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Product manual
Articulated robot
IRB 6400RF
M2004
Product manual
IRB 6400RF - 200/2.5
IRB 6400RF - 200/2.8
M2004
ID: 3HAC027076-001
Revision: A
The information in this manual is subject to change without notice and should not be construed as a
commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind
of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose
or the like.
In no event shall ABB be liable for incidental or consequential damages arising from use of this manual
and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's written permission, and
contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
©Copyright 2006 ABB All right reserved.
ABB AB
Robotics Products
SE-721 68 Västerås
Sweden
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1: Safety
13
1.1: Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2: General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.1 Safety in the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.3: Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.1 Safety risks during installation and service work on robot . . . . . . . . . . . . . . . . . . . . . . . . . . .15
1.3.2 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1.3.3 Safety risks related to pneumatic/hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
1.3.4 Safety risks during operational disturbances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
1.3.5 Risks associated with live electric parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
1.4: Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.4.1 Safety fence dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
1.4.2 Fire extinguishing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
1.4.3 Emergency release of the robot’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
1.4.4 Brake testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
1.4.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
1.4.6 Safe use of the FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
1.4.7 Work inside the robot's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
1.4.8 Translate the information on safety and information labels. . . . . . . . . . . . . . . . . . . . . . . . . . .28
1.5: Safety related instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
1.5.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
1.5.2 DANGER - Moving robots are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
1.5.3 DANGER - First test run may cause injury or damage! . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
1.5.4 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
1.5.5 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
2: Installation and commissioning
37
2.1: Transporting and Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
2.1.1 Stability / Risk of Tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
2.1.2 System CD ROM and Diskette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
2.2: On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
2.2.1 Lifting the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
2.2.2 Assembling the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
2.2.3 Stress Forces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
2.2.4 Amount of Space required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
2.2.5 Manually releasing the Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
2.2.6 Process Media Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
2.2.7 Restricting the Working Space. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
2.2.8 Position Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
2.2.9 Mounting Holes for Equipment on the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
2.2.10 Signal Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
2.3: Application Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.3.1 Media Outlet on Upper Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
2.3.2 Media Outlet with CAN/DeviceNet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
2.3.3 Signal Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
2.4: Customer Connector Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3: Decommissioning
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63
Table of Contents
3.1: General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.1.1 robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.2: Scrapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.2.1 General warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.2.2 Oil and grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.2.3 Parts requiring special treatment when scrapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.2.4 IRB 6400R Balancing cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.2.5 Scrapping Balancing cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4: Maintenance
69
4.1: Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.2: Instructions for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.2.1 Checking the oil and grease levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.2.2 Oil change gearbox, axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.2.3 Inspect and lubricate the bearings, balancing units axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.2.4 Lubricating piston rod, balancing unit axis 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.2.5 Oil change, axes 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.2.6 Oil change gearbox, axis 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.2.7 Oil change gearbox, axis 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.2.8 Lubricating gearbox, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.2.9 Excess grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.2.10 Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.2.11 Checking mechanical stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.2.12 Replacement of SMB battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.2.13 Cleaning of robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5: Repair
91
5.1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.1.2 Document guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5.1.3 Caution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.2: Mounting instructions for bearings and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.2.1 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.2.2 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.2.3 Instructions for tightening screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.2.4 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.2.5 Checking for Play in Gearboxes and Wrist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.3: Motor Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.4: Motors Axes 1–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.4.1 Changing motor including pinion axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.4.2 Changing motor including pinion axes 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.5: Motors and Gears Axes 4–6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.5.1 Motor axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.5.2 Intermediate gear, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.5.3 Replacing final gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.6: Dismounting tube shaft, upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.6.1 Replacing seals and bearings, upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.6.2 Axes 5 and 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.6.3 Wrist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.6.4 Arm extender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.6.5 Motor axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
5.6.6 Motor axes 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5.6.7 Checking backlash in axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
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5.6.8 Adjusting backlash in axis 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
5.6.9 Adjusting the intermediate gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
5.6.10 Adjusting the intermediate gear unit bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
5.7: Balancing Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.7.1 Dismounting balancing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
5.7.2 Replacing guide ring, balancing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
5.7.3 Replacing bearings, balancing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
5.8: Arm System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.8.1 Upper arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
5.8.2 Parallel bar with bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
5.8.3 Balancing weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
5.8.4 Lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
5.8.5 Parallel arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
5.8.6 Parallel arm - Inner bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
5.8.7 Parallel arm - Outer bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
5.8.8 Gearbox 1-3 including base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
5.8.9 Gearbox axis 1-3, seals axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
5.8.10 Gearbox axis 1-3, seals axis 2/3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
5.8.11 Brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
5.8.12 Replace serial measurement board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
5.8.13 Replace stop pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
5.9: Cable Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5.9.1 Robot harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
5.9.2 Customer Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
5.9.3 Cabling, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
5.10: Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
5.10.1 Position Switch axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
5.10.2 Signal lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
5.10.3 Fork lift device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
6: Calibration
159
6.1: Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
6.1.1 When to calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
6.1.2 Types of calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
6.1.3 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
6.2: Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
6.2.1 Calibration movement directions for all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
6.2.2 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
6.2.3 Checking the calibration position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
7: Tools
171
7.1: Tool List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
8: Parts list / Spare part list
173
8.1: Rebuilding Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
8.2: Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
8.2.1 Position Switch Axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
8.2.2 Signal Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
8.2.3 Forklift Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
8.2.4 Wrist kit 6400R 200kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
8.2.5 Process Media Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
8.2.6 Mechanical stop 15 degr. axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
8.2.7 Mechanical stop 7,5 degr. axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
3HAC027076-001 Revision: A
Table of Contents
8.2.8 Mechanical stop axes 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
8.3: Spare Part List robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
8.3.1 Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
8.3.2 Axis 1-3 Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
8.3.3 Upper Arm Complete. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
8.3.4 Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
8.3.5 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
9: Mechanical drawings
191
9.1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
9.2: Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Mechanical drawing 1:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Mechanical drawing 1:2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Mechanical drawing 1:3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Mechanical drawing 1:4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Mechanical drawing 1:5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Mechanical drawing 2:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Mechanical drawing 2:2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Mechanical drawing 2:3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Mechanical drawing 2:4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Mechanical drawing 2:5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Mechanical drawing 2:6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Mechanical drawing 2:6.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Mechanical drawing 2:7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Mechanical drawing 2:8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Mechanical drawing 2:9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Mechanical drawing 2:10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Mechanical drawing 2:11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Mechanical drawing 2:12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Mechanical drawing 2:13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Mechanical drawing 2:14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Mechanical drawing 2:15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Mechanical drawing 2:17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Mechanical drawing 2:18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Mechanical drawing 2:19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Mechanical drawing 2:20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
10: Circuit diagram
219
10.1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
10.2: Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Sheet 101: Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Sheet 102: Connection Point Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Sheet 103: Legend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Sheet 104: Brake Unit / Serial Measurement Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Sheet 105: Axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Sheet 106: Axes 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Sheet 107: Axes 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Sheet 108: Axis 4 / Signal lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Sheet 109: Axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Sheet 109,1: Axis 5 (Long Cable). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Sheet 110: Axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Sheet 111: Customer Power/Signal Connection CANBUS / P-BUS / I-BUS . . . . . . . . . . . . . . . . 232
Sheet 112: Customer Power/Signal Connection Extended. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Sheet 113: Customer Power/Signal Connection or feeding Servo Gun/Fan . . . . . . . . . . . . . . . . . 234
Sheet 114: Switches Axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
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Table of Contents
Sheet 115: Switches Axis 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236
Sheet 116: Switches Axis 2/3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237
3HAC027076-001 Revision: A
Table of Contents
3HAC027076-001 Revision: A
Overview
About this manual
This manual contains instructions for:
•
mechanical and electrical installation of the robot
•
maintenance of the robot
•
mechanical and electrical repair of the robot.
Usage
This manual should be used during:
•
installation, from lifting the robot to its work site and securing it to the foundation to
making it ready for operation
•
maintenance work
•
repair work and calibration.
Who should read this manual?
This manual is intended for:
•
installation personnel
•
maintenance personnel
•
repair personnel.
Prerequisites
A maintenance/repair/ installation craftsman working with an ABB Robot must:
•
be trained by ABB and have the required knowledge of mechanical and electrical
installation/repair/maintenance work.
Organization of chapters
© Copyright 2006 ABB. All rights reserved.
The manual is organized in the following chapters:
Chapter
Contents
Safety
Safety information
Installation and commissioning
Information about installation of the robot.
Decommissioning
Environmental information about the robot.
Maintenance
Information about maintenance work, including
maintenance schedules.
Repair
Information about repair work.
Calibration
Information about calibration of the robot.
Tools
Tools needed to repair the robot.
Parts list / Spare part list
Part list
References
Reference
Document Id
Product specification - IRB 6400RF M2004
3HAC026552-001
3HAC027076-001 Revision: A
9
Reference
Document Id
Product manual - IRC5
3HAC021313-001
Operating manual - IRC5 with FlexPendant
3HAC16590-1
Operating manual - Levelmeter Calibration
3HAC022907-001
Operating manual - Service Information System
3HAC025709-001
Technical reference manual - System parameters
3HAC17076-1
Application manual - Additional axes and stand alone controller
3HAC021395-001
Revisions
Revision
Description
-
First edition.
A
Changes made in:
• Prerequisites in section Overview
© Copyright 2006 ABB. All rights reserved.
• Oil change in section Maintenance
10
3HAC027076-001 Revision: A
Product documentation, M2004
General
The robot documentation may be divided into a number of categories. This listing is based on
the type of information contained within the documents, regardless of whether the products
are standard or optional. This means that any given delivery of robot products will not contain
all documents listed, only the ones pertaining to the equipment delivered.
However, all documents listed may be ordered from ABB. The documents listed are valid for
M2004 robot systems.
Product manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
is divided into two parts:
Product manual, procedures
•
Safety information
•
Installation and commissioning (descriptions of mechanical installation, electrical
connections and loading system software)
•
Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
•
Repair (descriptions of all recommended repair procedures including spare parts)
•
Additional procedures, if any (calibration, decommissioning)
© Copyright 2006 ABB. All rights reserved.
Product manual, reference information
•
Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
•
Part list
•
mechanical drawings or exploded views
•
Circuit diagrams
The product manual published as a PDF consists of only one file where the two parts are
presented together, as one Product manual.
RobotWare manuals
The following manuals describe the robot software in general and contain relevant reference
information:
•
RAPID Overview: An overview of the RAPID programming language.
•
RAPID reference manual : Description of all RAPID instructions.
•
Technical reference manual - System parameters: Description of system
parameters and configuration workflows.
3HAC027076-001 Revision: A
11
Application manuals
Specific applications (e.g. software or hardware options) are described in Application
manuals. An application manual can describe one or several applications.
An application manual generally contains information about:
•
The purpose of the application (what it does and when it is useful)
•
What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)
•
How to use the application
•
Examples of how to use the application
Operating manuals
This group of manuals is aimed at those having first hand operational contact with the robot,
i.e. production cell operators, programmers and trouble shooters. The group of manuals
includes:
Getting started - IRC5 and RobotStudio Online
•
Operating manual - IRC5 with FlexPendant
•
Operating manual - RobotStudio Online
•
Trouble shooting manual for the controller and robot
© Copyright 2006 ABB. All rights reserved.
•
12
3HAC027076-001 Revision: A
1: Safety
Introduction
1: Safety
1.1: Introduction
Overview
The safety information in this manual is divided in two categories:
general safety aspects, important to attend to before performing any service work on
the robot. These are applicable for all service work and are found in section General
safety information on page 14.
•
specific safety information, pointed out in the procedure at the moment of the danger.
How to avoid and eliminate the danger is either detailed directly in the procedure, or
further detailed in separate instructions, found in section Safety related instructions on
page 29.
© Copyright 2006 ABB. All rights reserved.
•
3HAC027076-001 Revision: A
13
1: Safety
1.2.1 General safety information
1.2: General safety information
1.2.1 Safety in the robot system
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 are 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. Operating manual - IRC5 with
FlexPendant (M2004) 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.
Limitation of liability
Any information given in this manual regarding safety, must not be construed as a warranty
by ABB that the industrial robot will not cause injury or damage even if all safety instructions
are complied with.
14
Type of information
Detailed in document
Section
Installation of safety
devices
Product manual for the robot
Installation and commissioning
Changing operating
modes
Operating manual - IRC5 with
FlexPendant (RobotWare 5.0)
Start-up
Operating modes
Restricting the working
space
Product manual for the robot
Installation and commissioning
3HAC027076-001 Revision: A
© Copyright 2006 ABB. All rights reserved.
Related information
1: Safety
1.3.1 Safety risks
1.3: Safety risks
1.3.1 Safety risks during installation and service work on robot
Overview
This section includes information of general safety risks to be considered when performing
installation and service work on the robot.
General risks during installation and service
•
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.
Nation/region specific regulations
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.
© Copyright 2006 ABB. All rights reserved.
Non-voltage related risks
•
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
parallel arm.
•
Energy, stored in the robot for the purpose of counterbalancing certain axes, may be
released if the robot, or parts thereof, are dismantled.
•
When dismantling/assembling mechanical units, watch out for falling objects.
•
Be aware of stored heat energy in the controller.
•
Never use the robot as a ladder, i.e. do not climb on the robot motors or other part
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.
3HAC027076-001 Revision: A
15
1: Safety
1.3.1 Safety risks during installation and service work on robot
To be observed by the supplier of the complete system
•
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.
Complete robot
Safety risk
Description
Hot components!
Caution!
Motors and gears are HOT after running the robot!
Touching the motors and gears may result in burns!
Removed parts may result in
collapse of robot!
Warning!
Take any necessary measures to ensure that the robot
does not collapse as parts are removed, e.g. secure the
lower arm with fixtures if removing motor, axis 2.
Cabling
Safety risk
Description
Caution!
The cable packs are sensitive to mechanical damage!
They must be handled with care, especially the
connectors, in order to avoid damaging them!
Gearboxes and motors
Safety risk
Description
Gears may be damaged if
excessive force is used!
Caution!
Whenever parting/mating motor and gearbox, the gears
may be damaged if excessive force is used!
16
3HAC027076-001 Revision: A
© Copyright 2006 ABB. All rights reserved.
Cable packs are sensitive to
mechanical damage!
1: Safety
1.3.2 Safety risks related to tools/workpieces
1.3.2 Safety risks related to tools/workpieces
Safe handling
It must be possible to safely turn off tools, such as milling cutters, etc. 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.
CAUTION!
© Copyright 2006 ABB. All rights reserved.
Ensure that a gripper is prevented from dropping a workpiece, if such is used.
3HAC027076-001 Revision: A
17
1: Safety
1.3.3 Safety risks related to pneumatic/hydraulic systems
1.3.3 Safety risks related to pneumatic/hydraulic systems
General
Special safety regulations apply to pneumatic and hydraulic systems.
Residual energy
•
Residual energy may be present in these systems. 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.
•
Dump valves should be used in case of emergency.
•
Shot bolts should be used to prevent tools, etc., from falling due to gravity.
© Copyright 2006 ABB. All rights reserved.
Safe design
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3HAC027076-001 Revision: A
1: Safety
1.3.4 Safety risks during operational disturbances
1.3.4 Safety risks during operational disturbances
General
•
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.
•
Care must be taken at all times.
•
Corrective maintenance 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.
Qualified personnel
Extraordinary risks
© Copyright 2006 ABB. All rights reserved.
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.
3HAC027076-001 Revision: A
19
1: Safety
1.3.5 Risks associated with live electric parts
1.3.5 Risks associated with live electric parts
Voltage related risks, general
•
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 robot’s working space.
Voltage related risks, controller IRC5
•
Be aware of stored electrical energy (DC link, ultra capacitor bank) in the controller.
•
Units inside the controller, e.g. I/O modules, can be supplied with power from an
external source.
•
The mains supply/mains switch
•
The transformers
•
The power unit
•
The control power supply (230 VAC)
•
The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
•
The drive unit (700 VDC)
•
The drive system power supply (230 VAC)
•
The service outlets (115/230 VAC)
•
The customer power supply (230 VAC)
•
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, robot
A danger of high voltage is associated with the robot in:
•
The power supply for the motors (up to 800 VDC).
•
The user connections for tools or other parts of the installation (max. 230 VAC, see
chapter Installation and commissioning in the Product manual).
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.
20
3HAC027076-001 Revision: A
© Copyright 2006 ABB. All rights reserved.
A danger of high voltage is associated with the following parts:
1: Safety
1.4.1 Safety actions
1.4: Safety actions
1.4.1 Safety fence dimensions
General
Install a safety cell around the robot to ensure safe robot installation and operation.
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 IRB 6400RF - Section 1.5/Description,
Robot Motion).
© Copyright 2006 ABB. All rights reserved.
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating
tool or other device fitted to the robot.
3HAC027076-001 Revision: A
21
1: Safety
1.4.2 Fire extinguishing
1.4.2 Fire extinguishing
NOTE!
© Copyright 2006 ABB. All rights reserved.
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot (robot or
controller)!
22
3HAC027076-001 Revision: A
1: Safety
1.4.3 Emergency release of the robot’s arm
1.4.3 Emergency release of the robot’s arm
Description
In an emergency situation, any of the robot's axes may be released manually by pushing the
brake release buttons on the robot.
How to release the brakes is detailed in section:
•
Manually releasing the Brakes on page 46.
The robot arm may be moved manually on smaller robot models, but larger models may
require using an overhead crane or similar.
Increased injury
© Copyright 2006 ABB. All rights reserved.
Before releasing the brakes, make sure that the weight of the arms does not increase the
pressure on the trapped person, further increasing any injury!
3HAC027076-001 Revision: A
23
1: Safety
1.4.4 Brake testing
1.4.4 Brake testing
When to test
During operation the holding brake 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 the holding brake of each axis motor may be checked as detailed below:
1. Run each robot axis to a position where the combined weight of the robot 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.
© Copyright 2006 ABB. All rights reserved.
If the robot does not change position as the motors are switched off, then the brake
function is adequate.
24
3HAC027076-001 Revision: A
1: Safety
1.4.5 Risk of disabling function "Reduced speed 250 mm/s"
1.4.5 Risk of disabling function "Reduced speed 250 mm/s"
NOTE!
© Copyright 2006 ABB. All rights reserved.
Do not change "Transm gear ratio" or other kinematic parameters from the FlexPendant or a
PC. This will affect the safety function Reduced speed 250 mm/s.
3HAC027076-001 Revision: A
25
1: Safety
1.4.6 Safe use of the FlexPendant
1.4.6 Safe use of the FlexPendant
NOTE!
The enabling device is a push button located on the side of the FlexPendant 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.
To ensure safe use of the FlexPendant, the following must be implemented:
The enabling device must never be rendered inoperative in any way.
•
During programming and testing, the enabling device must be released as soon as
there is no need for the robot to move.
•
The programmer must always bring the FlexPendant with him/her, when entering the
robot's working space. This is to prevent anyone else taking control of the robot
without the programmer knowing.
© Copyright 2006 ABB. All rights reserved.
•
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3HAC027076-001 Revision: A
1: Safety
1.4.7 Work inside the robot's working range
1.4.7 Work inside the robot's working range
WARNING!
If work must be carried out within the robot’s work envelope, the following points must be
observed:
The operating mode selector on the controller must be in the manual mode position to
render the enabling device operative and to block operation from a computer link or
remote control panel.
•
The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in
position "manual mode with reduced speed". This should be the normal position when
entering the working space. The position "manual mode with full speed (100%)" may
only be used by trained personnel who are aware of the risks that this entails.
•
Pay attention to the rotating axes of the robot! Keep a distance to the axes in order not
to get entangled with hair or clothing. Also be aware of any danger that may be caused
by rotating tools or other devices mounted on the robot or inside the cell.
•
Test the motor brake on each axis, according to section Brake testing on page 24.
© Copyright 2006 ABB. All rights reserved.
•
3HAC027076-001 Revision: A
27
1: Safety
1.4.8 Translate the information on safety and information labels
1.4.8 Translate the information on safety and information labels
Labels on the product
Both the robot and the controller are marked with several safety and information labels,
containing important information about the product. The information is useful for all
personnel handling the robot system, eg. during installation, service or operation.
Translation possibilities
The labels fitted to the product contain space for adding a fourth language underneath the
three standard languages (English, German and French).
Add a local language to the label by:
•
using a transparent sticker over the standard label with text added in a fourth language.
Drawings detailing the design (text, figure, dimensions) of the standard labels can be
ordered from ABB. Notice that each label is identified according to the article number
located in the lower corner of the label.
Example of transparent sticker
© Copyright 2006 ABB. All rights reserved.
The figure below shows the location of the free space on one of the labels on the robot, where
the fourth language can be added. The figure also shows a transparent sticker, containing the
text in Swedish.
xx0500002517
A
28
Free space for adding a fourth language
3HAC027076-001 Revision: A
1: Safety
1.5.1 Safety related instructions
1.5: Safety related instructions
1.5.1 Safety signals, general
General
This section specifies all dangers that may arise from performing the work detailed in the
manual. Each danger is detailed in its own section consisting of:
•
A caption specifying the danger level (DANGER, WARNING or CAUTION) and the
type of danger.
•
A brief description of what will happen if the operator/service personnel do not
eliminate the danger.
•
An instruction of how to eliminate the danger to facilitate performing the activity at
hand.
Danger levels
The table below defines the captions specifying the danger levels used throughout this
manual.
Symbol
Designation
Signification
DANGER
Warns that an accident will occur if the instructions
are not followed, resulting in a serious or fatal injury
and/or severe damage to the product. It applies to
warnings that apply to danger with, for example,
contact with high voltage electrical units, explosion
or fire risk, risk of poisonous gases, risk of crushing,
impact, fall from height etc.
WARNING
Warns that an accident may occur if the instructions
are not followed, that can lead to serious injury,
possibly fatal, and/or great damage to the product. It
applies to warnings that apply to danger with, for
example, contact with high voltage electrical units,
explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height etc.
ELECTRICAL
SHOCK
The electrocution or electrical shock symbol
indicates electrical hazards which could result in
severe personal injury or death.
CAUTION
Warns that an accident may occur if the instructions
are not followed, that can result in injury and/or
damage to the product. It also applies to warnings of
risks that include burns, eye injury, skin injury,
hearing damage, crushing or slipping, tripping,
impact, fall from height etc. Furthermore, it applies to
warnings that include function requirements when
fitting and removing equipment, where there is a risk
of damaging the product or causing a breakdown.
danger
© Copyright 2006 ABB. All rights reserved.
warning
Electrical shock
caution
3HAC027076-001 Revision: A
29
1: Safety
1.5.1 Safety signals, general
Symbol
Designation
Signification
ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates
DISCHARGE (ESD) electrostatic hazards which could result in severe
damage to the product.
Electrostatic discharge
(ESD)
NOTE
Note symbols alert you to important facts and
conditions.
TIP
Tip symbols direct you to specific instructions, where
to find additional information or how to perform a
certain operation in an easier way.
Note
© Copyright 2006 ABB. All rights reserved.
Tip
30
3HAC027076-001 Revision: A
1: Safety
1.5.2 DANGER - Moving robots are potentially lethal!
1.5.2 DANGER - Moving robots are potentially lethal!
Description
Any moving robot is a potentially lethal machine.
When running the robot, it may perform unexpected and sometimes irrational movements.
