ABB IRB 340 M2000, M2004 Robot Product manual (part 1 of 2), procedures

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Product manual, procedures
IRB 340
Document ID: 3HAC 022546-001
Revision -
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.
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 2003 ABB All rights reserved.
ABB Automation Technology Products AB
Robotics
SE-721 68 Västerås
Sweden
CONTENTS
1 Introduction ....................................................................................................... 7
1.1 How to use this Manual ............................................................................. 7
1.2 What you must know before you use the Robot........................................ 7
1.3 Identification .............................................................................................. 8
1.4 Structure Manipulator ................................................................................ 10
1.5 Structure Controller ................................................................................... 15
1.6 Electronics unit .......................................................................................... 15
1.6.1 The computer system consists of the following parts ...................... 16
1.6.2 Drive system:................................................................................... 16
1.6.3 Miscellaneous.................................................................................. 17
2 Safety ................................................................................................................. 19
2.1 General...................................................................................................... 19
2.1.1 Introduction...................................................................................... 19
2.2 Applicable Safety Standards ..................................................................... 19
2.3 Fire-Extinguishing...................................................................................... 19
2.4 Definitions of Safety Functions.................................................................. 20
2.5 Safe Working Procedures ......................................................................... 20
2.5.1 Normal operations ........................................................................... 20
2.6 Programming, Testing and Servicing......................................................... 21
2.7 Safety Functions........................................................................................ 21
2.7.1 The safety control chain of operation .............................................. 21
2.7.2 Emergency stops............................................................................. 22
2.7.3 Mode selection using the operating mode selector ......................... 22
2.7.4 Programming and testing at reduced speed.................................... 23
2.7.5 Testing at full speed......................................................................... 23
2.7.6 Automatic operation......................................................................... 23
2.7.7 Enabling device ............................................................................... 24
2.7.8 Hold-to-run control........................................................................... 24
2.7.9 General Mode Safeguarded Stop (GS) connection ......................... 24
2.7.10 Automatic Mode Safeguarded Stop (AS) connection .................... 25
2.7.11 Limiting the working space ............................................................ 25
2.7.12 Supplementary functions ............................................................... 25
2.8 Safety Risks Related to End Effectors ...................................................... 26
2.8.1 Gripper............................................................................................. 26
2.8.2 Tools/workpieces ............................................................................. 26
2.8.3 Pneumatic/hydraulic systems .......................................................... 26
2.9 Risks during Operational Disturbances ..................................................... 26
Product Manual IRB 340
3
2.10 Risks during Installation and Service ...................................................... 26
2.11 Dimensioning the safety fence ................................................................ 28
2.12 Standards of interest when the robot is part of a cell .............................. 28
2.13 Risks Associated with Live Electric Parts................................................ 28
2.13.1 Controller ....................................................................................... 28
2.13.2 Manipulator.................................................................................... 29
2.13.3 Tools, material handling devices, etc............................................. 29
2.14 Emergency Release of Mechanical Arm ................................................. 29
2.15 Limitation of Liability ................................................................................ 29
2.16 Related Information ................................................................................. 29
3 Decommissioning ............................................................................................. 31
3.1 General...................................................................................................... 31
3.1.1 Hazardous material ......................................................................... 31
3.1.2 Oil and Greases............................................................................... 31
4 Installation and Commissioning...................................................................... 33
4.1 Transporting and Unpacking ..................................................................... 33
4.1.1 System CD ROM and Diskette ........................................................ 33
4.2 On-Site Installation .................................................................................... 35
4.2.1 Lifting the Manipulator and Controller.............................................. 35
4.2.2 Assembling the Robot ..................................................................... 36
4.2.3 Stress Forces................................................................................... 38
4.2.4 Amount of Space required ............................................................... 39
4.2.5 Manually engaging the Brakes ........................................................ 39
4.2.6 Mounting Equipment on the Manipulator......................................... 40
4.2.7 Loads............................................................................................... 41
4.2.8 Moving the Robot by hand............................................................... 41
4.2.9 Connecting the controller to the manipulator................................... 44
4.2.10 Dimensioning the safety fence ...................................................... 44
4.2.11 Mains power connection ................................................................ 44
4.2.12 Inspection before start-up.............................................................. 46
4.2.13 Start-up .......................................................................................... 47
4.3 Customer Connections on Manipulator ..................................................... 55
4.3.1 Connection of Extra Equipment to the Manipulator ......................... 58
5 Maintenance ...................................................................................................... 61
5.1 Maintenance Schedule.............................................................................. 62
5.2 Instructions for Maintenance ..................................................................... 62
5.2.1 General Instructions for the Manipulator ......................................... 62
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Product Manual IRB 340
5.2.2 Telescopic Shaft, Axis 4, Plain Bearings. ........................................ 62
5.2.3 Telescopic Shaft, WashDown and Stainless, Axis 4, Plain Bearing 63
5.2.4 Vacuum System .............................................................................. 63
5.2.5 Bar System...................................................................................... 64
5.2.6 Substitute greases........................................................................... 64
5.2.7 Joint Balls ........................................................................................ 64
5.2.8 Upper Arms ..................................................................................... 65
5.2.9 Hoses .............................................................................................. 65
5.2.10 Spring Units ................................................................................... 65
5.2.11 Movable Plate with Swivel ............................................................. 65
5.2.12 Gearboxes, Axes 1-3..................................................................... 65
5.2.13 Manipulator Fan ............................................................................ 66
5.2.14 Location of Maintenance Points .................................................... 67
5.2.15 Changing the Battery in the Measuring System ............................ 68
5.3 Cleaning of Robot ..................................................................................... 70
5.3.1 Standard Cleaning........................................................................... 70
5.3.2 Wash Down Cleaning ...................................................................... 70
6 Repairs............................................................................................................... 73
6.1 General Description .................................................................................. 73
6.1.1 Document Guidance........................................................................ 74
6.1.2 Caution ............................................................................................ 75
6.1.3 Mounting Instructions for Bearings and Seals................................. 75
6.1.4 Instructions for Tightening Screw Joints.......................................... 77
6.1.5 Tightening Torques .......................................................................... 78
6.1.6 Checking for Play in Gearboxes and Wrist...................................... 79
6.2 Axis 1, 2 and 3 .......................................................................................... 81
6.2.1 Replacing Motor/Gearbox Unit ........................................................ 81
6.2.2 Exchange of Motor or Gearbox ....................................................... 82
6.2.3 Replacing the Upper Arm ................................................................ 83
6.2.4 Replacement of Joint Balls.............................................................. 84
6.3 Axis 4 ........................................................................................................ 87
6.3.1 Replacing Motor/Gearbox Unit ........................................................ 87
6.3.2 Exchange of Motor or Gearbox ....................................................... 87
6.3.3 Replacing the Telescopic Shaft ....................................................... 89
6.3.4 Replacing the Plain Bearings, Washdown and Stainless Ver..........
sions ................................................................................................... 90
6.4 Movable Plate with Swivel......................................................................... 93
6.4.1 Dismounting Movable Plate............................................................. 93
6.4.2 Replacement of Joint Balls.............................................................. 93
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6.5 Parallel Arm System .................................................................................. 95
6.5.1 Replacing Parallel Arms................................................................... 95
6.5.2 Replacing the Spring Unit ................................................................ 95
6.5.3 Exchange of Wear Rings ................................................................. 96
6.6 Cabling....................................................................................................... 99
6.6.1 Dismounting the Complete Cabling ................................................. 99
6.6.2 Replacing the Serial Measurement Board ....................................... 99
6.6.3 Replacing Pushbutton Unit and Warning Lamp ...............................100
6.6.4 Replacing the Fan............................................................................100
6.7 Vacuum System.........................................................................................101
6.7.1 Dismounting Ejector Unit .................................................................101
6.7.2 Exchange of Hoses..........................................................................101
6.8 Calibration..................................................................................................103
6.8.1 General ............................................................................................103
6.8.2 Checking the Calibration Position ....................................................103
6.8.3 Fine Calibration Procedure on the Teach Pendant ..........................104
6.8.4 Fine Calibration................................................................................105
6.8.5 Updating Revolution Counter...........................................................107
6.8.6 Calibration Equipment......................................................................109
6.9 Corrective action in case of a collision.......................................................111
6.9.1 Overview ..........................................................................................111
6.9.2 Telescopic Shaft...............................................................................111
6.9.3 Spring Units......................................................................................112
6.9.4 Rollers..............................................................................................112
6.9.5 Bars .................................................................................................112
6.9.6 Joint Balls.........................................................................................113
6.9.7 Universal Joints................................................................................113
6.10 Special Tools List .....................................................................................115
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Product Manual IRB 340
Introduction
1 Introduction
1.1 How to use this Manual
This manual provides information on installation, preventive maintenance,
troubleshooting, and how to carry out repairs on the manipulator and controller.
