Escolar Documentos
Profissional Documentos
Cultura Documentos
3HAC 13491-1/M2000/Rev. 4
IRB 7600 - 500/2.3
IRB 7600 - 400/2.55
IRB 7600 - 150/3.5
The information in this document is subject to change without notice and should not be construed as a
commitment by ABB Automation Technology Products AB, Robotics. ABB Automation Technology
Products AB, Robotics assumes no responsibility for any errors that may appear in this document.
In no event shall ABB Automation Technology Products AB, Robotics be liable for incidental or
consequential damages arising from use of this document or of the software and hardware described
in this document.
This document and parts thereof must not be reproduced or copied without ABB Automation
Technology Products AB, Roboticss written permission, and contents thereof must not be imparted to
a third party nor be used for any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this document may be obtained from ABB Automation Technology Products AB,
Robotics at its then current charge.
Description
1 Description
1.1 Structure
A new world of possibilities opens up with ABBs new Power Robot family. It comes
in three versions, 500 kg, 400 kg, and 150 kg handling capacities.
The IRB 7600 is ideal for heavy-weight applications, regardless of industry. Typical
areas can be handling of heavy fixtures, turning car bodies, lifting engines, handling
heavy parts, loading and unloading of machine cells, alternatively handling large and
heavy pallet layers.
There is more to this benchmark product than sheer power. We have added a range of
software products - all falling under the umbrella designation of Active Safety - to
protect not only personnel in the unlikely event of an accident, but also the robot itself.
When handling payloads of 500 kg, it is clear that safety features are vital in protecting
the new investment.
There are a large number of process options for spot welding and material handling
integrated in the robot. For a complete description of process options for spot welding
see the Product Specification SpotPack.
The robot is equipped with the operating system BaseWare OS. BaseWare OS controls
every aspect of the robot, like motion control, development and execution of
application programs, communication etc. See Product Specification S4Cplus.
For additional functionality, the robot can be equipped with optional software for
application support - for example spot welding, communication features - network
communication - and advanced functions such as multi-tasking, sensor control, etc.
For a complete description on optional software, see the Product Specification
RobotWare Options.
Axis 3
Axis 4
Axis 6
Axis 5
Axis 2
Axis 1
Description
Different robot versions
The IRB 7600 is available in three versions. The following different robot types are
available:
Standard:
IRB 7600 - 500 kg / 2.3 m
IRB 7600 - 400 kg / 2.55 m
IRB 7600 - 150 kg / 3.5 m
Definition of version designation
IRB 7600 Mounting - Handling capacity / Reach
Prefix
Mounting
Floor-mounted manipulator
Handling capacity
yyy
Reach
x.x
Manipulator weight
Description
IRB 7600-500/2.3
IRB 7600-400/2.55
IRB 7600-150/3.5
2490 kg
2500 kg
2530 kg
3.4 kW
5.8 kW
Description
IRB 7600-500/2.3
7600-500/2.3
250
806
250
806
IRB 7600-400/2.55
IRB 7600-150/3.5
7600-400/2.55
1056
250
7600-150/3.50
2012
2012
250
250
Figure 2 View of the manipulator from the side and rear (dimensions in mm).
Allow 200 mm for cables behind the manipulator foot.
Description
R700
200
R700
Fork
lift device fr Gabelstapler
FHebevorrichtung
ork lift device
Description
1.2 Safety/Standards
The robot conforms to the following standards:
EN 292-1
Safety of machinery, terminology
EN 292-2
Safety of machinery, technical specifications
EN 954-1
Safety of machinery, safety related parts of control
systems
EN 60204
Electrical equipment of industrial machines
IEC 204-1
Electrical equipment of industrial machines
ISO 10218, EN 775
Manipulating industrial robots, safety
ANSI/RIA 15.06/1999 Industrial robots, safety requirements
ISO 9787
Manipulating industrial robots, coordinate systems
and motions
IEC 529
Degrees of protection provided by enclosures
EN 50081-2
EMC, Generic emission
EN 61000-6-2
EMC, Generic immunity
ANSI/UL 1740-1996 (option)Standard for Industrial Robots and Robotic
Equipment
CAN/CSA Z 434-94 (option)Industrial Robots and Robot Systems - General
Safety Requirements
The robot complies fully with the health and safety standards specified in the EECs
Machinery Directives.
The Power Robot Generation is designed with a unique combination of robot power and
control system intelligence.
The Service Information System (SIS)
The service information system gathers information about the robots usage and by that
determines how hard the robot has been used. The usage is characterised by the speed,
the rotation angles and the load of every axis.
With this data collection, the service interval of every individual robot of this generation
can be predicted, optimising and planning ahead service activities. The collection data
is available via the teach pendant or the network link to the robot.
The Power Robot Generation is designed with absolute safety in mind. It is dedicated to
actively or passively avoid collisions and offers the highest level of safety to the
operators and the machines as well as the surrounding and attached equipment. These
features are presented in the active and passive safety system.
The Active Safety System
The active safety system includes those software features that maintain the accuracy of
the robots path and those that actively avoid collisions which can occur if the robot
leaves the programmed path accidentally or if an obstacle is put into the robots path.
Description
The Active Brake System (ABS)
All robots run with an active brake system that supports the robots to maintain the
programmed path even in an emergency situation.
The ABS is active during all stop modes, braking the robot to a stop with the power of
the servo drive system along the programmed path. After a specific time the mechanical
brakes are activated ensuring a safe stop even in case of a failure of the drive system or
a power interruption.
The maximal applicable torque on the most loaded axis determines the stopping
distance.
The stopping process is in accordance with a class 1 stop.
While programming the robot in manual mode a class 0 stop, with mechanical brakes
only, applies.
The Self Tuning Performance (STP)
The Power Robot Generation is designed to run at different load configurations, many
of which occur within the same program and cycle.
The robots installed electrical power can thus be exploited to lift heavy loads, create a
high axis force or accelerate quickly without changing the configuration of the robot.
Consequently the robot can run in a power mode or a speed mode which can be
measured in the respective cycle time of one and the same program but with different
tool loads. This feature is based on QuickMoveTM.
The respective change in cycle time can be measured by running the robot in NoMotionExecution with different loads or with simulation tools, like RobotStudio.
The Electronically Stabilised Path (ESP)
The load and inertia of the tool have a significant effect on the path performance of a
robot. The Power Robot Generation is equipped with a system to electronically stabilise
the robots path in order to achieve the best path performance.
As the path performance as such is measured in a combination of speed and path accurac,
the user can choose himself the optimal configuration by applying the parameter WorldAccLim which can limit the linear acceleration along a programmed path.
This has an influence while accelerating and braking and consequently stabilises the
path during all motion operations with a compromise of the best cycle time. This feature
is secured through TrueMoveTM.
Over-speed protection
The speed of the robot is monitored by two independent computers.
Restricting the working space
The movement of each axis can be restricted using software limits.
As options there are safeguarded space stops for connection of limit switches to restrict
the working space.
Axes 1-3 can also be restricted by means of mechanical stops.
Collision detection (option)
In case an unexpected mechanical disturbance occurs, like a collision, electrode sticking,
etc., the robot will detect the collision, stop on the path and slightly back off from its stop
position, releasing tension in the tool.
The Passive Safety System
The Power Robot Generation has a dedicated passive safety system that by hardware
construction and dedicated solutions is designed to avoid collisions with surrounding
equipment. It integrates the robot system into the surrounding equipment safely.
8
Description
Compact robot arm design
The shape of the lower and upper arm system is compact, avoiding interference into
the working envelope of the robot.
The lower arm is shaped inward, giving more space under the upper arm to re-orientate
large parts and leaving more working space while reaching over equipment in front of
the robot.
The rear side of the upper arm is compact, with no components projecting over the edge
of the robot base even when the robot is moved into the home position.
Moveable mechanical limitation of main axes (option)
All main axes can be equipped with moveable mechanical stops, limiting the working
range of every axis individually. The mechanical stops are designed to withstand a
collision even under full load.
Zone switches on main axes (option)
All main axes can be equipped with zone switches. The double circuitry to the cam
switches is designed to offer personal safety according to the respective standards.
The Internal Safety Concept
The internal safety concept of the Power Robot Generation is based on a two-channel
circuit that is monitored continuously. If any component fails, the electrical power
supplied to the motors shuts off and the brakes engage.
Safety category 3
Malfunction of a single component, such as a sticking relay, will be detected at the next
MOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the faulty
section is indicated. This complies with category 3 of EN 954-1, Safety of machinery
- safety related parts of control systems - Part 1.
Selecting the operating mode
The robot can be operated either manually or automatically. In manual mode, the robot
can only be operated via the teach pendant, i.e. not by any external equipment.
Reduced speed
In manual mode, the speed is limited to a maximum of 250 mm/s (600 inch/min.).
The speed limitation applies not only to the TCP (Tool Centre Point), but to all parts of
the robot. It is also possible to monitor the speed of equipment mounted on the robot.
Three position enabling device
The enabling device on the teach pendant must be used to move the robot when in
manual mode. The enabling device consists of a switch with three positions, meaning
that all robot movements stop when either the enabling device is pushed fully in, or
when it is released completely. This makes the robot safer to operate.
Safe manual movement
The robot is moved using a joystick instead of the operator having to look at the teach
pendant to find the right key.
Emergency stop
There is one emergency stop push button on the controller and another on the teach
pendant. Additional emergency stop buttons can be connected to the robots safety
chain circuit.
Description
Safeguarded space stop
The robot has a number of electrical inputs which can be used to connect external safety
equipment, such as safety gates and light curtains. This allows the robots safety
functions to be activated both by peripheral equipment and by the robot itself.
Delayed safeguarded space stop
A delayed stop gives a smooth stop. The robot stops in the same way as at a normal
program stop with no deviation from the programmed path. After approx. 1 second the
power supplied to the motors is shut off.
Hold-to-run control
Hold-to-run means that you must depress the start button in order to move the robot. When
the button is released the robot will stop. The hold-to-run function makes program testing
safer.
Fire safety
Both the manipulator and control system comply with ULs (Underwriters Laboratory)
tough requirements for fire safety.
Safety lamp (option)
As an option, the robot can be equipped with a safety lamp mounted on the manipulator.
This is activated when the motors are in the MOTORS ON state.
10
Description
1.3 Installation
All versions of IRB 7600 are designed for floor mounting. Depending on the robot
version, an end effector with max. weight of 150 to 500 kg including payload, can be
mounted on the mounting flange (axis 6). See Load diagrams for IRB 7600 generation
robots from page 16 to page 21.
Extra loads (valve packages, transformers) can be mounted on the upper arm with a
maximum weight of 50 kg. On all versions an extra load of 500 kg can also be mounted
on the frame of axis 1. Holes for mounting extra equipment on page 24.
The working range of axes 1-3 can be limited by mechanical stops. Position switches
can be supplied on axes 1-3 for position indication of the manipulator.
External Mains Transformer
The robot system requires a 475 VAC power supply. Therefore an external transformer
will be included when a mains voltage other than 475V is selected.
Operating requirements
Protection standards
Standard and Foundry Manipulator
IP67
Cleanroom standards
Cleanroom class 100 for manipulator according to:
DIN EN ISO 14644: Cleanrooms and associated controlled environments
US Federal Standard 209 e - Air-clean-classes
Explosive environments
The robot must not be located or operated in an explosive environment.
Ambient temperature
Manipulator during operation
For the controller: Standard
Option
Complete robot during transportation and storage, -25oC (13oF) to +55oC (131oF)
for short periods (not exceeding 24 hours)
up to +70oC (158oF)
Relative humidity
Complete robot during transportation and storage Max. 95% at constant temperature
Complete robot during operation
Max. 95% at constant temperature
Mounting the manipulator
Maximum load in relation to the base coordinate system.
Force xy
Force z
Torque xy
Torque z
Endurance load
in operation
Max. load at
emergency stop
14000 N
32000 10000 N
31000 N
39000 16000 N
42000 Nm
11000 Nm
72000 Nm
19500 Nm
11
88 0.3
Description
12
Description
B
5
325
D
B
37,5 o
15
C
o
10
50
522
0.1
A
A-A
1.5
B-B
C-C
D
Two guiding pins required, dimensions see Figure 6
Figure 5 Option Base plate (dimensions in mm).
13
Description
14
Description
1.4 Load diagrams
The load diagrams include a nominal payload inertia, J0 of 35 kgm2, and an extra load
of 50 kg at the upper arm housing, see Figure 7.
At different arm load, payload and moment of inertia, the load diagram will be
changed.
For an accurate load diagram, please use the calculation program, ABBLoad for 7600
on:
inside.abb.com/atrm, click on Products --> Robots --> IRB 7600
or
http://www.abb.com/roboticspartner, click on Product range --> Robots --> IRB
7600.
Centre of gravity 50 kg
400
200
Figure 7 Centre of gravity for 50 kg extra load at arm housing (dimensions i mm).
15
Description
Load diagram for IRB 7600-500/2.3
Z (m)
1,30
1,20
150 kg
1,10
1,00
200 kg
0,90
0,80
250 kg
0,70
300 kg
0,60
350 kg
0,50
425 kg
0,40
400 kg
450 kg
475 kg
500 kg
0,30
0,20
0,10
L (m)
250 mm
0,00
0,00
0,10
0,20
0,30
0,40
0,50
0,60
0,70
0,80
Figure 8 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity).
16
Description
Load diagram for IRB 7600-500/2.3 Vertical Wrist (10o)
Vertical wrist
Pay
load
250 mm
10o 10o
Z
0,0
0,2
0,4
0,6
0,8
1,0
1,2
0,0
0,2
600 kg
550 kg
0,4
450 kg
300 kg
0,6
200 kg
0,8
1,0
1,2
Figure 9 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity) at Vertical Wrist (10o), J0 =35 kgm2.
17
Description
Load diagram for IRB 7600-400/2.55
Z (m)
1,30
1,20
150 kg
1,10
1,00
200 kg
0,90
0,80
250 kg
0,70
300 kg
0,60
350 kg
0,50
400 kg
0,40
425 kg
0,30
0,20
250 mm
0,10
0,00
0,00
L (m)
0,10
0,20
0,30
0,40
0,50
0,60
0,70
0,80
Figure 10 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity).
18
Description
Load diagram for IRB 7600-400/2.55 Vertical Wrist (10o)
Vertical wrist
Pay
load
10o 10o
250 mm
0,0
0,2
0,4
0,6
0,8
1,0
1,2
1,4
0,0
0,2
500 kg
450 kg
0,4
400 kg
300 kg
0,6
200 kg
0,8
1,0
1,2
1,4
Figure 11 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity) at Vertical Wrist (10o), J0 =35 kgm2.
19
Description
Load diagram for IRB 7600-150/3.5
Z (m)
2,00
1,90
80 kg
1,80
1,70
90 kg
1,60
100 kg
1,50
1,40
1,30
110 kg
1,20
1,10
1,00
120 kg
0,90
0,80
0,70
130 kg
0,60
0,50
140 kg
0,40
0,30
150 kg
0,20
250 mm
0,10
0,00
0,00 0,10 0,20 0,30 0,40 0,50 0,60 0,70 0,80 0,90 1,00 1,10
L (m)
Figure 12 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity).
20
Description
Load diagram for IRB 7600-150/3.5 Vertical Wrist (10o)
Vertical wrist
Pay
load
10o 10o
250 mm
0,0
0,2
0,4
0,6
0,8
1,0
1,2
1,4
1,6
1,8
2,0
2,2
0,0
0,2
170 kg
150 kg
0,4
130 kg
0,6
110 kg
90 kg
0,8
1,0
Figure 13 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity) at Vertical Wrist (10o), J0 =35 kgm2.
21
Description
Maximum load and moment of inertia for full and limited axis 5 (centre line down)
movement.
Note. Load in kg, Z and L in m and J in kgm2
Full movement of axis 5 (120o):
Axis 5
Maximum moment of inertia:
Ja5 = Mass ((Z+0.250)2 +L2) + max J0L 500 kgm2
Axis 6
Maximum moment of inertia:
Ja6 = Mass L2 + J0Z 315 kgm2
Centre of gravity
J0L = Maximum own moment of inertia
around the maximum vector in the X-Y-plane
J0Z = Maximum own moment of inertia around Z
Z
Figure 15 Moment of inertia when axis 5 centre line down.
22
Description
Mounting equipment
Extra loads can be mounted on the upper arm housing, the lower arm, and on the frame.
Definitions of distances and masses are shown in Figure 16 and Figure 17.
The robot is supplied with holes for mounting extra equipment (see Figure 18).
Maximum permitted arm load depends on centre of gravity of arm load and robot
payload.
Upper arm
Permitted extra load on upper arm housing plus the maximum handling
weight (See Figure 16):
M1 50 kg with distance a 500 mm, centre of gravity in axis 3 extension.
7600-500/2.3 /
250
806
M1
a
Mass
centre
M1
JH0
R
M4
543
473
200
800
600
600
View from above
1180
23
Description
Holes for mounting extra equipment
(2012)
(1056)
806
165
250
50
777
1075
100
780
477
M12 (4x)
2512,5
M12 (4x)
150
Figure 18 Holes for mounting extra equipment on the upper and the lower arm (dimensions in mm).
24
Description
Figure 19 Holes for mounting of extra load on the upper arm (dimensions in mm).
240
240
50
60
290
290
M16(4x)
(4x)
M16
Figure 20 Holes for mounting of extra load on the frame, and for mounting of fork lift device
(dimensions in mm).
25
Description
31
A
1,6
0,04 A
12 H7 Depth 15
12 x
0,2 A B
(24)
15
12
30
12 H7 Depth 15
0,04 A
1,6
200
0,02 A
A-A
Figure 21 The mechanical interface; mounting flange (dimensions in mm).
26
Description
27
Description
Rotation motion
Arm motion
Arm motion
Wrist motion
Bend motion
Turn motion
Range of movement
+180oto-180o
+85oto-60o
+60oto-180o
+300oto-300o
+100oto-100o
+300oto -300o
IRB 7600-500/2.3
Figure 22 The extreme positions of the robot arm specified at the wrist centre
(dimensions in mm).
28
Description
IRB 7600-400/2.55
IRB 7600-150/3.5
Figure 23 The extreme positions of the robot arm specified at the wrist centre (dimensions in mm).
29
Description
Performance according to ISO 9283
At rated maximum load, maximum offset and 1.6 m/s velocity on the inclined ISO test
plane, 1 m cube (for IRB 7600-500/2.3 a 0.63 m cube) with all six axes in motion.
IRB 7600
-400/2.55
Pose accuracy, AP
0.10 mm
Pose repeatability, RP
0.19 mm
Path repeatability, RT
1.27 mm
Pose stabilization time, Pst 0.38 s
-500/2.3
0.13 mm
0.24 mm
0.34 mm
0.29 s
-150/3.5
0.10 mm
0.19 mm
0.40 mm
0.75 s
Velocity
Maximum axis speeds.
IRB 7600
Axis no.
1
2
3
4
5
6
-400/2.55
-500/2.3
-150/3.5
75/s
60/s
60/s
100/s
100/s
160/s
75/s
60/s
60/s
100/s
100/s
160/s
100/s
60/s
60/s
100/s
100/s
190/s
The maximum allowed average speed for axis 1-3 at the maximum ambient
temperature of 50oC according to Table 1.
IP 54 for cooling fan.
Table 1
Variant
30
Maximum
average speed
axis 1 (rpm)
Maximum
average speed
axis 2 (rpm)
Maximum
average speed
axis 3 (rpm)
IRB 7600-500/2.3
5.4 - 7.0
1.4 - 1.5
1.2 - 1.6
IRB 7600-400/2.55
5.4 - 7.0
1.4 - 1.5
1.2 - 1.6
IRB 7600-150/3.5
4.1 - 5.3
1.3 - 1.4
2.2 - 2.9
Description
Arm protection
Note. The upper arm harness specification is based on the selection of lower arm
harness.
The Lower Arm Harness consists of a process cable package and supports, clamps
and brackets. The process cable package, containing special designed cables and hoses,
has been long term tested.
Product Specification IRB 7600 M2000
31
Description
The process cable package is routed along the lower arm to minimize space required
and to give no limitation in the robot working envelope. The cables and hoses are partly
placed in a protective hose to extend the lifetime.
The lower arm harness is connected to the upper arm harness at the connection point
under the axis 3 motor. The interface plate at the manipulator base is the place where
the floor harness and the process media are connected.
The Floor Harness consists of signal cables for customer signals. The floor harness is
connected to the lower arm harness at the interface plate at the manipulator base and to
the left side of the control cabinet. The signal connection inside the control cabinet
depends on chosen options. As example bus option and parallel option mean different
connections.
The cables and hose which are used to form the DressPack for the Material Handling
application has the following specification and capacity:
Table 2
Type
Pcs
Area
Allowed capacity
2+2
1
0,5 mm2
1,0 mm2
19
4
0,23 mm2
0,23 mm2
50 VAC/DC, 1 A rms
50 VAC/DC, 1 A rms
2
2
4
4
0,18 mm2
0,18 mm2
0,18 mm2
0,23 mm2
Media
Air (PROC 1)
12,5 mm
inner
diameter
Quad twisted under separate screen. Can also be used for very sensitive signals
Description
Option 057 Connection to cabinet
Floor cables for the DressPack are chosen. The number of cables and cable type
depends on chosen options. The length of the process cable package at the floor is
specified under the options below:
- Option 675-678 for parallel communication
- Option 660-663 for bus communication with CANDeviceNet
- Option 665-668 for bus communication with Profibus
- Option 670-673 for bus communication with Interbus
The connection inside the cabinet depends on communication type.
- If parallel communication is chosen, signals are found at terminals inside the
cabinet (XT5.1, XT5.2 and XT6)
- If bus communication is chosen, signals are both routed to valid bus card. The
remaining are found at terminals inside the cabinet (XT5.1, XT5.2 and XT6).
Communication
Option 2063 Parallel communication
The process cable package has been chosen for parallel communication. The number
as well as the type of signals are defined under Material handling application, Option
2204, 2205.
Option 2064 Bus communication
The process cable package has been chosen for bus communication. This alternative
includes both the signals for the bus communication as well as some parallel signals.
The number as well as the type of signals are defined under Material handling
application, Option 2204, 2205. The type of bus is defined by the choice of floor
cabling (see also option 057)
Option 2204 Material Handling axis 1 to axis 3
The Lower arm harness for the Material Handling has been chosen. This includes the
process cable package as well as brackets, connectors etc. to form a complete dressing
package from manipulator base to connectors on axis 3. Depending on the choice
above the process cable package will have different content. See tables below.
For all process cable packages some of the content are common. These common parts
for Material Handling application are shown in Table 3 below. Unique parts for
different option combinations are shown in Table 4, Table 5 and Table 6. These tables
are valid for option 2204 and 2205.
33
Description
option 2204
option 2205
Figure 25 Material Handling from base to axis 3, and Material Handling from axis 3 to axis 6.
Type
Pieces at
Connection point
Note
Allowed capacity
12,5 m inner
diameter
Media
Air (PROC 1)
Type
Customer Power (CP)
Utility Power
Protective earth
Customer Signals (CS)
Signals twisted pair
Signals twisted pair and
separate shielded
Pieces at
Terminal*
Pieces at
Connection point**
Allowed capacity
2+2
1
2+2
1
19
4
19
4
50 VAC, 5 A rms
50 VAC, 5 A rms
34
Description
Table for Material Handling with option 2064 and Can/DeviceNet
Table 5
Type
Customer Power (CP)
Utility Power
Protective earth
Customer Bus (CBus)
Bus signals
Bus signals
Signals twisted pair
Utility signals
Pieces at
Terminal*
Pieces at
Connection point**
Allowed capacity
2+2
1
2+2
1
4
4
2
2
4
4
Can/DeviceNet spec
50 VAC, 1 A rms
50 VAC, 1 A rms
50 VAC, 1 A rms
Type
Customer Power (CP)
Utility Power
Protective earth
Customer Bus (CBus)
Bus signals
Bus signals
Signals twisted pair
Utility signals
Pieces at
Terminal*
Pieces at
Connection point**
Allowed capacity
2+2
1
2+2
1
4
3
4
1
4
3
Interbus spec
50 VAC, 1 A rms
50 VAC, 1 A rms
50 VAC, 1 A rms
35
Description
36
1 MANIPULATOR
VARIANTS
021 IRB 7600-150/3.5
024 IRB 7600-400/2.55
025 IRB 7600-500/2.3
Manipulator colour
330 Standard
The manipulator is painted in ABB orange.
352 Ral code
Colours according to RAL-codes.
Protection
035 Standard (IP 67)
036 Foundry
Robot adapted for foundry or other harsh environments.
The robot has the FoundryPlus protection which means that the whole manipulator is
IP67 classified and steam washable. An excellent corrosion protection is obtained by a
special coating. The connectors are designed for severe environment, and bearings,
gears and other sensitive parts are highly protected.
37
R1.SW2/3
R3.FB7
R1.MP
R1.SMB
R1.PROC1 1 x 1/2
R1.CP/CS
R2.CP/CS
R2.PROC1 1 x 1/2
R2.MP 5/6
38
EQUIPMENT
691 Safety lamp
A safety lamp with an orange fixed light can be mounted on the manipulator.
The lamp is active in MOTORS ON mode.
The safety lamp is required on a UL/UR approved robot.
092 Fork lift device
Lifting device on the manipulator for fork-lift handling.
Note. When Cooling Fan for axis 1 motor unit is used, this must be disassembled in
order to use fork lift device.
087 Base plate
See chapter 1.3 Installation, for dimension drawing.
091 Brake release cover
A cover for the break release buttons.
113 Cooling fan for axis 1 motor (IP 54)
Cannot be combined with Cooling fan for axis 2 motor option 114.
For in use recommendations see 1.7 Cooling fan for axis 1-3 motor (options 113-115).
See Figure 28.
Not for protection Foundry.
114 Cooling fan for axis 2 motor (IP 54)
For in use recommendations see 1.7 Cooling fan for axis 1-3 motor (options 113-115).
Not for protection Foundry.
115 Cooling fan for axis 3 motor (IP 54)
For in use recommendations see 1.7 Cooling fan for axis 1-3 motor (options 113-115).
See Figure 28.
Not for protection Foundry.
Product Specification IRB 7600 M2000
39
Option 115
Option 113
Option 088
CONNECTION KITS
The connectors fit to the connectors at the manipulator base, axis 3 and 6 respectively.
The kit consists of connectors, pins and sockets.
2220 R1.CP/CS and PROC1
For the Customer Power/Customer Signal connector and one Process connector on the
manipulator base. Sockets for bus communication are included.
2221 R1.WELD and PROC2-4
For the Weld connector and three Process connectors on the manipulator base.
2222 R1.SW1 and SW2/3
For the position switch asis 1 connector and the position axis 2/3 connector on the
manipulator base.
40
POSITION SWITCHES
Position switches indicating the position of the three main axes. Rails with separate
adjustable cams are attached to the manipulator. The cams, which have to be adapted
to the switch function by the user, can be mounted in any position in the working range
for each switch. No machining operation of the cams is necessary for the adaptation,
simple hand tools can be used.
For axis 1, there are three redundant position zones available, each with two
independent switches and cams. For axes 2 and 3, two redundant position zones are
available, each with two independent switches and cams.
For axis 1 it is possible to mount a second set of position switches, doubling the number
of redundant zones to six.
Each position zone consists of two switches mechanically operated by separate cams.
Each switch has one normally open and one normally closed contact. See Product
Specification S4Cplus.
The design and components fulfil the demands to be used as safety switches.
These options may require external safety arrangements, e.g. light curtains, photocells
or contact mats.
The switches can be connected either to the manipulator base (R1.SW1 and R1.SW2/
3, see Figure 26), or to the controller. In the controller the signals are connected to
screw terminal XT8 Phoenix MSTB 2.5/12-ST-5.08.
Switch type Balluff Multiple position switches BNS, according to EN 60947-5-1 and
EN 60947-5-2.
Connection to
075 Manipulator
Connection on the manipulator base with one/two FCI Sealok 32-pin connector.
076 Cabinet
Connected to 12-pole screw terminals, Phoenix MSTB 2.5/12-ST-5.08, in the
controller. Position switch cables are included.
Position switches axis 1
071 Three redundant position zones are available, each with two independent switches and
cams.
41
42
Accessories
3 Accessories
There is a range of tools and equipment available, specially designed for the robot.
Basic software and software options for robot and PC
For more information, see Product Specification S4Cplus, and Product Specification
RobotWare Options.
Robot Peripherals
- Track Motion
- Tool System
- Motor Units
- Spot welding system for transformer gun
Tools
Brake release box
Includes six brake release buttons and 24V battery unit which can be connected to
R1.BU on the manipulator frame. The brake release box can be ordered from
ABB Automation Technology Products AB, Robotics, department S.
Calibration Cube
This calibration tool can be ordered from ABB Automation Technology Products AB,
Robotics, department S.
43
Accessories
44
Index
4 Index
A
accessories 43
Active Brake System 8
Active Safety System 7
motion 28
mounting
extra equipment 23
robot 11
mounting flange 26
N
noise level 4
Collision detection 8
colours 37
cooling device 4
E
Electronically Stabilised Path 8
emergency stop 9
enabling device 9
equipment
mounting 23
permitted extra load 23
F
fire safety 10
fork lift device 39
H
hold-to-run control 10
hole configuration 12
holes for mounting extra equipment 24
humidity 11
operating requirements 11
options 37
overspeed protection 8
P
Passive Safety System 8
payload 11
position switches 41
protection 37
protection standards 11
R
range of movement 28
reduced speed 9
Robot Peripherals 43
robot versions 4
S
lifting device 39
load 11
load diagrams 15
maintenance 27
manipulator colour 37
mechanical interface 26
temperature 11
troubleshooting 27
I
installation 11
Internal Safety Concept 9
L
45
Index
V
variants 37
W
weight 4
working space
restricting 8, 11, 42
Z
zone switches 9
46
27
29
31
51
Description
1 Description
1.1 Structure
The controller contains the electronics required to control the manipulator, external
axes and peripheral equipment.
The controller also contains the system software, i.e. the BaseWare OS (operating
system), which includes all basic functions for operation and programming.
Controller weight
250 kg
Controller volume:
Teach pendant
Operators panel
Mains switch
Disk drive
Figure 1 The controller is specifically designed to control robots, which means that optimal
performance and functionality is achieved.
Description
200
200
800
Cabinet extension
800
Option 124
820
Extended cover
500
Option 123
250
950
980 *
Lifting points
for forklift
500
52
623
Figure 2 View of the controller from the front, from above and from the side (dimensions in mm).
Description
1.2 Safety/Standards
The robot conforms to the following standards:
EN 292-1
Safety of machinery, terminology
EN 292-2
Safety of machinery, technical specifications
EN 954-1
Safety of machinery, safety related parts of control
systems
EN 60204
Electrical equipment of industrial machines
IEC 204-1
Electrical equipment of industrial machines
ISO 10218, EN 775
Manipulating industrial robots, safety
ANSI/RIA 15.06/1999
Industrial robots, safety requirements
ISO 9787
Manipulating industrial robots, coordinate systems
and motions
IEC 529
Degrees of protection provided by enclosures
EN 50081-2
EMC, Generic emission
EN 61000-6-2
EMC, Generic immunity
ANSI/UL 1740-1996 (option) Standard for Industrial Robots and Robotic
Equipment
CAN/CSA Z 434-94 (option) Industrial Robots and Robot Systems - General
Safety Requirements
The robot complies fully with the health and safety standards specified in the EECs
Machinery Directives.
The robot controller is designed with absolute safety in mind. It has a dedicated safety
system based on a two-channel circuit which is monitored continuously. If any
component fails, the electrical power supplied to the motors shuts off and the brakes engage.
Safety category 3
Malfunction of a single component, such as a sticking relay, will be detected at the next
MOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the faulty
section is indicated. This complies with category 3 of EN 954-1, Safety of machinery
- safety related parts of control systems - Part 1.
Selecting the operating mode
The robot can be operated either manually or automatically. In manual mode, the robot
can only be operated via the teach pendant, i.e. not by any external equipment.
Reduced speed
In manual mode, the speed is limited to a maximum of 250 mm/s (600 inch/min.).
The speed limitation applies not only to the TCP (Tool Centre point), but to all parts of
the robot. It is also possible to monitor the speed of equipment mounted on the robot.
Three position enabling device
The enabling device on the teach pendant must be used to move the robot when in
manual mode. The enabling device consists of a switch with three positions, meaning
that all robot movements stop when either the enabling device is pushed fully in, or
when it is released completely. This makes the robot safer to operate.
Description
Safe manual movement
The robot is moved using a joystick instead of the operator having to look at the teach
pendant to find the right key.
Over-speed protection
The speed of the robot is monitored by two independent computers.
Emergency stop
There is one emergency stop push button on the controller and another on the teach
pendant. Additional emergency stop buttons can be connected to the robots safety chain
circuit.
Safeguarded space stop
The controller has a number of electrical inputs which can be used to connect external
safety equipment, such as safety gates and light curtains. This allows the robots safety
functions to be activated both by peripheral equipment and by the robot itself.
Delayed safeguarded space stop
A delayed stop gives a smooth stop. The robot stops in the same way as at a normal
program stop with no deviation from the programmed path. After approx. 1 second the
power supplied to the motors shuts off.
Collision detection
In case an unexpected mechanical disturbance like a collision, electrode sticking, etc.
occurs, the robot will stop and slightly back off from its stop position.
Restricting the working space
The movement of each axis can be restricted using software limits.
There are safeguarded space stops for connection of limit switches to restrict the working
space.
For some robots the axes 1-3 can also be restricted by means of mechanical stops.
Hold-to-run control
Hold-to-run means that you must depress the start button in order to move the robot. When
the button is released the robot will stop. The hold-to-run function makes program testing
safer.
Fire safety
Both the manipulator and control system comply with ULs (Underwriters Laboratory)
tough requirements for fire safety.
Safety lamp
As an option, the robot can be equipped with a safety lamp mounted on the manipulator.
This is activated when the controller is in the MOTORS ON state.
Description
1.3 Operation
All operations and programming can be carried out using the portable teach pendant
(see Figure 3) and operators panel (see Figure 5).
.
Hold-to-run
Menu keys
Motion keys
Display
P5
P4
7
4
1
Window
keys
1
2
P1
8
5
2
0
9
6
3
Joystick
Enabling
device
P2
P3
Function keys
Emergency stop
button
Navigation keys
Cable 10 m
Figure 3 The teach pendant is equipped with a large display, which displays prompts,
information, error messages and other information in plain English.
Description
- File management
- System configuration
- Service and troubleshooting
- Automatic operation
User-defined keys (P1-P5)
Five user-defined keys that can be configured to set or reset an output (e.g. open/close
gripper) or to activate a system input.
Hold-to-run
A push button which must be pressed when running the program in manual mode with
full speed.
Enabling device
A push button which, when pressed halfway in, takes the system to MOTORS ON.
When the enabling device is released or pushed all the way in, the robot is taken to the
MOTORS OFF state.
Joystick
The joystick is used to jog (move) the robot manually; e.g. when programming the
robot.
Emergency stop button
The robot stops immediately when the button is pressed in.
Menu keys
File
Edit
View
1 Goto ...
Inputs/Outputs
2 Goto Top
3 Goto Bottom
Name
Value
I/O list
di1
di2
grip1
grip2
clamp3B
feeder
progno
1
1
0
1
0
1
1
13
Menu
4(6)
Line indicator
Cursor
Function keys
Using the joystick, the robot can be manually jogged (moved). The user determines the
speed of this movement; large deflections of the joystick will move the robot quickly,
smaller deflections will move it more slowly.
The robot supports different user tasks, with dedicated windows for:
- Production
8
Description
- Programming
- System setup
- Service and installation
Operators panel
MOTORS ON button
and indicating lamp
Emergency stop
If pressed in,
pull to release
MOTORS ON
Continuous light
Fast flashing light (4Hz)
Slow flashing light (1 Hz) = One of the safeguarded space stops is active
Note: The motors have been switched off
100%
Automatic mode
= Running production
Manual mode
at reduced speed
Optional:
Manual mode
= Testing at full program speed
at full speed
Equipped with this mode,
the robot is not approved
according to ANSI/UL
Figure 5 The operating mode is selected using the operators panel on the controller.
Description
Both the operators panel and the teach pendant can be mounted externally, i.e.
separated from the cabinet. The robot can then be controlled from there.
The robot can be remotely controlled from a computer, PLC or from a customers panel,
using serial communication or digital system signals.
For more information on how to operate the robot, see the Users Guide.
10
Description
1.4 Memory
Available memory
The controller has two different memories:
- a fixed DRAM memory of size 32 MB, used as working memory
- a flash disk memory, standard 64 MB, used as mass memory. Optional 128 MB.
The DRAM memory is used for running the system software and the user programs and
it is thus divided into three areas:
- system software
- system software execution data
- user RAPID programs, about 5.5 MB, see Figure 6 (when installing different
options, the user program memory will decrease, at most by about 0.7 MB).
The flash disk is divided into four main areas:
- a base area of 5 MB, with permanent code for booting
- a release area of 20 MB, where all the code for a specific release is stored
- a system specific data area of 10 MB, where all the run time specific data
including the user program for a system is stored at backup
- a user mass memory area which can be used for storing RAPID programs, data,
logs etc.
The flash disk is used for backup, i.e. when a power failure occurs or at power off, all
the system specific data including the user program, see Figure 6, will be stored on the
flash disk and restored at power on. A backup power system (UPS) ensures the
automatic storage function.
DRAM memory
32 MB
System
soft ware
Release storage
20 MB
Data
User RAPID
program 5.5 MB
Power
off store
11
Description
Several different systems, i.e. process applications, may be installed at the same time
in the controller, of which one can be active. Each such application will occupy another
10 MB of the flash memory for system data. The release storage area will be in common
as long as the process applications are based on the same release. If two different
releases should be loaded, the release storage area must also be doubled.
For RAPID memory consumption, see RAPID Developers Manual. As an example, a
MoveL or MoveJ instruction consumes 236 bytes when the robtarget is stored in the
instruction (marked with *) and 168 bytes if a named robtarget is used. In the latter
case, the CONST declaration of the named robtarget consumes an additional 280 bytes.
Additional software options will reduce the available user program memory, most of
them however only marginally, i.e. the user program area will still be about 5.5 MB.
Only the SpotWare option will reduce memory significantly, i.e. down to about 4.8 MB
depending on the number of simultaneous welding guns.
1.5 Installation
The controller is delivered with a standard configuration for the corresponding
manipulator, and can be operated immediately after installation. Its configuration is
displayed in plain language and can easily be changed using the teach pendant.
Operating requirements
Protection standards
Controller electronics
IEC529
IP54
Explosive environments
The controller must not be located or operated in an explosive environment.
Ambient temperature
Controller during operation
with option 473
Controller during transportation and storage,
for short periods (not exceeding 24 hours)
Relative humidity
Transportation, storage and operation
Vibration
Controller during transportation and storage
Bumps
Controller during transportation and storage
10-55 Hz:
55-150 Hz:
Max. 0.15 mm
Max. 20 m/s2
Power supply
Mains voltage
12
Mains frequency
48.5 to 61.8 Hz
Description
Rated power:
IRB 140, 1400, 2400
IRB 340, 14001, 24001,4400, 6400, 940
IRB 6600
IRB 7600
External axes cabinet
Computer system backup capacity
at power interrupt
Configuration
The robot is very flexible and can, by using the teach pendant, easily be configured to
suit the needs of each user:
Authorisation
Most common I/O
Instruction pick list
Instruction builder
Operator dialogs
Language
Date and time
Power on sequence
EM stop sequence
Main start sequence
Program start sequence
Program stop sequence
Change program sequence
Working space
External axes
Brake delay time
I/O signal
Serial communication
For a detailed description of the installation procedure, see the Product Manual Installation and Commissioning.
1.6 Programming
Programming the robot involves choosing instructions and arguments from lists of
appropriate alternatives. Users do not need to remember the format of instructions,
since they are prompted in plain English. See and pick is used instead of remember
and type.
13
Description
The programming environment can be easily customized using the teach pendant.
- Shop floor language can be used to name programs, signals, counters, etc.
- New instructions can be easily written.
- The most common instructions can be collected in easy-to-use pick lists.
- Positions, registers, tool data, or other data, can be created.
Programs, parts of programs and any modifications can be tested immediately without
having to translate (compile) the program.
Movements
A sequence of movements is programmed as a number of partial movements between
the positions to which you want the robot to move.
The end position of a movement is selected either by manually jogging the robot to the
desired position with the joystick, or by referring to a previously defined position.
The exact position can be defined (see Figure 7) as:
- a stop point, i.e. the robot reaches the programmed position
or
- a fly-by point, i.e. the robot passes close to the programmed position. The size
of the deviation is defined independently for the TCP, the tool orientation and
the external axes.
Stop point
Fly-by point
User-definable distance (in mm)
Figure 7 The fly-by point reduces the cycle time since the robot does not have to stop at
the programmed point. The path is speed independent.
Description
a standard PC.
Editing programs
Programs can be edited using standard editing commands, i.e. cut-and-paste, copy,
delete, find and change, undo etc. Individual arguments in an instruction can also be
edited using these commands.
No reprogramming is necessary when processing left-hand and right-hand parts, since
the program can be mirrored in any plane.
A robot position can easily be changed either by
- jogging the robot with the joystick to a new position and then pressing the
ModPos key (this registers the new position)
or by
- entering or modifying numeric values.
To prevent unauthorised personnel from making program changes, passwords can be
used.
Testing programs
Several helpful functions can be used when testing programs. For example, it is
possible to
- start from any instruction
- execute an incomplete program
- run a single cycle
- execute forward/backward step-by-step
- simulate wait conditions
- temporarily reduce the speed
- change a position
- tune (displace) a position during program execution.
For more information, see the Users Guide and RAPID Reference Manual.