However, all movements are performed with great force and may seriously injure any
personnel and/or damage any piece of equipment located within the robot working range.
Elimination
Action
Note
1. Before attempting to run the robot, make
sure all emergency stop equipment is
correctly installed and connected.
Emergency stop equipment such as gates,
tread mats, light curtains, etc.
2. If possible, use the hold-to-run button
whenever possible.
The hold-to-run button is used in manual
mode, not in automatic mode.
How to use the hold-to-run control in
RobotWare 5.0 is detailed in section How
to use the hold-to-run function in the
Operating manual - IRC5 with FlexPendant.
© Copyright 2006 ABB. All rights reserved.
3. Make sure no personnel are present within
the robot working range before pressing the
start button.
3HAC027076-001 Revision: A
31
1: Safety
1.5.3 DANGER - First test run may cause injury or damage!
1.5.3 DANGER - First test run may cause injury or damage!
Description
Since performing a service activity often requires disassembly of the robot there are several
safety risks to take into consideration before the first test run.
Elimination
Follow the procedure below when performing the first test run after a service activity (repair,
installation or maintenance):
Action
1. Remove all service tools and foreign objects from the robot and its working area!
2. Install all safety equipment properly!
3. Make sure all personnel are standing at a safe distance from the robot, i.e. out of its
reach behind safety fences, etc.!
© Copyright 2006 ABB. All rights reserved.
4. Pay special attention to the function of the part previously serviced!
32
3HAC027076-001 Revision: A
1: Safety
1.5.4 WARNING - The unit is sensitive to ESD!
1.5.4 WARNING - The unit is sensitive to ESD!
Description
ESD (electro static discharge) is the transfer of electrical static charge between two bodies at
different potentials, either through direct contact or through an induced electrical field. When
handling parts or their containers, personnel not grounded may potentially transfer high static
charges. This discharge may destroy sensitive electronics.
Elimination
Action
Note
Wrist straps must be tested frequently to ensure
that they are not damaged and are operating
correctly.
2. Use an ESD protective floor mat.
The mat must be grounded through a currentlimiting resistor.
3. Use a dissipative table mat.
The mat should provide a controlled discharge of
static voltages and must be grounded.
© Copyright 2006 ABB. All rights reserved.
1. Use a wrist strap
3HAC027076-001 Revision: A
33
1: Safety
1.5.5 WARNING - Safety risks during work with gearbox oil
1.5.5 WARNING - Safety risks during work with gearbox oil
Description
When handling the gearbox oil, there are several dangers to both personal injuries and product
damages! Following safety information must be regarded before performing any work with
the oil in the gearboxes!
Warnings and elimination
Warning
Description
Elimination / Action
Changing and draining
Make sure that protective gear
gearbox oil may require
like goggles and gloves are
handling hot oil of up to 90 °C! always worn during this activity.
-
Hot oil!
When opening the oil plug,
Open oil plug carefully and keep
there may be pressure present away from the opening. Do not
in the gearbox, causing oil to overfill the gearbox when filling.
spray from the opening!
-
-
Do not overfill!
-
Overfilling of gearbox oil can
lead to internal over-pressure
inside the gearbox which in
turn may:
• damage seals and
gaskets
• completely press out
seals and gaskets
• prevent the robot from
moving freely.
Make sure not to overfill the
gearbox when filling with oil!
After filling, check the correct oil
level.
Mixing types of oil may cause
severe damage to the
gearbox!
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!
Do not mix types of oil!
34
3HAC027076-001 Revision: A
© Copyright 2006 ABB. All rights reserved.
Possible pressure build
up in gearbox!
1: Safety
1.5.5 WARNING - Safety risks during work with gearbox oil
Warning
Description
Elimination / Action
Warm oil drains quicker than
cold oil.
When changing gearbox oil, first
run the robot for a time to heat
up the oil.
-
Heat up the oil!
-
© Copyright 2006 ABB. All rights reserved.
Specified amount
depends on drained
volume!
The specified amount of oil is After refilling, check the oil level.
based on the total volume of
the gearbox. When changing
the oil, the amount of refilled oil
may differ from the specified
amount, depending on how
much oil has previously been
drained from the gearbox.
3HAC027076-001 Revision: A
35
1: Safety
© Copyright 2006 ABB. All rights reserved.
1.5.5 WARNING - Safety risks during work with gearbox oil
36
3HAC027076-001 Revision: A
Installation and commissioning
Transporting and Unpacking
2: Installation and commissioning
2.1: Transporting and Unpacking
Unpacking
CAUTION!
Before starting to unpack and install the robot, read the safety regulations and other instructions very carefully. See Safety on page 13.
The installation shall be made by qualified installation personnel and should conform to all
national and local codes.
NOTE!
When you have unpacked the robot, check that it has not been damaged during transport or
while unpacking.
NOTE!
If the signal lamp option is selected, the signal lamp is fitted under the protective cover on
axis four housing to protect it during transport.
Operating conditions:
Ambient temperature
+5°C (41°F) to +50°C (122°F)
Relative humidity
Max. 95% at constant temperature
Storage conditions:
If the equipment is not going to be installed straight away, it must be stored in a dry area at
an ambient temperature between -25°C (-13°F) and +55°C (131°F).
When air transport is used, the robot must be located in a pressure-equalized area.
© Copyright 2006 ABB. All rights reserved.
The net weight of the robot is approximately:
Robot Type IRB 6400R M2004
Weight
2,5-200
2230 kg (4916 lb.)
2,8-200
2390 kg (5269 lb.)
Whenever the robot is transported, axis 2 must be bent backwards 30° and axis 3 must be
moved down to a position against the rubber stops on axis 2.
3HAC027076-001 Revision: A
37
Installation and Comissioning
2.1.1 Stability / Risk of Tipping
2.1.1 Stability / Risk of Tipping
WARNING!
When the robot is not fastened to the floor and standing still, the robot is not stable in the
whole working area. When the arms are moved, care must be taken so that the centre of
gravity is not displaced, as this could cause the robot to tip over.
The following table shows the positions where there is a risk of tipping. For definition of position 0 and 5, refer to Product Specification for IRB 6400RF.
In position NEW, with axis 2 at an angle of -35° and axis 3 at an angle of 0°, there is no risk
of the robot tipping.
Working Area Pos. 0
Version Load=0
kg
Working Area Pos. 5
NEW Pos.
Load=max
Load=0
kg
Load=max
Load=0
Load=max
kg
2.5-200
Stable
Risk of
tipping
Risk of
tipping
Risk of
tipping
Stable
Stable
2.8-200
Stable
Risk of
tipping
Risk of
tipping
Risk of
tipping
Stable
Stable
All other axes should have an angle of 0°.
For Foundry (F) version, see corresponding non F-version.
2.1.2 System CD ROM and Diskette
© Copyright 2006 ABB. All rights reserved.
The system CD ROM and the robot parameter disk are delivered with the robot system.
38
3HAC027076-001 Revision: A
Installation and Comissioning
2.2.1 On-site installation
2.2: On-site installation
2.2.1 Lifting the robot
General
If the integrated lifting ears on the front cannot be reached, the robot must be reoriented to the
sync position (applicable to versions 2.8-120 and 3.0-75 only).
The best way to lift the robot is to use four lifting straps of similar length with hooks and a
traverse crane, lifting tool 3HAC 3083-1 is recommended. Attach the straps to the integrated
lifting eyes on both sides of the frame (see Figure 1). The lifting strap dimensions must comply with the applicable standards for lifting. It is also possible to use two lifting devices
(option) for use with a fork lift truck (see Figure 2).
WARNING!
The following lifting instructions are valid for a “naked” robot. Whenever additional equipment is put on the robot, the centre of gravity can change and make lifting dangerous.Never
walk under a suspended load.
© Copyright 2006 ABB. All rights reserved.
Crane lift for:
2.5-200 and 2.8-200
Figure 1 Lifting the robot using a Traverse Crane
3HAC027076-001 Revision: A
39
Installation and Comissioning
2.2.1 Lifting the robot
Fork lift for:
2.5-200 and 2.8-200
400
View from the side
914
754
View from the rear
467
675
800
(If adjusted to recommended
transport position)
© Copyright 2006 ABB. All rights reserved.
1280
View from above
Figure 2 Lifting the robot using a Fork Lift Truck. (Dimensions in mm.)
WARNING!
Crane lifting is not permitted using the fork lift arrangement.
40
3HAC027076-001 Revision: A
Installation and Comissioning
2.2.2 Assembling the Robot
2.2.2 Assembling the Robot
Support points
The four support points of the robot foot must be mounted on four flat surfaces with a flatness
within the specification. Use shims if necessary. The rest of the surface must be flat within ±
2 mm. Footprint diagram, see Figure 3. Floor mounted models can be tilted max. 5o.
Levelness
The levelness requirement for the surface is as follows:
0.5
Bolting down the robot
The robot is fixed with eight M24 bolts which must be tightened alternately.
243.5 (4x)
317.34 (4x)
Y
317.34 (4x)
243.5 (4x)
B
R 400
B
Z
X
4x
∅ 0.1
37.
(4x)
5°
A
A
15
°
© Copyright 2006 ABB. All rights reserved.
x)
(4
∅ 50 (8x)
∅ 28 (8x)
100 ±0.5
+2
15 0
∅ 45 H7 (4x)
B-B
A-A
Figure 3 Bolting down the robot
NOTE!
All eight bolts must be used.
3HAC027076-001 Revision: A
41
Installation and Comissioning
2.2.2 Assembling the Robot
Suitable bolts
Suitable bolts
M24x140 Socket screw
Quality
8.8
Suitable washer
OD = 44 mm (1.7 in.)
ID = 25 mm (1 in.)
T = 4 mm (0.16 in.)
Tightening torque
775 Nm
It is recommended that the robot is mounted with M24x140, 8.8 socket screws (3) on two base
plates (1) with four locating bushings (2), that allows the same robot to be re-mounted without
program adjustment (see Figure 4).
For base plate measures (see Figure 5).
For locating bushing measures (see Figure 3).
3
2
1
Figure 4 Base Plate
42
3HAC027076-001 Revision: A
© Copyright 2006 ABB. All rights reserved.
When bolting a mounting plate or frame to a concrete floor, follow the general instructions
for expansion-shell bolts. The screw joint must be able to withstand the stress loads defined
in Chapter .
Installation and Comissioning
2.2.2 Assembling the Robot
15
+2
0
∅ 45 H9
+0,062
0
3x45º
A-A
800
717,34
64,35
156,5
82,66
0
R max 1,2
M24(x4)
153,84
M24(x4)
127
A
70
A
80
∅24(x6)
27
0
0
773
597
203
0
27
M16(x2)
Figure 5 Base Plate Measures
Orienting the robot
© Copyright 2006 ABB. All rights reserved.
To orient the robot when attaching it to the floor, three guide pins can be fitted in the appropriate holes, ∅ 8,5 mm (see Figure 6).
∅ 8,5 (3x)
Figure 6 Orientation Holes
3HAC027076-001 Revision: A
43
Installation and Comissioning
2.2.3 Stress Forces
2.2.3 Stress Forces
Stiffness
The stiffness of the foundation must be designed to minimize the influence on the dynamic
behavior of the robot. For optimal performance the frequency of the foundation with the robot
weight must be higher than 22 Hz
NOTE!
TuneServo can be used for adapting the robot tuning to a non-optimal foundation.
All Versions
Load
Endurance load
(in operation)
Max. load
(emergency stop)
Force xy
±14 000 N
±38 000 N
Force z
22 000 ±8 000 N
22 000 ±19 000 N
Torque xy
± 34 000 Nm
±61 000 Nm
Torque z
±7 000 Nm
±15 000 Nm
Y
X
Z
Figure 7 The Directions of the Stress Forces
44
3HAC027076-001 Revision: A
© Copyright 2006 ABB. All rights reserved.
Force xy and torque xy are vectors that can have any direction in the xy plane.
Installation and Comissioning
2.2.4 Amount of Space required
2.2.4 Amount of Space required
General
The amount of working space required to operate the robot is illustrated in Figure 8.
The working range for axis 1 is +/- 180°.
CAUTION!
There are no software or mechanical limits for the working space under the base of the robot.
NOTE!
All dimensions in illustration refer to the wrist centre in mm.
2.5-200 and 2.8-200
2.8
2.5
2762
2600
305
645
© Copyright 2006 ABB. All rights reserved.
909
1083
1229
2469
2800
Figure 8 The Working Space required for the robot.(Note! The 3.0 series is no longer available)
3HAC027076-001 Revision: A
45
Installation and Comissioning
2.2.5 Manually releasing the Brakes
2.2.5 Manually releasing the Brakes
General
All axes come equipped with holding brakes. When the position of a robot axis needs to be
changed without connecting the controller, an external voltage supply (24 V DC) must be
connected to enable disengagement of the brakes.
The voltage supply should be connected to the connector at the base of the robot (see Figure
9).
WARNING!
For robots with serial no. 64-15011 to 64-15015, the pins 37 (0V) and 33 (+24V) are used to
supply power for releasing the brakes.
Pin 11: 24V
Pin 12: 0V
Figure 9 Connection of External Voltage to enable Disengagement of the Brakes
WARNING!
External power must be connected as shown in Figure 9. Incorrectly connected power can
release all brakes, causing immediate movement of all axes.
When the controller or the voltage device is connected, as illustrated above, the brakes can be
released one by one by means of the push-buttons on the brake release unit on the exterior of
the axis 3 gear box. The push-buttons are marked with the appropriate axis name. The names
of the axes and their motion patterns are illustrated in Figure 10.
WARNING!
Be very careful when disengaging the brakes. The axes become activated very quickly and
may cause damage or injury.
46
3HAC027076-001 Revision: A
© Copyright 2006 ABB. All rights reserved.
Voltage connected
Installation and Comissioning
2.2.5 Manually releasing the Brakes
Axis 3
Axis 4
Axis 5
6
5
4
Axis 6
3
2
1
Brake release
Axis 2
Axis 1
© Copyright 2006 ABB. All rights reserved.
Figure 10 The Robot Axes and Motion Patterns
3HAC027076-001 Revision: A
47
Installation and Comissioning
2.2.6 Process Media Conduit
2.2.6 Process Media Conduit
General
It is recommended that the process media conduit is used in combination with the following
hoses and cables:
- 3x25 mm2 ELOCAB weld cable
- 3x35 mm2 ELOCAB weld cable
- Parker hoses type 837 BM-8WP
Restriction
This will give under specific circumstances a life span of 4 years with 3 shift operation
(2,000,000 cycles).
If the process media conduit is only used in an area between 100° and 180°, the inactive part
of the protective hose should be tied up to the upper guiding rail.
180°
100°
Restricted working space
© Copyright 2006 ABB. All rights reserved.
Figure 11 Restricted Working Space
48
3HAC027076-001 Revision: A
Installation and Comissioning
2.2.7 Restricting the Working Space
2.2.7 Restricting the Working Space
General
When installing the robot, make sure that it can move freely within its entire working space.
If there is a risk that it may collide with other objects, its working space should be limited,
both mechanically and using software. Installation of an optional extra stop for the main axes
1, 2 and 3 is described below.
Limiting the working space using software is described in the chapter Technical reference
manual- System parameters.
Axis 1
The range of rotation for axis 1 can be limited mechanically by fitting extra mechanical stops,
with 7.5° or 15° graduation.
Instructions for doing this are supplied with the kit.
WARNING!
The mechanical stop pin and the extra moveable mechanical stop arm for axis 1 must absolutely be replaced after a hard collision, if the pin or arm has been deformed.
© Copyright 2006 ABB. All rights reserved.
Movable stop
Holes for extra stops
Fixed stop
Figure 12 Mechanically limiting Axis 1
Axes 2 and 3
The working range of axes 2 and 3 is limited by mechanical stops and can be reduced by adding up to six fixed mechanical stops with 15° graduation.
The stops are fitted on the inside of the frame to each axis.
Extra stops must be fitted in a row, starting at the fixed stop.
WARNING!
When fitting extra stops, the cams for the position switch should not be mounted in position.
3HAC027076-001 Revision: A
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Installation and Comissioning
2.2.7 Restricting the Working Space
Holes for extra stops
© Copyright 2006 ABB. All rights reserved.
Figure 13 Mechanically limiting Axes 2 and 3
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2.2.8 Position Switches
2.2.8 Position Switches
General
Position switches can be installed on axis 1.
The switches can be connected to the controller. In the controller the signals are connected to
screw terminals.
Maximum voltage/current for the position switches:
Voltage:
240 Volt AC
Current:
6A
Instructions for fitting and adjusting of Cams and Stops
The cams are mounted in whole lengths and must therefore be cut to suit the application. Use
a sharp knife and a rubber hammer, for example.
It is important that the entry edge on the cam is chamfered to an angle of max. 30°. If the angle
is larger there is a risk of damaging the position switch (see Figure 14).
The ends of the cam, that are in the channel of the profile, must be cut at an angle of 90° so
that the contact area for the stop is as large as possible (see Figure 15).
When fitting the cam, it is important that the edges on the openings at the ends of the profile
are properly chamfered.
The cam stop comprises an M5 nut with an M5 x 6 stop screw. When the screw is tighten into
the material at the bottom of the profile, the nut is pushed up to the top of the channel and
forms a lock for the cam (see Figure 14).
1. Cam stop
© Copyright 2006 ABB. All rights reserved.
3
M5 nut
M5 x 6 stop screw
2. Adjustable cam
3. Profile
30°
1
2
Figure 14 Adjusting and locking the Cams for the Position Switch; the Figure shows the Position Breaker for Axis 2
3HAC027076-001 Revision: A
51
Installation and Comissioning
2.2.8 Position Switches
30°
90°
© Copyright 2006 ABB. All rights reserved.
Figure 15 Cutting the Cam
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2.2.9 Mounting Holes for Equipment on the robot
2.2.9 Mounting Holes for Equipment on the robot
CAUTION!
Never drill a hole in the robot without first consulting maintenance staff or the design department at ABB
Illustrations
A
A
D
E
D
E
M10 (2x) See E-E
Length of M10(x4) M10 (4x)
inside upper arm
<5 mm.
B
B
C
C
104 for “Hole 1”
93 for “Hole 2”
See E-E
50
685 (/2.5-X)
1030 (/2.8-X)
175
A-A
F
112
80
282
M10 (2x)
M10 (2x)
© Copyright 2006 ABB. All rights reserved.
B-B
F
378
C-C
(See F-F on the
next page)
260
93
150
M10 (4x) Depth 20
75
M10 (2x)
25
“Hole 2”
“Hole 1”
180
D-D
150
E-E
Figure 16 Holes for mounting Extra Equipment. (Dimensions in mm.)
3HAC027076-001 Revision: A
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Installation and Comissioning
2.2.9 Mounting Holes for Equipment on the robot
30o
D=10 H7 depth 10
8
M10 (6x) depth 18
D=80 H7
D=160 h7
60°
D=125
F-F
8
Figure 17 The mechanical Interface (Mounting Flange) ISO 9409-1-A125. (Dimensions in mm.)
30°
D=10 H7 Depth 10
8
M10 (6x) Depth 18
D=80 H7
D=160 h7
60°
D=125
10°
8
D=10 H7 Depth 10
F-F
Figure 18 The mechanical Interface of the Insulated Flange ISO 9409-1-A125. (Dimensions in mm.)
Quality of Screws for fitting Extra Equipment
Loads
It is important to define the loads properly (with regard to the position of centre of gravity and
inertia factor) in order to avoid jolting movements and unnecessary stops due to overloaded
motors.
For more information see Product Specification for IRB 6400RF for load diagrams, permitted
extra loads (equipment) and their positions. The loads must also be defined in the software,
see Operating manual - IRC5 with FlexPendant.
Stop Time and Braking Distances
For information about brake performance, please contact ABB.
54
3HAC027076-001 Revision: A
© Copyright 2006 ABB. All rights reserved.
When fitting tools on the robot’s mounting flange (see above), use only screws with quality
of 12.9. When fitting other equipment, standard screws with quality 8.8 can be used.
Installation and Comissioning
2.2.10 Signal Lamp
2.2.10 Signal Lamp
General
The connections for the signal lamp R2.H1 and R2.H2 are located under the cover for motor
axis 4.
NOTE!
When included in the robot delivery, the signal lamp is placed under the axis 4 cover during
transportation. Install the signal lamp according to steps 1-3 below before running the robot.
Installation of Signal Lamp
The following steps details how to install the signal lamp.
Action
1.
Dismount cover axis 4
2.
Mount the signal lamp to the bracket according to Figure 19
3.
Mount the cover
© Copyright 2006 ABB. All rights reserved.
.
Figure 19 Signal Lamp mounted on Bracket
Signal lamp
Cover axis 4
R2.H1
R2.H2
Figure 20 Connections of Signal Lamp
3HAC027076-001 Revision: A
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Installation and Comissioning
© Copyright 2006 ABB. All rights reserved.
2.2.10 Signal Lamp
56
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Installation and Comissioning
2.3.1 Application Interface
2.3: Application Interface
2.3.1 Media Outlet on Upper Arm
General
The harness for air supply and signals to upper arm is integrated into the robot arm system.
The inlets are located at robot base, see Figure 22, and outlets on the upper arm housing or
on the moveable part on the upper arm, see Figure 21.
Air connection R1.CAIR and R2.CAIR
G1/2" - 14
Max. 10 bar. One hose with inner diameter 13 mm.
Signal Connection on Upper Arm
Connections for R2.CP, R2.CS, R3.CANBUS and R3.IBUS/PBUS
For complete customer connector kit, see section For Connector R2 on page 61.
CS
FCI 12-pin UTO
CP
FCI 4-pin UTO
Field Bus
CAN/DeviceNet
Signal Connection at Base
Connections for R1.CP/CS. CP, CS signals and field bus are integrated in one connector.
For complete customer connector kit, see section For Connector R1 on page 61.
Signal Specification
© Copyright 2006 ABB. All rights reserved.
CAN/DeviceNet
- Signal
2
50V AC/DC, 250 mA, min. AWG24
- Power
2
50V AC/DC, 2A, AWG24
CS signal
10
50V AC/DC, 250 mA, AWG24
CP power
2 + earth
250V AC, 8A, 1.0 mm2
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Installation and Comissioning
2.3.1 Media Outlet on Upper Arm
R2.CP
R2.CS
R2.CAIR
R3.CANBUS
R3.IBUS/PBUS
Figure 21 Location of Customer Connections on Upper Arm / Arm Housing
R1.CP/CS
(field bus)
R1.MP
R1.SW1
R1.PROC3
R1.SMB
R1.PROC2
R1.SW2/3
R1.CAIR
R1.PROC1
Figure 22 Location of Customer Connections on Base
58
3HAC027076-001 Revision: A
© Copyright 2006 ABB. All rights reserved.
R1.WELD
Installation and Comissioning
2.3.2 Media Outlet with CAN/DeviceNet
2.3.2 Media Outlet with CAN/DeviceNet
General
The CAN/CP/CS cable is connected to connector R1.CP/CS on the robot foot and to terminal
inside the controller cabinet. The terminals are pre mounted in the cabinet if the robot is
ordered with option “Media Outlet on Upper Arm” (see Figure 23 and Figure 24).
For customer connections to connectors R2.CP, R2/CS and R3.CANBUS, see recommendations for connector kit in section For Connector R2 on page 61 .