Its intended audience is trained maintenance personnel with expertise in both
mechanical and electrical systems. The manual does not in any way assume to
take the place of the maintenance training course offered by ABB.
Anyone reading this manual should also have access to the User’s Guide.
The chapter entitled System Description provides general information on the
robot structure, such as its computer system, input and output signals, etc.
How to assemble the robot and install all signals, etc., is described in the chapter
on Installation and Commissioning.
If an error should occur in the robot system, you can find out why it has
happened in the chapter on Troubleshooting. If you receive an error message,
you can also consult the chapter on System and Error Messages in the User’s
Guide. It is very helpful to have a copy of the circuit diagram at hand when
trying to locate cabling faults.
Servicing and maintenance routines are described in the chapter on
Maintenance.
1.2 What you must know before you use the Robot
Normal maintenance and repair work
Usually requires only standard tools. Some repairs, however, require specific
tools. These repairs and the type of tool required, are described in more detail in
the chapter Repairs.
The power supply
Must always be switched off whenever work is carried out in the controller
cabinet. Note that even though the power is switched off, the orange-coloured
cables may be live. The reason for this is that these cables are connected to
external equipment and are consequently not affected by the mains switch on
the controller.
Circuit boards - printed boards and components
Must never be handled without Electro-Static Discharge (ESD) protection in
order not to damage them. Use the wrist strap located on the inside of the
controller door.
All personnel working with the robot system must be very familiar with the
safety regulations outlined in the chapter on Safety. Incorrect operation can
damage the robot or injure someone.
Product Manual
7
Introduction
1.3 Identification
Identification plates indicating the type of robot and serial number, etc., are located on
the manipulator (see Figure 1) and on the front of the controller (see Figure 2).
Note! The identification plates and label shown in the figures below, only serve as
examples. For exact identification see the plates on the robot in question.
ABB Robotics Products AB
S-721 68 Västerås Sweden Made in Sweden
Type:
IRB 6400R M2000
Robot version:
IRB 6400R/2.5-150
Man. order:
XXXXXX
Nom. load
See instructions
Serial. No:
6400R-XXXX
Date of manufacturing:
Net weight
2,5.120 : 2060 kg
2.5-150 : 2060 kg
2,5-200 : 2230 kg
IRB 140(0)
IRB 640
IRB 2400
IRB 340
Identification plate showin
the IRB 6400R / M2000
2000-XX-XX
2,8-150 : 2240 kg
2,8-200 : 2390 kg
3.0-100 : 2250 kg
IRB 4400
IRB 140
IRB 6400R
IRB 840/A
Figure 1 Examples of identification plate and its location on different manipulator types.
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Product Manual
Introduction
.
ABB Robotics Products AB
S-721 68 Västerås Sweden Made in Sweden
Type:
Robot version:
Voltage: 3 x 400 V
Power:
Man. order:
Re.No:
Serial. No:
Date of manufacturing:
Net weight:
IRB 6400R M2000
IRB 6400R/2.5-150
Frequency: 50-60 Hz
7.2 kVA
XXXXXX
RXXXXXXXXXX
64-XXXXX
2000-XX-XX
240 kg
Figure 2 Identification plate on the controller.
Product Manual
9
Introduction
1.4 Structure Manipulator
The robot is made up of two main parts, the manipulator and controller. The
controller is described in section 1.5.
The Manipulator is equipped with maintenance-free AC motors, which have
electromechanical brakes. The brakes lock the motors when the robot is inoperative
for more than 1000 hours. The time can be configured by the user.
The following figures show the various ways in which the different manipulators
move and their component parts.
Motor axis 5
Motor axis 6
Axis 3
Axis 4
Axis 5
Axis 6
Motor axis 4
Upper arm
Lower arm
Axis 2
Motor axis 1
Motor axis 2
Motor axis 3
Axis 1
Base
Figure 3 The motion patterns of the IRB 1400 and IRB 140.
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Product Manual
Introduction
Motor unit axis 4
Motor unit axis 5
Motor unit axis 6
Upper arm
Axis 4 Axis 3
Axis 6
Axis 5
Motor unit and
gearbox axis 1
Lower arm
Axis 2
Motor unit and
gearbox axis 2
Motor unit and
gearbox axis 3
Axis 1
Base
Figure 4 The motion patterns of the IRB 2400.
Axis 5
Upper arm
Axis 4
Motor axis 4
Motor axis 5
Motor axis 6
Axis 6
Axis 3
Lower arm
Axis 2
Motor axis 1
Motor axis 3
Axis 1
Motor axis 2
Base
Figure 5 The motion patterns of the IRB 4400
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Introduction
Upper arm
Axis 3
Axis4
Motor axis 4
Motor axis 5
Axis 5
Motor axis 6
Axis 6
Axis 2
Motor axis 1
Motor axis 2
Motor axis 3
Axis 1
Lower arm
Base
Figure 6 The motion patterns of the IRB 6400R M99.
Axis 3
Upper arm
Motor axis 6
Axis 6
Axis 2
Motor axis 2
Motor axis 3
Lower arm
Motor axis 1
Axis 1
Figure 7 The motion patterns of the IRB 640.
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Product Manual
Introduction
Motor 1(X)-axis
Motor 3(Z)-axis
Motor 2(Y)-axis
Motor 4(C)-axis
2(Y)-axis
3(Z)-axis
4(C)-axis
1(X)-axis
Figure 8 The motion patterns of the IRB 840/A
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Introduction
.
Axis 2
Axis 3
Axis 2
Upper arm (x3)
Y
Axis 3
Base box
Motors
encapsulated
Bars (x3)
Axis 1
Axis 4,
telescopic shaft
Swivel
X
Z
Figure 9 The motion patterns of the IRB 340.
Motor axis 4
Motor axis 5
Motor axis 6
Axis 3
Axis 4
Lower arm
Upper arm
Axis 5
Axis 2
Axis 6
Motor axis 1
Motor axis 3
Motor axis 2
Axis 1
Base
Figure 10 The motion patterns of the IRB 140.
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Product Manual
Structure
1.5 Structure Controller
The controller, which contains the electronics used to control the manipulator and
peripheral equipment, is specifically designed for robot control and consequently
provides optimal performance and functionality.
Figure 11 shows the location of the various components on the cabinet.
Teach pendant
Operator’s panel
Mains switch
Service outlet
Manipulator
connection
Figure 11 The exterior of the cabinet showing the location of the various units.
1.6 Electronics unit
Computer
Power Supply
Main computer
Axis computer
max.
+55°C
I/O computer
Computer
System
Optional board 1-5
Transformer
max.+70°C
Drive unit 1
Drive unit 2
Drive unit 3
DC Link
All control and supervisory electronics, apart from the serial measurement board that
is located inside the manipulator, are gathered together inside the controller.
Flashdisk
Battery unit
Figure 12 The locations of the electronics boards and units behind the front door.
Product Manual
15
Structure
1.6.1 The computer system consists of the following parts
Backplane:
One Main computer slot and 7 PCI slots.
Main computer:
Controls the entire robot system. Intel PentiumTM
- CPU. 32 MB DRAM. 10/100 Mb, 7/s Ethernet controller.
Mass Storage:
64 Mb Flash disk, (Optional 128 Mb).
Axis computer:
Control of the manipulator motors.
I/O computer:
Handles I/O communication (CAN, Ethernet, serial links).
Optional boards:
Handles external axis and I/O computers, field bus communication, etc.