15
Description
Other
Service
A special input can be set to order the robot to go to a service position. After service,
the robot is ordered to return to the programmed path and continue program execution.
You can also create special routines that will be automatically executed when the power
is switched on, at program start and on other occasions. This allows you to customise
each installation and to make sure that the robot is started up in a controlled way.
The robot is equipped with absolute measurement, making it possible to operate the
robot directly when the power is switched on. For your convenience, the robot saves
the used path, program data and configuration parameters so that the program can be
easily restarted from where you left off. Digital outputs are also set automatically to the
value prior to the power failure.
Description
1.9 Exception handling
Many advanced features are available to make fast error recovery possible.
Characteristic is that the error recovery features are easy to adapt to a specific
installation in order to minimise down time. Examples:
- Error Handlers (automatic recovery often possible without stopping
production).
- Restart on Path.
- Power failure restart.
- Service routines.
- Error messages: plain text with remedy suggestions, user defined messages.
- Diagnostic tests.
- Event logging.
17
Description
18
Description
Tool coordinates
Z
Base coordinates
X
Y
Axis 3
Axis 2
Axis 3
X
Base coordinates
Axis 1
Axis 1
Y
Tool coordinates
Z
Tool Centre Point (TCP)
Z User
coordinates
Object
coordinates
Y
X
World coordinates
X
X
Figure 9 The coordinate systems, used to make jogging and off-line programming easier.
The world coordinate system defines a reference to the floor, which is the starting
point for the other coordinate systems. Using this coordinate system, it is possible to
relate the robot position to a fixed point in the workshop. The world coordinate system
is also very useful when two robots work together or when using a robot carrier.
The base coordinate system is attached to the base mounting surface of the robot.
The tool coordinate system specifies the tools centre point and orientation.
The user coordinate system specifies the position of a fixture or workpiece
manipulator.
The object coordinate system specifies how a workpiece is positioned in a fixture or
workpiece manipulator.
The coordinate systems can be programmed by specifying numeric values or jogging
the robot through a number of positions (the tool does not have to be removed).
Each position is specified in object coordinates with respect to the tools position and
orientation. This means that even if a tool is changed because it is damaged, the old
program can still be used, unchanged, by making a new definition of the tool.
If a fixture or workpiece is moved, only the user or object coordinate system has to be
redefined.
19
Description
Stationary TCP
When the robot is holding a work object and working on a stationary tool, it is possible
to define a TCP for that tool. When that tool is active, the programmed path and speed
are related to the work object.
Program execution
The robot can move in any of the following ways:
- Joint motion (all axes move individually and reach
the programmed position at the same time).
- Linear motion (the TCP moves in a linear path).
- Circle motion (the TCP moves in a circular path).
Soft servo - allowing external forces to cause deviation from programmed position can be used as an alternative to mechanical compliance in grippers, where imperfection
in processed objects can occur.
If the location of a workpiece varies from time to time, the robot can find its position
by means of a digital sensor. The robot program can then be modified in order to adjust
the motion to the location of the part.
Jogging
The robot can be manually operated in any one of the following ways:
- Axis-by-axis, i.e. one axis at a time.
- Linearly, i.e. the TCP moves in a linear path (relative to one of the coordinate
systems mentioned above).
- Reoriented around the TCP.
It is possible to select the step size for incremental jogging. Incremental jogging can be
used to position the robot with high precision, since the robot moves a short distance
each time the joystick is moved.
During manual operation, the current position of the robot and the external axes can be
displayed on the teach pendant.
Singularity handling
The robot can pass through singular points in a controlled way, i.e. points where two
axes coincide.
Motion Supervision
The behaviour of the motion system is continuously monitored as regards position and
speed level to detect abnormal conditions and quickly stop the robot if something is not
OK. A further monitoring function, Collision Detection, is optional (see option Load
Identification and Collision Detection).
20
Description
External axes
Very flexible possibilities to configure external axes. Includes for instance high
performance coordination with robot movement and shared drive unit for several axes.
Big Inertia
One side effect of the dynamic model concept is that the system can handle very big
load inertias by automatically adapting the performance to a suitable level. For big,
flexible objects it is possible to optimise the servo tuning to minimise load oscillation.
Soft Servo
Any axis (also external) can be switched to soft servo mode, which means that it will
adopt a spring-like behaviour.
21
Description
External axes for robot types IRB 140, IRB 1400, and IRB 2400:
When more than three external axes are used, the drive units for external axis 4 and
upwards must be located in a separate cabinet as shown in Figure 10.
External axes for robot types IRB 6600 and IRB 7600:
The drive units for all external axes must be located in a separate cabinet as shown in
Figure 10.
Not supplied on delivery
Motor channel
Serial signals for
measurement and
drive system
SMB
Measurement
System 1
SMB
alt.
Measurement
System 2
Drive System 2
ABB Drives
22
Description
thick/thin cable
S4Cplus
multiport-tap
trunk line
R
node
thick/thin cable
node
node
I/O CPU
node
Daisy chain
node
node
node
node
R = terminating resistor
short drop max. 6m each
Figure 11 Example of a general DeviceNet bus.
23
Description
- Program controlled enabling/disabling of I/O units.
- Scaling of analog signals.
- Filtering.
- Polarity definition.
- Pulsing.
- TCP-proportional analog signal.
- Programmable delays.
- Simulated I/O (for forming cross connections or logical conditions without need
the for physical hardware).
- Accurate coordination with motion.
Signals can be assigned to special system functions, such as program start, so as to be
able to control the robot from an external panel or PLC.
The robot can function as a PLC by monitoring and controlling I/O signals:
- I/O instructions are executed concurrent to the robot motion.
- Inputs can be connected to trap routines. (When such an input is set, the
trap routine starts executing. Following this, normal program execution
resumes. In most cases, this will not have any visible effect on the robot motion,
i.e. if a limited number of instructions are executed in the trap routine.)
- Background programs (for monitoring signals, for example) can be
run in parallel with the actual robot program. Requires Multitasking option, see
Product Specification RobotWare.
Manual functions are available to:
- List all the signal values.
- Create your own list of your most important signals.
- Manually change the status of an output signal.
- Print signal information on a printer.
I/O signals can for some robots also be routed parallel or serial to connectors on the
upper arm of the robot.
Types of connection
The following types of connection are available:
- Screw terminals on the I/O units
- Industrial connectors on cabinet wall
- Distributed I/O-connections inside or on cabinet wall
For more detailed information, see Chapter 2, Specification of Variants and Options.
ABB I/O units (node types)
Several I/O units can be used. The following table shows the maximum number of
physical signals that can be used on each unit. Data rate is fixed at 500 Kbit/s.
24
Description
Digital
Analog
DSQC
Option
no.
In
Out
328
20x
16
16
Internal/External1
320
25x
16
16
Internal/External
Analog I/O
355
22x
AD Combi I/O
327
23x
16
16
Relay I/O
332
26x
16
16
Allen-Bradley
Remote I/O Slave
350
241
1282
128
Interbus Slave
351
242-285
642
64
Profibus DP Slave
352
243-287
1282
128
100
100
Type of unit
Simulated I/O3
Encoder interface
unit4
Encoder interface
unit5
354
244
377
249
Voltage
inputs
Voltage
output
3
2
Current
output
Power supply
Internal
Internal/External1
Internal/External1
30
30
1. The digital signals are supplied in groups, each group having 8 inputs or outputs.
2. To calculate the number of logical signals, add 2 status signals for Allen-Bradley Remote I/O unit and 1
for Interbus and Profibus DP.
3. A non physical I/O unit can be used to form cross connections and logical conditions without
physical wiring. No. of signals are to be configured. Some ProcessWares include SIM unit.
4. Dedicated for conveyor tracking only.
5. Only for PickMaster 4.0
Distributed I/O
The maximum number of logical signals is 1024 in total for the CAN/DeviceNet buses
(inputs or outputs, group I/O, analog and digital including field buses)
CAN1
Max. total no of units*
Data rate (fixed)
Max. total cable length
Cable type (not included)
CAN2 (option)
25
Description
Signal data
Permitted customer 24 V DC load
Digital inputs
24 V DC
max. 7,5 A
(option 201/203)
Optically-isolated
Rated voltage:
24 V DC
Logical voltage levels: 1
15 to 35 V
0
-35 to 5 V
Input current at rated input voltage:
6 mA
Potential difference:
max. 500 V
Time delays:
hardware
515 ms
software
3 ms
Time variations:
2 ms
Digital inputs
120 V AC
26
(option 205)
Single pole relays with one make contact (normally open)
Rated voltage:
24 V DC, 120 VAC
Voltage range:
19 to 35 V DC
24 to 140 V AC
Output current:
max. 2 A
Potential difference:
max. 500V
Time intervals: hardware (set signal)
typical 13 ms
hardware (reset signal) typical 8 ms
software
4 ms
(option 204)
Optically isolated
Rated voltage
Input voltage range: 1
Input voltage range: 0
Input current (typical):
Time intervals: hardware
software
120 V AC
90 to 140 V AC
0 to 45 V AC
7.5 mA
20 ms
4 ms
Description
Digital outputs
120 V AC
(option 204)
Optically isolated, voltage spike protection
Rated voltage
120 V AC
Output current:
max. 1A/channel, 12 A
16 channels
or
max. 2A/channel, 10 A
16 channels
(56 A in 20 ms)
min. 30mA
Voltage range:
24 to 140 V AC
Potential difference:
max. 500 V
Off state leakage current:
max. 2mA rms
On state voltage drop:
max. 1.5 V
Time intervals: hardware
12 ms
software
4 ms
Analog inputs (option 202)
Voltage Input voltage:
+10 V
Input impedance:
>1 Mohm
Resolution:
0.61 mV (14 bits)
Accuracy:
+0.2% of input signal
Analog outputs
Analog outputs
(option 202)
VoltageOutput voltage:
Load impedance:
Resolution:
CurrentOutput current:
Load impedance:
Resolution:
Accuracy:
min.
min.
+10 V
2 kohm
2.44 mV (12 bits)
4-20 mA
800 ohm
4.88 A (12 bits)
+0.2% of output signal
(option 203)
Output voltage (galvanically isolated):
Load impedance:
min.
Resolution:
Accuracy:
Potential difference:
Time intervals: hardware
software
0 to +10 V
2 kohm
2.44 mV (12 bits)
25 mV 0.5% of output
voltage
max. 500 V
2.0 ms
4 ms
System signals
Signals can be assigned to special system functions. Several signals can be given the
same functionality.
Digital outputs
Motors on/off
Executes program
Error
Automatic mode
Emergency stop
Restart not possible
Run chain closed
27
Description
Digital inputs
Motors on/off
Starts program from where it is
Motors on and program start
Starts program from the beginning
Stops program
Stops program when the program cycle is ready
Stops program after current instruction
Executes trap routine without affecting status of stopped
regular program1
Loads and starts program from the beginning1
Resets error
Resets emergency stop
System reset
Analog output
For more information on system signals, see Users Guide - System Parameters.
28
Description
1.14 Communication
The controller has three serial channels for permanent use - two RS232 and one
RS422 Full duplex - which can be used for communication point to point with
printers, terminals, computers and other equipment. For temporary use, like service,
there are two more RS 232 channels.
The serial channels can be used at speeds up to 19,200 bit/s (max. 1 channel with speed
19,200 bit/s).
The controller has two Ethernet channels and both can be used at 10 Mbit/s or
100 Mbit/s. The communication speed is set automatically.
Temporary
Main CPU console
Ethernet 10 Mbit/s
Permanent
Ethernet or serial
Figure 12 Point-to-point communication.
29
Description
30
1 SAFETY STANDARDS
EU - Electromagnetic Compatibility
693 The controller complies with the European Union Directive Electromagnetic
Compatibility 89/336/EEC. This option is required by law for end users in the
European Union.
UNDERWRITERS LABORATORY
695 UL/CSA
The robot is certified by Underwriters Laboratory to comply with the Safety Standard
ANSI/UL 1740-1996 Industrial Robots and Robotic Equipment and
CAN/CSA Z 434-94.
UL/UR certification is required by law in some US states and Canada.
UL (UL/CSA) means certification of complete product and UR (UL recognized
Component) means certification of component or not complete product.
Safety lamp (691) Door interlock (145 or 142) Operating mode selector standard
2 modes (193) are mandatory.
Not with Cabinet height 950 mm no cover (122), Cabinet height 1200 mm (123),
Cabinet height 1750 mm (124), Cabinet variant Prepared for Arcitec (112), Mains
connection type CEE17 connector (132, 133), Service outlet type 230V Europe (412).
696 UR (UL Recognized)
The robot is certified by Underwriters Laboratory to comply with the Safety Standard
UL 1740 Industrial Robots and Robotic Equipment. UL/UR certification is required
by law in some US states and Canada. UL (UL listed) means certification of complete
product and UR (UL Recognized Component) means certification of component or not
complete product.
Safety lamp (691), Door interlock (145 or 142), Operating mode selector standard 2
modes (193) are mandatory.
Not with Cabinet variant Prepared for Arcitec (112), Mains connection type CEE17
connector (132, 133), Service outlet type 230V Europe (412).
31
665
9 (x4)
690
730
20
705
Figure 14 Mounting plate for mounting of equipment (dimensions in mm)
M4 (x4)
M8 (x4)
o
45
196
193
223
70
62
140
96
Holes for
flange
184
200
Holes for
operators panel
Holes for
teach pendant holder
Teach pendant
connection
Connection to
the controller
90
5 (x2)
155
33
337
Connection flange
370
Figure 16 Operators panel mounted in a box (all dimensions in mm).
DOOR KEYS
461
462
463
464
466
Standard
Doppelbart
Square outside 7 mm
EMKA DB
Locking cylinder 3524
CONTROLLER COOLING
472 Ambient temperature up to 45oC (113oF)
Standard design. The computer unit is provided with a passive heat exchanger (cooling
fins on the rear part of the box).
473 Ambient temperature up to 52oC (125oF)
The computer unit is provided with an active Peltier cooling equipment (replaces the
cooling fins from option 472.
34
English
Swedish
German
French
Spanish
Portuguese
Danish
Italian
Dutch
Japanese
Czech
Finnish
Extension cable for the teach pendant:
606 10 m
An extension cable can be connected between the controller and the teach pendant.
The total length of cable between the controller and the teach pendant should not
exceed 30 m.
Note that the length of the optional operators panel cable must be included in the
limitation.
607 20 m
MAINS VOLTAGE
The control system can be connected to a rated voltage of between 200 V and 600 V,
3-phase and protective earthing. A voltage fluctuation of +10% to -15% is permissible.
151
152
153
154
155
156
157
158
200V
220V
400V
440V
475V
500V
525V
600V
For all robots except for IRB 6600/7600 the voltage range must be specified. This gives
the possibility to select between three different transformers.
35
560
300
398
MAINS SWITCH
141 Rotary switch 40 A in accordance with the standard in section 1.2 and IEC 337-1,
VDE 0113. Customer fuses for cable protection required.
142 Flange disconnector in accordance with the standard in section 1.2.
Includes door interlock for flange disconnector and a 20A circuit breaker with interrupt capacity
14 kA.
0058 Flange disconnector in accordance with the standard in section 1.2.
Includes door interlock for flange disconnector and a 20A circuit breaker with interrupt
36
145
147
37
X8 (CAN 2)
Ph.5-Pol
X7
CAN 1.3
X10 SIO1
Test
9-Pol D-sub
X20 DRIVE
SYSTEM 2
R
E
L
Ph.5-Pol
8-Pol
DB-44
9-Pol D-sub
X1 I/O COMPUTER
X11 CONSOLE
X9 SIO2
Ph.5-Pol
15-Pol D-sub
9-Pol D-sub
X9 (COM3, RS422)
X8
CAN 2
Ph.5-Pol
X5 MEASUREMENT SYSTEM 2
X2 AXIS COMPUTER
X6
CAN 1.2
25-Pol D-sub
CAN 2
NS MS
X4 MEASUREMENT SYSTEM 1
15-Pol D-sub
15-Pol D-sub
15-Pol
Female
FCI
X3 DRIVE SYSTEM 1
15-Pol
Male
FCI
25-Pol D-sub
Computer system
(COM1, RS232)
XT 31
(24V I/O)
Panel Unit
WARNING
DSQC 509
Manipulator connections
X1-X4
Safety Signals
115/230 VAC
MS NS
X3 X1-X4
CUSTOMER
CONNECTIONS
X1
X2
X4
XP5
XP58
XP6
RL2
XT21
Connection to
Position switches
RL1
XP8
Connection to
Customer power
Customer signals
Figure 20 I/O unit and screw terminal locations.
38
SAFETY SIGNALS
206 Internal connection
The signals are connected directly to screw terminals in the upper part of the cabinet
(see Figure 20).
207 External connection
The signals are connected via 64-pole standard industrial connector in accordance
with DIN 43652. The connector is located on the left-hand side of the controller.
Corresponding customer part is included.
39
GATEWAY UNITS
For more details, see I/O System on page 23.
241 Allen-Bradley Remote I/O
Up to 128 digital inputs and outputs, in groups of 32, can be transferred serially to a
PLC equipped with an Allen Bradley 1771 RIO node adapter. The unit reduces the
number of I/O units that can be mounted in cabinet by one. The field bus cables are
connected directly to the A-B Remote I/O unit in the upper part of the cabinet (see
Figure 20). Connectors Phoenix MSTB 2.5/xx-ST-5.08 or equivalent are included.
242 Interbus Slave
Up to 64 digital inputs and 64 digital outputs can be transferred serially to a PLC
equipped with an InterBus interface. The unit reduces the number of I/O units that
can be mounted in the cabinet by one. The signals are connected directly to the
InterBus slave unit (two 9-pole D-sub) in the upper part of the cabinet.
40
41
195
203
49
170
49
115
Figure 22 Dimension for units 231-234.
43
45
46
Drive unit GT, for 4 or 6 motors. Recommended motor types see Figure 23.
Drive unit ECB, for 3 or 6 motors. Recommended motor types see Figure 23.
Drive unit GT + ECB
Drive unit GT + GT + ECB
Drive unit
identity
Motor max
current Arms
Suitable motor
type
11.5-57
30
XL
5.5-26
14.5
XL
11 - 55A
24A
M, L
6 - 30A
16A
S, M, L
7.5-37
20
S, M, L, XL
4 - 19A
8,4A
S, M
2,5 - 11A
5A
1,5 - 7A
4A
Figure 23 Motor selection table. Motor types according to external axes Motor Unit.
47
7m
15 m, not available for IRB 140
22 m, not available for IRB 140
30 m, not available for IRB 140
3 m, only available for IRB 140
Manipulator connection (only available for IRB 340)
SERVICE OUTLET
Any of the following standard outlets with protective earthing can be chosen for
maintenance purposes.
The maximum load permitted is 500 VA (max. 100 W can be installed inside the
cabinet).
411 120 V in accordance with American standard; single socket, Harvey Hubble.
412 230 V mains outlet in accordance with DIN VDE 0620; single socket suitable for
EU countries.
MEMORY
Removable mass memory
320 Floppy drive
The disk drive normally works well at temperatures up to 40oC (104oF). The disk drive
48
49
50
Index
3 Index
A
absolute measurement 16
Allen-Bradley Remote I/O 23, 25, 40
analog signals 23, 27
automatic operation 15
B
backup
computer system backup 13
memory 11
base coordinate system 19
Big Inertia 21
bumps 12
C
cabinet wheels 32
CAN/DeviceNet 39
collision detection 6
communication 29
concurrent I/O 24
configuration 12, 13, 23
connection 48
mains supply 36
cooling device 3
coordinate systems 18
cross connections 23
cursor 7
event routine 16
explosive environments 12
extended memory 11
external axes 21
external panel 33
F
fire safety 6
flash disk memory 11
fly-by point 14
function keys 7
H
hold-to-run 8
hold-to-run control 6
humidity 12
I
I/O units 24
I/O-system 23
incremental jogging 20
inputs 23
installation 12
Interbus Slave 23, 25, 40
interrupt 24
J
jogging 20
joystick 8
diagnostics 17
digital signals 23, 26
display 7
distributed I/O 25
LAN/Ethernet 39
language 13
lighting
connection 48
teach pendant 35
E
editing
position 15
programs 15
emergency stop 6, 7
emergency stop button 8
enabling device 5, 8
display 7
Encoder interface unit 25, 41
M
mains supply 36
mains switch 36
mains voltage 35
maintenance 17
manipulator cable 48
length 48
protection 48
51
Index
mass memory 11
memory
backup 11
extended 11
flash disk 11
mass storage 11
RAM memory 11
menu keys 7
mirroring 15
motion 18
motion keys 7
motion performance 18
Motion Supervision 20
Multitasking 24
N
navigation keys 7
noise level 3
O
object coordinate system 19
operating mode 9
operating mode selector 9, 34
operating requirements 12
operation 7
operator dialogs 13
operators panel 9, 33
options 31
outputs 23
over-speed protection 6
P
password 13, 15
performance 18
PLC functionality 24
position
editing 15
execution 20
programming 14, 19
position fixed I/O 24
power supply 12
production window 15
Profibus 39
Profibus DP Slave 23, 25, 41
program
editing 15
testing 15
52
programming 13
protection standards 12
Q
QuickMove 18
R
RAPID Language 16
reduced speed 5
S
safe manual movements 6
safeguarded space stop 6
delayed 6
safety 5
safety lamp 6
serial communication 29
service 17
service outlets 48
signal data 26
singularity handling 20
Soft Servo 21
space requirements 3
standards 5
stationary TCP 20
stop point 14
structure 3
system signals 27
T
TCP 19
teach pendant 7
cable 35
language 35
lighting 35
temperature 12
testing programs 15
tool coordinate system 19
tools centre point 19
trap routines 24
troubleshooting 17
TrueMove 18
U
user coordinate system 19
user-defined keys 8
Product Specification S4Cplus M2000/BaseWare OS 4.0
Index
V
variants 31
vibration 12
volume 3
W
window keys 7
windows 7
working space
restricting 6
world coordinate system 19
53
Index
54
Product Specification
RobotWare Options
3HAC 9218-1/Rev.2
BaseWare OS 4.0
The information in this document is subject to change without notice and should not be construed as a
commitment by ABB Automation Technology Products AB, Robotics. ABB Automation Technology
Products AB, Robotics assumes no responsibility for any errors that may appear in this document.
In no event shall ABB Automation Technology Products AB, Robotics be liable for incidental or
consequential damages arising from use of this document or of the software and hardware described
in this document.
This document and parts thereof must not be reproduced or copied without ABB Automation Technology Products AB, Robotics written permission, and contents thereof must not be imparted to a third
party nor be used for any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this document may be obtained from ABB Automation Technology Products AB,
Robotics at its then current charge.
Introduction
1 Introduction
RobotWare is a family of software products from ABB Automation Technology
Product AB, Robotics, designed to make you more productive and lower your cost of
owning and operating a robot.
ABB Automation Technology Product AB, Robotics has invested many man-years
into the development of these products and they represent knowledge and experience
based on several thousand robot installations.
Within the RobotWare family there are three classes of products:
BaseWare OS - This is the operating system of the robot and constitutes the kernel of
the RobotWare family. BaseWare OS provides all the necessary features for
fundamental robot programming and operation. It is an inherent part of the robot but
can be provided separately for upgrading purposes.
For the description of BaseWare OS, see Product Specification S4Cplus.
BaseWare Options - These products are options that run on top of BaseWare OS of the
robot. They represent functionality for robot users that need additional functionality,
for example run multitasking, transfer information from file to robot, communicate
with a PC, perform advanced motion tasks etc.
ProcessWare - ProcessWare products are designed for specific process applications
like welding, gluing and painting. They are primarily designed to improve the process
result and to simplify installation and programming of applications. These products
also run on top of BaseWare OS.
Introduction
2 BaseWare Options
[544] Absolute Accuracy
Absolute Accuracy (AbsAcc) is a calibration concept, which ensures a TCP absolute
accuracy of better than 1 mm in the entire working range.
The user is supplied with robot calibration data (error parameter file) and a certificate
that shows the performance (Birth Certificate).
The difference between an ideal robot and a real robot can be typically 8 mm, resulting
from mechanical tolerances and deflection in the robot structure. Absolute Accuracy
option is integrated in the controller algorithms for compensation of this difference,
and does not need external equipment or calculation.
Features
Compensation of mechanical tolerances.
Compensation of deflection due to load (tool, object and equipment on arm).
Applications
Any application where Absolute Accuracy is needed to facilitate:
- Exchangeability of robots
- Off-line programming with minimum touch-up.
- On-line programming with accurate linear movement as well as accurate
reorientation of tool
- Re-use of programs between applications
Controller algorithms
Inherent mechanical tolerances and deflection due to load in the robot structure
decrease the robots absolute accuracy. Practical compensation of such errors is a
complex and highly non-linear problem. The ABB solution is to compensate positions
internally in the controller, resulting in a defined and measurable robot TCP (Tool
Center Point) accuracy. A generic robot control model is used for each robot family and
robot individuals are described by a set of error parameters, generated during
calibration at ABB Automation Technology Products, Robotics. Accuracy of each
robot will be ascertained and verified through the Birth Certificate which statistically
describes the robot accuracy in a large sample of robot positions.
[542] ScreenViewer
[542] ScreenViewer
This option adds a user window to display user defined screens with advanced display
functions. The user window can be displayed at any time, regardless of the execution
state of the RAPID programs.
User defined screens
The user defined screens are composed of:
A fixed background with a size of 12 lines of 40 characters each. These characters
can be ASCII and/or horizontal or vertical strokes (for underlining, separating or
framing).
1 to 5 function keys.
1 to 4 pop-up menus containing from 1 to 10 choices.
1 to 30 display and input fields defined by:
- Their position and size.
- Their type (display, input).
- Their display format (integer, decimal, binary, hexadecimal, text).
- A possible boundary with minimum and maximum limits.
Example of a user defined screen. The ### represent the fields.
SpotTim
Program number: ###
PHASES
SQUEEZE
PREHEAT
COOLING
## HEAT
COLD
LASTCOLD
POSTHEAT
HOLD
Next
View
File
|
|
|
|
|
|
|
|
|
XT
##
##
##
##
##
##
##
##
|
|
|
|
|
|
|
|
|
|
CURENT (A)
START | END
|
####
|
| ####
####
|
|
|
####
| ####
|
Prev.
(Copy)
Valid
[542] ScreenViewer
A screen event can occur
- When a new screen is displayed (to initialize the screen contents).
- After a chosen interval (to refresh a screen).
- When a menu choice or a function key is selected (to execute a specific action,
or change the screen).
- When a new value is entered in a field, or when a new field is selected (to execute some specific action).
The commands that can be executed on screen events are
- Reading/writing RAPID or I/O data.
- Reading/writing fields contents.
- Arithmetical (+, -, /, *, div) or logical (AND, OR, NOT, XOR) operations on the
data read.
- Comparing data read (=, <, >) and carrying out a command or not, depending
on the comparison result.
- Displaying a different screen.
Capacities
The user screens can be grouped in a screen package file under a specific name. Up to
8 packages can be loaded at the same time.
A certain amount of memory (approx. 50 kbytes) is reserved for loading these screen
packages.
- The screen package to be displayed is selected using the far right hand menu
View (which shows a list of the screen packages installed).
ScreenMaker
ScreenMaker is a complete tool for creating and editing screens for the ScreenViewer
on desktop computers running Windows 95/98 or Windows NT.
See ScreenMaker Product Specification.
10
[532] Multitasking
[532] Multitasking
Up to 10 programs (tasks) can be executed in parallel with the normal robot program.
- These additional tasks start automatically at power on and will continue until
the robot is powered off, i.e. even when the main process has been stopped and
in manual mode.
- They are programmed using standard RAPID instructions, except for motion
instructions.
- They can be programmed to carry out various activities in manual or automatic
mode, and depending on whether or not the main process is running.
- Communication between tasks is carried out via I/O or global data.
- Priorities can be set between the processes.
Examples of applications:
- The robot is continuously monitoring certain signals even when the robot
program has stopped, thus taking over the job traditionally allocated to a PLC.
- An operator dialogue is required at the same time as the robot is doing, for
example, welding. By putting this operator dialogue into a background task, the
operator can specify input data for the next work cycle without having to stop
the robot.
- The robot is controlling a piece of external equipment in parallel with the
normal program execution.
Performance
When the various processes are programmed in the correct way, no performance
problems will normally occur:
- When the priorities for the various processes are correctly set, the normal
program execution of the robot will not be affected.
- Because monitoring is implemented via interrupts (instead of checking
conditions at regular intervals), processor time is required only when
something actually happens.
- All input and output signals are accessible for each process.
Note that the response time of Multitasking does not match that of a PLC. Multitasking
is primary intended for less demanding tasks. The normal response time is about 5 ms,
but in the worst cases, e.g. when the processor is computing new movements, it can be
up to 120 ms.
The available program memory can be divided up arbitrarily between the processes.
However, each process in addition to the main process will reduce the total memory,
see Product Specification S4Cplus.
11
13
14
15
16
17
18
19
GetNextSym
GetDataVal
Get the value of a data, specified with a string for the name
SetDataVal
Set the value of a data, specified with a string for the name
20
AliasIO
ArgName
BookErrNo
TextTabGet
TextGet
Function used to get a text string from the system text tables
(installed at cold start).
TextTabInstall
TextTabFreeToUse
IsSysId
SetSysData
ReadCfgData
WriteCfgData
PFDOVal
Get the value of the specified digital output signal at the time
for power failure.
PFGOVal
Get the value of the specified digital output group at the time
for power failure.
PFRestart
Trigg Functions
TriggSpeed
StepBwdPath
TriggStopProc
21
22
22
23
24
[547]Sensor Synchronization
Start/stop synchronization
Connect to an object in the start window
Disconnect from current object
25
26
27
28
29
30
31
32
Ethernet
RS232/RS422
Examples of applications:
- Production is controlled from a superior computer. Information about the robot
status is displayed by the computer. Program execution is started and stopped
from the computer, etc.
- Transferring programs and parameters between the robot and a PC. When many
different programs are used in the robot, the computer helps in keeping track of
them and by doing back-ups.
RAPID instruction included in this option
SCWrite
33
34
35
36
[551] ArcWare
3 ProcessWare
[551] ArcWare
ArcWare comprises a large number of dedicated arc welding functions, which make the
robot well suited for arc welding. It is a simple yet powerful program since both the
positioning of the robot and the process control and monitoring are handled in one and
the same instruction.
I/O signals, timing sequences and weld error actions can be easily configured to meet
the requirements of a specific installation.
ArcWare functions
A few examples of some useful functions are given below.
Adaptation to different equipment
The robot can handle different types of weld controllers and other welding equipment.
Normally communication with the welding controller uses parallel signals but a serial
interface is also available.
Advanced process control
Voltage, wire feed rate, and other process data can be controlled individually for each
weld or part of a weld. The process data can be changed at the start and finish of a
welding process in such a way that the best process result is achieved.
Testing the program
When testing a program, welding, weaving or weld guiding can all be blocked. This
provides a way of testing the robot program without having the welding equipment
connected.
Automatic weld retry
A function that can be configured to order one or more automatic weld retries after a
process fault.
Weaving
The robot can implement a number of different weaving patterns up to 10 Hz
depending on robot type. These can be used to fill the weld properly and in the best
possible way. Weaving movement can also be ordered at the start of the weld in order
to facilitate the initial striking of the arc.
37
[551] ArcWare
Wire burnback and rollback
These are functions used to prevent the welding wire sticking to the work object.
Fine adjustment during program execution
The welding speed, wire feed rate, voltage and weaving can all be adjusted whilst
welding is in progress. This makes trimming of the process much easier because the
result can be seen immediately on the current weld. This can be done in both manual
and automatic mode.
Seam finding and tracking
Seam finding and tracking can be implemented using a number of different types of
sensors. Please contact your nearest local ABB office for more information.
Interface signals
The following process signals are, if installed, handled automatically by ArcWare. The
robot can also support dedicated signals for workpiece manipulators and sensors.
38
Digital outputs
Power on/off
Gas on/off
Wire feed on/off
Wire feed direction
Weld error
Error information
Weld program number
Description
Turns weld on or off
Turns gas on or off
Turns wire feed on or off
Feeds wire forward/backward
Weld error
Digital outputs for error identification
Parallel port for selection of program number, or
3-bit pulse port for selection of program number, or
Serial CAN/Devicenet communication
Digital inputs
Arc OK
Voltage OK
Current OK
Water OK
Gas OK
Wire feed OK
Manual wire feed
Weld inhibit
Weave inhibit
Stop process
Wirestick error
Supervision inhibit
Torch collision
Description
Arc established; starts weld motion
Weld voltage supervision
Weld current supervision
Water supply supervision
Gas supply supervision
Wire supply supervision
Manual command for wire feed
Blocks the welding process
Blocks the weaving process
Stops/inhibits execution of arc welding instructions
Wirestick supervision
Program execution without supervision
Torch collision supervision
Analog outputs
Voltage
Wire feed
Current
Voltage adjustment
Current adjustment
Description
Weld voltage
Velocity of wire feed
Weld current
Voltage synergic line amplification
Current synergic line amplification
[551] ArcWare
Analog inputs (cont.)
Description (cont.)
Voltage
Current
39
40
[556] Arcitec
[556] Arcitec
This option is intended to be used in combination with the Arcitec power sources.
It shall only be ordered by the supplying unit of Arcitec.
The package is a special software, used together with the ArcWare package, to be able
to control not only the robot program but also the set up, configuration and
programming of the power source. Thus the robot teach pendant will be used for
programming and tuning both the robot and the power source.
The package also includes a special aid for easy welding programming, i.e. the synergic
function. This means that there is a pre-programmed relationsship between the wire
feed rate and all other data components in the power source, making it easy to control
the entire welding process, just by tuning the wire feed rate.
41
[553] SpotWare
[553] SpotWare
The Spotweld options are general and flexible software platforms for creation of
customized and easy to use function packages for different types of spotweld systems
and process equipments.
The SpotWare option is used for sequential welding with one or several pneumatic gun
equipments. If welding with several pneumatic guns at the same time is desired then
the SpotWare Plus option has to be used instead.
The SpotWare option provides dedicated spotweld instructions for fast and accurate
positioning combined with gun manipulation, process start and supervision of the weld
equipment.
Communication with the welding equipment is normally carried out by means of
digital inputs and outputs but a serial interface is also available for some type of weld
timers.
It should be noted that the SpotWare options are general and can be extensively
customized. They have a default ready to use functionality directly after install but it
is intended that some configuration data, RAPID data and RAPID routines has to be
changed during the customizing.
SpotWare features
Some examples of useful functions are given below:
- Fast and accurate positioning using the unique QuickMove and TrueMove
concept.
- Gun pre-closing.
- Quick start after a weld.
- Handling of an on/off gun with two strokes.
- Dual/single gun.
- Manual actions for welding and gun control.
- Simulation possibilities for test purposes.
- Reverse execution with gun control.
- Spot counters.
- User-defined supervision and error recovery. Weld error recovery with
automatic rewelding.
- User-defined continuous supervision of the weld equipment, such as weld
current signal and water cooling start. Note: This feature requires the
MultiTasking option.
- Wide customizing possibilities.
42
[553] SpotWare
Principles of SpotWare
The SpotWare functions will be controlled by separate internal program processes,
which will run in parallel. For instance the robot movements, the continuous supervision and the spot welding will be handled in different independent processes. This
means that if for instance the program execution and thus the robot movements is
stopped, then the welding and supervision will continue until they come to a well
defined process stop. For example, the welding process will carry on and finish the
weld and open the gun, although the program has been stopped during the weld phase.
For well defined points in the welding sequence and movements, calls to user routines
offer adaptations to the plant environment. A number of predefined parameters are also
available to shape the behaviour of the SpotWare instructions.
Programming principles
Both the robot movement and the control of the spot weld equipment are embedded in
the basic spot weld instructions SpotL and SpotJ.
The spot welding process is specified by:
- Spotdata: spot weld process data
- Gundata: spot weld equipment data
- The system modules SWUSRC and SWUSRF: RAPID routines and global data
for changing of process and test behaviour.
- System parameters: the I/O Signal configuration.
Spot welding instructions
Instruction
Used to:
SpotL
SpotJ
Used to define:
spotdata
gundata
43
44
Used to:
SpotML
SpotMJ
Used to define:
spotmdata
gunmdata
45
46
47
Used to:
SpotL
SpotJ
SetForce
CalibL
CalibJ
Calibrate
STTune
STTuneReset
48
Data type
Used to define:
spotdata
gundata
forcedata
simdata
Simulation modes
49
50
Instruction
Used to:
SpotML
SpotMJ
[569] DispenseWare
[569] DispenseWare
The DispenseWare package provides support for different types of dispensing
processes such as gluing and sealing.
The DispenseWare application provides fast and accurate positioning combined with a
flexible process control.
Communication with the dispensing equipment is carried out by means of digital and
analog outputs.
DispenseWare is a package that can be extensively customized. The intention is that
the user adapts some user data and routines to suit a specific dispensing equipment and
the environmental situation.
Dispensing features
The DispenseWare package contains the following features:
- Fast and accurate positioning.
- Handling of on/off guns as well as proportional guns.
- Speed proportional or constant analog outputs.
- Up to five different guns can be handled simultaneously, controlled by 1 - 5
digital output signals (for gun on/off control) and 1 - 2 analog output signals
(for flow control).
- Four different gun equipment, each controlled by 1 - 5 digital output signals
and 1 - 2 analog output signals, can be handled in the same program.
- Possibility to use different anticipated times for the digital and analog signals.
- Possibility to use equipment delay compensation for the TCP speed
proportional analog signals.
- Global or local flow rate correction factors.
- Dispensing instructions for both linear and circular paths.
- Dispensing in wet or dry mode.
- Wide opportunities of customizing the functionality to adapt to different types
of dispensing equipment.
- Possibility to restart an interrupted dispense sequence.
Programming principles
Both the robots movement and the dispensing process control are embedded in the
instructions, DispL and DispC respectively.
51
[569] DispenseWare
The gluing process is specified by:
- Bead specific dispensing data. See Data types - beaddata.
- Equipment specific dispensing data. See Data types - equipdata.
- RAPID routines and global data for customizing purposes. See Predefined Data
and Programs - System Module DPUSER.
- The I/O configuration. See System Parameters - DispenseWare
Dispensing instructions
Instruction
Used to:
DispL
Move the TCP along a linear path and perform dispensing with
the given data
DispC
Dispensing data
52
Data type
Used to define:
beaddata
equipdata
[571] PalletWare
[571] PalletWare
General
PalletWare is a ready-to-use software package for the S4Cplus controller, focused on
palletizing. PalletWare imports data created with PalletWizard, the included off-line
PC-tool, to execute the defined palletizing cycles. PalletWare has a predefined
interface for connecting PLC (Programmable Logic Controller), which is the most
common way to control external equipment such as infeeders, outfeeders and sensor
equipment. The standard package includes software components such as priority and
scheduling routines that are ready to use. The package also includes components that
can be customized, e.g. grip tool control routines.
PalletWare supports system integrators who want to customize the system, by
presenting a standardized interface.
What is included
Included in the PalletWare package is software components to control robot motion,
and to communicate with the user and external equipment.
In order to minimize commissioning time, PalletWare is equipped with a standardized
set of modules, referred to as the Standard Package Add-On. Advanced users can
replace these modules with their own if special customizing is needed. PalletWare is
also delivered with template user routines that handles the most common solutions.
PalletWare offers a standardized interface where to connect all external equipment
such as infeeders, PLC, signal board, grip tool, sensor equipment etc. The package
includes a set of predefined signals connected to a simulated board. The integrator has
to implement the signal board and connect the signals. The configuration file for the
signals has also to be modified depending on what type of board is used. Because of
the large amount of signals, it is recommended to use a field bus such as for example
Profibus.
PalletWare features
PalletWare offers for example following functionality:
- Multiplacing
- Parallel processing, up to 5 stations simultaneously
- Multistationary production
- User dialogue interface with Screen Viewer
- On-line tuning of geometrical data
- Safety functionality
- Prepared PLC interface
- Prepared MMI interface
53
[571] PalletWare
- Tool control
- Standardized error handling
- Predefined user routines
Programming principles
PalletWare is added to the BaseWare system. PalletWare consists of predefined motion
principles and communication routines for communicating with external equipment. It
is not necessarily needed to implement any RAPID code. However, the system supports
integrators for customizing by standardized functions and instructions.
Customizing PalletWare
PalletWare can be up-and-running without any need for implementing RAPID code,
but it must be adapted to the current robot cell and its physical lay-out. For instance,
there are a number of steps which are compulsory, e.g:
- Connect external equipment such as infeeders, tool, PLC etc., via the predefined
interface.
- Connect safety equipment such as emergency stop, safety fences etc.
- Define tooldata if the tool does not match the templates
- Check the set-up in the configuration module PAL_CFG.
- Define/teach work objects to the stations
- Define/teach robtarget with tool in zero orientation
- Create and load pallet cycles with PalletWizard.
In addition to this, PalletWare offers a great deal of customizing possibilities for
advanced users, e.g.
- Using tools with suction cups or mechanical gripper
- Sliding uppermost layer to gain pallet height
- Controlling orientation on infeeder
- Add or skip safety height movements between stations
- Set priority when working with several pallet cycles in parallel.
- Etc.
Pallet Wizard
Pallet Wizard is a complete and easy to use stand alone tool running on a PC under
Windows 95/98 or Windows NT, for off line programming of palletizing or
depalletizing processes. It is delivered as a part of the PalletWare option package.
In PalletWizard the complete cell with its different components like the products, the
tools, the in/out feeders and pallet stations as well as the pallet cycles with the layers
and the pattern descriptions can be defined.
54
[571] PalletWare
PalletWizard offers for example the following features:
- Detailed On-line help
- Wizards for defining the products, tools, cell definition, station configurations,
pallet composition and the pallet cycles
- Automatic pick- and place definition
- Automatic calculating of grip zones to be used for the tool
- Software based collision detection
- Library of predefined patterns
Several different pallet cycles can be combined into a production cycle and saved into
a file, which can be downloaded to the robot. At the robot the operator can then select
what specific pallet cycle to run and on which infeeder and pallet station.