For installation without CAN/CP/CS cable connected between robot and controller, see recommendations for connector kit in section For Connector R1 on page 61.
Illustration
R2.CP
R2.CS
R2.CAIR
R3.CANBUS
Figure 23 Location of Customer Connections on Upper Arm / Arm Housing
XT6
XT5
© Copyright 2006 ABB. All rights reserved.
R1.CP/CS
Foundry
XS6
Robot Controller (top view)
A
XS6
A
A-A
XT6 XT5
Figure 24 CAN Bus Connection in Cabinet
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Installation and Comissioning
2.3.3 Signal Connections
2.3.3 Signal Connections
With CAN bus
Signal name
Customer
terminal
controller,
XT5-XT6
Customer connector on
robot base, R1.CP/CS
(cable not supplied)
Customer connector on upper
arm/arm housing, R2.CPR2.CS-R3.CANBUS
CPA
XT6.1
R1.CP/CS.1 (3p D-Sub)
R2.CP.A
CPB
XT6.2
R1.CP/CS.2 (3p D-Sub)
R2.CP.B
PE
XT6.3
R1.CP/CS.3 (3p D-Sub)
R2.CP.C
CSA
XT5.1
R1.CP/CS.1 (25p D-Sub)
R2.CS.A
CSB
XT5.2
R1.CP/CS.2 (25p D-Sub)
R2.CS.B
CSC
XT5.3
R1.CP/CS.3 (25p D-Sub)
R2.CS.C
CSD
XT5.3
R1.CP/CS.4 (25p D-Sub)
R2.CS.D
CSE
XT5.5
R1.CP/CS.5 (25p D-Sub)
R2.CS.E
CSF
XT5.6
R1.CP/CS.6 (25p D-Sub)
R2.CS.F
CSG
XT5.7
R1.CP/CS.7 (25p D-Sub)
R2.CS.G
CSH
XT5.8
R1.CP/CS.8 (25p D-Sub)
R2.CS.H
CSJ
XT5.9
R1.CP/CS.9 (25p D-Sub)
R2.CS.J
CSK
XT5.10
R1.CP/CS.10 (25p D-Sub)
R2.CS.K
Power supply
Signals
CAN/DeviceNet
60
XS6.3
R3.CAN bus.1
+24VCAN
XS6.5
R1.CP/CS.1 (9pD-Sub)
R3.CAN bus.2
0VCAN
XS6.1
R1.CP/CS.2 (9pD-Sub)
R3.CAN bus.3
CAN_H
XS6.4
R1.CP/CS.5 (9pD-Sub)
R3.CAN bus.4
CAN_L
XS6.2
R1.CP/CS.9 (9pD-Sub)
R3.CAN bus.5
3HAC027076-001 Revision: A
© Copyright 2006 ABB. All rights reserved.
DRAIN
Installation and Commissioning
Customer Connector Kit
2.4: Customer Connector Kit
For Connector R1
R1.CP/CS
3HAC 11989-1
Year model:
IRB 6400RF M2004
Content:
Hood IP 68, Triple screw cap, D-sub adapter, D-sub 25p, D-sub 9p,
Power D-sub, Sockets (0.20–0.56 mm2), Power sockets (1.5 mm2),
Shield rings for D-sub, Label (R1.CP/CS), screws.
Installation:
See 3HAC 12332-1 (Included in the kit.)
Type:
D-subs integrated in one AMP Hood IP 68.
Special tool
need:
Crimping tool, stripping pliers.
D-Sub 9p
D-Sub 25p
Adapter
D-Sub Power
© Copyright 2006 ABB. All rights reserved.
For Connector R2
R2.CP+R2.CS
3HAC 11991-1
Year model:
IRB 6400RF M2004
Content:
Multiple connector 4p, Multiple connector 12p, Adapters,
Pins (0.25–0.5 mm2), Pins (0.5–1.5 mm2), Angled shrinking hoses
12p+4p, Bottle shaped shrinking hose 12p, Label (R2.CP, R2.CS).
Installation:
See 3HAC 12332-1 (Included in the kit.)
Type:
Burndy. Angle or bottle shaped. Pins for two wire dimensions 12p.
Special tool need:
Crimping tool, hot air gun, stripping pliers.
R3.CANBUS
3HAC 12030-1
Year model:
IRB 6400RF M2004
Content:
Male connector.
Installation:
See 3HAC 12332-1 (Included in the kit.)
Type:
Straight.
Special tool need:
Crimping tool, hot air gun, stripping pliers.
For Connector R3
3HAC027076-001 Revision: A
61
Installation and Commissioning
© Copyright 2006 ABB. All rights reserved.
Customer Connector Kit
62
3HAC027076-001 Revision: A
Decomissioning
3.1.1 General
3: Decommissioning
3.1: General
The components of the robot are manufactured from many different materials. Some of them
are listed below to facilitate scrapping, i.e. so that the components can be disposed of in a way
that does not have a detrimental effect on anyone’s health or the environment.
3.1.1 robots
Material
Examples of components
Part of
Grey cast iron
Counter-weight
IRB 6400RF
Batteries,
NiCad or Lithium
Serial measurement board
All robot types
Copper
Cables, motors
All robot types
Cast iron/nodular iron
Base, lower arm, upper arm, parallel bar/arm All robot types
Steel
Gears, screws, base-frame, etc.
All robot types
Samarium-Cobalt
Brakes, motors
IRB 1400, 2400,
4400
Neodymium
Brakes, motors
IRB 6400, 640
Plastic/rubber (PVC)
Cables, connectors, drive belts, etc.
All robot types
Oil, grease
Gearboxes
All robot types
Aluminium
Covers, sync. brackets
All robot types
Castings in wrist, upper arm tubular
IRB 1400, 2400
3.2: Scrapping
WARNING!
© Copyright 2006 ABB. All rights reserved.
The Counter-weight for robots 6400 contains grey cast iron and must therefore always be
recycled.
3.2.1 General warning
WARNING!
Before removing any parts from the robot, study the dismantling instructions for the component in question. Dismantling instructions can be found under Repairs.
3.2.2 Oil and grease
Where possible, arrange for the oil and grease to be recycled. Dispose of via an authorized
person/contractor in accordance with local regulations. Do not dispose of oil and grease near
lakes, ponds, ditches, down drains, or on to soil. Incineration may be carried out under controlled conditions in accordance with local regulations.
Also note that:
•
Spills may form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired.
•
Spillage may penetrate the soil causing ground water contamination.
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Decomissioning
3.2.3 Parts requiring special treatment when scrapping
3.2.3 Parts requiring special treatment when scrapping
© Copyright 2006 ABB. All rights reserved.
Special care is needed when removing certain parts from the robot, before scrapping the part
in question. The types of robot on which there are such parts are listed below together with a
description of how they should be removed.
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3HAC027076-001 Revision: A
Decomissioning
3.2.4 IRB 6400R Balancing cylinder
3.2.4 IRB 6400R Balancing cylinder
The balancing cylinder contains 1–2 pre-loaded spiral springs. Before scrapping (melting
down, or other form of destruction) the springs must be unloaded in a safe way, (see Scrapping Balancing cylinders on page 66).
There are different types of balancing cylinder with a pre-loading force between 4500–8000
N
The free length of the unloaded springs is about 300–400 mm excluding the length of the balancing cylinder.
Double Spiral spring
Single Spiral spring
© Copyright 2006 ABB. All rights reserved.
Figure 25 Balancing cylinder, IRB 6400.
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65
Decomissioning
3.2.5 Scrapping Balancing cylinders
3.2.5 Scrapping Balancing cylinders
WARNING!
It is most important that no enclosed spaces remain when the scrap is shipped to the steel plant
for recycling.
General method
The normal way to scrap the balancing cylinder is to use a so-called shredder or scrapping
mill. All the balancing cylinders can be treated in this way.
All-enclosed scrapping mills in which the scrap is ground to chips, e.g “Newell heavy duty
shredder plant 2205” or similar, are available at all major scrap merchants.
Alternative methods
If a scrapping mill is not available, the balancing cylinder (except 3HAA 0001-EZ) can be
opened by means of a blowpipe as shown in the sketches (see Scrapping balancing cylinders
on page 66).
• Balancing unit for IRB 6400RF.
Cut a hole (250 x 150 mm) in the mantel surface and then cut all the uncovered spring.
Finally cut a hole (40 mm) in the piston rod, alt. A, or cut off the piston rod end, alt. B.
• Balancing unit for Shelf version.
Cut a hole (250 x 150 mm) in the outer mantel surface and cut the uncovered spring so
it will be possible to cut another hole (200 x 100 mm) in the inner mantel surface. Cut
the inner spring and cut off the piston rod end.
ca. 250
Cut off Piston rod
© Copyright 2006 ABB. All rights reserved.
ca. 200
Figure 26 Scrapping balancing cylinders
66
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Decomissioning
3.2.5 Scrapping Balancing cylinders
ca. 250
Ca Ø 40mm
Cut off Spiral spring
Hole in the Piston rod
Alternative A
ca. 250
Cut off Piston rod
Cut off Spiral spring
Alternative B
© Copyright 2006 ABB. All rights reserved.
Figure 27 Scrapping balancing cylinders
Figure 28 scrapping Balancing cylinders
3HAC027076-001 Revision: A
67
Decomissioning
© Copyright 2006 ABB. All rights reserved.
3.2.5 Scrapping Balancing cylinders
68
3HAC027076-001 Revision: A
Maintenance
Intervals
4: Maintenance
4.1: Intervals
Inspection
Prescribed
maintenance
twice a
year
Maintenance intervals
once a 4 000 h
year
or
2 years
Balancing unit axis 2
Bearings, inspection
5 years
20 000 h
or
4 years
X
X1
Balancing unit axis 2
Bearings, greasing
Balancing unit axis 2
Piston rod/Guide ring
X2
Cabling (see Cabling Life
Time on page 70).
X3
Mechanical stop axis 1
X4
X
Gearbox 6
Grease changing
X5
Gearbox axis 1
Oil changing (see Operating life of gearbox axis
1 on page 71).
X6
Gearboxes axes 2-5
Oil changing
X
Oil level axes 1-5
X
3 years7
Accumulator for-measuring system
Exchange
Position Switch
© Copyright 2006 ABB. All rights reserved.
12 000 h
or
3 years
X1
X
X8
1. For foundry operation.
2. If the robot operation is utilized in adverse conditions (for example: particleladen environments, such as
spot welding, grinding, deflashing, etc.), perform preventive maintenance more
frequently to ensure proper reliability of the robot system. See Lubricating piston
rod, balancing unit axis 2 on page 78.
3. Inspect all visible cabling. Change if damaged (valid for all cabling except
cabling on axes 1 and 4).
4.Check the mechanical stop devices for deformation and damage. If the stop pin or
the adjustable stop arm is bent, it must be replaced. See Checking mechanical
stop on page 85.
5.For press-tending refer to grease changing and operating life for gearbox axis 6,
see Grease change axis 6 on page 71 and Operating life of gearbox axis 1 on
page 71.
6. Recommended interval for oil change axis 1, see Oil exchange axis 1 on page
70. Approx. estimate of operating life of gearbox axis 1 as a function of the cycle
time. For press-tending see Operating life of gearbox axis 1 on page 71.
7. see Location of SMB battery on page 86
3HAC027076-001 Revision: A
69
Maintenance
Intervals
8. Not required in an ordinary industrial environment
Cabling Life Time
Min. life time
No. of cycles
robot cabling axis 1
Customer cabling axis 1
robot cabling axis 4
Customer cabling axis 4
6
4· 10
3· 106
2· 106
1· 106
25mm2 SW-cabling internal
35mm2 SW-cabling internal
(Rotation
angle)
Figure 29 Cabling life time (3-shift = 500 000 cycles per year or 5 000 h per year).
NOTE!
The rest of the robot and customer cabling = 8 years.
Oil exchange axis 1
20000 h
4
3
2
1
5000 h
5 s (PT)
10 s (SW)
(Cycle time)
Figure 30 Recommended interval for Oil exchange axis 1. (3-shift)
70
3HAC027076-001 Revision: A
© Copyright 2006 ABB. All rights reserved.
Operation
(years)
Maintenance
Intervals
Operating life of gearbox axis 1
Life time (operation) (h)
40 000
30 000
20 000
10 000
3
4
5
6
7
8
Cycle time (s)
9
Figure 31 Approx. estimate of operating life of gearbox axis 1 as a function of the cycle time for press-tending.
Grease change axis 6
Operation (h)
25 000
20 000
15 000
© Copyright 2006 ABB. All rights reserved.
10 000
5 000
50
100
150
Moment of
inertia Ja66 (kgm2)
Figure 32 Recommended interval for changing grease on axis 6
Operating life of gearbox axis 6
The table below details the approx. estimate of operating life of gearbox axis 6 as a function
of the moment of inertia Ja6. Ja6 according to the Product Specification, chapter 3.
3HAC027076-001 Revision: A
71
Maintenance
Intervals
Life time (operation) (h)
45 000
40 000
35 000
30 000
25 000
20 000
15 000
10 000
5 000
50
100
150
Moment of
inertia Ja66 (kgm2)
© Copyright 2006 ABB. All rights reserved.
Figure 33 Approx. estimate of operating life of gearbox axis 6.
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3HAC027076-001 Revision: A
Maintenance
Instructions for maintenance
4.2: Instructions for maintenance
General instructions for the robot
Check regularly:
for any oil leaks. If a major oil leak is discovered, call for service personnel.
for excessive play in gears. If play develops, call for service personnel.
that the cabling between the control cabinet and robot is not damaged.
Check after a collision with external objects:
that the upper and lower arms and the wrist is not damaged. If damage is discovered, call for
service personnel.
NOTE!
© Copyright 2006 ABB. All rights reserved.
Cleaning, see Cleaning of robot on page 89.
3HAC027076-001 Revision: A
73
Maintenance
4.2.1 Checking the oil and grease levels
4.2.1 Checking the oil and grease levels
Axis 6
The level in the gearbox is checked by adding new grease until grease comes out through the
special draining hole, see Lubricating gearbox, axis 6 on page 82.
Axes 1, 2, 3, 4 and 5.
The level is checked by opening the oil plugs. See Oil change gearbox, axis 1 on page 75, Oil
change, axes 2 and 3 on page 79 and Oil change gearbox, axis 4 on page 80.
Oil levels
Minimum 15 mm under the level of the filling plug, see Oil plugs. on page
75 <11>
Axis 2/3
Minimum 20 mm under the level of the filling plug, see Oil plugs, axes 2 and
3. on page 79 <14>
Axis 4/5
Minimum 10 mm under the level of the filling plug, see Drain hole axis 4 on
page 80 <B>
© Copyright 2006 ABB. All rights reserved.
Axis 1
74
3HAC027076-001 Revision: A
Maintenance
4.2.2 Oil change gearbox, axis 1
4.2.2 Oil change gearbox, axis 1
Procedure
The following procedures details how to change oil in gearbox, axis 1.
Action
1. Remove the three plugs with sealing rings, see Figure 34.
• ventilation plug (10) (breather)
•
level plug (11) and filling plug
•
drain nut (12).
2. Drain off the used oil through the hose.
3. Refit the drain nut (12).
4. Fill up with new oil until the oil level reaches the lower edge of the fill and level hole.
5. Refit the filling plug (11) and ventilation plug (10).
6. Tightening torque, oil plugs: 60 Nm
Oil type and volume
Volume approx
11.2 liters. (3.35 US gallon)
Type of oil:
ABB 1171 2016-604
Equivalents:
- Castrol Alpha SP 320
- Esso Spartan EP 320
- Klüber Lamora 320
- Mobil Mobilgear X320
- Shell Omala Oil 320
- Texaco Meropa 320
- Statoil Loadway EP
© Copyright 2006 ABB. All rights reserved.
10
11
12
Figure 34 Oil plugs.
3HAC027076-001 Revision: A
75
Maintenance
4.2.3 Inspect and lubricate the bearings, balancing units axis 2
4.2.3 Inspect and lubricate the bearings, balancing units axis 2
General
The bearings should be inspected and lubricated every 12 000 hours (4 000 hours for
Foundry).
NOTE!
Make sure the shaft between the upper and lower arms does not rotate when unscrewing the
lock nut.
Required equipment
Type of grease:
ABB 3HAB 3537-1
Equivalents:
Shell Alvania WR 2
Preparations
Action
1.
Move axis 2 to the sync position.
2.
Remove the locknuts, the outer support washers, and sealing rings.
Inspect
1.
Fit the auxiliary shafts on the upper and lower axes (upper: aux. shaft
3HAC 5276-1, lower: aux. shaft 3HAC 5275-1). The shafts should be tightened to
their bottom position.
2.
Off-load the bearings using an M10x50 screw at the cylinder top.
3.
Put out the cylinder so that the inner rings are fully exposed. Wipe the inner rings
clean and check that there are no pressure marks or other similar deformations. It
is quite normal for the bearing races to have a darker color than the surrounding
material.
4.
Inspect the bearings, support washers and sealing rings.
5.
Push in the cylinder, make sure the inner support washers and sealing rings gets
in correct position.
6.
Remove the auxiliary shafts.
7.
Inspect the parts to ensure nothing looks abnormal, see Repairs.
Lubrication
Action
1.
76
Fit the lubricating tool 3HAC 5222-1. The tool should be tightened to the bottom
position using hand power only.
3HAC027076-001 Revision: A
© Copyright 2006 ABB. All rights reserved.
Action
Maintenance
4.2.3 Inspect and lubricate the bearings, balancing units axis 2
Action
2.
Grease through the nipple. Continue greasing until the clean grease exudes behind
the inner sealing ring. Repeat procedure for the other bearings.
3.
Remove the lubricating tool and clean the threads on the shaft ends free from
grease. Clean also from old grease on the inner side.
4.
Refitt the outer sealing rings, apply some grease on the support washers, apply
Loctite 243 on the KM nuts, not on the shafts, and tighten them to a torque of 5060 Nm.
5.
Check play (min. 0.1 mm) between support washer and bearingseat at both bearings.
6.
Remove the M12 screw.
Related information
© Copyright 2006 ABB. All rights reserved.
For more information about the procedure of replacing bearings, see Replacing bearings, balancing unit on page 132.
3HAC027076-001 Revision: A
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Maintenance
4.2.4 Lubricating piston rod, balancing unit axis 2
4.2.4 Lubricating piston rod, balancing unit axis 2
General
Move axis 2 to a position where the balancing units are in the horizontal position.
Wear
Check the guide ring for wear. If there is a risk of metallic contact between the piston rod and
the end cover, the guide ring must be replaced. For replacement, see Replacing guide ring,
balancing unit on page 131.
The article number of the guide ring is 3HAC 3476-1.
Lubrication
The piston rods should be lubricated. Clean the piston rod and apply new grease when necessary.
- Castrol Spheerol SX2 or equivalent
- Shell SRS 4000
- OK Super Grease L2.
- Statoil Uniway 2X2N
© Copyright 2006 ABB. All rights reserved.
Type of grease:
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Maintenance
4.2.5 Oil change, axes 2 and 3
4.2.5 Oil change, axes 2 and 3
Required equipment
Volume approx:
Axis 2 11.5 liters. (3.35 US gallon)
Axis 3 12.0 liters. (3.50 US gallon)
Type of oil:
ABB 1171 2016-604
Equivalents:
- Castrol Alpha SP 320
- Esso Spartan EP 320
- Klüber Lamora 320
- Mobil Mobilgear X320
- Shell Omala Oil 320
- Texaco Meropa 320
- Statoil Loadway EP
Procedures
Action
1.
Remove the three plugs with sealing rings see Figure 35.
• Ventilation plug (13) (breather)
• Level plug (14) and filling plug
• Drain plug (15)
Drain off the used oil through the drain hole.
3.
Clean the drain plug (15) before refitting.
4.
Refit the drain plug with sealing ring.
5.
Fill up with new oil until the oil level reaches the lower edge of the level hole.
6.
Refit the filling plug (14) and ventilation plug (13).
7.
Tightening torque, oil plugs: 60 Nm
© Copyright 2006 ABB. All rights reserved.
2.
13
14
15
Figure 35 Oil plugs, axes 2 and 3.
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Maintenance
4.2.6 Oil change gearbox, axis 4
4.2.6 Oil change gearbox, axis 4
Required equipment
Volume approximately.:
6 liters (1.75 US gallon).
Correct oil level for axis 4 is to the lower edge of the
upper oil level plug (B).
Type of oil:
ABB 1171 2016-604
Equivalents:
- Castrol Alpha SP 320
- Esso Spartan EP 320
- Klüber Lamora 320
- Mobil Mobilgear X320
- Shell Omala Oil 320
- Texaco Meropa 320
- Statoil Loadway EP
Procedures
Action
1.
Move the upper arm to the horizontal position.
2.
Remove the plugs (A) and (B).
3.
Drain off the old oil through the hole (A). See Figure 36.
4.
Clean the magnetic drain plug before refitting.
5.
Refit the drain plug (A).
6.
Fill up with new oil until the oil level reaches the lower edge of the filling hole (B).
© Copyright 2006 ABB. All rights reserved.
B
A
Figure 36 Drain hole axis 4
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Maintenance
4.2.7 Oil change gearbox, axis 5
4.2.7 Oil change gearbox, axis 5
Action
1.
Move the upper arm to the horizontal position with axis 4 turned +90o
2.
Open the oil plug 1, and then oil plug 2 so that air can enter, see Figure 37
3.
Rotate axis 4 manually backwards and forwards to drain the oil, after first releasing
the brake on axis 4.
4.
Clean the magnetic drain plug before refitting.
5.
Turn axis 4 through -90o before filling oil. Fill oil through hole 2 until the oil is level
with the lower edge of the filler hole.
Volume approximately:
6.5 liters (1.717 US gallon)
NOTE!
Correct oil level for axis 5 is to the lower edge of the oil
level plug.
Type of oil:
ABB 1171 2016-604
Equivalents:
- Castrol Alpha SP 320
- Esso Spartan EP 320
- Klüber Lamora 320
- Mobil Mobilgear X320
- Shell Omala Oil 320
- Texaco Meropa 320
- Statoil Loadway EP
© Copyright 2006 ABB. All rights reserved.
2
1
Figure 37 Oil change axis 5.
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Maintenance
4.2.8 Lubricating gearbox, axis 6
4.2.8 Lubricating gearbox, axis 6
This section details how to lubricate the gearbox, axis 6.
Important information!
When using compressed air driven tools as a filling device, do not use more than 0.1 bar
pressure. Also when using a hand grease gun, caution must be taken to avoid high pressure.
This is to prevent damage to the seals.
Volume and type
The amount and type of grease is listed below.
Type
Art no.
Volume (new gearbox)
Volume
(change)
Optimol Longtime PD 0
3HAA 1001-294
0,30 liter / 0.085 gallon
1 liter / 0.28
gallon
Lubricating instructions
NOTE!
It is important that the drain plug is completely removed.
All the following instructions refer to the illustration on Filling and drain plug. on page 84.
Action
1.
Remove the plug from the drain hole on flange of gearbox (1).
2.
Remove the plug from the filling hole of motor housing (2)
3.
Place the two holes as far away from each other as possible to ensure that the
grease is changed at every part inside the gearbox.
4.
Add grease through the hole of the motor housing (2).
5.
Continue to add grease until new grease comes from the drain hole (1).
6.
Remove any excess grease as described in Excess grease on page 83.
© Copyright 2006 ABB. All rights reserved.