Computer power supply:
Four regulated and short-circuit-protected output voltages (±12V, 5V, 3.3V).
24V DC Input.
Battery unit:
Rechargeable NiCd battery and battery management card.
1.6.2 Drive system:
DC-link:
converts a three-phase AC voltage to a DC voltage.
Drive unit:
controls the torque of 2-3 motors.
When the maximum capacity for external axes is utilized, a second control cabinet is
required. The external axes cabinet comprises AC connection, main switch,
contactors, transformer, DC-link, drive module(s), and supply unit, but no computer
unit.
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Product Manual
Structure
Panel unit
I/O units (x4)
AC connection
Connector
Computer System
Motors On and brake contactors
Floppy disk (Opt.)
Figure 13 The location of units under the top cover.
1.6.3 Miscellaneous
Process power supply
230V AC supply, distributes DC power to computer system.
Panel unit:
Gathers and coordinates all signals that affect operational and personal safety.
I/O units:
Enables communication with external equipment by means of digital inputs and
outputs, analog signals, or field buses.
I/O units can alternatively be located outside the cabinet. Communication with robot
data is implemented via a stranded wire CAN bus, which allows the units to be
positioned close to the process.
Serial measurement board (in the manipulator):
Gathers resolver data and transfers it serially to the robot computer board. The serial
measurement board has battery backup so that the revolution information will not be
lost during a power failure.
Connector units:
Distributes signals between computer system and process.
Base connector unit
Product Manual
17
Structure
- Axis computer
- I/O computer
Drive and Measurement System.
Serial ports, CAN bus, Safety system, TPU.
Axis 3 connector unit (Optional)
- Extra axis computer
D and M Sys.
I/O connector unit (Optional)
- Extra I/O computer
18
Serial ports, CAN bus.
Product Manual
Safety
2
Safety
2.1
General
This information on safety covers functions that have to do with the operation of the
industrial robot.
The information does not cover how to design, install and operate a complete system,
nor does it cover all peripheral equipment, which can influence the safety of the total
system.
To protect personnel, the complete system must be designed and installed in
accordance with the safety requirements set forth in the standards and regulations of
the country where the robot is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable
safety laws and regulations in the country concerned are observed and that the safety
devices necessary to protect people working with the robot system have been designed
and installed correctly.
People who work with robots must be familiar with the operation and handling of the
industrial robot, described in the applicable documents, e.g. Users’s Guide and
Product Manual.
The diskettes which contain the robot’s control programs must not be changed in
any way because this could lead to the deactivation of safety functions, such as
reduced speed.
2.1.1
Introduction
Apart from the built-in safety functions, the robot is also supplied with an interface for
the connection of external safety devices.
Via this interface, an external safety function can interact with other machines and
peripheral equipment. This means that control signals can act on safety signals
received from the peripheral equipment as well as from the robot.
In the Product Manual - Installation and Commissioning, instructions are provided for
connecting safety devices between the robot and the peripheral equipment.
2.2
Applicable Safety Standards
The robot is designed in accordance with the requirements of ISO10218, Jan. 1992,
Industrial Robot Safety. The robot also fulfils the ANSI/RIA 15.06-1999 stipulations.
2.3
Fire-Extinguishing
Use a CARBON DIOXIDE extinguisher in the event of a fire in the robot (manipulator or controller).
Product Manual
19
Safety
2.4
Safety
Definitions of Safety Functions
Emergency stop – IEC 60204-1, 10.7
A condition which overrides all other robot controls, removes drive power from robot
axis actuators, stops all moving parts and removes power from other dangerous
functions controlled by the robot.
Enabling device – ISO 11161, 3.4
A manually operated device which, when continuously activated in one position only,
allows hazardous functions but does not initiate them. In any other position, hazardous
functions can be stopped safely.
Safety stop – ISO 10218 (EN 775), 6.4.3
When a safety stop circuit is provided, each robot must be delivered with the
necessary connections for the safeguards and interlocks associated with this circuit. It
is necessary to reset the power to the machine actuators before any robot motion can
be initiated. However, if only the power to the machine actuators is reset, this should
not suffice to initiate any operation.
Reduced speed – ISO 10218 (EN 775), 3.2.17
A single, selectable velocity provided by the robot supplier which automatically
restricts the robot velocity to that specified in order to allow sufficient time for people
either to withdraw from the hazardous area or to stop the robot.
Interlock (for safeguarding) – ISO 10218 (EN 775), 3.2.8
A function that interconnects a guard(s) or a device(s) and the robot controller and/or
power system of the robot and its associated equipment.
Hold-to-run control – ISO 10218 (EN 775), 3.2.7
A control which only allows movements during its manual actuation and which causes
these movements to stop as soon as it is released.
2.5
Safe Working Procedures
Safe working procedures must be used to prevent injury. No safety device or circuit
may be modified, bypassed or changed in any way, at any time.
2.5.1
Normal operations
Note! All normal operations in automatic mode must be executed from outside the safeguarded space.
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Product Manual
Safety
Safety
2.6
Programming, Testing and Servicing
The robot is extremely heavy and powerful, even at low speed. When entering into the
robot’s safeguarded space, the applicable safety regulations of the country concerned
must be observed.
Operators must be aware of the fact that the robot can make unexpected movements.
A pause (stop) in a pattern of movements may be followed by a movement at high
speed. Operators must also be aware of the fact that external signals can affect robot
programs in such a way that a certain pattern of movement changes without 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 (10 inches/s) when the operating mode selector is in position < 250 mm/s. This should be the normal position when entering the working space. The position 100% – full speed – may
only be used by trained personnel who are aware of the risks that this entails.
Check axis by axis in positions where the load of the manipulator arm and the
gripper apply the maximum static torque on each axis. Do the brake function test
by switching to motors Off when the axis has maximum load and check that the
axis maintains its position.
Do not change “Transm gear ratio” or other kinematic parameters from the Teach
Pendant Unit or a PC. This will affect the safety function Reduced speed 250 mm/s.
- During programming and testing, the enabling device must be released as
soon as there is no need for the robot to move.
The enabling device must never be rendered inoperative in any way.
- The programmer must always take the Teach Pendant Unit with him/her when
entering through the safety gate to the robot’s working space so that nobody
else can take over control of the robot without his/her knowledge.
2.7
2.7.1
Safety Functions
The safety control chain of operation
The safety control chain of operation is based on dual electrical safety chains which
interact with the robot computer and enable the MOTORS ON mode.
Each electrical safety chain consist of several switches connected in such a way that
all of them must be closed before the robot can be set to MOTORS ON mode (LIM 1/
2, ES1/2, GS 1/2, TPU En1/2, Man1/2, Auto1/2. See section Figure 14 on page 22).
The MOTORS ON mode means that drive power is supplied to the motors.
Product Manual
21
Safety
Safety
If any contact in the safety chain of operation opens, the robot always reverts to the
MOTORS OFF mode. The MOTORS OFF mode means that drive power is removed
from the robot’s motors and the brakes are applied.
K2
K1
K1
Drive
Unit
M
K2
Interlocking
EN RUN
&
&
Man2
Man1
+
+
LIM1
Auto1
TPU
En1
ES1
GS1
AS1
LIM2
External
contactors
TPU
En2
ES2
GS2
Auto2
AS2
Figure 14 Safety control chain of operation
The status of the switches is indicated by LEDs on top of the panel unit in the control
cabinet and is also displayed on the Teach Pendant Unit (I/O window).
After a stop, the switch must be reset at the unit which caused the stop, before the
robot can be ordered to start again.
The safety chains must never be bypassed, modified, or changed in any other way.
2.7.2
Emergency stops
An emergency stop should be activated if there is a danger to people or equipment.
Built-in emergency stop buttons are located on the operator’s panel of the robot
controller and on the Teach Pendant Unit.
External emergency stop devices (buttons, etc.) can be connected to the safety chain
by the user (see Product Manual - Installation and Commissioning). They must be
connected in accordance with the applicable standards for emergency stop circuits.
Before commissioning the robot, all emergency stop buttons or other safety equipment
must be checked by the user to ensure their proper operation.
Before switching to MOTORS ON mode again, establish the reason for the stop
and rectify the fault.