55
Index
INDEX
4 Index
A
AbsAcc 5
Absolute Accuracy 5
Advanced functions 14
arc welding 37, 40
Arcitec 41
ArcWare 37
ArcWare Plus 40
B
BaseWare 5
BaseWare Options 3
BaseWare OS 3
C
Collision Detection 7
communication
robot and PC 33
continuous movement 13
Contour tracking 12
Conveyor Tracking 23, 27, 29
coordinated motion 12
cross-connection
locigal conditions 16
output 15
procedure call 15
Friction Compensation 13
FTP 32
I
I/O Plus 36
independent movement 13
input or output signals
interrupts 17
Interbus Configuration Tool 34
interrupt routine movement 16
interrupts
from analog input or output signals 17
L
Load Identification 7
logical conditions
cross connections 16
N
NFS 32
O
output
in fixed position 15
P
D
data
read and write 14, 33
transfer 14
Discrete Applications Platform 22
DispenseWare 51
E
electronically linked motors 24
error handler movement 16
Ethernet Services 32
F
file
read and write 14, 33
fixed position
PalletWare 53
parallel processing 11
PLC functionality 16
printout 14
ProcessWare 3, 37
Profibus Configuration Tool 35
Profibus DP 35
program
back-up 33
transfer 33
R
RAP Communication 31
read
data 14
file 14
57
Index
58
Table of Contents
0.0.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
0.0.2 Product Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Chapter 1: Safety, service
1.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Section 1.1: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
13
23
31
3HAC 16261-1
Table of Contents
4.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.2.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.2.3 Mechanically restricting the working range of axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.2.4 Mechanically restricting the working range of axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.2.5 Position switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Section 4.3: On-site installation, controller cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
73
135
ii
3HAC 16261-1
Table of Contents
137
149
165
171
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
10.2.1 Calibration, prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Preliminaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
10.2.2 Fine calibration procedure on TPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
10.2.3 Initialization of Levelmeter 2000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
Fine calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
10.2.4 Resetting of Levelmeter 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
10.2.5 Calibration, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
10.2.6 Calibration, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
10.2.7 Calibration, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
10.2.8 Calibration, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
10.2.9 Calibration, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
10.2.10 Calibration, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
Section 10.3: Calibration - Calibration Pendulum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
10.3.1 How to calibrate the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
10.3.2 Calibration, prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
10.3.3 Calibration pendulum kit, contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
3HAC 16261-1
iii
Table of Contents
Preliminaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
10.3.4 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
10.3.5 Calibration procedure on TPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
10.3.6 Initialization of calibration pendulum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
10.3.7 Calibration sensor mounting positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
10.3.8 Calibration, all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
10.3.9 Calibrating axes 3-4, IRB 7600/2.3/500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Section 10.4: After calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
221
iv
3HAC 16261-1
0.0.1 Overview
0.0.1 Overview
About This
Manual
This information product is a manual containing instructions for installing the complete robot
system, mechanically as well as electrically.
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
Contents
Safety, Service
Reference Information
Unpacking
On-site Installation
Electrical connections
Start-up
Robot controller
10
Calibration
11
Decommissioning
References
3HAC 16261-1
Reference
Document Id
3HAC 13347-1
3HAC 14189-2
0.0.1 Overview
Revisions
Revision
Description
First edition
Manual completed with references to pagenumbers and numbering of sections (manipulator sections).
3HAC 16261-1
General
The complete product documentation kit for the robot, including controller, manipulator and
any hardware option, consists of the manuals listed below:
Installation and
Commissioning
Manual
Repair Manual
Maintenance
Manual
Safety, Service
Reference Information
Unpacking
On-site Installation
Electrical connections
Start-up
Calibration
Safety, Service
Reference Information
Remove/Refitting instructions for all controller cabinet details considered spare parts
Safety, Service
Reference Information
Maintenance schedules
Instructions for all maintenance activities specified in the maintenance schedule, for
example cleaning, lubrication, inspection etc.
The information is generally divided into separate chapters for the manipulator and the controller, respectively.
Software manuals
The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during operation.
A complete listing of all available software manuals is available from ABB Robotics.
3HAC 16261-1
Hardware option
manual
Each hardware option is supplied with its own documentation. Each document set contains
the types of information specified above:
Installation information
Repair information
Maintenance information
3HAC 16261-1
1 Safety, service
1.0.1 Introduction
Definitions
This chapter details safety information for service personnel i.e. personnel performing installation, repair and maintenance work.
Sections
2. Safety risks lists dangers relevant when servicing the robot system. The dangers are split into different categories:
Safety risks related to gripper/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
3. Safety actions details actions which may be taken to remedy or avoid dangers.
Safety fence dimensions
Fire extinguishing
Emergency release of the manipulators arm
Brake testing
Risk of disabling function "Reduced speed 250 mm/s"
Safe use of the Teach Pendant Unit enabling device
Work inside the manipulators working range
3HAC 16261-1
1 Safety, service
1.1.1 Safety, service - General
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.
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.
General
Documents
Type of information
Detailed in document
Users Guide
Start-up
Section
3HAC 16261-1
1 Safety, service
1.2.1 Safety risks related to gripper
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
Grippers/end effectors must be designed so that they retain workpieces in the event of a power
failure or a disturbance of the controller.
General
Residual energy
Safe design
Residual energy may be present in these systems so, after shutdown, particular care
must be taken.
The pressure in pneumatic and hydraulic systems must be released before starting to
repair them.
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.
General
Qualified personnel
Extraordinary
risks
3HAC 16261-1
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.
1 Safety, service
1.2.5 Safety risks during installation and service
Nation/region
specific regulations
Non-voltage
related risks
To be observed
by the supplier of
the complete system
The instructions in the Product Manual - Installation and Commissioning must always
be followed.
Emergency stop buttons must be positioned in easily accessible places so that the
robot can be stopped quickly.
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 of the robot system, the regulations
applicable in the country concerned and the instructions of ABB Robotics must be complied
with.
Safety zones, which have to be crossed before admittance, must be set up in front of
the robot's working space. Light beams or sensitive mats are suitable devices.
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. In addition
to the risk of being hit by moving robot parts, you run the risk of being crushed by the
tie rod.
Energy, stored in the robot for the purpose of counterbalancing certain axes, may be
released if the robot, or parts thereof, is dismantled.
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
Voltage related
risks, controller
Although troubleshooting may, on occasion, have to be carried out while the power
supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
The mains supply to the robot must be connected in such a way that it can be turned
off outside the robots working space.
3HAC 16261-1
1 Safety, service
1.2.6 Risks associated with live electric parts
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. Note: 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
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.
3HAC 16261-1
The user connections for tools or other parts of the installation (max. 230 VAC, see
Installation and Commissioning Manual)
1 Safety, service
1.3.1 Safety fence dimensions
General
Fit a safety fence or enclosure around the robot to ensure a safe robot installation.
Dimensioning
Dimension the fence or enclosure to enable it to withstand the force created if the load being
handled by the robot is dropped or released at maximum speed. Determine the maximum
speed from the maximum velocities of the robot axes and from the position at which the robot
is working in the work cell (see Product Specification - Description, Robot Motion).
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating
tool or other device fitted to the manipulator.
Description
In an emergency situation, any of the manipulators axes may be released manually by pushing the brake release buttons on the manipulator or on an optional external brake release unit.
How to release the brakes is detailed in section "Manually releasing the brakes".
The manipulator arm may be moved manually on smaller robot models, but larger models
may require using an overhead crane or similar.
Increased injury
Before releasing the brakes, make sure that the weight of the arms does not increase the
pressure on the trapped person, which may further increase any injury!
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.
10
3HAC 16261-1
1 Safety, service
1.3.5 Risk of disabling function "Reduced speed 250 mm/s"
3HAC 16261-1
11
1 Safety, service
1.3.7 Work inside the manipulators working range
12
3HAC 16261-1
2 Reference information
2.0.1 Introduction
General
3HAC 16261-1
This chapter presents generic pieces of information, complementing the more specific information in the following chapters.
13
2 Reference information
2.1.1 Applicable Safety Standards
Standards,
general
Standards,
robot cell
14
The following standards are applicable when the robot is part of a robot cell:
EN 811 - Safety distances to prevent danger zones being reached by the lower limbs.
EN 294 - Safety distances to prevent danger zones being reached by the upper limbs.
3HAC 16261-1
2 Reference information
2.1.2 Screw joints
General
This section details how to tighten the various types of screw joints on 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.
UNBRAKO
screws
UNBRAKO is a special type of screw recommended by ABB in certain screw joints. It features special surface treatment (Gleitmo as described below), and is extremely resistant to
fatigue.
Whenever used, this is specified in the instructions and in such cases no other type of replacement screw is allowed. Using other types of screw will void any warranty and may potentially
cause serious damage or injury!
Gleitmo treated
screws
Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.
Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this
the screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should
be used.
Screws lubricated
in other ways
Screws lubricated with Molycote 1000 (or another lubricant) should only be used when specified in the repair, maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1. Lubricate the thread of the screw.
2. Lubricate between the plain washer and screw head.
3. Tighten to the torque specified in section "Tightening torque" below. Screw dimensions
of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or
smaller may be tightened without a torque wrench if this is done by trained and qualified personnel.
3HAC 16261-1
Lubricant
Art. no.
1171 2016-618
15
2 Reference information
2.1.2 Screw joints
Tightening torque
Below are tables specifying the torque values for different screw joint types:
Dimension
M2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
Screws with
hexagon socket
head, dry
Screws with
hexagon socket
head, lubricated
16
Dimension
Tightening torque
(Nm)
Class 8.8 "dry"
Tightening torque
(Nm)
Class 10.9 "dry"
Tightening torque
(Nm)
Class 12.9 "dry"
M5
M6
10
M8
24
34
40
M10
47
67
80
M12
82
115
140
M16
200
290
340
Dimension
M8
28
34
M10
55
66
M12
96
115
M16
235
280
3HAC 16261-1
2 Reference information
2.1.3 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 the use of lifting equipment when handling components with a weight
exceeding 22 kg to avoid inflicting injury. A wide range of lifting tools and devices is available for each manipulator model.
Example
3HAC 16261-1
17
2 Reference information
2.1.4 Standard toolkit
General
All service (repairs, maintenance and installation) instructions contain lists of tools required
to perform the specified activity.
All special tools required are listed directly in the instructions while all the tools that are
considered standard are gathered in the Standard toolkit and defined in the table below.
In this way, the tools required are the sum of the Standard Toolkit and any tools listed in the
instruction.
Contents,
standard toolkit,
3HAC 15571-1
18
Qty
Tool
Rem.
To be shorted to 12mm
3HAC 16261-1
2 Reference information
2.1.5 Special tools
General
All service (repairs, maintenance and installation) instructions contain lists of tools required
to perform the specified activity. The required tools are a sum of standard tools, defined in
section Standard toolkit on page 18, and of special tools, listed directly in the instructions and
also gathered in the table below.
The table below is an overview of all the special tools required when performing service
activities on the IRB 6600/6650/7600. The tools are gathered in two kits: Basic Toolkit
(3HAC 15571-3) and Extended Toolkit (3HAC 15571-2).
The special tools are also listed directly in the current instructions.
3HAC 16261-1
Description
Angel bracket
68080011-LP
3HAB 3409-86
3HAB 3409-89
Cal. tool
68080011-GM
Calibration bracket
3HAC 13908-9
3HAC 13908-4
3HAC 15716-1
3HAC 12342-1
3HAC 13659-1
3HAC 13660-1
Gearbox crank
3HAC 16488-1
3HAC 13056-2
3HAC 13056-3
3HAC 13056-4
3HAC 15520-1
3HAC 15520-2
3HAC 14445-1
3HAC 14446-1
3HAC 15521-1
3HAC 15521-2
3HAC 13120-2
3HAC 13120-3
3HAC 13120-4
3HAC 13120-5
3HAC 14628-2
3HAC 14628-1
3HAC 14627-3
3HAC 14627-2
Hydraulic cylinder
3HAC 11731-1
3HAC 13086-1
19
2 Reference information
2.1.5 Special tools
Description
3HAC 13086-2
6369901-348
3HAC 15560-1
3HAC 15607-1
3HAC 15994-1
3HAC 15536-1
3HAC 16131-1
3HAC 14457-3
3HAC 14457-4
3HAC 15556-1
3HAC 13698-1
3HAC 12731-1
3HAC 14691-1
3HAC 14459-1
3HAC 15534-1
3HAC 13605-1
3HAC 12734-1
Measuring pin
3HAC 13908-5
Mech stop ax 3
3HAC 12708-1
Mech stop ax 3
3HAC 12708-2
3HAC 13527-1
3HAC 13453-1
3HAC 13452-1
3HAC 17129-1
3HAC 15767-1
3HAC 12475-1
3HAC 15814-1
3HAC 14972-1
3HAC 14631-1
3HAC 14973-1
Rotation tool
3HAC 17105-1
Sensor plate
3HAC 0392-1
Support, base
3HAC 15535-1
Sync. adapter
3HAC 13908-1
3HAC 15943-2
3HAC 15943-1
3HAC 68080011GU
3HAA 1001-186
Note a) Calibration tools for IRB 6600/6650/7600 when CalPen is not used (standard).
Note b) Special tools that may be rent from ATRP/S.
20
3HAC 16261-1
2 Reference information
2.1.6 Performing a leak-down test
General
After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil
must be tested. This is done in a leak-down test.
Required equipment
Equipment, etc.
Leakdown tester
Note
3HAC 0207-1
Procedure
Step
3HAC 16261-1
Action
Note/Illustration
1.
2.
3.
Apply compressed air, and raise the pressure Recommended value: 0.2 - 0.25
with the knob until the correct value is shown on bar (20 - 25 kPa)
the manometer.
4.
5.
Wait for approx. 8-10 minutes. No pressure loss If the compressed air is signifimust be detected.
cantly colder or warmer than the
gearbox to be tested, a slight pressure increase or decrease respectively may occur. This is quite
normal.
6.
7.
Spray suspected leak areas with leak detection Art. no. specified above!
spray .
Bubbles indicate a leak.
8.
When the leak has been localized: take the necessary measures to correct the leak.
21
2 Reference information
2.1.7 Lifting equipment and lifting instructions
General
Many repair and maintenance activities require different pieces of lifting equipment, which
are specified in each activity instruction.
However, how to use each piece of lifting equipment is not detailed in the activity instruction,
but in the instruction delivered with each piece of lifting equipment.
This implies that the instructions delivered with the lifting equipment should be stored for
later reference.
22
3HAC 16261-1
3 Unpacking
3.0.1 Pre-installation procedure
Chapter 3: Unpacking
3.0.1 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:
Step
Weight, manipulator
3HAC 16261-1
Action
Info/Illustration
1.
2.
Make sure the manipulator has not been damaged, by visually inspecting the manipulator
and control cabinet exterior.
3.
4.
5.
6.
7.
Before moving the manipulator, please observe Described in Risk of tipping/Stabilthe risk of tipping!
ity on page 29.
8.
When these prerequisites have been met, the Specified in Lifting manipulator
manipulator may be taken to its installation site. with fork lift on page 32.
Manipulator model
Weight
2490 kg
2500 kg
2530 kg
23
3 Unpacking
3.0.1 Pre-installation procedure
The table below shows the different forces and torques working on the manipulator during
different kinds of operation.
NOTE! These forces and torques are extreme values that are rarely encountered during operation. The values also never reach their maximum simultaneously!
Requirements on
foundation,
manipulator
Force
Force xy
14000 N
31000 N
Force z
32000 10000 N
39000 16000 N
Torque xy
2000 Nm
72000 Nm
Torque z
11000 Nm
19500 Nm
The table below shows the requirements for the foundation where the manipulator is to be
fitted:
Requirement
Value
Min. levelness
0.5 mm
Max. tilt
Note
The limit for the maximum payload on the
manipulator is reduced if the manipulator is
tilted from 0.
Contact ABB for further information about
acceptable payload.
24
22 Hz
The table below shows the allowed storage conditions for the manipulator:
Parameter
Value
-25C
+55C
+70C
The table below shows the allowed operating conditions for the manipulator:
Parameter
Value
+5C
+50C
3HAC 16261-1
3 Unpacking
3.0.1 Pre-installation procedure
Protection
classes, manipulator
3HAC 16261-1
Equipment
Protection class
IP 67
25
3 Unpacking
3.0.2 Working range, IRB 7600 - 150/3.5
Illustration
The illustration below shows the unrestricted working range of IRB 7600 - 150/3.5:
R B 7600-150/3.5
xx0100000101
26
3HAC 16261-1
3 Unpacking
3.0.3 Working range, IRB 7600 - 400/2.55
Illustration
The illustration below shows the unrestricted working range of IRB 7600 - 400/2.55:
R B 7600-400/2.55
xx0100000100
3HAC 16261-1
27
3 Unpacking
3.0.4 Working range, IRB 7600 - 500/2.3
Illustration
The illustration below shows the unrestricted working range of IRB 7600 - 500/2.3:
R B 7600-500/2.3
en0100000099
28
3HAC 16261-1
3 Unpacking
3.0.5 Risk of tipping/Stability
Risk of tipping
When the manipulator is not fastened to the floor and standing still, the manipulator is not
stable in the whole working area. Moving the arms will displace the centre of gravity, which
may cause the manipulator to tip over. DO NOT change the manipulator position before
securing it to the foundation.
Stabililty
The figure below shows the manipulator in its shipping position, which also is its most stable
position.
50
m
xx0100000103
1. DO NOT change the manipulator position before securing it to its foundation. The
shipping position is the most stable.
3HAC 16261-1
29
3 Unpacking
3.0.5 Risk of tipping/Stability
30
3HAC 16261-1
4 On-site Installation
3HAC 16261-1
31
4 On-site Installation
4.1.1 Lifting manipulator with fork lift
General
The manipulator may be moved using a fork lift. Special aids are available.
This section applies to the IRB 7600 as well as IRB 6600.
Different designs
There are two different versions of the fork lift that fit one design of the frame respectevily.
The different designs of the frame and of the fork lift attachments are shown in the figure
below. Determine which fork lift set fits the current manipulator.
Note! The distance between the attachment holes for the fork lift pockets, shown in the following figure, are different depending on the design of the frame. This means that the fork
lift sets are unique for one type of frame, they are in other words not compatible!
Except for the shorter distance between the attachment holes, the later design of the frame
also includes an extra oil plug, located as shown in the figure below.
2
A
xx0200000386
32
Frame version without oil plug on the side (C), fork lift set to be used: 3HAC 0604-2
Frame version with oil plug on the side (C), fork lift set to be used: 3HAC 0604-1
Oil plug
3HAC 16261-1
4 On-site Installation
4.1.1 Lifting manipulator with fork lift
Required equipment
Equipment, etc. Art. no.
Note
Standard toolkit
Illustration, 3HAC
0604-2
The figure below shows how to attach the fork lift set, 3HAC 0604-2, to the manipulator.
C
B
xx0100000102
3HAC 16261-1
Spacer (2 pcs)
33
4 On-site Installation
4.1.1 Lifting manipulator with fork lift
Illustration, 3HAC
0604-1
The figure below shows how to attach the fork lift set, 3HAC 0604-1, to the manipulator.
A
B
xx0200000379
Spacer (2 pcs)
The section below details how to secure the fork lift set to the manipulator in order to lift and
move the manipulator using the fork lift ONLY!
The IRB 6600/6650 manipulator weighs 1725 kg! All lifting equipment used must be dimensioned accordingly!
The IRB 7600 manipulator weighs 2550 kg! All lifting equipment used must be dimensioned
accordingly!
The shorter fork lift pocket weighs 22 kg while the longer version weighs 60 kg! Use a suitable
lifting device to avoid injury to personnel!
No personnel must under any circumstances be present under the suspended load.
34
3HAC 16261-1
4 On-site Installation
4.1.1 Lifting manipulator with fork lift
Step
Info/Illustration
10
1.
Action
m
xx0200000079
10
50
m
xx0200000387
3HAC 16261-1
2.
Fit the two spacers to the manipulator Shown in the figures Illustration, 3HAC
and secure.
0604-2 on page 33 or Illustration, 3HAC
0604-1 on page 34!
3.
Shown in the figure Illustration, 3HAC 06042 on page 33 or Illustration, 3HAC 0604-1
on page 34!
4 pcs; M16x60; tightening torque: 60 Nm
12 Nm (not oil lubricated screws).
Make sure the original screws are always
used (or replacements of equivalent quality:
M16, quality 12.9)!
35
4 On-site Installation
4.1.1 Lifting manipulator with fork lift
Step
Action
Info/Illustration
4.
5.
Secure the second fork lift pocket on Shown in figure Illustration, 3HAC 0604-2
the other side of the manipulator with on page 33 or Illustration, 3HAC 0604-1 on
securing screws.
page 34!
4 pcs; M16x60; tightening torque: 60 Nm
12 Nm (not oil lubricated screws).
Make sure the original screws are always
used (or replacements of equivalent quality:
M16, quality 12.9)!
6.
xx0200000380
36
3HAC 16261-1
4 On-site Installation
4.1.2 Lifting manipulator with lifting slings
General
Illustration, lifting
slings
The figure below shows how to lift the complete manipulator with lifting slings.
Note the recommended manipulator position shown in the figure below and in the instruction!
Attempting to lift a manipulator in any other position may result in the manipulator tipping
over, causing severe damage or injury!
C
E
I
L
B
xx0200000153
3HAC 16261-1
Load hook
Shortening hook
Chain
Hook
37
4 On-site Installation
4.1.2 Lifting manipulator with lifting slings
Required equipment
Equipment
Art. no.
Slings attached
directly onto
manipulator
The section below details how to lift and move the manipulator using lifting slings when these
are to be attached directly onto the manipulator frame.
The IRB 6600/6650 manipulator weighs 1725 kg! All lifting equipment used must be dimensioned accordingly!
The IRB 7600 manipulator weighs 2550 kg! All lifting equipment used must be dimensioned
accordingly!
No personnel must under any circumstances be present under the suspended load!
Step
Action
Note
1.
2.
Make sure the manipulator is positioned Release the brakes if required as detailed
as shown in the figure on the right. If it is in Manually releasing the brakes on page
not, position it that way.
40.
50
m
xx0100000103
38
3.
4.
3HAC 16261-1
4 On-site Installation
4.1.3 Lifting manipulator with round slings
General
The manipulator may be lifted with round slings according to the illustration below.
Illustration
C
m
720-860
xx0200000315
3HAC 16261-1
39
4 On-site Installation
4.1.4 Manually releasing the brakes
General
The section below details how to release the holding brakes of each axis motor. It applies to
IRB 7600 as well as IRB 6600/6650. Differences between the versions are highlighted in the
affected sections.
The brakes may be released by:
Internal brake release unit: using push buttons on the manipulator. This requires either
that the controller is connected or that power is supplied to the R1.MP connector (on
manipulator base), 0V on pin 12 and 24V on pin 11.
IRB 7600: External brake release unit: using push-buttons on an external brake
release unit. This does NOT require the controller to be connected. The external unit
is used when there are no push-buttons on the manipulator.
Supplying power on the wrong pins may cause all brakes on the manipulator to be released!
Illustration, IRB
6600/6650
The internal brake release unit on the IRB 6600/6650 is located at the frame, as shown in the
figure below.
6
5
4
3
2
1
xx0300000044
40
Internal brake release unit with push buttons, located on the manipulator frame
3HAC 16261-1
4 On-site Installation
4.1.4 Manually releasing the brakes
Illustration, IRB
7600 base
The internal brake release unit on the IRB 7600 is located either at the base or at the frame.
The figure below shows the unit located at the base.
xx0200000375
Illustration, IRB
7600 frame
Internal brake release unit with push buttons, located on the manipulator base
The internal brake release unit on the IRB 7600 is located either at the base or at the frame.
The figure below shows the unit located at the frame.
6 5 4
3 2 1
xx0200000376
3HAC 16261-1
Internal brake release unit with push buttons, located on the manipulator frame
41
4 On-site Installation
4.1.4 Manually releasing the brakes
Internal brake
release unit,
releasing the
brakes
The procedure below details how to release the holding brakes when the robot is equipped
with an internal brake release unit.
When relasing 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
Illustration, IRB
7600 external
brake release unit
connections
Action
Info/Illustration
1.
2.
Release the holding brake on a particular manipulator axis by pressing the appropriate button on
the internal brake release panel.
The brake will function again as soon as the button is released.
The illustration below shows where to connect the external brake release unit in order to
release the manipulators holding brakes.
C
D
xx0100000104
42
Connector R1.BU
3HAC 16261-1
4 On-site Installation
4.1.4 Manually releasing the brakes
Illustration IRB
7600, external
brake release unit
connectors
The illustration below shows the connectors on the manipulator and on the external brake
release unit.
D
E
xx0200000081
Connector R1.MP
Connector R1.BU
Connect to R1.BU
Required equipment
External brake
release unit (only
IRB 7600)
Equipment
Art. no.
3HAC 12987-1
This section details how to release the holding brakes when the robot is equipped with an
external brake release unit (only IRB 7600).
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
1.
3HAC 16261-1
Action
Info/Illustration
Remove the rear cover plate on the base of Shown in Illustration, IRB 7600
the manipulator by unscrewing its attachment external brake release unit connecscrews and plain washers
tions on page 42!
43
4 On-site Installation
4.1.4 Manually releasing the brakes
Step
44
Action
Info/Illustration
2.
3.
4.
Release the holding brake of each manipulator axis by pressing the respective button on
the external brake release unit.
5.
6.
3HAC 16261-1
4 On-site Installation
4.1.5 Lifting the base plate
General
Equipment
Note
Standard toolkit
Lifting slings
Hole configuration
xx0200000096
The base plate weighs 335 kg! All lifting equipment used must be dimensioned accordingly!
3HAC 16261-1
Action
Info/Illustration
1.
Fit lifting eyes in the three lifting holes. Shown in the figure Hole configuration on
page 45!
2.
45
4 On-site Installation
4.1.6 Securing the base plate
General
Base plate,
dimensions
2x 503
2x 453
2x 247
2x 182
2x 90 2x 90
2x 451
2x 407
2x 321
2x 273
B
B
455
A
A
540
480
A-A
B-B
xx0100000105
Base plate,
grooves and
holes
46
The illustration below shows the orienting grooves and guide sleeve holes in the base plate.
3HAC 16261-1
4 On-site Installation
4.1.6 Securing the base plate
B
xx0300000045
Required equipment
Equipment
Base plate
Standard toolkit
3HAC 16261-1
Note
47
4 On-site Installation
4.1.6 Securing the base plate
Base plate
This section details how to secure the base plate to the foundation.
The table specifies any recommendations made by ABB:
Variable
Recommendation
The base plate weighs 335 kg! All lifting equipment used must be dimensioned accordingly!
Step
48
Action
Info/illustration
1.
2.
3.
4.
Use the base plate as a template and drill 16 If possible, observe the recommenattachment holes as required by the selected dations specified in the table above.
bolt dimension.
ABB does not assume any responsibility for other foundation qualities,
due to great variations in the foundation properties.
5.
6.
7.
8.
3HAC 16261-1
4 On-site Installation
4.1.7 Orienting and securing the manipulator
General
This section details how to orient and secure the manipulator to the base plate after fitting it
to the foundation, in order to run the robot safely. The requirements made on the foundations
are shown in the following tables and figures.
The section below applies to IRB 7600 as well as IRB 6600/6650. The only difference
between these robot models is that IRB 7600 is secured using 12 attachment bolts while IRB
6600/6650 uses 8 attachment bolts.
Illustration,
manipulator fitted
to base plate
The illustration below shows the IRB 7600 manipulator base fitted to the base plate. The IRB
6600/6650 manipulator base does not have the attachment holes A (4 pcs).
A B
xx0100000107
Attachment
screws
3HAC 16261-1
Manipulator attachment bolts and washers, 4 pcs M24 x 120 (IRB 7600 only)
Levelling screws
The table below specifies the type of securing screws and washers to be used for securing the
manipulator to the base plate/foundation.
M24 x 120
Quality
Quality 8.8
Suitable washer:
Thickness: 4 mm
Outer diameter: 44 mm
Inner diameter: 25 mm
Tightening torque:
775 Nm
49
4 On-site Installation
4.1.7 Orienting and securing the manipulator
Securing the
manipulator
The procedure below details how to secure the manipulator to the base plate after fitting the
plate to the foundation.
Step
Action
Info/Illustration
1.
2.
3.
4.
Guide the manipulator gently using two Make sure the manipulator base is corM24 screws while lowering it into its
rectly fitted onto the guide sleeves!
mounting position.
5.
6.
Tighten the bolts in a criss-cross pattern to ensure that the base is not distorted.
The illustration below shows the hole configuration used when securing the manipulator, IRB
6600.
R400
4
x
15
4x3
7,5
xx0200000029
50
3HAC 16261-1
4 On-site Installation
4.1.7 Orienting and securing the manipulator
The illustration below shows the hole configuration used when securing the manipulator, IRB
7600.
4x
10
4
5 .5
x1 x7
4
4x
37.5
xx0300000046
Cross section,
guide sleeve hole
The illustration below shows the cross section of the guide sleeve holes.
xx0100000109
3HAC 16261-1
51
4 On-site Installation
4.1.8 Fitting equipment on manipulator
General
Illustration, fitting
of extra equipment on lower
arm
The illustration below shows the mounting holes available for fitting extra equipment on the
lower arm.
Make sure not to damage the manipulator cabling on the inside of the lower arm when fitting
extra equipment. Always use appropriate attachment screws!
xx0100000115
52
3HAC 16261-1
4 On-site Installation
4.1.8 Fitting equipment on manipulator
100
82.5
50
7.5
61.5
150
440.5
xx0100000120
Illustration, fitting
of extra equipment on upper
arm
The illustration below shows the mounting holes available for fitting extra equipment on the
upper arm.
R700
M12 (4x)
325
xx0100000116
3HAC 16261-1
53
4 On-site Installation
4.1.8 Fitting equipment on manipulator
Illustration, fitting
of extra equipment on frame
The illustration below shows the mounting holes available for fitting extra equipment on the
frame.
600
xx0100000117
xx0100000118
54
3HAC 16261-1
4 On-site Installation
4.1.8 Fitting equipment on manipulator
Illustration, fitting
on mounting
flange
The illustration below shows the mounting holes available for fitting equipment on the
mounting flange.
0
x3
2
1
30
15
A-A
A
xx0100000119
Fastener quality
3HAC 16261-1
When fitting tools on the mounting flange (see the figures above), use only screws with quality 12.9. When fitting other equipment, standard screws with quality 8.8 can be used.
55
4 On-site Installation
4.1.9 Loads
4.1.9 Loads
General
Any loads mounted on the manipulator must be defined correctly and carefully (with regard
to the position of center 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 Users
Guide.
Manipulator motor brake performance depends on any loads attached. For further information about brake performance, please contact ABB Robotics.
56
3HAC 16261-1
4 On-site Installation
4.2.1 Introduction
General
The working range of the manipulator may be limited to eliminate the risk of collisions. The
following axes may be restricted:
Axis 1, hardware (mechanical stop) and software (signal from adjustable position
switch)
Axis 2, hardware (mechanical stop) and software (signal from adjustable position
switch)
Axis 3, hardware (mechanical stop) and software (signal from adjustable position
switch)
This section describes the utilization of the mechanical stops and the position switches.
3HAC 16261-1
57
4 On-site Installation
4.2.2 Mechanically restricting the working range of axis 1
General
The working range of axes 1 is limited by fixed mechanical stops and can be reduced by
adding additional mechanical stops giving 7.5 or 15 graduation in both directions.
Mechanical
stops, axis 1
The illustration below shows the mounting position of the mechanical stops on axis 1.
B
xx0300000049
Required equipment
Equipment, etc. Spare part no. Art. no.
58
Note
7.5, mechanical
stop for axis 1
15, mechanical
stop for axis 1
Standard toolkit
3HAC 15571-1 The contents are defined in the section Standard toolkit on page 24.
3HAC 16261-1
4 On-site Installation
4.2.2 Mechanically restricting the working range of axis 1
Installation,
mechanical stops
axis 1
The procedure below details how to mount the mechanical stops on axis 1. An assembly
drawing is also enclosed with the product.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The addititonal mechanical stop must be replaced after a hard collision if the mechanical stop
has been deformed!
Step
3HAC 16261-1
Action
Note/Illustration
1.
2.
59
4 On-site Installation
4.2.3 Mechanically restricting the working range of axis 2
General
The working range of axis 2 is limited by fixed mechanical stops and can be reduced by
adding up to six additional mechanical stops with 15 graduation in respective direction.
Mechanical
stops, axis 2
The illustration below shows the mounting position of the mechanical stops on axis 2.
A
B
xx0300000047
Required equipment
Equipment, etc.
60
Note
3HAC 13787-1
3HAC 11077-1
Standard toolkit
3HAC 15571-1
3HAC 16261-1
4 On-site Installation
4.2.3 Mechanically restricting the working range of axis 2
Installation,
mechanical stops
axis 2
The procedure below details how to mount the mechanical stops on axis 2. An assembly
drawing is also enclosed with the product.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The addititonal mechanical stop must be replaced after a hard collision if the mechanical stop
has been deformed!
Step
3HAC 16261-1
Action
Note/Illustration
1.
2.
61
4 On-site Installation
4.2.4 Mechanically restricting the working range of axis 3
General
The working range of axis 3 is limited by fixed mechanical stops and can be reduced by
adding additional mechanical stops with 20 graduation in respective direction.
Mechanical
stops, axis 3
The illustration below shows the mounting position of the mechanical stops on axis 3.
xx0300000048
Required equipment
Equipment, etc.
62
Note
Standard toolkit
3HAC 16261-1
4 On-site Installation
4.2.4 Mechanically restricting the working range of axis 3
Installation,
mechanical stops
axis 3
The procedure below details how to mount the mechanical stops on axis 3. An assembly
drawing is also enclosed with the product.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The addititonal mechanical stop must be replaced after a hard collision if the mechanical stop
has been deformed!
Step
3HAC 16261-1
Action
Note/Illustration
1.
2.
63
4 On-site Installation
4.2.5 Position switches
General
Position switches can be installed on axes 1-3. The position switches consist of cams and cam
stops as shown in the figures below.
The position switch kits may be delivered in one of two ways:
Axis 1
Fitted by ABB Robotics on delivery. In this case, the cams still must be fitted and
locked by the user. For axis 1, the cover for the cams must also be fitted.
Description
Art. no
3HAC 12750-1
3HAC 12785-1
3HAC 12788-1
A
F
C
xx0100000158
64
Cam
Protection sheet
Rail
Rail attachment
3HAC 16261-1
4 On-site Installation
4.2.5 Position switches
Axis 2
E
B
C
F
xx0100000159
3HAC 16261-1
Cam
Rail
Rail Attachment
65
4 On-site Installation
4.2.5 Position switches
Axis 3
C
B
xx0100000160
Specifications
Connections
66
Cam
Rail
Rail attachment
Parameter
Value
Voltage
Current
Max. 6 A
The position switches may be connected to different points on the robot system:
R1.SW1 at the manipulator base. Customer connection kit is recommended! Also see
"Customer Connection Kit"!
3HAC 16261-1
4 On-site Installation
4.2.5 Position switches
Fitting and
adjusting cams
and stops
The instruction below details how to fit and adjust the parts of the position switches:
Step
Illustration,
adjust and secure
cams
Action
Info/Illustration
1.
2.
3.
4.
Make sure the ends of the profile are chamfered to enable the cam to run through the
profile.
5.
Fit the cam with the M5 screw and nut. Tighten Shown in the figure Illustration,
the M5 screw to secure the cam.
adjust and secure cams on page
67.
The illustration below show how to adjust and secure the position switch cams and profiles.
C
30
xx0100000113
3HAC 16261-1
Adjustable cam
Profile
67
4 On-site Installation
4.2.5 Position switches
The illustration below show how to cut the position switch cam.
o
30
o
90
xx0100000114
68
3HAC 16261-1
4 On-site Installation
4.2.5 Position switches
3HAC 16261-1
69
4 On-site Installation
4.3.1 Lifting the controller cabinet
Lifting device
Use the four lifting devices on the cabinet or a fork lift when lifting the controller cabinet
S4Cplus M2000A as shown below.
The figure below shows the maximum angle between the lifting straps when lifting the controller.
60
xx0100000153
70
Fork lift
3HAC 16261-1
4 On-site Installation
4.3.2 Required installation space, control cabinet
Dimensions
The figure below shows the required installation space for the S4Cplus M2000A control cabinet:
A
A
xx0100000156
3HAC 16261-1
Distance to wall
71
4 On-site Installation
4.3.3 Bolt pattern, control cabinet
Dimensions
The figure below shows the bolt pattern for the S4Cplus M2000A control cabinet:
720
400
xx0100000157
72
3HAC 16261-1
5 Electrical connections
3HAC 16261-1
73
5 Electrical connections
5.1.1 Connecting the manipulator to the control cabinet
General
Connect the manipulator and control cabinet to each other after securing them to the foundation. The lists below specify which cables to be used in each application.
Location of connectors
XS
Application interface
XS20
I/O connections
XS8
X13/X5
Operators panel
XS78
XS77/X7
DeviceNet
LAN/XTDF
Mains connection
X24VE/VS
External axes
IBS
Position switches
XS41
Manipulator cables
XS58
XS2
Ext. contr. panel
Main cable
categories
All cables between manipulator and control cabinet are divided into the following categories:
Cable category
Description
Manipulator cables
Position switch cables (option) Handles supply to and feedback from any position switches
and cooling fans on the manipulator.
74
Handles communication with equipment fitted on the manipulator by the customer, including databus communication,
low voltage signals and high voltage power supply + protective earth.
3HAC 16261-1
5 Electrical connections
5.1.1 Connecting the manipulator to the control cabinet
These categories are divided into sub-categories which are specified below:
Manipulator
cables
These cables are included in the standard delivery. They are completely premanufactured and ready to plug in.
Cable subcategory
Connection Connection
point,
point,
cabinet
manipulator
Description
Manipulator
cable, power
R1.MP
Manipulator
cable, signals
R1.SMB
XP2
Manipulator
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
Manipulator
cable, signals
Position switch
cables
3HAC 16261-1
These cables are not included in the standard delivery, but can be included in the delivery if
the Position switch option is ordered. (The position switches can also be ordered without
cables.) The cables are completely pre-manufactured and ready to plug in.
Cable
Article
number
Connection Connection
point,
point,
cabinet
manipulator
3HAC 13175-1
XP8
R1.SW
3HAC 13175-2
XP8
R1.SW
3HAC 13175-4
XP8
R1.SW
XP58
R1.SW2/3
XP58
R1.SW2/3
XP58
R1.SW2/3
75
5 Electrical connections
5.1.1 Connecting the manipulator to the control cabinet
Customer cables
External axes
cables
These cables are not included in the standard delivery, but can be included in the delivery of
each specific option. The cables are not ready to plug in, but requires connection to terminals
inside the control cabinet as well as keying. These activities are detailed in Customer Connection Kit.
Connection
point,
cabinet
Connection
point,
manipulator
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
3HAC 13174-2
XT/XP5.1
XT/XP6
DP/M
R1.CP/CS
3HAC 13174-4
XT/XP5.1
XT/XP6
DP/M
R1.CP/CS
Cable
Article number
These cables are not included in the standard delivery, but can be included if the External
axes option is ordered. The cables are ready to plug in.
76
Connection Connection
point,
point,
cabinet
manipulator
XS45
XS47
XP41
3HAC 16261-1
5 Electrical connections
5.1.2 Connection of manipulator cables to control cabinet, S4Cplus M2000A
General
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 to connect the controller to the
manipulator.
Connections to
the cabinet
xx0100000247
The connections on the manipulator are located on the rear of the robot base.
3HAC 16261-1
77
5 Electrical connections
5.1.3 Connection of mains power to control cabinet, S4Cplus M2000A
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
xx0100000248
Cable gland
Step Action
78
Info/Illustration
1.
2.
3.
3HAC 16261-1
5 Electrical connections
5.1.3 Connection of mains power to control cabinet, S4Cplus M2000A
Step Action
4.
Connection
through a power
socket
Info/Illustration
Connect phase:
1 to L1 (Not dependent on phase sequence)
2 to L2
3 to L3
5.
6.
7.
It is also possible to connect the mains supply through an optional wall socket of type 3x32A
or 4x32A or via an industrial Harting connector (DIN 41 640). See the figure below. Cable
connectors are supplied (option 132 - 134).
A
xx0100000162
3HAC 16261-1
DIN connector
79
5 Electrical connections
5.2.1 Signal Classes
Overview
Signals
80
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.).
Measuring signals: Analog measuring and control signals (resolver and analog I/O).
3HAC 16261-1
5 Electrical connections
5.2.2 Selecting Cables
Controller cables:
All cables laid in the controller must be capable of withstanding 70o C. In addition.
Power Signal:
Control signals:
Shielded cables.
Measuring
signals:
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 supply of I/O loads is required.
Allen-Bradley
Remote I/O:
Cables according to Allen-Bradley specification, e.g. "Blue hose", should be used for connections between DSQC 350 and the Allen-Bradley PLC bus.
Interbus-S:
Cables according to Phnix specification, e.g. "Green type", should be used for connections
between the DSQC 351 and external Interbus-S bus.
Profibus DP:
Cables according to Profibus DP specification should be used for connections between the I/
O unit DSQC 352 and the external Profibus DP bus.
Ethernet:
3HAC 16261-1
81
5 Electrical connections
5.2.3 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 neutralisation, especially if a diode is connected
across the coil. Varistors give shorter turn-off times. Neutralising the coils lengthens the life of
the switches that control them
Clamping with a
diode
The diode should be 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 be dimensioned for the same current as the relay coil, and a voltage of
twice the supply voltage.
