plug in.
The cabling transfers drive power and resolver data for drive and control of the six
axes.
Distribution box
cables
Cable sub-category
XM1
XM1.1
XR1
XR1.1
XM2
XM2.1
XR2
XR2.1
XM3
XM3.1
XR3
XR3.1
XM4
XM4.1
XR4
XR4.1
XM5
XM5.1
XR5
XR5.1
XM6
XM6.1
XR6
XR6.1
These cables are included in the standard delivery. They are completely pre-manufactured and ready to plug in.
Cable subcategory
Distribution box
cable, power
50
Description
Transfers drive
power from the
drive units in the
control cabinet to
the manipulators
distribution box.
Connection
Connection point,
point, cabinet distribution box
XS1
R1.MP
3HAC 16638-1
Manipulator
Electrical connections
Cable subcategory
Distribution box
cable, signals
Description
Connection
Connection point,
point, cabinet distribution box
R1.SMB
Distribution box
cable, power
Cable
Article number
3HAC 11818-1
3HAC 11818-2
3HAC 11818-4
Cable
Article number
3HAC 7998-1
3HAC 7998-2
3HAC 7998-4
Distribution box
cable, signals
3HAC 16638-1
51
Manipulator
Electrical connections
General
Section "Connecting the distribution box to the control cabinet" specifies which
cables to use in order to connect the manipulators distribution box to the controller.
Connectors on
the distribution
box
R1.SMB
R1.MP
XM4
XM1
XM5
XM2
XM6
XM3
XR1
XR2
XR3
XR4
XR5
XR6
xx0200000430
The connectors on the controller cabinet are located as detailed in part "Connectors on the controller cabinet, S4CPlus".
52
3HAC 16638-1
Controller
Chapter 4:Controller
Introduction
Definitions
3HAC 16638-1
This chapter contains necessary information for installing the controller to the
working site.
53
Controller
Unpacking
Section A: Unpacking
Transporting and unpacking, S4Cplus
General
Before starting to unpack and install the robot system, read the safety regulations
and other instructions very carefully. These are found in separate sections in the
Users Guide and Product manual.
The installation must be done by qualified installation personnel and should conform to all national and local codes.
When you have unpacked the cabinet, check that it has not been damaged during
transport or while unpacking.
Weight,
controller cabinet
Storage
conditions,
controller cabinet
The table below shows the weights for the controller cabinet:
Controller
Weight
240 kg
30 kg
The table below shows the allowed storage conditions for the controller:
Parameter
Value
-25C
+55C
54
3HAC 16638-1
Controller
Unpacking
The table below shows the allowed operating conditions for the controller:
Operating conditions, controller
cabinet
Protection class,
controller
3HAC 16638-1
Parameter
Value
+5C
+45C
Equipment
Protection class
Control cabinet
IP 54
Programming unit
IP 54
IP 54
55
Controller
On-site Installation
Lifting device
Use the four lifting devices on the cabinet or a fork lift when lifting the controller
cabinet S4Cplus as shown below.
The figure below shows the minimum angle between the lifting straps and the
cabinet when lifting the controller.
B
xx0100000153
Cabinet delivered
without top cover
56
Fork lift
If the controller is delivered without its top cover, a fork lift must be used. Do not
use lifting devices!
3HAC 16638-1
Controller
On-site Installation
Dimensions
The figure below shows the required installation space for the S4CPlus control
cabinet:
A
200
200
800
800
820
950
980*
500
70
620
xx0100000156
3HAC 16638-1
57
Controller
On-site Installation
Dimensions
The figure below shows the bolt pattern for the S4CPlus control cabinet:
720
400
xx0100000157
58
3HAC 16638-1
Controller
On-site Installation
The external power transformer (option) is located outside the controller as shown
in the figure below:
B
A
xx0100000154
Cable glands for input and output cables (large gland; input cable, small
gland; output cable)
Required equipment
Equipment, etc.
3HAC 16638-1
Note
3HAC 11668-1
Input cables
Rec. 16 mm 2
Output cables
Rec. 6 mm 2
59
Controller
On-site Installation
Equipment, etc.
Note
Circuit breaker
Dimensioned for
the expected currents
Standard toolkit
3HAC 15571-1
Connections
3HAC 5582-2
3HAC 11668-11
The procedure below details how to connect the external power transformer unit.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supply to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it!
Before handling, make sure you are connected to earth through a special ESD
wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD
protection button for connection of the bracelet. Use it!
Step
60
Action
Note/Illustration
1.
2.
Detailed in "Transformer
input" below!
3HAC 16638-1
Controller
On-site Installation
Step
Shop mains
power supply
Action
Note/Illustration
3.
4.
Detailed in "Controller
input" below!
The procedure below details how to connect the Shop mains power supply.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supply to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it!
Before handling, make sure you are connected to earth through a special ESD
wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD
protection button for connection of the bracelet. Use it!
Step
1.
Transformer input
Action
Note/Illustration
Make sure the shop supply is fitted with suit- Fuse size specified in the
able circuit breakers and fuses.
table above!
Step
1.
3HAC 16638-1
Action
Note/Illustration
61
Controller
On-site Installation
Step
Transformer
output
Action
Note/Illustration
2.
3.
4.
5.
Tightening torque:
approx. 2 Nm
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supply to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it!
Before handling, make sure you are connected to earth through a special ESD
wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD
protection button for connection of the bracelet. Use it!
Step
62
Action
Note/Illustration
1.
Run a cable from the transformer unit through Shown in the figure
the output cable outlet to the robot controller. above!
2.
3.
4.
Tightening torque:
approx. 2 Nm
3HAC 16638-1
Controller
On-site Installation
Controller input
Step
Note/Illustration
1.
2.
3.
4.
3HAC 16638-1
Action
Phase 2 to L2
Phase 3 to L3
0 to XT26.N
A
B
C
D
xx0100000155
A: Terminal X26
B: Connectors
D: Cable glands
63
Controller
On-site Installation
The external DDU (option) is located outside the control cabinet. The figure
below shows the required installation space for the DDU.
300
xx0200000340
64
3HAC 16638-1
Controller
On-site Installation
The DDU is to be suspended nearby the control cabinet, using the bolt pattern
shown in the figure below.
260
xx0200000374
Connection to
earth
If the difference of potential between the control system and the DDU is too large
or there are suspicions of shorter drops in voltage, the DDU must be connected to
earth. This is done at the connection point GND (see the part "Connectors on the
DDU").
Fan cooling
The main power from the control cabinet also feeds two fans in the DDU via an
internal transformer with three input taps.
The transformer wires are connected as
3HAC 16638-1
65
Controller
On-site Installation
Overheating
Changing the
connection of the
transformer
A line voltage lower than 480V is used, while the fans are connected as
480V. This causes a reduced fan cooling. See Changing the connection of
the transformer below.
The fuse, located at the screw terminal, has caused the fans to stop.
Too heavy drive at too high ambient temperature. See the manual External axes.
The default connection of the transformer is the nominal mains input 480V. The
cooling is, however, reduced, when a lower line voltage is used and there may be
a risk that the drive unit is triggered at a high surrounding temperature. Therefore,
if the line voltage differs from 480V, it is recommended to switch over the default
connection to 440V or 400V instead.
To change the voltage, remove the lid of the DDU and switch the connections on
the screw terminals (see the part "Connections to screw terminals").
66
3HAC 16638-1
Controller
On-site Installation
Increasing the
airflow
xx0200000373
Cabling
3HAC 16638-1
Vent
Covering plate
67
Controller
Electrical connections
General
Connect the manipulator and control cabinet to each other after securing them to
the foundation. The lists below specify which customer cables to be used.
Manipulator cabling is specified in chapter Manipulator, section Electrical
connections.
Customer cables
68
These cables are not included in the standard delivery, but are included in the
delivery of each specific option. The cables are not ready to plug in, but require
connection to terminals inside the control cabinet as well as keying. These activities are detailed in Customer Connection Kit.
Connection Connection
point,
point,
cabinet
manipulator
Cable
Art. no.
3HAC 13173-1
XT/XP5.1
XT/XP6
XS6
R1.CP/CS
3HAC 13173-2
XT/XP5.1
XT/XP6
XS6
R1.CP/CS
3HAC 13173-4
XT/XP5.1
XT/XP6
XS6
R1.CP/CS
3HAC 13174-1
XT/XP5.1
XT/XP6
DP/M
R1.CP/CS
XT/XP5.1
XT/XP6
DP/M
R1.CP/CS
3HAC 16638-1
Controller
Electrical connections
Cable
3HAC 16638-1
Art. no.
Connection Connection
point,
point,
cabinet
manipulator
XT/XP5.1
XT/XP6
DP/M
R1.CP/CS
3HAC 14890-4
R1.CP/CS
3HAC 14890-1
R1.CP/CS
3HAC 14890-6
R1.CP/CS
R1.CP/CS
3HAC 15644-1
R1.CP/CS
3HAC 15644-5
R1.CP/CS
69
Controller
Electrical connections
General
Connections to
the cabinet
xx0100000247
70
**
3HAC 16638-1
Controller
Electrical connections
General
The section "Connecting the manipulator to the control cabinet" specifies which
cables to use and to which connectors these are to be connected, in order to connect the DDU (distributed drive unit) to either the controller, the manipulator or
to the external axis.
Connections to
the DDU
S77
XS78
XP40
GND
XP49
xx0200000372
The connections on the manipulator are located on the rear of the robot base.
3HAC 16638-1
71
Controller
Electrical connections
General
Connect the power supply either inside the cabinet, or to a optional socket on the
left-hand side of the cabinet or the lower section of the front. The cable connector
is supplied but not the cable.
Dimension the mains supply cables and fuses in accordance with the rated power
and line voltage, see rating plate on the controller.
Connections to
the mains switch
C
D
xx0100000248
XT 26
Cable gland
Connector
Step
1.
72
Action
Info/Illustration
3HAC 16638-1
Controller
Electrical connections
Step
Connection
through a power
socket
Action
Info/Illustration
2.
3.
4.
Connect phase:
1 to L1 (Not dependent on phase
sequence)
2 to L2
3 to L3
5.
6.
7.
It is possible to connect the mains supply via an industrial Harting connector (DIN
41 640). See the figure below:
Cable connectors are supplied (option 132 - 134).
A
xx0100000162
3HAC 16638-1
DIN connector
73
Controller
Electrical connections
C - 2: Signal connections
Signal Classes
Overview
Signals
74
Different rules apply to the different classes when selecting and laying cable. Signals from different classes must not be mixed.
Control signals: Digital operating and data signals (digital I/O, safety
stops, etc.).
3HAC 16638-1
Controller
Electrical connections
Selecting Cables
Controller cables:
Power Signal:
Control signals:
Shielded cables.
Measuring
signals:
A thin cable according to DeviceNet specification release 1.2, must be used, e.g.
ABB article no. 3HAB 8277-1. The cable is shielded and has four conductors, two
for electronic supply and two for signal transmission.
Note that a separate cable for suppling I/O loads is required.
3HAC 16638-1
75
Controller
Electrical connections
Allen-Bradley
Remote I/O:
Interbus-S:
Cables according to Phoenix specification, e.g. "Green type", should be used for
connections between the DSQC 351 and external Interbus-S bus.
Profibus DP:
Ethernet:
76
3HAC 16638-1
Controller
Electrical connections
Interference elimination
External units
External relay coils, solenoids, and other units that will be connected to the controller must be neutralized. The figure below illustrates how this can be done.
The turn-off time for DC relays increases after neutralization, especially if a diode
is connected across the coil. Varistors give shorter turn-off times. Neutralizing the
coils lengthens the life of the switches that control them.
Clamping with a
diode
The diode should be dimensioned for the same current as the relay coil, and a
voltage of twice the supply voltage.
+24V
0V
xx0100000163
Clamping with a
varistor
The varistor should be dimensioned for the same current as the relay coil, and a
voltage of twice the supply voltage.
+24V
0V
xx0100000164
3HAC 16638-1
77
Controller
Electrical connections
Clamping with an
RC circuit
0V
xx0100000165
78
3HAC 16638-1
Controller
Electrical connections
Connection types
General
I/O, external emergency stops, safety stops, etc. can be supplied on screw connections or as industrial connectors.
Connections
3HAC 16638-1
Designation
Connection type
X(T)
Screw terminal
XP
Pin (male)
XS
Sockets (female)
79
Controller
Electrical connections
Overview
Installation
The installation should comply with the IP54 (NEMA 12) protective standard.
1. Bend unused conductors backwards and attach them to the cable
using a clasp, or similar.
To prevent interference, ensure that unused conductors are not connected at the
other end of the cable (antenna effect).
In environments with much interference, disconnected conductors should be
grounded (0V) at both ends.
80
3HAC 16638-1
Controller
Electrical connections
Connections to connectors
Location of connectors
If ordered, industrial connectors can be found on the left-hand side or front of the
control cabinet (depending on the customer order). Also see the figure in section
"Connectors on control cabinet"!
The manipulator arm (not IRB 940 Tricept) is equipped with round Burndy/Framatome connectors (customer connector not included).
Connectors,
description
Each industrial connector has accommodation for four rows of 16 conductors with
a maximum conductor area of 1.5 mm 2. The pull-relief clamp must be used when
connecting the shield to the case.
Outline diagram
3HAC 16638-1
81
Controller
Electrical connections
A
E
C
D
H
J
R
N
P
xx0100000174
82
ES (emergency stop)
LS (Limit switch)
Contactor
Mains
Drive unit
Manual mode
Motor
Automatic mode
RUN
EN1
3HAC 16638-1
Controller
Electrical connections
EN2
Function of the
MOTORS ON/
MOTORS OFF circuit
The circuit monitors all safety related equipment and switches. If any of the
switches is opened, the MOTORS ON/MOTORS OFF circuit switches the power
to the motors off.
Connection of
safety chains
3HAC 16638-1
As long as the two chains are not identical, the robot will remain in MOTORS
OFF mode.
The supply from internal 24V (X3/X4:12) and 0 V (X3/X4:7) is displayed. For an
external supply of GS and AS, X3/X4:10,11 is connected to 24V and X3/X4:8,9
is connected to external 0V. Connection tables for X1-X4 are given in "External
customer connections on panel X1 - X4".
83
Controller
Electrical connections
24V
X3:12
X4:12
Ext LIM1
24V
K1
0V
X1:11 12
ES1
X3:10
Opto GS1
isol.
TPU En1
8
11
&
Opto AS1
isol.
Auto1
K1
EN
Run
Intern
locking
K2
Man1
External contactors
0V
24 V
0V
X3:3
X4:3
4
4
CONT1
CONT2
Ext LIM2
X2:11 12
K2
Opto GS2
isol.
TPU En2
11
9
Drive Unit
ES2
X4:10
24 V
&
Opto AS2
isol.
Auto2
Man2
xx0100000166
84
Limit switch
Load: 300 mV
Max. voltage drop: 1 V
External connectors
Load: 10 mA
Max. voltage drop: 4 V
GS/AS load at 24 V
25 mA
>18 V
<5V
Max. + 35 VDC
Min. - 35 VDC
3HAC 16638-1
Controller
Electrical connections
3HAC 16638-1
300 V
Signal class
Control signals
85
Controller
Electrical connections
Connection of
ES1/ES2 on panel
unit
The diagram below shows the terminals for the emergency circuits.
The supply from internal 24V (X1/X2:10) and 0V (X1/X2:10) is displayed. For
an ext. supply, X1/X2:3 is connected to ext. 24V and X1/X2:8 is connected to ext.
0V (dotted lines).
A
24V 0V
B
X1:3
1:4
X1:7
X1:10
X1:9
X1:8
X1:1
X1:2
24V
X1:6
E
24V
G
24V 0V
F
B
2:4
X2:7
X2:8
X2:1
X2:2
24V
X2:6
H
24V
X2:4
X2:5
J
xx0100000191
86
3HAC 16638-1
Controller
Electrical connections
Internal
Ext shop
TPU
Cabinet
ES1 internal
Internal
ES2 internal
Technical data
3HAC 16638-1
120 VAC: 4 A
48 VDC L/R: 50 mA
24 VDC L/R: 2 A
24 VDC R load: 8 A
40 mA
300 V
Signal class
Control signals
87
Controller
Electrical connections
Connection to
MOTORS ON/
MOTORS OFF
contactor
The diagram below shows the connection of terminals for customer use.
A
B
X3:2
1
X4:2
1
xx0100000193
K1 (Motor on/off 1)
K1 (Motor on/off 2)
Technical data
88
Max. voltage
48 VDC
Max. current
4A
300 V
Signal class
Control signals
3HAC 16638-1
Controller
Electrical connections
Connection to
operating mode
selector
The diagram below shows the connection of terminals for customer use.
S1.1.x1 8
A
7
6
5
S1.1.x1 4
D
3
2
1
xx0100000197
Auto 1
MAN1
100% (Option)
Auto 2
MAN2
100% (Option)
Technical data
3HAC 16638-1
Max. voltage
48 VDC
Max. current
4A
300 V
Signal class
Control signals
89
Controller
Electrical connections
Connection to
brake contactor
The diagram below shows the connection of terminals for customer use.
A
X4:5
6
xx0100000199
K3 (Brake)
Technical data
90
Max. voltage
48 VDC
Max. current
4A
300 V
Signal class
Control signals
3HAC 16638-1
Controller
Electrical connections
Outline diagram
The diagram shows the customer connections X1 - X4 located on the panel unit.