2.7.3
Mode selection using the operating mode selector
The applicable safety requirements for using robots, laid down in accordance with
ISO/DIS 10218, are characterised by different modes, selected by means of control
devices and with clear-cut positions.
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Product Manual
Safety
Safety
One automatic and two manual modes are available:
Manual mode:
< 250 mm/s - max. speed is 250mm/s
100% - full speed
Automatic mode: The robot can be operated via a remote control device
The manual mode, < 250 mm/s or 100%, must be selected whenever anyone enters the
robot’s safeguarded space. The robot must be operated using the Teach Pendant Unit
and, if 100% is selected, using Hold-to-run control.
In automatic mode, the operating mode selector is switched to
, and all safety
arrangements, such as doors, gates, light curtains, light beams and sensitive mats, etc.,
are active. Nobody may enter the robot’s safeguarded space. All controls, such as
emergency stops, the control panel and control cabinet, must be easily accessible from
outside the safeguarded space.
2.7.4
Programming and testing at reduced speed
Robot movements at reduced speed can be carried out as follows:
1. Set the operating mode selector to <250 mm/s
2. Programs can only be started using the Teach Pendant Unit with the enabling
device activated.
The automatic mode safeguarded space stop (AS) function is not active in this mode.
2.7.5
Testing at full speed
Robot movements at programmed speed can be carried out as follows:
1. Set the operating mode selector to 100%
2. Programs can only be started using the Teach Pendant Unit with the enabling
device activated.
For “Hold-to-run control”, the Hold-to-run button must be activated. Releasing the
button stops program execution.
The 100% mode may only be used by trained personnel. The applicable laws and
regulations of the countries where the robot is used must always be observed.
2.7.6
Automatic operation
Automatic operation may start when the following conditions are fulfilled:
1. The operating mode selector is set to
2. The MOTORS ON mode is selected
Either the Teach Pendant Unit can be used to start the program or a connected remote
control device. These functions should be wired and interlocked in accordance with
the applicable safety instructions and the operator must always be outside the
safeguarded space.
Product Manual
23
Safety
2.7.7
Safety
Enabling device
When the operating mode selector is in the MANUAL or MANUAL FULL SPEED
position, the robot can be set to the MOTORS ON mode by depressing the enabling
device on the Teach Pendant Unit.
Should the robot revert to the MOTORS OFF mode for any reason while the enabling
device is depressed, the latter must be released before the robot can be returned to the
MOTORS ON mode again. This is a safety function designed to prevent the enabling
device from being rendered inactive.
When the enabling device is released, the drive power to the motors is switched off,
the brakes are applied and the robot reverts to the MOTORS OFF mode.
If the enabling device is reactivated, the robot changes to the MOTORS ON mode.
2.7.8
Hold-to-run control
This function is always active when the operating mode selector is in the MANUAL
FULL SPEED position. It is possible to set a parameter to make this function active
also when the operating mode selector is in the MANUAL position.
When the Hold-to-run control is active, the enabling device and the Hold-to-run
button on the Teach Pendant Unit (TPU) must be depressed in order to execute a
program. When the button is released, the axis (axes) movements stop and the robot
remains in the MOTORS ON mode.
Here is a detailed description of how to execute a program in Hold-to-run control:
1. Activate the enabling device on the TPU.
2. Choose execution mode using the function keys on the TPU:
- Start (continuous running of the program)
- FWD (one instruction forwards)
- BWD (one instruction backwards)
3. Wait for the Hold-to-run alert box.
4. Activate the Hold-to-run button on the TPU.
Now the program will run (with the chosen execution mode) as long as the Hold-torun button is pressed. Releasing the button stops program execution and activating the
button will start program execution again.
For FWD and BWD execution modes, the next instruction is run by releasing and
activating the Hold-to-run button.
It is possible to change execution mode when the Hold-to-run button is released and
then continue the program execution with the new execution mode, by just activating
the Hold-to-run button again, i.e. no alert box is shown.
If the program execution was stopped with the Stop button on the TPU, the program
execution will be continued by releasing and activating the Hold-to-run button.
When the enabling device on the TPU is released, the sequence described above must
be repeated from the beginning.
2.7.9
General Mode Safeguarded Stop (GS) connection
The GS connection is provided for interlocking external safety devices, such as light
24
Product Manual
Safety
Safety
curtains, light beams or sensitive mats. The GS is active regardless of the position of
the operating mode selector.
When this connection is open the robot changes to the MOTORS OFF mode. To reset
to MOTORS ON mode, the device that initiated the safety stop must be interlocked in
accordance with applicable safety regulations. This is not normally done by resetting
the device itself.
2.7.10 Automatic Mode Safeguarded Stop (AS) connection
The AS connection is provided for interlocking external safety devices, such as light
curtains, light beams or sensitive mats used externally by the system builder. The AS
is especially intended for use in automatic mode, during normal program execution.
The AS is bypassed when the operating mode selector is in the MANUAL or
MANUAL FULL SPEED position.
2.7.11 Limiting the working space
Note! Not valid for IRB 340 and IRB 140
For certain applications, movement about the robot’s main axes must be limited in
order to create a sufficiently large safety zone. This will reduce the risk of damage to
the robot if it collides with external safety arrangements, such as barriers, etc.
Movement about axes 1, 2 and 3 can be limited with adjustable mechanical stops or by
means of electrical limit switches. If the working space is limited by means of stops or
switches, the corresponding software limitation parameters must also be changed. If
necessary, movement of the three wrist axes can also be limited by the computer
software. Limitation of movement of the axes must be carried out by the user.
2.7.12 Supplementary functions
Functions via specific digital inputs:
- A stop can be activated via a connection with a digital input. Digital inputs
can be used to stop programs if, for example, a fault occurs in the peripheral
equipment.
Functions via specific digital outputs:
- Error – indicates a fault in the robot system.
- Cycle_on – indicates that the robot is executing a program.
- MotOnState/MotOffState – indicates that the robot is in MOTORS ON /
MOTORS OFF mode.
- EmStop - indicates that the robot is in emergency stop state.
- AutoOn - indicates that the robot is in automatic mode.
Product Manual
25
Safety
2.8
2.8.1
Safety
Safety Risks Related to End Effectors
Gripper
If a gripper is used to hold a workpiece, inadvertent loosening of the workpiece must
be prevented.
2.8.2
Tools/workpieces
It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that
guards remain closed until the cutters stop rotating.
Grippers must be designed so that they retain workpieces in the event of a power
failure or a disturbance of the controller. It should be possible to release parts by
manual operation (valves).
2.8.3
Pneumatic/hydraulic systems
Special safety regulations apply to pneumatic and hydraulic systems.
Residual energy may be present in these systems so, after shutdown, particular care
must be taken.
The pressure in pneumatic and hydraulic systems must be released before starting to
repair them. Gravity may cause any parts or objects held by these systems to drop.
Dump valves should be used in case of emergency. Shot bolts should be used to
prevent tools, etc., from falling due to gravity.
2.9
Risks during Operational Disturbances
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.
Remedial action must only ever be carried out by trained personnel who are familiar
with the entire installation as well as the special risks associated with its different
parts.
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
applicable safety regulations. Care must be taken at all times.
2.10
Risks during Installation and Service
Never use the robot as a ladder, i.e. do not climb on the robot motors or other parts
during service work. There is a serious risk of slipping because of the high temperature of the motors or oil spills that can occur on the robot.
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Product Manual
Safety
Safety
Note! 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.
Special attention must be paid to the following points:
- 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 instructions in the Product Manual - Installation and Commissioning
must always be followed.
- 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.
- 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.
- Emergency stop buttons must be positioned in easily accessible places so that
the robot can be stopped quickly.
- 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 away from the
robot’s working space.
- 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.
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.
Even if the power supply for the robot is turned off, you can still injure yourself.
- The axes are affected by the force of gravity when the brakes are released. In
addition to the risk of being hit by moving robot parts, you run the risk of
being crushed by the tie rod.
- Energy, stored in the robot for the purpose of counterbalancing certain axes,
may be released if the robot, or parts thereof, is dismantled.
- When dismantling/assembling mechanical units, watch out for falling
objects.