+24V
0V
xx0100000164
Clamping with an
RC circuit
R 100 ohm, 1W C 0.1 - 1 mF. >500V max. voltage, 125V nominal voltage.
+24V DC,
or AC voltage
0V
xx0100000165
82
3HAC 16261-1
5 Electrical connections
5.2.4 Connection types
General
I/O, external emergency stops, safety stops, etc. can be supplied on screw connections or as
industrial connectors.
Connections
3HAC 16261-1
Designation
Connection type
X(T)
Screw terminal
XP
Pin (male)
XS
Sockets (female)
83
5 Electrical connections
5.2.5 Connections to screw terminals
Overview
This section describes how to connect conductors to screw terminals. Detailed information
about connection location and functions will be found in the circuit diagram (Service Manual).
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.
84
3HAC 16261-1
5 Electrical connections
5.2.6 Connections to connectors (option)
Location of connectors
The industrial connectors can be found on the front of the control cabinet. See the figure
below and the figure in section "Control cabinet connections manipulator"!
The manipulator arm is equipped with round Burndy/Framatome connectors (customer connector not included).
xx0100000249
XS
Application interface
XS20
I/O connections
XS8
X13/X5
Operators panel
XS78
XS77/X7
DeviceNet
LAN/XTDF
Mains connection
X24VE/VS
External axes
IBS
Position switches
XS41
Manipulator cables
XS58
XS2
Ext. contr. panel
Connectors,
description
Each industrial connector has accomodations 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.
3HAC 16261-1
85
5 Electrical connections
5.3.1 The MOTORS ON/MOTORS OFF circuit
Outline diagram
The MOTORS ON/MOTORS OFF circuit is made up of two identical chains of switches.
The diagram shows the available customer connections, AS, GS and ES.
A
E
C
D
H
J
R
N
P
xx0100000174
Function of the
MOTORS ON/
MOTORS OFF
circuit
86
ES (emergency stop)
LS (Limit switch)
Contactor
Mains
Drive unit
Manual mode
Motor
Automatic mode
RUN
EN1
EN2
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.
As long as the two chains are not identical, the robot will remain in MOTORS OFF mode.
3HAC 16261-1
5 Electrical connections
5.3.1 The MOTORS ON/MOTORS OFF circuit
Connection of
safety chains
24V
X3:12
X4:12
Ext LIM1
24V
K1
0V
X1:11 12
ES1
X3:10
Opto GS1
isol.
TPU En1
&
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
Drive Unit
ES2
X4:10
Opto GS2
isol.
TPU En2
&
11
9
24 V
Opto AS2
isol.
Auto2
Man2
xx0100000166
Connection of
ES1/ES2 on panel
unit
3HAC 16261-1
Limit switch
External connectors
GS/AS load at 24 V
25 mA
>18 V
<5V
Max. + 35 VDC
Min. - 35 VDC
300 V
Signal class
Control signals
The diagram below shows the terminals for the emergency circuits.
Supply from internal 24V (X1/X2:10) and 0V (X1/X2:10) is displayed. When ext. supply,
X1/X2:3 is connected to ext. 24V and X1/X2:8 is connected to ext. 0V (dotted lines).
87
5 Electrical connections
5.3.1 The MOTORS ON/MOTORS OFF circuit
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
Internal
Ext shop
Internal
TPU
ES2 internal
Cabinet
ES1 internal
Technical data
88
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
3HAC 16261-1
5 Electrical connections
5.3.1 The MOTORS ON/MOTORS OFF circuit
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
Max. voltage
48 VDC
Max. current
4A
Max. potential in relation to the cabinet earthing and other signal groups 300 V
Signal class
Connection to
operating mode
selector
Control signals
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 16261-1
Max. voltage
48 VDC
Max. current
4A
89
5 Electrical connections
5.3.1 The MOTORS ON/MOTORS OFF circuit
Technical data
Connection to
brake contactor
300 V
Signal class
Control signals
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 16261-1
5 Electrical connections
5.3.2 External customer connections on panel X1 - X4
Outline diagram
The diagram shows the customer connections X1 - X4 located on the panel unit
WARNING
REMOVE JUMPERS BEFORE CONNECTING
ANY EXTERNAL EQUIPMENT
xx0100000205
Connection of X1:
12-pole type
Phoenix COMBICON connector
Connection of X2:
12-pole type
Phoenix COMBICON connector
3HAC 16261-1
Signal
Terminal
Comment
number
ES1 out: A
ES1 out: B
ES1 top
24 V panel
ES1 internal
Sep. ES1: A
Sep. ES1: B
ES1 bottom
0V
10
Ext. LIM1: A
11
Ext. LIM1: B
12
Signal
Terminal
Comment
number
ES2 out: A
91
5 Electrical connections
5.3.2 External customer connections on panel X1 - X4
Connection of X3:
12-pole type
Phoenix COMBICON connector
Connection of X4:
12-pole type
Phoenix COMBICON connector
92
Signal
Terminal
Comment
number
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
Terminal
Comment
number
Ext. MON 1: A
Motor contactor 1
Ext. MON 1: B
Motor contactor 1
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
Terminal
Comment
number
Ext. MON 2: A
Motor contactor 2
Ext. MON 2: B
Motor contactor 2
24 V panel
External contactor 2 24 V
CONT2
External contactor 2
Ext. BRAKE A
Ext. BRAKE B
3HAC 16261-1
5 Electrical connections
5.3.2 External customer connections on panel X1 - X4
3HAC 16261-1
Signal
Terminal
Comment
number
0V
GS2-
AS2-
GS2+
10
AS2+
11
24 V panel
12
93
5 Electrical connections
5.3.3 Connection of external safety relay
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:
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
94
Panel unit
Robot 1
Robot 2
External supply
Safety relay
3HAC 16261-1
5 Electrical connections
5.3.3 Connection of external safety relay
3HAC 16261-1
To other equipment
Safety gate
95
5 Electrical connections
5.4.1 External 24V supply
How to connect
the external supply
An external supply is recommended to make use of the advantages offered by the galvanic
insulation on the I/O units or on the panel unit.
An external supply must be used in the following cases:
When the emergency stop circuits must be independent of whether or not the robot
has power on, for example.
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
96
Max. 60 V continuously
Max. 500 V during 1 minute
3HAC 16261-1
5 Electrical connections
5.4.2 24V I/O supply
General
24 VDC supply
available at XT 31
3HAC 16261-1
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.
24V I/O available for customer connections at XT 31 is shown in the figure in "Connections
to screw terminals".
XT.31.2
24 V (through a 2 A fuse)
XT.31.1
XT.31.4
97
5 Electrical connections
5.4.3 115/230 VAC supply
General
98
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
115 VAC/230 VAC available for customer connections at XT 21 is shown in the figure in
"Connection to screw terminals".
FU2 - 201
230 VAC
FU1 - 202
115 VAC
N - 203
3HAC 16261-1
5 Electrical connections
5.5.1 Connection of the CAN bus
Illustration
The illustration below shows an example of how to connect the CAN bus:
C
A
X6 CAN1.2
X7 CAN1.3
G
D
D
E
X15, X6, X7
1.
2.
3.
4.
5.
1. 0V_CAN
2. CAN_L
3. drain
4. CAN_H
5. 24V_I/O
xx0100000241
CAN bus
Control cabinet
I/O
CAN 1.1
Used for internal I/O unit mounted inside the cabinet. No terminating resistor is to be
mounted 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!).
3HAC 16261-1
99
5 Electrical connections
5.5.1 Connection of the CAN bus
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 in 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
Termination
resistors in CAN
bus
The CAN chain must be terminated with terminating resistors in 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 in 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
X8
1. 0V_CAN
2. CAN_L
3. drain
4. CAN_H
5. 24V_I/O
1. 0V_CAN
2. CAN_L
3. drain
4. CAN_H
5. 24V_I/O
1.
2.
3.
4.
5.
xx0100000242
100
Controller
I/O
3HAC 16261-1
5 Electrical connections
5.5.1 Connection of the CAN bus
A
B
C
D
xx0100000243
3HAC 16261-1
101
5 Electrical connections
5.5.2 Interbus-S, slave DSQC 351
General
Supply
The Interbus-S slave must be fed externally to avoid shutting down the Interbus-S 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 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
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 show the layout of the DSQC 351 board:
X20
X21
X5
X3
xx0100000225
102
X3
Power connector
X5
DeviceNet connector
X20
Interbus-S, input
X21
Interbus-S, output
3HAC 16261-1
5 Electrical connections
5.5.2 Interbus-S, slave DSQC 351
Communication
concept
The Interbus-S system is able to communicate with a number of external devices, depending
on the number of process words occupied by each unit. The robot may be equipped with one
or two DSQC 351. The Interbus-S inputs and outputs are accessible in the robot as general
inputs and outputs.
For application data, refer to Interbus-S, International Standard, DIN 19258.
Below is shown an outline diagram of the communication concept:
E
A
B
In
C
Out
In
*1
D
Out
In
Out
*1
xx0100000224
Master PLC
64 inputs/64 outputs
*1
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
Connections,
connector X20,
Interbus-S IN
6
9
xx0100000220
The table below show the connections to connector X20, Interbus-S IN:
3HAC 16261-1
Signal name
X20 pin
Function
TPDO1
TPDI1
GND
Ground connection
NC
Not connected
103
5 Electrical connections
5.5.2 Interbus-S, slave DSQC 351
Connections,
connector X21,
Interbus-S OUT
Signal name
X20 pin
Function
NC
Not connected
TPDO1-N
TPDI1-N
NC
Not connected
NC
Not connected
6
9
xx0100000220
The table below show the connections to connector X21, Interbus-S OUT:
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
1
xx0100000221
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.
The figure and table below show the location and significance of the the LEDs on the board.
104
3HAC 16261-1
5 Electrical connections
5.5.2 Interbus-S, slave DSQC 351
3HAC 16261-1
Designation
Color
Description
POWER-24 VDC
Green
NS/MS
Green/red
CAN Tx/CAN Rx
Green/red
POWER- 5 VDC
Green
RBDA
Red
BA
Green
RC
Green
105
5 Electrical connections
5.5.3 Profibus-DP, slave DSQC 352
General
Supply
The Profibus does not need any external power feed. 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, Internation 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 show the layout of the DSQC 352 board:
X20
X5
X3
xx0100000223
Communication
concept
X3
Power connector
X5
DeviceNet connector
X20
Profibus connection
The Profibus-DP system is able to communicate with a number of external devices, depending on the number of process words occupied by each unit. The robot may be equipped with
one or two DSQC 352. The Profibus-DP inputs and outputs are accessible in the robot as
general inputs and outputs.
Below is shown an outline diagram of the communication concept:
E
A
F
C
xx0100000222
106
3HAC 16261-1
5 Electrical connections
5.5.3 Profibus-DP, slave DSQC 352
Master PLC
Termination
Connections, X5
DeviceNet
connectors
Connections,
connector X20,
Profibus-DP
6
9
xx0100000220
The table below show the connections to connector X20, Interbus-S IN:
Connections,
connector X3
Signal name
X20 pin
Function
Shield
Cable screen
NC
Not connected
RxD/TxD-P
Receive/Transmit data P
Control-P
GND
+5 VDC
NC
Not connected
RxD/TxD-N
Receive/Transmit data N
NC
Not connected
Ground
1
xx0100000221
3HAC 16261-1
Signal name
X3 pin
Function
0 VDC
107
5 Electrical connections
5.5.3 Profibus-DP, slave DSQC 352
Signal name
X3 pin
Function
NC
Not connected
GND
Ground connection
NC
Not connected
+ 24 VDC
The figure and table below show the location and significance of the the LEDs on the board.
The designations refer to LEDs shown in the figure in section "Layout, DSQC 352" above.
Designation
Color
Description
Profibus active
Green
NS/MS
Green/red
CAN Tx/CAN Rx
Green/red
108
3HAC 16261-1
5 Electrical connections
5.6.1 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
3HAC 16261-1
For setup parameters, see Users Guide, section System Parameters, Topic: I/O Signals.
109
5 Electrical connections
5.6.2 Distributed I/O, digital sensors
General
Technical data
Allowed types of
digital sensors
The table below shows the allowed types of digtal sensors to be used, and their signal levels
respectively:
110
Sensor type
Signal level
High, "1"
Low, "0"
High, "01"
No signal, "00"
Low, "10"
Error status, "11" (stop program running)
3HAC 16261-1
5 Electrical connections
5.6.3 Distributed I/O, digital I/O DSQC 328 (option)
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
10
11
12
13
14
15
16
OUT
IN
X2
1
10
10
X4
1
10
10
12
X5
xx0100000240
Connections,
connector X1
Status LEDs
3HAC 16261-1
Unit function
Signal name
X1 pin
Out ch 1
Out ch 2
Out ch 3
Out ch 4
111
5 Electrical connections
5.6.3 Distributed I/O, digital I/O DSQC 328 (option)
Connections,
connector X2
Unit function
Signal name
X1 pin
Out ch 5
Out ch 6
Out ch 7
Out ch 8
10
Connections,
connector X3
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
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.
112
3HAC 16261-1
5 Electrical connections
5.6.3 Distributed I/O, digital I/O DSQC 328 (option)
Connections,
connector X4
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
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 16261-1
113
5 Electrical connections
5.6.4 AD Combi I/O, DSQC 327 (optional)
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 Userss Guide - System Parameters, Topic: Controller. Also see the
Circuit Diagram.
Layout, DSQC
327
OUT
MS
IN
NS
X1
X3
OUT
9
10
11
12
13
14
15
IN
X2
1
10
X4
10
X6
1
10
16
10
12
X5
xx0100000239
Status LEDs
Connector X5 is a CAN connector further described in section "Connection and address keying of the CAN bus".
Connections,
connector X1
114
3HAC 16261-1
5 Electrical connections
5.6.4 AD Combi I/O, DSQC 327 (optional)
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
Connections,
connector X3
3HAC 16261-1
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
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
115
5 Electrical connections
5.6.4 AD Combi I/O, DSQC 327 (optional)
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.
116
3HAC 16261-1
5 Electrical connections
5.6.5 Analog I/O, DSQC 355 (optional)
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 show the layout of the DSQC 355 board:
X7
X8
X7
X8
Bus s tatus
S2S3
X2
X5 X3
Analog I/O
DS QC 355
X5
AB B F lexible Automation
X3
xx0100000238
3HAC 16261-1
X3
Not used
X5
X7
Analog outputs
X8
Analog inputs
117
5 Electrical connections
5.6.5 Analog I/O, DSQC 355 (optional)
Connections,
connectors X7
analog output
13
xx0100000236
Signal name
X7 pin
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 pre-oscillation
current.
118
3HAC 16261-1
5 Electrical connections
5.6.5 Analog I/O, DSQC 355 (optional)
Connections,
connectors X8
analog input
xx0100000237
3HAC 16261-1
Signal name
X7 pin
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
+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
119
5 Electrical connections
5.6.5 Analog I/O, DSQC 355 (optional)
Signal name
X7 pin
GND
32
Explanation
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 pre-oscillation
current.
The figure and table below show the location and significance of the the LEDs on the board.
Designation
Color
Description
NS/MS
Green/red
RS232 Rx
Green
RS232 Tx
Green
Green
+5VDC / +12VDC /
-12VDC
120
3HAC 16261-1
5 Electrical connections
5.6.6 Encoder interface unit, DSQC 354 (optional)
General
One encoder input (synchronisation of conveyor position with robot movements). The
encoder is supplied with 24 V and 0 V, and sends position information in 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
User reference Description Conveyor Tracking. For setup parameters, see Users Guide - System Parameters, Topic: Controller. Also see the Circuit Diagram.
Layout, DSQC
354
The figure below show the layout of the DSQC 354 board:
X20
X5
X3
xx0100000233
3HAC 16261-1
X3
Not used
X5
X20
Conveyor connection
121
5 Electrical connections
5.6.6 Encoder interface unit, DSQC 354 (optional)
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
Connections,
connectors X20
encoder and
digital input
connections
122
AA
AB
AC
Encoder
AD
Sync switch
AE
AF
Encoder unit
AG
Galvanic isolation
Signal name
X20 pin
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
3HAC 16261-1
5 Electrical connections
5.6.6 Encoder interface unit, DSQC 354 (optional)
Signal name
X20 pin
Not used
13
Not used
14
Not used
15
Not used
16
Explanation
The figure below show the layout of the pins in connector X20:
16
xx0100000235
The figure and table below show the location and significance of the the LEDs on the board.
Designation
Color
Description
NS/MS
Green/red
ENC 1A/1B
Green
3HAC 16261-1
123
5 Electrical connections
5.6.6 Encoder interface unit, DSQC 354 (optional)
124
Designation
Color
Description
DIGIN1
Green
Digital input. Lit when digital input is active. The input is used
for external start signal/conveyor synchronisation point.
If there is no light, there is an error due to one or more of the
following reasons:
Faulty power supply for input circuit (internal or
external).
3HAC 16261-1
5 Electrical connections
5.7.1 Allen-Bradley, general
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 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.
Illustration
The following illustration 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 16261-1
125
5 Electrical connections
5.7.2 RIO, remote I/O for Allen-Bradley PLC DSQC 350
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
The RIO-unit should be connected to an Allen-Bradley PLC using a screened, two conductor
cable.
Layout, DSQC
350
The figure below show the layout of the DSQC 350 board:
X5
X9
X3
X8
DS QC 350
xx0100000226
Connections,
connector X8
X3
Not used
X5
X8
RIO in
X9
RION out
1
xx0100000221
126
3HAC 16261-1
5 Electrical connections
5.7.2 RIO, remote I/O for Allen-Bradley PLC DSQC 350
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
1
xx0100000221
Signal name
X9 pin
Function
Blue
Clear
Shield
Cabinet ground
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
This product incorporates a communications link which is licensed under patents and proprietary technology of Allen-Bradley Company, Inc. Allen-Bradley Company, Inc. does not
warrant or support this product. All warranty and support services for this product are the
responsibility of and provided by ABB Flexible Automation.
The figure and table below show the location and significance of the the LEDs on the board.
The designations refer to LEDs shown in the figure in section "Layout, DSQC 350" above.
Designation
Color
Description
NS/MS
3HAC 16261-1
127
5 Electrical connections
5.7.2 RIO, remote I/O for Allen-Bradley PLC DSQC 350
128
Designation
Color
Description
NAC STATUS
Green
3HAC 16261-1
5 Electrical connections
5.7.3 Communication, serial links
General
T he 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).
Further
information
COM1 (computer system) - RS 232 115 kbps. This was formerly referred to as Com2.
COM3 - RS 422 full duplex TXD4, TXD4-N, RXD4, RXD4-N, transmission speed 300 38 400 b/s. This was formerly referred to as SIO2.
For temporary use : MC/CONSOLE - RS 232 115 kb/s. This was formerly referred to
as Com1.
For setup parameters, see User's Guide - System Parameters, Topic: I/O Signals.
Circuit Diagram.
Technical data
See Product Specification for controller S4Cplus. Separate documentation is included when
the option RAP Serial link is ordered.
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
3HAC 16261-1
129
5 Electrical connections
5.7.3 Communication, serial links
The table below shows the signals from the COM1 (RS232):
Connections on
DSQC 504, D-sub
connector X10,
COM2
Signal
Pin
Description
DCD
RX
Receive Data
TX
Transmit Data
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
Connections on
DSQC 504, D-sub
connector X9,
COM3
6
9
xx0100000220
130
X9 socket
3HAC 16261-1
5 Electrical connections
5.7.3 Communication, serial links
Connections to
MC/CONSOLE
X9 socket
0V
The figure below shows the MC/CONSOLE connection behind the service hatch:
xx0100000218
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 16261-1
Signal
Pin
Description
RX
Receive Data
TX
Transmit Data
GND
Signal Ground
131
5 Electrical connections
5.7.4 Communication, Ethernet
General
Connection of
LAN (Main computer)
E thernet hub
xx0100000217
External computer
Controller Robot 1
Controller Robot 2
Used for connection of shielded twisted-pair Ethernet (TPE), or as defined in IEEE 802.3: 10/
100 BASE-T. Maximum node-to-node distance 100 meter. The main computer board has no
termination for a cable shield. The cable shield must be grounded at the cabinet wall with a
cable gland. 10BASE-T is a point-to-point net, connected via a HUB, see the figure above.
Signal
X1 Pin
Description
TX+
TX-
RX+
NC
Not Connected
NC
Not Connected
RX-
NC
Not Connected
NC
Not Connected
132
3HAC 16261-1
5 Electrical connections
5.7.4 Communication, Ethernet
X1
LAN
PWR
HDD
STATUS
X2
xx0100000216
Connection of
Service
(I/O Computer)
Used for connection of a laptop to the service outlet on cabinet front (behind service hatch)
on the controller.
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.
3HAC 16261-1
133
5 Electrical connections
5.7.5 External operators panel
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 following figure shows the main dimensions of the external operators panel:
B
M8 (x4)
M4 (x4)
62
C
45
70
140
184
200
E
90
5 (x2)
155
F
G
xx0100000214
134
3HAC 16261-1
6 Start-up
6.0.1 Inspection before start-up
Chapter 6: Start-up
6.0.1 Inspection before start-up
General
Check:
3HAC 16261-1
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
135
6 Start-up
6.0.2 Start-up
6.0.2 Start-up
General
4. To switch from MOTORS OFF to MOTORS ON, press the enabling device on the
teach pendant.
5. Update the revolution counters as described in "Updating the revolution
counters".
6. Check the calibration position as described in "Checking the calibration position".
7. When the controller, with the manipulator electrically connected, is powered up
for the first time, ensure that the power supply is connected for at least 36 hours
continuously, in order to fully charge the batteries for the serial measurement
board. It takes approx. 4 hours to fully charge a computer system battery.
8. After having checked the above, verify that:
the start, stop and mode selection (including the key lock switches) control devices
work as intended.
each axis moves and is restricted as intended.
emergency stop and safety stop (where included) circuits and devices are functional.
it is possible to disconnect and isolate the external power sources.
the teach and playback facilities work correctly.
the safeguarding is in place.
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
136
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.
3HAC 16261-1
7 Robot controller
7.0.1 BootImage
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:
3HAC 16261-1
137
7 Robot controller
7.0.2 Start window
When is it
shown?
xx0100000168
The start window displays the start menu and will appear in the following cases:
Possible actions
Restart the
system, Reboot
The BootImage will be re-executed, used to apply changes in the system settings (see section
"Reboot").
Load a system
from diskettes,
Boot Disks
Set network settings for Main Computer or check how to configure your PC (see section
"Network Settings").
Choose a system
from the mass
storage memory,
Select System
If there are one or more systems in the mass storage memory, you can choose to activate one
of them (see section "Select System).
138
3HAC 16261-1
7 Robot controller
7.0.3 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 16261-1
Button
Function
YES
NO
139
7 Robot controller
7.0.4 Boot Disk Window
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".
Illustration/Info
xx0100000170
140
3HAC 16261-1
7 Robot controller
7.0.5 LAN Settings Window
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
NONE
CANCEL
returns to the Start window, as shown in the figure in section "Start Window", without changing any settings.
Parameter
Type
Description
MAC ID
Node identification
Current IP
Node identification
IP
Network setting
(Subnet mask)
Network setting
(Gateway)
Network setting
Node
identification
Configure for
fixed IP network
1. Press FIX IP .
2. Fill in the assigned IP address for the Main Computer, and the Subnet Mask and
Gatway for the Network and press OK .
You will be asked to reboot the system.
Configure for
DHCP distributed
IP network
1. Press DHCP .
2. The value for IP will change to DHCP.
3. Press OK.
You will be asked to reboot the system.
141
7 Robot controller
7.0.6 Service Settings Window
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".
Parameter
Description
Service Setting
142
IP
Subnet mask
Gateway
3HAC 16261-1
7 Robot controller
7.0.7 System selection window
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
returns to the Start window as shown in the figure in section "Start Window".
The window shows all systems installed on the controller mass storage memory.
Step Action
1.
Illustration/Info
xx0100000172
3HAC 16261-1
143
7 Robot controller
7.0.8 How to perform a Restart
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 Action
Illustration/Info
1.
Press the button Miscellaneous and select Service window or System Parameter window
2.
Miscellaneous button:
xx0100000194
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 PStart, with exception for such modules which are automatically loaded, due to settings in the
System Parameters/Controller/Task Modules.
Step Action
1.
Illustration/info
Miscellaneous button:
xx0100000194
X-START, change
active controller
system
2.
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 present 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
1.
Illustration/Info
Press the button Miscellaneous and select Service win- Miscellaneous button:
dow.
xx0100000194
144
3HAC 16261-1
7 Robot controller
7.0.8 How to perform a Restart
Step Action
I-START, start in
Query mode
Illustration/Info
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".
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 can be done. An IStart will restart the current system and give the opportunity 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.
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 presented.
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 down loaded 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".
Step Action
1.
Illustration/Info
2.
3HAC 16261-1
145
7 Robot controller
7.0.8 How to perform a Restart
Step Action
146
Illustration/Info
3.
4.
Press C-START .
3HAC 16261-1
7 Robot controller
7.0.9 How to Start in Query Mode
Preconditions for
selecting Query
Mode start
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") if "Use Query Mode at System Boot" was
selected when creating the system in RobInstall (see section "Change options or system pack
revision").
Types of Query
Mode
The first question from the system is what Query Mode to start. Depending on your needs,
you should select one of the following three:
Silent Mode, pushbutton Silent . If Silent Mode is selected, the operating system will
be installed with the system configured as defined in RobInstall.
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, on top of 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 Action
Query Mode
Illustration/Info
1.
2.
3.
Install xxx? For every option that was selected in RobInstall (see section "Change options or system pack revision") it is now possible to select Yes to keep the option,
or No to remove it from the system.
If Query Mode was chosen as start-up query mode, the following steps will be required to
start the system:
Step Action
3HAC 16261-1
Illustration/info
1.
2.
147
7 Robot controller
7.0.9 How to Start in Query Mode
Step Action
3.
Illustration/info
148
4.
5.
3HAC 16261-1
General
The robot system may 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
Floppy Disks
Connected to IOC
When downloading, the controller software can be transferred to the controller storage memory in three ways as shown in the figure above.
3HAC 16261-1
using Ethernet connected direct to the IO computer (IOC) service outlet on the front of
the controller cubicle,
using Ethernet connected via a local area network (LAN) to the main computer (MC).
149
Boot Image
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. At start-up of the controller, without any 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 cold start and then the Boot Image will be reactivated.
150
3HAC 16261-1
RobotWare
CD-ROM contents
Installation of the
RobotWare on the
PC (except FTP
Client)
Contents
Description
1.
RobInstall
2.
Documentation
3.
Controller OS Package
4.
5.
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 presented, 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 16261-1
151
General
Nomenclature
How to use
RobInstall
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
This is a complete controller software, i.e. controller operating system, based on the system pack and the key. It can also include any
user files to be added to the home directory on the controller storage
memory.
Robinstall is used to create and install the controller software in the S4Cplus robot controller.
With RobInstall, you can:
Step Action
152
Illustration/Info
1.
2.
3HAC 16261-1
Step Action
3.
Illustration/Info
xx0100000185
3HAC 16261-1
153
Setting up the
system
Step Action
Illustration/info
1.
2.
3.
Enter a name for the new controller system. Select a saving location or use the default directory,
normally "Program Files\ABB
Robotics\system" (see the figure
below, position 1).
4.
5.
xx0100000179
xx0100000180
xx0100000181
154
3HAC 16261-1
Step Action
6.
Illustration/info
Add or remove
external options
Step Action
1.
Illustration(info
xx0100000182
Add or remove
additional system
parameters
2.
3.
4.
Press Finish to create the controller system or press Next to continue to "Parameter Data" (see
section "Add or remove additional
system parameters).
Step Action
1.
Illustration/Info
xx0100000183
3HAC 16261-1
155
Step Action
Change options
or system pack
revision
Illustration/Info
2.
3.
4.
5.
6.
Press Finish to create the controller system or press Next to continue to "Options" (see section
"Change options or system pack
revision").
Step Action
1.
Illustration/Info
xx0100000184
156
2.
3.
3HAC 16261-1
Step Action
3HAC 16261-1
Illustration/Info
4.
5.
157
Actions
Step Action
1.
Illustration/Info
xx0100000189
2.
3.
xx0100000190
158
3HAC 16261-1
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:
If using a direct
connection
between PC and
IOC service outlet
on controller
...and continue in
section:
"Download Robot Controller System" below!
Network Intranet
connection with fixed IP
addresses
"If using Network Intranet con"Download Robot Controlnection with fixed IP addresses " ler System" below!
below!
Network Intranet
connection with DHCP
(Dynamic Host
Configuration Protocol)
Step Action
Illustration/Info
1.
2.
Make sure that the Network protocol is set for TCP/IP properties.
3.
xx0100000178
3HAC 16261-1
159
If using
Network Intranet
connection with
fixed IP
addresses
If using Network
Intranet connection with DHCP
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.
Configure the IP address to be used for the robot controller from the TPU.
Step Action
1.
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 Action
1.
Illustration/Info
xx0100000176
160
3HAC 16261-1
Step Action
Illustration/Info
2.
Select a target system as in the fig- If a direct connection is used with the patch
ure, position 1.
cable between the PC and the controller front,
then just select the default IP address
(192.168.125.1) and "Direct" option.
In other cases, write the correct IP address for
the robot controller and select "Hostname or IPaddress". RobInstall will store already used IP
addresses, which can later be selected with the
down arrow.
3.
4.
5.
6.
RobInstall will now create a system After downloading it is possible to restart the
file and download it to the controller. controller with the new downloaded controller
system. Otherwise, the controller may be
restarted from the Teach Pendant Unit as
detailed in section "Reboot".
xx0100000177
xx0100000175
3HAC 16261-1
161
Create Boot
Diskettes from
RobInstall
Step Action
1.
Illustration/Info
xx0100000173
2.
xx0100000175
xx0100000188
162
3.
4.
3HAC 16261-1
Step Action
5.
3HAC 16261-1
Illustration/Info
163
Customizing RobInstall
Step Action
1.
Illustration/Info
xx0100000186
2.
xx0100000187
3.
164
3HAC 16261-1
Directory
All RobotWare System Packages and Option Packages are stored in a media pool directory
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").
xx0200000156
Naming
conventions
3HAC 16261-1
Art. no./folder
name
Description
3HAXaaaa-1.00
3HAXbbbb-1.02
3HAXcccc-1.01
3HYZdddd-1.00
Each package is stored in a directory, the name of which is an article number ending with the
sub-number and with the revision number as shown in the table above. All the system packs
and option packs in one media pool must have the correct revision numbers in their directory
names. Thus a later revision can be loaded into the program pool, to be added to the old one,
without changing the article number.
165
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.
File system
requirements
166
Directory view
xx0100000260
xx0100000261
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.
3HAC 16261-1
Files in root
directory, hd0a
The root directory of the mass storage memory is called hd0a. This includes several components:
File name
Description
E.g. 3HAC6811-1.00
bin
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 the mass storage memory will be impossible to
use.
3HAC 16261-1
167
Illustration
Media pool
S ys tem Pack in
/3haxbbbb-1.nn
*.* s ignature no
S ys tem pool
E xt Option in
/3haxcccc-1.nn
*.* relkey.txt
Created files
key.id
program.id
My s ys tem
/s ys tem_n
key.id
program.id
keys tr.txt
/s ys par
*.cfg
xx0100000262
Files to be
prepared
168
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.
3HAC 16261-1
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
1. Connect a console to the MC/CONSOLE outlet on the controller and execute the
command dosFsShow .
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!
Increasing
storage capacity
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 C-START (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).
Removing systems using the FileManager or FTP-client may be hazardous since the \bin and
BootRom.sys directories the must be kept intact.
Proceed with utmost care to avoid accidentally removing such files or directories!
3HAC 16261-1
169
170
3HAC 16261-1
10 Calibration
10.0.1 Introduction
Definitions
When to calibrate
This chapter details two different methods of how to calibrate the IRB 7600. The chapter is
divided into the following sections:
General information. This section contains general information that is valid for both
methods of calibration.
Calibration - Levelmeter 2000. This section details how to calibrate the robot with Levelmeter 2000.
Calibration - Calibration Pendulum. This section details how to calibrate the robot with
Calibration Pendulum.
After calibration. This section details how to verify that all calibration positions are correct after calibration.
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 on page
174 if the contents of the revolution counter memory are lost. This may occur when:
3HAC 16261-1
a robot axis has been moved with the control system disconnected
171
10 Calibration
10.1.1 Determine the appropriate method of calibration
Determine the
correct calibration method
Depending on the robot version, the IRB 7600 robot can be calibrated with two different
methods.
Levelmeter 2000
Calibration pendulum
To determine which method to use, identify the profiles at axis 1 according to the figure
below.
xx0200000377
172
Profile at axis 1, the robot must be calibrated with the Levelmeter 2000
Profile at axis 1, the robot must be calibrated with the Calibration Pendulum
3HAC 16261-1
10 Calibration
10.1.2 Calibration scales
Introduction
IRB 7600
xx0100000198
3HAC 16261-1
173
10 Calibration
10.1.3 Updating the revolution counter
Manually running
the manipulator
to the calibration
position
This section details the first step when updating the revolution counter; manually running the
manipulator to the calibration position.
Step
Action
Illustration
1.
2.
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.
Shown in Calibration
scales on page 173.
This section details the second step when updating the revolution counter; storing the revolution counter setting.
If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, which in
turn may cause damage or injury!
Step
1.
Action
Illustration
xx0100000194
2.
3.
xx0100000201
174
3HAC 16261-1
10 Calibration
10.1.3 Updating the revolution counter
Step
4.
Action
Illustration
xx0100000202
3HAC 16261-1
5.
6.
7.
8.
Not required.
9.
175
10 Calibration
10.2.1 Calibration, prerequisites
General
The calibration procedure may be described as comparing the direction of two sensors, the
reference sensor and the calibration sensor, while manually running the robot to its calibration
position, thus reducing the sensor difference to close to zero.
This procedure may be performed using a calibration kit with one sensor or two. Using one
sensor requires moving the sensor between its reference position on the robot base and the
calibration position for each axis respectively. Using a kit with two sensors enables letting the
reference sensor remain in its position on the base.
The article numbers of relevant equipment are specified in their instructions respectively.
Calibration order
When calibrating, the axis must consistently be run towards the calibration position in the
same direction, in order to avoid position errors caused by backlash in gears etc. Positive
directions are shown in the figure below.
If the axis is run past the calibration position by mistake, it must be run back to its original
position before making a new attempt to run to the calibration position.
6+
4+
5+
3+
2+
1+
xx0200000089
176
3HAC 16261-1
10 Calibration
10.2.1 Calibration, prerequisites
Using Levelmeter
2000
Using Levelmeter 2000 to perform the calibration requires firstly initializing the equipment.
How to perform this is detailed in "Initialization of Levelmeter 2000".
Location of sensors
The positions where the calibration sensor and reference sensor should be fitted during calibration, are specified in their instructions respectively.
3HAC 16261-1
177
10 Calibration
10.2.2 Fine calibration procedure on TPU
Preliminaries
10.2.2 Fine calibration procedure on TPU
General
The section below details how to use the Teach Pendant Unit (TPU) when performing a finecalibration of the robot. The way of fitting the calibration equipment to each axis is detailed
in "Fine calibration".
Procedure
Step
1.
Action
Note/Illustration
xx0100000194
2.
3.
xx0100000201
Explanation of status:
Synchronized: all axes are calibrated
and their positions are known. The unit
is ready for use.
178
3HAC 16261-1
10 Calibration
10.2.2 Fine calibration procedure on TPU
Step
4.
Action
Note/Illustration
xx0100000203
5.
6.
7.
8.
xx0100000204
3HAC 16261-1
179
10 Calibration
10.2.3 Initialization of Levelmeter 2000
General
Whenever Levelmeter 2000 is used for calibrating the robot, the equipment must first be
initialized as detailed below.
The Levelmeter 2000 is shown for reference below:
+
0000000
00000
Port/Sensor
oo
GON
50
A
B
BATT
LEVELMETER 2000
+
ON/MODE
ZERO SELECT
ENTER
SEND/ESC
HOLD
WYLER
OUT
xx0200000083
Overview
Measuring unit
Selection pointer
Sensor connection
Shown below is an outline of how to initialize the Levelmeter 2000. Detailed procedures are
given further down.
Step
Action
Info/Illustration
1.
Select the correct filter type. Detailed in Select filter type on page 180.
2.
3.
Install sensor.
4.
180
Action
Info/Illustration
1.
Press ON/MODE until the dot flashes under FILTER. Shown in the figure above!
2.
Press ENTER.
3.
4.
3HAC 16261-1
10 Calibration
10.2.3 Initialization of Levelmeter 2000
Measuring units
Step
Action
Info/Illustration
1.
2.
Press ENTER.
3.
4.
Press ENTER.
Installation of
sensor
Step
Result
3HAC 16261-1
Action
Info/Illustration
1.
2.
Press ON/MODE .
3.
4.
Press ENTER.
5.
6.
Press ENTER.
Wait until the "A" flashes again.
7.
Press ENTER.
181
10 Calibration
10.2.4 Resetting of Levelmeter 2000
Fine calibration
10.2.4 Resetting of Levelmeter 2000
General
Before calibrating each axis, the equipment must first be reset as detailed below.
The Levelmeter 2000 is shown for reference below:
+
0000000
00000
Port/Sensor
oo
GON
50
A
B
BATT
LEVELMETER 2000
+
ON/MODE
ZERO SELECT
ENTER
SEND/ESC
HOLD
WYLER
OUT
xx0200000083
Measuring unit
Selection pointer
Sensor connection
X
Y
B
xx0100000207
Attachment screws
Always fit the sensor in the same direction when resetting it as when performing the calibration
for each axis!
182
3HAC 16261-1
10 Calibration
10.2.4 Resetting of Levelmeter 2000
Initializing
Step
Result
3HAC 16261-1
Action
Info/Illustration
1.
2.
Press ENTER.
3.
4.
Press HOLD .
5.
6.
Press ENTER.
183
10 Calibration
10.2.5 Calibration, axis 1
General
This section details how to perform the actual fine calibration of axis 1 using special calibration equipment.
Equipment
Article no.
3HAC 13908-4
xx0200000090
Reference sensor
position
Procedure
Step
1.
184
Action
Illustration
3HAC 16261-1
10 Calibration
10.2.5 Calibration, axis 1
Step
2.
Action
Illustration
A
C
B
xx0100000212
3HAC 16261-1
3.
4.
5.
C: Calibration tool
185
10 Calibration
10.2.6 Calibration, axis 2
General
This section details how to perform the actual fine calibration of axis 2 using special calibration equipment.
Equipment
Art. no.
Note
Standard toolkit
3HAC 15571-1
Sensor fixture
6808 0011-GM
Angle bracket
6808 0011-LP
6369 901-347
6369 901-348
Isopropanol
1177 1012-108
xx0200000091
186
3HAC 16261-1
10 Calibration
10.2.6 Calibration, axis 2
Reference sensor
position
This illustration show the orientation of the reference sensor in relation to the manipulator
base:
2
3
4
5
6
xx0200000088
1-6
Orientation of the reference sensor in relation to the manipulator base (sticker facing
upwards)
Procedure
Step
Action
Illustration
1.
Clean the calibration surface with isopropanol . Art. no. specified above!
2.
3.
Remove the cover plate on the reference surface on the manipulator base.
4.
Clean the area where the reference sensor fix- Art. no. specified above!
ture goes with isopropanol .
5.
Fit the reference sensor fixture on the reference Art. no. specified above!
surface on the manipulator base.
Orientation specified above!
NOTE that the M8 screw must be
replaced with an M6 x 25 and flat
washer when fitting the bracket!
6.
7.
Fit the calibration sensor on the sensor fixture. Shown in the figure above!
Carefully tighten the securing screws.
8.
9.
3HAC 16261-1
187
10 Calibration
10.2.6 Calibration, axis 2
Step
Action
Illustration
188
3HAC 16261-1
10 Calibration
10.2.7 Calibration, axis 3
General
This section details how to perform the actual fine calibration of axis 3 using special calibration equipment.
Equipment
Art. no.
Info
Standard toolkit
3HAC 15571-1
Sensor fixture
6808 0011-GM
Sync adapter
3HAC 13908-1
Guide pin
2111 2021-399
6369 901-347
6369 901-348
Sensor plate
3HAC 0392-1
Sensor unit
6808 0011-GU
Isopropanol
1177 1012-108
xx0200000092
3HAC 16261-1
189
10 Calibration
10.2.7 Calibration, axis 3
Reference sensor
position
This illustration show the orientation of the reference sensor in relation to the manipulator
base:
2
3
4
5
6
xx0200000088
1-6
Orientation of the reference sensor in relation to the manipulator base (sticker facing
upwards)
Procedure
Step
190
Action
Illustration/Info
1.
2.
Clean the manipulator turning disk with isopro- Art. no. specified above!
panol .
3.
4.
Clean the area where the reference sensor fix- Art. no. specified above!
ture goes with isopropanol .
5.
Fit the reference sensor fixture on the reference surface on the manipulator base.
6.
7.
Fit the calibration sensor on the sensor fixture. Shown in the figure above!
Carefully tighten the securing screws.
8.
9.
10.
11.
3HAC 16261-1
10 Calibration
10.2.8 Calibration, axis 4
General
This section details how to perform the actual fine calibration of axis 4 using special calibration equipment.
Equipment
Art. no.
Info
Standard toolkit
3HAC 15571-1
Sensor fixture
6808 0011-GM
Sync adapter
3HAC 13908-1
Guide pin
2111 2021-399
3HAC 16261-1
Sensor plate
3HAC 0392-1
Sensor unit
6808 0011-GU
Isopropanol
1177 1012-108
191
10 Calibration
10.2.8 Calibration, axis 4
xx0200000093
Reference sensor
position
This illustration show the orientation of the reference sensor in relation to the manipulator
base:
2
3
4
5
6
xx0200000088
192
1-6
Orientation of the reference sensor in relation to the manipulator base (sticker facing
upwards)
3HAC 16261-1
10 Calibration
10.2.8 Calibration, axis 4
Procedure
Step
Action
Illustration
1.