WARNING
REMOVE JUMPERS BEFORE CONNECTING
ANY EXTERNAL EQUIPMENT
xx0100000205
grey field
Connection of X1:
12-pole type
Phoenix COMBICON connector
3HAC 16638-1
Jumper
Signal
ES1 out: A
ES1 out: B
ES1 top
24 V panel
ES1 internal
Sep. ES1: A
Sep. ES1: B
91
Controller
Electrical connections
Connection of X2:
12-pole type
Phoenix COMBICON connector
Connection of X3:
12-pole type
Phoenix COMBICON connector
Signal
ES1 bottom
0V
10
Ext. LIM1: A
11
Ext. LIM1: B
12
Signal
ES2 out: A
ES2 out: B
ES2 top
0V
ES2 internal
Sep. ES2: A
Sep. ES2: B
ES2 bottom
24 V panel
10
Ext. LIM2: A
11
Ext. LIM2: B
12
Signal
92
Ext. MON 1: A 1
Motor contactor 1
Ext. MON 1: B 2
Motor contactor 1
3HAC 16638-1
Controller
Electrical connections
Connection of X4:
12-pole type
Phoenix COMBICON connector
Signal
0V
External contactor 1 0 V
CONT1
External contactor 1
No connection
No connection
0V
GS1-
AS1-
GS1+
10
AS1+
11
24 V panel
12
Signal
3HAC 16638-1
Ext. MON 2: A 1
Motor contactor 2
Ext. MON 2: B 2
Motor contactor 2
24 V panel
External contactor 2 24 V
CONT2
External contactor 2
Ext. BRAKE A 5
Ext. BRAKE B 6
0V
GS2-
AS2-
GS2+
10
AS2+
11
24 V panel
12
93
Controller
Electrical connections
Description
The motor contactors K1 and K2 in the controller can operate with external equipment if external relays are used.
The figure below shows two examples of how to connect the external safety
relays:
94
3HAC 16638-1
Controller
Electrical connections
Connection
examples
X4:4
CONT 2
24 V X4:3
E xt MON 2
X4:2
0V
K2
X4:1
X3:2
K1
E xt MON 1
X3:1
24 V
0 V X3:3
CONT 1 X3:4
E
AS
AS
GS
GS
F
G
E
K
H
J
xx0100000246
3HAC 16638-1
Panel unit
95
Controller
Electrical connections
Robot 1
Robot 2
External supply
Safety relay
To other equipment
Safety gate
C - 4: Supplies
External 24V supply
How to connect
the external supply
When there is a risk that major interference can be carried over into the
internal 24V supply.
The external supply neutral wire must be connected to the chassis such that the
maximum permitted potential difference in the chassis earth is not exceeded. For
example, a neutral wire can be connected to the chassis earth of the controller, or
some other common earthing point.
Technical data
Potential difference to chassis earth Max. 60 V continuously
Max. 500 V during 1 minute
96
3HAC 16638-1
Controller
Electrical connections
3HAC 16638-1
97
Controller
Electrical connections
General
24 VDC supply
available at XT 31
98
The 24V I/O is not galvanically separated from the rest of the controller voltages.
Voltage
24.0 - 26.4V
Ripple
Max. 0.2V
Max. 7A
Current limit
13,5 ~0A.
XT.31.2
24 V (through a 2 A fuse)
XT.31.1
XT.31.4
3HAC 16638-1
Controller
Electrical connections
General
This voltage is used in the robot for supplying optional service outlets. The AC
supply is not galvanically separated from the rest of the controller voltages.
Voltage
Max. 500 VA
6.3 A
3.15 A
XT.21.1-5
230 VAC
XT.21.6-8
115 VAC
XT.21.9-13
C - 5: Buses
Connection of the CAN bus
Illustration
3HAC 16638-1
The illustration below shows an example of how to connect the CAN bus:
99
Controller
Electrical connections
C
A
X6 CAN1.2
X7 CAN1.3
G
D
D
E
X15, X6, X7
1.
2.
3.
4.
5.
0V_CAN
CAN_L
drain
CAN_H
24V_I/O
1.
2.
3.
4.
5.
xx0100000241
100
CAN bus
3HAC 16638-1
Controller
Electrical connections
Control cabinet
I/O
CAN 1.1
Used for internal I/O unit mounted inside the cabinet. No terminating resistor is
fitted on CAN 1.1 regardless of whether any I/O units are used or not. CAN 1.1 is
connected to socket X15 on the Base connector unit (see Connection of the CAN
bus).
CAN 1.2
If CAN 1.2 is not used, a terminating resistor must be connected to the X6 socket
(exceptional case see below!).
If CAN 1.2 is used, the terminating resistor should be moved to the last I/O unit
on the CAN 1.2 chain.
If CAN 1.2, for example, is not connected at the end of any CAN chain but somewhere between the end points of the chain, then no terminating resistor should be
mounted in CAN 1.3. This is in accordance with the basic rule, i.e. the CAN chain
should be terminated in both end points.
CAN 1.3
3HAC 16638-1
101
Controller
Electrical connections
Termination
resistors in CAN
bus
The CAN chain must be terminated with terminating resistors at each end!
CAN 2
The illustration below shows an example of how to connect the CAN 2 bus:
If CAN 1.2, for example, is not connected at the end of any CAN chain but somewhere between the end points of the chain, then no terminating resistor should be
mounted in CAN 1.3.
B
D
X8 CAN 2
1. 0V_CAN
2. CAN_L
3. drain
4. CAN_H
5. 24V_I/O
X8
1. 0V_CAN
2. CAN_L
3. drain
4. CAN_H
5. 24V_I/O
1.
2.
3.
4.
5.
xx0100000242
102
Controller
I/O
3HAC 16638-1
Controller
Electrical connections
A
B
C
D
xx0100000243
3HAC 16638-1
103
Controller
Electrical connections
General
Supply
The Interbus-S slave must be fed externally to avoid shutting down the InterbusS net if a robot cell is switched off. The 24V power supply must be fed from
outside the control cabinet and be connected to pin 2 on the Phoenix connector
located on the Interbus-S cards front panel marked 24V.
Technical data
Further information
For setup parameters, see Users Guide - System Parameters, Topic: Controller.
Also see the Circuit Diagram.
Unit ID
The unit ID to be entered in the Interbus-S master is 3. The length code depends
on the selected data. Width between 1 and 4.
Layout, DSQC
351
The figure below shows the layout of the DSQC 351 board:
104
3HAC 16638-1
Controller
Electrical connections
X20
X21
X5
X3
xx0100000225
Communication
concept
X3
Power connector
X5
DeviceNet connector
X20
Interbus-S, input
X21
Interbus-S, output
3HAC 16638-1
105
Controller
Electrical connections
E
A
B
In
C
Out
In
*1
D
Out
In
Out
*1
xx0100000224
Master PLC
64 inputs/64 outputs
*1
xx
Termination link
A link is connected between pins 5 and 9 in the plug on the interconnection cable
connected to the OUT connector of each unit. The link informs the Interbus-S unit
that more units are connected further out in the chain. (The last unit in the chain
does not have a cable connected and therefore no link).
Connections, X5
DeviceNet connectors
106
3HAC 16638-1
Controller
Electrical connections
Connections,
connector X20,
Interbus-S IN
6
9
xx0100000220
The table below shows the connections to connector X20, Interbus-S IN:
Connections,
connector X21,
Interbus-S OUT
Signal name
X20 pin
Function
TPDO1
TPDI1
GND
Ground connection
NC
Not connected
NC
Not connected
TPDO1-N
TPDI1-N
NC
Not connected
NC
Not connected
6
9
xx0100000220
The table below shows the connections to connector X21, Interbus-S OUT:
3HAC 16638-1
107
Controller
Electrical connections
Connections,
connector X3
Signal name
X21 pin
Function
TPDO2
TPDI2
GND
Ground connection
NC
Not connected
+5V
+ 5 VDC
TPDO2-N
TPDI2-N
NC
Not connected
RBST
Synchronization
xx0100000221
108
Signal name
X3 pin
Function
0 VDC
NC
Not connected
GND
Ground connection
NC
Not connected
+ 24 VDC
+ 24 VDC
The designations refer to LEDs shown in the figure in section "Layout, DSQC
352" above.
3HAC 16638-1
Controller
Electrical connections
The figure and table below show the location and significance of the LEDs on the
board.
3HAC 16638-1
Designation
Color
Description
POWER-24 VDC
Green
NS/MS
Green/red
CAN Tx/CAN Rx
Green/red
POWER- 5 VDC
Green
Lit when both 5 VDC supplies are within limits, and no reset is active.
RBDA
Red
BA
Green
RC
Green
109
Controller
Electrical connections
General
Supply
The Profibus does not need any external power supply. All the robot cells are
connected to the trunk cable through a special D-sub connector which works as a
very short drop cable. Because of this the profibus will work correctly even if a
robot cell is turned off.
Technical data
Also see the Profibus-DP specification, International Standard DIN E 19245, part
3.
Further information
For setup parameters, see Users Guide - System Parameters, Topic: I/O Signals.
Also see the Circuit diagram.
Layout, DSQC
352
The figure below shows the layout of the DSQC 352 board:
110
3HAC 16638-1
Controller
Electrical connections
X20
X5
X3
xx0100000223
Communication
concept
X3
Power connector
X5
DeviceNet connector
X20
Profibus connection
E
A
F
C
xx0100000222
3HAC 16638-1
111
Controller
Electrical connections
Master PLC
Termination
Connections, X5
DeviceNet connectors
Connections,
connector X20,
Profibus-DP
6
9
xx0100000220
The table below shows the connections to connector X20, Interbus-S IN:
112
Signal name
X20 pin
Function
Shield
Cable screen
NC
Not connected
RxD/TxD-P
Receive/Transmit data P
Control-P
GND
+5 VDC
Ground
3HAC 16638-1
Controller
Electrical connections
Connections,
connector X3
Signal name
X20 pin
Function
NC
Not connected
RxD/TxD-N
Receive/Transmit data N
NC
Not connected
xx0100000221
Signal name
X3 pin
Function
0 VDC
NC
Not connected
GND
Ground connection
NC
Not connected
+ 24 VDC
The figure and table below show the location and significance of the LEDs on the
board.
The designations refer to LEDs shown in the figure in section "Layout, DSQC
352" above.
3HAC 16638-1
Designation
Color
Description
Profibus active
Green
113
Controller
Electrical connections
Designation
Color
Description
NS/MS
Green/red
CAN Tx/CAN Rx
Green/red
C - 6: I/O units
Distributed I/O units
General
Up to 20 units can be connected to the same controller but only four of these can
be installed inside the controller. Normally a distributed I/O unit is placed outside
the controller.
Connection
The maximum total length of the distributed I/O cable is 100 m (from one end of
the chain to the other end).
The controller can be one of the end points or be placed somewhere in the middle
of the chain.
Parameter setup
114
For setup parameters, see Users Guide, section System Parameters, Topic: I/O
Signals.
3HAC 16638-1
Controller
Electrical connections
General
Technical data
Allowed types of
digital sensors
The table below shows the allowed types of digital sensors to be used, and their
signal levels respectively:
3HAC 16638-1
Sensor type
Signal level
High, "1"
Low, "0"
High, "01"
No signal, "00"
Low, "10"
Error status, "11" (stop program running)
115
Controller
Electrical connections
General
The digital I/O unit handles digital communication between the robot system and
any external systems.
Technical data
No. of inputs
No. of outputs
Supply voltage
24 VDC
Supply source
Further information
For setup parameters, see Users Guide - System Parameters, Topic: Controller.
Also see the Circuit Diagram.
Layout, DSQC
328
OUT
MS
IN
NS
X1
X3
OUT
9
10
11
12
13
14
15
16
IN
X2
1
10
10
X4
1
10
10
12
X5
xx0100000240
116
Status LEDs
3HAC 16638-1
Controller
Electrical connections
Connections,
connector X1
Connections,
connector X2
Unit function
Signal name
X1 pin
Out ch 1
Out ch 2
Out ch 3
Out ch 4
Out ch 5
Out ch 6
Out ch 7
Out ch 8
10
3HAC 16638-1
Unit function
Signal name
X2 pin
Out ch 9
Out ch 10
Out ch 11
Out ch 12
Out ch 13
Out ch 14
Out ch 15
117
Controller
Electrical connections
Connections,
connector X3
Unit function
Signal name
X2 pin
Out ch 16
10
Unit function
Signal name
X3 pin
In ch 1
In ch 2
In ch 3
In ch 4
In ch 5
In ch 6
In ch 7
In ch 8
Not used
10
The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected
to ground, to prevent disturbances, causes a short rush of current when setting the
input.
When connecting outputs, sensitive to pre-oscillation current, a series resistor
(100 W) may be used.
Connections,
connector X4
118
Unit function
Signal name
X4 pin
In ch 9
In ch 10
3HAC 16638-1
Controller
Electrical connections
Unit function
Signal name
X4 pin
In ch 11
In ch 12
In ch 13
In ch 14
In ch 15
In ch 16
Not used
10
The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected
to ground, to prevent disturbances, causes a short rush of current when setting the
input.
When connecting outputs, sensitive to pre-oscillation current, a series resistor
(100 W) may be used.
3HAC 16638-1
119
Controller
Electrical connections
General
The digital I/O unit handles digital and analog communication between the robot
system and any external systems.
Technical data
No. of digital inputs
Supply voltage
24 VDC
Supply source, analog I/O 24 V_CAN (with galvanically isolated DC/AC converter)
Further information
For setup parameters, see Users Guide - System Parameters, Topic: Controller.
Also see the Circuit Diagram.
Layout, DSQC
327
120
3HAC 16638-1
Controller
Electrical connections
OUT
MS
IN
NS
X1
X3
10
11
12
13
14
15
IN
X2
1
10
X4
10
X6
1
10
OUT
16
10
12
X5
xx0100000239
Status LEDs
Connections,
connector X1
3HAC 16638-1
Unit function
Signal name
X1 pin
Out ch 1
Out ch 2
Out ch 3
Out ch 4
Out ch 5
Out ch 6
Out ch 7
Out ch 8
10
121
Controller
Electrical connections
Connections,
connector X2
Connections,
connector X3
122
Unit function
Signal name
X2 pin
Out ch 9
Out ch 10
Out ch 11
Out ch 12
Out ch 13
Out ch 14
Out ch 15
Out ch 16
10
Unit function
Signal name
X3 pin
In ch 1
In ch 2
In ch 3
In ch 4
In ch 5
In ch 6
In ch 7
In ch 8
Not used
10
3HAC 16638-1
Controller
Electrical connections
Connections,
connector X4
Connections,
connectors X6
Unit function
Signal name
X4 pin
In ch 9
In ch 10
In ch 11
In ch 12
In ch 13
In ch 14
In ch 15
In ch 16
Not used
10
Signal name:
X6 pin:
Explanation:
AN_ICH1
AN_ICH2
0V
0 VA
AN_OCH1
Out channels 1
AN_OCH2
Out channels 2
The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected
to ground, to prevent disturbances, causes a short rush of current when setting the
input.
When connecting outputs, sensitive to pre-oscillation current, a series resistor
(100 W) may be used.
3HAC 16638-1
123
Controller
Electrical connections
General
The analog I/O unit handles communication between the robot system and any
external systems through analog sensors.
Technical data
No. of analog inputs
4 (-10 V/+10 V)
3 (-10 V/+10 V)
1 (4-20 mA))
Supply voltage
24 VDC
Further information
For setup parameters, see Users Guide - System Parameters, Topic: Controller.
Also see the Circuit Diagram.
Layout, DSQC
355
The figure below shows the layout of the DSQC 355 board:
124
3HAC 16638-1
Controller
Electrical connections
X7
X8
X8
Bus s tatus
X7
S2S3
X2
X5 X3
Analog I/O
DS QC 355
X5
AB B F lexible Automation
X3
xx0100000238
Connections,
connectors X7
analog output
X3
Not used
X5
X7
Analog outputs
X8
Analog inputs
13
12
24
xx0100000236
3HAC 16638-1
125
Controller
Electrical connections
Explanation:
ANOUT_
ANOUT_
ANOUT_
ANOUT_
Not used
Not used
Not used
Not used
Not used
Not used
10
Not used
11
Not used
12
Not used
13
Not used
14
Not used
15
Not used
16
Not used
17
Not used
18
GND
19
Analog output 1, 0 V
GND
20
Analog output 2, 0 V
GND
21
Analog output 3, 0 V
GND
22
Analog output 4, 0 V
GND
23
GND
24
The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected
to ground, to prevent disturbances, causes a short rush of current when setting the
input.
Connect a resistor (100 W) in series when connecting outputs, sensitive to preoscillation current.
126
3HAC 16638-1
Controller
Electrical connections
Connections,
connectors X8
analog input
17
16
32
xx0100000237
3HAC 16638-1
Explanation:
ANIN_1
ANIN_2
ANIN_3
ANIN_4
Not used
Not used
Not used
Not used
Not used
Not used
10
Not used
11
Not used
12
Not used
13
Not used
14
Not used
15
Not used
16
+24 V out
17
127
Controller
Electrical connections
Explanation:
+24 V out
18
+24 V out
19
+24 V out
20
+24 V out
21
+24 V out
22
+24 V out
23
+24 V out
24
GND
25
Analog input 1, 0 V
GND
26
Analog input 2, 0 V
GND
27
Analog input 3, 0 V
GND
28
Analog input 4, 0 V
GND
29
GND
30
GND
31
GND
32
The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected
to ground, to prevent disturbances, causes a short rush of current when setting the
input.
Connect a resistor (100 W) in series when connecting outputs, sensitive to preoscillation current.
128
The figure and table below show the location and significance of the LEDs on the
board.
Designation
Color
Description
NS/MS
Green/
red
RS232 Rx
Green
3HAC 16638-1
Controller
Electrical connections
Designation
Color
Description
RS232 Tx
Green
Green
+5VDC / +12VDC /
-12VDC
3HAC 16638-1
129
Controller
Electrical connections
General
One encoder input (synchronization of conveyor position with robot movements). The encoder is supplied with 24 V and 0 V, and sends position
information on two channels. This information is computed by the on-board
computer using quadrature decoding (QDEC) to determine position and
direction.
Technical data
No. of encoder inputs
1 (24 VDC)
Supply voltage
24 VDC
Supply source
Further information
130
User reference Description Conveyor Tracking. For setup parameters, see Users
Guide - System Parameters, Topic: Controller. Also see the Circuit Diagram.