Step
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Maintenance
4.2.9 Excess grease
4.2.9 Excess grease
The following actions should be considered before refitting the plugs.
All the following instructions refer to the illustrations Filling and drain plug. on page 84.
WARNING!
To prevent over-pressure and the risk of leakage, the gearbox must be drained from excess
grease before the plugs are replaced
Step
Action
1.
Turn the filling hole of motor housing (2) facing down.
2.
Open the drain hole (1) on the flange of the motor.
3.
Rotate axis 6 backwards and forwards a couple of times until excess grease is
pressed out of the hole on motor housing (2). The amount that should come out
is min. 0.1 liters and max 0.2 liters.
4.
Use compressed air through the hole on the motor housing to get the excess
grease out, where the application makes it difficult to make big axis movements,
or if the grease is cold.
NOTE!
© Copyright 2006 ABB. All rights reserved.
It is still necessary to move the axis backwards and forwards as much as possible.
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Maintenance
4.2.10 Illustrations
4.2.10 Illustrations
A
B
2
1
2
1
Figure 38 Filling and drain plug.
Pos.
Description
1
Drain plug
2
Filling plug
NOTE!
© Copyright 2006 ABB. All rights reserved.
The positions of the filling(2) and drain (1) plugs are facing each other.
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Maintenance
4.2.11 Checking mechanical stop
4.2.11 Checking mechanical stop
Check regularly, as follows:
Article number
Check
Fixed stop
-that the stop is not damaged
Stop pin
-that the stop pin can move in both direc- 3HAC 3667-1
tions
-that the stop pin is not bent.
Adjustable stop
-that the stops are not damaged.
3HAC 4656-1 15° (Option)
-If the fixed stop arm is damaged, it must 3HAC 4657-1 7.5° (Option)
be replaced.
-If the pin is bent, a collision between the
swinging stop arm and the stop pin has
probably occurred. A bent stop pin must
always be replaced by a new one.
-If any of the adjustable stops are damaged, they must be replaced by new
ones
-If any damper is deformed it must be
replaced.
© Copyright 2006 ABB. All rights reserved.
Mechanical stop
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Maintenance
4.2.12 Replacement of SMB battery
4.2.12 Replacement of SMB battery
Location of SMB battery
The SMB battery (SMB = serial measurement board) is located on the left hand side of the
frame as shown in the figure below.
A
Figure 39 Battery location
A
SMB battery cover
Equipment, etc.
Spare part no.
Note
Battery pack
3HAC 16831-1
Battery includes protection circuits. Replace it
only with given spare part no. or an ABB
approved equivalent.
Standard toolkit
-
See Tool List on page 171.
Circuit Diagram
See Circuit diagram on page 219.
Removal, battery
The procedure below details how to remove the SMB battery.
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© Copyright 2006 ABB. All rights reserved.
Required equipment
Maintenance
4.2.12 Replacement of SMB battery
1.
Action
Note
Move the robot to its calibration position.
This is done in order to facilitate
the updating of the revolution
counter.
2.
WARNING!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3.
esd
WARNING!
The unit is sensitive to ESD, before handling the
unit please observe the safety information in
WARNING - The unit is sensitive to ESD! on
page 33.
4.
Remove the SMB battery cover by unscrewing its See Location of SMB battery on
attachment screws.
page 86.
5.
Pull out the battery and disconnect the battery
cable.
See Location of SMB battery on
page 86.
6.
Remove the SMB battery. Battery includes
protection circuits. Replace it only with the
specified spare part or with an ABB approved
equivalent.
See Location of SMB battery on
page 86.
Refitting, battery
© Copyright 2006 ABB. All rights reserved.
The procedure below details how to refit the SMB battery.
Action
1.
Note
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
in section WARNING - The unit is sensitive to
ESD! on page 33.
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Maintenance
4.2.12 Replacement of SMB battery
Action
Note
3.
Reconnect the battery cable to the SMB battery Art. no. is specified in Required
pack and fit it to the frame.
equipment on page 86. Shown in the
figure Location of SMB battery on
page 86.
4.
Secure the SMB battery cover with its
attachment screws.
Shown in the figure Location of SMB
battery on page 86.
5.
Update the revolution counter.
Detailed in section Updating revolution
counters on page 165.
6.
DANGER!
© Copyright 2006 ABB. All rights reserved.
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in section DANGER - First test
run may cause injury or damage! on page 32.
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Maintenance
4.2.13 Cleaning of robot
4.2.13 Cleaning of robot
Instructions
The protection class is IP 67, which means that the robot is watertight, assuming that no covers or other protective parts have been removed. When cleaning the robot, the bearings, electrical connection boxes, switches, and contacts need no extra protection, but the following
must be taken into consideration
Cleaning
For steam cleaning:
Note
• water pressure at nozzle: max. 2500 kN/m2 (25
bar)
• type of nozzle: fan jet, min. 45º spread
• flow: max. 100 liters/min.
• distance from nozzle to encapsulation: min. 0.4 m
• water temperature: max. 80º C
Cleaning with water:
• avoid pointing the water jet at bearing seals, contacts, and other seals
• fan jet nozzle should be used, min. 45º spread
• max. water pressure on enclosures: 50 kN/m2
(0.5 bar)
• flow: max. 100 liters/min.
NOTE!
© Copyright 2006 ABB. All rights reserved.
Higher pressures and temperatures should not be used because this will shorten the service
life of paintwork, rust inhibitors, signs, and labels.
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Maintenance
© Copyright 2006 ABB. All rights reserved.
4.2.13 Cleaning of robot
90
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Repairs
5.1.1 Introduction
5: Repair
5.1: Introduction
5.1.1 General information
The industrial robot system IRB 6400 comprises two separate units; the control cabinet and
the mechanical unit. The service of the mechanical unit is described in this document.
As regards service, the mechanical unit is divided into the following main parts:
•
Electrical System
•
Motor Units
•
Mechanical System
The Electrical System is routed through the entire robot and consists of two major systems;
power cabling and signal cabling. The power cabling feeds the robot axes' motor units. The
signal cabling feeds the various controlling parameters like axis positions, motor revs, etc.
The AC type Motor Units provide the motive power for the various robot axes via gears.
Mechanical brakes, electrically released, lock the motor units when the robot is inoperative
for more than 1000 hours.
The Mechanical System has 6 axes, enabling the flexible robot motions.
Axis 3
Axis4
Axis 5
Axis 6
© Copyright 2006 ABB. All rights reserved.
Axis 2
Axis 1
Figure 40 The robot axes and motion patterns.
Axis No. 1 rotates the robot via a frame.
Axis No. 2, which provides the lower arm´s reciprocating movement, is supported in the
frame. The Lower Arm forms together with the Parallel Arm and the Parallel Bracket, a par-
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Repairs
5.1.1 General information
allelogram against the Upper Arm. The Parallel Bracket is mounted in bearings in the Parallel
Arm and in the Upper Arm.
Axis No. 3 provides elevation of the robot's upper arm.
Axis No. 4, located in the Upper Arm, provides a rotary motion of the Upper Arm.
The Wrist is bolted to the Upper Arm's forward end and comprises the axes Nos. 5 and 6. The
latter axes form a cross.
Axis No. 5 provides a tilting motion and Axis No. 6 a turning motion. A connection is
arranged for various customer tools at the front end of the wrist in the Turn Disc. The tool (or
robot) can be equipped with pneumatic control via an external air supply (option). The signals
to/from the tool can be supplied via internal customer connections (option).
WARNING!
The Control Cabinet must be switched off during all service work on the robot! Before doing
any work on the robot measurement system (measurement board, cabling), the accumulator
power supply must always be disconnected.
When service work is finished, the calibration position should always be checked with the
system disc.
The Brake Release Unit should be connected as indicated in Manually releasing the Brakes
on page 46.
WARNING!
© Copyright 2006 ABB. All rights reserved.
Special care must be taken when the brakes are operated manually. This applies particularly
when the robot is started up, either for the first time or after a stoppage. The safety instructions
in the Programming Manual must be complied with at all times.
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5.1.2 Document guidance
5.1.2 Document guidance
The subsequent chapters describe the type of service work that can be carried out by the Customer´s own service staff on site. Certain types of work, requiring special experience or special aids, are not dealt with in this manual. In such cases, the defective module or component
should be replaced on site. The faulty item should be sent to ABB for service.
Calibration. Recalibration of the robot may have to be carried out after replacing mechanical
unit parts or when the motor and feedback unit have been separated; or when a resolver error
has occurred or the power supply between a measurement board and resolver has been interrupted. The procedure is described in detail in Calibration on page 159.
WARNING!
When work is done on the robot signal cabling, this may result in the robot moving to incorrect positions. After doing such work, it is important that the robot calibration position is
checked. If a calibration fault is discovered, the robot must be recalibrated.
For more information, see Calibration on page 159.
Tools. Two types of tools are required for various service jobs involving dismantling; on the
one hand, conventional tools like socket and ratchet spanners, etc.; on the other hand, special
tools may be necessary, depending on what type of service is being carried out. The conventional tools are not dealt with in this manual, based on the assumption that the service personnel have sufficient technical basic competence. However, service work requiring the use of
special tools is described in this manual.
© Copyright 2006 ABB. All rights reserved.
Exploded views. In the Spare Parts chapter of this manual, there are a number of exploded
view mechanical drawings illustrating the robot parts, intended to facilitate quick identification of both the type of service required and the composition of the various components. The
parts are item numbered on the mechanical drawings. The mechanical drawings are referred
to in the manual text within "arrow heads" (< >) as exploded view numbers. Where reference
is made to mechanical drawings, other than those specified in the paragraph title, the mechanical drawing number is included in the item number reference, for example <5/19> or <10:2/
5>, the digit(s) before the slash referring to the mechanical drawing number.
Numbers in brackets ( ) refer to figures in the text.
The mechanical drawings also include information such as article number, designation and
relevant data.
NOTE!
This manual is not to be considered as a substitute for a proper training course. This document
is intended for use after the course has been completed.
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Repairs
5.1.3 Caution
5.1.3 Caution
WARNING!
© Copyright 2006 ABB. All rights reserved.
The mechanical unit contains several parts which are too heavy to lift manually. As these
parts must be moved with precision during any maintenance and repair work, it is important
to have a suitable lifting device available.
The robot should always be switched to MOTORS OFF before allowing anyone to enter its
working space.
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5.2.1 Mounting instructions for bearings and seals
5.2: Mounting instructions for bearings and seals
5.2.1 Bearings
General
Action
1.
Let the new bearing remain in its wrapping until it is time for fitting, to avoid contamination of the bearing.
2.
Ensure that all parts included in the bearing fitting are free from burrs, grinding waste
and other contamination. Cast components must be free from foundry sand.
3.
Bearing rings, inner rings and roller elements must under no circumstances be subjected to direct impact. Also, the roller elements must not be exposed to any stresses
during the assembly work.
Tapered Bearings
Action
1.
The bearing should be tensioned gradually until the recommended pre-tension is
achieved.
2.
It is important to note that the roller elements must be rotated a specified number of
turns before pre-tensioning is carried out, and also rotated during the pre-tensioning
sequence.
3.
The above procedure must be carried out to enable the roller elements to adjust to the
correct position against the race flange. Also, it is important that the bearing is properly
aligned, as this will directly affect the life span of the bearing.
© Copyright 2006 ABB. All rights reserved.
Greasing Bearings
Action
1.
The bearing must be greased after fitting. The main reason for this is the requirement
for cleanliness. Good quality lubricating grease should be used, for example 3HAB
3537-1.
2.
Grooved ball bearings should be filled with grease from both sides.
3.
Tapered roller bearings and axial needle bearings shall be greased in the split condition.
4.
The bearings must not be completely filled with grease. However, if space is available
beside the bearing fitting, the bearing may be totally filled with grease when mounted,
as surplus grease will be thrown out from the bearing when the robot is started up.
5.
During operation, the bearing should be filled to 70–80% of the available volume.
6.
Ensure that grease is handled and stored properly, to avoid contamination.
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Repairs
5.2.2 Seals
5.2.2 Seals
Rotating Seals
NOTE!
The most common cause of leakage is incorrect fitting
Action.
1.
The sealing surfaces should be protected during transport and mounting.
2.
The seal should be kept in the original wrappings or be well protected.
3.
Sealing surfaces must be inspected before mounting. If scratches or damage are
found, that may result in future leakage, the seal must be replaced.
4.
Seals should also be checked before mounting to ensure that:
•
there is no damage to the sealing edge (feel with a fingernail)
•
the seal is of the correct type (provided with cutting edge)
•
there is no other damage.
5.
Grease the seal just before fitting it, but not too early as there is a risk of dirt and
foreign particles adhering to the seal. The space between the dust tongue and sealing
lip should be filled to 2/3 with grease of quality 3HAB 3537-1. The rubber coated
external diameter must also be greased.
6.
The fitting of seals and gears must be carried out on clean workbenches.
7.
Mount the seal correctly. If it is misaligned, there is a risk of leakage due to the pumping effect.
8.
Always mount the seal with a mounting tool. Never hammer directly on the seal, as
this may result in leakage.
9.
Use a protective sleeve for the sealing lip during mounting, when sliding over threads,
key ways, etc.
Action
96
1.
Check the flange surfaces. They must be even and free from pores. It is easy to check
flatness using a gauge on the fastened joint (without sealing compound).
2.
Differences in surface level or the presence of burrs due to incorrect machining are
not permissible. If flange surfaces are defective, the parts must not to be used,
because leakage could result.
3.
The surfaces must be properly cleaned in accordance with ABB recommendations.
4.
Distribute the sealing compound evenly over the surface, preferably with a brush.
5.
Tighten the screws evenly when fastening the flange joint.
3HAC027076-001 Revision: A
© Copyright 2006 ABB. All rights reserved.
Flange Seals and Static Seals
Repairs
5.2.2 Seals
O-rings
Action
Check the o-ring grooves. The grooves must be geometrically correct and free from
pores and contamination.
2.
Check the o-ring with regard to surface defects, burrs, shape accuracy, etc.
3.
Ensure that the correct o-ring size is used.
4.
Tighten the screws evenly when assembling.
5.
Defective o-rings and o-ring grooves must not be used.
6.
Fitting defective parts will result in leakage. Grease the o-ring with lubricant 3HAB
3537-1 before mounting.
© Copyright 2006 ABB. All rights reserved.
1.
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5.2.3 Instructions for tightening screw joints
5.2.3 Instructions for tightening screw joints
General
It is of the utmost importance that all screw joints be tightened with the correct torque.
Application
The following tightening torques are to be used for all screw joints in metallic materials
unless otherwise specified in the text.
These instructions do not apply to screw joints comprising soft or brittle materials.
For screws with a higher property class than 8.8, the data for 8.8 must be used unless otherwise specified.
Screws treated with Gleitmo (lubricated)
WARNING!
When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should
be used.
Screws treated with Gleitmo can be unscrewed and screwed in again 3-4 times before the slip
coating disappears. Screws can also be treated with Molycote 1000.
When screwing in new screws that are not Gleitmo treated, these should first be lubricated
with Molycote 1000 and tightened to the specified torque.
Assembly
Lubrication with molybdenum disulphide grease (Molycote 1000) should only be used when
specified in the text.
Screws lubricated with Molycote 1000 and then torque tightened, should also to be lubricated
between the washer and the head of the screw.
Screws with dimension M8 or larger should be tightened with a torque-wrench, if possible.
© Copyright 2006 ABB. All rights reserved.
Screws with dimension M6 or smaller may be tightened to the correct torque using tools without torque indication, by personnel with adequate mechanical training and instruction.
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5.2.4 Tightening torques
5.2.4 Tightening torques
Screws with slotted or cross recessed head
Tightening torque - Nm
Dimension
Class 4.8 “Dry”
M 2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
Screws with hexagon socket head
Tightening torque - Nm
Class 10.9
Molycote 1000
Gleitmo 610
Class 12.9
Molycote 1000
Gleitmo 610
24
28
35
M 10
47
55
70
M 12
82
95
120
M 16
200
235
300
Class 8.8 “Dry”
M5
6
M6
10
M8
© Copyright 2006 ABB. All rights reserved.
Dimension
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5.2.5 Checking for Play in Gearboxes and Wrist
5.2.5 Checking for Play in Gearboxes and Wrist
NOTE!
When checking for play in gearboxes the brakes must be disengaged.
When trying to move an arm manually when the brakes are engaged, some play can be felt.
The play that can be felt is between the brake disk and the motor shaft, not in the gearbox
itself. This is because the rotating brake disk is connected to the motor shaft by splines. This
is why the brakes must be disengaged before testing for play in the gearboxes and wrist. The
brakes are disengaged by pressing the enable button on the teach pendant.
NOTE!
© Copyright 2006 ABB. All rights reserved.
The play in the brake disk does not affect the robot motion or accuracy.
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Motor Units
5.3: Motor Units
General
Each robot axis is provided with a motor unit consisting of:
• A synchronous AC motor
• A brake unit
• A feedback unit.
A gear on the output shaft of the motor forms together with the gear on each axis,
The electro-magnetic brake is built into the motor unit. The brake is released by a 24 V DC
supply. For brake release see Manually releasing the Brakes on page 46.
The feedback unit consists of a resolver mounted on the motor shaft and is built into the motor
unit in a similar way as the brake.
Power and signal connections to the motor units are via separate cables between
connections points inside the robot and each motor. The cables are connected to the motor
units with connectors.
• The feedback unit is fitted by the motor manufacturer and must never be separated
from the motor.
• The communication angle is + 90° (COMOFF=2048).
The motors never need commutating.
• The motor, resolver and brake is to be regarded as an replacement motor unit. Faulty
motor units are repaired by the motor manufacturer at the request of the ABB service
organization.
• The cable routing is shown in Figure 41. Note that the signal connection and the power
connection must not be entwined.
© Copyright 2006 ABB. All rights reserved.
Signal connection
Power connection
Figure 41 Cable routing in the motor unit.
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Repairs
© Copyright 2006 ABB. All rights reserved.
Motor Units
102
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Repairs
5.4.1 Motors Axes 1–3
5.4: Motors Axes 1–3
5.4.1 Changing motor including pinion axis 1
Refer to mechanical drawing no. 2:5.
Removal:
WARNING!
Be careful not to tap or hit the shaft axially, nor displace the shaft axially in any way, as this
could give rise to an incorrect air gap in the brake.
Action
1.
WARNING!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Unscrew the motor flange, 4 screws <104>.
3.
Unscrew the 3 screws on the top of the motor.<3-5> Remove the cover.
4.
Disconnect connectors in the motor.
5.
Use a portable power supply 24V DC to release the brakes (pin no.11, +24V and
pin no.12, 0V) so it is possible to pull out and turn the motor and minimize the risk
of damaging the pinion and gear.
6.
Attach a hoist and the lifting device (3HAC 6876-1) to the motor. The weight of the
motor is 17 kg.
7.
Pull and turn out the motor. In case of difficulty use two screws in the threaded
holes (M10) on the motor flange to push out the motor from its attachment.
© Copyright 2006 ABB. All rights reserved.
Refitting:
Action
1.
Ensure that sealing surfaces are clean and not scratched.
2.
Apply oil to the sealing surfaces to ensure that the O-ring runs smoothly
3.
Release the brakes.
4.
Attach a hoist and the lifting device (3HAC 6876-1) to the motor.
5.
Turn the motor carefully so that the pinion and the gears in the gearbox fits
together.
6.
Apply Loctite 243 to the four screws and tighten with a torque of 47 Nm.
7.
Calibrate the robot as described in Calibration on page 159.
8.
Refit the connectors and the cover.
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Repairs
5.4.2 Changing motor including pinion axes 2 and 3
5.4.2 Changing motor including pinion axes 2 and 3
Refer to mechanical drawing 2:5.
Removal:
WARNING!
Be careful not to tap or hit the shaft axially, nor displace the shaft axially in any way, as this
could give rise to an incorrect air gap in the brake.
Secure the axis with mechanical stops, 3HAC 3665-1 (part of 3HAC 4658-1), so that the
balancing weight for the axis cannot fall down.
Action
1.
WARNING!
2.
Release the brakes on that axis where the motor change should be done, to ensure
that the robot axis is disengaged or in what way the axis is moving.
3.
Then you can lock the axis into place by mounting one or more moveable stops,
3HAC 3665-1 (part of 3HAC 4658-1), to prevent the axis from falling.
4.
Drain the gearbox oil, see Oil change, axes 2 and 3 on page 79 and unscrew the
motor flange, 4 screws <104>.
5.
Unscrew the 3 screws on the top of the motor <3-5>. Remove the cover.
6.
Disconnect connectors from the motor.
7.
Use a portable power supply 24V DC to release the brakes (pin no.11, +24V and
pin no.12, 0V) so it is possible to pull and turn the motor out and minimize the risk
of damaging the pinion and gear.
8.
Attach a hoist and the lifting device (3HAC 6876-1) to the motor. The weight of the
motor is 17 kg.
9.
Pull and turn out the motor, in case of difficulty use two screws in the threaded
holes (M10) on the motor flange to push out the motor from its attachment.
Refitting
Action
104
1.
Ensure that sealing surfaces are clean and not scratched.
2.
Apply oil to the sealing surfaces to ensure that the O-ring runs smoothly.
3.
Attach a hoist and the lifting device (3HAC 6876-1) to the motor.
4.
Release the brakes and turn the motor carefully so that the pinion and the gears in
the gearbox fit together.
5.
Refit the connectors and the cover.
6.
Apply Loctite 243 to the four motor screws and tighten with a torque of 47 Nm.
7.
Remove the extra mechanical stops.
3HAC027076-001 Revision: A
© Copyright 2006 ABB. All rights reserved.
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Repairs
5.4.2 Changing motor including pinion axes 2 and 3
Action
Fill the gearbox with oil, ABB 1171 2016-604, volume 12 liters. Regarding replacements oils, see the Maintenance Manual IRB 6400.
9.
Calibrate the robot as described in Calibration on page 159.
© Copyright 2006 ABB. All rights reserved.
8.
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105
Repairs
© Copyright 2006 ABB. All rights reserved.
5.4.2 Changing motor including pinion axes 2 and 3
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Repairs
5.5.1 Motors and Gears Axes 4–6
5.5: Motors and Gears Axes 4–6
5.5.1 Motor axis 4
Refer to Mechanical drawing 2:10 on page 208.
WARNING!
Be careful not to tap or hit the end of the shaft (axially), nor displace the shaft axially in any
way. This could give rise to an incorrect air gap in the brake.
Removal:
Action
1.
WARNING!
© Copyright 2006 ABB. All rights reserved.
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Drain the gearbox by removing oil plugs <48> and <27> as described in Oil change
gearbox, axis 4 on page 80.
3.
Secure axis 4 so it cannot rotate when the motor is removed.
4.
Use a portable power supply 24 VDC to release the brakes (pin no.11, +24V and
pin no.12, 0V). Now it is possible to pull and turn the motor out and minimize the
risk of damaging the pinion and gear.
5.
Unscrew the four cable inlet cover screws.
6.
Dismount the cover from motor 4.
7.
Attach a hoist and the lifting device (3HAC 9043-1) to the motor.
8.
Pull out the motor and turn it. In case of difficulty, use two screws in the threaded
holes (M10) on the motor flange to push out the motor from its attachment.
9.
Disconnect the electrical connectors.
Refitting:
Action
1.
Ensure that sealing surfaces are clean and not scratched.