- Be aware of stored energy (DC link) and hot parts in the controller.
- Units inside the controller, e.g. I/O modules, can be supplied with power from
an external source.
Product Manual
27
Safety
2.11
Safety
Dimensioning the safety fence
A safety fence must be fitted around the robot to ensure a safe robot installation. The
fence must be dimensioned to withstand the force created if the load being handled by
the robot is dropped or released at maximum speed. The maximum speed is determined
from the maximum velocities of the robot axes and from the position at which the robot
is working in the workcell (see Product Specification - Description, Robot Motion).
Applicable standards are ISO/DIS 11161 and prEN 999:1995.
2.12
Standards of interest when the robot is part of a cell
EN 294
Safety of machinery - Safety distance to prevent danger zones being reached by
the upper limbs.
EN 349
Safety of machinery - Minimum gaps to avoid crushing of parts of the human
body.
EN 811
Safety of machinery - Safety distance to prevent danger zones being reached by
the lower limbs.
Pr EN 999
Safety of machinery - The positioning of protective equipment in respect of
approach speeds of the human body.
EN 1088
Safety of machinery - Inter locking device associated with guards principles for
design and selection.
Table 1
2.13
Standards of interest when the robot is part of a cell
Risks Associated with Live Electric Parts
2.13.1 Controller
A danger of high voltage is associated with the following parts:
- The mains supply/mains switch
- The power unit
- The power supply unit for the computer system (55V AC)
- The rectifier unit (260V AC and 370V DC. NB: Capacitors!)
- The drive unit (370V DC)
- The service outlets (115/230V AC)
- 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
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Product Manual
Safety
Safety
2.13.2 Manipulator
A danger of high voltage is associated with the manipulator in:
- The power supply for the motors (up to 370V DC)
- The user connections for tools or other parts of the installation (max.
230V AC, see Product Manual - Installation and Commissioning)
2.13.3 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.
2.14
Emergency Release of Mechanical Arm
If an emergency situation occurs where a person is trapped by the mechanical robot
arm, the brake release buttons should be pressed whereby the arms can be moved to
release the person. To move the arms by manpower is normally possible on the
smaller robots (1400 and 2400), but for the bigger ones it may not be possible without
a mechanical lifting device such as an overhead crane.
If power is not available the brakes are applied and therefore manpower may not be
sufficient for any robot.
Before releasing the brakes, be sure that the weight of the arms does not enhance
the pressure on the trapped person.
2.15
Limitation of Liability
The above information regarding safety must not be construed as a warranty by
ABB Robotics that the industrial robot will not cause injury or damage even if all
safety instructions have been complied with.
2.16
Related Information
Described in:
Installation of safety devices Product Manual - Installation and Commissioning
Changing robot modes
User’s Guide - Starting up
Limiting the working space
Product Manual - Installation and Commissioning
Product Manual
29
Safety
30
Safety
Product Manual
Decomissioning
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 on
the environment.
3.1.1
3.1.2
Hazardous material
Material
Example application
Lithium or NiCad Batteries
Serial meausurement board
Copper
Cables, motors
Cast iron/Nodular iron
Base, lower arm, upper arm, parallel bar/arm
Steel
Gears, screws, baseframe
Neodymium
Brakes, motors
Plastic/Rubber (PVC)/Composites
Cables, connectors, parallel bars
Oil, Grease
Gearboxes
Aluminium
Covers, sync. brackets
Oil and Greases
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 must
be carried out under controlled conditions in accordance with local regulations.
Also note the following:
o Spills may form a film on water surfaces causing damage to organisms. Oxygen
transfer could also be impaired.
o Spillage may penetrate the soil causing ground water contamination.
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31
Decomissioning
32
Decommissioning
Product Manual
Installation and Commissioning
4
Installation and Commissioning
4.1
Transporting and Unpacking
NB!
Before starting to unpack and install the robot, read the safety regulations and
other instructions very carefully. These are found in separate sections in the
User’s Guide and Product manual.
The installation shall be made by qualified installation personnel and should
conform to all national and local codes.
When you have unpacked the robot, check that it has not been damaged during
transport or while unpacking.
Check especially following items:
- Composite arms (upper arms and bar system); no hacks
- Joint balls; no scratches
- Ventilation hose; no holes
Operating Conditions
Ambient temperature
+ 5°C (41°F) to +52°C (125°F) (manipulator)
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.
The net weight of the different variants of the manipulator is approximately:
- Standard and WashDown : 140 kg (308.4 pounds)
- Stainless : 165 kg (364 pounds)
Whenever the manipulator is transported, it must be in mounting position, it’s not
allowed to turn the manipulator up side down.
4.1.1
System CD ROM and Diskette
The system CD ROM and the manipulator parameter disk are delivered with the robot
system.
See Product Manual for S4Cplus or IRC5 Procedures, “Installation and Commissioning”.
Product Manual
33
Installation and Commissioning
34
Product Manual
4.2
4.2.1
On-Site Installation
Lifting the Manipulator and Controller
Never walk under a suspended load!
The best way to lift the manipulator is to use lifting straps and a traverse crane. Attach
the straps to the three lifting eyes on the base box (see Figure 15). The lifting strap
dimensions must comply with the applicable standards for lifting.
Crane lift
Ventilation hose
L=1000 mm / 40 inch
Figure 15 Lifting the Manipulator using a Traverse Crane.
Product Manual
35
It is also possible to lift the manipulator using a fork lift. To do that let the manipulator
rest in its standard delivery loading stool.
Fork lift
Figure 16 Lifting the Manipulator using a Fork Lift.
4.2.2
Assembling the Robot
Manipulator
The three support points of the manipulator base box shall be mounted against three
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 17. The
levelness requirement for the surface is as follows:
0.5
36
Product Manual
Area for
calibration tool
26
39
o
67
= Available footprint of frame
Axis 3
R 370
A
120
A
o
The amount of
space is shown
in Figure 4.
(3x
)
A
A
Axis 2
40
M1
6
12
33
)
Y
( +0.0
o
Axis 1
25
H8
A
0
30
A
X
Clamping plane
A-A
Figure 17 Bolting the Manipulator (Dimensions in mm).
The manipulator is fixed with three M16 bolts, tightened alternately.
Suitable bolts:Standard and Stainless versions:
M16x45 8.8 Socket screw with washer
(The length of the screws depends on the design of the frame.)
Wash Down version:
The bolts’ length shall be selected to protrude through the
mounting flange, and shall be sealed with Loctite or equal.
Product Manual
37
Tightening torque:150 Nm (oil lubricated)
Guide sleeves (Art.No 3HAC9519-1) can be added to two optional holes of the three
bolt holes, to allow the same manipulator to be re-mounted without program
adjustment (see Figure 17).
The screw joint must be able to withstand the stress loads defined in Section 4.2.3
below.
Mounting the Arm System and movable Plate
After the manipulator has been mounted, as described in Section above, the arm
system and movable plate are assembled according to Repairs chapter Section 6.4.
Mounting the Telescopic Shaft, Axis 4
After the arm system has been mounted, as described in Section above, the telescopic
shaft is assembled as described in Repairs chapter, Section 6.3.3.
Mounting the Ventilation Hose
Standard
Mount the ventilation hose (see Figure 15) with two hose clips, 3HAC 4428-1,
supplied with the robot.
Wash Down and Stainless
Wash Down ventilation hose is already fitted. If External Air Connection (option 061)
is ordered, the Wash Down ventilation has to be exchanged and the same screws will
be used to mount the new, tightening torque 4 Nm.
Hose to Tool Point
Mount the hose from the air filter down to the movable plate as described in foldout 7.
See Foldouts in part 2 of this manual, Reference Information.
4.2.3
Stress Forces
Stiffness
The stiffness of the frame must be designed to minimize the influence on the dynamic
behaviour of the robot. For optimal performance the frequency of the frame with the
robot weight must be higher than 17 Hz.
TuneServo can be used for adapting the robot tuning to a non-optimal foundation.
Forces
Maximum force in each fixing point are 500 N referring to the z-direction in the base
coordinate system, regarding coordinate system see the Product Specification for
IRB 340.
A robot frame is not included in the delivery.