3HAC 16638-1
Controller
Electrical connections
Layout, DSQC
354
The figure below shows the layout of the DSQC 354 board:
X20
X5
X3
xx0100000233
3HAC 16638-1
X3
Not used
X5
X20
Conveyor connection
131
Controller
Electrical connections
Encoder connections
A
B
24 VDC
AD
0V
AE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Opto
Opto
Opto
Opto
Opto
Opto
AG
xx0100000234
132
AA
AB
AC
Encoder
AD
Sync switch
AE
AF
Encoder unit
AG
Galvanic isolation
3HAC 16638-1
Controller
Electrical connections
Connections,
connectors X20
encoder and digital input connections
Explanation:
24 VDC
24 VDC supply
0V
0V
ENC
Encoder 24 VDC
ENC
Encoder 0 VDC
ENC_A
Encoder phase A
ENC_B
Encoder phase B
DIGIN
DIGIN
0V
DIGIN
Not used
10
Not used
11
Not used
12
Not used
13
Not used
14
Not used
15
Not used
16
The figure below shows the layout of the pins in connector X20:
16
xx0100000235
3HAC 16638-1
133
Controller
Electrical connections
The figure and table below show the location and significance of the LEDs on the
board.
Designation
Color
Description
NS/MS
Green/red
ENC 1A/1B
Green
134
3HAC 16638-1
Controller
Electrical connections
3HAC 16638-1
Designation
Color
Description
DIGIN1
Green
135
Controller
Electrical connections
General
The unit handles communication between the robot system and any external systems through relay outputs and digital inputs.
Technical data
No. of digital inputs
Supply voltage
24 VDC
Supply source
Further information
For setup parameters, see Users Guide - System Parameters, Topic: Controller.
Also see the Circuit Diagram.
Layout, DSQC
332
The figure below shows the layout of the DSQC 332 board:
A
OUT
MS
IN
NS
OUT
9
10
11
12
13
14
15
16
IN
X1
X2
16
16
X3
X4
16
16
12
X5
xx0100000232
136
Status LEDs
3HAC 16638-1
Controller
Electrical connections
Connections,
connector X1
Connections,
connector X2
3HAC 16638-1
X1
X2
X3
X4
X5
Signal name
X1 pin
Function
Out ch 1a
Contact, relay 1
Out ch 1b
Contact, relay 1
Out ch 2a
Contact, relay 2
Out ch 2b
Contact, relay 2
Out ch 3a
Contact, relay 3
Out ch 3b
Contact, relay 3
Out ch 4a
Contact, relay 4
Out ch 4b
Contact, relay 4
Out ch 5a
Contact, relay 5
Out ch 5b
10
Contact, relay 5
Out ch 6a
11
Contact, relay 6
Out ch 6b
12
Contact, relay 6
Out ch 7a
13
Contact, relay 7
Out ch 7b
14
Contact, relay 7
Out ch 8a
15
Contact, relay 8
Out ch 8b
16
Contact, relay 8
Signal name
X2 pin
Function
Out ch 9a
Contact, relay 9
137
Controller
Electrical connections
Connections,
connector X3
138
Signal name
X2 pin
Function
Out ch 9b
Contact, relay 9
Out ch 10a
Contact, relay 10
Out ch 10b
Contact, relay 10
Out ch 11a
Contact, relay 11
Out ch 11b
Contact, relay 11
Out ch 12a
Contact, relay 12
Out ch 12b
Contact, relay 12
Out ch 13a
Contact, relay 13
Out ch 13b
10
Contact, relay 13
Out ch 14a
11
Contact, relay 14
Out ch 14b
12
Contact, relay 14
Out ch 15a
13
Contact, relay 15
Out ch 15b
14
Contact, relay 15
Out ch 16a
15
Contact, relay 16
Out ch 16b
16
Contact, relay 16
Signal name
X3 pin
In ch 1
In ch 2
In ch 3
In ch 4
In ch 5
In ch 6
In ch 7
In ch 8
0 v for In ch 1-8
Not used
10
Not used
11
3HAC 16638-1
Controller
Electrical connections
Connections,
connector X4
3HAC 16638-1
Signal name
X3 pin
Not used
12
Not used
13
Not used
14
Not used
15
Not used
16
Signal name
X4 pin
In ch 9
In ch 10
In ch 11
In ch 12
In ch 13
In ch 14
In ch 15
In ch 16
0 v for In ch 9-16
Not used
10
Not used
11
Not used
12
Not used
13
Not used
14
Not used
15
Not used
16
139
Controller
Electrical connections
General
The unit handles communication between the robot system and any external systems through galvanically isolated outputs and inputs.
Technical data
No. of inputs
No. of outputs
Supply voltage
120 VAC
Further information
For setup parameters, see Users Guide - System Parameters, Topic: Controller.
Also see the Circuit Diagram.
Layout, DSQC
320
The figure below shows the layout of the DSQC 320 board:
A
OUT
MS
IN
NS
OUT
9
10
11
12
13
14
15
16
IN
X1
X2
16
16
X3
X4
16
16
12
X5
xx0100000231
140
Status LEDs
X1
X2
3HAC 16638-1
Controller
Electrical connections
Connections,
connector X1
Connections,
connector X2
3HAC 16638-1
X3
X4
X5
Function
Out ch 1a
Out ch 1b
Out ch 2a
Out ch 2b
Out ch 3a
Out ch 3b
Out ch 4a
Out ch 4b
Out ch 5a
Out ch 5b
10
Out ch 6a
11
Out ch 6b
12
Out ch 7a
13
Out ch 7b
14
Out ch 8a
15
Out ch 8b
16
Signal
name
X2 pin
Function
Out ch 9a
Out ch 9b
141
Controller
Electrical connections
Connections,
connector X3
142
Signal
name
X2 pin
Function
Out ch 10a
Out ch 10b
Out ch 11a
Out ch 11b
Out ch 12a
Out ch 12b
Out ch 13a
Out ch 13b
10
Out ch 14a
11
Out ch 14b
12
Out ch 15a
13
Out ch 15b
14
Out ch 16a
15
Out ch 16b
16
Signal
name
X3 pin
Function
In ch 1a
In ch 1b
In ch 2a
In ch 2b
In ch 3a
In ch 3b
In ch 4a
In ch 4b
In ch 5a
In ch 5b
10
3HAC 16638-1
Controller
Electrical connections
Connections,
connector X4
3HAC 16638-1
Signal
name
X3 pin
Function
In ch 6a
11
In ch 6b
12
In ch 7a
13
In ch 7b
14
In ch 8a
15
In ch 8b
16
Signal
name
X4 pin
Function
In ch 9a
In ch 9b
In ch 10a
In ch 10b
In ch 11a
In ch 11b
In ch 12a
In ch 12b
In ch 13a
In ch 13b
10
In ch 14a
11
In ch 14b
12
In ch 15a
13
In ch 15b
14
In ch 16a
15
In ch 16b
16
143
Controller
Electrical connections
C - 7: Communication
Communication concept, Allen-Bradley
General
The robot may communicate with the Allen Bradley system only, or be used in
combination with the I/O system in the robot. For example, the inputs to the robot
may come from the Allen Bradley system while the outputs from the robot control
external equipment go via general I/O addresses and the Allen Bradley system
only reads the outputs as status signals.
Definitions
The Allen Bradley system can communicate with up to 64 external systems. Each
of these systems is called a Rack and is given a Rack Address 0-63. Basically, each
robot connected to the Allen Bradley system will occupy one rack.
Each rack is divided into four sections called Quarters. Each quarter provides 32
inputs and 32 outputs and a rack will subsequently provide 128 inputs and 128
outputs. A rack may also be shared by 2, 3, or 4 robots. Each of these robots will
then have the same rack address, but different starting quarters must be specified.
144
3HAC 16638-1
Controller
Electrical connections
Illustration
The illustration below shows a block diagram of the Allen-Bradley system, where
Robot 1 uses a full rack while robot 2 and robot 3 share one rack. The rack address,
starting quarter, and other required parameters such as baud rate, LED status etc.
are entered in the configuration parameters.
Allen Bradley
control system
Robot 2 - 64 in / 64 out
Quarter 1
64 in / 64 out
Quarter 4
Rack ID 12 (example)
Rack size 4
Starting quarter 1
Quarter 1
Quarter 2
Quarter 2
Rack ID 13 (example)
Rack size 2
Starting quarter 1
Quarter 3
Other systems
Quarter 3
Quarter 4
Robot 3 - 64 in / 64 out
Quarter 3
64 in / 64 out
Quarter 4
Rack ID 13 (example)
Rack size 2
Starting quarter 3
en0100000255
3HAC 16638-1
145
Controller
Electrical connections
General
The unit handles communication between the robot system and the Allen Bradley
system.
Technical data
No. of digital inputs
Further information
For setup parameters, see Users Guide - System Parameters, Topic: I/O Signals.
Also see Circuit Diagram.
Connection
Layout, DSQC
350
The figure below shows the layout of the DSQC 350 board:
X5
X9
X3
X8
DS QC 350
AB B F lexible Automation
xx0100000226
146
3HAC 16638-1
Controller
Electrical connections
Connections,
connector X8
X3
Not used
X5
X8
RIO in
X9
RION out
xx0100000221
Connections,
connector X9
Signal name
X8 pin
Function
LINE1 (blue)
Remote I/O in
LINE2 (clear)
Remote I/O in
Shield
Remote I/O in
Cabinet ground
Remote I/O in
xx0100000221
3HAC 16638-1
Signal name
X9 pin
Function
Blue
Clear
Shield
Cabinet ground
147
Controller
Electrical connections
Termination
When the robot is last in a RIO loop, the loop must be terminated with a termination resistor according to Allen-Bradleys specification.
Warranty
The figure and table below show the location and significance of the LEDs on the
board.
The designations refer to LEDs shown in the figure in section "Layout, DSQC
350" above.
Designation
Color
148
Description
Indicates that a supply voltage is present, and
has a level above 12 VDC.
If there is no light, check that voltage is present on
power unit and in power connector. If not, check
cables and connectors.
If power is applied to the unit but it does not work,
replace the unit.
NS/MS
CAN Tx/CAN Rx
Yellow
NAC STATUS
Green
3HAC 16638-1
Controller
Electrical connections
General
Further information
Technical data
3HAC 16638-1
The robot has three serial channels, which can be used by the customer to communicate with printers, terminals, computers, and other equipment (see the figure
in "Connections" below).
COM1 (computer system) - RS 232 115 kbps. This was formerly referred
to as Com2.
COM2 - RS 232 with RTS-CTS-control and support for XON/XOFF, transmission speed 300 - 38 400 bps. This was formerly referred to as SIO1.
For temporary use: MC/CONSOLE - RS 232 115 kbps. This was formerly
referred to as Com1.
For setup parameters, see User's Guide - System Parameters, Topic: I/O
Signals.
Circuit Diagram.
149
Controller
Electrical connections
Connections
xx0100000219
External computer
Customer terminals, on base connector board: X10 (COM2) and X9 (COM3), see
section "Connection to screw terminals".
Connections on
DSQC 504, COM1
6
9
xx0100000220
The table below shows the signals from the COM1 (RS232):
150
Signal
Pin
Description
DCD
RX
Receive Data
TX
Transmit Data
3HAC 16638-1
Controller
Electrical connections
Connections on
DSQC 504, D-sub
connector X10,
COM2
Signal
Pin
Description
DTR
GND
Signal Ground
DSR
RTS
Request To Send
CTS
Clear To Send
RI
Ring Indicator
NC
10
Not Connected
6
9
xx0100000220
X10 pin
1
0V
8
9
3HAC 16638-1
151
Controller
Electrical connections
Connections on
DSQC 504, D-sub
connector X9,
COM3
6
9
xx0100000220
Connections to
MC/CONSOLE
X9 socket
0V
The figure below shows the MC/CONSOLE connection behind the service hatch:
xx0100000218
152
3HAC 16638-1
Controller
Electrical connections
External computer
Standard RS232 port intended for temporary use, e.g. connection of laptop/PC.
The table below shows the signals on the MC/CONSOLE (RS232):
3HAC 16638-1
Signal
Pin
Description
RX
Receive Data
TX
Transmit Data
GND
Signal Ground
153
Controller
Electrical connections
Communication, Ethernet
General
Connection of
LAN (Main computer)
E thernet hub
xx0100000217
External computer
Controller Robot 1
Controller Robot 2
154
Signal
X1 Pin
Description
TX+
3HAC 16638-1
Controller
Electrical connections
Signal
X1 Pin
Description
TX-
RX+
NC
Not Connected
NC
Not Connected
RX-
NC
Not Connected
NC
Not Connected
X1
LAN
PWR
HDD
STATUS
X2
xx0100000216
3HAC 16638-1
155
Controller
Electrical connections
Connection of
Service (I/O Computer)
Used for connection of a laptop to the service outlet on the front of the controller
cabinet (behind service hatch).
The figure below shows how to connect a laptop to the service outlet:
E thernet
xx0100000215
For setup parameters, see Users Guide - System Parameters, Topic: I/O Signals.
Also see the Circuit Diagram. Separate documentation is included when the
option Ethernet services is ordered.
156
3HAC 16638-1
Controller
Electrical connections
General
All necessary components are supplied, except for the external enclosure.
Dimensions for
installation
Install the assembled panel in a housing which satisfies protection class, IP 54, in
accordance with IEC 144 and IEC 529!
The figure below shows the main dimensions of the external operators panel:
A
B
M8 (x4)
M4 (x4)
62
C
45
70
140
184
200
E
90
5 (x2)
155
F
G
xx0100000214
3HAC 16638-1
157
Controller
Electrical connections
158
3HAC 16638-1
Controller
Start-up
Section D: Start-up
Inspection before start-up
General
Check that:
3HAC 16638-1
Device
XS3
Panel unit
A5-A6, B5-B6
X1.3-4, X2.3-4
A3-A4, B3-B4
X1.9-10, X2.9-10
A1-A2, B1-B2
X1.7-8, X2.7-8
General stop +
A11-A12, B11-B12
X3.10-12, X4.10-12
General stop -
A13-A14, B13-B14
X3.7-8, X4.7-8
Auto stop +
A7-A8, B7-B8
X3.11-12, X4.11-12
Auto stop -
A9-A10, B9-10
X3.7-9, X4.7-9
A15-A16, B15-16
X1.5-6, X2.5-6
159
Controller
Start-up
Start-up
General
160
3HAC 16638-1
Controller
Start-up
at reduced speed, the robot operates properly and has the capability to
handle the product or workpiece.
in automatic (normal) operation, the robot operates properly and has the
capability to perform the intended task at the rated speed and load.
Operating the
robot
3HAC 16638-1
Starting and operating the robot is described in the Users Guide. Before start-up,
make sure that the robot cannot collide with any other objects in the working
space.
161
Controller
Installation of controller software
General
The robot system may be delivered with or without system software. When the
system is not delivered with software, this must be downloaded in one of a number
of ways.
Software installed
on delivery
If the robot controller is ordered with the software installed on delivery, the controller software and settings are already stored in the storage memory and the
system is ready to use.
Software not
installed on delivery
If the robot controller is ordered and delivered without software or if you want to
reconfigure your system, the RobInstall tool must be used to install the controller
software. The RobInstall tool is included on the RobotWare CD-ROM (see section
"RobotWare CD-ROM"). The RobInstall tool can be used both for creation of the
controller software and for downloading it to the controller system.
Types of software
loading
A
B
C
D
E
xx0100000192
162
3HAC 16638-1
Controller
Installation of controller software
Floppy Disks
Connected to IOC
Boot Image
using Ethernet connected via a local area network (LAN) to the main computer (MC).
The transfer and installation of the controller software to the controller storage
memory via Ethernet or floppy disks is executed by a basic program named Boot
Image.
This basic program must always be in the storage memory. When starting the
controller, with no controller software installed, Boot Image will start and ask the
operator for controller software installation instructions. If the controller software
is already installed and a warm start is performed, Boot Image is not used. The
installed controller software can be deleted by a cold start and then the Boot Image
will be reactivated.
3HAC 16638-1
163
Controller
Installation of controller software
RobotWare CD-ROM
The CD contains all the System software and should therefore be treated and
stored carefully.
164
Contents
Description
1.
RobInstall
A PC tool used to create and install the controller operating system in the robot control system.
2.
Documentation
On-line documentation for the RobInstall application and the Controller Operating System
Package.
3.
Controller OS Package
4.
A tool (created in LabView) for viewing MotionTest Signals (oscilloscope function) and also
for logging these signals.
5.
FTP Client
On the CD is also included a so called FTP client named Voyager. Please note that this is not
an ABB product but a shareware program,
which means that it can be installed and used
for a limited time, but that it has to be registered for permanent use. Registering means
that a certain fee must be paid to the vendor.
The FTP client is used to transport files manually between the PC and the robot controller
storage memory. These actions are carried out
in the same way as in a file manager or in Windows Explorer.
3HAC 16638-1
Controller
Installation of controller software
Installation of the
RobotWare on the
PC (except FTP
Client)
This section describes how to install the software delivered on the RobotWare
CD-ROM onto a PC hard drive, to be transferred to the robot system.
1. Insert the CD in your reader.
1. The Install Shield will automatically start and guide you through the
install process (if it does not start, double-click the CD icon on your PC).
When the setup type window is displayed, it is recommended to select
the Custom button. Then Next button will open the Select Components
window, where normally all the four options, RobInstall, Documentation, Controller OS Package and Test Signal Viewer should be marked
as selected.
Installation of the
FTP Client on the
PC
This section describes how to install the FTP Client onto a PC hard drive.
1. In the Explorer, select and open the directory "ftp" on the CD.
2. Double-click the file ftpvsetup.exe.
The Install Shield for the FTP client will start and guide you through the installation. Please read the "Readme" file for information about license regulations.
3HAC 16638-1
165
Controller
Installation of controller software
General
Nomenclature
166
Since most systems have the operating system installed already on delivery, the
RobotWare CD-ROM is normally not needed. However it should be used when:
Concept:
Means:
System pack
Key
This is a text string, or a special file with the text string, which
is used to define and open both the BaseWare and all ordered
RobotWare options.
System
Robinstall is used to create and install the controller software in the S4Cplus robot
controller. With RobInstall, you can:
3HAC 16638-1
Controller
Installation of controller software
Step
Action
Illustration/Info
1.
2.
3.
xx0100000185
3HAC 16638-1
167
Controller
Installation of controller software
Setting up the
system
Step
Action
Illustration/Info
1.
Start RobInstall as
described in section "How
to use Robinstall".
2.
xx0100000179
3.
xx0100000180
4.
168
3HAC 16638-1
Controller
Installation of controller software
Step
Action
Illustration/Info
5.
6.