2.
Attach a hoist and the lifting device (3HAC 9043-1) to the motor.
3.
Apply oil to the sealing surfaces to ensure that the O-ring runs smoothly.
4.
Apply Loctite 574 in form of a string to the surface around the locating hole for
motor axis 4.
5.
Refit the connectors and the cover.
6.
Refit the motor with the motor label facing down.
7.
Use a portable power supply 24 VDC to release the brakes (pin no.11, +24V and
pin no.12, 0V). Turn the motor carefully so that the pinion and the gears in the
gearbox fit together.
3HAC027076-001 Revision: A
107
Repairs
5.5.1 Motor axis 4
Action
Apply Loctite 243 to the four M8x25 motor screws and tighten with a torque of 47
Nm.
9.
Fill the gearbox with oil as described in Oil change gearbox, axis 4 on page 80.
10.
Calibrate the robot as described in Calibration on page 159
© Copyright 2006 ABB. All rights reserved.
8.
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Repairs
5.5.2 Intermediate gear, axis 4
5.5.2 Intermediate gear, axis 4
Refer to Mechanical drawing 2:10 on page 208.
Removal:
Action
1.
WARNING!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Drain the gearbox of oil.
3.
Secure axis 4 mechanically.
4.
Remove the cover <28>.
5.
Remove the motor as described in Motor axis 4 on page 107.
6.
Unscrew the screws <14>.
7.
Unscrew nuts <18> and remove the wedges <17> and remove screws <14>.
8.
Pull out the intermediate gear unit.
Refitting:
© Copyright 2006 ABB. All rights reserved.
Action
1.
Refit the gear and tighten screws <14> only very slightly by hand.
2.
Refit the motor as described in Motor axis 4 on page 107.
3.
Adjust the backlash by moving the intermediate wheel to obtain the minimum backlash (0.01-0.03 mm) between the final gear and the motor gear, at three points, by
turning axis 4. Ensure that when axis 4 is turned, the gears do not “scrape”
together.
4.
Tighten screws <14> with a torque of 70 Nm.
5.
Apply oil to the sliding surface and insert the 3 wedges <17> with 4 tension washers
<43> at each wedge and the nuts <18> on studs <16>. Apply Loctite <39> and
tighten with a torque of 8 Nm.
6.
NOTE!
Make sure that the wedges are mounted turned in the right direction, and fit the
tension washers with their concave sides facing each other.
3HAC027076-001 Revision: A
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Repairs
5.5.2 Intermediate gear, axis 4
Action
7.
NOTE!
Check the backlash.
Refit cover <28> with screw <30>and washer <31> with a new seal <29> and
tighten with a torque of 10 Nm.
9.
Refit the motor. Fill oil and calibrate as described in Oil change gearbox, axis 4 on
page 80.
© Copyright 2006 ABB. All rights reserved.
8.
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Repairs
5.5.3 Replacing final gear
5.5.3 Replacing final gear
Refer to Mechanical drawing 2:10 on page 208.
Removal:
Action
1.
WARNING!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Dismount cabling in the upper arm as in section Robot harness on page 147.
3.
Dismount adjustable intermediate gear as in section Intermediate gear, axis 4 on
page 109.
4.
Mount the special hydraulic tool, 6896 134-AN, to the tubular shaft end.
5.
Remove the cover in the gear <11> and mount nipple, SKF 234 063, with NIKE
quick coupling, I-AQU 8.
6.
Mount tool, 6396 134-AT with hydraulic cylinder NIKE I-CH 612, on the gear <11>
with three hexagon screws M12x70 10.9.
7.
Connect pump 3HAB 8582-1 to the cylinder and nipple in the gear.
8.
Pump up the pressure, with both taps on the valve open. When the gear moves
sufficiently so that the pressure disappears between the gear and the shaft, close
one of the taps. Continue pumping in this way until the gear has been removed.
WARNING!
Be careful with the surface at the end of the shaft.
Otherwise there may be oil leakage.
© Copyright 2006 ABB. All rights reserved.
Refitting:
Action
1.
Heat up the gear <11> to 160 oC using an induction heater or oven.
2.
Mount tool 6896 134-BU on the end of the tube shaft.
3.
NOTE!
The following steps must be carried out in sequence while the gear is still hot.
4.
Refit gear on the tube shaft.
5.
Mount tool, 6896 134-FK.
6.
Mount hydraulic cylinder NIKE I-CH 612 with regulator.
7.
Press the gear on the shaft with a force of 16 000 N, equivalent to 8.7-9.2 MPA,
check the pressure gauge (part of pump 3HAB 8582-1).
3HAC027076-001 Revision: A
111
Repairs
5.5.3 Replacing final gear
Action
Check that the distance ring <12> is pressed in position behind the gear.
9.
The pressure must be retained until the gear has cooled down and shrunk on to the
shaft.
10.
Refit intermediate wheel as in section Intermediate gear, axis 4 on page 109.
11.
Refit the cabling in the upper arm as in section Robot harness on page 147.
12.
Calibrate the robot as described in Chapter Calibration on page 159.
© Copyright 2006 ABB. All rights reserved.
8.
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Repairs
5.5.3 Dismounting tube shaft, upper arm
5.6: Dismounting tube shaft, upper arm
Refer to Mechanical drawing 2:10 on page 208.
Removal:
Action
1.
WARNING!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Dismount wrist as in Wrist on page 117.
3.
Dismount cabling in upper arm as in section Robot harness on page 147.
4.
Dismount the motor axis 4 as described in section Motor axis 4 on page 107.
5.
Dismount the adjustable intermediate gear as in section Intermediate gear, axis 4
on page 109.
6.
Dismount final gear as in section Replacing final gear on page 111.
7.
Remove the mechanical stop <23> for axis 4.
8.
Rotate axis 4 so that the damper <22> is visible and can be removed.
9.
Remove the stop on shaft <20>.
10.
Press the tube shaft out with tool 3HAB 8079-1.
11.
NOTE!
The extender 3HAB 8008-1, included in 3HAB 8079-1, can also be used to get the
tube through the second bearing
© Copyright 2006 ABB. All rights reserved.
12.
Knock the bearing <6> out.
Refitting:
Action
1.
Cover the sliding surfaces, for the seal rings, with some tape.
2.
Apply some grease on the diameters of the tubular shaft where the seals must
pass.
3.
“Fix” the NILOS-ring <7> in the upper arm housing with some grease.
4.
Refit the seal <8> on tube shaft.
5.
Refit bearing <6>. Use tool 6896 134-S + 6896 134-S + NIKE 1-CH-612. Alternatively, heat up the bearing to 120°C and Refit on the shaft. Let the bearing cool
down before further assembly.
6.
Grease the bearing.
3HAC027076-001 Revision: A
113
Repairs
5.5.3 Dismounting tube shaft, upper arm
Action
Press the shaft into the housing using the tools 6896 134-FL, 3HAB 1428-1 + NIKE
1-CH-612, 3HAC 1894-1, 3HAC 1893-1.
8.
Refit the distance ring <12> on the tube.
9.
Refit the final gear according to section Replacing final gear on page 111.
10.
Refit the motor and intermediate wheel as in Motor axis 4 on page 107 and
section Intermediate gear, axis 4 on page 109.
11.
Refit the stop <20> on the tube shaft. Lock the screws <21> with Loctite 243 and
tighten with a torque of 84 Nm.
12.
Refit the damper <22> and the mechanical stop <23> with seal and tighten screws
<25> with a torque of 22 Nm. Use Loctite 243. Apply some grease on the sliding
surfaces.
13.
Refit the cabling as in section Robot harness on page 147.
14.
Calibrate the robot as described in chapter Calibration on page 159.
© Copyright 2006 ABB. All rights reserved.
7.
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3HAC027076-001 Revision: A
Repairs
5.6.1 Replacing seals and bearings, upper arm
5.6.1 Replacing seals and bearings, upper arm
Refer to Mechanical drawing 2:10 on page 208.
Removal:
Action
1.
WARNING!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Dismount the tube shaft as in section Dismounting tube shaft, upper arm on page
113.
3.
Knock bearing <6> off the tube shaft <5>.
4.
Knock bearing <6> out, inside housing <3>.
5.
Knock out the sealing <10>.
Refitting:
Action
1.
Mount a new sealing ring <10>, apply some grease on the diameter inside the
upper arm house. Use tool 6896 134-FA.
2.
Refit seal ring <8> on to the tube shaft.
3.
Refit bearing <6> according to section Dismounting tube shaft, upper arm on page
113, point 15.
© Copyright 2006 ABB. All rights reserved.
4.
NOTE!
Let the bearing cool down before mounting the shaft.
5.
Apply grease in the bearing.
6.
Refit the tube shaft as described in section Dismounting tube shaft, upper arm on
page 113, step 11–17.
7.
Install bearing <6> in the housing.Apply grease in the bearing. Use tool 6896 134FC + Nike 1-CH-612.
8.
Continue with the tube shaft mounting according to section Dismounting tube shaft,
upper arm on page 113, step 18–24.
3HAC027076-001 Revision: A
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Repairs
5.6.2 Axes 5 and 6
5.6.2 Axes 5 and 6
The wrist includes axes 5 and 6 and forms a complete exchangeable unit, comprising motor
units and gears.
See spare parts list for types of wrist that can be supplied and for article numbers.
Some maintenance and repair work can be carried out by your own service personnel:
•
Oil change as described in the Oil change gearbox, axis 5 on page 81 and Lubricating
gearbox, axis 6 on page 82.
•
Change of motor and gear, axis 6.
•
Change of motor, axis 5.
•
Checking backlash, axes 5 and 6.
•
Adjusting backlash in axis 5.
© Copyright 2006 ABB. All rights reserved.
When a complete service of the wrist is required, including mounting/adjusting of gear axis 5,
the wrist should be sent to ABB for service.
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Repairs
5.6.3 Wrist
5.6.3 Wrist
Refer to Mechanical drawing 2:8 on page 206.
Removal:
Action
Note/Illustration
1.
WARNING!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
Remove the cables to motor axis 6 as
described in section.
Detailed in Cabling, axis 6 on page
154.
3.
Attach a hoist to the wrist so that it cannot rotate.
4.
Unscrew screws <6>.
Detailed in Mechanical drawing 2:8
on page 206.
5.
Pull out the wrist from the upper arm.
• If an arm extender is mounted, the
cables must be dismounted before
pulling out the wrist, see Arm
extender on page 118.
Detailed in
6.
Remove the cables to motor axis 5.
© Copyright 2006 ABB. All rights reserved.
Figure 42
Refitting:
Action
Note/Illustration
1.
Refit the cables to motor axis 5.
2.
Refit the friction washers <12> between
upper arm and wrist.
Detailed in Mechanical drawing 2:8
on page 206.
3.
Lubricate screws <6> with Molycote 1000
and tighten with a torque of 120 Nm.
Detailed in Mechanical drawing 2:8
on page 206.
4.
Refit cable harness to axis 6 as described in
section Cabling, axis 6 on page 154.
5.
Calibrate the robot as described in
chapter Calibration on page 159.
3HAC027076-001 Revision: A
117
Repairs
5.6.4 Arm extender
5.6.4 Arm extender
Refer to Mechanical drawing 2:8 on page 206 and Mechanical drawing 2:9 on page 207.
Removal
Action
1.
WARNING!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Dismount the wrist as described in section Wrist on page 117.
3.
Connect a hoist to the extender <3>.
4.
Unscrew screws <2:8/6> for the extender and remove it.
Refitting
Action
Lift the extender in position.
2.
Mount friction washers <12> between upper arm and extender.
3.
Lubricate the screws <2:8/6> with Molycote 1000 and tighten with a torque of
120 Nm.
4.
Mount the wrist as described in section Wrist on page 117.
© Copyright 2006 ABB. All rights reserved.
1.
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Repairs
5.6.5 Motor axis 5
5.6.5 Motor axis 5
Refer to Mechanical drawing 2:11 on page 209.
Removal
Action
1.
WARNING!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Dismount the wrist as described in section Wrist on page 117.
3.
Drain the oil by opening both magnetic plugs.
4.
Remove screws <3>. Press out the motor <2> use two screws in the threaded
holes (M8) on the motor flange to push out the motor from its attachment. Keep
track of the shims <7> between the motor flange and wrist housing.
5.
Measure the distance between the motor flange and the outer surface of the gear.
Use tool 6896 134-GN. Make a written note of the distance.
6.
WARNING!
Be careful not to tap or hit the end of the shaft (axially), nor displace the shaft
axially in any way. This could give rise to an incorrect air gap in the brake.
7.
WARNING!
© Copyright 2006 ABB. All rights reserved.
Make sure the oil injector is filled with oil.
8.
Press out the gear from the shaft.
NOTE!
This gear is matched with the other parts of the bevel gear <5> for axis 5. If the motor is
changed, the gear must be moved over to the new motor axis. If the gear is damaged, the
complete bevel gear set unit must be replaced.
Please contact ABB when replacement of the bevel gear set unit is necessary.
Refitting
Action
1.
3HAC027076-001 Revision: A
Check that there is an o-ring on the new motor, (the o-ring should be mounted from
the supplier).
119
Repairs
5.6.5 Motor axis 5
Action
2.
Remove the cover on the motor.
3.
Clean the hole where the pinion is to be mounted and the pinion with isopropanol
(Art. No.1177 1012-208).
4.
Apply a thin film of mineral oil (CS 320) to the pinion shaft and the pinion hole.
5.
NOTE!
The oil is applied to make the pinion run smoothly and to achieve an even friction
torque when assembling the pinion.
6.
Place the motor and pinion in the press fixture, see Press fixture. on page 120.
120
7.
Press the pinion on to the new motor and check the pressing force according to the
table below.
8.
If the pressing force is outside the given range, or if the pinion “jumps” in bit by bit,
it must be dismounted, checked, cleaned, and oiled before it is assembled once
again.
9.
The new motor with pinion must be measured and modified with the existing shims
to the measured value on the old motor. Use tool 6896 134-GN.
10.
Release the brake. Mount the motor. Use a new O-ring <2.3>. Apply Loctite 243 on
screws <3> and tighten with a torque of 24 Nm.
11.
Fill the gearbox with oil according to the Oil levels on page 74.
3HAC027076-001 Revision: A
© Copyright 2006 ABB. All rights reserved.
Figure 43 Press fixture.
Repairs
5.6.6 Motor axes 6
5.6.6 Motor axes 6
Refer to Mechanical drawing 2:11 on page 209 and Mechanical drawing 2:12 on page 210.
NOTE!
It is not necessary to remove the wrist from the upper arm see Wrist on page 117.
Removal:
Action
1.
WARNING!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Dismount cabling for axis 6 as described in Cabling, axis 6 on page 154.
3.
Drain the oil in axis 5. Open both magnetic plugs.
4.
Unscrew screws <2:11/13>. Dismount shaft <2:11/12> with help of 2 screws (M8
threads in the shaft).
5.
Loosen screw <2:11/31> and remove the cover <2:11/38>.
6.
NOTE!
© Copyright 2006 ABB. All rights reserved.
If the wrist is turned so the cover is on the upper side, it is not necessary to drain
all the oil in the wrist before removing the cover.
7.
Remove the cover <2:11/16> by deforming it (a new cover must be fitted).
8.
Loosen screws <2:11/33>.
9.
Free the motor including gear from the shaft <2:11/34> and lift out.
10.
Loosen screws <2:12/4>. Dismount the gear with the help of 2 screws (M8 threads
in the motor flange).
11.
Loosen screws <2:12/5>. Dismount the pinion with tool 3HAA 7601-043.
Refitting:
Action
1.
Mount the pinion on a new motor. Use a pin screw, M5x120 with nut, to press the
gear in place. If this is difficult, warm the pinion slightly. Tighten screw <2:12/5> with
a torque of 6 Nm and apply Loctite 243.
2.
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Repairs
5.6.6 Motor axes 6
Action
3.
NOTE!
Be careful not to tap or hit the end of the shaft (axially), nor displace the
shaft axially in any way. This could give rise to an incorrect air gap in the
brake.
4.
5.
Mount the gear on the motor, tighten with screws <2:12/4>. Use a new O-ring
<2:12/2>.
6.
Turn the gear so that the screw hole and magnetic oil plug come in the right position.
7.
Lubricate the screws with Molycote 1000 and tighten with a torque of 35 Nm.
8.
Mount the motor unit in the wrist. Fix against item <2:11/34>.
9.
Lubricate the screws <2:11/33> with Molycote 1000 and tighten with a torque of 70/
120 Nm.
10.
Mount shaft <2:11/12> with screws <2:11/13> and Loctite 243, tightening torque 24
Nm.
11.
Mount cover <2:11/16> (new cover) and cover <2:11/38>. Use a new gasket
<2:11/28>. Cross tighten screws <2:11/31> to 10 Nm.
Fill oil in axis 5 as described in Oil levels on page 74.
13.
Fill axis 6 with grease as described in Excess grease on page 83.
14.
Calibrate the robot as described in chapter Calibration on page 159.
© Copyright 2006 ABB. All rights reserved.
12.
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5.6.7 Checking backlash in axes 5 and 6
5.6.7 Checking backlash in axes 5 and 6
Checking total backlash axis 5
Refer to Mechanical drawing 2:11 on page 209.
Action
1.
Mount the tool 3HAB 7449-1 on the
mounting flange, see Figure 44.
2.
Search for the largest backlash.
3.
Make sure that the brake is engaged.
4.
Apply the dial indicator against the
mounting flange on axis 6, 195 mm from
the centre on axis 5, see Figure 44.
Note/Illustration
700
195
Tool
3HAB 7449-1
D=160 h7
40 N / 10 N
Axis 5
Wrist centre
Figure 44
Apply the spring balance (0-50 N) 700
mm from the centre on axis 5, see Figure 44.
6.
Load the spring balance to 40 N, then
decrease to 10 N.
7.
Reset the dial indicator in this position.
8.
Change the direction of pull and load to
40 N, then decrease to 10 N.
9.
Read the value on the dial indicator.
10.
Decrease the measured value by 0.02
mm (to compensate for the measurement force 10 N).
© Copyright 2006 ABB. All rights reserved.
5.
•
3HAC027076-001 Revision: A
If the measured backlash value
is ≥ 0.25 mm, an adjustment of
the backlash is recommended.
123
Repairs
5.6.7 Checking backlash in axes 5 and 6
Checking backlash axis 6
Refer to Mechanical drawing 2:11 on page 209.
Action
1.
Action
Mount the tool 6896 134-CF, see Figure 45.
190
500
Axis 6
150 N / 30 N
Figure 45
2.
Make sure that the brake is engaged.
3.
Apply the dial indicator against the tool 190
mm from the centre of axis 6, see Figure 44.
4.
Apply the spring balance 500 mm from the
centre on axis 6, see Figure 44.
5.
Load the spring balance to 150 N. then
decrease to 30 N.
6.
Reset the dial indicator in this position.
7.
Change the pull angle and load to 150 N,
then decrease to 30 N.
8.
Read the value on the dial indicator.
9.
Decrease the measured value by 0.04 mm
(to compensate for the measurement force
10 N). If the measured backlash value is ≤
0.06 mm, it is within the normal tolerances.
NOTE!
© Copyright 2006 ABB. All rights reserved.
The backlash in the gear unit cannot be adjusted. If necessary, the gear unit must be replaced,
see section Motor axes 6 on page 121.
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Repairs
5.6.8 Adjusting backlash in axis 5
5.6.8 Adjusting backlash in axis 5
Refer to Mechanical drawing 2:11 on page 209.
Action
1.
Remove the cover <38>. Investigate the cause of the excessive backlash on
axis 5. Then take action as described in one of the following alternatives:
A.
The intermediate gear unit <37> is stuck, the backlash between gears
<5> and <34> is excessive. The backlash must be 0 to 0.08 mm, measured
at three different points.
• Adjust the backlash as describedMotor axis 4 on page 107
B.
The intermediate gear unit <37> has become loose. Check that the gears
<5> and other parts (<18>, <20>, <21>, <22> and <43>) are not damaged or
loose.
• Replace damaged parts and adjust the backlash as described in
Adjusting the intermediate gear unit on page 126.
C.
There is backlash in the bearings of the intermediate gear unit <37>.
• Adjust the bearing as described in section Adjusting the intermediate gear unit bearings on page 127
© Copyright 2006 ABB. All rights reserved.
• Adjust to the correct backlash as described in section Adjusting
backlash in axis 5 on page 125.
3HAC027076-001 Revision: A
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Repairs
5.6.9 Adjusting the intermediate gear unit
5.6.9 Adjusting the intermediate gear unit
Refer to Mechanical drawing 2:11 on page 209.
Action
1.
Remove the wedges <21>. Check that they are not damaged.
2.
Adjust the intermediate gear unit <37> with the centre screw <18>.
• The gear mesh backlash between the pinion <5> and the gearwheel must
be 0 - 0.08 mm. Measure the backlash at three different places.
• Use the tool 6896 134-AU and a dial indicator on a magnetic foot.
Tighten the intermediate gear unit <37> using the screw <18>, to a torque of 93 Nm
± 5%.
4.
Apply oil on and mount the wedges <21> and the 4 tension washers <43> (fit them
as shown on mechanical drawing 2:11).
5.
Tighten the wedges alternately with the nuts <22>. Torque 12 Nm ± 5%. Apply
Loctite 243 to lock the nuts.
6.
Check the total backlash after tightening as described in section Checking
backlash in axes 5 and 6 on page 123.
© Copyright 2006 ABB. All rights reserved.
3.
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5.6.10 Adjusting the intermediate gear unit bearings
5.6.10 Adjusting the intermediate gear unit bearings
Refer to figure below.
The roller bearing (1) must be pre-tensioned to eliminate any backlash.
Action
1.
Remove the stop screw (2) and the locknut (3).
2.
Clean the threads in the hub (4) and the
locknut (3).
3.
Apply Loctite 290 on the threads in the
hub and the locknut.
4.
Tighten the locknut (3). Torque 85 Nm ±
5% (for a replacement bearing).
5.
Use the tool 3HAB 1022-1 together
with the torque-wrench.
6.
Fit the stop screw (2), extra locking. Apply
Loctite 243.
Note/Illustration
4
1
2
3
Figure 46 Intermediate wheel unit
NOTE!
© Copyright 2006 ABB. All rights reserved.
If the same bearing is fitted again, the torque should be 70-75 Nm.
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Repairs
© Copyright 2006 ABB. All rights reserved.
5.6.10 Adjusting the intermediate gear unit bearings
128
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5.7.1 Balancing Unit
5.7: Balancing Unit
5.7.1 Dismounting balancing unit
Refer to Mechanical drawing 2:14 on page 212 (Foundry).
Dismounting:
Action
1.
WARNING!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Place the lower arm in sync position.
3.
Secure the arm system against movement, we recommend use of a movable stop
axes. 2/3 (art. no. 3HAC 3665-1) included in Mech. stop ax.2/3 set (art. no. 3HAC
4658-1)
4.
Dismount one of the protection hoods <12>on top of the cylinder and insert an M12
screw and tighten until the spring force is neutralized. The length of the cylinder is
now locked.
5.
Prepare the lift, use lifting tool 3HAC 11601-1.
6.
WARNING!
© Copyright 2006 ABB. All rights reserved.
Make sure that the shaft between the upper and lower arms does not rotate when
unscrewing the lock nuts. Use key handle 46 mm.
7.
Dismount <7> and <8> and lift away the cylinder.