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Product Manual
4.2.4
Amount of Space required
The amount of space required to operate the manipulator is illustrated in Figure 18.
Manipulator
R=362.5
324
∅ 1246
397
34
270
795
1160
Figure 18 The amount of Space required for the Manipulator.
4.2.5
Manually engaging the Brakes
All axes (except ax 4) come equipped with holding brakes. When the position of a
manipulator axis needs to be changed without connecting the controller, an external
voltage supply (24 V D.C.) must be connected to enable engagement of the brakes.
The voltage supply should be connected to the FCI connector under the cover
(see Figure 19).
Internal connector
FCI connector: R1.MP4-6
1
4
7
2
3
5
6
8
91
10
11
12
13
14
15
0V
+ 24 V D.C.
NOTE!
Be careful not to
interchange the
24 V- and 0 V
pins.
If they are mixed
up, damage can
be caused to
electrical
components.
Figure 19 Connection of External Voltage to enable Engagement of the Brakes.
When the controller or the voltage device is connected, illustrated above, the brakes
can be engaged by means of the push-button, location shown in Figure 20.
Product Manual
39
A
Figure 20 Location of Brake Release Button.
Table 2
A
4.2.6
Location of Brake Release Button
Brake Release Button
Mounting Equipment on the Manipulator
External equipment, for example hoses and wiring mounted on the arms of the
manipulator must have a maximum weight of 300 g/m, see also the Product
Specification for IRB 340.
NB! Never drill a hole in the manipulator without first consulting maintenance
staff or the design department at ABB.
2xR1/4”
Ø52
Key grip = Width 22/h7 mm
Height 6 mm
Ø25
Mounting flange R3/8”, depth 14 mm
(Whitworth ISO-228/1)
Figure 21 The mechanical Interface (Mounting Flange).
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Product Manual
4.2.7
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 breakdown of arm system.
For more information see the Product Specification for IRB 340 for load diagrams,
permitted extra loads (equipment) and their positions. The loads must also be defined
in the software, see User’s Guide.
4.2.8
Moving the Robot by hand
Note! If any emergency situation occurs and the robot has to be moved by hand,
please follow the suggestions below!
Overview
Moving the IRB 340 by hand may cause sever damage to the robot. If the robot is
moved by hand outside it´s working envelope, parts on the robot may be damaged.
Below are some examples of parts that can be damaged.
Extreme Position of Robot Arm
In order to prevent damage it is important not to step over the extreme position of the
robot arm or exceed the extreme values of the angles. See illustration below!
Figure 22 Extreme values of angles
Table 3
Position P1
Position P2
U = 100°
U = -46.1°
V = 95.5°
V = -50.6°
W = 134.5°
W = 43.9°
Mechanical Stop
When angle V = -57° is mechanical stop reached.
Product Manual
41
Below are some examples of parts that can be damaged if the instructions above not
are followed!
Universal Joints
Upper and/or lower universal joints may be damaged if the angle is greater than 45
degrees. When the robot is moved by hand outside the working area, the universal
joint is forced to be the mechanical stop of the axis. The universal joint is not designed
to operate at angles greater than 45 degrees. As a result of the applied forces to the
bearings and other parts, the universal joint(s) can be destroyed.
Forks on the Spring Units
The forks on the spring units, can be bent apart, when the robot is moved by hand.
This occurs when the cylinder of the spring unit gets jammed against the upper arms.
This will force the forks to spread apart.
A broken fork cannot keep the rollers in place and secure a proper function of the
robot arm. When the forks are destroyed the roller caps may fall out the next time the
robot is moved by hand. This can also occur randomly during production.
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Product Manual
Using the Teach Pendant to move the Robot
Using the teach pendant to move the robot, will assure that the robot never exceeds the
working envelope.
A sticker according to the picture below can be ordered from ABB After Sales. Article
no. 3HAC 4613-1.
We recommend operators to use the teach pendant to move the robot. If the operators
normally not are using the teach pendant, the bottom part of the sticker can be cut
away.
WashDown cleaning
WashDown cleaning and procedures according to the Maintenance chapter in this
Product Manual, should be followed! See Section 5.3.2
Product Manual
43
4.2.9
Connecting the controller to the manipulator
Two cables are used to connect the controller to the manipulator, one for measuring
signals and the other for motor and brakes.
The connection on the manipulator is located on the rear of the robot base.
Connection on left-hand side of cabinet
The cables are connected to the left side of the cabinet using an industrial connector
and a Burndy connector (see Figure 23). A connector is designated XP when it has
pins (male) and XS when it has sockets (female). A screwed connection is designated
XT.
Motor cable, XP1
XS1
XS2
Measurement cable, XP2
Figure 23 Connections on the cabinet wall.
4.2.10 Dimensioning the safety fence
A safety fence must be fitted around the robot to ensure a safe robot installation. The
fence must be dimensioned to withstand the force created if the load being handled by
the robot is dropped or released at maximum speed. The maximum speed is
determined from the max. velocities of the robot axes and from the position at which
the robot is working in the workcell. See Product Specification, section 3.8. The max.
speed for a load mounted on the IRB 340 is 10 m/s.
Applicable standards are ISO/DIS 11161 and prEN 999:1995.
4.2.11 Mains power connection
Before starting to connect the mains, make sure that the other end of the cable is
disconnected from the line voltage.
The power supply can be connected either inside the cabinet, or to a optional socket on
the left-hand side of the cabinet or the lower section of the front. The cable connector
is supplied but not the cable. The mains supply cables and fuses should be
dimensioned in accordance with rated power and line voltage, see rating plate on the
controller.
Connection to the mains switch
Remove the left cover plate under the top lid. Pull the mains cable (outer diameter
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Product Manual
10.20 mm) through the gland (see Figure 24) located on the left cabinet wall.
XT 26
PE
Cable gland
Connector
Figure 24 Mains connection inside the cabinet.
Connect as below: For more information, also see Circuit Diagram in part 2 of this
manual, Reference Information.
1. Release the connector from the knob by depressing the red button located on the
upper side of the breaker (see Figure 24).
2. Connect phase:
Table 4
1 to L1
N.B. Not dependent on phase sequence.
2 to L2
3 to L3
0 to XT26.N
line neutral is needed only for option 432
Protective earth to earth
sign
NOTE!
Max. conductor size is 6 mm2 (AWG 10). Tighten torque 2.3-2.5 Nm.
Retighten after approx. 1 week.
3. Snap the breaker on the knob again and check that it is fixed properly in the right
position.
4. Tighten the cable gland.
5. Fasten the cover plate.
Connection via a power socket
You can also connect the mains supply via an optional wall socket of type CEE 3x16
and 3x32 A, or via an industrial Harting connector (DIN 41 640). See Figure 25.
Product Manual
45
Cable connectors are supplied (option 133 - 134).
CEE connector
DIN connector
Figure 25 Mains connection via an optional wall socket.
4.2.12 Inspection before start-up
Before switching on the power supply, check that the following have been performed:
1. The robot has been properly mechanically mounted and is stable
2. The controller mains section is protected with fuses.
3. The electrical connections are correct and corresponds to the identification plate on
the controller.
4. The teach pendant and peripheral equipment are properly connected.
5. That limiting devices that establish the restricted space (when utilized) are installed.
6. The physical environment is as specified.
7. The operating mode selector on the operator’s panel is in Manual mode position.
When external safety devices are used check that these have been connected or that
the following circuits in either XS3 (connector on the outside left cabinet wall) or X1X4 (screw terminals on the panel unit) are strapped:
Table 5
XS3
Panel unit
External limit switches
A5-A6, B5-B6
X1.3-4, X2.3-4
External emergency stop
A3-A4, B3-B4
X1.9-10, X2.9-10
External emergency stop
internal 24 V
A1-A2, B1-B2
X1.7-8, X2.7-8
General stop +
A11-A12, B11-B12
X3.10-12, X4.10-12
General stop -
A13-A14, B13-B14
X3.7-8, X4.7-8
Auto stop +
A7-A8, B7-B8
X3.11-12, X4.11-12
Auto stop -
A9-A10, B9-10
X3.7-9, X4.7-9
Motor off clamping
A15-A16, B15-16
X1.5-6, X2.5-6
For more information, see Product Manual for S4Cplus or IRC5.