If no external options or
parameters are to be
added or changed, press
Finish to create the new
controller system. Otherwise press Next to continue to "Additional Keys"
(see section "Add or
remove external
options").
xx0100000181
Add or remove
external options
Step
1.
Action
Illustration/Info
xx0100000182
3HAC 16638-1
169
Controller
Installation of controller software
Step
Add or remove
additional system
parameters
Action
Illustration/Info
2.
3.
4.
Step
Action
Illustration/Info
1.
2.
xx0100000183
170
3HAC 16638-1
Controller
Installation of controller software
Step
Change options
or system pack
revision
Action
Illustration/Info
3.
To remove manipulator
calibration data, press
Remove.
4.
5.
To remove additional
parameters, select the
parameter in the "Loaded
Additional Parameters" list
and press Remove.
6.
Step
1.
Action
Illustration/Info
xx0100000184
3HAC 16638-1
171
Controller
Installation of controller software
Step
172
Action
Illustration/Info
2.
3.
4.
5.
3HAC 16638-1
Controller
Installation of controller software
Actions
Step
1.
Action
Illustration/Info
xx0100000189
2.
xx0100000190
3HAC 16638-1
173
Controller
Installation of controller software
Step
3.
174
Action
Illustration/Info
3HAC 16638-1
Controller
Installation of controller software
Selecting type of
set-up
Before a system can be downloaded to a robot controller using the RobInstall tool
some preparations and set up must be done. This may be done in one of two ways:
...and continue
in section:
If using a direct
connection
between PC and
IOC service outlet
on controller
3HAC 16638-1
"Download Robot
Controller System"
below!
"Download Robot
Controller System"
below!
Step
Action
Illustration/Info
1.
Connect a patch-cable
between the Ethernet connection on the front of the
controller and the corresponding connection on
the PC/Laptop.
2.
175
Controller
Installation of controller software
Step
3.
Action
Illustration/Info
xx0100000178
If using Network
Intranet connection with fixed IP
addresses
176
Step
Action
Illustration/Info
1.
2.
3.
Perform a X-START (see section "x-START") or CSTART (see section "C-start") on the S4Cplus controller.
4.
3HAC 16638-1
Controller
Installation of controller software
If using Network
Intranet connection with DHCP
Step
1.
Action
Illustration/Info
Download Robot
Controller System
Before downloading, check the following:
Make sure there is at least 25 Mb free disk space on the controller mass storage
memory. For information on how to perform a manual storage capacity check, see
section "Check Storage Capacity".
Make sure that the robot controller displays the Start Window on the Teach Pendant Unit (see section "Start window").
Step
1.
Action
Illustration/Info
To download a controller
system, press Download as
in the figure below:
xx0100000176
3HAC 16638-1
177
Controller
Installation of controller software
Step
Action
Illustration/Info
2.
3.
xx0100000177
4.
5.
xx0100000175
178
3HAC 16638-1
Controller
Installation of controller software
Step
6.
3HAC 16638-1
Action
Illustration/Info
179
Controller
Installation of controller software
Step
1.
Action
Illustration/Info
xx0100000173
180
3HAC 16638-1
Controller
Installation of controller software
Step
2.
Action
Illustration/Info
xx0100000175
xx0100000188
3HAC 16638-1
3.
4.
5.
181
Controller
Installation of controller software
RobInstall preferences
Customizing RobInstall
Step
Action
Illustration/Info
1.
2.
xx0100000186
xx0100000187
182
3HAC 16638-1
Controller
Installation of controller software
Step
3.
3HAC 16638-1
Action
Illustration/Info
183
Controller
Robot controller
General
The BootImage is a basic program which is used to start up the system from
"scratch".
Purpose of the
program
This program is already installed in the controller at delivery and is used to:
184
3HAC 16638-1
Controller
Robot controller
Start window
When is it
shown?
xx0100000168
The start window displays the start menu and will appear in the following cases:
Possible actions
The BootImage will be re-executed, used to apply changes in the system settings
(see the part "Reboot Window").
Load a system
from diskettes,
Boot Disks
Set network settings for the Main Computer or check how to configure your PC
(see the part "Network Settings Window").
3HAC 16638-1
185
Controller
Robot controller
Choose a system
from the mass
storage memory,
Select System
186
If there is one or more systems in the mass storage memory, you can choose to
activate one of them (see the part "System selection window").
3HAC 16638-1
Controller
Robot controller
Reboot Window
When is it
shown?
The Reboot window will be displayed if any of the system settings are changed or
when Reboot is pressed in the Start window as shown in the figure below:.
xx0100000169
3HAC 16638-1
Button
Function
YES
NO
187
Controller
Robot controller
When is it
shown?
The Boot Disk window will be displayed when Boot Disks is pressed in the Start
window as shown in the figure in section "Start window".
How to create
boot disks
Information on how to create boot disks from RobInstall can be found in section
"Create Boot Diskettes from Robinstall".
Action
Illustration/Info
188
3HAC 16638-1
Controller
Robot controller
When is it
shown?
xx0200000209
3HAC 16638-1
LAN Settings
Service Settings
CANCEL
189
Controller
Robot controller
When is it
shown?
The LAN Settings window will be displayed when LAN Settings is pressed in the
Network Settings window as shown in the figure in section "Network Settings".
en0100000256.gif
NONE
CANCEL
Node identification
190
Parameter
Type
Description
MAC ID
Node identification
Current IP
Node identification
IP
Network setting
3HAC 16638-1
Controller
Robot controller
Parameter
Configure for
fixed IP network
Type
Description
(Gateway)
Network setting
Configure for
DHCP distributed
IP network
1. Press DHCP.
1. The value for IP will change to DHCP.
2. Press OK.
You will be asked to reboot the system.
3HAC 16638-1
191
Controller
Robot controller
When is it
shown?
The Service Settings window will be displayed when Service Settings is pressed
in the Network Settings window as shown in the figure in section "Network Settings".
en0100000257
OK
returns to the Start window as shown in the figure in section "Start Window".
Service Setting
Parameter
Description
192
IP
Required to configure your PCs network settings for communication between RobInstall and the I/O Computer.
Subnet mask
Required to configure your PCs network settings for communication between RobInstall and the I/O Computer.
Gateway
Required to configure your PCs network settings for communication between RobInstall and the I/O Computer.
3HAC 16638-1
Controller
Robot controller
When is it
shown?
The Select System window will be displayed when Select System is pressed in the
Start window, as shown in the figure in section "Start Window".
xx0100000171
CANCEL
How to select
system
The window shows all systems installed on the controller mass storage memory.
Step
1.
Action
Illustration/Info
xx0100000172
3HAC 16638-1
193
Controller
Robot controller
General
Performing a restart may be done in a number of ways. These are detailed below:
Reboot (Warm
start), apply
changed settings
When executing a Warm start, the system reboots with the current system, e.g. to
make new or changed settings take effect.
Step
1.
Action
Illustration/Info
Miscellaneous button:
xx0100000194
2.
A P-Start will warm start the current system, with a reinstallation of the RAPID
language and all auto-loaded modules. This means that all RAPID program and
system modules currently loaded in the working memory will be closed, and thus
have to be reloaded again after the P-Start, with the exception of such modules that
are automatically loaded, due to settings in the System Parameters/Controller/
Task Modules.
Step
Action
Illustration/info
1.
Miscellaneous button:
2.
xx0100000194
194
3HAC 16638-1
Controller
Robot controller
Step
X-START, change
active controller
system
Action
Illustration/info
3.
4.
Press P-START.
The system will reboot, reinstall RAPID and
its auto-loaded modules, and return to the
Welcome window as shown in the second figure in section "Select System".
An X-start will exit the running system, store system data on the mass storage
memory, and then execute the BootImage to display the Start window. Any system
stored in the mass storage memory may then be selected as described in section
"Select System".
When performing an X-Start all stored system data will be restored (similar to
performing a warm start).
Step
Action
Illustration/Info
1.
Miscellaneous button:
2.
3.
4.
Press X-START.
The system will reboot and return to the Start
window as shown in the figure in section
"Start Window".
xx0100000194
I-START, start in
Query mode
3HAC 16638-1
An I-start can be done if "Use Query Mode at System Boot" was selected when
creating the running system in RobInstall (see section "Change options or system
pack revision"). An I-Start will restart the current system and give the opportunity
195
Controller
Robot controller
to set some values at start-up, e.g. language, IRB type (within the same model) or
options (see section "Start in Query Mode").
Step
Action
Illustration/Info
1.
Miscellaneous button:
2.
3.
4.
Press I-START.
The system will start to reboot, then pause to
ask for Silent, Easy, or Query mode. For more
information on the different modes, continue
to section "Start in Query Mode".
xx0100000194
C-START (Cold
start), delete the
active system
When executing a C-Start, the system exits the running system and deletes it from
the mass storage memory. The BootImage is then executed and the Start window
as shown in the figure in section "Start Window" is displayed.
Use C-start with caution. Since it deletes the current system, it should not be used
to just switch between installed systems. For this purpose, use X-Start (see section
"X-start").
It will take quite some time to implement a Cold start. Just wait until the robot shows
the Start window. When the Start window is shown, a new system can be selected
if available in the mass storage memory (see section "Select System) or a new
system can be downloaded and started (see section "Transfer Robot Controller
System using Ethernet connection" or "Transfer Robot Controller System using
floppy disks").
Do not touch any key, joystick, enable device, or emergency stop during the cold
start until the Start window is shown as in the figure in section "Start Window".
196
3HAC 16638-1
Controller
Robot controller
Step
1.
Action
Illustration/Info
Miscellaneous button:
xx0100000194
3HAC 16638-1
2.
3.
4.
Press C-START.
197
Controller
Robot controller
Pre-conditions
for selecting
Query Mode start
If "Use Query Mode at System Boot" was selected when creating the system in
RobInstall (see section "Change options or system pack revision"), it is possible
to set some values, e.g. language, IRB type (within the same model) or options, at
the first start-up of the system, using a C-Start (see section "C-start"), or later on
when performing an I-Start (see section "I-start").
Types of Query
Mode
The first question from the system is which Query Mode to start. Depending on
your needs, you should select one of the following three:
Easy Query Mode, pushbutton Easy Query. In Easy Query Mode you can
change language, remove selected options and select service or standard
mode (see section "Easy Query Mode").
Query Mode, pushbutton Query. In Query Mode you can, as well as the
things in Easy Query, select DC-link, change Robot type (within the same
family) and for IRB 7600, select balancing unit (see section "Query
Mode").
If Easy Query was chosen as start-up query mode, the following steps will be
required to start the system:
Step
198
Action
Illustration/Info
1.
2.
3HAC 16638-1
Controller
Robot controller
Step
3.
Query Mode
Action
Illustration/Info
If Query Mode was chosen as start-up query mode, the following steps will be
required to start the system:
Step
Action
Illustration/info
1.
2.
3.
3HAC 16638-1
4.
5.
199
Controller
System directory structure
Directory
All RobotWare System Packages and Option Packages are stored in a media pool
directory (folder) as shown in the table below.
Two revisions of the same system package may exist in the pool. By default, after
having installed RobInstall, a directory "MediaPool" will be found in the directory
Program Files\ABB Robotics\, and will also be the current one. However any
directory in the structure can be set up as the current media pool in the Preference
window (see section "Robinstall Preferences").
xx0100000259
Naming conventions
200
Description
3HAXaaaa-1.00
3HAXbbbb-1.02
3HAXcccc-1.01
3HYZdddd-1.00
3HAC 16638-1
Controller
System directory structure
Directory
All systems created with the RobInstall will be stored in a system pool. The
default name of such a system pool is "system" as shown below. Each system
stored in the system pool is a directory with the name of the system as shown in
the table below.
By default, after installing RobInstall, a directory "system" will be found in Program Files\ABB Robotics\ and will also be the current one. However any directory in the structure can be set up as the current system directory in the Create New
System window or Select System window.
Directory view
xx0100000260
xx0100000261
File system
requirements
3HAC 16638-1
The system directory must hold these files and directories to allow software installation:
A syspar directory containing .cfg files to be included in the software installation procedure. All system parameter files, included when creating a system with RobInstall, are stored in this syspar directory as shown in the
table in section "System Pool Directory".
A directory called Home. In this home directory the user can include any
file or files, which should be downloaded to the controller together with the
operating system. Such files will then be placed in the home directory of
the system in the controller.
201
Controller
System directory structure
The root directory of the mass storage memory is called hd0a. This includes several components:
File name
Description
BootImage code
BootRom.sys
MC.cfg
ctrl.bin
system.dir
system directories
Directories and
subdirectories
Each system directory holds a number of subdirectories, defining for instance language, options, robots, etc.
"Home" directory
The system directory is the "home" directory for the system. When using the
address "home:" in the RAPID program, this directory will be addressed.
"Bin" subdirectory
The subdirectory bin, containing the storage area for all system data, e.g. at power
break. This means that at warm start, in addition to restoring the operating system
from the control system package, all system data is restored from this directory
and reloaded into the working memory.
Never change
these directories!
Never delete or change the \bin or BootRom.sys directories in the root directory.
If this is done, the controller cannot be restarted and it will be impossible to use
the mass storage memory.
202
3HAC 16638-1
Controller
System directory structure
Illustration
Media pool
S ystem Pack in
/3haxbbbb-1.nn
*.* si gnature no
S ystem pool
E xt Option in
/3haxcccc1.nn
*.* relkey.txt
Created files
key.id
program.id
My syst em
/syst em_n
key.id
program.id
keystr.txt
/syspar
*.cfg
xx0100000262
Files to be prepared
3HAC 16638-1
RobInstall creates a file named Key.id from the key strings specifying the
options to be installed from the System Pack and the external option programs to be installed.
Unless deselected in RobInstall, the latest revision of the System Pack and
External Option Programs is selected as default (see section "Change
options or system pack revisions").
These are copied from the media pool and concatenated into one target
file that also holds the key.id and the syspar directory. This may then be
downloaded to the controller via Ethernet or a set of diskettes. The target
file is temporarily stored in the system directory before downloading or creating diskettes.
203
Controller
System directory structure
General
In some cases it is very important that there is enough free space in the mass
storage memory, before attempting to download new system software. How to
check its capacity, and if required increase it, is detailed below.
A manual check on the free space can be done in one of the following ways:
Checking storage
capacity from the
Teach Pendant
Unit
Checking storage
capacity through
connection to the
MC/CONSOLE
port
There should always be at least 25 Mb free disk space on the controller mass
storage memory before attempting to download a new system. For information on
how to increase storage capacity, see below!
If the capacity of the mass storage memory is less than 25 Mb when a new controller system is to be downloaded, storage memory must be released by removing
old systems from the mass storage memory. This can be done in one of the following ways:
1. Boot up on the system you would like to remove and then make a CSTART (see section "C-start").
2. Use the FileManager in the Teach Pendant Unit, see Users Guide - File
Manager, for more information on how to use the FileManager.
3. Use a third-party "ftp" client (like FTPVoyager supplied on the RobotWare CD).
204
3HAC 16638-1
Controller
System directory structure
3HAC 16638-1
205
Controller
System directory structure
206
3HAC 16638-1
Calibration
Chapter 5:Calibration
When to calibrate
Calibrate the measurement system carefully if any of the resolver values has been
changed. This may occur when parts affecting the calibration position have been
replaced on the robot.
Calibrate the system roughly as detailed in section "Updating the revolution
counter" if the contents of the revolution counter memory are lost. This may occur
when:
3HAC 16638-1
a robot axis has been moved with the control system disconnected
207
Calibration
General
Section A: General
How to calibrate the robot system
General
This section provides an overview of the procedure required when calibrating the
robot system. Many of the steps in the procedure are detailed in other sections to
which references are given.
Procedure
Step
208
Action
Note/Illustration
1.
2.
3.
Manually, run the robot axes to a posi- Use the calibration scales or distion close to the correct calibration
tances to locate this position,
position.
detailed in "Correct orientation
of axes".
4.
5.
6.
3HAC 16638-1
Calibration
General
Additional
information
In addition to the basic calibration procedure detailed above, a number of calibration related actions may be performed:
Action
Detailed in section:
How to manually check the current calibration Checking the calibration position
position.
3HAC 16638-1
209
Calibration
General
Calibration tool
kit, 3HAC xxxxx-x
The calibration tool kit, 3HAC xxxxx-x, can be ordered from ABB Automation
Technologies AB, Robotics.
The kit contains:
210
Digital indicator
Magnetic stand
Tool case
3HAC 16638-1
Calibration
Preliminaries
Section B: Preliminaries
Correct orientation of axes
General
3HAC 16638-1
211
Calibration
Preliminaries
Index marks
The figure below shows the index marks of axes 4-5-6 and the correct position of
the spiral cable. It also shows the calibration distance on axes 1-2-3.
C
B
G
D
xx0200000341
212
3HAC 16638-1
Calibration
Preliminaries
Correct position
of axes 1-2-3
The procedure below details how to check and eventually correct the orientation
of axis 4.
Axis 4 has no mechanical limitation! Cabling inside the manipulator may be damaged if axis 4 is oriented incorrectly when performing calibration of the robot!
If work must be carried out within the robots work envelope, the following points
must be observed:
The operating mode selector on the controller must be in the manual mode position
to render the enabling device operative and to block operation from a computer link
or remote control panel.
The robots speed is limited to max. 250 mm/s when the operating mode selector
is in position < 250 mm/s. This should be the normal position when entering the
working space. The position 100%full speed may only be used by trained personnel who are aware of the risks that this entails.
Step Action
Note
3HAC 16638-1
213
Calibration
Preliminaries
Step Action
Note
Step
214
Action
Note/Illustration
1.
2.
3HAC 16638-1
Calibration
Preliminaries
General
Check the calibration position before beginning any programming of the robot
system. This may be done as detailed below.
Step
1.
Action
Note/Illustration
xx0100000195
2.
3.
xx0100000196
3HAC 16638-1
215
Calibration
Preliminaries
Manually running
the manipulator
to the sync position
This section details the first step when updating the revolution counter; manually
running the manipulator to the synchronization position.
Step
Action
Illustration
1.
2.
Press the enabling device on the teach pen- Calibration marks shown
dant and, using the joystick, move the robot in section "Correct orienmanually so that the calibration marks or dis- tation of axes".
tances lie within the tolerance zone.
3.