8.
Dismount the inner races with a puller.
Mounting:
Action
1.
Place rings, support washers, sealing rings on the upper and lower pivot shaft,
(grease the support washer to fix them in place).
2.
Place the inner races of the bearings on the new balancing cylinder use tool 3HAC
5281-1
3.
Mount the auxiliary shafts on the upper and lower shafts. (Upper shaft: auxiliary
shaft 3HAC 5275-1, lower shaft: auxiliary shaft 3HAC 5276-1.)
4.
Hang up the new balancing unit on the upper auxiliary shaft, adjust the length
between the bearings with the M12 screw (if the distance is to long the bearings will
be damage) while pushing the balancing cylinder carefully in place by hand force
on to the lower shaft, (do not use a hammer of any type, the bearings may be
damaged).
3HAC027076-001 Revision: A
129
Repairs
5.7.1 Dismounting balancing unit
Action
5.
Dismount the auxiliary shafts, grease the bearings with tool 3HAC 5222-1.
6.
NOTE!
It is of great importance that the bearings are thoroughly lubricated. Lubricate the
bearings with ABB art. no. 3HAB 3537-1 (Shell ALVANIA WR2) or equivalent
grease
Dismount the tool, and clean the threads on the shaft ends.
8.
Mount the outer support rings, sealing rings <7>, <8> and the lock nut <5>. Use a
KM-10 socket, Loctite 243 and a torque wrench to lock the nuts to a torque of 120
Nm.
9.
Dismount the M12x50 screw <12> on the top of the cylinder, remount the plastic
plug. Check that there is a margin between support washers and cylinder ears (min.
0.1 mm).
10.
Move axis 2 in both directions to make sure that everything working accurately.
© Copyright 2006 ABB. All rights reserved.
7.
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5.7.2 Replacing guide ring, balancing unit
5.7.2 Replacing guide ring, balancing unit
Refer to Mechanical drawing 2:15 on page 213.
NOTE!
Use reconditioning kit 3HAC 8982-1
Removal:
Action
1.
WARNING!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Move axis 2 to a position where the balancing unit is in the horizontal position.
3.
Remove the circlip from the end cover of balancing unit.
4.
Remove the worn out guide ring and clean the piston rod.
Refitting:
Action
Place the two halves around the piston rod with the smallest outer diameter facing
outwards, locate the new guiding ring in the end cover.
2.
Install the circlip.
3.
Lubricate the piston rod, see Lubricating piston rod, balancing unit axis 2 on page
78.
© Copyright 2006 ABB. All rights reserved.
1.
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131
Repairs
5.7.3 Replacing bearings, balancing unit
5.7.3 Replacing bearings, balancing unit
Refer to Mechanical drawing 2:15 on page 213.
NOTE!
Use reconditioning kit 3HAC 8983-1 (Foundry).
Action
Dismantle the balancing unit according to section Dismounting balancing unit on
page 129.
2.
Push out the old bearing, using tool 3HAC 8981-1.
3.
Turn the tool upside down. Place the new bearing on the tool with the bearing
number upwards (facing the tool). Push the new bearing down.
4.
Mount the balancing unit according to section Dismounting balancing unit on page
129.
© Copyright 2006 ABB. All rights reserved.
1.
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5.8.1 Arm System
5.8: Arm System
5.8.1 Upper arm
Refer to: Mechanical drawing 2:1 on page 198, Mechanical drawing 2:2 on page 199,
Mechanical drawing 2:3 on page 200 and Mechanical drawing 2:8 on page 206
Removal:
WARNING!
Secure axis 3 with mechanical stops, 3HAC 3665-1 (part of 3HAC 4658-1), so that the balancing weight for axis 3 cannot fall down.
Action
1.
WARNING!
© Copyright 2006 ABB. All rights reserved.
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Dismount balancing units <2:1/5> as described in Dismounting balancing unit on
page 129 or Replacing guide ring, balancing unit on page 131.
3.
Remove the cables and air hose inside the upper arm as in Robot harness on page
147.
4.
Attach a hoist and the lifting device (3HAC 1817-1) to the upper arm. See Figure
47.
Figure 47 Lifting the upper arm.
5.
Remove the parallel arm<2:1/3> see section Parallel arm on page 139.
6.
Remove the KM nut <2:2/208> on each shaft.
7.
Remove the stop screws <2:2/201> in the axis 4 housing.
8.
Remove the protective plates <2:3/10> on the inner side of the shaft, unscrew the
shafts <2:2/200>. The bearing is pressed out with the shaft.
9.
Lift the upper arm away.
WARNING!
Be careful with the threads on the shafts.
3HAC027076-001 Revision: A
133
Repairs
5.8.1 Upper arm
Refitting:
NOTE!
Mount the left side first, complete, robot seen from behind!
Action
1.
Move the upper arm to its mounting position.
2.
Mount V-ring <2:2/203> and distance ring <2:2/202> on shaft <2:2/200>.
3.
Clean the cones in the axis 4 housing and on the shaft. Lubricate the M80 thread
and the cones with Molycote 1000.
4.
Mount the shaft <2:2/200> in the axis 4 housing. Tighten with a torque of 400 Nm.
5.
Apply Loctite 243 on stop screw <2:2/201> and tighten with 34 Nm.
6.
Mount sealing ring <2:2/204>, turn the largest diameter inwards.
7.
Lubricate the bearings <2:2/205> before installation on the shaft. Use lubricant
3HAB3537-1 (Shell Alvania WR2) <2:2/11>.
8.
Install the bearing with pressing tool 3HAC 5025-1.
9.
Fill with grease <2:2/11> outside bearing
10.
Install the o-ring <2:2/213 + 2:2/11> on sealing ring <2:2/213> and insert in the
lower arm.
11.
Install the o-ring <2:2/212 + 2:2/11> on the shaft.
12.
Install the sealing assembly <2:2/207>.
13.
Mount the KM nut <2:2/208>. Apply Loctite 243 and tighten the nut to 90 Nm.
14.
NOTE!
134
15.
Mount the right side according to paragraphs 10-18 (similar to the left side except
the distance ring <2:2/202>
16.
Mount the parallel bar.
17.
Mount the cabling as described Robot harness on page 147.
18.
Mount the balancing units as described in Dismounting balancing unit on page 129.
3HAC027076-001 Revision: A
© Copyright 2006 ABB. All rights reserved.
If the pressing tool is not used, tighten to 180 Nm, then loosen the nut again and
tighten with a torque of 90 Nm.
Repairs
5.8.2 Parallel bar with bearings
5.8.2 Parallel bar with bearings
Refer to Mechanical drawing 2:1 on page 198.
Removal:
WARNING!
Secure axis 3 with mechanical stops, 3HAC 3665-1 (part of 3HAC 4658-1), so that the balancing weight for axis 3 cannot fall down, and secure the upper arm with a hoist or similar.
Action
1.
WARNING!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Attach a hoist and lifting device to the parallel bar.
3.
Dismount screw and washer <:lt>224, 223<:gt> on the lower bearing of the parallel
bar.
4.
Dismount screw and washer <:lt>224, 223<:gt> on the upper bearing of the parallel
bar".
5.
Press the shafts out with a hydraulic press and toll 3HAC 5021-1
6.
Lift the bar away.
Refitting:
© Copyright 2006 ABB. All rights reserved.
Action
1.
Lift the parallel bar in position.
2.
Place the axial washer and cover washer on each side of the bearing
3.
Place and centre the parallel bar
4.
Apply a thin coat of grease on the shaft
5.
Press the shaft with a hydraulic press and tool (3HAC 5021-1)
6.
Apply Loctite 243 and mount the screw and washer<224, 223>.
WARNING!
Do not forget to remove the 2 extra mechanical stops!
3HAC027076-001 Revision: A
135
Repairs
5.8.3 Balancing weight
5.8.3 Balancing weight
Refer to Mechanical drawing 2:1 on page 198.
Removal:
Action
1.
WARNING!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Attach a hoist with two lifting eyes to the balancing weight.
3.
Loosen the four M16x120 screws.
4.
Lift the weight away.
Refitting:
Action
Mount in reverse order. Tighten the four M16x120 screws with a torque of 300 Nm.
© Copyright 2006 ABB. All rights reserved.
1.
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5.8.4 Lower arm
5.8.4 Lower arm
Refer to Mechanical drawing 2:1 on page 198.
Removal:
WARNING!
Be careful! Make sure that the upper arm is locked in position and
cannot move.
Action
1.
WARNING!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Dismount the balancing weight for axis 3. (see Balancing weight on page 136).
3.
Attach a hoist to the upper arm.
4.
Remove the locking screw and washer <223, 224> on the parallel arm and the
upper arm, press the shafts out with a hydraulic press and tool no.3HAC 5021-1
and lift the parallel bar away.
5.
Remove the harness on the upper and lower arms as described in chapter Cable
Harness on page 147.
6.
Dismount the upper arm as described in Upper arm on page 133.
7.
Dismount the two balancing units <4> as described in Dismounting balancing unit
on page 129 or Replacing guide ring, balancing unit on page 131.
8.
Dismount the M16x70 screws between the parallel arm and gearbox axis 3 and
between lower arm and gearbox axis 2, (the lower arm must be reorientated to
make it possible to dismount all the screws) save at least two parallel placed
screws on each side.
9.
Attach a hoist to the lower arm.
© Copyright 2006 ABB. All rights reserved.
10.
WARNING!
Danger! Be sure that the lower arm is properly attached to the hoist before loosening the last screws.
11.
Dismount the last four screws.
12.
Place a crowbar between the gearbox axis 3 and the parallel arm, and press the
lower and parallel arms together.
13.
Place a crowbar between gearbox axis 2 and the lower arm, and press to release
the guiding.
14.
Lift and remove the lower arm.
15.
Dismount the parallel arm as in Parallel arm on page 139.
3HAC027076-001 Revision: A
137
Repairs
5.8.4 Lower arm
Refitting:
Action
Mounting in reverse order.
© Copyright 2006 ABB. All rights reserved.
1.
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Repairs
5.8.5 Parallel arm
5.8.5 Parallel arm
Refer to Mechanical drawing 2:7 on page 205.
For complete sets of special tools for service on parallel arm, see chapter Tool List on page
171.
Removal:
Action
1.
WARNING!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Remove the lower arm as in Lower arm on page 137.
3.
Place the arm on a workbench.
4.
Attach a hoist to the parallel arm.
5.
Place the Cylinder NIKE CHF 612 (1) and tools 3HAC 5526-1 (2) and 3HAC 55231 (3) see Dismounting Parallel arm and Bearings on page 140.
6.
Force the parallel arm to the right, seen from the rear.
7.
Lift the parallel arm away.
Refitting:
© Copyright 2006 ABB. All rights reserved.
Action
1.
Place the parallel arm in position.
2.
Press the parallel arm into the lower arm with NIKE CHF 612 (1) and tools 3HAC
5526-1 (2) and 3HAC 5523-1 (3),
3.
Mount the lower arm as described in Lower arm on page 137.
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Repairs
5.8.5 Parallel arm
Dismount Parallel arm / Lower arm
1
Dismount inner bearing
2
4
2
3
3
1
Dismount outer bearing
5
2
1
© Copyright 2006 ABB. All rights reserved.
Figure 48 Dismounting Parallel arm and Bearings
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Repairs
5.8.6 Parallel arm - Inner bearing
5.8.6 Parallel arm - Inner bearing
Removal:
Action
1.
Place the cylinder NIKE CHF 612 (1) and tools 3HAC 5526-1 (2), 3HAC 5523-1 (3)
and 3HAC 5522-1 (4).
2.
Press the bearing off.
Refitting:
Action
1.
Refit in reverse order.
5.8.7 Parallel arm - Outer bearing
Removal:
Action
1.
Place the cylinder NIKE CHF 612 (1) and tools 3HAC 5526-1 (2), 3HAC 5523-1 (3)
and 3HAC 5522-2 (5).
2.
Press the bearing off.
Refitting:
© Copyright 2006 ABB. All rights reserved.
Action
1.
3HAC027076-001 Revision: A
Refit in reverse order.
141
Repairs
5.8.8 Gearbox 1-3 including base
5.8.8 Gearbox 1-3 including base
The gearbox axis 1-3 including base shall be replaced as one unit. The robot arm system unit
including counter balancing weight axis 3, balancing units axis 2 and tooling are disassembled from the gearbox unit axis 1–3 and lifted by a special lifting device.
An instruction of the replacement of the gearbox unit axis 1–3 is included in the spare part.
A summary of the repair work is given below. Instruction for replacement of gearbox axis
1-3: 3HAC 12512-1
The arm system is remounted in a new complete gearbox unit axis 1-3. If a complete gearbox
unit axes 1–3 cannot be used, the motor axes 1–3, must be transferred to the new gearbox
before the arm system can be installed. Mechanical stops axis 1, any position switches on axes
1–3 etc. must be transferred to the new gearbox unit.
Removal
Action
1.
WARNING!
2.
Remove components installed on the gear box like stop pin axis 1, vernier scales,
positions switches etc.
3.
Release all bolts except 2 x 4 safety bolts in the fittings between lower arm and
parallel arm and the gearbox output shafts axis 2 and 3.
4.
Install the lifting device (3HAC 6878-1) on the upper arm. Refer to Figure 49.
5.
Release the balancing units from the shafts on the gear box.
6.
Disconnect the controller and free the harness from the connector plate, at axis 13 motors, SMB unit and brake release unit and lift it out from the axis 1 centre hole.
7.
Remove the remaining 4 + 4 bolts and lift the arm system including the cabling
away from the gear unit.
Refitting
Action
142
1.
Lift the new gearbox in position
2.
Transfer the motors to the new gearbox
3.
Lift the arm system in position and install it on axis 2 side with the four safety bolts.
4.
Install it on axis 3 side with four safety bolts.
5.
Mount the robot cabling and connect the controller.
6.
Install the balancing units.
7.
Remove the lifting device from upper arm.
8.
Install the remaining bolts on both sides and perform the torque tightening.
3HAC027076-001 Revision: A
© Copyright 2006 ABB. All rights reserved.
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Repairs
5.8.9 Gearbox axis 1-3, seals axis 1
Action
9.
Install the remaining components to the new gear unit.
Figure 49 Lifting position
5.8.9 Gearbox axis 1-3, seals axis 1
Inner and outer seal on axis 1 can be replaced. Contact ABB for information about spare parts,
Instruction and special tools.
The inner seal can be replaced without dismounting the gearbox axis 1-3 from the robot arm
system.
Replacement of the outer seal can be made only on a separate gearbox.
© Copyright 2006 ABB. All rights reserved.
Instruction for replacement of seals axis 1 on gearbox axis 1-3: 3HAC 12513-1
5.8.10 Gearbox axis 1-3, seals axis 2/3
Seals on output shafts on axis 2/3 can be replaced. Contact ABB for information about spare
parts, Instruction and special tools.
Replacement of the seals can be made only on a separate gearbox.
Instruction for replacement of seals axis 2/3 on gearbox axis 1-3: 3HAC 12513-1
3HAC027076-001 Revision: A
143
Repairs
5.8.11 Brake release unit
5.8.11 Brake release unit
Refer to Mechanical drawing 2:5 on page 202.
Removal:
Action
1.
WARNING!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Remove the push-button unit <6> located in the frame.
3.
Disconnect connectors R3.BU1-6(X8), R3.BU1-3(X9), R3.BU4-6(X10).
Refitting:
Action
Refit in reverse order.
© Copyright 2006 ABB. All rights reserved.
1.
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Repairs
5.8.12 Replace serial measurement board
5.8.12 Replace serial measurement board
Refer to Mechanical drawing 2:6 on page 203.
Removal:
Action
1.
WARNING!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Remove the cover <17> located in the frame.
3.
Disconnect connectors R2.SMB, R2.SMB 1-4, R2.SMB 3-6.
4.
Disconnect connector R2.G (battery connector) from the SMB.
Refitting:
Action
Refit in reverse order.
© Copyright 2006 ABB. All rights reserved.
1.
3HAC027076-001 Revision: A
145
Repairs
5.8.13 Replace stop pin
5.8.13 Replace stop pin
Refer to Mechanical drawing 2:5 on page 202.
Removal:
Action
1.
WARNING!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Remove the cover on top of the housing.
3.
Remove the M20x90 bolt <101> and the compression spring <102>.
4.
Lift up the stop pin <8>. Check the washer item 103.
5.
Replace with new if damaged.
Refitting:
Action
Use Loctite 415 (glue). Apply Loctite 638 (glue) on 10 mm of the threaded end.
Lubricate the rest of item 101. Tighten.
2.
Check the function of the stop pin.
3.
Mount the bolt <101> and the compression spring <102>.
4.
Refit the cover on top of the housing.
© Copyright 2006 ABB. All rights reserved.
1.
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5.9.1 Cable Harness
5.9: Cable Harness
5.9.1 Robot harness
Refers to Mechanical drawing 2:1 on page 198, Mechanical drawing 2:3 on page 200,
Mechanical drawing 2:5 on page 202, Mechanical drawing 2:6 on page 203 and Mechanical
drawing 2:10 on page 208.
It is recommended that all work on the robot harness is undertaken with axis 1 to 4 at 0º.
WARNING!
Placing more cables/hoses in the harness, without prior consent from ABB Robotics, may
compromise lifetime.
Removal
We recommend that a team of at least two people undertake the job of changing a harness.
When the robot is equipped with a welding harness, this must first be removed from the base
up to the harness clamp in the frame, to facilitate removal of the robot harness.
Action
Action
1.
WARNING!
© Copyright 2006 ABB. All rights reserved.
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
Remove the 4 screws <2:5/100> in the cover
<2:5/15> that protects the connectors on the
base.
3.
Remove the connectors R1.MP and R1.SMB
from the attaching plate.
4.
Unscrew the 3 screws on motors 1, 2, and 3
and remove the covers. Remove the connectors from the motors.
5.
Remove the brake release units <2:5/6> and
the cover of the Serial measurement board
<2:6/17> and remove the connectors.
6.
Unscrew the 4 screws from the cable gland
plate to the serial measurement board and the
brake release board on the inside of the frame
and pull out the cables.
7.
Remove the cable guide <2:5/42> located
between the lower and parallel arms by pressing the split part so it overlaps. Open it up and
take out the cables.
robot
front
Figure 50 Cable harness guide.
3HAC027076-001 Revision: A
147
Repairs
5.9.1 Robot harness
Action
8.
Action
Remove the hose clamp from the cover <2:5/
10> on the frame.
Avoid folding!
Hose clamp
Figure 51 Cable harness clamp.
9.
Remove the hose clamp from the cover <2:5/
10> on the frame.
10.
Pull the harness up through the base from the
front side of the robot.
11.
Remove the cover <2:1/7> on the arm housing
and unscrew the holders for cable guide <2:1/
251> and cable guide <2:1/252> from the tubular shaft.
12.
Remove the 4 screws on top of motor 4 and
remove the connectors. Unscrew the screws
for the clamping strap fixture below motor 4
(new clamping strap fixtures are included with
the harness).
13.
Remove the cover <2:3/13> on the upper arm
tube and remove the connectors to motors 5
and 6.
14.
Remove the harness fixtures underneath the
arm housing and on the front side of the upper
part of the upper arm.
15.
Pull the harness out of the tubular axle and
down through the lower arm.
WARNING!
© Copyright 2006 ABB. All rights reserved.
It should be remembered that connectors and wiring are sensitive parts of a harness and must
be treated with care.
148
3HAC027076-001 Revision: A
Repairs
5.9.1 Robot harness
Refitting
Action
1.
Point 8-7 and 5-1 in reverse. Position harness
according to Figure 52. The finished position of
the cables on the frame should be according to
Figure 53.
Note/Illustration
B
A
C
Figure 52 Location of harnesses in holder.
Welding harness
Customer harness
Robot harness
2.
WARNING!
Do not twist the cables in the base.
© Copyright 2006 ABB. All rights reserved.
3.
Pull the harness up through the lower arm and
pre-fit the attachment plate for the fixture in the Position of SMB
arm housing (there is insufficient space to do gland plate
this when the harness is in position).
Cables to motor
axis 4-6
Figure 53 Position of cables on the frame.
4.
The cables to motor 4 are then pulled through
the arm housing and fitted before the cables to
motors 5 and 6 are pulled through the arm
housing. The harness is twisted ½ turn
between the attachments in the under arm and
upper arm so that the cables have the same
length when they are subjected to bending
(This twist must be retained).
Cable fixture point
Figure 54 Position of cables on the frame.
5.
3HAC027076-001 Revision: A
Put the cables for motor 5-6 through the upper
arm tube.
149
Repairs
5.9.1 Robot harness
Action
6.
Perform step 9-11 in removal in reverse.
Observe the right position of the cables
(printed on cables and guide).
7.
Perform step 6 in removal in reverse.
8.
Position the screws for the hose clamps at the
correct places (see Figure 51).
Note/Illustration
© Copyright 2006 ABB. All rights reserved.
Figure 55 Right position of the cable
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5.9.2 Customer Harness
5.9.2 Customer Harness
Refers to Mechanical drawing 2:1 on page 198, Mechanical drawing 2:3 on page 200,
Mechanical drawing 2:5 on page 202, Mechanical drawing 2:6 on page 203 and Mechanical
drawing 2:10 on page 208.
It is recommended that all work on the customer harness is undertaken with axis 1 to 4 at 0º.
WARNING!
Placing more cables/hoses in the harness, without prior consent from ABB Robotics, may
compromise lifetime.
Removal
We recommend that a team of at least two people undertake the job of changing a harness.
When the robot is equipped with a welding harness, this must first be removed from the base
up to the harness clamp in the frame, to facilitate removal of the customer harness (se the section about changing welding harness).
Action
Action
1.
WARNING!
© Copyright 2006 ABB. All rights reserved.
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
Remove the 4 screws <2:5/100> in the cover
<2:5/15> that protects the connectors on the
base.
3.
Remove the connectors R1.CP/CS, R1.CAIR
and R1.SW2/3 if such is fitted from the attaching plate.
4.
Remove connector R2.SW2/3 from position
switches ax 2/3 if such are fitted.
5.
Remove the cable guide <2:5/42> located
between the lower and parallel arms by pressing the split part so it overlaps. Open it up and
take out the cables.
robot
front
Figure 56 Cable harness guide, axes 2, 3.
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Repairs
5.9.2 Customer Harness
Action
6.
Action
Remove the hose clamp from the cover <2:5/
10> on the frame.
Avoid folding!
Hose clamp
Figure 57 Cable harness clamp.
7.
Pull the harness up through the base from the
front side of the robot.
8.
Remove the 4 screws on the connection box
(placed on arm housing or on the upper arm
tube). Pull out the box, remove air connection
nipple R2.CAIR and remove the backside
cover (4 screws).
9.
Remove connectors R2.CP, R2.CS and
R2.CBUS (D-SUB connector inside box).
10.
Remove the gland plate from the backside
plate.
11.
Remove the cover <2:1/7> on the arm housing
and unscrew the holders for cable guide <2:1/
251> and cable guide <2:1/252> from the tubular shaft.
12.
Remove the harness fixtures underneath the
arm housing.
13.
Pull the harness out of the tubular axle and
down through the lower arm.
WARNING!
It should be remembered that connectors and wiring are sensitive parts of a harness and must
be treated with care.
Action
1.
Perform step 6-5 and 3-1 in removal in reverse.