2.
Clean the manipulator turning disk with isopropanol . Art. no. specified above!
3.
Fit the Sync adapter and Sensor unit on the turning Art. no. specified above!
disk.
4.
5.
Fit the reference sensor fixture on the reference sur- Art. no. specified above!
face on the manipulator base.
Orientation specified above!
6.
7.
8.
Manually run axis 4 in with the joystick to the correct Within 0.40 units
position as indicated by the level meter.
9.
3HAC 16261-1
193
10 Calibration
10.2.9 Calibration, axis 5
General
This section details how to perform the actual fine calibration of axis 5 using special calibration equipment.
Equipment
Art. no.
Info
Standard toolkit
3HAC 15571-1
Sensor fixture
6808 0011-GM
Sync adapter
3HAC 13908-1
Guide pin
2111 2021-399
6369 901-347
6369 901-348
Sensor plate
3HAC 0392-1
Sensor unit
6808 0011-GU
Isopropanol
1177 1012-108
xx0200000094
194
3HAC 16261-1
10 Calibration
10.2.9 Calibration, axis 5
Reference sensor
position
This illustration show the orientation of the reference sensor in relation to the manipulator
base:
2
3
4
5
6
xx0200000088
1-6
Orientation of the reference sensor in relation to the manipulator base (sticker facing
upwards)
Procedure
Step
Action
Illustration
1.
2.
Clean the manipulator turning disk with isopropanol . Art. no. specified above!
3.
4.
5.
Fit the reference sensor fixture on the reference sur- Art. no. specified above!
face on the manipulator base.
Orientation specified above!
6.
7.
8.
Manually run axis 5 in with the joystick to the correct Within 0.40 units
position as indicated by the level meter.
9.
3HAC 16261-1
195
10 Calibration
10.2.10 Calibration, axis 6
General
This section details how to perform the actual fine calibration of axis 6 using special calibration equipment.
Equipment
Art. no.
Info
Standard toolkit
3HAC 15571-1
Sensor fixture
6808 0011-GM
Sync adapter
3HAC 13908-1
Guide pin
2111 2021-399
Sensor plate
3HAC 0392-1
Sensor unit
6808 0011-GU
Isopropanol
1177 1012-108
xx0200000095
196
3HAC 16261-1
10 Calibration
10.2.10 Calibration, axis 6
Reference sensor
position
This illustration show the orientation of the reference sensor in relation to the manipulator
base:
2
3
4
5
6
xx0200000088
1-6
Orientation of the reference sensor in relation to the manipulator base (sticker facing
upwards)
Procedure
Step
3HAC 16261-1
Action
Illustration
1.
2.
3.
4.
Manually run axis 6 in with the joystick to the correct Within 0.40 units
position as indicated by the level meter.
5.
6.
7.
197
10 Calibration
10.3.1 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
Additional information
Action
Illustration
1.
2.
Check that all required hardware is available Required hardware is specified in the
for calibrating the robot.
calibrating procedures for each axis.
3.
4.
Manually, run the robot axes to be calibrated Use the calibration scales fitted to
to a position close to the correct calibration each robot axis to locate this position.
position.
5.
6.
7.
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 position Checking the calibration position on
page 202.
An alternative calibration position for axis 1 may be
defined
How to change to a new offset value for the alternative New calibration offset, axis 1 on page
calibration position
218.
198
How to retrieve a new calibration offset for the alternative calibration position
3HAC 16261-1
10 Calibration
10.3.2 Calibration, prerequisites
General
The calibration procedure may be described as comparing the direction of two sensors, the
reference sensor and the calibration sensor, while running the robot to its calibration position,
thus reducing the sensor difference to close to zero.
All article numbers of relevant equipment are specified in their instructions respectively.
Peripheral equipment
The robot must be free from any peripheral equipment during calibration. Fitted welding guns
and similar will cause erroneous calibration positions.
Calibration order
When calibrating, the axis must consistently be run towards the calibration position in the
same direction, in order to avoid position errors caused by backlash in gears etc. Positive
directions are shown in the figure below.
This is normally handled by the robot calibration software.
NOTE The figure shows an IRB 7600, but the positive direction is the same for all robots!
6+
4+
5+
3+
2+
1+
xx0200000089
Location of sensors
The positions where the calibration sensor and reference sensor should be fitted during calibration, are specified in Calibration sensor mounting positions on page 206.
Where to find the calibration sensor and reference sensor respectively during calibration in
Calibration scales on page 173.
3HAC 16261-1
199
10 Calibration
10.3.3 Calibration pendulum kit, contents
General
The calibration pendulum kit contains all required hardware to calibrate all robot models
(except IRB 6400R) using the calibration pendulum method.
These kits may be rented from ABB at this time, but not purchased.
200
Qty
Contents
Art. no.
Inclinometer, Wyler
Zerotronic
3HAC 12837-7
3HAC 15144-1
Leveltronic NT/41
3HAC 15732-1
Calibration pendulum
3HAC 4540-1
3HAC 16423-1
3HAC 14034-1
Batteries
Thread tap, M8
Location pin
3HAC 14137-1
58 mm long
For IRB 6600 and IRB 7600, axis 1
Location pin
3HAC 14137-2
68 mm long
For IRB 140, IRB 1400, IRB 2400 and
IRB 4400, axis 1
User documentation
Rem.
3HAC 16261-1
10 Calibration
10.3.3 Calibration pendulum kit, contents
May be turned both ways to fit IRB 140, IRB 1400, IRB 2400 and IRB 4400.
A
B
C
D
C
xx0200000276
Illustration,
adapter turning
disk
Guide pin, 8 mm
Guide pin, 6 mm
Screw, M10
Screw, M6
xx0200000278
3HAC 16261-1
Locating shaft
Hand wheel
201
10 Calibration
10.3.4 Checking the calibration position
Preliminaries
10.3.4 Checking the calibration position
General
Check the calibration position before any programming of the robot system can begin. This
may be done in one of two ways:
Using the program CALxxxx in the system software (xxxx signifying the robot type;
IRB xxxx)
Step
Action
Button
1.
Run the program \SYSTEM\UTILITY\SERVICE\CALIBRAT\CALxxxx in the system and follow the instructions displayed on the teach
pendant.
2.
3.
Step
Action
Illustration
1.
2.
xx0100000195
xx0100000196
202
3.
4.
Check that the calibration marks for that partic- Shown in Calibration scales on
ular axis align correctly. If they do not, update page 173.
the revolution counters !
Detailed in Updating the revolution
counter on page 174.
3HAC 16261-1
10 Calibration
10.3.5 Calibration procedure on TPU
General
This section details how to use the Teach Pendant Unit (TPU) when calibrating the robot
using the calibration pendulum method.
Procedure
Step
Action
Illustration
1.
2.
3.
4.
xx0300000009
xx0200000188
5.
xx0200000190
3HAC 16261-1
6.
7.
203
10 Calibration
10.3.6 Initialization of calibration pendulum
General
Whenever calibration pendulum is used for calibrating the robot, the equipment must first be
initialized as detailed below.
The Levelmeter 2000 is shown for reference below:
+
0000000
00000
oo
GON
Port/Sensor
50
BATT
LEVELMETER 2000
+
ON/MODE
ZERO SELECT
Sensor A
ENTER
SEND/ESC
HOLD
WYLER
OUT
Sensor B
xx0200000126
Overview
Selection pointer
Measuring unit
Shown below is an outline of how to initialize the Levelmeter 2000. Detailed procedures are
specified in the manual supplied by the manufacturer.
Step
204
Action
Info/Illustration
1.
2.
Connect the Levelmeter 2000 to the COM2 port in the Shown in the figure in seccontrol cabinet through the connector marked OUT . tion General on page 204.
3.
4.
Detailed in Connection of
sensors on page 205.
3HAC 16261-1
10 Calibration
10.3.6 Initialization of calibration pendulum
Address
Step
Action
Info/Illustration
Action
Info/Illustration
1.
Marked A and B .
Shown in the figure in section General
on page 204.
2.
Press ON/MODE .
3.
4.
Press ENTER.
5.
6.
Press ENTER.
Wait until the "A B" flashes again.
7.
Press ENTER.
1.
Connection of
sensors
Step
Result
3HAC 16261-1
205
10 Calibration
10.3.7 Calibration sensor mounting positions
Calibration
10.3.7 Calibration sensor mounting positions
Introduction
This section specifies the mounting positions and directions of all calibration sensors on all
robot systems using the Calibration Pendulum method.
Additional information on calibration, alternative calibration positions etc, may be found in
the Installation Manual.
Reference sensor
The illustrations below show the mounting position and direction for the reference sensor :
xx0200000183
206
Calibration pendulum in reference sensor position NOTE! The pendulum is only fitted
in one position at a time!
3HAC 16261-1
10 Calibration
10.3.7 Calibration sensor mounting positions
Axis 1
The illustrations below show the mounting position and direction for the calibration sensor,
axis 1:
B
A
C
xx0200000177
Axis 2
Calibration pendulum NOTE! The pendulum is only fitted in one position at a time!
Locating pin
The illustrations below show the mounting position and direction for the calibration sensor,
axis 2:
xx0200000178
3HAC 16261-1
207
10 Calibration
10.3.7 Calibration sensor mounting positions
Axis 3
The illustrations below show the mounting position and direction for the calibration sensor,
axis 3:
xx0200000179
Calibration sensor, axis 3 NOTE! The pendulum is only fitted in one position at a time!
NOTE! The IRB 7600/2.3/500 version requires a slightly different sensor mounting position
than the other versions, the sensor being turned 90. This is shown in the figure below.
xx0300000016
Any special considerations to be taken when calibrating this robot version is detailed in section Calibrating axes 3-4, IRB 7600/2.3/500 on page 213.
208
3HAC 16261-1
10 Calibration
10.3.7 Calibration sensor mounting positions
Axis 4
The illustrations below show the mounting position and direction for the calibration sensor,
axis 4:
xx0200000179
Calibration sensor, axis 4 NOTE! The pendulum is only fitted in one position at a time!
NOTE! The IRB 7600/2.3/500 version requires a slightly different sensor mounting position
than the other versions, the sensor being turned 90. This is shown in the figure below.
xx0300000016
Any special considerations to be taken when calibrating this robot version is detailed in section Calibrating axes 3-4, IRB 7600/2.3/500 on page 213.
3HAC 16261-1
209
10 Calibration
10.3.7 Calibration sensor mounting positions
Axis 5
The illustrations below show the mounting position and direction for the calibration sensor,
axis 5:
A
B
xx0200000180
Axis 6
Calibration sensor, axis 5 NOTE! The pendulum is only fitted in one position at a time!
The illustrations below show the mounting position and direction for the calibration sensor,
axis 6:
A
B
xx0200000180
210
Calibration sensor, axis 6 NOTE! The pendulum is only fitted in one position at a time!
3HAC 16261-1
10 Calibration
10.3.8 Calibration, all axes
General
This section is valid for all robot models using the calibration pendulum procedure except
IRB 6400R.
It details how to perform the actual fine calibration of each axis using special calibration
equipment. The position to fit calibration sensors differ between different models and different axes.
Sensor mounting
positions
Equipment
Article no.
Note
Calibration pendulum,
complete set
3HAC 15716-1
3HAC 16423-1
3HAC 14034-1
Isopropanol
1177 1012-208
The position of the calibration sensors are shown in Calibration sensor mounting positions
on page 206.
Procedure
Step
3HAC 16261-1
Action
Illustration
1.
2.
3.
4.
Remove any protective covers from the reference sensor, calibration sensor and
locating pin attachment points.
The same calibration pendulum is used as
a "calibration sensor" and as a "reference
sensor" depending on its function at the
time. In the instruction below, the pendulum
will be called "calibration sensor" or reference sensor" depending on the function.
5.
6.
211
10 Calibration
10.3.8 Calibration, all axes
Step
7.
Action
Illustration
0000000
00000
Port/Sensor
oo
GON
50
E
D
BATT
LEVELMETER 2000
+
ON/MODE
ZERO SELECT
Sensor A
ENTER
SEND/ESC
HOLD
WYLER
OUT
Sensor B
xx0200000126
212
8.
9.
Click OK .
A number of menus will flash by briefly on
the TPU, but no action is required on behalf
of the operator until a specific action is displayed.
10.
11.
D: Measuring unit
E: Selection pointer
3HAC 16261-1
10 Calibration
10.3.9 Calibrating axes 3-4, IRB 7600/2.3/500
General
Due to the fact that the upper arm tube is slightly shorter on the version than on others, the
calibration sensor position on the upper arm is changed. This applies to calibrating axes 3 and
4 of the IRB 7600/2.3/500 only.
xx0300000020
Procedure
Step
3HAC 16261-1
Action
Info/Illustration
1.
Remove any cable holders by unscrewing Shown in the figure in section General
their respective attachment screws.
on page 213.
This is to facilitate fitting the calibration
sensor.
2.
213
10 Calibration
10.4.1 Post calibration procedure
General
Perform the following procedure after calibrating any manipulator axes. The procedure is
intended to verify that all calibration positions are correct.
Procedure
Step
214
Action
Illustration
1.
2.
3.
4.
5.
6.
7.
3HAC 16261-1
10 Calibration
10.5.1 Alternative calibration position
General
Illustration
C
xx0100000258
3HAC 16261-1
Calibration position 0
215
10 Calibration
10.5.2 Alternative calibrating
General
The manipulator may be calibrated in any of three positions, shown in Alternative calibration
position on page 215.
Procedure
Step
216
Action
Illustration
1.
2.
3.
Select Normal position, and check the calibration marks for each
axis.
4.
Run the calibration program again and select the desired calibration position (Left or Right) as shown in Alternative calibration
position on page 215.
5.
6.
Note the new calibration offset on the label, located on the frame
to the left of motor axis 1 (remove the cover between axes 2 and
3). The new calibration offset values can be found as detailed in
Retrieving offset values on page 219.
7.
8.
9.
Move the sync marks for axis 1 on the base to the new position.
10.
3HAC 16261-1
10 Calibration
10.5.3 New calibration position, axis 1
Procedure
Use this instruction to change to a new calibration position for axis 1 during definition of a
new calibration position.
Step
Action
Illustration
1.
2.
xx0100000194
xx0100000200.
3HAC 16261-1
3.
4.
5.
Select axis 1.
6.
217
10 Calibration
10.5.4 New calibration offset, axis 1
Procedure
Use this instruction when changing to a new calibration offset for axis 1 during definition of
a new calibration position.
Step
1.
Action
Illustration
xx0100000194
2.
3.
4.
5.
6.
xx0100000201
218
3HAC 16261-1
10 Calibration
10.5.5 Retrieving offset values
Procedure
Use this instruction when retrieving new offset values for axis 1 during definition of a new
calibration position.
Step
Action
Illustration
1.
2.
xx0100000194
xx0100000200
3.
4.
5.
xx0100000200
3HAC 16261-1
219
10 Calibration
10.5.5 Retrieving offset values
220
3HAC 16261-1
11 Decommissioning
11.0.1 Balancing device, IRB 7600 and IRB 6600/6650
General
This information is valid for all versions of IRB 6600/6650 as well as IRB 7600!
There is much energy stored in the balancing device. Therefore a special procedure is
required to dismantle it. The coil springs inside the balancing device exert a potentially lethal
force unless dismantled properly.
Required equipment
Equipment, etc.
Standard toolkit
3HAC 15571-1
Note
The contents are defined in
section Standard toolkit on
page 18!
Cutting torch
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!
Procedure
The instruction below details how to cut open the balancing device housing and removing the
tension in the coil springs before opening the device.
Step
3HAC 16261-1
Action
Info/Illustration
1.
2.
221
11 Decommissioning
11.0.1 Balancing device, IRB 7600 and IRB 6600/6650
Step
3.
Action
Info/Illustration
500 mm
xx0200000082
4.
222
5.
6.
3HAC 16261-1
Table of Contents
0.0.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
0.0.2 Product Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Chapter 1: Safety, service
1.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Section 1.1: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
13
23
3HAC 16263-1
Table of Contents
167
193
ii
3HAC 16263-1
Table of Contents
209
3HAC 16263-1
iii
Table of Contents
iv
3HAC 16263-1
0.0.1 Overview
0.0.1 Overview
About This
Manual
This information product is a manual containing instructions for repairing the complete robot
system, mechanically as well as electrically.
It also contains the electrical circuit diagram of the manipulator as well as the controller.
Usage
Prerequisites
Organization of
Chapters
Chapter
Contents
Safety
Reference information
Manipulator
Controller
Appendix
References
Reference
Document Id
3HAC 13347-1
3HAC 14189-1
Revisions
Revision
Description
First revision
3HAC 16263-1
Manual completed with references to pagenumbers and numbering of sections (manipulator sections).
0.0.1 Overview
3HAC 16263-1
General
The complete product documentation kit for the robot, including controller, manipulator and
any hardware option, consists of the manuals listed below:
Installation and
Commissioning
Manual
Repair Manual
Maintenance
Manual
Safety, Service
Reference Information
Unpacking
On-site Installation
Electrical connections
Start-up
Calibration
Safety, Service
Reference Information
Remove/Refitting instructions for all controller cabinet details considered spare parts
Safety, Service
Reference Information
Maintenance schedules
Instructions for all maintenance activities specified in the maintenance schedule, for
example cleaning, lubrication, inspection etc.
The information is generally divided into separate chapters for the manipulator and the controller, respectively.
Software manuals
The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during operation.
A complete listing of all available software manuals is available from ABB Robotics.
3HAC 16263-1
Hardware option
manual
Each hardware option is supplied with its own documentation. Each document set contains
the types of information specified above:
Installation information
Repair information
Maintenance information
3HAC 16263-1
1 Safety, service
1.0.1 Introduction
Definitions
This chapter details safety information for service personnel i.e. personnel performing installation, repair and maintenance work.
Sections
2. Safety risks lists dangers relevant when servicing the robot system. The dangers are split into different categories:
Safety risks related to gripper/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
3. Safety actions details actions which may be taken to remedy or avoid dangers.
Safety fence dimensions
Fire extinguishing
Emergency release of the manipulators arm
Brake testing
Risk of disabling function "Reduced speed 250 mm/s"
Safe use of the Teach Pendant Unit enabling device
Work inside the manipulators working range
3HAC 16263-1
1 Safety, service
1.1.1 Safety, service - General
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.
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.
General
Documents
Type of information
Detailed in document
Users Guide
Start-up
Section
3HAC 16263-1
1 Safety, service
1.2.1 Safety risks related to gripper
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
Grippers/end effectors must be designed so that they retain workpieces in the event of a power
failure or a disturbance of the controller.
General
Residual energy
Safe design
Residual energy may be present in these systems so, after shutdown, particular care
must be taken.
The pressure in pneumatic and hydraulic systems must be released before starting to
repair them.
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.
General
Qualified personnel
Extraordinary
risks
3HAC 16263-1
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.
1 Safety, service
1.2.5 Safety risks during installation and service
Nation/region
specific regulations
Non-voltage
related risks
To be observed
by the supplier of
the complete system
The instructions in the Product Manual - Installation and Commissioning must always
be followed.
Emergency stop buttons must be positioned in easily accessible places so that the
robot can be stopped quickly.
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 of the robot system, the regulations
applicable in the country concerned and the instructions of ABB Robotics must be complied
with.
Safety zones, which have to be crossed before admittance, must be set up in front of
the robot's working space. Light beams or sensitive mats are suitable devices.
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. In addition
to the risk of being hit by moving robot parts, you run the risk of being crushed by the
tie rod.
Energy, stored in the robot for the purpose of counterbalancing certain axes, may be
released if the robot, or parts thereof, is dismantled.
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
Voltage related
risks, controller
Although troubleshooting may, on occasion, have to be carried out while the power
supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
The mains supply to the robot must be connected in such a way that it can be turned
off outside the robots working space.
3HAC 16263-1
1 Safety, service
1.2.6 Risks associated with live electric parts
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. Note: 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
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.
3HAC 16263-1
The user connections for tools or other parts of the installation (max. 230 VAC, see
Installation and Commissioning Manual)
1 Safety, service
1.3.1 Safety fence dimensions
General
Fit a safety fence or enclosure around the robot to ensure a safe robot installation.
Dimensioning
Dimension the fence or enclosure to enable it to withstand the force created if the load being
handled by the robot is dropped or released at maximum speed. Determine the maximum
speed from the maximum velocities of the robot axes and from the position at which the robot
is working in the work cell (see Product Specification - Description, Robot Motion).
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating
tool or other device fitted to the manipulator.
Description
In an emergency situation, any of the manipulators axes may be released manually by pushing the brake release buttons on the manipulator or on an optional external brake release unit.
How to release the brakes is detailed in section "Manually releasing the brakes".
The manipulator arm may be moved manually on smaller robot models, but larger models
may require using an overhead crane or similar.
Increased injury
Before releasing the brakes, make sure that the weight of the arms does not increase the
pressure on the trapped person, which may further increase any injury!
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.
10
3HAC 16263-1
1 Safety, service
1.3.5 Risk of disabling function "Reduced speed 250 mm/s"
3HAC 16263-1
11
1 Safety, service
1.3.7 Work inside the manipulators working range
12
3HAC 16263-1
2 Reference information
2.0.1 Introduction
General
3HAC 16263-1
This chapter presents generic pieces of information, complementing the more specific information in the following chapters.
13
2 Reference information
2.1.1 Applicable Safety Standards
Standards, general
Standards, robot
cell
14
The following standards are applicable when the robot is part of a robot cell:
EN 811 - Safety distances to prevent danger zones being reached by the lower limbs.
EN 294 - Safety distances to prevent danger zones being reached by the upper limbs.
3HAC 16263-1
2 Reference information
2.1.2 Screw joints
General
This section details how to tighten the various types of screw joints on 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.
UNBRAKO
screws
UNBRAKO is a special type of screw recommended by ABB in certain screw joints. It features special surface treatment (Gleitmo as described below), and is extremely resistant to
fatigue.
Whenever used, this is specified in the instructions and in such cases no other type of replacement screw is allowed. Using other types of screw will void any warranty and may potentially
cause serious damage or injury!
Gleitmo treated
screws
Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.
Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this
the screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should
be used.
Screws lubricated
in other ways
Screws lubricated with Molycote 1000 (or another lubricant) should only be used when specified in the repair, maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1. Lubricate the thread of the screw.
2. Lubricate between the plain washer and screw head.
3. Tighten to the torque specified in section "Tightening torque" below. Screw dimensions
of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or
smaller may be tightened without a torque wrench if this is done by trained and qualified personnel.
3HAC 16263-1
Lubricant
Art. no.
1171 2016-618
15
2 Reference information
2.1.2 Screw joints
Tightening torque
Below are tables specifying the torque values for different screw joint types:
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 "dry"
Tightening torque
(Nm)
Class 12.9 "dry"
M5
M6
10
M8
24
34
40
M10
47
67
80
M12
82
115
140
M16
200
290
340
Dimension
M8
28
34
M10
55
66
M12
96
115
M16
235
280
Screws with
hexagon socket
head, dry
Screws with
hexagon socket
head, lubricated
16
3HAC 16263-1
2 Reference information
2.1.3 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 the use of lifting equipment when handling components with a weight
exceeding 22 kg to avoid inflicting injury. A wide range of lifting tools and devices is available for each manipulator model.
Example
3HAC 16263-1
17
2 Reference information
2.1.4 Standard toolkit
General
All service (repairs, maintenance and installation) instructions contain lists of tools required
to perform the specified activity.
All special tools required are listed directly in the instructions while all the tools that are
considered standard are gathered in the Standard toolkit and defined in the table below.
In this way, the tools required are the sum of the Standard Toolkit and any tools listed in the
instruction.
Contents,
standard toolkit,
3HAC 15571-1
18
Qty
Art. no.
Tool
Rem.
3HAC 16263-1
2 Reference information
2.1.5 Special tools, IRB 6600/6650/7600
General
All service (repairs, maintenance and installation) instructions contain lists of tools required
to perform the specified activity. The required tools are a sum of standard tools, defined in
section Standard toolkit on page 18, and of special tools, listed directly in the instructions and
also gathered in the table below.
The table below is an overview of all the special tools required when performing service
activities on the IRB 6600/6650/7600. The tools are gathered in two kits: Basic Toolkit
(3HAC 15571-3) and Extended Toolkit (3HAC 15571-2).
The special tools are also listed directly in the current instructions.
3HAC 16263-1
Description
Angel bracket
68080011-LP
3HAB 3409-86
3HAB 3409-89
Cal. tool
68080011-GM
Calibration bracket
3HAC 13908-9
3HAC 13908-4
3HAC 15716-1
3HAC 12342-1
3HAC 13659-1
3HAC 13660-1
Gearbox crank
3HAC 16488-1
3HAC 13056-2
3HAC 13056-3
3HAC 13056-4
3HAC 15520-1
3HAC 15520-2
3HAC 14445-1
3HAC 14446-1
3HAC 15521-1
3HAC 15521-2
3HAC 13120-2
3HAC 13120-3
3HAC 13120-4
3HAC 13120-5
3HAC 14628-2
3HAC 14628-1
3HAC 14627-3
3HAC 14627-2
Hydraulic cylinder
3HAC 11731-1
19
2 Reference information
2.1.5 Special tools, IRB 6600/6650/7600
Description
3HAC 13086-1
3HAC 13086-2
6369901-348
3HAC 15560-1
3HAC 15607-1
3HAC 15994-1
3HAC 15536-1
3HAC 16131-1
3HAC 14457-3
3HAC 14457-4
3HAC 15556-1
3HAC 13698-1
3HAC 12731-1
3HAC 14691-1
3HAC 14459-1
3HAC 15534-1
3HAC 13605-1
3HAC 12734-1
Measuring pin
3HAC 13908-5
Mech stop ax 3
3HAC 12708-1
Mech stop ax 3
3HAC 12708-2
3HAC 13527-1
3HAC 13453-1
3HAC 13452-1
3HAC 17129-1
3HAC 15767-1
3HAC 12475-1
3HAC 15814-1
3HAC 14972-1
3HAC 14631-1
3HAC 14973-1
Rotation tool
3HAC 17105-1
Sensor plate
3HAC 0392-1
Support, base
3HAC 15535-1
Sync. adapter
3HAC 13908-1
3HAC 15943-2
3HAC 15943-1
3HAC 68080011-GU
3HAA 1001-186
Note a) Calibration tools for IRB 6600/6650/7600 when CalPen is not used (standard).
Note b) Special tools that may be rent from ATRP/S.
20
3HAC 16263-1
2 Reference information
2.1.6 Performing a leak-down test
General
After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil
must be tested. This is done in a leak-down test.
Required equipment
Equipment, etc.
Leakdown tester
Note
3HAC 0207-1
Procedure
Step
3HAC 16263-1
Action
Note/Illustration
1.
2.
Remove the topmost oil plug on the gear in Art. no. specified above!
question, and replace it with the leakdown
tester .
Adapters may be required, which are
included in the leakdown tester kit.
3.
Apply compressed air, and raise the pres- Recommended value: 0.2 - 0.25 bar
sure with the knob until the correct value is (20 - 25 kPa)
shown on the manometer.
4.
5.
Wait for approx. 8-10 minutes. No pressure If the compressed air is significantly
loss must be detected.
colder or warmer than the gearbox to
be tested, a slight pressure increase or
decrease respectively may occur. This
is quite normal.
6.
7.
8.
21
2 Reference information
2.1.7 Lifting equipment and lifting instructions
General
Many repair and maintenance activities require different pieces of lifting equipment, which
are specified in each activity instruction.
However, how to use each piece of lifting equipment is not detailed in the activity instruction,
but in the instruction delivered with each piece of lifting equipment.
This implies that the instructions delivered with the lifting equipment should be stored for
later reference.
22
3HAC 16263-1
Definitions
This chapter details all repair activities recommended for the manipulator, including for any
external units of the manipulator.
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 16263-1
Remaining instructions for all the spare parts in e.g. the manipulators external units, if
any.
23
Location of cable
harness
The cable harness is located throughout the manipulator as shown in the figure below. The
brake release unit can be located at two alternative places, either at the rear of the base or at
the side of the frame. Depending on the location, the two types of harnesses are distinguished
some from each other!
Any differences are pointed out in the instructions!
E
J
B
K
A
D
1
L M
N
L M
xx0100000140
24
Connectors at motor 3; R2.FB3 and R2.MP3 and for signal lamp R2.H1 and R2.H2
3HAC 16263-1
Connector R1.MP
Connector R1.SMB
Required equipment
Equipment, etc. Spare part no. Art. no.
Removal, cable
harness, axes 1-4
Note
Standard toolkit
Circuit Diagram
The procedure below details how to remove the lower cable harness.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them!
Step
1.
3HAC 16263-1
Action
Note/Illustration
In order to facilitate refitting of cable harness, Axes 2 and 3 may be tilted slightly to
run the manipulator to the specified position improve access.
Run the manipulator to the specified position:
Axis 1: 0
Axis 2: 0
Axis 3: 0
Axis 4: 0
Axis 5: +90
Axis 6: no significance
2.
Remove the rear cover plate on the manipulator by unscrewing its attachment screws.
3.
4.
5.
6.
25
Step
Action
Note/Illustration
7.
8.
R 2.S MB
R 1.S MB 1-3
R 1.S MB 4-6
R 1.G
R 2.G
xx0200000118.wmf
9.
FB3 FB4
FB5 FB6
MP3
MP4
MP5
MP6
xx0100000142.wmf
MP3
FB6
FB5
MP5
MP
FB3
FB4
xx0100000143.wmf
26
3HAC 16263-1
Location of cable
harness, axes 5-6
The connectors on the upper arm harness are located as specified in the figure below.
D
B
C
xx0100000145
Removal, cable
harness, axes 5-6
The procedure below details how to remove the upper arm cable harness.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Axis 5 must be oriented in the correct position (+90 ) to allow opening the motor 6 cover!
Step
3HAC 16263-1
Action
Note/Illustration
1.
2.
27
Step
28
Action
Note/Illustration
3.
4.
5.
6.
Disconnect connector R2.M5/6 at the rear cable divi- Shown in the figure Location
sion point.
of cable harness, axes 5-6
on page 27!
7.
8.
3HAC 16263-1
Location of cable
harness
The cable harness is located throughout the manipulator as shown in the figure below. The
brake release unit can be located at two alternative places, either at the rear of the base or at
the side of the frame. Depending on the location, the two types of harnesses are distinguished
some from each other!
Any differences are pointed out in the instructions!
E
J
B
K
A
D
1
L M
N
L M
xx0100000140
3HAC 16263-1
Connectors at motor 3; R2.FB3 and R2.MP3 and for signal lamp R2.H1 and R2.H2
29
Connector R1.MP
Connector R1.SMB
Required equipment
Refitting, cable
harness, axes 1-4
Equipment, etc.
Note
3HAC 12782-1
3HAC 14940-1
3HAC 11440-1
Standard toolkit
Circuit Diagram
The procedure below details how to refit the lower cable harness.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them!
Step
1.
30
Action
Note/Illustration
In order to facilitate refitting of cable harness, Axes 2 and 3 may be tilted slightly
run the manipulator to the specified position
to improve access.
Axis 1: 0 degrees
Axis 2: 0 degrees
Axis 3: 0 degrees
Axis 4: 0 degrees
Axis 6: no significance
2.
3.
4.
5.
3HAC 16263-1
Step
Action
Note/Illustration
6.
7.
MP2 MP1
MP4
SMB
MP3
MP5 MP6
xx0100000141.wmf
8.
R 2.S MB
R 1.S MB1-3
R 1.S MB4-6
R 1.G
R 2.G
xx0200000118
9.
10. Secure the correct adapter plate to the harness with its two attachment screws.
11.
FB3 FB4
FB5 FB6
MP3
MP4
MP5
MP6
xx0100000142
MP6
MP3
FB6
FB5
MP5
MP
FB3
FB4
xx0100000143
3HAC 16263-1
31
Step
Location of cable
harness axes 5-6
Action
Note/Illustration
15.
16.
17.
The connectors on the upper arm are located as specified in the figure below.
D
B
C
xx0100000145
Refitting, cable
harness, axes 5-6
The procedure below details how to refit the upper cable harness.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
32
3HAC 16263-1
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them!
Step
1.
Action
Note/Illustration
Axis 6: no significance
2.
Gently insert the cable harness from the rear into the
upper arm.
3.
4.
5.
6.
Secure any excess cable length tightly to the large Excess cable length may be
plate in the wrist housing, using cable straps.
present if upper arm length is
Use the attachment holes in the large plate intended not the maximum.
for the cable straps!
7.
8.
9.
Refit the left hand side wrist cover with its attachment screws.
10.
11.
12.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- 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 16263-1
33
The complete arm system is defined as the complete manipulator except for the base and
gearbox axis 1, i.e. the upper and lower arms, balancing device and frame. This is shown in
the figure below.
E
F
xx0100000150
34
Gearbox, axis 1
Motor, axis 1
Upper arm
Lower arm
Frame
Balancing device
3HAC 16263-1
Required equipment
Equipment, etc.
Lifting device,
manipulator
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!
Note
The procedure below details how to lift and remove the complete arm system.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The complete arm system weighs 2000 kg! All lifting equipment used must be dimensioned
accordingly!
Step
1.
Action
Note/Illustration
50
m
xx0100000103
3HAC 16263-1
2.
Drain the oil from the gearbox, axis 1. Detailed in section "Oil change, gearbox
axis 1" in the Maintenance Manual.
3.
4.
35
Step
36
Action
Note/Illustration
5.
6.
Remove the block for calibration from Shown in the figure Location of complete
the bottom of the frame.
arm system on page 34!
7.
Remove the arm system from the base Shown in the figure Location of complete
by unscrewing the 24 base attachment arm system on page 34!
screws.
8.
3HAC 16263-1
The complete arm system is defined as the complete manipulator except for the base and
gearbox axis 1, i.e. the upper and lower arms, balancing device and frame. This is shown in
the figure below.
E
F
xx0100000150
3HAC 16263-1
Gearbox, axis 1
Motor, axis 1
Upper arm
Lower arm
Frame
Balancing device
37
Required equipment
Equipment, etc.
Standard toolkit
Note
The procedure below details how to lift and refit the complete arm system.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The complete arm system weighs 2000 kg! All lifting equipment used must be dimensioned
accordingly!
Step
38
Action
Note/Illustration
1.
2.
Lift the complete arm system and move Make sure all the hooks and attachments
it at very low speed, making sure it does maintain in correct position while lifting
not tip!
the manipulator!
Make sure the lift is done completely
level, adjust the length of the chains as
detailed in enclosed instruction!
3HAC 16263-1
Step
3.
Action
Note/Illustration
A
A
B
xx0300000070
4.
Look through the empty mounting hole of This is a complex task to be performed
motor axis 1, to assist in aligning the
with outmost care in order to avoid injury
assembly during refitting of the arm sys- or damage!
tem.
The guiding pin in the gearbox must be
fitted to the guiding hole of the frame (B).
Lower the arm system with guidance
from the guide pins previously fitted to
the frame.
5.
6.
Remove the guide pins and secure the Shown in the figure Location of complete
arm system to the base with the 24 base arm system on page 37!
attachment screws and washers.
24 pcs, M12 x 110; 12.9 quality
UNBRAKO, tightening torque: 110 Nm.
Reused screws may be used, providing
they are lubricated as detailed in Screw
joints on page 15 before fitting.
7.
Refit the block for calibration at the bot- Shown in the figure Required equipment
tom of the frame.
on page 38!
8.
9.
Refill the gearbox axis 1 with lubricating Detailed in "Oil change, gearbox axis 1"
oil.
in the Maintenance Manual.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- 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 16263-1
39
The turning disk is located in the center of the wrist unit as shown in the figure below.
A more detailed view of the component and its position may be found in the Foldout section
Wrist complete on page 219!
xx0100000129
Turning disk
Required equipment
Equipment, etc.
Standard toolkit
40
Note
3HAC 16263-1
Removal, turning
disk
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Step
3HAC 16263-1
Action
Note/Illustration
1.
2.
3.
41
The turning disk is located in the center of the wrist unit as shown in the figure below.
A more detailed view of the component and its position may be found in the Foldout section
Wrist complete on page 219!
xx0100000129
Turning disk
Required equipment
Equipment, etc.
Note
Turning disk
3HAC 13193-1
O-ring
Grease
3HAB 3537-1
Standard toolkit
3HAC 15571-1
42
3HAC 16263-1
Refitting, turning
disk
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Step
1.
Action
Note/Illustration
B
A
C
xx0100000130
B: Turning disk
2.
3.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- 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 16263-1
43
Location of wrist
unit
The wrist unit is located in the frontmost part of the upper arm as shown in the figure below.
A more detailed view of the component and its position may be found in the Foldout section
Wrist complete on page 219!
B C
H
xx0100000147
Wrist unit
Turning disc
Cover, axis 5
Rear cover
Required equipment
Equipment, etc.
Standard toolkit
3HAC 12734-1
44
Note
3HAC 16263-1
Equipment, etc.
Circuit Diagram
Removal, wrist
unit
Note
The procedure below details how to remove the complete wrist unit.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The wrist unit weighs 200 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
Remove all equipment fitted to the turning Shown in the figure Location of wrist
disk.
unit on page 44!
2.
3.
4.
5.
6.
Disconnect connector R2.M5/6 at the rear Shown in the figure Location of wrist
cable division point .
unit on page 44!
7.
8.
9.
10. Pull the cabling forwards through the upper Make sure the attachments do not get
arm tube.
stuck inside the tube!
11.
3HAC 16263-1
45
Location of wrist
unit
The wrist unit is located in the frontmost part of the upper arm as shown in the figure below.
A more detailed view of the component and its position may be found in the Foldout section
Wrist complete on page 219!
B C
H
xx0100000147
Wrist unit
Turning disc
Cover, axis 5
Rear cover
Required equipment
46
Equipment, etc.
Note
Wrist unit
3HAC 16628-1
Friction washer
3HAC 11755-1
Standard toolkit
3HAC 12734-1
3HAC 16263-1
Equipment, etc.
Circuit Diagram
Refitting, wrist
unit
Note
The procedure below details how to refit the complete wrist unit.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The wrist unit weighs 200 kg! All lifting equipment used must be dimensioned accordingly!
Step
3HAC 16263-1
Action
Note/Illustration
1.
Remove the cover, axis 5 from the wrist unit to Art. no. specified in Required
be fitted. Fit the Lifting tool, wrist unit to the
equipment on page 46!
wrist unit.
2.
3.
4.
5.
Secure the wrist unit with its attachment screws Screws: M12 x 50, UNBRAKO
and washers.
quality 12.9, tightening torque: 115
Nm.
Reused screws may be used, providing they are lubricated as
detailed in Screw joints on page 15
before fitting.
6.
Secure the cable harness with the cable attach- Make sure the cabling is not
ment inside the upper arm as well as on the
twisted!
rear of the upper arm.
7.
8.
9.
10.
Refit the rear cover with its attachment screws. Shown in the figure Location of
wrist unit on page 46!
11.
47
Step
Action
Note/Illustration
12.
13.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- 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.
48
3HAC 16263-1
Location of upper
arm
The upper arm is located on top of the manipulator as shown in the figure below.
A more detailed view of the component and its position may be found in the Foldout section
Upper arm on page 217!
G A
H
F
B
D
E
C
xx0100000148
Upper arm
Required equipment
Equipment, etc.
Standard toolkit
3HAC 16263-1
Note
49
Equipment, etc.
Removal, upper
arm
Note
3HAC 14457-3
3HAC 15536-1
3HAC 15556-1
Hoisting block
The procedure below details how to remove the complete upper arm.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The complete upper arm weighs 450 kg without any additional equipment fitted! Use a suitable
lifting device to avoid injury to personnel!
Step
50
Action
Note/Illustration
1.
2.
3.
4.
5.
6.
7.
8.
9.
3HAC 16263-1
Step
Action
Note/Illustration
3HAC 16263-1
51
Location of upper
arm
The upper arm is located on top of the manipulator as shown in the figure below.
A more detailed view of the component and its position may be found in the Foldout section
Upper arm on page 217!
G A
H
F
B
D
E
C
xx0100000148
52
Upper arm
3HAC 16263-1
Required equipment
Equipment, etc.
3HAC 11054-1
Washer
3HAC 11828-1
Standard toolkit
3HAC 15571-1
3HAC 14457-3
3HAC 15536-1
3HAC 15556-1
Hoisting block
3HAC 14627-2
80 mm.
For guiding "Sealing, axis 2/3".
3HAC 14627-3
100 mm.
For guiding "Sealing, axis 2/3".
Refitting, upper
arm
Note
The procedure below details how to refit the complete upper arm.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force
is used!
The complete upper arm weighs 450 kg without any additional equipment fitted! Use a suitable
lifting device to avoid injury to personnel!
3HAC 16263-1
53
Step
1.
Action
Note/Illustration
xx0200000125
54
2.
Fit the lifting eye to the attachment hole in Shown in the figure Location of upper
the wrist unit.
arm on page 52!
Art. no. is specified in Required equipment on page 53!
3.
4.
5.
Use the hoisting block to adjust the tension in the chain in order to lift the upper
arm completely level.
6.
7.
8.
9.
3HAC 16263-1
Step
Action
Note/Illustration
10.
11.
12.
13.
14.
15.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- 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 16263-1
55
Location of lower
arm
A
D
xx0100000149
56
Lower arm
3HAC 16263-1
Attachment
points, lower arm
The lower arm attachment points are located as shown in the figure below:
The figure (1) shows gearbox 3, but the location of sealing axis 2/3 in relation to the
gearbox is identical for axis 3.