Note that axis 6 does not have any mechanical stop and can thus be calibrated at the
wrong faceplate revolution. Do not operate
axis 6 manually before the robot has been
calibrated.
4.
This section details the second step when updating the revolution counter; storing
the revolution counter settings.
If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, which in turn may cause damage or injury!
216
3HAC 16638-1
Calibration
Preliminaries
Step
1.
Action
Illustration
xx0100000194
2.
xx0100000200
3.
xx0100000201
4.
xx0100000202
5.
3HAC 16638-1
217
Calibration
Preliminaries
Step
218
Action
Illustration
6.
7.
8.
9.
Not required.
3HAC 16638-1
Calibration
Preliminaries
General
The section below details how to use the Teach Pendant Unit (TPU) when performing a fine-calibration of the robot.
Procedure
Step
Action
Note/Illustration
1.
2.
xx0100000194
xx0100000200
3HAC 16638-1
219
Calibration
Preliminaries
Step
3.
Action
Note/Illustration
Choose Calibration
from the View menu. The
Calibration window appears.
xx0100000201
Explanation of status:
Synchronized: all axes are calibrated and their positions are
known. The unit is ready for use.
4.
xx0100000203
220
3HAC 16638-1
Calibration
Preliminaries
Step
5.
Action
Note/Illustration
xx0100000204
3HAC 16638-1
6.
7.
8.
221
Calibration
Calibration
Section C: Calibration
Directions for all axes
The figure below shows the positive and negative directions for each axis.
+
4
+
+
xx0200000355
222
3HAC 16638-1
Calibration
Calibration
Jogging
directions
The figure below shows the linear directions when jogging the robot.
+Y
+Z
+X
+Z
xx0200000378
3HAC 16638-1
223
Calibration
Calibration
Introduction
This section details how to calibrate the complete robot, using calibration tools.
The section is divided into the following parts:
Before calibration
Before calibration
Required equipment
Calibration order
Calibration, axis 5
Calibration, axis 6
Calibration, axis 4
Before calibrating the robot, make sure that the requirements in the previous sections "General" and "Preliminaries" are met!
Required equipment
Calibration order
224
Equipment, etc.
Art. no.
Note
The order of calibration of the axes 1, 2 and 3 is of no importance, but the remaining axes must be calibrated in the following sequence: 5 - 6 - 4.
3HAC 16638-1
Calibration
Calibration
Calibration axis 1,
2 and 3
The procedure below details how to calibrate axis 1, but it is the same for axes 2
and 3. Calibrate one axis at a time and then repeat the procedure for the remaining
axes.
Step
Action
Note/Illustration
1.
2.
Operate current axis (axis 1, 2 or 3) in manual mode with the joystick until only 40-50
mm of the movable part of the actuator is
visible.
3.
Insert the gauge block between the platform and the actuator cover (see adjacent
figure) and then gently contract the actuator until the gauge block fits exactly but is
not jammed.
Note! All three actuators should have
approximately the same length when one
of them is calibrated.
xx0200000351
3HAC 16638-1
4.
5.
A: 26 mm
225
Calibration
Calibration
Calibration, axis 5
Step
1.
Action
Note/Illustration
xx0200000352
226
3HAC 16638-1
Calibration
Calibration
Step
2.
3HAC 16638-1
Action
Note/Illustration
3.
4.
227
Calibration
Calibration
Calibration axis 6
Step
Action
Note/Illustration
1.
2.
xx0200000353
3.
228
3HAC 16638-1
Calibration
Calibration
Step
Calibration, axis 4
Action
Note/Illustration
4.
Move the robot in +/-Z (in base) and Directions shown in Directions
adjust axis 6 until the indicator shows for all axes.
minimum change (usually a few hundredths of a millimeter) while travelling from the middle of the tool to one
end (i.e. if the indicator shows 0.46
mm while travelling from the center of
the tool to one end of the tool, rotate
axis 6 by 0.46 mm).
5.
6.
Step
1.
2.
Action
Note/Illustration
Axis 4: 0 degrees.
xx0200000354
3HAC 16638-1
229
Calibration
Calibration
Step
230
Action
Note/Illustration
3.
4.
5.
6.
3HAC 16638-1
Calibration
After calibration
General
Perform the following procedure after calibrating any manipulator axes. The procedure is intended to verify that all calibration positions are correct.
Procedure
Step
3HAC 16638-1
Action
Illustration
1.
2.
3.
4.
Adjust the calibration marks when the calibra- Shown in section "Cortion is done.
rect orientation of axes".
5.
6.
231
Calibration
After calibration
232
3HAC 16638-1
Index
3HAC 16638-1
233
Index
234
3HAC 16638-1
Repair Manual
Industrial Robot IRB 940 Tricept
3HAC 16640-1 / M2000 / Rev. IRB 940 Tricept
Table of Contents
Overview
Product Documentation, IRB 940 Tricept
Chapter 1: Safety, service
Introduction
Safety, service - General
Section A: References
Limitation of Liability
Applicable Safety Standards
Related information
Section B: Safety risks
3HAC 16640-1
1
3
5
5
6
7
7
7
8
9
9
9
9
10
10
11
13
13
13
14
14
15
15
15
17
17
18
20
21
21
22
22
27
34
38
43
Table of Contents
49
55
58
62
67
72
77
82
85
89
ii
89
92
95
99
99
100
103
106
109
113
116
120
125
129
132
135
135
136
137
138
139
140
141
142
143
144
144
3HAC 16640-1
Table of Contents
3HAC 16640-1
145
145
146
146
147
148
149
150
151
151
152
153
154
155
156
157
157
158
159
160
161
162
163
164
165
166
166
167
168
169
170
170
171
172
173
174
175
176
177
iii
Table of Contents
iv
178
179
180
181
182
183
184
185
186
187
187
188
189
190
191
192
193
194
195
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
211
212
213
214
3HAC 16640-1
Table of Contents
3HAC 16640-1
215
216
217
218
219
220
221
222
223
224
225
226
227
228
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
Table of Contents
vi
3HAC 16640-1
Overview
About This
Manual
Usage
Prerequisites
Organization of
Chapters
Chapter
Contents
1.
Safety
2.
Reference information
3.
Manipulator
4.
Controller
References
3HAC 16640-1
Reference
Document Id
Reference
Document Id
Revisions
Revision
Description
First edition
3HAC 16640-1
General
Overview,
Installation and
Commissioning
Manual
The Installation and Commissioning Manual contains the following main chapters:
Overview, Repair
Manual
Overview,
Maintenance
Manual
3HAC 16640-1
Safety, Service
Reference Information
Unpacking
On-site Installation
Electrical connections
Start-up
Robot controller
Calibration
Safety, Service
Reference Information
Safety, Service
Reference Information
Maintenance schedules
Maintenance activities
Disposal
The chapters for the maintenance activities include instructions for all the maintenance activities specified in the maintenance schedule.
3HAC 16640-1
Safety, service
Definitions
This chapter details safety information for service personnel i.e. personnel performing installation, repair and maintenance work.
Sections
B. Safety risks lists dangers relevant when servicing the robot system.
The dangers are split into different categories:
Safety risks related to end effector
Safety risks related to tools/workpieces
Safety risks related to pneumatic/hydraulic systems
Safety risks during operational disturbances
Safety risks during installation and service
Risks associated with live electric parts
3HAC 16640-1
Safety, service
Validity and
responsibility
The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment, which can influence the safety
of the total system. To protect personnel, the complete system must be designed
and installed in accordance with the safety requirements set forth in the standards
and regulations of the country where the robot is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable
safety laws and regulations in the country concerned are observed and that the
safety devices necessary to protect people working with the robot system have
been designed and installed correctly. Personnel working with robots must be
familiar with the operation and handling of the industrial robot, described in the
applicable documents, e.g. Users Guide and Product Manual.
Connection of
external safety
devices
Apart from the built-in safety functions, the robot is also supplied with an interface for the connection of external safety devices. Via this interface, an external
safety function can interact with other machines and peripheral equipment. This
means that control signals can act on safety signals received from the peripheral
equipment as well as from the robot.
In the Product Manual - Installation and Commissioning, instructions are provided for connecting safety devices between the robot and the peripheral equipment.
3HAC 16640-1
Safety, service
References
Section A: References
Limitation of Liability
General
Any information given in this information product regarding safety, must not be
construed as a warranty by ABB Robotics that the industrial robot will not cause
injury or damage even if all safety instructions have been complied with.
Standards
3HAC 16640-1
Safety, service
References
Related information
General
Documents
Type of information
Detailed in document
Users Guide
Section
Start-up
3HAC 16640-1
Safety, service
Safety risks
Safe handling
It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure
that guards remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
General
Residual energy
Safe design
3HAC 16640-1
Residual energy may be present in these systems so, after shutdown, particular care must be taken.
Gravity may cause any parts or objects held by these systems to drop.
Shot bolts should be used to prevent tools, etc., from falling due to gravity.
Safety, service
Safety risks
General
Qualified
personnel
Extraordinary
risks
The industrial robot is a flexible tool which can be used in many different
industrial applications.
All work must be carried out professionally and in accordance with the
applicable safety regulations.
Remedial action must only be carried out by qualified personnel who are
familiar with the entire installation as well as the special risks associated
with its different parts.
If the working process is interrupted, extra care must be taken due to risks other
than those associated with regular operation. Such an interruption may have to be
rectified manually.
Nation/region
specific regulations
10
Those in charge of operations must make sure that safety instructions are
available for the installation in question.
Those who install the robot must have the appropriate training for the robot
system in question and in any safety matters associated with it.
To prevent injuries and damage during the installation, lifting and transport of the
robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with.
3HAC 16640-1
Safety, service
Safety risks
Non-voltage
related risks
To be observed
by the supplier of
the complete system
Turntables or the like should be used to keep the operator out of the
robot's working space.
The axes are affected by the force of gravity when the brakes are released
or when the motors or other components are removed.
Never use the robot as a ladder, i.e. do not climb on the robot motors or
other parts during service work. There is a serious risk of slipping because
of the high temperature of the motors or oil spills that can occur on the
robot.
The supplier of the complete system must ensure that all circuits used in
the safety function are interlocked in accordance with the applicable standards for that function.
The supplier of the complete system must ensure that all circuits used in
the emergency stop function are interlocked in a safe manner, in accordance with the applicable standards for the emergency stop function.
Voltage related
risks, general
3HAC 16640-1
The mains supply to the robot must be connected in such a way that it can
be turned off outside the robots working space.
11
Safety, service
Safety risks
Voltage related
risks, controller,
S4Cplus
Units inside the controller, e.g. I/O modules, can be supplied with power
from an external source.
The power supply unit for the computer system (230 VAC)
The rectifier unit (400-480 VAC and 700 VDC. N.B.: Capacitors!)
The power supply unit for tools, or special power supply units for the
machining process
The external voltage connected to the control cabinet remains live even
when the robot is disconnected from the mains.
Additional connections
Voltage related
risks, manipulator, IRB 940 Tricept
Voltage related
risks, tools, material handling
devices, etc.
Tools, material handling devices, etc., may be live even if the robot system is in
the OFF position. Power supply cables which are in motion during the working
process may be damaged.
12
The user connections for tools or other parts of the installation (max. 230V
AC, see Product Manual - Installation and Commissioning)
3HAC 16640-1
Safety, service
Safety actions
General
Install a safety cell around the robot to ensure safe robot installation and operation.
Dimensioning the
fence or enclosure
- withstand any impact from a tool failure. Due to the high kinetic energy
associated with HSM (High Speed Machining), a tool failure poses a serious risk as any debris can cause serious personal injury. Both walls and
ceilings must be designed and dimensioned so that they can withstand any
projectiles that they may be subjected to. Windows must be made from
suitable safety glass. Study the planned process to determine the forces
involved and appropriate materials.
- isolate gases and mist generated by the machining process and spray
mist lubrication. Study the planned process to determine the fumes
involved and appropriate ventilation/filtering system.
Fire extinguishing
Use a CARBON DIOXIDE (CO 2 ) extinguisher in the event of a fire in the robot
(manipulator or controller)!
3HAC 16640-1
13
Safety, service
Safety actions
Description
In an emergency situation, any of the manipulators axes may be released manually by pushing the brake release buttons on the distribution box for the manipulator. How to release the brakes is detailed in section "Manually releasing the
brakes" in the Installation Manual.
The manipulator arms may be moved manually when the brakes has been
released.
Increased injury
Before releasing the brakes, make sure that the weight of the arms does not
increase the pressure on the trapped person, further increasing any injury!
Brake testing
When to test
During operation the holding brakes of each axis motor wear normally. A test may
be performed to determine whether the brake can still perform its function.
How to test
The function of each axis motor holding brakes may be checked as detailed
below:
1. Run each manipulator axis to a position where the combined weight of
the manipulator arm and any load is maximized (max. static load).
2. Switch the motor to the MOTORS OFF position with the Operating
mode selector on the controller.
3. Check that the axis maintains its position.
If the manipulator does not change position as the motors are switched off, then
the brake function is adequate.
14
3HAC 16640-1
Safety, service
Safety actions
3HAC 16640-1
15
Safety, service
Safety actions
16
3HAC 16640-1
Reference Information
General
3HAC 16640-1
This chapter presents generic pieces of information, complementing the more specific information in the following chapters.
17
Reference Information
Screw joints
General
This section details how to tighten the various types of screw joints in the manipulator as well as the controller.
The instructions and torque values are valid for screw joints comprising metallic
materials and does not apply to soft or brittle materials.
Any instructions given in the repair, maintenance or installation procedure
description override any value or procedure given here, i.e. these instruction are
only valid for standard type screw joints.
Tightening torque
Screws with
slotted or cross
recess head
Screws with
hexagon socket
head
18
The tightening torque values for different types of screw joint are specified in the
tables below:
Dimension
M2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
Dimension
Tightening
torque (Nm)
Class 8.8 "dry"
Tightening
torque (Nm)
Class 10.9
Tightening
torque (Nm)
Class 12.9
M5
M6
10
17
M8
24
28
40
M10
47
55
70
M12
82
95
120
3HAC 16640-1
Reference Information
3HAC 16640-1
Dimension
Tightening
torque (Nm)
Class 8.8 "dry"
Tightening
torque (Nm)
Class 10.9
Tightening
torque (Nm)
Class 12.9
M16
200
235
300
19
Reference Information
Weight specifications
Definition
Within all repair and maintenance instructions, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are highlighted in this way.
ABB recommends handling all components with a weight exceeding 22 kg using
lifting equipment to avoid inflicting injury.
Example
20
3HAC 16640-1
Manipulator
Chapter 3:Manipulator
Introduction
Definitions
This chapter details all repair activities recommended for the manipulator, including the manipulators distribution box.
It is made up of separate units, each detailing a specific repair activity, e.g.
Removal or Refitting of a certain component on the manipulator. Each unit contains all information required to perform the activity, e.g. spare parts numbers,
required special tools and materials.
The chapter is divided into:
3HAC 16640-1
Replacement instructions for all the spare parts in the manipulators distribution box
21
Manipulator
Manipulator repairs
Location
The three actuators are located on the manipulator as shown in the figure below.
D
A
C
xx0200000296
22
3HAC 16640-1
Manipulator
Manipulator repairs
Actuator
Actuator servomotor
Lower joint
Actuator fork
Center tube
Wrist
Required equipment
Equipment, etc.
Hook wrench
Note
3 mm pin, shown in
figure the below!
xx0200000350
Safety
3HAC 16640-1
23
Manipulator
Manipulator repairs
- When replacing motors/reducers, make sure that those parts of the robot which
could move unexpectedly are mechanically blocked as specified in the individual
procedures.
- Before removing, clean the work area and the components to be removed.
- Place the removed components in a clean container.
The actuator with motor weighs 40 kg! All lifting equipment used must be dimensioned accordingly!
Preparatory work
Step
24
Action
Note/Illustration
1.
2.
3.
3HAC 16640-1
Manipulator
Manipulator repairs
Removal of actuator
The procedure below details how to remove an actuator, including the motor. The
procedure is the same for all actuators. Make sure the preparatory work above is
done before removing an actuator!
Step
3HAC 16640-1
Action
Note/Illustration
1.
Remove the eletric cabling from the servomotor located on the actuator to be
removed.
Move and secure the cabling so it can not
get damaged during removal of the actuator.
2.
3.
Use a heating gun to loosen the threadlocking substance, before unscrewing the
lower joint from the lower platform.
4.
To release the bottom end of the actuator Shown in the figure above!
from the lower platform, unscrew the lower Specified above!
joint using thehook wrench.
Make sure the center tube and wrist are
anchored as detailed in the preparatory
work above!
5.
Unscrew the four attachment screws hold- Shown in the figure above!
ing the actuator to the actuator fork.
6.
7.
8.
25
Manipulator
Manipulator repairs
Removal of motor
The procedure below details how to remove the motor from a dismounted actuator.
Step
1.
Action
Note/Illustration
A
B
D
C
xx0200000302
26
2.
3.
4.
A: Servomotor
D: Backlash-free coupling
3HAC 16640-1
Manipulator
Manipulator repairs
Location
D
A
C
xx0200000296
3HAC 16640-1
Actuator
Actuator servomotor
27
Manipulator
Manipulator repairs
Lower joint
Actuator fork
Center tube
Wrist
Required equipment
Equipment, etc.
3HAC 17151-1
Note
Thread-locking substance
Hook wrench
3 mm pin
xx0200000350
Safety
28
3HAC 16640-1
Manipulator
Manipulator repairs
- Turn off all electrical power, hydraulic and pneumatic pressure supplies to the
robot!
- When replacing motors/reducers, make sure that those parts of the robot which
could move unexpectedly are mechanically blocked as specified in the individual
procedures.
Please observe the following when refitting components:
- Carefully clean the mating surfaces.
- Ensure that there are no damaged surfaces or other parts that need rectifying or
replacing.
- Replace all gaskets.
The actuator with motor weighs 40 kg! All lifting equipment used must be dimensioned accordingly!
Refitting of motor
In case the servomotor has been removed from the actuator, refit it as detailed in
procedure below.
Step
1.
Action
Note/Illustration
xx0200000303
3HAC 16640-1
A: Actuator shaft
B: 0mm
29
Manipulator
Manipulator repairs
Step
2.