Position harness according to Figure 58. The
finished position of the cables on the frame
should be according to Figure 59 below.
Action
Connector R2.SW2/3
Note that the cable goes under the other cables
Figure 58 Position of the cables on the frame.
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© Copyright 2006 ABB. All rights reserved.
Refitting
Repairs
5.9.2 Customer Harness
Action
Action
2.
WARNING!
Do not twist the cables in the base.
3.
Pull the harness up through the lower arm and
pre-fit the attachment plate for the fixture in the
arm housing (there is insufficient space to do
this when the harness is in position).
4.
Pull the harness through the arm housing.
Position the various harnesses correctly in the
cover on the base (see Position of the cables
on the frame. on page 152).
B
A
C
Figure 59 Location of harnesses in holder.
Welding harness
Customer harness
Robot harness
If the connection box should be fitted to the
arm housing, skip this point. Pull the cables
through the upper arm tube.
6.
Perform step 9-7 in removal in reverse.
7.
Perform step 10 in removal in reverse.
8.
Perform step 4 in removal in reverse.
© Copyright 2006 ABB. All rights reserved.
5.
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5.9.3 Cabling, axis 6
5.9.3 Cabling, axis 6
Refer to Mechanical drawing 2:8 on page 206.
Removal:
Action
1.
WARNING!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Run axis 5 to +90° position (Tool flange facing down and parallel with floor).
3.
Remove the covers for the cables to axis 6 on the upper arm tube and wrist.
4.
Dismount connectors R2.MP6, R2.FB6 from the robot harness. Loosen the cable
bracket and the sealing with screws <9>.
5.
Dismount the cover at the back of the motor.
6.
Dismount connectors R3.MP6, R3.FB6 under the cover at the rear of motor 6.
7.
NOTE!
Be careful not to damage the cables or resolver
8.
Loosen the carrier mounted on the motor with the M4x8 screw in the bottom (not
shown in mechanical drawing 2:8).
Action
1.
154
Mount in reverse order. (Keep axis 5 in 90° position.)
3HAC027076-001 Revision: A
© Copyright 2006 ABB. All rights reserved.
Refitting
Repairs
5.10.1 Options
5.10: Options
5.10.1 Position Switch axis 1
Refers to Mechanical drawing 2:17 on page 214.
Removal
Action
1.
WARNING!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Dismount the protective plates.
3.
Dismount the Rail bracket <5> and the 12 screws <8> from the under side of the
base.
4.
If the cams run into and overlaps on both rail sections, the cams must be dismounted before the rails.
5.
Dismount the connector from the bracket on the left side of the robot base (seen
from behind).
6.
Dismount the two screws and remove the position switch.
Refitting
Action
Mount in reverse order.
© Copyright 2006 ABB. All rights reserved.
1.
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5.10.2 Signal lamp
5.10.2 Signal lamp
Refer to Mechanical drawing 2:1 on page 198, Mechanical drawing 2:10 on page 208 and
Mechanical drawing 2:20 on page 217.
Removal
Action
1.
WARNING!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Remove cover on axis 4 <2:1/7>.
3.
Dismount the two screws that attach the signal lamp <2:1/117> to the bracket <2:1/
2>.
4.
Dismount the three screws on the cover on motor axis 4 <2:10/1> and remove the
cover.
5.
Dismount the cable gland <2:20/5>.
6.
Disconnect the connectors R2.H1 and R2.H2 <2:20/7>.
Refitting
Action
1.
Refit in reverse order.
Figure 60 Location of snap attachments
© Copyright 2006 ABB. All rights reserved.
Refitting
Action
1.
156
Refit in reverse order.
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5.10.3 Fork lift device
5.10.3 Fork lift device
Refer to Mechanical drawing 2:1 on page 198.
Removal
Action
1.
WARNING!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Attach a hoist to the lifting device <100>.
3.
Loosen the M16x60 screws <100.1> and washers <100.2>.
Refitting
Action
Mount in reverse order. Tighten the M16x60 screws with a 300 Nm torque.
© Copyright 2006 ABB. All rights reserved.
1.
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© Copyright 2006 ABB. All rights reserved.
5.10.3 Fork lift device
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6.1.1 Introduction
6: Calibration
6.1: Introduction
General
This chapter includes general information about different calibration methods and also details
procedures that do not require specific calibration equipment.
When the robot system must be recalibrated, it is done according to documentation enclosed
with the calibration tools.
6.1.1 When to calibrate
The system must be calibrated if any of the below occurs.
The resolver values are changed
If resolver values are changed, the robot must be recalibrated using the calibration methods
supplied from ABB. Calibrate the robot carefully with standard calibration. The different
methods are briefly described in section Types of calibration on page 160, and further detailed
in separate Calibration manuals.
If the robot has Absolute Accuracy calibration, it is also recommended but not always needed
to be calibrated for new Absolute Accuracy.
The resolver values will change when parts affecting the calibration position are replaced on
the robot, e.g. motors, wrist or part of transmission.
Contents of the revolution counter memory are lost
© Copyright 2006 ABB. All rights reserved.
If the contents of the revolution counter memory are lost, the counters must be updated as
detailed in section Updating revolution counters on page 165. This will occur when:
•
the battery is discharged
•
a resolver error occurs
•
the signal between a resolver and measurement board is interrupted
•
a robot axis is moved with the control system disconnected
The revolution counters must also be updated after the robot and controller are connected at
the first installation.
The robot is rebuilt
If the robot has been rebuilt, e.g. after a crash or when the robot has been changed for other
reachability, it needs to be recalibrated for new resolver values.
If the robot has Absolute Accuracy calibration, it needs to be calibrated for new Absolute
Accuracy.
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6.1.2 Types of calibration
6.1.2 Types of calibration
Overview
This section specifies the different types of calibration and the calibration methods that are
supplied from ABB.
Types of calibration
Description
Calibration method
Standard
calibration
The calibrated robot is positioned at home
Levelmeter calibration
position, i.e. the axes positions (angles) are
(alternative method)
set to 0º.
Standard calibration data is found in the file
calib.cfg, supplied with the robot at delivery.
The file identifies the correct resolver/motor
position corresponding to the robot home
position.
From deliveries together with RobotWare 5.0.5
and higher, the data will instead be found on
the SMB (serial measurement board) in the
robot, and not in a separate file.
Absolute Accuracy
calibration
(optional)
Based on standard calibration, and besides
CalibWare
positioning the robot at home position, the
Absolute Accuracy calibration also
compensates for:
• mechanical tolerances in the robot
structure
• deflection due to load.
Absolute Accuracy calibration focuses on
positioning accuracy in the Cartesian
coordinate system for the robot.
Absolute Accuracy data is found in the file
absacc.cfg, supplied with the robot at delivery.
The file replaces the calib.cfg file and identifies
motor positions as well as absacc-compensation parameters.
From deliveries together with RobotWare 5.0.6
and higher, the data will instead be found on
the SMB (serial measurement board) in the
robot, and not in a separate file.
A robot calibrated with AbsAcc has a sticker
next to the identification plate of the robot.
To regain 100% Absolute Accuracy performance, the robot must be recalibrated for
Absolute Accuracy!
xx0400001197
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© Copyright 2006 ABB. All rights reserved.
Type of calibration
Repairs
6.1.3 Calibration methods
6.1.3 Calibration methods
Each calibration method is detailed in a separate manual. Below is a brief description of the
methods available.
Levelmeter Calibration - alternative method
Levelmeter Calibration is referred to as the alternative method for calibration of ABB robots,
because of the less accurate values obtained during calibration. The method uses the same
principles as Calibration Pendulum but does not have as good of mechanical tolerances to the
toolkit parts as the standard method with Calibration Pendulum.
This method may, after calibration, require modifications in the robot program, and is therefore not recommended.
The calibration equipment for Levelmeter Calibration is ordered as separate parts for each
robot and the operating manual for Levelmeter Calibration is enclosed with the Levelmeter
2000.
CalibWare - Absolute Accuracy calibration
In order to achieve a good positioning in the Cartesian coordinate system, Absolute Accuracy
is used as a TCP calibration. The tool CalibWare guides through the calibration process and
calculates new compensation parameters. This is detailed further in the manual Instructions
for level meter calibration.
If a service operation is done to a robot with Absolute Accuracy, a new absolute accuracy calibration is required in order to establish full performance. For most cases after motor and
transmission replacements that do not include taking apart the robot structure, standard calibration is sufficient. Standard calibration also supports wrist exchange.
References
Article numbers for the calibration tools are listed in section Tools on page 171.
© Copyright 2006 ABB. All rights reserved.
The article numbers for the operating manuals for calibration are also listed in section References on page 9.
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6.1.3 Calibration scales and correct axis position
6.2: Calibration scales and correct axis position
Introduction
This section specifies the calibration scale positions and/or correct axis position for the
6400RF robot model.
Calibration scales/marks, IRB 6400RF
xx0200000176
162
Pos
Axis
Art.no
Description
A
1
3HAC4810-4
3HAA1001-73
3HAC4810-6
Sync bracket
Sync plate
Sync plate
B
2
3HAC4810-1
3HAC4832-1
3HAC4832-2
3HAC4810-3
Sync bracket
Sync plate with nonie
Sync plate
Sync bracket
3HAC027076-001 Revision: A
© Copyright 2006 ABB. All rights reserved.
The illustration below shows the location of the calibration scales on specific plates and the
calibration marks directly in the casting at axes 2 and 3.
Repairs
6.1.3 Calibration scales and correct axis position
Pos
Axis
Art.no
Description
C
3
3HAC4810-3
3HAC4832-1
3HAC4832-3
3HAC4810-2
Sync bracket
Sync plate with nonie
Sync plate
Sync bracket
D
4
3HAA1001-76
3HAA1001-79
Sync plate
Sync plate with nonie
E
5
3HAA1001-77
3HAA1001-79
Sync plate
Sync plate with nonie
F
6
3HAA1001-78
3HAA1001-174
Sync plate
Sync plate with nonie
Calibration marks at axes 2 and 3
© Copyright 2006 ABB. All rights reserved.
The calibration marks at axes 2, 3 and 6 shown in the figure above, consist of two single
marks that should be positioned opposite to one another when the robot is standing in its calibration position. One of the marks is more narrow than the other and should be positioned
within the limits of the wider mark.
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6.2.1 Calibration movement directions for all axes
6.2.1 Calibration movement directions for all axes
Overview
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.
Calibration movement directions, 6 axes
© Copyright 2006 ABB. All rights reserved.
Note! The figure shows an IRB 7600, but the positive direction is the same for all 6-axis
robots, except the positive direction of axis 3 for IRB 6400R which is in the opposite direction!
xx0200000089
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6.2.2 Updating revolution counters
6.2.2 Updating revolution counters
General
This section details how to perform a rough calibration of each robot axis, i.e. updating the
revolution counter value for each axis, using the pendant.
Step 1 - Manually running the robot to the calibration position
This procedure details the first step when updating the revolution counter; manually running
the robot to the calibration position.
WARNING!
Axis 4 has no mechanical limitation! Cabling inside the robot may be damaged if axis 4 is
oriented incorrectly when performing calibration of the robot!
Action
Note
1. Select axis-by-axis motion mode.
2. Jog the robot to place the calibration marks Shown in section Calibration scales and
within the tolerance zone.
correct axis position on page 162.
3. When all axes are positioned, store the
revolution counter settings.
Detailed in section:
Step 2 - Storing the revolution counter
setting with the FlexPendant on page 166
Correct calibration position of axis 4 and 6
When running the robot to calibration position, it is extremely important to make sure that
axes 4 and 6 of the below mentioned robots are positioned correctly. The axes can be calibrated at the wrong turn, resulting in wrong calibrated robot.
Make sure the axes are positioned according to the correct calibration values, not only according to the calibration marks. The correct values are found on a label, located either on the
lower arm or underneath the flange plate on the base.
© Copyright 2006 ABB. All rights reserved.
At delivery the robot is in the correct position, do NOT rotate axis 4 or 6 at power up before
the revolution counters are updated.
If one of the below mentioned axes are rotated one or more turns from its calibration position
before updating the revolution counter, the correct calibration position will be lost due to
uneven gear ratio. This affects the following robots:
Robot variant
Axis 4
Axis 6
IRB 140
Yes
Yes
IRB 1600
No
Yes
IRB6400 / 200kg
Yes
No
IRB6400RF / 200kg
Yes
No
IRB6600-175/2.55
Yes
No
IRB6600/6650 / others
Yes
Yes
IRB6600ID/6650ID
Yes
No
IRB7600
Yes
Yes
If the calibration marks seem to be wrong (even if the motor calibration data is correct), try
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6.2.2 Updating revolution counters
to rotate the axis one turn, update the revolution counter and check the calibration marks
again (try both directions, if needed).
Step 2 - Storing the revolution counter setting with the FlexPendant
This procedure details the second step when updating the revolution counter; storing the revolution counter setting with the FlexPendant (RobotWare 5.0).
Action
1. On the ABB menu, tap Calibration.
All mechanical units connected to the system are shown along with their calibration
status.
en0400000771
3. Tap Update Revolution Counters....
A dialog box is displayed, warning that updating the revolution counters may change
programmed robot positions:
• Tap Yes to update the revolution counters.
• Tap No to cancel updating the revolution counters.
Tapping Yes displays the axis selection window.
4. Select the axis to have its revolution counter updated by:
• Ticking in the box to the left
• Tapping Select all to update all axes.
Then tap Update.
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2. Tap the mechanical unit in question.
A screen is displayed: tap Rev. Counters.
Repairs
6.2.2 Updating revolution counters
Action
5. A dialog box is displayed, warning that the updating operation cannot be undone:
• Tap Update to proceed with updating the revolution counters.
• Tap Cancel to cancel updating the revolution counters.
Tapping Update updates the ticked revolution counters and removes the tick from the
list of axes.
6.
CAUTION!
© Copyright 2006 ABB. All rights reserved.
If a revolution counter is incorrectly updated, it will cause incorrect robot positioning,
which in turn may cause damage or injury!
Check the calibration position very carefully after each update.
See section Checking the calibration position on page 168.
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6.2.3 Checking the calibration position
6.2.3 Checking the calibration position
General
Check the calibration position before beginning any programming of the robot system. This
may be done in one of two ways:
•
Using a MoveAbsJ instruction with argument zero on all axes.
•
Using the Jogging window on the teach pendant.
Using a MoveAbsJ instruction on the FlexPendant, IRC5
This section describes how to create a program, which runs all the robot axes to their zero
position.
Action
Note
1. On ABB menu tap Program Editor.
2. Create a new program.
3. Use MoveAbsJ in the Motion&Proc menu.
4. Create the following program: MoveAbsJ
[[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,
9E9]]\NoEOffs, v1000, z50, Tool0
5. Run the program in manual mode.
6. Check that the calibration marks for the axes align The calibration marks are shown in
correctly. If they do not, update the revolution
section Calibration scales and
counters!
correct axis position on page 162.
How to update the revolution
counters is detailed in section
Updating revolution counters on
page 165.
Using the Jogging window on the FlexPendant, IRC5
This section describes how to jog the robot to all axes zero position.
Action
Note
1. Tap Jogging in the ABB menu.
2. Tap Motion mode to choose group of axes to jog.
3. Tap axes 1-3 to jog axes 1, 2 or 3.
4. Manually run the robots axes to a position where the axis
position value read on the FlexPendant, is equal to zero.
168
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7. Check that the positions of axes 1-2-3 are
Detailed in section Updating
reached and that the calibration marks on axes 4- revolution counters on page 165.
5-6 are aligned correctly.
If they are not, update the revolution counters!
Repairs
6.2.3 Checking the calibration position
Action
Note
The calibration marks are
shown in section Calibration
scales and correct axis
position on page 162.
How to update the counters
is detailed in section
Updating revolution counters
on page 165.
6. Check that the positions of axes 1-2-3 are reached and
that the calibration marks on axes 4-5-6 are aligned
correctly.
If they are not, update the revolution counters!
Detailed in section Updating
revolution counters on page
165.
© Copyright 2006 ABB. All rights reserved.
5. Check that the calibration marks for the axes align
correctly. If they do not, update the revolution counters!
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© Copyright 2006 ABB. All rights reserved.
6.2.3 Checking the calibration position
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Tool List
7: Tools
7.1: Tool List
All sections e.g Motor Axes 1-3 refers to sections in Repair on page 91.
The need for special tools has been reduced to a minimum. When tools are needed for dismounting/mounting work, a description is given in the Product Manual, Chapter Repairs.
During the ordinary service training courses arranged by ABB, detailed descriptions of the
tools are given together with their use
Motors Axes 1-3
.
Description
Art. nr.
Lifting Device Axes 1–3 motor
3HAC 6876-1
Mechanical Stop Axes 2-3, 6-p
3HAC 4658-1
Remarks
© Copyright 2006 ABB. All rights reserved.
Motors/Gears Axes 4-6
Description
Art. nr.
Lifting device, axis 4 motor
3HAC 9043-1
Hydraulic Pump, complete
3HAB 8582-1
Oil injector, gear axis 5
6369 901-280
Nipple, gear axis 5
6896134-AA
Nipple, gear axis 5
6896901-282
Pressing tool, final gear
6896 134-AT/-AN
Valve
6369 901-281
234063
Hydraulic cylinder
6369 901-283
CHF 612
Mounting tool tube shaft
3HAB 1428-1
Holding tool, final gear
6896 134-FK
Pressing tool, tube shaft
3HAB 8079-1
Pressing tool, front bearing, tube shaft
6896 134-S
Pressing tool, housing and rear bearing
6896 134-FL
Pressing tool, seal inside housing
6896 134-FA
Dismounting rear bearing and housing, axis 4
6896 0011-YJ
Puller gear motor axis 6
3HAA 7601-043
Measurement tool, wrist
6896 134-CE
Measurement tool, wrist
6896 134-CD
Measurement tool, wrist
6896 134-CF
Measurement fixture, gear motor shaft axis 5
6896 134-GN
Measurement tool, wrist
3HAB 7449-1
Tightening tool, wrist
3HAB 1022-1
3HAC027076-001 Revision: A
Remarks
226 270
1018219
171
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Tool List
Description
Art. nr.
Remarks
Mounting tool tube shaft
3HAC 1893-1
Mounting tool tube shaft
3HAC 1894-1
Balancing Cylinders
Description
Art. nr.
Auxiliary shaft Bearing Race
3HAC 5281-1
Auxiliary shaft
3HAC 5276-1
Auxiliary shaft
3HAC 5275-1
Screw
M12x40
Lifting Device
3HAC 11601-1
Lubricating tool
3HAC 5222-1
Press tool
3HAC 8981-1
KM 10 Socket
6369901-480
Remarks
Arm System
Art. nr.
Remarks
Lifting device Upper Arm
3HAC 1817-1
Lifting device Complete Arm system
3HAC 6878-1
KM 12 Socket
3HAC 5347-1
Mounting tool - Lower Arm/Parallel Arm
3HAC 5216-1
CHF 612 included
Dismounting tool - Lower Arm/Parallel
Arm
3HAC 5302-1
CHF 612 included
Mounting/Dismounting tool - Parallel Bar
3HAC 5021-1
CHF 612 included
Pressing tool
3HAC 5025-1
Miscellaneous
Description
Art. nr.
Remarks
Tool for TCP adjustment
3HAA 0001-UA
X=-15 mm, Z=-150 mm
Calibration set for Vision
3HAA 0001-XR
Bracket
172
Lifting Tool
3HAC 3083-1
Calibration Equipment
See Chapter 9
On-Board Calibration Equipment
See Chapter 10
3HAC027076-001 Revision: A
© Copyright 2006 ABB. All rights reserved.
Description
Parts List/Spare Parts List
Rebuilding Parts
8: Parts list / Spare part list
8.1: Rebuilding Parts
General
The following chapters (1.1-1.5) describe the main details that differ from the basic version
IRB 6400R / 2.5-150.
Warning!
This list is valid for rebuilding to a standard. Options like Foundry or insulated tool flange are
not included.
For the latest update, see the database SEROP/S Rebuilding Parts for IRB 6X00.
IRB 6400R / 2.5-200
Mechanical drawing 1:1 on page 193.
Item
2
Qty
Article No.
Name of Item
1
3HAC 6933-1
Motor Axis 2, with pinion
1
3HAC 8497-2
Motor Axis 4, complete
3HAC 6668-3
Wrist Unit
3
1
3HAC 6668-4
Wrist Unit, insulated
4
1
3HAC 7020-2
Balancing Weight, 299 kg
IRB 6400R / 2.8-200
Mechanical drawing 1:2 on page 194.
Item
© Copyright 2006 ABB. All rights reserved.
6
7
3HAC027076-001 Revision: A
Qty
Article No.
Name of Item
1
3HAC 6933-1
Motor Axis 2, with pinion
1
3HAC 8497-2
Motor Axis 4, complete
1
3HAC 7134-1
Arm Extension
8
3HAB 7700-69
Screw, M12x50
8
3HAA 1001-134
Washer
1
9ABA 142-92
Pin, 10x30
2
3HAA 1001-297
Friction Washer
3HAC 6668-3
Wrist Unit
3HAC 6668-4
Wrist Unit, insulated
1
3HAC 7021-2
Balancing weight 436 kg
1
3HAC 7128-1
Cover, 345
1
3HAC 7962-1
Cable Axis 5
1
3HAC 7964-1
Cable Axis 6
173
Parts List/Spare Parts List
Rebuilding Parts
IRB 6400RF (Protection Foundry
)
174
Foundry Art.
no.
Standard
Name of item
Art. no.
502
25 ml
12691907-1
Loctite 577
1:3–1:5
503
25 ml
12340011-116
Loctite 574
1:3–1:5
504
200 ml 3HAC 8286-1
Dinitrol 3624
1:3–1:5
515
12
9ADA 205-73
Set screw, cup point 1:3–1:5
18
2
3HAC 7816-1
Protection cover 40- 2:1–2:3
p
21
1
3HAC 7561-1
Dustcap for recepta- 2:1–2:3
cles, 12-p
22
1
3HAC 9889-1
Item 502, 503, 504,
515
2:1–2:3
108
1
3HAC 8014-1
3HAC
8012-1
Harness assembly
CP/CS a4
2:1–2:3
108
1
3HAC 8013-1
3HAC
8011-1
Harness assembly
CP/CS a3
2:1–2:3
207
2
3HAC 7817-1
3HAA100 Sealing assembly
1-126
+2216008
5-1
2:1–2:3
211
2
3HAA 1001-658
O-Ring
2:1–2:3
212
2
3HAB 3722-29
O-Ring
2:1–2:3
213
2
3HAC 6627-1
Sealing ring
2:1–2:3
230
4
3HAC 7343-1
3HAC
3484-1
Ring
2:1–2:3
231
8
3HAC 7253-1
3HAC
3478-1
Support washer
2:1–2:3
233
4
3HAC 7349-1
3HAC
3483-1
Lock nut
2:1–2:3
270
1
3HAC 7074-1
Protection sheet
2:1–2:3
271
10
9ADA 629-56
Torx pan head roll.
Screw
2:1–2:3
272
2
3HAC 8131-1
Protection sheet
2:1–2:3
273
1
3HAC 8103-1
Protection box
2:1–2:3
9
1
3HAC 8414-1
3HAC
8009-1
Harness assembly
robot
2:5–2:6
14
1
3HAC 7258-1
3HAC
4241-1
Connector plate
2:5-2:6
44
2
3HAC 8271-1
Bracket
2:5–2:6
111
2
9ADA 629-56
Torx pan head roll.