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Product Manual
4.2.13 Start-up
General
1. Switch on the mains switch on the cabinet.
2. The robot performs its self-test on both the hardware and software. This test takes
approximately 1 minute.
If the robot is supplied with software already installed, proceed to pos. 3 below.
Otherwise continue as follows (no software installed):
- Connect the batteries for memory backup (see Figure 26).
Install the software as described in Product Manual for S4Cplus or IRC5.
Batteries
Connect the batteries
to the connectors X3
and X4, situated below
the batteries.
Figure 26 Location of batteries, view from above.
3. A welcome message is shown on the teach pendant display.
4. To switch from MOTORS OFF to MOTORS ON, press the enabling device on the
teach pendant.
5. Update the revolution counters according to Section .
6. Check the calibration position according to Section .
7. When the controller with the manipulator electrically connected are powered up for
the first time, ensure that the power supply is connected for at least 36 hours
continuously, in order to fully charge the batteries for the serial measurement board.
After having checked the above, verify that
8. the start, stop and mode selection (including the key lock switches) control devices
function as intended.
9. each axis moves and is restricted as intended.
10. emergency stop and safety stop (where included) circuits and devices are
functional.
11. it is possible to disconnect and isolate the external power sources.
12. the teach and playback facilities function correctly.
13. the safeguarding is in place.
14. in reduced speed, the robot operates properly and has the capability to handle the
Product Manual
47
product or work piece, and
15. in automatic (normal) operation, the robot operates properly and has the capability
to perform the intended task at the rated speed and load.
16. The robot is now ready for operation.
Updating the revolution counter
When pressing the enabling device on a new robot, a message will be displayed on the
teach pendant telling you that the revolution counters are not updated. When such a
message appears, the revolution counter of the manipulator must be updated using the
calibration marks on the manipulator (see Figure 31).
Examples of when the revolution counter must be updated:
- when one of the manipulator axes has been manually moved with the controller disconnected.
- when the battery (on the manipulator) is empty.
- when there has been a resolver error
- when the signal between the resolver and the measuring panel unit has been
interrupted
WARNING:
Working inside the robot working range is dangerous.
Press the enabling device on the teach pendant and, using the joystick, manually move
the robot so that the calibration marks lie within the tolerance zone. For axes 1-3 the
pin should be inside the nut and for axis 4, the marks must be in line (see Figure 31).
When all axes have been positioned as above, the revolution counter settings are
stored using the teach pendant, as follows:
1. Press the Misc. window key (see Figure 27).
1
2
P1
7
8
9
4
1
5
2
0
6
3
P2
P3
Figure 27 The Misc. window key from which the Service window can be chosen.
2. Select Service in the dialog box shown on the display.
3. Press Enter
48
.
Product Manual
4. Then, choose View: Calibration. The window in Figure 28 appears.
File
Edit
View
Calib
Service Calibration
Unit
Status
1(1)
IRB
Not rev. counter update
Figure 28 This window shows the status of the revolution counters.
If there are several units connected to the robot, these will be listed in the window.
5. Select the desired unit in the window, as in Figure 28. Choose Calib: Rev. Counter
Update. The window in Figure 29 appears.
Rev. Counter Update!
IRB
To calibrate, include axes and press OK.
Axis
Status
1(6)
X
X
X
X
1
2
3
4
5
6
Incl
Not updated
Not updated
Calibrated
Calibrated
Not updated
Not updated
All
Rev. Counter
Rev. Counter
Rev. Counter
Rev. Counter
Cancel
OK
Figure 29 The dialog box used to select axes whose revolution counters are to be updated.
6. Press the function key All to select all axes if all axes are to be updated. Otherwise,
select the desired axis and press the function key Incl (the selected axis is marked
with an x).
Product Manual
49
7. Confirm by pressing OK. A window like the one in Figure 30 appears.
Rev. Counter Update!
IRB
The Rev. Counter for all marked axes
will be update.
It cannot be undone.
OK to continue?
Cancel
OK
Figure 30 The dialog box used to start updating the revolution counter.
8. Start the update by pressing OK.
If a revolution counter is incorrectly updated, it will cause incorrect positioning.
Thus, check the calibration very carefully after each update. Incorrect updating
can damage the robot system or injure someone.
9. Check the calibration position as described in Section .
10.Save the system parameters on floppy disk.
50
Product Manual
Calibration mark, axes 1-3
Pin
Nut
Calibration mark, axis 4
Calibration marks
Figure 31 Calibration marks on the manipulator.
These marks are intended only for resolver counter update. See Section 6.8 in Repairs
chapter.
Checking the calibration position
There are two ways to check the calibration position and they are described below.
Using the diskette, Controller Parameters:
Run the program \ SERVICE \ CALIBRAT \ CAL 340 on the diskette, follow
instructions displayed on the teach pendant. When the robot stops, switch to
MOTORS OFF. Check that the calibration marks for each axis are at the same level,
see Figure 31. If they are not, the setting of the revolution counters must be repeated.
Using the Jogging window on the teach pendant:
Open the Jogging window
and choose running axis-by-axis. Using the joystick,
move the robot so that the read-out of the positions is equal to -13,2 degrees. Check
that the calibration marks for each axis are at the same level, see Figure 31. If they are
not, the setting of the revolution counters must be repeated.
Product Manual
51
Operating the robot
Starting and operating the robot is described in the User’s Guide. Before start-up,
make sure that the robot cannot collide with any other objects in the working space.
Defining working area
To Define the Working area.
• Press the Miscellaneous key
to open the System Parameters window.
• Select System Parameters from the dialog box that appears.
• Press OK or Enter
.
• Choose Topics: Manipulator
• Press OK or Enter
.
• Choose Types: Robot
• Press OK or Enter
.
Type the desired values for Upper and Lower work area on axes x, y, and z.
Work area restrictions in x and y directions, (max. 0.566 m) and (min. -0.566 m) and
in z direction (max. 1.11 m) and (min. 0.86 m).
The default working areas for the x and y directions are ± 0.4 m.
R = 0.566
Axis 3
Upper Work Area y
x
Axis 1
Marked area = actual working area
with this configuration
Lower Work Area y
Axis 2
Lower work area x
Upper work area x
y
Figure 32 Working area restrictions for x and y directions
52
Product Manual
The default working area in the z direction is +860 mm to +1160 mm.
+1160 mm
+.860 mm
+1110 mm
z
r 1014
ø967mm
Marked area = actual working area
ø1132 mm
Figure 33 Working area restrictions for z direction
Product Manual
53
54
Product Manual
Customer connections
4.3
Customer Connections on Manipulator
Two Options of Customer Connections are available.
1. Option 218-5
Signals and power. Number of signals: 23 signals (49 V, 250 mA), 10 power signals
(250 V, 2 A). Cable between manipulator and controller not supplied.
Also see Section 4.3.1 below.
2. Option 218-9
A vacuum system, including three signals: grip, drop and vacuum level guard. The
signals are connected to one 12-pole screw terminal in the controller. The cable
between the manipulator and the controller is included. See the Product
Specification for IRB 340, Chapter 2, Specification of Variants and Options for
further information.
Air supply: Regarding air quality, only use dry and clean air. Maximum particle size
5 µm
Option 218-5
R1.CP
R1.CS
(under
cover)
R2.CP
R2.CS
Air
Vacuum system, option 218-9
R1.CS
Note! R1.CS are not the same contact for option 218-5 and 218-9
Figure 34 Location of Customer Connections.
To connect to power and signal conductors from the connection unit to the
manipulator, the following parts are recommended:
Table 6
Connector R2.CS - Recommended connecting Parts
Connector R2.CS. Signals on Manipulator. (Regarding Item No. see Figure 35)
Item
Name
ABB Art. No.
Type
Comments
1
Socket con. 23p
3HAC 7446-4
UTO 018 23 SHT
FCI
Product Manual
55
Customer connections
Table 6
Connector R2.CS - Recommended connecting Parts
Connector R2.CS. Signals on Manipulator. (Regarding Item No. see Figure 35)
56
Item
Name
ABB Art. No.