Action
Note/Illustration
A
B
D
C
xx0200000302
Refitting of actuator
A: Servomotor
D: Backlash-free coupling
The procedure below details how to refit the actuator, including the motor. The
procedure is the same for all actuators.
Step
30
Action
Note/Illustration
1.
2.
3HAC 16640-1
Manipulator
Manipulator repairs
Step
3.
Action
Note/Illustration
A
B
xx0200000304
A: Clamp
B: Circlip
4.
Adjust the circlip so that the actuator remains tight against the left
hand side.
5.
Fit the clamps and tighten the four 4 pcs; tightening torque: 10 Nm.
hexagonal screws that hold the
clamps.
6.
xx0200000305
3HAC 16640-1
A: Sealing cap
31
Manipulator
Manipulator repairs
Step
Commissioning
Action
Note/Illustration
7.
8.
9.
Step
Action
Note/Illustration
1.
2.
3.
Detailed in Installation
Manual.
When performing the first test run after a service activity (repair, installation or
maintenance), it is vital that:
- all normal safety equipment is installed properly, e.g. TPU enabling device.
32
3HAC 16640-1
Manipulator
Manipulator repairs
- all personnel is standing at a safe distance from the manipulator, i.e. out of its
reach behind any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
3HAC 16640-1
33
Manipulator
Manipulator repairs
Location
The servomotors of axes 1, 2 and 3 are located on top of the actuators, as shown
in the figure below.
xx0200000297
34
3HAC 16640-1
Manipulator
Manipulator repairs
Required equipment
Safety
Note
Circuit Diagram
3HAC 16640-1
Preparatory work
Follow the instructions below for preparatory work, before commencing the
removal of a motor.
Step
3HAC 16640-1
Action
Note/Illustration
1.
Support the wrist before disconnecting the servomotor from the actuator, in order to keep the lower
platform stable and reduce the risk of injury and/or
damage.
2.
3.
35
Manipulator
Manipulator repairs
Step
4.
Removal
Note/Illustration
The procedure below details how to remove the servomotor, axes 1, 2 and 3.
Step
36
Action
Action
Note/Illustration
1.
2.
3.
3HAC 16640-1
Manipulator
Manipulator repairs
Step
4.
Action
Note/Illustration
A
B
D
C
xx0200000302
5.
3HAC 16640-1
A: Servomotor
D: Backlash-free coupling on
servomotor shaft
37
Manipulator
Manipulator repairs
Location
The servomotors of axes 1, 2 and 3 are located on top of the actuators, as shown
in the figure below.
xx0200000297
38
3HAC 16640-1
Manipulator
Manipulator repairs
Required equipment
Equipment, etc. Spare part no. Art. no.
Servomotor, axes
1-3
3HAC 17152-1
Circuit Diagram
Safety
Note
3HAC 16640-1
Refitting
3HAC 16640-1
The procedure below details how to refit the servomotor, axes 1-3.
39
Manipulator
Manipulator repairs
Step
1.
Action
Note/Illustration
A
xx0200000308
40
A: 10 0.5 mm
3HAC 16640-1
Manipulator
Manipulator repairs
Step
2.
Action
Note/Illustration
79
51
xx0200000447
3.
3HAC 16640-1
41
Manipulator
Manipulator repairs
Commissioning
Follow the instructions below before commissioning after refitting motor on axes
1, 2 and 3.
Step
Action
Note/Illustration
1.
2.
3.
Detailed in Installation
Manual.
When performing the first test run after a service activity (repair, installation or
maintenance), it is vital that:
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its
reach behind any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
42
3HAC 16640-1
Manipulator
Manipulator repairs
Location
The motor unit of axis 4 is located inside the center tube sleeve, at the lower part
of the center unit, as shown in the figure below.
B
C
A
xx0200000299
3HAC 16640-1
Gimbal
Lower platform
43
Manipulator
Manipulator repairs
Required equipment
Equipment, etc. Spare part no. Art. no.
Note
Lifting bracket
String
Circuit Diagram
Safety
The center unit is very heavy and in a vertically orientated robot, there is a risk of
pinching between the center tube and the axis 4 motor.
44
3HAC 16640-1
Manipulator
Manipulator repairs
Preparatory work
Follow the instructions below for preparatory work, before commencing the
removal of the motor unit on axis 4.
Step
Removal
Note/Illustration
1.
2.
3.
The procedure below details how to remove the motor unit on axis 4. Make sure
the preparatory work above is done before removing the actuator!
Step
3HAC 16640-1
Action
Action
Note/Illustration
1.
2.
3.
45
Manipulator
Manipulator repairs
Step
4.
Action
Note/Illustration
A
B
C
D
xx0200000306
46
5.
6.
B: Cable connector
holder
C: Housing
D: Lower plate
E: Center tube
3HAC 16640-1
Manipulator
Manipulator repairs
Step
7.
Action
Note/Illustration
A
B
D
xx0200000363
A: 6 pcs: M8.
B: 12 pcs: M6.
3HAC 16640-1
8.
Lift the center tube, using a hoist or lift, Shown in the figure above!
until the bottom of the center tube
almost reaches the gimbal.
When lifting the center tube, be very
careful not to stretch or squash the
cables inside. Eliminate the risk of
stretching the cabling by feeding it
through at the top at the same rate as
the center tube is lifted, with the help
of a string.
9.
47
Manipulator
Manipulator repairs
Step
Action
Note/Illustration
10.
Remove the 12 screws that hold the Shown in the figure above!
center tube sleeve to the lower platOn reassembly the same locatform interface.
ing pin is refitted!
Remove the locating pin that positions
the center tube sleeve.
11.
A
B
C
xx0200000307
48
12.
13.
14.
15.
B: Spacer
3HAC 16640-1
Manipulator
Manipulator repairs
Location
The motor unit of axis 4 is located inside the center tube sleeve, at the lower part
of the center unit, as shown in the figure below.
B
C
A
xx0200000299
3HAC 16640-1
Gimbal
Lower platform
49
Manipulator
Manipulator repairs
Required equipment
Equipment, etc. Spare part no. Art. no.
Servomotor, axis 4
Note
3HAC 17153-1
Lifting bracket
Circuit Diagram
Safety
3HAC 16640-1
Refitting
The procedure below details how to refit the motor unit, axis 4.
Step
1.
50
Action
Note/Illustration
Fit the axis 4 motor unit to the center 8 pcs: tightening torque: 33
shaft and tighten the screws. Ensure it Nm.
has the same orientation as the old
one
3HAC 16640-1
Manipulator
Manipulator repairs
Step
2.
Action
Note/Illustration
A
B
C
xx0200000307
3HAC 16640-1
3.
4.
5.
6.
B: Spacer
51
Manipulator
Manipulator repairs
Step
7.
Action
Note/Illustration
Locate the center tube using the location pin, center tube, as reference and
fit the 18 screws.
A
B
D
xx0200000363
52
8.
9.
3HAC 16640-1
Manipulator
Manipulator repairs
Step
10.
Action
Note/Illustration
A
B
C
D
xx0200000306
3HAC 16640-1
11.
12.
13.
A: Top plate
B: Cable connector
holder
C: Housing
D: Lower plate
E: Center tube
53
Manipulator
Manipulator repairs
Commissioning
Follow the instructions below before commissioning after refitting the motor, axis
4.
Step
Action
Note/Illustration
1.
2.
3.
Detailed in Installation
Manual.
When performing the first test run after a service activity (repair, installation or
maintenance), it is vital that:
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its
reach behind any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
54
3HAC 16640-1
Manipulator
Manipulator repairs
Location
The lower joint is located between the actuator and the lower platform, as shown
in the figure below.
C
D
A
xx0200000298
3HAC 16640-1
Lower platform
Actuator
Calibration spacer
55
Manipulator
Manipulator repairs
Required equipment
Equipment, etc. Spare part no. Art. no.
Note
Hook wrench
3 mm pin
xx0200000350
Safety
56
3HAC 16640-1
Manipulator
Manipulator repairs
Preparatory work
Follow the instructions below for preparatory work, before commencing the
removal of the lower joint.
Step
Removal
Note/Illustration
1.
Run actuators to half way in length. All the actuators should also have an equal length.
This is done in order to allow the actuator to retract
when the lower joint is unscrewed.
2.
3.
The procedure below details how to remove a lower joint. The procedure is the
same for all actuators. Make sure the preparatory work above is done before separating the parts!
Step
3HAC 16640-1
Action
Action
Note/Illustration
1.
Use a heating gun to loosen the thread-locking substance, before removing the lower
joint.
2.
3.
Loosen the lower joint from the lower platform Shown in figure above!
using a hook wrench, 3 mm pin.
Specified above!
4.
5.
57
Manipulator
Manipulator repairs
Location
The lower joint is located between the actuator and the lower platform, as shown
in the figure below.
C
D
A
xx0200000298
58
Lower platform
Actuator
Calibration spacer
3HAC 16640-1
Manipulator
Manipulator repairs
Required equipment
Equipment, etc.
Lower joint
3HAC 17154-1
Note
Thread-locking substance
Hook wrench
3 mm pin
xx0200000350
Safety
3HAC 16640-1
59
Manipulator
Manipulator repairs
Refitting
The procedure below details how to refit the lower joint. The procedure is the
same for all actuators.
Step
Commissioning
Note/Illustration
1.
Fit the calibration spacer and the cover Spare part no. specified above!
to the new lower joint.
2.
3.
Follow the instructions below before commissioning after refitting the lower joint.
Step
60
Action
Action
Note/Illustration
1.
2.
Detailed in Installation
Manual.
3HAC 16640-1
Manipulator
Manipulator repairs
Step
3.
Action
Note/Illustration
When performing the first test run after a service activity (repair, installation or
maintenance), it is vital that:
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its
reach behind any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
3HAC 16640-1
61
Manipulator
Manipulator repairs
Removal of wrist
Location
The wrist is located on the lower platform, as shown in the figure below.
E
C
F
A
xx0200000300
62
Wrist
Center tube
Gimbal
Lower platform
3HAC 16640-1
Manipulator
Manipulator repairs
Required equipment
Equipment, etc. Spare part no. Art. no.
Note
Lifting bracket
Safety
Punch tool
Lifting jack
The wrist weighs 36 kg! All lifting equipment used must be dimensioned accordingly!
3HAC 16640-1
63
Manipulator
Manipulator repairs
Preparatory work
Follow the instructions below for preparatory work, before commencing the
removal of the wrist unit.
Step
64
Action
Note/Illustration
1.
2.
3.
3HAC 16640-1
Manipulator
Manipulator repairs
Removal
The procedure below details how to remove the wrist. Make sure the preparatory
work above is done before removing the wrist!
Step
1.
Action
Note/Illustration
A
B
D
xx0200000363
3HAC 16640-1
A: Attachment screws,
axis 4 motor to centre
tube: 6 pcs, M8 x 60.
B: Attachment screws
2.
Remove the spiral cable cover on the Shown in the figure above!
back of centre tube sleeve and the spiral cable inspection cover on the
same sleeve.
3.
65
Manipulator
Manipulator repairs
Step
Note/Illustration
4.
5.
6.
7.
8.
66
Action
xx0200000364
3HAC 16640-1
Manipulator
Manipulator repairs
Refitting of wrist
Location
The wrist is located on the lower platform, as shown in the figure below.
E
C
F
A
xx0200000300
3HAC 16640-1
Wrist
Center tube
Gimbal
Lower platform
67
Manipulator
Manipulator repairs
Required equipment
Safety
Equipment, etc.
Wrist
3HAC 17155-1
Note
Punch tool
Lifting jack
Stroke of at least
100 mm.
68
3HAC 16640-1
Manipulator
Manipulator repairs
Refitting
Step
Action
Note/Illustration
1.
2.
Ensure that the jack is correctly positioned underneath the lower platform, and
that it is in its lowest position. Place the
wrist on the jack.
3.
4.
5.
xx0200000367
3HAC 16640-1
69
Manipulator
Manipulator repairs
Step
Commissioning
Note/Illustration
6.
Lift the wrist with the jack until it is possi- 12 pcs; tightening torque: 10
ble to fasten the attachment screws
Nm.
through the wrist flange into the lower
Shown in the figure above!
platform. Press the wrist to its topmost
position by tightening two of the attachment screws, 180in relation to each
other.
Check that the bearing runs smoothly by
turning the wrist manually.
7.
8.
9.
10.
Refit the spiral cable cover and the spiral Shown in the figure above!
cable inspection cover with their sealings.
Step
70
Action
Action
Note/Illustration
1.
2.
Detailed in Installation
Manual.
3HAC 16640-1
Manipulator
Manipulator repairs
Step
3.
Action
Note/Illustration
When performing the first test run after a service activity (repair, installation or
maintenance), it is vital that:
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its
reach behind any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
3HAC 16640-1
71
Manipulator
Manipulator repairs
Location
The center unit includes the center tube, wrist, spiral cable, linear guide and axis
4 motor unit. It is located in the center of the manipulator, as shown in the figure
below. When removed, the housing and the gimble is left mounted on the center
unit, as shown in the figure below.
C
I
H
G
E
B
A
F
xx0200000301
72
Center unit
Lower joint
Wrist unit
Upper platform
Center tube
Gimbal
Linear guide
Lower platform
3HAC 16640-1
Manipulator
Manipulator repairs
Required equipment
Equipment, etc.
Hook wrench
Note
3 mm pin
xx0200000350
Safety
The center unit weighs over 100 kg! All lifting equipment must be dimensioned
accordingly!
3HAC 16640-1
73
Manipulator
Manipulator repairs
Preparatory work
Follow the instructions below for preparatory work, before commencing the
removal of the center unit.
Step
Removal
Note/Illustration
1.
2.
3.
The procedure below details how to remove the center unit. Make sure the preparatory work above is done before removal!
Step
1.
74
Action
Action
Note/Illustration
3HAC 16640-1
Manipulator
Manipulator repairs
Step
2.
Action
Note/Illustration
xx0200000365
3HAC 16640-1
3.
4.
75
Manipulator
Manipulator repairs
Step
5.
Action
Note/Illustration
xx0200000309
76
6.
7.
3HAC 16640-1
Manipulator
Manipulator repairs
Location
The center unit includes the center tube, wrist and axis 4 motor unit. It is located
in the center of the manipulator, as shown in the figure below. When removed, the
housing and the gimble is left mounted on the center unit, as shown in the figure
below.
C
I
H
G
E
B
A
F
xx0200000301
3HAC 16640-1
Center unit
Lower joint
Wrist
Upper platform
Center tube
Gimbal
Linear guide
Lower platform
77
Manipulator
Manipulator repairs
Required equipment
Equipment, etc.
Center Unit
3HAC 17156-1
Note
Thread-locking substance
Hook wrench
3 mm pin
xx0200000350
Safety
78
3HAC 16640-1
Manipulator
Manipulator repairs
Refitting
Step
3HAC 16640-1
Action
Note/Illustration
1.
2.
79
Manipulator
Manipulator repairs
Step
3.
Action
Note/Illustration
B
C
xx0200000310
80
A: center unit
B: Gimbal
C: Upper platform
D: Master
4.
5.
3HAC 16640-1
Manipulator
Manipulator repairs
Commissioning
Follow the instructions below before commissioning after refitting the center unit.
Step
Action
Note/Illustration
1.
2.
3.
When performing the first test run after a service activity (repair, installation or
maintenance), it is vital that:
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its
reach behind any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
3HAC 16640-1
81
Manipulator
Manipulator repairs
Location
The spiral cable is located inside the center tube, running from the top of the
manipulator to the wrist unit.
C
A
xx0200000312
82
Spiral cable
Wrist unit
3HAC 16640-1
Manipulator
Manipulator repairs
Required equipment
Equipment, etc.
Safety
Note
These procedures
include references
to the tools
required.
The center unit is very heavy and in a vertically orientated robot, there is a risk of
pinching between the center tube and the axis 4 motor.
3HAC 16640-1
83
Manipulator
Manipulator repairs
Preparatory work
Follow the instructions below for preparatory work, before commencing the
removal of the spiral cable.
Step
Removal
Note/Illustration
1.
2.
3.
The procedure below details how to remove the spiral cable. Make sure the preparatory work above is done before removal!
Step
84
Action
Action
Note/Illustration
1.
2.
3.
3HAC 16640-1
Manipulator
Manipulator repairs
Location
The spiral cable is located inside the center tube, running from the top of the
manipulator down to the wrist unit.
C
A
xx0200000312
3HAC 16640-1
Spiral cable
Wrist unit
85
Manipulator
Manipulator repairs
Required equipment
Equipment, etc.
Spiral Cable
3HAC 17157-1
Safety
Note
These procedures
include references
to the tools required.
86
3HAC 16640-1
Manipulator
Manipulator repairs
Refitting
Step
Action
Note/Illustration
1.
2.
3.
xx0200000366
Commissioning
Follow the instructions below before commissioning after refitting the spiral cable
and wrist unit.
Step
1.
3HAC 16640-1
Action
Note/Illustration
87
Manipulator
Manipulator repairs
Step
Action
Note/Illustration
2.
3.
When performing the first test run after a service activity (repair, installation or
maintenance), it is vital that:
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its
reach behind any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
88
3HAC 16640-1
Manipulator
Distribution box repairs
Location
The battery is located in the distribution box as shown in the figure below.
xx0200000394
3HAC 16640-1
Battery
89
Manipulator
Distribution box repairs
Required equipment
Equipment, etc. Spare part no. Art. no.
Battery
Safety
Note
4944026-4
Removal
The procedure below details how to remove the battery from the distribution box.
Step
90
Action
Note/Illustration
1.
2.
3.
3HAC 16640-1
Manipulator
Distribution box repairs
Refitting
The procedure below details how to refit the battery to the distribution box.
Step
3HAC 16640-1
Action
Note/Illustration
1.
2.
3.
91
Manipulator
Distribution box repairs
Location
The serial measurement card is located in the distribution box as shown in the
figure below.
xx0200000394
92
Battery
3HAC 16640-1
Manipulator
Distribution box repairs
Required equipment
Equipment, etc.
Safety
Note
3HAC 14505-1
Removal
The procedure below details how to remove the serial measurement card from the
distribution box.
Step
3HAC 16640-1
Action
Note/Illustration
1.
2.
3.
4.