Screw
2:5–2:6
5
1
3HAC 4267-1
Upper arm, foundry
2:10
3HAC
3774-1
Mechanical
drawing
3HAC027076-001 Revision: A
© Copyright 2006 ABB. All rights reserved.
Item Qty
Parts List/Spare Parts List
Rebuilding Parts
Foundry Art.
no.
Standard
Name of item
Art. no.
Mechanical
drawing
101
1
3HAC 8349-1
3HAC
3963-1
Arm extension 345
2:8–2:9
101
1
3HAC 8350-1
3HAC
3964-1
Arm extension 550
2:8–2:9
110
2
3HAC 8256-1
Foundry Logotype
2:4
1
3HAC 8184-1
3HAC
4417-1
Control cable power,
7m
1
3HAC 9288-1
3HAC
7363-1
Control cable Can/
CP/CS
1
3HAC 9631-1
3HAC
7068-1
Control Profibus/CP/
CS
© Copyright 2006 ABB. All rights reserved.
Item Qty
3HAC027076-001 Revision: A
175
Parts List/Spare Parts List
© Copyright 2006 ABB. All rights reserved.
Rebuilding Parts
176
3HAC027076-001 Revision: A
Parts List/Spare Parts List
8.2.1 Options
8.2: Options
8.2.1 Position Switch Axis 1
Mechanical
drawing No.
Article No.
Name
Rem
3HAC 10068-11
Position switch axis 2:17
1, complete/one
function
Add-on kit/Spare
part
3HAC 10069-22
Position switch axis 2:17
1, complete/two
function
Add-on kit/Spare
part
3HAC 10071-23
Position switch axis 2:17
1, complete/three
function
Add-on kit/Spare
part
© Copyright 2006 ABB. All rights reserved.
1. Based on 3HAC 8478-1
2. Based on 3HAC 8478-2
3. Based on 3HAC 8478-3
Item
Qty
Article No.
Name of Item
1
1
3HAC 8015-1
Pos SW 1 function
1
1
3HAC 8016-1
Pos SW 2 functions
1
1
3HAC 8017-1
Pos SW 3 functions
4
-
3HAC 5414-1
Cam kit ax1:1
4.101
2
3HAC 9858-7
Cam
4.102
16
9ADA 267-5
Hexagon nut
M5
4.103
16
9ADA 205-45
Set screw, cup point
M5x6
5
1
3HAC 8493-1
Pos SW ax1 Mtrl. set
5.6
1
3HAC 4766-1
Connector bracket R1.SW1
5.8
16
9ADA 618-56
Torx pan head screw
5.10
1
3HAC 5439-1
Cable bracket R1.SW1
5.11
2
3HAC 8131-1
Protection sheet
5.12
1
9ADA 183-81
Hex socket head cap screw
5.14
1
3HAC 8103-1
Protection box
5.15
1
3HAC 9858-1
Rail complete axis 1
5.16
1
3HAC 7074-1
Protection sheet
3HAC027076-001 Revision: A
Dimension
M6x16
M16x35
177
Parts List/Spare Parts List
8.2.2 Signal Lamp
8.2.2 Signal Lamp
Article No.
Name
Mechanical drawing No.
3HAC 4804-1
Part List
2:20
Qty
Article No.
Name of Item
Dimension
1
1
3HAC 2552-1
Lamp
2
1
3HAC 2987-1
Lamp Holder
3
1
3HAB 3772-21
O-ring
4
1
3HAC 4909-1
Bracket, signal lamp
5
1
3HAC 4772-2
Cable gland (tabular dr.)
Pg7 (Pr12,5)
4,0-7,0
6
1
3HAC 4772-3
Cable gland (tabular dr.)
Pg9 (Pr15,2)
4,0- 6,0
7
2
5217 649-87
Connector
8
2
5217 649-70
Pin
0.5-0.75 mm2
9
1100
3HAC 3198-1
Cable
3 x AWG20
10
2
9ADA 629-56
Torx pan head roll. screw
M6x16
11
2
2166 2055-3
Cable straps, outdoors
4,8x208
13
1
1234 0011-116
Flange sealing
904
1
3HAC 9650-1
Assembly instruction, Signal
lamp
© Copyright 2006 ABB. All rights reserved.
Item
178
3HAC027076-001 Revision: A
Parts List/Spare Parts List
8.2.3 Forklift Set
8.2.3 Forklift Set
Article No.
Name
Mechanical
drawing No.
3HAC 10578-11
Forklift set
2:1
Rem
Add-on kit/Spare
part
1. Based on 3HAC 4765-1
Item
Qty
Article No.
Name of Item
100
2
3HAC 4364-1
Fork Lift Device
100.1
8
3HAA 1001-186 Washer
100.2
8
3HAB 3409-86
M16x60/12.9
© Copyright 2006 ABB. All rights reserved.
Hex socket head cap screw
Dimension
3HAC027076-001 Revision: A
179
Parts List/Spare Parts List
8.2.4 Wrist kit 6400R 200kg
8.2.4 Wrist kit 6400R 200kg
Article No.
Name
Mechanical
drawing No.
Rem
3HAC 10383-1
Wrist kit
2:25
Add-on kit
Option
Dimensio
Comments
n
Item
Qty
Article No.
Name of Item
1
1
3HAC 8628-1
Cover A
2
1
3HAC 8629-1
Cover B
3
1
3HAC 8630-1
Cover C
4
1
3HAC 8632-1
Plug
5
4
3HAC 10384-1
Distance screw
6
1
3HAB 3772-36
O-ring
7
2
3HAC 9313-1
Distance
8
2
9ADA 183-52
Hex socket screw.
M10x35
9
2
9ADA 312-8
Plain washer
10,5x20x2
10
10
9ADA 312-6
Plain washer
6,4x12x1,
6
11
1
2126 0023-2
Hexagonal nut
Pr 18,6
© Copyright 2006 ABB. All rights reserved.
14,1x1,6
180
3HAC027076-001 Revision: A
Parts List/Spare Parts List
8.2.5 Process Media Conduit
8.2.5 Process Media Conduit
Article No.
Mechanical
Rem
drawing No.
Name
3HAC 10016-11 Process Media Conduit
2:24
Add-on kit/Spare part
© Copyright 2006 ABB. All rights reserved.
1. Based on 3HAC 6018-10
Item Qty
Article No.
Name of Item
1
1
3HAC 6018-1
Lower process media guide
2
1
3HAC 6018-8
Attachment, p.media guide
3
1
3HAC 6018-9
Attachment, p.media guide
4
18
9ADA 629-56
Torx pan head roll. screw
M6x16
5
8
9ADA 312-6
Plain washer
6,4x12x1,6
6
4
3HAC 6018-13
Spacer
20x12x25
7
1
3HAC 6018-26
Upper p.guide w. support
8
2
3HAC 6018-3
Attachment profile
9
1
3HAC 6018-11
Attachment, p.media guide
10
4
6355 0004-HF
Hose Clamp 80
11
8
9ADA 183-35
Hex socket head cap screw
M8x16
14
1
3HAC 6018-7
Attachment
T=5
15
2
9ADA 183-51
Hex socket head cap screw
M10x30
17
1
3HAB 7116-1
Loctite 243
18
1
2166 2055-6
Cable straps, outdoors
19
1
3HAC 4731-3
Welding Bracket Lower Arm
20
4
9ADA 56-26
Hex socket head cap screw
21
1
3HAC 6018-14
Attachment, p.media guide
22
1
3HAC 6018-28
Protection hose
23
2
9ADA 183-49
Hex socket head cap screw
M10x20
24
5
3HAC 4127-8
Counters. hex head screw
M8x25
25
2
3HAC 4738-1
Welding Cable Clamp
3HAC027076-001 Revision: A
Dimension
7,6x368
M10x45
181
Parts List/Spare Parts List
8.2.6 Mechanical stop 15 degr. axis 1
8.2.6 Mechanical stop 15 degr. axis 1
Article No.
Name
Mechanical
drawing No.
Rem
3HAC 4656-1
Part List
2:1 (item 101)
Add-on kit/Spare part
Qty
Article No.
Name of Item
Dimension
1
2
3HAC 4089-2
Stop lug 5deg, casting
3
4
3HAB 3409-86
Hex socket head cap screw
4
4
3HAA 1001-186
Washer
5
1
3HAC 4660-1
Assembly of mech. stop ax 1
M16x60/12.9
© Copyright 2006 ABB. All rights reserved.
Item
182
3HAC027076-001 Revision: A
Parts List/Spare Parts List
8.2.7 Mechanical stop 7,5 degr. axis 1
8.2.7 Mechanical stop 7,5 degr. axis 1
Article No.
Name
Mechanical
drawing No.
3HAC 4657-1
Part List
2:1 (item 101)
Article No.
Name of Item
1
2
3HAC 4089-2
Stop lug 5deg, casting
2
2
3HAC 4090-2
Stop lug 2.5deg, casting
3
4
3HAB 3409-86
Hex socket head cap screw
4
4
3HAA 1001-186
Washer
5
1
3HAC 4660-1
Assembly of mech. stop ax 1
Add-on kit/Spare
part
Dimension
M16x60/12.9
© Copyright 2006 ABB. All rights reserved.
Item Qty
Rem
3HAC027076-001 Revision: A
183
Parts List/Spare Parts List
8.2.8 Mechanical stop axes 2 and 3
8.2.8 Mechanical stop axes 2 and 3
Article No.
Name
Mechanical
drawing No.
3HAC 4658-1
Part List
2:3 (item 102,103)
Rem
Article No.
Name of Item
Dimension
1
6
3HAC 3665-1
Stop ax.2/3
2
6
3HAB 3409-69
Hex socket head cap screw
3
6
3HAA 1001-632
Washer
4
1
3HAC 4659-1
Assembly of mech stop 2/3
M12x50/12.9
© Copyright 2006 ABB. All rights reserved.
Item Qty
Add-on kit/Spare
part
184
3HAC027076-001 Revision: A
Parts List/Spare Parts List
8.3.1 Spare Part List robot
8.3: Spare Part List robot
8.3.1 Robot
Drawing number 3HAC 3972-1
Item
Number
Actions and
Supplements
Spare P. Number
Parallel Arm +
Bearings
3HAC 4058-1
Painted1
3HAC 7169-1
Balancing Unit
3HAC 3608-1
Painted1
3HAC 9484-1
Foundry
Balancing Weight 3HAC 9737-1
318 kg/299 kg
Iron, Painted1
3HAC 7020-2
Balancing Weight 3HAC 9749-1
476 kg/436 kg
Iron, Painted1
3HAC 7021-2
© Copyright 2006 ABB. All rights reserved.
1. All painted parts are in orange color. Other colors in stock, available with longer
time of delivery.
3HAC027076-001 Revision: A
185
Parts List/Spare Parts List
8.3.2 Axis 1-3 Complete
8.3.2 Axis 1-3 Complete
Drawing number 3HAC 4644-1
Item
Number
Actions and Supplements
Spare P.
Number
Gearbox Axis 1–3 3HAC 9687-1 Painted1 (Foundry Version)
3HAC 7149-1
Seal Kit Axis 1
3HAC 12069-1
Seal Kit Axis 2–3
3HAC 12069-2
Gearbox axis 1–3
with motors.
Ver.2.5-200, 2.8200
Motor axis 1 (3HAC 6930-1)
Motor axis 2 (3HAC 6933-1)
Motor axis 3 (3HAC 6935-1)
Painting and protection on
request.
3HAC 7149-4
Lower Arm
3HAC 4344-1 Painted1 (3HAC 4725-1 /
3 HAC 5127-1)
3HAC 7150-1
Motor Axis 1 +
Pinion
3HAC 4646-1 Painted1 (3HAC 8279-1 +
3HAC 4520-1)
3HAC 6930-1
Motor Axis 2 +
Pinion 200kg
3HAC 4648-1 Painted1, (3HAC 8280-1 +
3HAC 4520-1)
3HAC 6935-1
Motor Axis 3 +
Pinion 150–
200kg
3HAC 4649-1 Painted1 (3HAC 8280-1 +
3HAC 4520-1)
3HAC 6935-1
Brake release
unit
3HAC 4615-1 Push button guard
Brake release card
3HAC 6499-1
3HAC 4620-1
Cover R1
3HAC 4680-1 Painted1
3HAC 7126-1
1
Cover Mechanical Stop
3HAC 5500-1 Painted
3HAC 7165-1
Cover SMB
3HAC 4605-1 Painted1, with Sealing
3HAC 7166-1
© Copyright 2006 ABB. All rights reserved.
1. All painted parts are in orange color. Other colors in stock, available with longer
time of delivery.
186
3HAC027076-001 Revision: A
Parts List/Spare Parts List
8.3.3 Upper Arm Complete
8.3.3 Upper Arm Complete
Drawing number 3HAC 3973-1
Item
Actions and Supplements
1
Spare Part No.
Motor Axis 4 +
Pinion 200 kg
3HAC 4070-1
Painted (3HAC 3606-1+
3HAC 8418-1)
Axis 4 Housing
3HAC 3938-1
Painted1
Cover Axis 4
3HAC 4807-1
Painted1
3HAC 7015-1
1
3HAC 7167-1
1
Upper Arm
© Copyright 2006 ABB. All rights reserved.
Number
3HAC3774-1
Painted
3HAC 6937-1
Arm Extender
345
3HAC 8349-1
Painted
3HAC 9160-1
Foundry
Arm Extender
550
3HAC 8350-1
Painted1
3HAC 9161-1
Foundry
Cover Axis 4
3HAA 1001-33 Painted1
Wrist
3HAC 3975-1
Painted1 (3HAC 5127-1),
Motor Axis 6 + Gear Unit 6 +
Motor Axis 5
Wrist 200 kg,
insulated
3HAC 3610-1 + 3HAC 13998- 3HAC 14000-4
1 + 3HAC 3606-1
Wrist 200 kg
Foundry
3HAC 3610-1 + 3HAC 13997- 3HAC 14000-6
1 + 3HAC 3606-1
Motor Axis 5
200 kg
3HAC 3606-1
Motor Axis 6 +
Gearbox
3HAC 3974-1
3HAC 8606-2
Motor Axis 6 +
Gearbox 200 kg
Painted1 (3HAC 3610-1 +
3HAC 13997-1)
3HAC 14003-1
Motor Axis 6 +
Gearbox 200
kg, insulated
Painted1 (3HAC 3610-1 +
3HAC 13998-1)
3HAC 14004-1
3HAC 3610-1
Painted1
3HAC 7157-2
3HAB 8402-1
1
3HAC 7017-1
Motor Axis 6
Cover 200 kg
3HAC027076-001 Revision: A
Painted
187
Parts List/Spare Parts List
8.3.4 Harness
8.3.4 Harness
Item
Number
Actions and
Supplements
Spare P. Number
3HAC 8013-1
Foundry
3HAC 10662-2
Harness CP/CS
Axis 4
3HAC 8014-1
Foundry
3HAC 10663-2
© Copyright 2006 ABB. All rights reserved.
Harness CP/CS
Axis 3
188
3HAC027076-001 Revision: A
Parts List/Spare Parts List
8.3.5 Miscellaneous
8.3.5 Miscellaneous
Item
Cover
Cover
Number
Actions and
Supplements
Spare P. Number
3HAC 4547-1
Painted1
3HAC 7129-1
3HAC 4674-1
1
3HAC 7128-1
Painted
© Copyright 2006 ABB. All rights reserved.
1.
All painted parts are in orange color. Other colors in stock, available with longer
time of delivery.
3HAC027076-001 Revision: A
189
Parts List/Spare Parts List
© Copyright 2006 ABB. All rights reserved.
8.3.5 Miscellaneous
190
3HAC027076-001 Revision: A
Foldouts
Introduction
9: Mechanical drawings
9.1: Introduction
Overview
© Copyright 2006 ABB. All rights reserved.
This chapter includes mechanical drawings with illustrations of the robot.
3HAC027076-001 Revision: A
191
Foldouts
Illustrations
9.2: Illustrations
© Copyright 2006 ABB. All rights reserved.
Mechanical drawing 1:1
3HAC027076-001 Revision: A
193
Foldouts
Illustrations
© Copyright 2006 ABB. All rights reserved.
Mechanical drawing 1:2
194
3HAC027076-001 Revision: A
Foldouts
Illustrations
© Copyright 2006 ABB. All rights reserved.
Mechanical drawing 1:3
3HAC027076-001 Revision: A
195
Foldouts
Illustrations
© Copyright 2006 ABB. All rights reserved.
Mechanical drawing 1:4
196
3HAC027076-001 Revision: A
Foldouts
Illustrations
© Copyright 2006 ABB. All rights reserved.
Mechanical drawing 1:5
3HAC027076-001 Revision: A
197
Foldouts
Illustrations
© Copyright 2006 ABB. All rights reserved.
Mechanical drawing 2:1
198
3HAC027076-001 Revision: A
Foldouts
Illustrations
© Copyright 2006 ABB. All rights reserved.
Mechanical drawing 2:2
3HAC027076-001 Revision: A
199
Foldouts
Illustrations
© Copyright 2006 ABB. All rights reserved.
Mechanical drawing 2:3
200
3HAC027076-001 Revision: A
Foldouts
Illustrations
© Copyright 2006 ABB. All rights reserved.
Mechanical drawing 2:4
3HAC027076-001 Revision: A
201
Foldouts
Illustrations
© Copyright 2006 ABB. All rights reserved.
Mechanical drawing 2:5
202
3HAC027076-001 Revision: A
Foldouts
Illustrations
© Copyright 2006 ABB. All rights reserved.
Mechanical drawing 2:6
3HAC027076-001 Revision: A
203
Foldouts
Illustrations
© Copyright 2006 ABB. All rights reserved.
Mechanical drawing 2:6.1
204
3HAC027076-001 Revision: A
Foldouts
Illustrations
© Copyright 2006 ABB. All rights reserved.
Mechanical drawing 2:7
3HAC027076-001 Revision: A
205
Foldouts
Illustrations
© Copyright 2006 ABB. All rights reserved.
Mechanical drawing 2:8
206
3HAC027076-001 Revision: A
Foldouts
Illustrations
© Copyright 2006 ABB. All rights reserved.
Mechanical drawing 2:9
3HAC027076-001 Revision: A
207
Foldouts
Illustrations
© Copyright 2006 ABB. All rights reserved.
Mechanical drawing 2:10
208
3HAC027076-001 Revision: A
Foldouts
Illustrations
© Copyright 2006 ABB. All rights reserved.
Mechanical drawing 2:11
3HAC027076-001 Revision: A
209
Foldouts
Illustrations
© Copyright 2006 ABB. All rights reserved.
Mechanical drawing 2:12
210
3HAC027076-001 Revision: A
Foldouts
Illustrations
© Copyright 2006 ABB. All rights reserved.
Mechanical drawing 2:13
3HAC027076-001 Revision: A
211
Foldouts
Illustrations
© Copyright 2006 ABB. All rights reserved.
Mechanical drawing 2:14
212
3HAC027076-001 Revision: A
Foldouts
Illustrations
© Copyright 2006 ABB. All rights reserved.
Mechanical drawing 2:15
3HAC027076-001 Revision: A
213
Foldouts
Illustrations
© Copyright 2006 ABB. All rights reserved.
Mechanical drawing 2:17
214
3HAC027076-001 Revision: A
Foldouts
Illustrations
© Copyright 2006 ABB. All rights reserved.
Mechanical drawing 2:18
3HAC027076-001 Revision: A
215
Foldouts
Illustrations
© Copyright 2006 ABB. All rights reserved.
Mechanical drawing 2:19
216
3HAC027076-001 Revision: A
Foldouts
Illustrations
© Copyright 2006 ABB. All rights reserved.
Mechanical drawing 2:20
3HAC027076-001 Revision: A
217
Foldouts
© Copyright 2006 ABB. All rights reserved.
Illustrations
218
3HAC027076-001 Revision: A
Circuit diagram
Introduction
10: Circuit diagram
10.1: Introduction
Overview
© Copyright 2006 ABB. All rights reserved.
This chapter includes the complete circuit diagram for the robot.
3HAC027076-001 Revision: A
219
Circuit diagram
© Copyright 2006 ABB. All rights reserved.
Introduction
220
3HAC027076-001 Revision: A
Circuit diagram
Diagrams
10.2: Diagrams
© Copyright 2006 ABB. All rights reserved.
Sheet 101: Contents
3HAC027076-001 Revision: A
221
Circuit diagram
Diagrams
© Copyright 2006 ABB. All rights reserved.
Sheet 102: Connection Point Location
3HAC027076-001 Revision: A
222
Circuit diagram
Diagrams
© Copyright 2006 ABB. All rights reserved.
Sheet 103: Legend
3HAC027076-001 Revision: A
223
Circuit diagram
Diagrams
© Copyright 2006 ABB. All rights reserved.
Sheet 104: Brake Unit / Serial Measurement Board
3HAC027076-001 Revision: A
224
Circuit diagram
Diagrams
© Copyright 2006 ABB. All rights reserved.
Sheet 105: Axis 1
3HAC027076-001 Revision: A
225
Circuit diagram
Diagrams
© Copyright 2006 ABB. All rights reserved.
Sheet 106: Axes 2
3HAC027076-001 Revision: A
226
Circuit diagram
Diagrams
© Copyright 2006 ABB. All rights reserved.
Sheet 107: Axes 3
3HAC027076-001 Revision: A
227
Circuit diagram
Diagrams
© Copyright 2006 ABB. All rights reserved.
Sheet 108: Axis 4 / Signal lamp
3HAC027076-001 Revision: A
228
Circuit diagram
Diagrams
© Copyright 2006 ABB. All rights reserved.
Sheet 109: Axis 5
3HAC027076-001 Revision: A
229
Circuit diagram
Diagrams
© Copyright 2006 ABB. All rights reserved.
Sheet 109,1: Axis 5 (Long Cable)
3HAC027076-001 Revision: A
230
Circuit diagram
Diagrams
© Copyright 2006 ABB. All rights reserved.
Sheet 110: Axis 6
3HAC027076-001 Revision: A
231
Circuit diagram
Diagrams
© Copyright 2006 ABB. All rights reserved.
Sheet 111: Customer Power/Signal Connection CANBUS / P-BUS / I-BUS
3HAC027076-001 Revision: A
232
Circuit diagram
Diagrams
© Copyright 2006 ABB. All rights reserved.
Sheet 112: Customer Power/Signal Connection Extended
3HAC027076-001 Revision: A
233
Circuit diagram
Diagrams
© Copyright 2006 ABB. All rights reserved.
Sheet 113: Customer Power/Signal Connection or feeding Servo Gun/Fan
3HAC027076-001 Revision: A
234
Circuit diagram
Diagrams
© Copyright 2006 ABB. All rights reserved.
Sheet 114: Switches Axis 1
3HAC027076-001 Revision: A
235
Circuit diagram
Diagrams
© Copyright 2006 ABB. All rights reserved.
Sheet 115: Switches Axis 2
3HAC027076-001 Revision: A
236
Circuit diagram
Diagrams
© Copyright 2006 ABB. All rights reserved.
Sheet 116: Switches Axis 2/3
3HAC027076-001 Revision: A
237
3HAC027076-001, Revision A, en
ABB AB
Robotics Products
S-721 68 VÄSTERÅS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax:
+46 (0) 21 132592

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