The figure (2) shows a cut view through the lower arm pivot point in axis 2 (item B in
the figure above!).
201
A
B
(1)
(2)
404
401
202
204
406
402
403
D
405
409
E
xx0200000031
3HAC 16263-1
Gear box
Lower arm
Frame
Shaft hole
201
202
Attachment screw
204
Washer
401
Bearing
402
Thrust washer
403
Bushing
404
Retaining ring
405
Shaft
406
Protection plug
409
Protection washer
57
Required equipment
Equipment, etc.
3HAC 14691-1
3HAC 13452-1
3HAC 14457-3
3HAC 12475-1
3HAC 13086-1
3HAC 13086-2
Standard toolkit
3HAC 15571-1
Removal, lower
arm
Note
Tool that may be rent from
ABB.
The procedure below details how to remove the complete lower arm.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The lower arm weighs 225 kg! All lifting equipment used must be dimensioned accordingly!
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!
Step
58
Action
Note/Illustration
1.
2.
Disconnect and remove the cables from Detailed in section Removal of cable harinside the lower arm.
ness on page 24.
Release any cable attachments.
3HAC 16263-1
Step
Action
Note/Illustration
3.
4.
Unload the balancing device in order to Detailed in section Unloading the balancmake the piston rod and front ear adjust- ing device on page 88.
able when pulling the front shaft out.
5.
Remove the securing screw from the bal- Shown in the figure Location of lower
ancing device front shaft.
arm on page 56.
6.
40
16
xx0300000060
8.
9.
10.
11.
12.
13.
xx0300000015
3HAC 16263-1
59
Step
Action
Note/Illustration
14.
Apply the press (/puller) tool as shown in Art. no. is specified in Required equipthe figure to the right and mount the
ment on page 58!
hydraulic pump to it.
15.
16.
17.
18.
19.
Remove the sealing from the lower arm. Shown in the figure Attachment points,
lower arm on page 57!
On reassembly a new sealing must be
used!
xx0300000010
60
3HAC 16263-1
Location of lower
arm
A
D
xx0100000149
3HAC 16263-1
Lower arm
61
Attachment
points, lower arm
The lower arm attachment points are located as shown in the figure below:
The figure (1) shows gearbox 3, but the location of sealing axis 2/3 in relation to the
gearbox is identical for axis 3.
The figure (2) shows a cut view through the lower arm pivot point in axis 2 (item B in
the figure above!).
201
A
B
(1)
(2)
404
401
202
204
406
402
403
D
405
409
E
xx0200000031
62
Gear box
Lower arm
Frame
Shaft hole
201
202
Attachment screw
204
Washer
401
Bearing
402
Thrust washer
403
Bushing
404
Retaining ring
405
Shaft
406
Protection plug
409
Protection washer
3HAC 16263-1
Required equipment
Equipment, etc.
Bearing
3HAC 4310-1
VK-cover
3HAA 2166-23
Guidings
Power supply
24 VDC, 1.5 A.
For releasing the brakes.
3HAC 13452-1
3HAC 13453-1
Grease
3HAB 3537-1
Standard toolkit
3HAC 16263-1
Note
63
Refitting, lower
arm
The procedure below details how to refit the complete lower arm.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The lower arm weighs 225 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
Fit a new VK-cover on new lower arm or Part no. specified in Required equipment
replace existing if damaged.
on page 63!
2.
xx0200000262
64
3.
Fit the new sealing, axis 2/3 on the guid- Always use a new sealing when reasings.
sembling!
Art. no. specified in Required equipment
on page 63!
4.
5.
3HAC 16263-1
Step
6.
Action
Note/Illustration
In case the holes of the lower arm and Connect power supply to connector
the ones of the gearbox axis 2 doesnt R2.MP2:
match, use power supply to release the
+ : pin 2
motor axis 2 brakes and rotate the pin - : pin 5
ion and gear with the rotation tool.
xx0200000165
8.
9.
10.
E
F
A B
xx0300000014
11.
3HAC 16263-1
A: Retaining ring
B: Protection washer
C: Bearing
D: Thrust washer
E: Shaft
F: Protection washer
65
Step
Action
Note/Illustration
12.
13.
Set the indicator to zero and press the Approx. force: 30-50 kN.
shaft in with the hydraulic cylinder of the
press tool.
14.
15.
16.
17.
18.
19.
Press the bearing in with the press tool, Always use a new bearing when reasaxis 2 bearing.
sembling!
Art. no. specified in Required equipment
on page 63!
20.
21.
22.
23.
24.
25.
26.
Refit and reconnect all cables inside the Detailed in section Refitting of cable harlower arm.
ness on page 29.
Resecure any cable attachments.
27.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- 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.
66
3HAC 16263-1
Location of SMB
related equipment
The SMB related equipment (SMB = serial measurement board) is located on the left hand
side of the frame as shown in the figure below.
A more detailed view of the component and its position may be found in the Foldout section
Frame-Lower arm 1 on page 213!
Note that the manipulator is shown with the SMB cover already removed!
B C D GE F H
xx0100000138
SMB battery
SMB cover
SMB unit
Pins
Required equipment
Equipment, etc. Spare part. no. Art. no.
Removal, battery
Note
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!
Circuit Diagram
3HAC 16263-1
67
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Follow these instruction to prevent the unit to be damaged from ESD:
The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to electrostatic
voltages.
Before handling, make sure you are connected to earth through a special ESD wrist bracelet
or similar.
Step
Removal, SMB
unit
Action
Note/Illustration
1.
2.
3.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Follow these instruction to prevent the unit to be damaged from ESD:
The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to electrostatic
voltages.
Before handling, make sure you are connected to earth through a special ESD wrist bracelet
or similar.
Step
68
Action
Note/Illustration
1.
2.
Remove the SMB cover by unscrewing its Shown in the figure Location of SMB
attachment screws.
related equipment on page 67!
Pull the battery cable through the hole in the
SMB cover.
3.
Remove the two locknuts and washers from Shown in the figure Location of SMB
the pins securing the board.
related equipment on page 67!
4.
5.
3HAC 16263-1
Location of SMB
related equipment
The SMB related equipment (SMB = serial measurement board) is located on the left hand
side of the frame as shown in the figure below.
A more detailed view of the component and its position may be found in the Foldout section
Frame-Lower arm 1 on page 213!
Note that the manipulator is shown with the SMB cover already removed!
B C D GE F H
xx0100000138
SMB battery
SMB cover
SMB unit
Pins
Required equipment
3HAC 16263-1
Equipment, etc.
SMB Unit
3HAC 16014-1
SMB Battery
3HAC 16831-1
Note
Battery includes protection circuits.
Replace it only with given spare
part no. or an ABB approved eqvivalent.
Cable, battery/SMB
board
3HAC 13151-1
Standard toolkit
Circuit Diagram
69
Refitting, battery
Step
Refitting, SMB
board
Action
Note/Illustration
1.
2.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Follow these instruction to prevent the unit to be damaged from ESD:
The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to electrostatic
voltages.
Before handling, make sure you are connected to earth through a special ESD wrist bracelet
or similar.
Step
70
Action
Note/Illustration
1.
2.
Fit the SMB unit onto the pins and con- Art. no. is specified Required equipment on
nect all connectors to the board.
page 69!
Shown in the figure Location of SMB
related equipment on page 69!
R1.SMB1-3, R1.SMB4-6 and R2.SMB
3.
4.
Pull the battery cable through the hole Shown in the figure Location of SMB
in the SMB cover .
related equipment on page 69!
3HAC 16263-1
Step
Action
Note/Illustration
5.
Secure the SMB cover with its attach- Shown in the figure Location of SMB
ment screws .
related equipment on page 69!
6.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- 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 16263-1
71
Different designs
Depending on the robot version, the brake release unit may be located either at the base or at
the frame. The following two figures show the different locations.
The early design includes a brake release unit with or without push buttons, located at the
base. The later design instead includes a brake release unit with push buttons, placed together
with the SMB unit on the left hand side of the frame.
The different designs are not compatible.
Location of brake
release unit, base
The early design includes a brake release unit with or without push buttons, located at the base
as shown in the figure below.
B
xx0200000127
72
3HAC 16263-1
Location of brake
release unit,
frame
The later design includes a brake release unit with push buttons, placed together with the
SMB unit on the left hand side of the frame as shown in the figure below.
D
xx0200000226
Buttons
SMB cover
Required equipment
Equipment, etc.
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page
18!
3HAC 16263-1
Note
73
Removal of brake
release unit,
located at base
The procedure below details how to remove the brake release circuit, located at the rear of the
base. See the figure Location of brake release unit, base on page 72.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Step
Removal of brake
release unit,
located on frame
Action
Note/Illustration
1.
2.
Unscrew the four attachment screws, brake release Shown in the figure Location
circuit on the outside of the base.
of brake release unit, base on
page 72!
3.
The procedure below details how to remove the brake release unit, located on the side of the
frame. See the figure Location of brake release unit, frame on page 73.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Follow these instruction to prevent the unit to be damaged from ESD:
The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to electrostatic
voltages.
Before handling, make sure you are connected to earth through a special ESD wrist bracelet
or similar.
Step
1.
74
Action
Note/Illustration
3HAC 16263-1
Step
2.
Action
Note/Illustration
A
2
C
xx0200000129
3HAC 16263-1
3.
4.
A: Connector X8
B: Connector X9
C: Connector X10
75
Different designs
Depending on the robot version, the brake release unit may be located either at the base or at
the frame. The following two figures show the different locations.
The early design includes a brake release unit with or without push buttons, located at the
base. The later design instead includes a brake release unit with push buttons, placed together
with the SMB unit on the left hand side of the frame.
The different designs are not compatible.
Location of brake
release unit, base
The early design includes a brake release unit with or without push buttons, located at the base
as shown in the figure below.
B
xx0200000127
76
3HAC 16263-1
Location of brake
release unit,
frame
The later design instead includes a brake release unit with push buttons, placed together with
the SMB unit on the left hand side of the frame as shown in the figure below.
D
xx0200000226
Buttons
SMB cover
Required equipment
Equipment, etc.
3HAC 12989-1
3HAC 16036-1
Standard toolkit
3HAC 16263-1
Note
77
Equipment, etc.
Refitting of brake
release circuit,
located at base
Note
These procedures include references to the tools required.
The procedure below details how to refit the brake release circuit, located at the rear of the
base. See the figure Location of brake release unit, base on page 76.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Step
Refitting of brake
release unit,
located on frame
Action
Note/Illustration
1.
Place the brake release circuit in the base of the Part no. specified in Required
robot.
equipment on page 77!
Shown in the figure Location of
brake release unit, base on page
76!
2.
3.
4.
The procedure below details how to refit the brake release unit, located on the side of the
frame. See the figure Location of brake release unit, frame on page 77.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Follow these instruction to prevent the unit to be damaged from ESD:
The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to electrostatic
voltages.
Before handling, make sure you are connected to earth through a special ESD wrist bracelet
or similar.
78
3HAC 16263-1
Step
Action
Note/Illustration
1.
2.
A
2
C
xx0200000129
3.
A: Connector X8
B: Connector X9
C: Connector X10
Close the SMB cover with attachment screws. Eventual synchronization detailed in
If the battery has been disconnected the robot "Calibration" in the Installation and
Commissioning Manual.
must be synchronized.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- 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 16263-1
79
The balancing device is located on rear top of the frame as shown in the figure below.
F
G, H
K
A
C
N
B, L
D, M
E
xx0100000139
80
Balancing device
Bearing attachment
Rear cover
Balancing device front eye shaft, including securing screw and washer
Plug
3HAC 16263-1
Required equipment
Equipment, etc
Note
3HAB 3409-90
M16 x 90
3HAC 14457-3
3HAC 15767-1
3HAC 12475-1
Hydraulic cylinder
3HAC 11731-1
Hydraulic pump
3HAC 13086-1
Securing screw
9ADA 183-66
3HAC 13120-5
Standard toolkit
3HAC 15571-1
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The balancing device weighs 300 kg! All lifting equipment used must be dimensioned accordingly!
Step
1.
3HAC 16263-1
Action
Note/Illustration
81
Step
2.
Action
Note/Illustration
xx0200000454
82
3.
Apply lifting eye, M12 to the balancing device Art. no. specified in Required
and raise to unload the device.
equipment on page 81!
4.
5.
6.
7.
8.
Secure the two bearing attachments to the bal- Shown in the figure Location of
ancing device by replacing the plug on the out- balancing device on page 80!
side of each attachment, with a screw.
M12 x 35
9.
Remove the two bearing attachments from the Shown in the figure Location of
frame by unscrewing their four attachment
balancing device on page 80!
screws.
Make sure the parallel pins are not
lost!
10.
Fit two guide pins, through the upper holes of Art. no. specified in Required
the bearing attachments, to the frame.
equipment on page 81!
11.
Lift the balancing device gently backwards to a Note! Make sure not to burden the
secure area, allowing the bearing attachments guide pins with the weight of the
to slide on the guide pins.
balancing device!
3HAC 16263-1
The balancing device is located on rear top of the frame as shown in the figure below.
F
G, H
K
A
C
N
B, L
D, M
E
xx0100000139
3HAC 16263-1
Balancing device
Bearing attachment
Rear cover
Balancing device front eye shaft, including securing screw and washer
Plug
83
Required equipment
Equipment
Note
Balancing device
3HAC 14214-1
O-ring, 2 pcs
3HAB 3772-44
Locking screw,
lower arm
3HAB 3409-90
M16 x 90
Securing screw
9ADA 183-66
Bearing grease
3HAB 3537-1
Grease
Locking liquid
Loctite 243.
To apply to the securing screw in
the shaft.
Grease pump
3HAC 13120-5
3HAC 14457-3
Hydraulic pump
3HAC 13086-1
Hydraulic cylinder
3HAC 11731-1
3HAC 15767-1
3HAC 17129-1
Standard toolkit
3HAC 15571-1
84
3HAC 16263-1
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!
The balancing device weighs 300 kg! All lifting equipment used must be dimensioned accordingly!
Step
1.
Action
Note/Illustration
Secure the lower arm to the frame by insert- Shown in the figure Location of baling the locking screw into the hole (1).
ancing device on page 83!
xx0200000454
3HAC 16263-1
2.
Secure the bearing attachments to the balancing device with two screws, on the outside of the attachments.
M12 x 35.
3.
4.
5.
6.
Lift the balancing device behind the manipu- Note! Make sure not to burden the
lator.
guide pins with the weight of the balBring the device forward, gliding the bearing ancing device!
attachments on to the guide pins (upper
holes).
7.
85
Step
Action
Note/Illustration
8.
Secure the rear of the balancing device by Shown in the figure Location of balfitting the two bearing attachments with their ancing device on page 83!
four attachment screws to the frame.
4 pcs, M16x90; 12.9 quality
UNBRAKO, tightening torque: 300
Nm 30 Nm.
Reused screws may be used, providing they are lubricated as detailed
in Screw joints on page 15 before fitting.
9.
Remove the screws from outside of the bearing attachments and refit the plugs.
10.
11.
12.
13.
14.
Refit the securing screw and washer in to the M16x180, tightening torque: 50 Nm.
shaft using locking liquid.
Locking liquid specified in Required
equipment on page 84!
15.
16.
17.
xx0200000454
86
3HAC 16263-1
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- 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 16263-1
87
This section implies that the lower arm is already secured according to the instruction for the
current repair activity, e.g removal of the balancing device.
The figure below shows the hydraulic cylinder mounted on the press tool.
A
C
1
0
D
xx0200000174
Bolt (4 pcs)
Hydraulic cylinder
Fix plate
Required equipment
Equipment, etc.
88
Note
3HAC 15767-1
Hydraulic cylinder
3HAC 11731-1
Hydraulic pump
Standard toolkit
3HAC 16263-1
Unloading the
balancing device
The procedure below details how to unload the balancing device, using the press tool 3HAC
15767-1. How to remove the press tool, is detailed in section Restoring the balancing device
on page 90.
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!
Step
1.
Action
Note/Illustration
xx0200000175
3HAC 16263-1
2.
3.
4.
5.
Fit the hydraulic cylinder to the press tool. Art. no. specified in Required equipment on page 88!
See the figure Press tool and hydraulic cylinder on page 88!
6.
Connect the hydraulic pump to the cylinder. Art. no. specified in Required equipment on page 88!
7.
See the figure Press tool and hydraulic cylinder on page 88!
Do not apply more pressure than necessary, it could damage bearings and
sealings at the shaft.
8.
See the figure Press tool and hydraulic cylinder on page 88!
9.
10.
89
Restoration is done after repair work that has included the unloading of the balancing device.
The figure below shows the hydraulic cylinder mounted on the press tool.
A
C
1
0
D
xx0200000174
Bolt (4 pcs)
Hydraulic cylinder
Fix plate
Required equipment
Equipment, etc. Spare part no. Art. no.
90
Note
Hydraulic cylinder
Hydraulic pump
Standard toolkit
3HAC 16263-1
The procedure below details how to restore the balancing device, i.e. removing the press tool
3HAC 15767-1.
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!
Step
3HAC 16263-1
Action
Note/Illustration
1.
2.
3.
4.
5.
6.
7.
Refit the support shaft and the lubricated o- Make sure the o-rings are seated propring.
erly!
8.
Refit the rear cover to the balancing device 4 pcs: M10x30, tightening torque: 50
with its attachment screws.
Nm.
Reused screws may be used, providing they are lubricated as detailed in
Screw joints on page 15 before fitting.
91
Location of motor
The motor axis 1 is located on the left hand side of the manipulator as shown in the figure
below:
xx0100000123
Motor, axis 1
Required equipment
Equipment, etc.
Standard toolkit
3HAC 14459-1
Power supply
92
Note
24 VDC, 1.5 A.
For releasing the
brakes.
3HAC 12342-1
3HAC 16263-1
Equipment, etc.
Note
Removal, motor
These procedures
include references to
the tools required.
3HAC 13347-1 Included in Repair Manual, part 2.
The motor weighs 32 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
Remove the Cover for connector access on top Shown in the figure Location of
of the motor by unscrewing its four attachment motor on page 92!
screws.
2.
Remove the cable gland cover at the cable exit Shown in the figure Location of
by unscrewing its two attachment screws.
motor on page 92!
xx0200000199
4.
Apply Lifting tool, motor axis 1, 4, 5 to the motor. Art. no. specified in Required
equipment on page 92!
5.
6.
3HAC 16263-1
-: pin 5
Remove the motor by unscrewing its four attach- Art. no. specified in Required
ment screws and plain washers.
equipment on page 92!
If required, use the Extension 300mm for bits 1/
2.
93
Step
94
Action
Note/Illustration
7.
If required, press the motor out of position by fit- Art. no. specified in Required
ting Removal tool, motor to the motor attachequipment on page 92!
ment screw holes.
Always use the removal tools in
pairs!
8.
9.
3HAC 16263-1
Location of motor
The motor axis 1 is located on the left hand side of the manipulator as shown in the figure
below.
xx0100000123
Motor, axis 1
Required equipment
Equipment, etc.
Note
Motor, axis 1
3HAC 14207-1
O-ring
Grease
3HAB 3537-1
Standard toolkit
3HAC 15571-1
3HAC 14459-1
3HAC 12342-1
Power supply
3HAC 16263-1
95
Equipment, etc.
Circuit Diagram
Refitting, motor
Note
3HAC 13347-1
The motor weighs 32 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
Make sure the o-ring on the circumference of the Art no. specified in Required
motor is seated properly. Lightly lubricate the o- equipment on page 95!
ring with grease .
2.
Apply Lifting tool, motor axis 1, 4, 5 to the motor. Art no. specified in Required
equipment on page 95!
3.
96
-: pin 5
4.
5.
6.
7.
8.
Refit the cable gland cover at the cable exit with Make sure the cover is tightly
its two attachment screws.
sealed!
9.
Refit the cover for connector access of the motor Shown in the figure Location of
with its four attachment screws.
motor on page 95!
Make sure the cover is tightly
sealed!
3HAC 16263-1
Step
Action
Note/Illustration
11.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- 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 16263-1
97
Location of motor
The motor axis 2 is located on the left hand side of the manipulator as shown in the figure
below.
C
A
xx0100000124
Motor, axis 2
Required equipment
Equipment, etc.
98
Note
Standard toolkit
3HAC 15534-1
Power supply
24 VDC, 1.5 A.
For releasing the brakes.
Lock screw
M16 x 60 8.8.
For securing the lower arm.
3HAC 12342-1
3HAC 16263-1
Equipment, etc.
Note
Circuit Diagram
Removal, motor
The motor weighs 32 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
2.
3.
4.
5.
6.
7.
3HAC 16263-1
8.
9.
-: pin 5
99
Step
Action
Note/Illustration
12. Lift the motor to get the pinion away from the
gear and disconnect the brake release voltage.
13. Remove the motor by gently lifting it straight
out.
100
3HAC 16263-1
Location of motor
The motor axis 2 is located on the left hand side of the manipulator as shown in the figure
below.
C
A
xx0100000124
Motor, axis 2
Required equipment
Equipment, etc.
Note
Motor, axis 2
3HAC 14209-1
O-ring
Grease
3HAB 3537-1
Standard toolkit
3HAC 15571-1
3HAC 15521-1
3HAC 15521-2
3HAC 15534-1
3HAC 12342-1
Power supply
3HAC 16263-1
24 VDC, 1.5 A.
For releasing the brakes.
101
Equipment, etc.
Note
3HAC 17105-1
Circuit Diagram
Refitting, motor
3HAC 13347-1
The motor weighs 32 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
Make sure the o-ring on the circumference of Art no. specified in Required equipthe motor is seated properly. Lightly lubricate ment on page 101!
the o-ring with grease .
2.
3.
4.
5.
102
-: pin 5
3HAC 16263-1
Step
6.
Action
Note/Illustration
If necessary, use the rotation tool in order to Art no. specified in Required equiprotate the motor pinion when mating it to the ment on page 101!
gear!
xx0200000165
8.
9.
10. Reconnect all connectors beneath the motor Connect in accordance with markcover.
ings on connectors.
11. Refit the cable gland cover at the cable exit
with its two attachment screws.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- 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 16263-1
103
Location of motor
The motor axis 3 is located on the left hand side of the manipulator as shown in the figure
below.
xx0100000125
Motor, axis 3
Required equipment
Equipment, etc.
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!
3HAC 15534-1
Power supply
104
Note
24 VDC, 1.5 A.
For releasing the brakes.
3HAC 12342-1
3HAA 1001186
3HAC 16263-1
Equipment, etc.
Note
Circuit Diagram
Removal, motor
The motor weighs 32 kg! All lifting equipment used must be dimensioned accordingly!
Step
1.
Action
Note/Illustration
B
A
3HAC 16263-1
2.
3.
4.
5.
6.
105
Step
106
Action
Note/Illustration
7.
8.
9.
10.
If required, press the motor out of position by Art. no. specified in Required equipfitting removal tool, motor to the motor attach- ment on page 104!
ment screw holes.
Always use the removal tools in
pairs!
11.
Apply the Lifting tool, motor axis 2, 3, 4 to the Art. no. specified in Required equipmotor.
ment on page 104!
12.
13.
3HAC 16263-1
Location of motor
The motor axis 3 is located on the left hand side of the manipulator as shown in the figure
below.
xx0100000125
Motor, axis 3
Required equipment
Equipment, etc.
Note
Motor, axis 3
3HAC 14209-1
O-ring
Grease
3HAB 3537-1
Standard toolkit
3HAC 15571-1
3HAC 15521-1
3HAC 15521-2
3HAC 15534-1
Extension 300 mm
for bits 1/2"
3HAC 12342-1
Power supply
3HAC 16263-1
3HAC 17105-1
107
Equipment, etc.
Note
Circuit Diagram
Refitting, motor
3HAC 13347-1
Step
Action
Note/Illustration
1.
Make sure the o-ring on the circumference of Art no. specified in Required equipthe motor is seated properly. Lightly lubricate ment on page 107!
the o-ring with grease .
2.
3.
4.
5.
108
-: pin 5
3HAC 16263-1
Step
6.
Action
Note/Illustration
If necessary, use the rotation tool in order to Art. no. specified in Required equiprotate the motor pinion when mating it to the ment on page 107!
gear!
xx0200000165
8.
9.
10.
11.
12.
Refit the cover on top of the motor with its four Make sure the cover is tightly
attachment screws.
sealed!
13.
Fork lift
Lifting slings
Mechanical stop
14.
15.
16.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- 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 16263-1
109
Location of motor
The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below.
xx0100000126
Motor, axis 4
Required equipment
Equipment, etc.
Standard toolkit
Power supply
24 VDC, 1.5 A.
For releasing the brakes.
3HAC 12342-1
Circuit Diagram
110
Note
3HAC 16263-1
Removal, motor
The motor weighs 22 kg! All lifting equipment used must be dimensioned accordingly!
Step
1.
Action
Note/Illustration
2.
3.
4.
5.
6.
3HAC 16263-1
7.
8.
-: pin 5
111
Step
9.
Action
Note/Illustration
If required, press the motor out of position by fitting Art. no. specified in Required
Removal tool, motor to the motor attachment screw equipment on page 110!
holes.
Always use the removal tools
in pairs!
112
3HAC 16263-1
Location of motor
The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below.
xx0100000126
Motor, axis 4
Required equipment
Equipment, etc.
Note
Motor, axis 4
3HAC 14210-1
O-ring
Grease
3HAC 3537-1
Standard toolkit
3HAC 15571-1
3HAC 15534-1
3HAC 14459-1
3HAC 15521-1
3HAC 15521-2
Power supply
3HAC 16263-1
3HAC 17105-1
3HAC 12342-1
113
Equipment, etc.
Note
Circuit Diagram
Refitting, motor
3HAC 13347-1
The motor weighs 22 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
Make sure the o-ring on the circumference Art. no. specified in Required equipof the motor is seated properly. Lightly lubri- ment on page 113!
cate the o-ring with grease .
2.
4.
5.
114
-: pin 5
3HAC 16263-1
Step
6.
Action
Note/Illustration
If necessary, use the rotation tool in order to Art. no. specified in Required equiprotate the motor pinion when mating it to the ment on page 113!
gear!
A
xx0200000165
8.
9.
10.
11.
Refit the cable gland cover at the cable exit Shown in the figure Location of motor
with its two attachment screws.
on page 113!
12.
13.
Fork lift.
Lifting slings.
14.
15.
16.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- 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 16263-1
115
Location of motor
The motor axis 5 is located in the rear of the wrist unit as shown in the figure below.
Notice that the left hand side cover already is removed in the figure!
xx0100000127
Motor, axis 5
Required equipment
Equipment, etc.
Standard toolkit
Power supply
24 VDC, 1.5 A.
For releasing the brakes.
3HAC 12342-1
Circuit Diagram
116
Note
3HAC 16263-1
Removal, motor
The motor weighs 22 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
2.
3.
4.
5.
6.
7.
3HAC 16263-1
-: pin 5
8.
Remove the motor by unscrewing its four attachment Art. no. specified in
screws and plain washers.
Required equipment on
page 116!
If required, use the Extension 300 mm for bits 1/2 .
9.
Apply the lifting tool, motor axis 1, 4, 5 to the motor for Art. no. specified in
a vertical lift.
Required equipment on
page 116!
10.
Fit the two guide pins in two of the motor attachment Art. no. specified in
screw holes.
Required equipment on
page 116!
11.
12.
Lift the motor to get the pinion away from the gear and
disconnect the brake release voltage.
13.
117
Location of motor
The motor axis 5 is located in the rear of the wrist unit as shown in the figure below.
Notice that the left hand side cover already is removed in the figure.
xx0100000127
Motor, axis 5
Required equipment
Equipment, etc.
Note
Motor, axis 5
3HAC 14725-1
O-ring
Grease
3HAC 3537-1
Standard toolkit
3HAC 15571-1
3HAC 15521-1
3HAC 15521-2
3HAC 14459-1
Extension 300 mm
for bits 1/2"
3HAC 12342-1
Power supply
24 VDC, 1.5 A.
For releasing the brakes.
118
3HAC 17105-1
3HAC 16263-1
Equipment, etc.
Note
Circuit Diagram
Refitting, motor
3HAC 13347-1
The motor weighs 22 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
Make sure the o-ring on the circumfer- Art. no. specified in Required equipment
ence of the motor is seated properly.
on page 118!
Lightly lubricate the o-ring with grease .
2.
3.
3HAC 16263-1
-: pin 5
4.
5.
119
Step
6.
Action
Note/Illustration
xx0200000165
8.
9.
10.
Refit the cable gland cover at the cable Shown in the figure Location of motor on
exit with its two attachment screws.
page 118!
11.
Refit the cover on top of the motor with Make sure the cover is tightly sealed!
its four attachment screws.
12.
13.
If cables are loose, place them correctly and tie them up with cable ties.
14.
15.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- 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.
120
3HAC 16263-1
Location of motor
The motor axis 6 is located in the center of the wrist unit as shown in the figure below.
A more detailed view of the component and its position may be found in the Foldout section
Wrist complete on page 219.
xx0100000128
Motor, axis 6
Required equipment
Equipment, etc.
Standard toolkit
Power supply
24 VDC, 1.5 A.
For releasing the brakes.
3HAC 12342-1
Circuit Diagram
3HAC 16263-1
Note
121
Removal, motor
Step
1.
Action
Note/Illustration
In horizontal position: drain the oil from gearbox, axis 6. Detailed in "Oil change,
gearbox axis 6" in the
Maintenance Manual.
3.
4.
5.
Connect to connector
R3.MP6
+: pin 2
122
-: pin 5
6.
7.
8.
Lift the motor to get the pinion away from the gear and
disconnect the brake release voltage.
9.
3HAC 16263-1
Location of motor
The motor axis 6 is located in the center of the wrist unit as shown in the figure below.
A more detailed view of the component and its position may be found in the Foldout section
Wrist complete on page 219!
xx0100000128
Motor, axis 6
Required equipment
Equipment, etc.
Note
Motor, axis 6
3HAC 14211-1
O-ring
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!
3HAC 12342-1
Power supply
24 VDC, 1.5 A.
For releasing the brakes.
Grease
3HAC 16263-1
3HAB 3537-1
123
Equipment, etc.
Note
Circuit Diagram
Refitting, motor
Step
Action
Note/Illustration
1.
Make sure the o-ring on the circumference of Art. no. specified in Required equipthe motor is seated properly. Lightly lubricate ment on page 123!
the o-ring with grease .
2.
124
-: pin 5
3.
4.
5.
6.
7.
8.
9.
Refit the cover on top of the motor with its six Make sure the cover is tightly sealed!
attachment screws.
10.
11.
3HAC 16263-1
Step
12.
Action
Note/Illustration
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- 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 16263-1
125
Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure below.
A more detailed view of the component and its position may be found in the Foldout section
Base incl. Frame on page 211!
D
B
C
A
E
xx0100000133
Gearbox, axis 1
Frame
Base
Required equipment
Equipment, etc.
126
Note
Standard toolkit
Support, base
3HAC 15535-1
3HAC 15560-1
3HAC 15556-1
3HAC 16263-1
Equipment, etc.
Note
Removal, gearbox
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force
is used!
The gear box weighs 200 kg! All lifting equipment used must be dimensioned accordingly!
The base (without gearbox 1) weighs 310 kg! All lifting equipment used must be dimensioned
accordingly!
Step
3HAC 16263-1
Action
Note/Illustration
1.
Remove motor 1.
2.
3.
4.
5.
6.
7.
8.
9.
127
Step
Action
Note/Illustration
10.
11.
Lift the manipulator base to allow fitting the Art. no. specified in Required equipSupport, base on each sides of the base. ment on page 126!
12.
13.
14.
A
B
xx0100000134
128
15.
16.
17.
A: Washers, 3 pcs
B: Gearbox 1 attachment
screws, 18 pcs
3HAC 16263-1
Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure below.
A more detailed view of the component and its position may be found in the Foldout section
Base incl. Frame on page 211!
D
B
C
A
E
xx0100000133
Gearbox, axis 1
Frame
Base
Required equipment
3HAC 16263-1
Equipment, etc.
Note
Gearbox, axis 1
3HAC 10828-1
O-ring
3HAB 3772-54
O-ring
3HAB 3772-55
Sealing ring
3HAC 11581-4
Grease
3HAC 3537-1
129
Equipment, etc.
Note
Standard toolkit
3HAC 15571-1
Support, base
3HAC 15535-1
3HAC 15560-1
3HAC 15556-1
Refitting, gearbox
The gear box weighs 200 kg! All lifting equipment used must be dimensioned accordingly!
The base (without gearbox 1) weighs 310 kg! All lifting equipment used must be dimensioned
accordingly!
Step
1.
130
Action
Note/Illustration
3HAC 16263-1
Step
2.
Action
Note/Illustration
Make sure the two o-rings on the circumfer- Art no. specified in Required equipence of the gearbox are seated properly in ment on page 129!
their grooves respectively. Lightly lubricate
the o-rings with grease .
Make sure the small o-ring around the oil
hole is fitted properly!
A
D
C
xx0200000055
A: Guide pin
3.
4.
5.
6.
7.
Secure the gearbox and the three washers 18 pcs, M16x90; 12.9 quality
with the 18 attachment screws, base to gear- UNBRAKO, tightening torque: 300
box .
Nm.
Reused screws may be used, providing they are lubricated as detailed in
Screw joints on page 15 before fitting.
A
B
xx0100000134
8.
3HAC 16263-1
A: Washers, 3 pcs
131
Step
Action
Note/Illustration
9.
10.
11.
12.
13.
14.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- 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.
132
3HAC 16263-1
Location of gearbox
The axis 2 gearbox is located in the lower arm rotational center as shown in the figure below.
A more detailed view of the component and its position may be found in the Foldout section
Frame-Lower arm 1 on page 213!
F
I
E
C
(A)
B
D
xx0100000135
Motor, axis 2
Motor attachment
Required equipment
Equipment, etc.
3HAC 16263-1
Note
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page
18!
3HAC 12731-1
3HAC 13660-1
133
Equipment, etc.
M16 x 60 8.8.
Included in the fixture, lower
arm.
Removal, gearbox
Note
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The gearbox weighs 125 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
2.
C
xx0200000260
3.
134
If the manipulator is fitted with moveable mechanical stops on axis 2 (not stock equipment), these
must be removed at this point.
The attachment holes of the mechanical stops are
used to attach the fixture, lower arm.
3HAC 16263-1
Step
Action
Note/Illustration
4.
Secure the lower arm to the frame by inserting the Art. no. specified in Required
locking screw into the hole.
equipment on page 133!
Shown in the figure Location of
gearbox on page 133!
5.
B D
C
xx0200000261
6.
Unload the balancing device shaft by using a spe- Detailed in Unloading the balcific press tool.
ancing device on page 88.
7.
8.
9.
A
xx0300000064
10. Remove the motor attachment by unscrewing the Shown in the figure Location of
front gearbox attachment screws.
gearbox on page 133!
11.
3HAC 16263-1
135
Step
Action
Note/Illustration
12.
Fit the Lifting tool, gearbox axis 2 , to the gearbox. Art. no. is specified in Required
equipment on page 133!
13.
14.
If required, apply an M16 screw to the hole shown Art. no. is specified in Required
in the figure to press it free.
equipment on page 133!
A
xx0200000033
136
15.
16.
3HAC 16263-1
Location of gearbox
The axis 2 gearbox is located in the lower arm rotational center as shown in the figure below.
A more detailed view of the component and its position may be found in the Foldout section
Frame-Lower arm 1 on page 213!
F
I
E
C
(A)
B
D
xx0100000135
Motor, axis 2
Motor attachment
Sealing (between gear box and lower arm not shown in figure )
Required equipment
3HAC 16263-1
Equipment, etc.
Note
Gearbox, axis 2
3HAC 12641-1
O-ring
3HAB 3772-51
Lubricating oil
3HAC 0860-1
Amount: 4450 ml
137
Equipment, etc.
Grease
3HAB 3537-1
Standard toolkit
3HAC 12731-1
Refitting, gearbox
Note
The gearbox weighs 125 kg! All lifting equipment used must be dimensioned accordingly!
138
3HAC 16263-1
Step
1.
Action
Note/Illustration
xx0200000125
3.
4.
Fit the Lifting tool, gearbox axis 2 , to the gear- Art. no. is specified in Required
box.
equipment on page 137!
5.
Make sure the o-ring is fitted to the rear of the Art. no. is specified in Required
gearbox. Lightly grease the o-ring.
equipment on page 137!
xx0100000136
3HAC 16263-1
6.
7.
Fit the gearbox onto the guide pins and slide Make sure the gearbox is seated
it into position.
properly!
8.
139
Step
9.
Action
Note/Illustration
A
xx0300000064
17. Restore the balancing device by removing the Detailed in Restoring the balancing
balancing device tools.
device on page 90.
18. Remove the fixture, lower arm.
19. Remove the locking screw, lower arm.
20. Refit any mechanical stops if such were
removed during disassembly.
21. Refit any equipment to the turning disc if such
was removed during assembly.
22. Recalibrate the robot.
140
3HAC 16263-1
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- 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 16263-1
141
Location of gearbox
The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.
A more detailed view of the component and its position may be found in the Foldout section
Upper arm on page 217!
A
H
C
F
E
G
D
xx0100000137
Gearbox, axis 3
Motor, axis 3
Required equipment
Equipment, etc.
Standard toolkit
142
3HAC 15571-1
Note
The contents are defined in
section Standard toolkit on
page 18!
3HAC 16263-1
Equipment, etc.
Note
3HAC 14457-4
3HAC 12708-2
3HAA 1001-186
Removal, gearbox
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force
is used!
The gearbox weighs 125 kg! All lifting equipment used must be dimensioned accordingly!
Step
1.
Action
Note/Illustration
B
A
xx0300000051
3HAC 16263-1
2.
3.
143
Step
Action
Note/Illustration
4.
Remove the Sealing, axis 2/3 between gear- On reassembly a new sealing must
box and lower arm.
be used!
Art. no. is specified in Required
equipment on page 146, in the refitting instruction!
5.
6.
7.
A
xx0200000033
144
8.
9.
3HAC 16263-1
Location of gearbox
The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.
A more detailed view of the component and its position may be found in the Foldout section
Upper arm on page 217!
A
H
C
F
E
G
D
xx0100000137
3HAC 16263-1
Gearbox, axis 3
Motor, axis 3
145
Required equipment
Equipment, etc.
Note
Gearbox, axis 3
3HAC 12641-1
O-ring
3HAB 3772-51
Grease
3HAB 3537-1
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!
3HAC 14457-4
Refitting, gearbox
The gearbox weighs 125 kg! All lifting equipment used must be dimensioned accordingly!
Step
146
Action
Note/Illustration
1.
2.
Fit two guide pins 180in relation to each Art. no. is specified in Required equipother in the attachment holes of gearbox 3. ment on page 146!
3HAC 16263-1
Step
Action
Note/Illustration
3.
4.
Make sure the o-ring is fitted to the rear of Art. no. is specified in Required equipthe gearbox. Apply grease to the o-ring to ment on page 146!
make sure it sticks in its groove during
A
assembly.
xx0100000136
5.
6.
7.
8.
9.
10. Refit the upper arm with a new sealing, axis Detailed in section Refitting of com2/3 .
plete upper arm on page 52.
Art. no. specified in Required equipment on page 146!
11. Refit the motor.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- 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 16263-1
147
Location of gearbox
The axis 4 gearbox is located at the rear of the upper arm as shown in the figure below.
A more detailed view of the component and its position may be found in the Foldout section
Upper arm on page 217!
K
J
A
B
C
E
F
G
H
xx0100000144
148
Gearbox, axis 4
Gear, Z3
Motor, axis 4
Motor flange
3HAC 16263-1
Required equipment
Equipment, etc.
Standard toolkit
Note
3HAC 15571-1
Removal, gearbox
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force
is used!
Step
3HAC 16263-1
Action
Note/Illustration
1.
Drain the gearbox oil from the primary gearbox Detailed in "Oil change, gearbox
through the oil plug, draining.
axis 4" in the Maintenance Manual .
2.
Drain the gearbox oil from the secondary gear- Detailed in "Oil change, gearbox
box through the oil plug, draining.
axis 4" in the Maintenance Manual .
3.
4.
Remove the cover, axis 4 gearbox by unscrew- Shown in the figure Location of
ing its attachment screws.
gearbox on page 148!
5.
Loosen the gear attachment screws but do not Shown in the figure Location of
remove the gear Z3.
gearbox on page 148!
6.
7.
Remove gear Z3 from the gearbox by unscrew- Shown in the figure Location of
ing the 15 gear attachment screws .
gearbox on page 148!
If required, insert screws into three holes in gear
Z3 to press it out.
8.
9.
M10.
149
Location of gearbox
The axis 4 gearbox is located at the rear of the upper arm as shown in the figure below.
A more detailed view of the component and its position may be found in the Foldout section
Upper arm on page 217!
K
J
A
B
C
E
F
G
H
xx0100000144
150
Gearbox, axis 4
Gear, Z3
Motor, axis 4
Motor flange
3HAC 16263-1
Required equipment
Equipment, etc
Note
Gearbox, axis 4
3HAC 11384-3
Gear, Z3
3HAC 11488-1
O-ring
O-ring
Friction washer
3HAC 10122-27
3HAC 11423-3
Grease
3HAB 3537-1
Standard toolkit
Refitting, gearbox
Step
3HAC 16263-1
Action
Note/Illustration
1.
Make sure the two o-rings on the cirArt no. is specified in Required equipment
cumference of the gearbox are seated on page 151!
properly in their grooves respectively.
Lightly lubricate the o-rings with grease.
2.
Lubricate the gearbox, motor and motor Art no. is specified in Required equipment
attachment mating surfaces with
on page 151!
grease.
151
Step
3.
Action
Note/Illustration
xx0200000067
152
4.
5.
6.
7.
8.
9.
10.
3HAC 16263-1
Step
11.