93
Manipulator
Distribution box repairs
Refitting
The procedure below details how to refit the serial measurement card to the distribution box.
Step
94
Action
Note/Illustration
1.
2.
3.
Refit the three screws holding the serial measurement card and the battery to the enclosure.
4.
3HAC 16640-1
Manipulator
Distribution box repairs
Location
The brake release card is located in the distribution box as shown in the figure
below.
xx0200000393
3HAC 16640-1
95
Manipulator
Distribution box repairs
Required equipment
Equipment, etc.
Safety
Note
3HAC 0017-1
Removal
The procedure below details how to remove the brake release card from the distribution box.
Step
96
Action
Note/Illustration
1.
2.
3.
3HAC 16640-1
Manipulator
Distribution box repairs
Refitting
The procedure below details how to refit the brake release card to the distribution
box.
Step
3HAC 16640-1
Action
Note/Illustration
1.
2.
3.
97
Manipulator
Distribution box repairs
98
3HAC 16640-1
Controller repair
Chapter 4:Controller
Introduction
Definitions
This chapter details all repair activities recommended for the controller.
It is made up of separate units, each detailing a specific repair activity, e.g.
Removal or Refitting of a certain component in the controller. Each unit contains
all information required to perform the activity, e.g. spare parts numbers, required
special tools and materials.
The chapter is divided into:
3HAC 16640-1
Remaining instructions
99
Controller repair
A
xx0200000105
Opening
Computer unit
100
3HAC 16640-1
Controller repair
Step
Action
Note/Illustration
1.
2.
3.
4.
xx0200000016
xx0200000017
5.
3HAC 16640-1
101
Controller repair
Step
Action
Note/Illustration
6.
7.
If work is to be performed on
the computer unit while in
the service position, it must
be locked in this position.
This is done by placing the
puck (located on the lower
left side) on the metal bar.
Alternatively, the computer
unit may be lifted straight up
and placed on a work bench.
xx0200000018
Closing
Step
1.
102
Action
Note/Illustration
3HAC 16640-1
Controller repair
The air filter is located in the air filter magazine in the front hatch.
A
xx0200000284
Required equipment
Equipment, etc.
Air filter
3HAB 8028-1
3HAC 16640-1
Note
These procedures include references to the
tools required.
103
Controller repair
Step
Action
Note/Illustration
1.
2.
3.
xx0200000001
xx0200000003
Step
1.
104
Action
Note/Illustration
Fit the air filter in the magazine. Art. no. is specified above!
3HAC 16640-1
Controller repair
Step
2.
Action
Note/Illustration
xx0200000006
3HAC 16640-1
105
Controller repair
A
xx0200000103
Battery unit
Required equipment
106
Equipment, etc.
Note
Battery unit
3HAC 5393-2
To be replaced as
a complete unit
3HAC 16640-1
Controller repair
Equipment, etc.
Note
Removal, battery
unit
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it!
Before handling, make sure you are connected to earth through a special ESD
wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD
protection button for connection of the bracelet. Use it!
Step
1.
Action
Note/Illustration
X1
X1
X2
X2
X2
X1
X2
X3
xx0200000004
2.
3HAC 16640-1
107
Controller repair
Step
3.
Action
Note/Illustration
xx0200000005
Refitting, battery
unit
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it!
Before handling, make sure you are connected to earth through a special ESD
wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD
protection button for connection of the bracelet. Use it!
Step
108
Action
Note/Illustration
1.
2.
3.
3HAC 16640-1
Controller repair
Location of I/O
and gateway units
The I/O and gateway units are located as shown in the figure below.
xx0200000009
3HAC 16640-1
I/O and gateway units located beneath the top cover of the cabinet
109
Controller repair
Required equipment
Equipment, etc.
Removal
Note
3HAB 7229-1
DSQC 328
Analog I/O
AD Combi I/O
3HAB 7230-1
DSQC 327
3HAB 7231-1
DSQC 320
3HAB 9669-1
DSQC 332
Step
1.
110
Action
Note/Illustration
3HAC 16640-1
Controller repair
Step
2.
Action
Note/Illustration
by hand when
replacing a gateway unit (position 2b in the
figure).
2a
3a
2b
3b
xx0200000010
3.
Refitting
Step
1.
3HAC 16640-1
Action
Note/Illustration
111
Controller repair
Step
2.
112
Action
Note/Illustration
3HAC 16640-1
Controller repair
Location of
bleeder resistor
The bleeder resistor is located behind the drive units, as shown in the figure below.
xx0200000007
3HAC 16640-1
Drive units
113
Controller repair
Required equipment
Removal
Equipment, etc.
Bleeder resistor
3HAC 4560-5
Note
Step
Action
Note/Illustration
1.
2.
3.
1
2
xx0200000015
4.
114
3HAC 16640-1
Controller repair
Refitting
Step
3HAC 16640-1
Action
Note/Illustration
1.
2.
3.
Detailed in section
"Replacement of drive
units and rectifier".
4.
Detailed in section
"Replacement of power
supply unit".
115
Controller repair
Location of mass
storage memory
The mass storage memory is located in the computer system, which is shown in
the figure below.
A
xx0200000105
Computer system
Required equipment
Equipment, etc.
Note
116
3HAC 16640-1
Controller repair
Equipment, etc.
Note
Removal
The procedure below details how to remove the mass storage memory.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it!
Before handling, make sure you are connected to earth through a special ESD
wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD
protection button for connection of the bracelet. Use it!
Step
Action
Note/Illustration
1.
2.
xx0200000019
3.
3HAC 16640-1
117
Controller repair
Step
4.
Refitting
Action
Note/Illustration
The procedure below details how to refit the mass storage memory.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it!
Before handling, make sure you are connected to earth through a special ESD
wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD
protection button for connection of the bracelet. Use it!
Step
1.
Action
Note/Illustration
xx0200000019
2.
118
3HAC 16640-1
Controller repair
Step
3HAC 16640-1
Action
Note/Illustration
3.
4.
119
Controller repair
The internal cooling fan is located in the computer system, which is shown in the
figure below.
A
xx0200000105
Computer system
Required equipment
Equipment, etc.
Note
3HAC 6655-1
120
These procedures
include references
to the tools
required.
3HAC 16640-1
Controller repair
Removal
The procedure below details how to remove the internal cooling fan.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it!
Before handling, make sure you are connected to earth through a special ESD
wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD
protection button for connection of the bracelet. Use it!
Step
1.
3HAC 16640-1
Action
Note/Illustration
121
Controller repair
Step
2.
Action
Note/Illustration
E
xx0200000020
3.
Refitting
A: Upper fan
B: Lower fan
C: Locking tabs
D: Connector E5
E: Connector E6
The procedure below details how to refit the internal cooling fan.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it!
122
3HAC 16640-1
Controller repair
Before handling, make sure you are connected to earth through a special ESD
wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD
protection button for connection of the bracelet. Use it!
Step
1.
Action
Note/Illustration
Tip the internal cooling fan with its top towards Art. no. specified above!
the cabinet wall and fit it into the hole (see the
figure).
xx0200000021
2.
3HAC 16640-1
A: Push direction
123
Controller repair
Step
124
Action
Note/Illustration
3.
4.
3HAC 16640-1
Controller repair
Location of drive
units and rectifier
The drive units and rectifier are located as shown in the figure below.
xx0200000007
3HAC 16640-1
Drive units
125
Controller repair
Required equipment
Equipment, etc.
Note
3HAB 8101-17
DSQC 545A
3HAB 8101-18
DSQC 546A
Removal
Step
1.
126
Action
Note/Illustration
3HAC 16640-1
Controller repair
Step
2.
Action
Note/Illustration
Disconnect connectors X1
and X2, four connectors
each (see position 1 in the
figure).
1
xx0200000013
3.
4.
xx0200000014
5.
3HAC 16640-1
127
Controller repair
Refitting
Step
128
Action
Note/Illustration
1.
2.
3.
4.
Swing the power supply unit back into position. Detailed in section
"Replacement of power
supply unit"
3HAC 16640-1
Controller repair
xx0200000007
3HAC 16640-1
Drive units
129
Controller repair
Required equipment
Equipment, etc.
3HAC 12924-2
Note
Removal
The procedure below details how to remove the system fan unit.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it!
Before handling, make sure you are connected to earth through a special ESD
wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD
protection button for connection of the bracelet. Use it!
Step
Action
Note/Illustration
1.
2.
xx0200000008
130
3HAC 16640-1
Controller repair
Step
3.
Refitting
Action
Note/Illustration
The procedure below details how to refit the system fan unit.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it!
Before handling, make sure you are connected to earth through a special ESD
wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD
protection button for connection of the bracelet. Use it!
Step
3HAC 16640-1
Action
Note/Illustration
1.
2.
3.
Detailed in section
"Replacement of bleeder
resistor" in the Repair
Manual.
131
Controller repair
Location of power
supply unit
xx0200000011
Power supply unit folded out from the cabinet (view from above)
Required equipment
Equipment, etc.
Note
3HAB 4297-1
DSQC 506
132
3HAC 16640-1
Controller repair
Removal
The procedure below details how to remove the power supply unit.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it!
Before handling, make sure you are connected to earth through a special ESD
wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD
protection button for connection of the bracelet. Use it!
Step
Action
Note/Illustration
1.
2.
3.
xx0200000012
3HAC 16640-1
4.
5.
133
Controller repair
Step
6.
Refitting
Action
Note/Illustration
The procedure below details how to refit the power supply unit.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it!
Before handling, make sure you are connected to earth through a special ESD
wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD
protection button for connection of the bracelet. Use it!
Step
134
Action
Note/Illustration
1.
2.
3.
4.
3HAC 16640-1
This chapter contains all the circuit diagrams for the IRB 940 Tricept.
3HAC 16640-1
135
contact
R1 SMB
contact
R1 MP
3HAC 16640-1
en0200000410
+EC1
+EC1
136
3HAC 16640-1
-XM1.1
WM1
-XM1
AWG16
grey
-R1MP
en0200000411
Motor
axis 1
+M1
4.0
+EC1
M
3
A2
A1
PE
D6
A3
A4
D8
A5
A6
AWG16
yel/gr
-XTPE
AWG16
yel/gr
D10
PE
PE
PE
PE
PE
PE
PE
PE
4.3
PE1
-RT1
C1
-Y1
AWG20
blue
10
=M1/3, Axis 1
AWG20
blue
C3
CE
CE
-SMB
9.5
Serial
measuring
board
-XR1.1
WR1
-XR1
AWG22
blue
-XP1-4
14
R2.SMB1-4
15
18
Resolver 1
-B1
CE
137
3HAC 16640-1
-XM2.1
WM2
-XM2
AWG16
grey
-R1MP
en0200000412
Motor
axis 2
+M2
3.0
+EC1
A8
A7
PE
A9
A10
A11 A12
AWG16
yel/gr
-XTPE
PE
PE
5.3
PE1
3.4
PE1
C4
-Y2
AWG20
blue
10
=M1/4, Axis 2
-RT2
AWG20
blue
C5
CE
CE
-SMB
9.5
Serial
measuring
board
-XR2.1
WR2
-XR2
AWG22
blue
-XP1-4
16
R2.SMB1-4
17
19
Resolver 2
-B2
CE
138
3HAC 16640-1
-XM3.1
WM3
-XM3
AWG16
grey
-R1MP
en0200000414
Motor
axis 3
+M3
3.0
+EC1
PE
B2
AWG16
yel/gr
-XTPE
PE
PE
6.3
PE1
4.3
PE1
C15
-RT3
C6
-Y3
AWG20
blue
10
=M1/5, Axis 3
AWG20
blue
C7
CE
CE
-SMB
9.5
Serial
measuring
board
-XR3.1
WR3
-XR3
AWG22
blue
-XP1-4
21
10
R2.SMB1-4
22
20
Resolver 3
-B3
CE
139
3HAC 16640-1
Wmotor4.1
-XMTR4
Wmotor4
-XM4.1
PE
WM4
B4
D11
B3
-XM4
AWG16
grey
-R1MP
en0200000415
Motor
axis 4
+M4
3.0
+EC1
D12
B5
D13
AWG16
yel/gr
-XTPE
PE
7.3
PE1
5.3
PE1
-RT4
C8
-Y4
AWG20
blue
10
=M1/6, Axis 4
AWG20
blue
C9
CE
CE
-SMB
9.5
Serial
measuring
board
Wmotor4.1
-XMTR4
-XR4.1
WR4
-XR4
AWG22
blue
-XP3-6
12
13
14
15
R2.SMB3-6
14
15
11
10
18
Resolver 4
-B4
CE
140
3HAC 16640-1
-XM5.1
Wmotor5
18x
-XMTR5-6
PE
WM5
B6
en0200000416
Motor
axis 5
D15
B7
-XM5
AWG16
grey
-R1MP
Wmotor_5-6
Spiral 28x
+M5
3.0
+EC1
D14
B8
D9
AWG16
yel/gr
-XTPE
PE
12
8.3
PE1
6.3
PE1
-RT5
10
11
-Y5
-X5
AWG20
blue
CE
CE
-SMB
Wbrake5
-XR5.1
WR5
-XR5
AWG22
blue
-XP3-6
Wmotor5
-XMTR5-6
9.5
Serial
measuring
board
Wmotor6_and_brake 5
18
10
=M1/7, Axis 5
AWG20
blue
C11 C10
21
22
16
24
R2.SMB3-6
23
17
20
19
19
Resolver 5
-B5
25
CE
141
3HAC 16640-1
-XMTR5-6
Wmotor_5-6
+M6
en0200000417
Motor
axis 6
PE
WM6
-XM6.1
B10
B9
-XM6
AWG16
grey
-R1MP
motor6_and_brake 5
3.0
+EC1
B11
AWG16
yel/gr
-XTPE
PE
16
9.1
PE1
7.3
PE1
14
15
C12
-Y6
AWG20
blue
27
36
10
=M1/8, Axis 6
-RT6
AWG20
blue
C2
CE
CE
-SMB
9.5
Serial
measuring
board
-XR6.1
WR6
-XR6
AWG22
blue
-XP3-6
30
31
21
33
10
R2.SMB3-6
32
22
29
28
20
Resolver 6
-B6
34
CE
142
3HAC 16640-1
PE1
earth conn.
(screw)
distribution
box chassie
AWG10
yel/gr
-XTPE
R1MP D1
AWG20
blue
=M1
+FO
8.3/
en0200000418
3.0
EC1
D2
AWG10
5m
yel/gr
PE
D3
D4
earth conn.
(screw)
cover
earth conn.
(screw)
mounting plate
PE
-SMB
3.6
Serial
measuring
board
R2SMB
9
PE
WSMB
canbus
8x
R1SMB A
CE
CE
R2G 2
blue
7,2VDC/4Ah
Battery
-G
black
Circuit Diagram, IRB 940 Tricept - =M1/9, Serial Measure board, Earth connec-
143
3HAC 16640-1
en0200000419
3.0
+EC1
-BU
Brake
release
unit
-X9
-X8
AWG16
blue
-R1MP
10
11
B14 B15
-X10
5
AWG16
blue
144
This chapter contains the circuit diagram for the controller S4Cplus. The chapter is divided into the separate systems..
3HAC 16640-1
145
3HAC 16640-1
146
3HAC 16640-1
147
3HAC 16640-1
148
3HAC 16640-1
149
3HAC 16640-1
150
3HAC 16640-1
151
3HAC 16640-1
152
3HAC 16640-1
153
3HAC 16640-1
154
3HAC 16640-1
155
3HAC 16640-1
156
3HAC 16640-1
157
3HAC 16640-1
158
Sheet 3-3. Main Computer and Hard Disk / Flash Disk Drive
3HAC 16640-1
159
3HAC 16640-1
160
3HAC 16640-1
161
3HAC 16640-1
162
3HAC 16640-1
163
3HAC 16640-1
164
3HAC 16640-1
165
3HAC 16640-1
166
3HAC 16640-1
167
3HAC 16640-1
168
3HAC 16640-1
169
3HAC 16640-1
170
3HAC 16640-1
171
3HAC 16640-1
172
3HAC 16640-1
173
3HAC 16640-1
174
3HAC 16640-1
175
3HAC 16640-1
176
3HAC 16640-1
177
3HAC 16640-1
178
3HAC 16640-1
179
3HAC 16640-1
180
3HAC 16640-1
181
Sheet 5-13. Control Cable IRB 640, 840, 4400 and 6400S/PE
3HAC 16640-1
182
3HAC 16640-1
183
3HAC 16640-1
184
3HAC 16640-1
185
3HAC 16640-1
186
3HAC 16640-1
187
3HAC 16640-1
188
3HAC 16640-1
189
3HAC 16640-1
190
Sheet 6-5. External axes no. 7th - 9th Control Signal Connection
3HAC 16640-1
191
Sheet 6-6. Axis Computer 2 and Axis Connector Unit if External Axis Cabinet
3HAC 16640-1
192
3HAC 16640-1
193
3HAC 16640-1
194
3HAC 16640-1
195
Sheet 7-2. Digital Part of Combi I/O and Digital I/O Unit Input Part
3HAC 16640-1
196
3HAC 16640-1
197
Sheet 7-4. Combi I/O Unit Digital and Analogue Output Part
3HAC 16640-1
198
3HAC 16640-1
199
3HAC 16640-1
200
3HAC 16640-1
201
3HAC 16640-1
202
3HAC 16640-1
203
3HAC 16640-1
204
3HAC 16640-1
205
3HAC 16640-1
206
3HAC 16640-1
207
3HAC 16640-1
208
3HAC 16640-1
209
3HAC 16640-1
210
3HAC 16640-1
211
3HAC 16640-1
212
3HAC 16640-1
213
3HAC 16640-1
214
3HAC 16640-1
215
3HAC 16640-1
216
3HAC 16640-1
217
3HAC 16640-1
218
3HAC 16640-1
219
3HAC 16640-1
220
3HAC 16640-1
221
3HAC 16640-1
222
3HAC 16640-1
223
3HAC 16640-1
224
3HAC 16640-1
225
3HAC 16640-1
226
3HAC 16640-1
227
3HAC 16640-1
228
3HAC 16640-1
229
3HAC 16640-1
230
3HAC 16640-1
231
3HAC 16640-1
232
3HAC 16640-1
233
3HAC 16640-1
234
3HAC 16640-1
235
3HAC 16640-1
236
3HAC 16640-1
237
3HAC 16640-1
238
3HAC 16640-1
239
Sheet 9-13. Drive Unit and Control Cable Drive Unit GT+CCB
3HAC 16640-1
240
3HAC 16640-1
241
3HAC 16640-1
242
Index
3HAC 16640-1
243
Index
244
3HAC 16640-1
Maintenance Manual
Industrial Robot IRB 940 Tricept
3HAC 16639-1 / M2000 / Rev. IRB 940 Tricept
Table of Contents
Overview
Product Documentation, IRB 940 Tricept
Chapter 1: Safety, service
Introduction
Safety, service - General
Section A: References
Limitation of Liability
Applicable Safety Standards
Related information
Section B: Safety risks
3HAC 16639-1
1
3
5
5
6
7
7
7
8
9
9
9
9
10
10
11
13
13
13
14
14
15
15
15
17
17
18
20
21
21
22
22
23
24
24
Table of Contents
25
25
27
ii
29
29
31
33
33
34
34
35
36
36
37
37
40
44
47
47
49
51
51
3HAC 16639-1
Overview
About This
Manual
Usage
Prerequisites
Organization of
Chapters
Chapter
3HAC 16639-1
Contents
1.