Action
Note/Illustration
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- 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 16263-1
153
Location of gearbox
The axis 5 gearbox is located in the wrist unit as shown in the figure below.
A more detailed view of the component and its position may be found in the Foldout section
Wrist complete on page 219!
A N
H
G
xx0100000146
154
Wrist housing
Gear, Z3
Wheel unit
Gearbox, axis 5
Oil plug, primary, filling (draining plug on the opposite side of the wrist housing, not
shown in figure)
VK-cover
3HAC 16263-1
Required equipment
Equipment, etc.
Note
Standard toolkit
Removal, gearbox
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Step
3HAC 16263-1
Action
Note/Illustration
1.
2.
3.
4.
5.
6.
7.
Remove the gearbox, axis 5 , by unscrew- Shown in the figure Location of gearing its attachment screws and removing the box on page 154!
washers .
18 pcs: M10 x 40.
8.
Apply two lifting eyes to the gearbox, axis Art. no. is specified in Required equip5, in opposite positions.
ment on page 155!
9.
155
Step
10.
Removal, wheel
unit
Action
Note/Illustration
The procedure below details how to remove the wheel unit. Also see the figure above!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Step
Action
Note/Illustration
1.
2.
3.
Make a short cut in the centre of the VKcover and remove it from the wheel unit by
bending.
4.
Shown in the figure Location of gearbox on page 154 and in the figure
below!
7 pcs: M6 x 16.
5.
xx0200000068
156
A: Gear Z4
C: VK-cover
6.
Apply removal tool to the center hole of gear Art. no. is specified in Required
Z4 to press the wheel unit free.
equipment on page 155!
7.
3HAC 16263-1
Location of gearbox
The axis 5 gearbox is located in the wrist unit as shown in the figure below:
A more detailed view of the component and its position may be found in the Foldout section
Wrist complete on page 219!
A N
H
G
xx0100000146
3HAC 16263-1
Wrist housing
Gear, Z3
Wheel unit
Gearbox, axis 5
Oil plug, primary, filling (draining plug on the opposite side of the wrist housing, not
shown in figure)
VK-cover
157
Required equipment
Equipment, etc.
Note
Gearbox, axis 5
3HAC 11384-3
O-ring
O-ring
Friction washer
3HAC 10122-27
Gear, Z3
3HAC 11488-1
VK-cover, 170 x 15
Gasket, cover
3HAC 11409-5
Grease
3HAC 3537-1
Locking liquid
3HAB 7116-1
LocTite 243
Isopropanol
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!
Refitting, gearbox
Step
1.
158
Action
Note/Illustration
Make sure the two o-rings on the cirArt. no. specified in Required equipment
cumference of the gearbox are seated on page 158!
properly in their grooves respectively.
Lightly lubricate the o-rings with grease .
3HAC 16263-1
Step
3HAC 16263-1
Action
Note/Illustration
2.
3.
4.
5.
6.
7.
Secure the gearbox with its attachment Shown in the figure Location of gearbox
screws and washers.
on page 157!
18 pcs: M10 x 40: tightening torque: 65
Nm.
Reused screws may be used, providing
they are lubricated as detailed in Screw
joints on page 15 before fitting.
8.
Refit gear Z3 to the gearbox, axis 5 with Shown in the figure Location of gearbox
its attachment screws.
on page 157!
9 pcs: M12 x 50; 12.9 quality UNBRAKO,
tightening torque: 115 Nm.
6 pcs: M16 x 60: tightening torque: 300
Nm.
Reused screws may be used, providing
they are lubricated as detailed in Screw
joints on page 15 before fitting.
9.
10.
11.
12.
13.
14.
15.
16.
159
Refitting, wheel
unit
The procedure below details how to refit the wheel unit. Also see the figure Location of
gearbox on page 157!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Step
Action
Note/Illustration
1.
2.
3.
4.
5.
6.
xx0200000068
A: Gear Z4
C: VK-cover
160
Clean the surface beneath the VK-cover with Art. no. specified in Required equipisopropanol.
ment on page 158!
3HAC 16263-1
Step
Action
Note/Illustration
8.
9.
Refit the cover, axis 5 gearbox with its attach- Shown in the figure Location of
ment screws and secure with locking liquid. gearbox on page 157!
14 pcs; tightening torque: 10 Nm.
Reused screws may be used, providing they are lubricated as
detailed in Screw joints on page 15
before fitting.
Art. no. specified in Required equipment on page 158!
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- 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 16263-1
161
Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.
A more detailed view of the component and its position may be found in the Foldout section
Wrist complete on page 219!
E
C
B
D
xx0100000131
Gearbox, axis 6
Washers
Required equipment
Equipment, etc.
Standard toolkit
162
Note
3HAC 16263-1
Removal, gearbox
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force
is used!
Step
Action
Note/Illustration
1.
2.
3.
Remove the gearbox by unscrewing its 18 Shown in the figure Location of gearattachment screws and both washers.
box on page 162!
4.
A
xx0200000032
3HAC 16263-1
163
Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.
A more detailed view of the component and its position may be found in the Foldout section
Wrist complete on page 219!
E
C
B
D
xx0100000131
Gearbox, axis 6
Washers
Required equipment
164
Equipment, etc.
Note
Gearbox, axis 6
3HAC 10122-22
Washers
O-ring
3HAB 3772-49
Grease
3HAB 3537-1
Standard toolkit
3HAC 15571-1
3HAC 16263-1
Equipment, etc.
Note
Refitting, gearbox
Step
1.
Action
Note/Illustration
Make sure the o-ring is fitted to the rear of Art. no. specified in Required equipthe gearbox. Lightly lubricate the o-ring
ment on page 164!
with grease.
xx0100000132
3HAC 16263-1
2.
3.
4.
165
Step
Action
Note/Illustration
5.
6.
7.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- 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.
166
3HAC 16263-1
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 16263-1
Remaining instructions
167
X1
X1
X1
X1
X2
X2
X2
X2
X1
X2
X3
Rectifier
A0
xx0200000103
Battery unit
Required equipment
Equipment, etc.
Note
Battery unit
3HAC 5393-2
To be replaced as a complete
unit
Standard toolkit
Removal, battery
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.
168
3HAC 16263-1
Step Action
Note/Illustration
X1
X1
X2
X2
X1
X1
X2
X2
X2
X3
Rectifier
A0
xx0200000004
xx0200000005
Refitting, battery
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.
Step Action
3HAC 16263-1
Note/Illustration
169
Location of I/O
and gateway units
The I/O and gateway units are located as shown in the figure below.
I/O-4
I/O-3
I/O-1
I/O-2
xx0200000009
I/O and gateway units located on the panel shutter on the left side of the cabinet.
Required equipment
Equipment, etc.
170
Note
3HAB 7229-1
DSQC 328
Analog I/O
3HNE 00554-1
DSQC 355
AD Combi I/O
3HAB 7230-1
DSQC 327
3HAB 7231-1
DSQC 320
3HAB 9669-1
DSQC 332
3HNE00025-1
DSQC 350
3HNE00006-1
DSQC 351
3HNE00009-1
DSQC 352
Standard toolkit
3HAC 15571-1
3HAC 16263-1
Removal
Step Action
Note/Illustration
1. Disconnect any connectors from the unit. The actual number of connectors vary
Note which connector goes where, to facil- depending on type of unit.
itate reassembly.
2. Lift the unit until the upper claw, that holds
the unit to the rail, is released. Use:
a screwdriver when replacing I/O
units (position 2a in the figure).
2a
3a
2b
3b
xx0200000010
Refitting
Step Action
Note/Illustration
1. Hook the unit back onto the mounting rail and snap it gently
in position.
2. Reconnect all connectors disconnected during removal.
3HAC 16263-1
171
Location of
bleeder resistor
The bleeder resistor is located behind the air outlet device, as shown in the figure below.
xx0200000007
Required equipment
Removal
Equipment, etc.
Bleeder resistor
3HAC 4560-5
Note
Step Action
Note/Illustration
172
3HAC 16263-1
Step Action
Note/Illustration
xx0200000015
3. Push down and pull out the bleeder resistor unit to release the bleeder resistor unit
from the enclosure. (see position 2 and 3
in the figure).
Refitting
Step Action
Note/Illustration
3HAC 16263-1
173
X1
X1
X1
X1
X2
X2
X2
X2
X1
X2
X3
Rectifier
A0
xx0200000105
Opening
Computer unit
Step Action
Note/Illustration
174
3HAC 16263-1
xx0200000018
3HAC 16263-1
175
Closing
Step Action
Note/Illustration
176
3HAC 16263-1
Location of mass
storage memory
The mass storage memory is located in the computer system, which is shown in the figure
below.
X1
X1
X1
X1
X2
X2
X2
X2
X1
X2
X3
Rectifier
A0
xx0200000105
Computer system
Required equipment
Equipment, etc.
3HAC 7519-2
Note
Removal
These procedures
include references to
the tools required.
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 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.
Step Action
Note/Illustration
3HAC 16263-1
177
Step Action
Note/Illustration
2. Open the cover on the right side of the computer system by unsnapping the two snaps
(item 1 in the figure).
xx0200000019
Refitting
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 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.
Step Action
Note/Illustration
1. Fit the mass storage memory in position and Art. no. is specified above!
secure it with its M4 attachment screw (item
1 in the figure)
1
xx0200000019
178
3HAC 16263-1
Step Action
Note/Illustration
3. Close the cover on the right side of the computer unit and secure it with the snaps (item
1 in the figure).
3HAC 16263-1
179
The internal cooling fan is located in the computer system, which is shown in the figure
below.
X1
X1
X1
X1
X2
X2
X2
X2
X1
X2
X3
A0
xx0200000105
Computer system
Required equipment
Equipment, etc.
Note
3HAC 6655-1
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 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.
Step Action
Note/Illustration
180
3HAC 16263-1
Step Action
Note/Illustration
E
xx0200000020
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 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.
3HAC 16263-1
181
Step Action
Note/Illustration
1. Tip the internal cooling fan with its top towards the cabinet wall and fit it into the hole (see the figure). Art. no.
specified above!
xx0200000021
A: Push direction
2. With the wall between the upper lock spring hooks, push See the figure above!
the fan unit up and in until the locking tab snaps to the
wall.
3. Reconnect the connector E5 or E6 respectively, depending on which fan was replaced.
4. Put the computer unit back in regular operation position. Detailed in "Putting the
computer in the service
position".
182
3HAC 16263-1
Location of drive
units and rectifier
The drive units and rectifier are located as shown in the figure below.
B
A
xx0200000007
Drive units
Required equipment
Equipment, etc.
Note
3HAB 8101-17
DSQC 545A
3HAB 8101-18
DSQC 546A
Removal
3HAC 16263-1
183
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.
Step Action
Note/Illustration
X1
X1
X1
X1
X2
X2
X2
X2
1
X1
2
X2
X3
X2
A0
Rectifier
xx0200000013
xx0200000014
Refitting
184
3HAC 16263-1
Step Action
Note/Illustration
1. Fit the unit into position and secure it with the spring.
3HAC 16263-1
Detailed in section
"Replacement of power
supply unit"
185
The system fan unit is located under the bleeder resistor unit, in the back of the controller as
shown in the figure below.
xx0200000007
Required equipment
Equipment, etc.
3HAC 15449-1
Removal
Note
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 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.
Step Action
186
Note/Illustration
Detailed in
"Replacement of bleeder resistor".
3HAC 16263-1
Step Action
Note/Illustration
A0
Rectifier
xx0200000008
Refitting
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 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.
Step Action
Note/Illustration
1. Fit the system fan unit into position and secure it (see
position 2 in the figure above).
3HAC 16263-1
Detailed in section
"Replacement of bleeder
resistor".
187
Location of power
supply unit
xx0200000011
Required equipment
Equipment, etc.
Note
3HAB 4297-1
DSQC 506
Removal
These procedures
include references to
the tools required.
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 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.
Step Action
Note/Illustration
1. Push the locking spring to the right to free the panel Shown in previous figure!
shutter, and Swing it out of the way.
188
3HAC 16263-1
Step Action
Note/Illustration
Refitting
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 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.
Step Action
Note/Illustration
1. Fit the power supply unit into position onto its hooks and Art. no. is specified above!
secure it with the attachment screw (see position 2 in the
section Removal).
2. Reconnect all connectors disconnected during removal. See position 1 in figure.
3. Swing the panel shutter back in possition and secure it
with the locking spring.
3HAC 16263-1
189
Location of power
supply unit
The Peltier cooler power supply unit is located as shown in the figure below.
1
2
Cover
M5 screw
Required equipment
Equipment, etc.
3HAB 13398-1
Removal
Note
These procedures include
references to the tools
required.
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.
Step Action
Note/Illustration
190
3HAC 16263-1
Step Action
Note/Illustration
Refitting
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.
Step Action
Note/Illustration
3HAC 16263-1
191
192
3HAC 16263-1
Definitions
This chapter is an appendix to the manual and contains part lists for the manipulator and
controller. The item numbers refers to Appendix 2: Foldouts.
The part list for the manipulator sometimes differ between robot version 500/2.3, and robot
versions 400/2.55 and 150/3.5.
3HAC 16263-1
193
Item Qty
Art. number
Description
Note
3HAC 12812-2
See
101
3HAC 12304-1
102
3HAC 13063-1
102
3HAC 13063-2
102
3HAC 13063-4
102
3HAC 13063-5
103
3HAC 10503-1
Wrist
103
3HAC 15992-1
Wrist Foundry
104
3HAC 14675-1
Balancing Device
105
3HAC 10523-1
Lower arm
106
3HAC 14940-1
108
3HAC 13079-1
109
3HAC 13077-1
110
3HAC 13082-1
111
3HAC 12311-1
112
3HAC 12129-1
Cover plate
112
3HAC 12129-1
Cover plate
113
9ADA 618-56
113
9ADA 618-56
114
3HAC 13416-1
Protection cover
M6x16
194
Item Qty
Art. number
Description
5.1
3HAC 12812-1
Mechanical stop
5.2
9ABA 142-92
Dimension
10x30
3HAC 16263-1
Item Qty
Art. number
Description
Note/Dimension
101.1 1
3HAC 10044-1
Base, machining
101.2 1
3HAC 12303-1
101.3 3
3HAC 11732-1
Washer
T=3
101.4 18
3HAB 7700-89
M16x90
101.5 1
3HAC 11529-1
101.6 1
3HAC 14453-1
101.7 1
3HAC 14453-2
Plug
101.8 1
3HAC 4428-2
Hose Clip
101.9 1
9ADA 618-56
M6x16
Base, machining,
3HAC 10044-1
Item
Frame incl ax 1
gearbox, 3HAC
12303-1
Art. number
Description
101.1.1 1
3HAC 10044-2
Base, casting
101.1.2 5
3HAC 4836-7
Protection plug
101.1.3 1
3HAC 1383-2
101.1.4 1
3HAC 14024-1
Protection screw
Item
Qty
Description
Note
Note
101.2.1 1
3HAC 15865-1
Frame machining
101.2.2 1
3HAC 10828-1
RV 500C-219,95 assembly
101.2.3 24
3HAB 7700-77
M12x110
101.2.4 24
3HAA 1001-134
Washer
13x19x1,5
3HAC 16263-1
Item Qty
Art. number
Description
Note
102.1 1
3HAC 13076-1
Material set ax 4
102.2 1
3HAC 10509-1
195
102.3 1
3HAC 13062-1
Axis 3
Item Qty
Art. number
Description
Note
102.1 1
3HAC 13076-1
Material set ax 4
102.2 1
3HAC 10509-5
102.3 1
3HAC 13062-1
Axis 3
Item Qty
Art. number
Description
Note
102.1 1
3HAC 13076-1
Material set ax 4
102.2 1
3HAC 15932-1
102.3 1
3HAC 13062-1
Axis 3
Item Qty
Art. number
Description
Note
102.1 1
3HAC 13076-1
Material set ax 4
102.2 1
3HAC 15932-2
102.3 1
3HAC 13062-1
Axis 3
Material set ax 4,
3HAC 13076-1
196
Item
Qty
Art. number
Description
102.1.1
3HAC 11523-1
Gear Z4 / 4
102.1.2
3HAC 14725-1
102.1.3
3HAB 3409-50
M10x40
102.1.4
3HAB 4233-1
Washer
102.1.5
3HAC 11499-1
Note/Dimension
3HAC 16263-1
3HAC 16263-1
102.1.6
18
3HAB 3409-60
102.1.7
T=3
102.1.8
3HAC 12642-1
102.1.9
3HAC 12640-1
102.1.10 10
3HAC 11409-6
Shoulder Screw
M6x8x8
102.1.12 2
3HAC 13564-1
Damper axis 4
102.1.13 2
3HAA 1001-17
102.1.14 2
3HAC 11925-1
102.1.15 4
3HAB 3409-81
M16x35
102.1.16 2
3HAA 1001-98
Gasket
T=1
102.1.17 8
9ADA 183-37
M8x25
102.1.18 8
9ADA 312-7
Plain washer
8,4x16x1,6
102.1.19 2
3HAA 2103-21
170x230x38
102.1.20 1
2216 261-18
Sealing
170x200x15
102.1.21 1
3HAB 3772-27
O-ring
170x5
102.1.22 1
3HAC 3774-7
Spacer ring
102.1.23 1
3HAC 11461-1
Sealing
102.1.24 1
3HAC 12060-1
Thrust washer
102.1.25 1
9ABA 135-45
102.1.26 1
3HAC 11928-1
102.1.27 1
3HAC 12126-1
Set of shims
102.1.28 2
2522 122-1
Magnetic plug
R1/4"
102.1.29 2
3HAC 16721-1
Magnetic plug
R1/2"
102.1.30 900 ml
3HAC 16843-1
Lubricating oil
102.1.32 1
9ABA 107-56
Parallel pin
102.1.33 2
102.1.34 1 ml
3HAB 7116-1
Locking liquid
102.1.35 30 g
3HAB 3537-1
Bearing grease
Item
Description
102.1.2.1 1
3HAC 14673-2
102.1.2.2 1
102.1.2.3 0
2152 2012-430
M10x80
170
10x20
T=0,5
Dimension
Rotational ac motor M2
O-ring
89,5x3
197
RV 125F incl.
gear, 3HAC
12642-1
RV 125F-97,909
assembly, 3HAC
11384-3
Cover ax 4 incl.
sealing, 3HAC
12640-1
Item
Description
Note/Dimension
102.1.8.1 1
3HAC 11384-3
102.1.8.2 1
3HAC 11488-1
Gear Z3 / 4, 5
102.1.8.3 9
3HAB 7700-69
102.1.8.4 6
3HAB 3409-86
Item
Description
Dimension
102.1.8.1.1 1
3HAC 11384-1
RV 125F, i=97,909
102.1.8.1.2 1
3HAB 3772-50
O-ring
196,52x2,62
102.1.8.1.3 1
3HAB 3772-49
O-ring
189,3x3,1
Item
Description
Note
See Cover axis 4, 3HAC 114234 on page 198!
102.1.9.1 1
3HAC 11423-4
Cover axis 4
102.1.9.2 1
3HAA 1001-628
Sealing
Cover axis 4,
3HAC 11423-4
Item
Description
Note
102.1.9.1.1 1
3HAC 11423-1
102.1.9.1.2 1
3HAC 11423-3
Qty
Art. number
Description
102.2.1 1
102.2.2 1
3HAC 1383-2
Item
Art. number
Description
Note
198
Qty
102.2.1 1
102.2.2 1
3HAC 1383-2
Note
3HAC 16263-1
Axis 3, 3HAC
13062-1
Item
Qty
Art. number
Description
102.3.1
3HAC 10502-3
102.3.2
3HAC 12641-1
102.3.3
20
3HAB 7700-89
102.3.4
20
3HAC 10264-1
Washer
102.3.5
3HAC 14724-1
102.3.6
3HAB 3409-50
102.3.7
3HAB 4233-1
Washer
102.3.8
3HAC 11719-1
Plug
R1/4
102.3.8
3HAC 16721-1
Magnetic plug
R1/2
102.3.9
102.3.10 1
RV 700F incl.
gear, 3HAC
12641-1
RV 700F-269,21
assembly, 3HAC
17272-1
Item
Note
See RV 700F-269,21 assembly,
3HAC 17272-1 on page 199!
RV 700F-269,21
assembly
102.3.2.2 1
3HAC 11636-1
Gear Z2 /2.3
Art. number
Description
102.3.2.1.1 1
3HAC 10122-21
RV 700F, i=269,21
102.3.2.1.2 1
3HAB 3772-51
O-ring
Item
Qty
10x30
Description
3HAC 17272-1
Qty
17x30x3
102.3.2.1 1
Item
9ABA 142-92
Note/Dimension
Art. number
Description
102.3.5.1 1
3HAC 14673-1
Rotational ac motor M1
102.3.5.2 1
3HAC 11632-1
Pinion Z1 /2.3
102.3.5.3 0
2152 2012-430
O-ring
Dimension
369,3x5,7
Dimension
89,5x3
Item
3HAC 16263-1
Qty
Art. number
Description
Note/Dimension
199
200
103.1
3HAC 11409-7
Cover, right
103.2
14
3HAC 11409-6
Shoulder Screw
M6x8x8
103.5
3HAC 16721-1
Magnetic plug
R1/2
103.6
3HAC 12642-1
103.7
18
3HAB 3409-50
M10x40
103.8
3HAC 10122-12
T=3
103.9
3HAC 10503-3
103.10 2
2522 122-1
Magnetic plug
103.11 4
9ADA 183-35
103.12 2
3HAC 10503-8
Damper ax 5
103.13 2
3HAC 10122-27
Friction washer
103.14 4
3HAB 3409-50
103.15 4
3HAB 4233-1
Washer
103.16 1
3HAC 14725-1
103.18 1
3HAC 11409-3
103.19 4
9ADA 618-56
M6x16
103.21 7
3HAB 3409-50
M10x40
103.22 7
3HAB 4233-1
Washer
103.24 1
3HAC 10503-14
103.25 1
3HAC 9953-1
103.26 2
9ADA 618-56
M6x16
103.28 1
3HAC 12707-1
Axis 6 complete
103.28 1
3HAC 12707-2
103.31 1
3HAA 2166-24
VK-Cover
103.32 21
3HAB 7700-89
M16x90
103.33 1
3HAC 10503-13
Wheel Unit
103.34 1
3HAA 1001-628
Sealing
103.35 7
9ADA 624-56
103.37 1
3HAB 7116-1
Locking liquid
103.38 1
3HAC 11440-5
103.39 3
2166 2055-3
103.40 1
3HAC 11440-1
Lubricating oil
103.42 750 ml
3HAC 0860-1
Lubricating oil
103.43 1
3HAC 5984-1
Label
103.43 1
3HAC 17260-1
Sprbarhetsetikett
R1/4"
M10x40
See Rot ac motor incl
pinion, 3HAC 14725-1
on page 201!
M6x16
3HAC 16263-1
103.43 1
3HAC 17260-2
Sprbarhetsetikett Wrist,
Foundry
Cover, right,
3HAC 11409-7
Item
RV 125F incl.
gear, 3HAC
12642-1
RV 125F-97,909
assembly, 3HAC
17273-1
3HAC 16263-1
Art. number
Description
103.1.1 1
3HAC 11409-1
103.1.2 1
3HAC 11409-5
Gasket, right
Item
Art. number
Description
Note/Dimension
103.6.1 1
3HAC 17273-1
RV 125F-97,909 assembly
See RV 125F-97,909
assembly, 3HAC 17273-1
on page 201!
103.6.2 1
3HAC 11488-1
Gear Z3 / 4, 5
103.6.3 9
3HAB 7700-69
103.6.4 6
3HAB 3409-86
Item
Qty
Qty
Qty
Note
Art. number
Description
103.6.1.1 1
3HAC 11384-1
RV 125F, i=97,909
103.6.1.2 1
3HAB 3772-50
O-ring
196,52x2,62
103.6.1.3 1
3HAB 3772-49
O-ring
189,3x3,1
Item
Art. number
Description
Dimension
103.16.1 1
3HAC 14673-2
Rotational ac motor M2
103.16.2 1
3HAC 10122-17
Pinion RV 125F-97,909
103.16
2152 2012-430
O-ring
Item
Qty
Qty
Dimension
89,5x3
Dimension
103.24.1 1
103.24.2 1
130x200x33
103.24.3 3
9ADA 618-56
M6x16
103.24.4 1 ml
3HAB 7116-1
Locking liquid
201
Axis 6 complete,
3HAC 12707-1
Axis 6 complete
Foundry, 3HAC
12707-2
Item
Qty
Art. number
Description
103.28.1
3HAC 10436-1
103.28.2
3HAC 17274-1
RV 125F-178,41 assembly
See RV 125F-178,41
assembly, 3HAC 172741 on page 203!
103.28.3
3HAC 10122-13
Washer, RV 125 F
T=3
103.28.4
18
3HAB 7700-8
M10x50
103.28.5
3HAC 13193-1
103.28.6
33
3HAB 7700-3
M10x25
103.28.7
2522 122-1
Magnetic plug
R1/4"
103.28.8
3HAC 11471-1
Sync. Plate
103.28.9
2152 2012-433
O-ring
104,5x3
103.28.10 2
9ADA 618-32
M4x8
103.28.11 6 ml
3HAB 7116-1
Locking liquid
103.28.13 1
3HAC 14726-1
103.28.14 4
9ADA 312-7
Plain washer
8,4x16x1,6
103.28.15 4
9ADA 183-37
M8x25
103.28.16 1
3HAC 14263-1
Protection cover
103.28.17 1
9ADA 624-69
Item
Qty
Art. number
Description
103.28.1
3HAC 16010-1
103.28.2
3HAC 17274-1
RV 125F-178,41 assembly
See RV 125F-178,41
assembly, 3HAC 172741 on page 203!
103.28.3
3HAC 10122-13
Washer, RV 125 F
T=3
103.28.4
18
3HAB 7700-8
M10x50
103.28.5
3HAC 13193-1
103.28.6
33
3HAB 7700-3
M10x25
103.28.7
2522 122-1
Magnetic plug
R1/4"
103.28.8
3HAC 11471-1
Sync. Plate
103.28.9
2152 2012-433
O-ring
104,5x3
103.28.10 2
9ADA 618-32
M4x8
103.28.11 6 ml
3HAB 7116-1
Locking liquid
202
Note/Dimension
Note
3HAC 16263-1
RV 125F-178,41
assembly, 3HAC
17274-1
103.28.13 1
3HAC 14726-1
103.28.14 4
9ADA 312-7
Plain washer
8,4x16x1,6
103.28.15 4
9ADA 183-37
M8x25
103.28.16 1
3HAC 14263-1
Protection cover
103.28.17 1
9ADA 624-69
Item
Art. number
Description
103.28.2.1 1
3HAC 10122-1
RV 125F, i=178,41
103.28.2.2 1
3HAB 3772-49
O-ring
Qty
Item
Qty
Art. number
Description
103.28.13.1 1
3HAC 14673-3
Rotational ac motor M3
103.28.13.2 1
3HAC 10122-19
Pinion RV 125F-178,41
103.28.13.3 0
2152 2012-430
O-ring
103.28.13.4 1
3HAC 12877-1
Gasket
Dimension
189,3x3,1
Dimension
89,5x3
Item
Qty
Art. number
Description
103.33.1 1
3HAC 11524-1
Gear Z4 / 5
103.33.2 1
3HAC 10503-12
Bearing Washer
103.33.3 1
3HAB 3710-19
103.33.4 1
3HAC 10503-15
Support Ring
103.33.5 1 ml
3HAB 7116-2
Locking liquid
Dimension
160x220x28
Item
3HAC 16263-1
Qty
Art. number
Description
108.201 2
3HAC 17213-1
108.202 60
3HAB 3409-84
108.203 3
3HAC 11828-1
Washer axis 3
Note/Dimension
M16x50
203
108.204 30
17x25x3
108.205 1
3HAC 11755-1
Friction Washer
108.206 20
3HAB 7700-69
108.207 20
108.210 1
3HAC 14300-1
Cable protector
108.212 1
3HAC 11771-1
108.213 1
3HAC 13960-1
108.214 2
3HAC 11750-1
Damper axis 3
108.215 2
3HAC 12990-1
Damper axis 2
108.216 2
9ADA 624-65
M6x60
108.217 2
9ADA 334-7
8,4x18x2
108.218 2
9ADA 618-57
M6x20
108.220 2
3HAC 9953-1
108.222 1
3HAC 14658-1
108.223 2
9ADA 183-48
M10x16
108.225 13
9ADA 618-56
M6x16
108.228 1
3HAC 3261-1
Cover upperarmcovers
108.229 1
3HAC 15431-1
Cable protection
108.230 1
3HAC 14880-1
108.231 1
2166 2055-3
108.232 5
3HAC 16721-1
Magnetic plug
R1/2
108.233 1
2522 122-1
Magnetic plug
R1/4"
M12x50
13x19x1,5
Item
204
Qty
Art. number
Description
Note/Dimension
109.301 1
3HAC 12641-1
109.302 1
3HAC 11198-1
Cover, machining
109.303 1
3HAC 14698-1
Friction washer
109.304 20
3HAB 3409-92
109.305 20
17x25x3
109.306 1
3HAC 14723-1
109.307 1
3HAC 14724-1
109.308 8
3HAB 3409-50
109.309 8
3HAB 4233-1
Washer
109.310 1
3HAC 12252-1
Bottom plate
109.311 1
3HAC 14131-1
109.312 1
3HAC 11774-3
Adapter, machined
109.313 1
3HAC 11769-1
109.320 1
3HAC 12671-5
381x438x1,0
3HAC 16263-1
RV 700F incl.
gear, 3HAC
12641-1
RV 700F-269,21
assembly, 3HAC
17272-1
3HAC 16263-1
109.321 1
3HAC 12671-6
109.322 1
3HAC 14024-1
Protection screw
109.324 24
9ADA 618-56
M6x16
109.325 3
9ADA 618-57
M6x20
109.326 1
3HAC 16014-1
109.327 1
3HAC 14788-3
109.328 1
3HAC 16831-1
Battery pack
109.329 1
3HAC 13151-1
Cable battery/SMB
109.330 2
3HAC 11526-1
Stud screw
109.331 1
3HAC 13152-1
Bracket SMB
109.332 1
3HAC 14791-3
109.334 6
9ADA 618-53
M6x8
109.335 1
3HAA 2166-23
VK-Cover
109.336 1
3HAC 13914-1
Attachment plate
109.337 2
3HAC 12625-1
Strap, Velcro
109.338 1
3HAC 14793-1
Bracket
109.339 1
3HAC 15619-1
Cable, FB7-SMB7
109.341 7600 ml
3HAC 16843-1
109.342 4800 ml
3HAC 16843-1
109.344 1 ml
3HAB 7116-1
Locking liquid
109.345 2
9ADA 298-4
109.346 1
3HAC 16036-1
109.347 1
3HAC 2744-1
109.348 4
9ADA 629-56
M6x16
109.349 2
9ADA 618-58
M6x25
109.350 1
3HAC 4813-1
109.351 10
9ADA 618-44
Item
M5x12
See RV 700F-269,21
assembly, 3HAC 172721 on page 205!
RV 700F-269,21 assembly
109.301.2 1
3HAC 11636-1
Gear Z2 /2.3
Art. number
Description
109.301.1.1 1
3HAC 10122-21
RV 700F, i=269,21
109.301.1.2 1
3HAB 3772-51
O-ring
M6
Note
3HAC 17272-1
Qty
M6x150
Description
109.301.1 1
Item
Dimension
369,3x5,7
205
Cover battery
box, 3HAC 147913
Item
Qty
Art. number
Description
109.306.1 1
3HAC 14673-1
Rotational ac motor M1
109.306.2 1
3HAC 11350-1
109.306.3 0
2152 2012-430
O-ring
Dimension
89,5x3
Item
Qty
Art. number
Description
109.307.1
3HAC 14673-1
Rotational ac motor M1
109.307.2
3HAC 11632-1
Pinion Z1 /2.3
109.307.3
2152 2012-430
O-ring
89,5x3
Item
Qty
Art. number
Description
Note
109.327.1
3HAC 14788-1
Cover, casting
109.327.2
3HAC 14788-2
Gasket
109.327.3
3HAC 14692-4
Rubber cloth
Item
Description
109.332.1 1
3HAC 14791-1
Cover
109.332.2 1
3HAC 14791-2
Gasket
109.332.2 1
3HAC 16977-1
Dimension
Note
Item
206
Qty
Art. number
Description
110.401 1
3HAC 4310-1
110.402 1
3HAC 13124-1
Thrust washer
110.403 1
3HAC 13122-1
Bushing
110.404 1
9ABA 135-32
110.405 1
3HAC 13123-1
Shaft
110.406 1
3HAC 4836-7
Protection plug
16x12,3x9x7
110.407 4
3HAB 7700-89
M16x90
Dimension
3HAC 16263-1
110.408 2
9ABA 107-56
Parallel pin
10x20
110.409 1
3HAC 12548-2
Protection washer
110.410 1
3HAC 11427-1
110.411 4
3HAA 1001-186
Washer
Grease
110.413 2
3HAC 4836-1
Protection plug
20x14,6x7,5x5,5
110.414 1
9ADA 183-490
M16x180
17x25x3
Item
3HAC 16263-1
Qty
Art. number
Description
111.501 1
3HAC 9760-5
111.501 1
3HAC 15932-4
111.502 1
3HAC 11755-1
Friction Washer
111.503 20
3HAB 7700-69
M12x50
111.504 20
3HAA 1001-134
Washer
13x19x1,5
111.505 1
9ABA 107-56
Parallel pin
10x20
Dimension
207
208
3HAC 16263-1
6 Appendix 2: Foldouts
6.0.1 Introduction
General
This is an appendix to the manual and contains more detailed views of components and their
location on the manipulator.
The numbered details are specified in the Appendix 1: Part List.
3HAC 16263-1
209
6 Appendix 2: Foldouts
6.0.1 Introduction
210
3HAC 16263-1
6 Appendix 2: Foldouts
6.0.2 Base incl. Frame
101.2.1
101.2.2
101.1
101.5
101.9
101.2.4
101.2.3
101.3
101.4
xx0200000329
3HAC 16263-1
211
6 Appendix 2: Foldouts
6.0.2 Base incl. Frame
212
3HAC 16263-1
6 Appendix 2: Foldouts
6.0.3 Frame-Lower arm 1
6 .1
.3 0 .3
1099.30 6
10
6 .2
.3 0
109
109
.3 0
109
1 .1
.3 0
.1
1 .1
109
109
.2
.3 0
.3 3
109
2 .1
.3 3
2 .1
7 .1
.3 0 .3
1 0 9 9 .3 0 7
0
1
xx0200000330
3HAC 16263-1
213
6 Appendix 2: Foldouts
6.0.3 Frame-Lower arm 1
214
3HAC 16263-1
6 Appendix 2: Foldouts
6.0.4 Frame-Lower arm 2
11
40
0.
4
40
0.
40
0.
11
11
110.410
110.414
109.303
109.304
109.305
xx0200000331
3HAC 16263-1
215
6 Appendix 2: Foldouts
6.0.4 Frame-Lower arm 2
216
3HAC 16263-1
6 Appendix 2: Foldouts
6.0.5 Upper arm
10
2.3
1
.1
.3
03
1
1
.2.
.
02
.2
3.2
10
1
.1.
2. 3
10
.4
2.3
.3
2
10
2
.1.
xx0200000333
3HAC 16263-1
217
6 Appendix 2: Foldouts
6.0.5 Upper arm
218
3HAC 16263-1
6 Appendix 2: Foldouts
6.0.6 Wrist complete
xx0200000332
3HAC 16263-1
219
Maintenance Manual
Industrial Robot
IRB 7600 - 500/2.3
IRB 7600 - 400/2.55
IRB 7600 - 150/3.5
M2000A
Table of Contents
0.0.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
0.0.2 Product Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Chapter 1: Safety, service
1.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Section 1.1: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
13
23
37
3HAC 16262-1
Table of Contents
43
5.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Section 5.1: Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
101
ii
3HAC 16262-1
0.0.1 Overview
0.0.1 Overview
About This
Manual
This information product is a manual containing instructions for maintenance of the complete
robot system, mechanically as well as electrically.
Usage
Prerequisites
Organization of
Chapters
Chapter
Contents
Safety, service
Reference information
Maintenance Schedules
Maintenance activities
References
Reference
Document Id
3HAC 13347-1
3HAC 14189-2
Revisions
Revision
Description
First edition
3HAC 16262-1
Various corrections in text and in figures due to reconstructions, new material etc.
Manual completed with references to pagenumbers and numbering of sections (manipulator sections).
0.0.1 Overview
3HAC 16262-1
General
The complete product documentation kit for the robot, including controller, manipulator and
any hardware option, consists of the manuals listed below:
Installation and
Commissioning
Manual
Repair Manual
Maintenance
Manual
Safety, Service
Reference Information
Unpacking
On-site Installation
Electrical connections
Start-up
Calibration
Safety, Service
Reference Information
Remove/Refitting instructions for all controller cabinet details considered spare parts
Safety, Service
Reference Information
Maintenance schedules
Instructions for all maintenance activities specified in the maintenance schedule, for
example cleaning, lubrication, inspection etc.
The information is generally divided into separate chapters for the manipulator and the controller, respectively.
Software manuals
The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during operation.
A complete listing of all available software manuals is available from ABB Robotics.
3HAC 16262-1
Hardware option
manual
Each hardware option is supplied with its own documentation. Each document set contains
the types of information specified above:
Installation information
Repair information
Maintenance information
3HAC 16262-1
1 Safety, service
1.0.1 Introduction
Definitions
This chapter details safety information for service personnel i.e. personnel performing installation, repair and maintenance work.
Sections
2. Safety risks lists dangers relevant when servicing the robot system. The dangers are split into different categories:
Safety risks related to gripper/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
3. Safety actions details actions which may be taken to remedy or avoid dangers.
Safety fence dimensions
Fire extinguishing
Emergency release of the manipulators arm
Brake testing
Risk of disabling function "Reduced speed 250 mm/s"
Safe use of the Teach Pendant Unit enabling device
Work inside the manipulators working range
3HAC 16262-1
1 Safety, service
1.1.1 Safety, service - General
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.
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.
General
Documents
Type of information
Detailed in document
Users Guide
Section
Start-up
On-site installation Manipulator
3HAC 16262-1
1 Safety, service
1.2.1 Safety risks related to gripper
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
Grippers/end effectors must be designed so that they retain workpieces in the event of a power
failure or a disturbance of the controller.
General
Residual energy
Safe design
Residual energy may be present in these systems so, after shutdown, particular care
must be taken.
The pressure in pneumatic and hydraulic systems must be released before starting to
repair them.
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.
General
Qualified personnel
Extraordinary
risks
3HAC 16262-1
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.
1 Safety, service
1.2.5 Safety risks during installation and service
Nation/region
specific regulations
Non-voltage
related risks
To be observed
by the supplier of
the complete system
The instructions in the Product Manual - Installation and Commissioning must always
be followed.
Emergency stop buttons must be positioned in easily accessible places so that the
robot can be stopped quickly.
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 of the robot system, the regulations
applicable in the country concerned and the instructions of ABB Robotics must be complied
with.
Safety zones, which have to be crossed before admittance, must be set up in front of
the robot's working space. Light beams or sensitive mats are suitable devices.
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. In addition
to the risk of being hit by moving robot parts, you run the risk of being crushed by the
tie rod.
Energy, stored in the robot for the purpose of counterbalancing certain axes, may be
released if the robot, or parts thereof, is dismantled.
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
Voltage related
risks, controller
Although troubleshooting may, on occasion, have to be carried out while the power
supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
The mains supply to the robot must be connected in such a way that it can be turned
off outside the robots working space.
3HAC 16262-1
1 Safety, service
1.2.6 Risks associated with live electric parts
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. Note: 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
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.
3HAC 16262-1
The user connections for tools or other parts of the installation (max. 230 VAC, see
Installation and Commissioning Manual)
1 Safety, service
1.3.1 Safety fence dimensions
General
Fit a safety fence or enclosure around the robot to ensure a safe robot installation.
Dimensioning
Dimension the fence or enclosure to enable it to withstand the force created if the load being
handled by the robot is dropped or released at maximum speed. Determine the maximum
speed from the maximum velocities of the robot axes and from the position at which the robot
is working in the work cell (see Product Specification - Description, Robot Motion).
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating
tool or other device fitted to the manipulator.
Description
In an emergency situation, any of the manipulators axes may be released manually by pushing the brake release buttons on the manipulator or on an optional external brake release unit.
How to release the brakes is detailed in section "Manually releasing the brakes".
The manipulator arm may be moved manually on smaller robot models, but larger models
may require using an overhead crane or similar.
Increased injury
Before releasing the brakes, make sure that the weight of the arms does not increase the
pressure on the trapped person, which may further increase any injury!
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.
10
3HAC 16262-1
1 Safety, service
1.3.5 Risk of disabling function "Reduced speed 250 mm/s"
3HAC 16262-1
11
1 Safety, service
1.3.7 Work inside the manipulators working range
12
3HAC 16262-1
2 Reference information
2.0.1 Introduction
General
3HAC 16262-1
This chapter presents generic pieces of information, complementing the more specific information in the following chapters.
13
2 Reference information
2.1.1 Applicable Safety Standards
Standards,
general
Standards,
robot cell
14
The following standards are applicable when the robot is part of a robot cell:
EN 811 - Safety distances to prevent danger zones being reached by the lower limbs.
EN 294 - Safety distances to prevent danger zones being reached by the upper limbs.
3HAC 16262-1
2 Reference information
2.1.2 Screw joints
General
This section details how to tighten the various types of screw joints on 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.
UNBRAKO
screws
UNBRAKO is a special type of screw recommended by ABB in certain screw joints. It features special surface treatment (Gleitmo as described below), and is extremely resistant to
fatigue.
Whenever used, this is specified in the instructions and in such cases no other type of replacement screw is allowed. Using other types of screw will void any warranty and may potentially
cause serious damage or injury!
Gleitmo treated
screws
Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.
Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this
the screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should
be used.
Screws lubricated
in other ways
Screws lubricated with Molycote 1000 (or another lubricant) should only be used when specified in the repair, maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1. Lubricate the thread of the screw.
2. Lubricate between the plain washer and screw head.
3. Tighten to the torque specified in section "Tightening torque" below. Screw dimensions
of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or
smaller may be tightened without a torque wrench if this is done by trained and qualified personnel.
Tightening torque
3HAC 16262-1
Lubricant
Art. no.
1171 2016-618
Below are tables specifying the torque values for different screw joint types:
15
2 Reference information
2.1.2 Screw joints
Screws with
slotted or cross
recess head
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 "dry"
Tightening torque
(Nm)
Class 12.9 "dry"
M5
M6
10
M8
24
34
40
M10
47
67
80
M12
82
115
140
M16
200
290
340
Dimension
M8
28
34
M10
55
66
M12
96
115
M16
235
280
Screws with
hexagon socket
head, dry
Screws with
hexagon socket
head, lubricated
16
3HAC 16262-1
2 Reference information
2.1.3 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 the use of lifting equipment when handling components with a weight
exceeding 22 kg to avoid inflicting injury. A wide range of lifting tools and devices is available for each manipulator model.
Example
3HAC 16262-1
17
2 Reference information
2.1.4 Standard toolkit
General
All service (repairs, maintenance and installation) instructions contain lists of tools required
to perform the specified activity.
All special tools required are listed directly in the instructions while all the tools that are
considered standard are gathered in the Standard toolkit and defined in the table below.
In this way, the tools required are the sum of the Standard Toolkit and any tools listed in the
instruction.
Contents,
standard toolkit,
3HAC 15571-1
18
Qty
Art. no.
Tool
Rem.
3HAC 16262-1
2 Reference information
2.1.5 Special tools, IRB 6600/6650/7600
General
All service (repairs, maintenance and installation) instructions contain lists of tools required
to perform the specified activity. The required tools are a sum of standard tools, defined in
section Standard toolkit on page 18, and of special tools, listed directly in the instructions and
also gathered in the table below.
The table below is an overview of all the special tools required when performing service
activities on the IRB 6600/6650/7600. The tools are gathered in two kits: Basic Toolkit
(3HAC 15571-3) and Extended Toolkit (3HAC 15571-2).
The special tools are also listed directly in the current instructions.
3HAC 16262-1
Description
Angel bracket
68080011-LP
3HAB 3409-86
3HAB 3409-89
Cal. tool
68080011-GM
Calibration bracket
3HAC 13908-9
3HAC 13908-4
3HAC 15716-1
3HAC 12342-1
3HAC 13659-1
3HAC 13660-1
Gearbox crank
3HAC 16488-1
3HAC 13056-2
3HAC 13056-3
3HAC 13056-4
3HAC 15520-1
3HAC 15520-2
3HAC 14445-1
3HAC 14446-1
3HAC 15521-1
3HAC 15521-2
3HAC 13120-2
3HAC 13120-3
3HAC 13120-4
3HAC 13120-5
3HAC 14628-2
3HAC 14628-1
3HAC 14627-3
3HAC 14627-2
Hydraulic cylinder
3HAC 11731-1
19
2 Reference information
2.1.5 Special tools, IRB 6600/6650/7600
Description
3HAC 13086-1
3HAC 13086-2
6369901-348
3HAC 15560-1
3HAC 15607-1
3HAC 15994-1
3HAC 15536-1
3HAC 16131-1
3HAC 14457-3
3HAC 14457-4
3HAC 15556-1
3HAC 13698-1
3HAC 12731-1
3HAC 14691-1
3HAC 14459-1
3HAC 15534-1
3HAC 13605-1
3HAC 12734-1
Measuring pin
3HAC 13908-5
Mech stop ax 3
3HAC 12708-1
Mech stop ax 3
3HAC 12708-2
3HAC 13527-1
3HAC 13453-1
3HAC 13452-1
3HAC 17129-1
3HAC 15767-1
3HAC 12475-1
3HAC 15814-1
3HAC 14972-1
3HAC 14631-1
3HAC 14973-1
Rotation tool
3HAC 17105-1
Sensor plate
3HAC 0392-1
Support, base
3HAC 15535-1
Sync. adapter
3HAC 13908-1
3HAC 15943-2
3HAC 15943-1
3HAC 68080011-GU
3HAA 1001-186
Note a) Calibration tools for IRB 6600/6650/7600 when CalPen is not used (standard).
Note b) Special tools that may be rent from ATRP/S.
20
3HAC 16262-1
2 Reference information
2.1.6 Performing a leak-down test
General
After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil
must be tested. This is done in a leak-down test.
Required equipment
Equipment, etc.
Leakdown tester
Note
3HAC 0207-1
Procedure
Step
3HAC 16262-1
Action
Note/Illustration
1.
2.
Remove the topmost oil plug on the gear in question, Art. no. specified above!
and replace it with the leakdown tester .
Adapters may be required, which are included in the
leakdown tester kit.
3.
4.
5.
6.
7.
8.
When the leak has been localized: take the necessary measures to correct the leak.
21
2 Reference information
2.1.7 Lifting equipment and lifting instructions
General
Many repair and maintenance activities require different pieces of lifting equipment, which
are specified in each activity instruction.
However, how to use each piece of lifting equipment is not detailed in the activity instruction,
but in the instruction delivered with each piece of lifting equipment.
This implies that the instructions delivered with the lifting equipment should be stored for
later reference.
22
3HAC 16262-1
General
This is a brief description of how to use the Service Information System, SIS. Details may be
found in:
Basic procedure
Step
3HAC 16262-1
Action
Reference
1.
2.
3.
4.
5.
6.
When a time limit, set in the parameters, How to access this is detailed in Reading
is exceeded, a message may be read on the SIS output logs on page 35.
the Tech Pendant Unit (TPU).
7.
If the log containing the message is to be These are described in Exporting the SIS
available from an external PC, or if the
data on page 36.
SIS parameters are to be entered from
an external PC, a set of software tools
are available to build such an application.
23
General
Service Information System (SIS) is a software function within the robot controller, which
simplifies maintenance of the robot system. It supervises the operating time and mode of the
robot, and alerts the operator when a maintenance activity is scheduled.
Supervised functions
Gearbox 1 operation time counter, based on percentage of the axis 1 gearbox service
interval
Gearbox 2 operation time counter, based on percentage of the axis 2 gearbox service
interval
Gearbox 3 operation time counter, based on percentage of the axis 3 gearbox service
interval
Gearbox 6 operation time counter, based on percentage of the axis 6 gearbox service
interval
xx0200000034
x OK
24
"OK" indicates that no service interval limit has been exceeded by that counter.
If any such limit was exceeded, the counter name would be followed by "NOK".
3HAC 16262-1
Calendar time
This is a clock within the control system that enables you to set a specific service interval,
based on calendar time:
xx0200000035
After this time, a message is accessible on the Tech Pendant Unit (TPU). How to access this
is detailed in section Reading the SIS output logs on page 35.
Operation time
Prev service
Date when the counter was reset last time, i.e. after the last service. This
date was entered manually as detailed in section Setting the SIS parameters on page 33.
Elapsed time
Elapsed time since the counter was reset the last time.
Next service
Date when next scheduled service is planned. This date is entered manually as detailed in section Setting the SIS parameters on page 33.
Remaining time
This is a function within the control system that counts the amount of time the "MOTORS
ON" signal is active, i.e. the amount of time the robot is in the operational mode.
xx0200000036
After this time, a message is accessible on the Teach Pendant Unit (TPU). How to access this
is detailed in section Reading the SIS output logs on page 35.
3HAC 16262-1
Service interval
The specified service interval until another service will be required. This
parameter was entered manually as detailed in section Setting the SIS
parameters on page 33.
Elapsed time
Operation time since the service interval was set the last time.
Remaining time
Remaining operation time until the time set in service interval has
expired.
25
Gearbox
Based on measurements, torque and RPM, for example, the system calculates an expected
service interval for each gearbox. When service is due, a message will be shown on the TPU.
How to access this is detailed in section Reading the SIS output logs on page 35.
en0200000037
Axis x OK
Service status for axis x, i.e. the automatically calculated time parameter
has not been exceeded.
Axis x NOK
The service interval for the axis in question has been reached.
Axis x N/A
en0200000038
This example shows the window for axis 1, but is also valid for the other axes.
26
Consumed time
Elapsed time
Remaining time
Remaining operation time for axis x until the service time parameter
value has been reached.
3HAC 16262-1
Reset values
en0200000040
Yes
No
Does not reset the counter, but returns to the previous menu.
en0200000041
3HAC 16262-1
Yes
No
Does not reset the counter, but returns to the previous menu.
27
en0200000039
Service interval
exceeded
Yes
No
Does not reset the counter, but returns to the previous menu.
When the service time has been exceeded for the selection made, a message (Service interval
exceeded!) is displayed below the data of the counter in question:
en0200000044
This window may be shown for any time mode; calendar time, operation time or gearbox
time.
In addition to this view, an error message is also displayed on the TPU when the service
interval is exceeded!
28
3HAC 16262-1
No data available
When no data is available for the selection made, a message (No data available!) is displayed
below the function in question:
en0200000043
This window may be shown for any time mode; calendar time, operation time or gearbox
time.
Exit
en0200000042
3HAC 16262-1
Yes
No
29
General
This section details the parameters that may be set with estimated values. The values can be
defined by the operating organization as knowledge of the robots working conditions are
accumulated.
Since the counters are to be used for purposes defined by the user, ABB cannot give any
recommendations regarding their definitions.
The figure below shows the options of parameters to be set.
en0200000049
Operation time
limit (service
level)
en0200000054
30
3HAC 16262-1
Operation time
warning
en0200000053
Calendar time
limit (service
level)
en0200000050
Calendar time
warning
en0200000051
3HAC 16262-1
31
Gearbox warning
other variables
en0200000052
32
3HAC 16262-1
General
If the SIS system is to function properly, a number of parameters must be set. How to do this
is detailed below.
Procedure
Step
Action
Rem.
1.
2.
Go to "System parameters/Manipulator/
types 2".
xx0200000045
en0200000046
3.
en0200000047
xx0100000200
3HAC 16262-1
33
Step
4.
Action
Rem.
en0200000048
en0200000049
5.
34
3HAC 16262-1
General
Whenever a set condition has expired (e.g. max allowed operation time before service), a
message to this effect will be shown in the Operational log.
Access to logs
How to open any log and show its contents is detailed in the "Users Guide", chapter "Service".
Available messages
Available in:
3HAC 16262-1
SIS message in
Operational log
Meaning
Calendar time
Service Message
Service is due!
X calendar days since
last service.
Calendar time
Service Message
X calendar days to
next service.
X number of calendar days remain until the manually set calendar time limit expires.
How to set the value determining when the message is to be shown, is detailed in section Setting
the SIS parameters on page 33.
Operation time
Service Message
Service is due!
X production hours
since last service.
Operation time
Service Message
X production hours to
next service.
X number of operation hours remain until the manually set operation time limit expires.
How to set the value determining when the message is to be shown, is detailed in section Setting
the SIS parameters on page 33.
Gearbox time
Service Message
Gearbox x requires
service!
Gearbox time
Service Message
X% of the service interval has expired for
gearbox x!
X percent of gearbox hours remain until the automatically calculated gearbox time limit expires.
How to set the value determining when the message is to be shown, is detailed in section Setting
the SIS parameters on page 33.
35
General
This section describes the available variables for entering SIS parameters as well as showing
any messages of exceeded time limits as detected by the SIS counters on an external PC using
"Webware SDK".
How to access these variables and how to perform the actual programming sequences are
detailed in the robot system Users Guide.
Definitions
36
The table below defines the names and functions of all software variables available for communication between the SIS and an external computer.
Signal
Unit
Counter
type
sisRestartDate
sec
Calendar time
sisCalendarT
sec
Calendar time
sisTotRunT
sec
Operation time Total number of operation seconds since the system was started. Corresponds to the operating
time counter on the control cabinet.
sisRunT
sec
sisL10h_1
hrs
Gearbox time
sisL10h_Time_1 sec
Gearbox time
sisL10h_2
hrs
Gearbox time
sisL10h_Time_2 sec
Gearbox time
sisL10h_3
hrs
Gearbox time
sisL10h_Time_3 sec
Gearbox time
sisL10h_6
hrs
Gearbox time
sisL10h_Time_6 sec
Gearbox time
Function
3HAC 16262-1
4 Maintenance Schedules
4.0.1 Specification of maintenance intervals
Description
3HAC 16262-1
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:
Calendar time: specified in months regardless of whether the robot system is run or
not
Operating time: specified in operating hours. More frequent running of the robot
means more frequent maintenance activities.
SIS: specified by the robot's SIS (Service Information System). How to access this
information is detailed in section "Access to SIS information". A typical value is given
for a typical work cycle, but the value will differ depending on how hard each part is
run.
37
4 Maintenance Schedules
4.0.2 Maintenance schedule, IRB 7600
General
The robot, consisting of manipulator and controller cabinet, must be maintained regularly to
ensure its function. The maintenance activities and their respective intervals are specified in
the table below.
Non-predictable situations also give rise to inspections of the robot. Any damages must be
atteded to immediately!
The inspection intervals do not specify the life of each component. Values for these are specified in Expected component life, IRB 7600 on page 41.
Activities and
intervals, standard equipment
38
The sections 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:
Maintenanc
Equipment
e activity
Interval
Note
Inspection
12 mths
Inspection
12 mths
Inspection
12 mths
Inspection
12 mths
Inspection
12 mths
Inspection
12 mths
Inspection
Balancing device
12 mths
"Inspection, balancing
device"
Inspection
Manipulator harness
12 mths
Inspection
Information labels
12 mths
Inspection
12 mths
"Inspection damper,
axis 2-5"
Inspection
Mechanical stop,
axis 1
12 mths
Changing
48 mths
Changing
48 mths
Detailed in section
3HAC 16262-1
4 Maintenance Schedules
4.0.2 Maintenance schedule, IRB 7600
Maintenanc
Equipment
e activity
Interval
Note
Changing
48 mths
Changing
48 mths
Changing
48 mths
Changing
48 mths
Replacement
Axis 1 gear
As specified by
the SIS, or typically 96 mths
Replacement
Axis 2 gear
As specified by
the SIS, or typically 96 mths
Replacement
Axis 3 gear
As specified by
the SIS, or typically 96 mths
Replacement
Axis 4 gear
96 mths
Replacement
Axis 5 gear
96 mths
Replacement
Axis 6 gear
As specified by
the SIS, or typically 96 mths
Replacement
Manipulator harness
"Remove/Refit, cable
harness" in Repair
Manual
Replacement
Lubrication
Balancing device
bearing
48 mths 3
Detailed in section
"Removal/Refitting of
SMB related equipment" in Repair Manual
"Lubrication, balancing
device bearing"
1)
If the robot is run at ambient temperatures higher than 50 C, the manipulator may require
maintenance more frequently.
2)
Replace when damage is detected or when approaching the life limit, specified in Expected
component life, IRB 7600 on page 41.
3)
The interval is the same as with the interval for changing axis 2 gear oil, because the type
and degree of operation is similar.
Activities and
intervals, optional
equipment
3HAC 16262-1
The table below specifies the required maintenance activities and intervals for common
optional equipment. Maintenance of other external equipment for the robot is detailed in separate documentation.
39
4 Maintenance Schedules
4.0.2 Maintenance schedule, IRB 7600
Maintenance
Equipment
activity
40
Interval
Note
Detailed in section
Inspection
UL lamp
"Inspection, UL-lamp"
Inspection
Mechanical stop
axis 1, 2 and 3
12 mths
Mechanical
"Inspection, mechanical
stops in addition stop, axis 1, 2 and 3"
to the fixed stops
Inspection
"Inspection, position
switches, axis 1, 2 and 3"
3HAC 16262-1
4 Maintenance Schedules
4.0.3 Expected component life, IRB 7600
General
The life of any component depends on how hard it is run, and it can vary greatly.
Expected life
Component
Expected life
Note
Manipulator harness
2,000,000 cycles
See note 1)
2,000,000 cycles
See note 1)
Balancing device
2,000,000 cycles
See note 2)
Gearbox
40,000 h
See note 3)
1)
The expected life can also be affected by grouping harnesses/cables other than standard
options.
The given life is based on a test cycle that for every axis goes from the calibration position to
minimum angle, to maximum angle and back to the calibration position. Deviations from this
test cycle will result in differences in expected life!
2)
The given life for the balancing device is based on a test cycle that goes from the initial
position to maximum extension, and back again. Deviations from this test cycle will result in
differences in expected life!
3)
The robot is dimensioned for a service life of 8 years (350,000 cycles per year) in a normal
spot welding application. Depending on the actual application, the life of individual gearboxes may vary greatly from this specification. The SIS (Service Information System) integrated in the robot software keeps track of the gearbox life in each individual case and will
notify the user when a service is due. The SIS is described in Service Information System (SIS)
on page 24.
3HAC 16262-1
41
4 Maintenance Schedules
4.0.4 Maintenance schedule, controller S4CPlus M2000A
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
Equipment
activity
Interval
Inspection
Controller cabinet
6 mths
Cleaning
Controller cabinet
Replacement
Battery unit
12 000 h/36
mths 1
Replacement
60 mths
1)
42
Hours denote operational time while months denote the actual calender time.
3HAC 16262-1
General
3HAC 16262-1
This chapter contains information on how to maintain the equipment in question, i.e. how to
perform the preventive maintenance activities specified in the maintenance schedule for the
same equipment.
43
Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure below.
B
C
D
A
xx0200000111
Gearbox axis 1
Motor, axis 1
Required equipment
Equipment, etc.
Lubricating oil
Standard toolkit
44
Note
3HAC 16262-1
Inspection, oil
level
The procedures below details how to inspect the oil level in gearbox axis 1.
Notice the two different methods depending on construction (oil plug, inspection, available
or not).
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!
Step
1.
Note/Illustration
The procedure below details how to inspect the oil level, axis 1 gearbox, when the oil plug,
inspection (shown in figure above) is not available .
Step
3HAC 16262-1
Action
Action
Note/Illustration
1.
2.
3.
4.
45
Inspection with
oil plug, inspection, available
The procedure below details how to inspect the oil level, axis 1 gearbox, when the oil plug,
inspection (shown in the figure Location of gearbox on page 44) is available .
Step
46
Action
Note/Illustration
1.
2.
3.
4.
3HAC 16262-1
Different designs
The cover of gearbox axis 2 is made in different designs, with different locations of the oil
plug hole for filling. The oil plug hole of the later design is located 33 mm below the original
placement. The measured distance to the oil level varies, depending on the design of the
cover.
The axis 2 gearbox is located in the lower arm rotational center. The figure below shows the
early design of the gearbox cover.
A
B2
xx0300000068
3HAC 16262-1
B2
47
The axis 2 gearbox is located in the lower arm rotational center. The figure below shows the
later design of the gearbox cover, where the oil plug for filling is located 33 mm below the
original placement.
B1
xx0200000112
B1
Required equipment
Equipment etc.
Lubricating oil
Standard toolkit
48
Note
3HAC 16262-1
Inspection, oil
level
The procedure below details how to inspect the oil level in gearbox axis 2.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!
Step
3HAC 16262-1
Action
Note/Illustration
1.
2.
3.
4.
49
Location of gearbox
The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.
C
xx0200000113
Gearbox, axis 3
Required equipment
Equipment
Lubricating oil
Standard toolkit
50
Note
3HAC 16262-1
Inspection, oil
level
The procedure below details how to inspect the oil level in gearbox axis 3.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!
Step
3HAC 16262-1
Action
Note/Illustration
1.
2.
3.
4.
5.
51
Location of gearbox
The axis 4 gearbox is located at the rear of the upper arm as shown in the figure below.
C
D
xx0200000107
Required equipment
Equipment, etc.
52
Note
Lubricating oil
Lubricating oil
3HAC 16843-1
Standard toolkit
3HAC 15571-1
3HAC 16262-1
Equipment, etc.
Inspection, oil
level
Note
These procedures include references to the tools required.
The procedure below details how to inspect the oil level in gearbox axis 4.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!
Step
3HAC 16262-1
Action
Note/Illustration
1.
Run the manipulator to the calibration posi- Shown in "Calibration" in the Installation
tion.
Manual!
2.
3.
4.
5.
6.
53
Step
54
Action
Note/Illustration
7.
8.
3HAC 16262-1
Location of gearbox
The axis 5 gearbox is located in the wrist unit as shown in the figure below.
xx0200000108
3HAC 16262-1
Wrist housing
Oil plug, filling, primary gearbox (draining on opposite side of wrist housing, not
shown in figure)
55
Required equipment
Equipment etc. Spare part no. Art. no.
Lubricating oil
Lubricating oil
Standard toolkit
Inspection, oil
level
Note
The procedure below details how to inspect the oil level in the gearbox axis 5.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!
Step
56
Action
Note/Illustration
1.
2.
Open the oil plug, filling, in the primary Shown in the figure Location of gearbox on
gearbox .
page 55!
3.
3HAC 16262-1
Step
3HAC 16262-1
Action
Note/Illustration
4.
5.
Open the oil plug, filling, in the second- Shown in the figure Location of gearbox on
ary gear .
page 55!
6.
7.
8.
57
Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.
C
B
A
xx0200000114
Gearbox, axis 6
Required equipment
Equipment
Lubricating oil
Standard toolkit
58
Note
3HAC 16262-1
Inspection, oil
level
The procedure below details how to inspect the oil level in the gearbox axis 6.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!
Step
3HAC 16262-1
Action
Note/Illustration
1.
2.
3.
4.
59
The balancing device is located at the top rear of the frame as shown in the figure below.
If damage is detected during inspection, a maintenance or an upgrade must be performed,
depending on version of balancing device! Balancing device 3HAC 14675-1 requires maintenance, while 3HAC 10538-1 requires an upgrade.
C
A, B
E
F
xx0200000110
60
Balancing device
Bearing attachment
Rear cover
3HAC 16262-1
Note
Balancing device
3HAC 14214-1
Standard toolkit
If detecting damage when inspecting balancing device, version 3HAC 14675-1, maintenance
must be performed!
The table below specifies the equipment required when maintaining the balancing device!
Equipment, etc.
Note
Maintenance kit
3HAC 15834-1
Maintenance kit
3HAC 14962-1
Documentation for
maintenance
3HAC 15943-1
Separator
4551-C
(Bahco)
If detecting damage when inspecting balancing device, version 3HAC 10538-1, an upgrade
must be performed!
The table below specifies equipment required when upgrading the balancing device!
3HAC 16262-1
Note
Upgrade kit
3HAC 14965-1
61
Note
3HAC 15864-2 Instruction for conversion from balancing device, 3HAC 10538-1, to
3HAC 14675-1
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!
Step
62
Action
Note
1.
2.
3.
4.
5.
3HAC 16262-1
Location of cable
harness, axes 1-4
The manipulator cable harness, axes 1-4, is located as shown in figure below.
C
A
D
xx0200000097
Lower arm
Connectors at base
Required equipment
Equipment
3HAC 11440-1
Standard toolkit
3HAC 16262-1
Note
63
Equipment
Inspection, cable
harness ax 1-4
Note
These procedures include references to the tools required.
The procedure below details how to inspect the cable harness of axes 1-4.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them!
Step
64
Action
Note/Illustration
1.
2.
3.
4.
3HAC 16262-1
Location of cable
harness, ax 5-6
The cable harness of axes 5-6 is located as shown in the figure below.
B
C
xx0200000155
Inspection, cable
harness, axes 5-6
The procedure below details how to inspect the cable harness of axes 5-6.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them!
Step
3HAC 16262-1
Action
Note
1.
2.
Check the attachments and connectors at the Shown in the figure Location of
cable harness division .
cable harness, ax 5-6 on page 65!
3.
65
Location of
mechanical stop
The mechanical stop axis 1 is located at the base as shown in figure below.
A
xx0200000151
Required equipment
Equipment
Inspection,
mechanical stop
Note
Mechanical stop ax 1
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!
The procedure below details how to inspect the mechanical stop axis 1.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Step
66
Action
Note/Illustration
1.
2.
3.
3HAC 16262-1
Location of the
mechanical stops
The figure below shows the location of the additional mechanical stops on axes 1, 2 and 3.
B
A
B
A
xx0200000150
Additional stop
Fixed stop
Required equipment
Equipment etc.
3HAC 16262-1
Note
Mechanical stop ax 1
Mechanical stop ax 1
Mechanical stop ax 2
3HAC 11077-1
Mechanical stop ax 3
3HAC 13128-2
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18.
67
Inspection,
mechanical stops
The procedure below details how to inspect the additional mechanical stops on axes 1, 2 and
3.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Step
68
Action
Note/Illustration
1.
Check the additional stops on axes 1, 2 and 3 Shown in the figure Location of the
for damage.
mechanical stops on page 67!
2.
3.
Axis 2: M16 x 50
Axis 3: M16 x 80
3HAC 16262-1
Location of
dampers
The figure below shows the location of all the dampers to be inspected.
B
A
xx0200000099
Required equipment
Equipment
3HAC 16262-1
Note
Damper axis 2
Damper axis 3
Damper axis 4
Damper axis 5
Standard toolkit
69
Inspection,
damper axis 2-5
The procedure below details how to inspect the dampers, axis 2-5
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Step
70
Action
Note/Illustration
1.
Check all dampers for damage, such as cracks or Shown in the figure Location
existing impressions larger than 1 mm.
of dampers on page 69!
In order to inspect dampers, axis 4, the two covers
on top of the upper arm must be removed!
2.
3.
3HAC 16262-1
The position switches, axes 1, 2 and 3, are located as shown in the figures below.
A
F
C
E
xx0100000158
Cam
Protection sheet
Rail
Rail attachment
E
B
C
F
xx0100000159
3HAC 16262-1
71
Cam
Rail
Rail attachment
C
B
xx0100000160
Cam
Rail
Rail attachment
Required equipment
72
Equipment, etc.
Note
3HAC 15715-1
To be replaced in case of
detected damage.
3HAC 16262-1
Equipment, etc.
Note
3HAC 15715-2
To be replaced in case of
detected damage.
3HAC 15715-2
To be replaced in case of
detected damage.
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page
18!
The procedure below details how to inspect the position switch, axes 1, 2 and 3.
See the figure Location of position switches on page 71 to locate the different components to
be inspected.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Step
Action
1.
2.
3.
4.
Check that the set screws holding the cams in position are firmly attached.
5.
3HAC 16262-1
Note/Illustration
73
Location of the
information
labels
Warning
B
A
B
Warning
D
C
B
A
B
X-X
xx0200000100
74
Warning sign, symbol of a lightning flash (located on motor cover), 3HAC 1589-1
3HAC 16262-1
E
G
Lifting of robot
H
Warning
Warning
F
xx0200000101
Required equipment
Equipment
Note
Step
3HAC 16262-1
Action
Note/Illustration
1.
2.
75
Location of ULlamp
The UL-lamp is located as shown in figure below. Notice that the location can vary depending
on how the customer harness for axes 4-6 is mounted.
B
A
C
D
xx0200000117
UL signal lamp
Warning sign
Warning label
Required equipment
Equipment, etc.
Note
Signal lamp
3HAC 10830-1
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!
76
3HAC 16262-1
Inspection, ULlamp
The procedure below details how to inspect the function of the UL-lamp.
Step
3HAC 16262-1
Action
Note/Illustration
1.
2.
77
Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure below:
B
C
D
A
xx0200000111
Gearbox, axis 1
Motor, axis 1
In some early versions of the manipulator, the oil plug for draining may be located in the base,
as shown in the figure below. (In the other versions of the manipulator the oil is drained with
a hose that may be reached behind the rear cover of the manipulator base.)
A
xx0300000065
78
3HAC 16262-1
Required equipment
Equipment, etc.
Lubricating oil
Note
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!
The specified amount of oil is based on the total volume of the gearbox. When changing the
oil, the amount of refilled oil may therefor differ from the specified amount, depending on how
much oil has previously been drained from the gearbox.
The correct oil level is specified in the section about inspection of oil level.
Changing, oil
The procedure below details how to change the oil in gearbox axis 1.
Please observe the following before commencing any repair work:
Turn off all electric power supply to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. securing the lower arm with fixtures before removing gearbox, axis 2.
When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains
quicker than cold oil.
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!
Step
1.
3HAC 16262-1
Action
Note/Illustration
79
Step
80
Action
Note/Illustration
2.
3.
4.
5.
Open the hose end and drain the oil into the Notice! The draining is time-convessel.
suming. Elapsed time depends on
the temperature of the oil.
6.
7.
8.
9.
10.
3HAC 16262-1
Location of gearbox
The axis 2 gearbox is located in the lower arm rotational center as shown in the figure below.
B1
xx0200000112
Gearbox, axis 2
Required equipment
Equipment, etc.
Lubricating oil
1/4" or 1/2".
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!
3HAC 16262-1
Note
81
The specified amount of oil is based on the total volume of the gearbox. When changing the
oil, the amount of refilled oil may therefor differ from the specified amount, depending on how
much oil has previously been drained from the gearbox.
The correct oil level is specified in the section about inspection of oil level.
Changing, oil
The procedure below details how to change the oil in gearbox axis 2.
Please observe the following before commencing any repair work:
Turn off all electric power supply to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. securing the lower arm with fixtures before removing gearbox, axis 2.
When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains
quicker than cold oil.
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!
Step
82
Action
Note/Illustration
1.
2.
3.
4.
5.
6.
3HAC 16262-1
Location of gearbox
The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.
C
xx0200000113
Gearbox, axis 3
Required equipment
Equipment, etc.
Lubricating oil
3HAC 16262-1
Note
1/4" or 1/2".
Standard toolkit
83
Equipment, etc.
Note
These procedures include references to the tools required.
The specified amount of oil is based on the total volume of the gearbox. When changing the
oil, the amount of refilled oil may therefor differ from the specified amount, depending on how
much oil has previously been drained from the gearbox.
The correct oil level is specified in the section about inspection of oil level.
Changing, oil
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!
Step
84
Action
Note/Illustration
1.
2.
3.
4.
5.
3HAC 16262-1
Step
3HAC 16262-1
Action
Note/Illustration
6.
7.
85
Location of gearbox
The axis 4 gearbox is located at the rear of the upper arm as shown in the figure below.
C
D
xx0200000107
Oil plug, filling, primary gearbox (draining not shown in figure, located further down on
the motor flange)
Required equipment
Equipment, etc.
Lubricating oil
Lubricating oil
86
Note
3HAC 16262-1
Equipment, etc.
Standard toolkit
Changing, oil
Note
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!
Step
3HAC 16262-1
Action
Note/Illustration
1.
Open the oil plug, draining, secondary gear Shown in the figure Location of gear.
box on page 86!
2.
Drain the oil from the secondary gearbox by Vessel capacity: 4000 ml.
running the upper arm -45from calibration
position.
3.
4.
5.
6.
7.
Refill the secondary gear with lubricating oil Art. no. and amount specified in
through the oil plug, filling, secondary gear . Required equipment on page 86 (BP
Energol GR-XP 320)!
Shown in the figure Location of gearbox on page 86!
87
Step
88
Action
Note/Illustration
8.
9.
3HAC 16262-1
Location of gearbox
The axis 5 gearbox is located in the wrist unit as shown in the figure below.
xx0200000108
Wrist housing
Oil plug, filling primary gearbox (draining on opposite side of wrist housing, not shown
in figure)
Required equipment
Equipment, etc.
Lubricating oil
3HAC 16262-1
Note
89
Equipment, etc.
Lubricating oil
Note
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!
The specified amount of oil is based on the total volume of the gearbox. When changing the
oil, the amount of refilled oil may therefor differ from the specified amount, depending on how
much oil has previously been drained from the gearbox.
The correct oil level is specified in the section about inspection of oil level.
Changing, oil
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!
Step
90
Action
Note/Illustration
1.
2.
3.
4.
5.
3HAC 16262-1
Step
3HAC 16262-1
Action
Note/Illustration
6.
7.
8.
9.
91
Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.
C
B
A
xx0200000114
Gearbox, axis 6
Required equipment
Equipment, etc.
Lubricating oil
Note
Standard toolkit
The specified amount of oil is based on the total volume of the gearbox. When changing the
oil, the amount of refilled oil may therefor differ from the specified amount, depending on how
much oil has previously been drained from the gearbox.
The correct oil level is specified in the section about inspection of oil level.
92
3HAC 16262-1
Changing, oil
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!
Step
3HAC 16262-1
Action
Note/Illustration
1.
2.
3.
4.
Remove the oil plug, filling from top of the Shown in the figure Location of gearbox
wrist.
on page 92!
5.
6.
93
Location of SMB
battery pack
The SMB battery pack is located on the left hand side of the frame, as shown in figure below.
Note that the manipulator is shown with the SMB cover already removed.
B C D E
xx0200000115
SMB cover
Required equipment
Equipment, etc.
Battery pack
3HAC 13150-1
Standard toolkit
Circuit diagram
94
Note
3HAC 16262-1
Replacement,
SMB battery pack
The procedure below details how to replace the SMB battery pack.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Follow these instruction to prevent the unit to be damaged from ESD:
The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to electrostatic
voltages.
Before handling, make sure you are connected to earth through a special ESD wrist bracelet
or similar.
Step
3HAC 16262-1
Action
Note/Illustration
1.
2.
Disconnect the battery from the cable, Shown in the figure Location of SMB batbattery/SMB board.
tery pack on page 94!
3.
4.
Refit the new battery pack and connect Art. no. specified in Required equipment
the cable, battery/SMB board to the
on page 94!
battery.
Shown in the figure Location of SMB battery pack on page 94!
5.
6.
95
xx0200000109
Lubrication nipple
Sealing spacer
Required equipment
Equipment, etc. Spare part no. Art. no.
Grease
Note
Grease pump
96
3HAC 16262-1
The procedure below details how to lubricate the spherical roller bearing.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Step
1.
3HAC 16262-1
Action
Note/Illustration
97
General
Activities
Periodicity
The periodicity of cleaning the manipulator varies a great deal depending on the actual environment and function of the robot. A contamined manipulator should be cleaned as required.
Special points
C
A
xx0100000265
98
Inside of base/axis 1
3HAC 16262-1
Required equipment
Equipment, etc. Note
Steam cleaner
High pressure
water cleaner
Always!
Never!
Foundry versions
3HAC 16262-1
The section below specifies special considerations when cleaning the manipulator.
Always use cleaning equipment as specified above! Any other cleaning equipment
may shorten the life of paintwork, rust inhibitors, signs, or labels!
Always check that all protective covers are fitted to the robot before cleaning!
Never point the water jet at bearing seals, contacts, and other seals!
Never remove any covers or other protective before cleaning the robot!
Never use any cleaning agents, e.g. compressed air or solvents, other than those
specified above!
Never spray with a high pressure cleaner onto the sealing cup at the bottom of the
motor 5 spiral cable (item A in the figure Special points on page 98!)!
Although the manipulator is watertight, avoid spraying with a high pressure cleaner
onto connectors and similar!
In working environments, e.g. foundries, where the manipulator may be exposed to fluids that
dry to make a crusty surface, e.g. release agents, clean the cable harnesses so that the crust
does not damage the cables:
Clean the spiral wound cables to motor 5 (item A in the figure Special points on page
98!) with water and a cloth!
99
100
3HAC 16262-1
General
3HAC 16246-1
This chapter contains information on how to maintain the equipment in question, i.e. how to
perform the preventive maintenance activities specified in the maintenance schedule for the
same equipment.
101
Inspection
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.
Step Action
102
Note/Illustration
1.
Inspect the cabinet interior to make sure there is no Replace any faulty seals as
contamination.
required.
If any contamination is found, the cabinet interior
must be cleaned and all gaskets and seals to the
cabinet inspected.
2.
3.
4.
3HAC 16246-1
X1
X1
X1
X1
X1
X2
X2
X2
X2
X2
X3
Rectifier
A0
xx0200000103
Battery unit
Required equipment
Equipment, etc.
Note
Battery unit
3HAC 5393-2
To be replaced as a complete
unit
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.
3HAC 16246-1
103
Step Action
Note/Illustration
X1
X1
X1
X2
X2
X2
X2
X1
X2
X3
Rectifier
A0
xx0200000004
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.
Step Action
Note/Illustration
2. Reconnect the cables and push the unit into position. See illustration above!
3. Secure it with the attachment screws.
104
3HAC 16246-1
Required equipment
Equipment, etc.
Internal cleaning
Art. no.
Note
Vacuum cleaner
ESD Safe
The procedure below details how to clean the interior 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.
Step
1.
Always!
Never!
3HAC 16246-1
Action
Note/Illustration
The section below specifies special considerations when cleaning the controller cabinet.
Always use cleaning equipment as specified above! Any other cleaning equipment
may shorten the life of paintwork, rust inhibitors, signs, or labels!
Always check that all protective covers are fitted to the controller before cleaning!
Never remove any covers or other protective devices before cleaning the controller!
Never use any cleaning agents, e.g. compressed air or solvents, other than those
specified above!
105
xx0200000002
Cover
Fan
Screw
Required equipment
Equipment, etc.
Note
Vacuum cleaner
Cleaning
ESD Safe
Step
1.
106
Action
Note/Illustration
3HAC 16246-1
Step
3HAC 16246-1
Action
Note/Illustration
2.
3.
4.
107
Location of drive
units
The illustration below shows the location of the drive units and air outlet device.
1
Drive units
Required equipment
Equipment, etc.
Vacuum cleaner
Cleaning
Note
ESD Safe
The following procedures detail how to clean the drive units, bleeder resistor and air outlet
device.
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.
Step
1.
2.
108
Action
Illustration/Note
3HAC 16246-1
Step
Refitting
Action
Illustration/Note
3.
4.
5.
Clean the back side of the drive units. See Note above.
6.
7.
Step Action
Note/Illustration
1. Fit the bleeder resistor into position and secure it with the Art. no. is specified above!
spring.
Also see the figure above!
2. Secure the cable disconnected during disassembly.
3. Refit the air outlet device.
4. Tighten the M5 screws.
3HAC 16246-1
109
Location of air
outlet
The illustration below shows the location of the air outlet shaft
Air outlet
Required equipment
Equipment, etc.
Vacuum cleaner
Cleaning
Note
ESD Safe
The following procedures detail how to clean the air outlet shaft.
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.
110
1.
2.
3.
4.
3HAC 16246-1
Refitting
The procedure below details how to refit the Drive units, bleeder resistor and 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.
Step Action
Note/Illustration
2. Refit the Bleeder resistor and system fan unit. Detailed in Repairs Manual, section
Replacement of system fan unit.
3. Refit the air outlet device.
4. Tighten the M5 screws.
3HAC 16246-1
111
Location of drain
filter
Filter holder
M5 screw
Drain filter
Required equipment
Equipment, etc.
Filter
3HAC 5393-2
Standard toolkit
Removal
Note
112
3HAC 16246-1
Step Action
Note/Illustration
Refitting
Step Action
Note/Illustration
2. Fit the filter holder, (pos.1) and secure it with the See the figure above!
M5 screw, (pos. 2).
3. Put the computer system back in the regular
operation position.
3HAC 16246-1
113
0.0.1 Overview
0.0.1 Overview
About This
Manual
This information product is a manual containing circuit diagrams for both the
manipulator and the controller cabinet.
Usage
Organization of
Chapters
Chapter
Contents
Revision
Description
First edition
Revisions
3HAC 13875-1
Contents ........................................................................................................................101
Connection Point Location ...........................................................................................102
Legend ..........................................................................................................................103
Brake Release Unit .......................................................................................................104
Service brake release unit (IRB 7600).......................................................................104.1
Serial Measurement Board ...........................................................................................105
Axis 1............................................................................................................................106
Axis 2............................................................................................................................107
Axis 3............................................................................................................................108
Axis 4............................................................................................................................109
Axis 5 (IRB 7600) ........................................................................................................110
Axis 5 (IRB 6600) .....................................................................................................110.1
Axis 6............................................................................................................................111
Customer Power/Signal/Bus Connections ....................................................................112
Customer Power/Signal/Bus and External axis .........................................................112.1
Customer Power/Signal/Bus Connections, ax 3-6.....................................................112.5
Switches axis 1 .......................................................................................................... ..113
Switches/ Fan axis 2 .....................................................................................................114
Switches/ Fan axis 3 .....................................................................................................115
Weld connections..........................................................................................................116
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Circuit Diagram
Contents
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Page
Circuit Diagram
Contents
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Circuit Diagram
Contents
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0.0.1 Overview
0.0.1 Overview
About This
Manual
This information product is a manual containing circuit diagrams for both the manipulator
and the controller cabinet.
Usage
Organization of
Chapters
Chapter
Contents
Revision
Description
First edition
Revisions
3HAC 16263-1
0.0.1 Overview
3HAC 16263-1
Contents ........................................................................................................................101
Connection Point Location ...........................................................................................102
Legend ..........................................................................................................................103
Brake Release Unit .......................................................................................................104
Service brake release unit (IRB 7600).......................................................................104.1
Serial Measurement Board ...........................................................................................105
Axis 1............................................................................................................................106
Axis 2............................................................................................................................107
Axis 3............................................................................................................................108
Axis 4............................................................................................................................109
Axis 5 (IRB 7600) ........................................................................................................110
Axis 5 (IRB 6600) .....................................................................................................110.1
Axis 6............................................................................................................................111
Customer Power/Signal/Bus Connections....................................................................112
Customer Power/Signal/Bus and External axis .........................................................112.1
Customer Power/Signal/Bus Connections, ax 3-6.....................................................112.5
Switches axis 1 .......................................................................................................... ..113
Switches/ Fan axis 2 .....................................................................................................114
Switches/ Fan axis 3 .....................................................................................................115
Weld connections..........................................................................................................116
Contents
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