Safety, service
2.
Reference information
3.
4.
5.
Disposal
References
Reference
Document Id
Revisions
Revision
Description
First edition
3HAC 16639-1
General
Overview,
Installation and
Commissioning
Manual
The Installation and Commissioning Manual contains the following main chapters:
Overview, Repair
Manual
Overview,
Maintenance
Manual
3HAC 16639-1
Safety, Service
Reference Information
Unpacking
On-site Installation
Electrical connections
Start-up
Robot controller
Calibration
Safety, Service
Reference Information
Safety, Service
Reference Information
Maintenance schedules
Maintenance activities
Disposal
The chapters for the maintenance activities include instructions for all the maintenance activities specified in the maintenance schedule.
3HAC 16639-1
Safety, service
Definitions
This chapter details safety information for service personnel i.e. personnel performing installation, repair and maintenance work.
Sections
B. Safety risks lists dangers relevant when servicing the robot system.
The dangers are split into different categories:
Safety risks related to end effector
Safety risks related to tools/workpieces
Safety risks related to pneumatic/hydraulic systems
Safety risks during operational disturbances
Safety risks during installation and service
Risks associated with live electric parts
3HAC 16639-1
Safety, service
Validity and
responsibility
The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment, which can influence the safety
of the total system. To protect personnel, the complete system must be designed
and installed in accordance with the safety requirements set forth in the standards
and regulations of the country where the robot is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable
safety laws and regulations in the country concerned are observed and that the
safety devices necessary to protect people working with the robot system have
been designed and installed correctly. Personnel working with robots must be
familiar with the operation and handling of the industrial robot, described in the
applicable documents, e.g. Users Guide and Product Manual.
Connection of
external safety
devices
Apart from the built-in safety functions, the robot is also supplied with an interface for the connection of external safety devices. Via this interface, an external
safety function can interact with other machines and peripheral equipment. This
means that control signals can act on safety signals received from the peripheral
equipment as well as from the robot.
In the Product Manual - Installation and Commissioning, instructions are provided for connecting safety devices between the robot and the peripheral equipment.
3HAC 16639-1
Safety, service
References
Section A: References
Limitation of Liability
General
Any information given in this information product regarding safety, must not be
construed as a warranty by ABB Robotics that the industrial robot will not cause
injury or damage even if all safety instructions have been complied with.
Standards
3HAC 16639-1
Safety, service
References
Related information
General
Documents
Type of information
Detailed in document
Users Guide
Section
Start-up
3HAC 16639-1
Safety, service
Safety risks
Safe handling
It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure
that guards remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
General
Residual energy
Safe design
3HAC 16639-1
Residual energy may be present in these systems so, after shutdown, particular care must be taken.
Gravity may cause any parts or objects held by these systems to drop.
Shot bolts should be used to prevent tools, etc., from falling due to gravity.
Safety, service
Safety risks
General
Qualified
personnel
Extraordinary
risks
The industrial robot is a flexible tool which can be used in many different
industrial applications.
All work must be carried out professionally and in accordance with the
applicable safety regulations.
Remedial action must only be carried out by qualified personnel who are
familiar with the entire installation as well as the special risks associated
with its different parts.
If the working process is interrupted, extra care must be taken due to risks other
than those associated with regular operation. Such an interruption may have to be
rectified manually.
Nation/region
specific regulations
10
Those in charge of operations must make sure that safety instructions are
available for the installation in question.
Those who install the robot must have the appropriate training for the robot
system in question and in any safety matters associated with it.
To prevent injuries and damage during the installation, lifting and transport of the
robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with.
3HAC 16639-1
Safety, service
Safety risks
Non-voltage
related risks
To be observed
by the supplier of
the complete system
Turntables or the like should be used to keep the operator out of the
robot's working space.
The axes are affected by the force of gravity when the brakes are released
or when the motors or other components are removed.
Never use the robot as a ladder, i.e. do not climb on the robot motors or
other parts during service work. There is a serious risk of slipping because
of the high temperature of the motors or oil spills that can occur on the
robot.
The supplier of the complete system must ensure that all circuits used in
the safety function are interlocked in accordance with the applicable standards for that function.
The supplier of the complete system must ensure that all circuits used in
the emergency stop function are interlocked in a safe manner, in accordance with the applicable standards for the emergency stop function.
Voltage related
risks, general
3HAC 16639-1
The mains supply to the robot must be connected in such a way that it can
be turned off outside the robots working space.
11
Safety, service
Safety risks
Voltage related
risks, controller,
S4Cplus
Units inside the controller, e.g. I/O modules, can be supplied with power
from an external source.
The power supply unit for the computer system (230 VAC)
The rectifier unit (400-480 VAC and 700 VDC. N.B.: Capacitors!)
The power supply unit for tools, or special power supply units for the
machining process
The external voltage connected to the control cabinet remains live even
when the robot is disconnected from the mains.
Additional connections
Voltage related
risks, manipulator, IRB 940 Tricept
Voltage related
risks, tools, material handling
devices, etc.
Tools, material handling devices, etc., may be live even if the robot system is in
the OFF position. Power supply cables which are in motion during the working
process may be damaged.
12
The user connections for tools or other parts of the installation (max. 230V
AC, see Product Manual - Installation and Commissioning)
3HAC 16639-1
Safety, service
Safety actions
General
Install a safety cell around the robot to ensure safe robot installation and operation.
Dimensioning the
fence or enclosure
- withstand any impact from a tool failure. Due to the high kinetic energy
associated with HSM (High Speed Machining), a tool failure poses a serious risk as any debris can cause serious personal injury. Both walls and
ceilings must be designed and dimensioned so that they can withstand any
projectiles that they may be subjected to. Windows must be made from
suitable safety glass. Study the planned process to determine the forces
involved and appropriate materials.
- isolate gases and mist generated by the machining process and spray
mist lubrication. Study the planned process to determine the fumes
involved and appropriate ventilation/filtering system.
Fire extinguishing
Use a CARBON DIOXIDE (CO 2 ) extinguisher in the event of a fire in the robot
(manipulator or controller)!
3HAC 16639-1
13
Safety, service
Safety actions
Description
In an emergency situation, any of the manipulators axes may be released manually by pushing the brake release buttons on the distribution box for the manipulator. How to release the brakes is detailed in section "Manually releasing the
brakes" in the Installation Manual.
The manipulator arms may be moved manually when the brakes has been
released.
Increased injury
Before releasing the brakes, make sure that the weight of the arms does not
increase the pressure on the trapped person, further increasing any injury!
Brake testing
When to test
During operation the holding brakes of each axis motor wear normally. A test may
be performed to determine whether the brake can still perform its function.
How to test
The function of each axis motor holding brakes may be checked as detailed
below:
1. Run each manipulator axis to a position where the combined weight of
the manipulator arm and any load is maximized (max. static load).
2. Switch the motor to the MOTORS OFF position with the Operating
mode selector on the controller.
3. Check that the axis maintains its position.
If the manipulator does not change position as the motors are switched off, then
the brake function is adequate.
14
3HAC 16639-1
Safety, service
Safety actions
3HAC 16639-1
15
Safety, service
Safety actions
16
3HAC 16639-1
Reference Information
General
3HAC 16639-1
This chapter presents generic pieces of information, complementing the more specific information in the following chapters.
17
Reference Information
Screw joints
General
This section details how to tighten the various types of screw joints in the manipulator as well as the controller.
The instructions and torque values are valid for screw joints comprising metallic
materials and does not apply to soft or brittle materials.
Any instructions given in the repair, maintenance or installation procedure
description override any value or procedure given here, i.e. these instruction are
only valid for standard type screw joints.
Tightening torque
Screws with
slotted or cross
recess head
Screws with
hexagon socket
head
18
The tightening torque values for different types of screw joint are specified in the
tables below:
Dimension
M2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
Dimension
Tightening
torque (Nm)
Class 8.8 "dry"
Tightening
torque (Nm)
Class 10.9
Tightening
torque (Nm)
Class 12.9
M5
M6
10
17
M8
24
28
40
M10
47
55
70
M12
82
95
120
3HAC 16639-1
Reference Information
3HAC 16639-1
Dimension
Tightening
torque (Nm)
Class 8.8 "dry"
Tightening
torque (Nm)
Class 10.9
Tightening
torque (Nm)
Class 12.9
M16
200
235
300
19
Reference Information
Weight specifications
Definition
In all repair and maintenance instructions, weights of the components handled are
sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in
this way.
ABB recommends handling all components with a weight exceeding 22 kg using
lifting equipment to avoid inflicting injury.
Example
20
3HAC 16639-1
Definitions
This chapter details all maintenance activities recommended for the manipulator.
This chapter is made up of separate units, each detailing a specific maintenance
activity. Each unit contains all the information required to perform the activity,
e.g. spare parts numbers, required special tools and materials.
3HAC 16639-1
21
Description
22
The intervals may be specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the robot.
3HAC 16639-1
General
Activities and
intervals
The section referred to in the table can be found in the different chapters for every
maintenance activity.
The table below specifies the required maintenance activities and intervals:
Maintenance
activity
Equipment
Interval
Detailed in section
Daily maintenance
Complete robot
Daily
"Daily maintenance"
1
Lubrication
Linear bearings
1000h
Lubrication
Actuator
1000h 1
Changing
Changing
"Lubrication, actuators"
1)
The interval is based on utilization under normal operating conditions. Operation under severe conditions such as increased ambient temperature or the presence of abrasive or grease absorbent dust will require a more regular maintenance
cycle.
3HAC 16639-1
23
General
Daily
maintenance
24
Not to use compressed air in sections of the machinery which may suffer
from chips or dust being blown into sensitive areas.
Only use soft cloths when cleaning so as not to cause abrasions on the
machine surfaces.
Not to use any solvents that may have an abrasive or corrosive effect on
the machine surfaces.
The daily maintenance of the robot and its surrounding environment includes:
Removing all chips and/or dust that result from the machining process.
Checking for signs of damage or wear on all cables, hoses and other components that can lead to a safety risk or interrupted production in case of
failure.
Checking levels of all lubrication and cooling fluids on both the manipulator
and auxiliary equipment.
Checking that all media supplies, such as compressed air and water, maintain the correct pressures and flows.
3HAC 16639-1
Location
The figure below shows the location of the grease lubrication nipple on the linear
guide bearing. The other linear bearing is located on the other side of the center
tube.
xx0200000293
Required equipment
Equipment, etc. Spare part no. Art. no.
Lubricant
3HAC 16639-1
Note
25
Lubrication
Step
26
Action
Note/Illustration
1.
2.
3.
Run the robot back and forth in the Z-direction several times.
4.
3HAC 16639-1
Lubrication, actuators
Location
The three actuators require lubrication with grease. There are four separate grease
nipples for the lubrication on each actuator. The grease nipple that faces up is used
so that as the grease is applied it falls onto the lead screw inside the actuator housing.
The figure below shows the location of the grease lubrication nipples on the actuator.
xx0200000294
Required equipment
3HAC 16639-1
Note
Lubricant
2 x 4 ml per actuator.
For lubrication of the
actuators.
Klberplex BEM
34-132
27
Lubrication
Step
28
Action
Note/Illustration
1.
2.
3.
4.
Lubricant specified
above!
Shown in the figure
above!
3HAC 16639-1
Location
The filter element is located in the overpressure (OP) unit as shown in the figure
below.
xx0200000420
Required equipment
3HAC 16639-1
Equipment, etc.
Filter
3HAC 17158-1
Art. no.
Note
29
Replacement of
filter
The procedure below details how to replace the filter element in the overpressure
unit.
Step
30
Action
Note/Illustration
1.
2.
3.
4.
5.
3HAC 16639-1
Location
C
xx0200000421
3HAC 16639-1
Regulator
Pressure guard
Air input
31
Adjusting
The procedure below details how to adjust the overpressure unit after installation
or after replacement of the filter element.
Step
Action
Note/Illustration
1.
2.
3.
Turn the pressure setting until the desired pressure (1 bar) is shown on the manometer. The input
pressure must be at least 1 bar greater than the
output pressure.
4.
32
3HAC 16639-1
Definitions
This chapter details all maintenance activities recommended for the control cabinet.
This chapter is made up of separate units, each detailing a specific maintenance
activity. Each unit contains all the information required to perform the activity,
e.g. spare parts numbers, required special tools and materials.
3HAC 16639-1
33
Description
34
The intervals may be specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the robot.
3HAC 16639-1
General
The robot controller must be maintained at regular intervals to ensure its function.
The maintenance activities and their respective intervals are specified in the table
below:
Intervals
Maintenance
activity
Equipment
Interval
Detailed in section
Inspection
Controller cabinet
6 mths
"Inspection, controller
cabinet"
Cleaning
Controller cabinet
"Cleaning, controller
cabinet"
Cleaning
Air filter
Replacement
Air filter
4 000 h/
24 mths 1
Replacement
Battery unit
12 000 h/
36 mths 1
"Replacement, battery
unit"
Replacement
60 mths
"Replacement, system
fan unit".
1)
3HAC 16639-1
Hours denotes operational time whereas months denotes actual calender time.
35
Inspection
Step
36
Action
Note/Illustration
1.
2.
3.
4.
5.
3HAC 16639-1
The air filter is located in the air filter magazine in the front hatch.
A
xx0200000284
Required equipment
Equipment, etc.
Air filter
3HAB 8028-1
3HAC 16639-1
Note
These procedures
include references to
the tools required.
37
Step
1.
Action
Note/Illustration
xx0200000001
2.
3.
xx0200000003
38
3HAC 16639-1
Step
Action
Note/Illustration
1.
2.
xx0200000006
3HAC 16639-1
39
A
xx0200000103
40
Battery unit
3HAC 16639-1
Required equipment
Equipment, etc.
Note
Battery unit
3HAC 5393-2
To be replaced as a
complete unit
Removal, battery
unit
These procedures
include references to
the tools required.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it!
Before handling, make sure you are connected to earth through a special ESD
wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD
protection button for connection of the bracelet. Use it!
3HAC 16639-1
41
Step
1.
Action
Note/Illustration
X1
X1
X2
X2
X2
X1
X2
X3
xx0200000004
2.
3.
xx0200000005
42
3HAC 16639-1
Refitting, battery
unit
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it!
Before handling, make sure you are connected to earth through a special ESD
wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD
protection button for connection of the bracelet. Use it!
Step
3HAC 16639-1
Action
Note/Illustration
1.
2.
3.
43
A
D
A
B
xx0200000007
44
Drive units
3HAC 16639-1
Required equipment
Equipment, etc.
3HAC 12924-2
Note
Removal
These procedures
include references to
the tools required.
The procedure below details how to remove the system fan unit.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it!
Before handling, make sure you are connected to earth through a special ESD
wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD
protection button for connection of the bracelet. Use it!
Step
Action
Note/Illustration
1.
2.
xx0200000008
3HAC 16639-1
45
Step
3.
Refitting
Action
Note/Illustration
The procedure below details how to refit the system fan unit.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it!
Before handling, make sure you are connected to earth through a special ESD
wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD
protection button for connection of the bracelet. Use it!
Step
46
Action
Note/Illustration
1.
2.
3.
Detailed in section
"Replacement of
bleeder resistor" in the
Repairs Manual.
3HAC 16639-1
Required equipment
Equipment, etc.
Note
Vacuum cleaner
Cleaning agent, exterior cleaning
Cleaning of
functional
components
The procedure below details how to clean the functional components of the controller cabinet.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it!
Before handling, make sure you are connected to earth through a special ESD
wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD
protection button for connection of the bracelet. Use it!
Step
3HAC 16639-1
Action
Note/Illustration
1.
2.
If the cabinet is equipped with heat exchangers, it is of the utmost importance that these
are cleaned.
Heat exchangers are normally found:
on the rear of power supplies
on drive units
47
Always!
Never!
48
The section below specifies special considerations when cleaning the controller
cabinet.
Always check that all protective covers are fitted to the controller before
cleaning!
Never remove any covers or other protective before cleaning the controller!
Never use any cleaning agents, e.g. compressed air or solvents, other
than those specified above!
3HAC 16639-1
xx0200000002
Air filter
Drive system
Computer system
Required equipment
Equipment, etc.
Cleaning agent
Note
Water 30-40C with
washing-up liquid or
detergent
Compressed air
3HAC 16639-1
49
Cleaning
Step
Action
1.
2.
3.
50
Note/Illustration
3HAC 16639-1
Disposal
Chapter 5:Disposal
Disposal
General
All used grease/oils and dead batteries must be disposed of in accordance with the
current legislation of the country in which the robot and the control unit have been
installed.
If the robot or the control unit is partially or completely disposed of, the various
parts must be grouped together according to their nature (e.g. all iron together and
all plastic together), and disposed of accordingly. These parts must also be disposed of in accordance with the current legislation of the country in which the
robot and control unit have been installed.
3HAC 16639-1
51
Disposal
52
3HAC 16639-1
Index
3HAC 16639-1
53
Index
54
3HAC 16639-1