Type
Comments
2
Gasket
2152 0363-5
UTFD 16 B
FCI
3
Socket
See Table 8 below
4
Pin con. 23p
3HAA 2602-3
UTG 061823 P04T
FCI EMC
5217 649-34
UTG 61823 PN
FCI
5
Pin
See Table 8 below
6
Adaptor
3HAA 2601-3
UTG 18 ADT
FCI EMC
7
Cable clamp
5217 649-36
UTG 18 PG
FCI
8
Shrinking hose
3HAA 2614-3
Bottled shaped
Shrinking hose
5217 1032-5
Angled
Product Manual
Customer connections
Table 7
Connector R2.CP - Recommended connecting Parts
Connector R2.CP. Power Signals on Manipulator. (Regarding Item No. see Figure 35)
Item
Name
ABB Art. No.
Type
Comments
1
Socket con. 12p
3HAC 7446-4
UTO 014 12 SHT
FCI
2
Gasket
21520363-3
UTFD 13 B
FCI
3
Socket
See Table 8 below
4
Pin con. 12p
3HAA 2602-2
UTO 61412 PN04
FCI EMC
5217 649-7
UTO 61412 PN
FCI
5
Pin
See Table 8 below
6
Adaptor
3HAA 2601-2
UTG 14 ADT
FCI EMC
7
Cable clamp
5217 649-8
UTG 14 PG
FCI
8
Shrinking hose
3HAA 2614-2
Bottled shaped
Shrinking hose
5217 1032-4
Angled
Table 8
Recommended Pins and Sockets
Name
ABB Part No.
Type
Comments
Pin
5217 649-72
24/26
FCI Machine tooling
5217 649-25
24/26
FCI Hand tooling
5217 649-70
20/22
FCI Machine tooling
5217 649-3
20/22
FCI Hand tooling
5217 649-68
16/20
FCI Machine tooling
5217 649-10
24/26
FCI Ground
5217 649-31
16/20
FCI Ground
5217 649-73
24/26
FCI Machine tooling
5217 649-26
24/26
FCI Hand tooling
5217 649-71
20/22
FCI Machine tooling
5217 649-69
16/18
FCI Machine tooling
5217 1021-4
DIN 43 652
Tin bronze (CuSu)
Socket
0.14 - 0.5mm2 AWG 20-26
5217 1021-5
DIN 43 652
Tin bronze (CuSu)
0.5 - 1.5mm2 AWG 16-20
Product Manual
57
Customer connections
4, 5
Customer side
Manipulator side
1, 3
8
6
2
7
Figure 35 FCI Connector
4.3.1
Connection of Extra Equipment to the Manipulator
Technical data for customer connections.
Customer Power CP
Conductor resistance<0,5 ohm, AWG 20 0,56 mm2
Max. voltage250V A.C.
Max. current2 A
Customer Signals CS
Conductor resistance<3 ohm, AWG 20 0.56 mm2
Max. voltage50V A.C. / D.C.
Max. current250 mA
Connections on Manipulator
R2.CS
R2.CP
Figure 36
58
Customer Connections.
Product Manual
Customer connections
Table 9
Signal Name
Customer Terminal Controller
(see Chapter 8, Installation and
Commissioning, 2.6 Connection to
Screw Terminal)
Customer Contact on
Manipulator
(Cable not supplied)
Power supply
CPA
XT6:1
R2.CP:A
CPB
XT6:2
R2.CP:B
CPC
XT6:3
R2.CP:C
CPD
XT6:4
R2.CP:D
CPE
XT6:5
R2.CP:E
CPF
XT6:6
R2.CP:F
CPJ
XT6:7
R2.CP:J
CPK
XT6:8
R2.CP:K
CPL
XT6:9
R2.CP:L
CPM
XT6:10
R2.CP:M
PE
R2.CP:G
Signals
Product Manual
CSA
XT5.1:1
R2.CS:A
CSB
XT5.1:2
R2.CS:B
CSC
XT5.1:3
R2.CS:C
CSD
XT5.1:4
R2.CS:D
CSE
XT5.1:5
R2.CS:E
CSF
XT5.1:6
R2.CS:F
CSG
XT5.1:7
R2.CS:G
CSH
XT5.1:8
R2.CS:H
CSJ
XT5.1:9
R2.CS:J
CSK
XT5.1:10
R2.CS:K
CSL
XT5.1:11
R2.CS:L
CSM
XT5.1:12
R2.CS:M
CSN
XT5.2:13
R2.CS:N
CSP
XT5.2:14
R2.CS:P
CSR
XT5.2:15
R2.CS:R
CSS
XT5.2:16
R2.CS:S
CST
XT5.2:17
R2.CS:T
CSU
XT5.2:18
R2.CS:U
CSV
XT5.2:19
R2.CS:V
CSW
XT5.2:20
R2.CS:W
CSX
XT5.2:21
R2.CS:X
CSY
XT5.2:22
R2.CS:Y
CSZ
XT5.2:23
R2.CS:Z
59
Customer connections
60
Product Manual
Maintenance
5
Maintenance
The robot is designed to be able to work under very demanding conditions with a
minimum of maintenance. Time between services can vary depending on the influence
of the environment the robot is exposed for. Always check that joints and rods are well
lubricated.
We strongly recommend that at every stop in production and after every wash down,
the robot is inspected concerning the following parts:
Tabell 10
Inspect regularly:
Telescopic shaft
Spring Units
Rollers
Bars
Joint Balls
Universal Joints
Nevertheless, certain routine checks and preventative maintenance must be carried out
at specified periodic intervals, as shown in the table below.
• The exterior of the robot should be cleaned as required. Use a vacuum cleaner
or wipe it with a cloth. Compressed air and harsh solvents that can damage the
sealing joints, bearings, lacquer or cabling, must not be used.
• Check that the sealing joints and cable glands are really airtight so that dust and
dirt are not sucked into the cabinet.
• Lubricate sealings at regular intervals and when needed, recommended
lubrication see 5.2.5.
Product Manual
61
Maintenance
5.1
Maintenance Schedule
Table 11
Maintenance Intervals
Prescribed Maintenance
Telescopic shaft, axis 4
Maintenance Intervals
Check
every 500
h
4,000 h or
2 years
X
X
Vacuum system
Bar system
X
1
X
Upper arms
Spring unit
12,000 h
or
3years
30,000 h
or
5years
X
X
X
X
Movable plate with swivel
X
Gearboxes, axes 1, 2, and 3
X
X
X2
Manipulator fan
Accumulator for measuring system Exchange
3 years 3
1. Only if option is chosen. Change interval is depending on the material in picked
objects. Porous objects may cause shorter cleaning intervals.
2. Check roller bearing.
3. See section 5.2.15.
5.2
Instructions for Maintenance
Numbers inside < > refers to maintenance points on the manipulator, see Figure 39.
5.2.1
General Instructions for the Manipulator
Check regularly:
• Wear of plain bearings in telescopic shaft (SA, SAS versions).
• Wear of bearing ring in joints of the arm system, lubricate.
• 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.
Cleaning:
• Clean the robot exterior with a cloth when necessary. Do not use aggressive
solvents which may damage paint or cabling.
• Cleaning instructions for Wash Down version see 5.3.
5.2.2
Telescopic Shaft, Axis 4, Plain Bearings.
Interval 500 h
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Product Manual
Maintenance
Apply grease at <1>.
Type of grease:
Volume:
Check and retighten set screws.
Mobilgrease FM 102 (see 5.2.6)
Optimol Obeen UF 2 (see 5.2.6)
1.3 ml
Interval 4,000 h or 2 Years
Exchange the part as described in Repairs chapter, section 6.3.4.
5.2.3
Telescopic Shaft, WashDown and Stainless, Axis 4, Plain Bearing
The wear on the bearings depends on the payload, cycle, environment, and
lubrication.
Interval 500 h
Rods
Check the wear of the rods on the inside of the plain bearing. If the rods are damaged
or worn out, replace the telescopic shaft as described in Repairs chapter section 6.3.3.
Apply a small amount of grease on the rods.
Plain Bearing
If the plain bearings are worn out or if the backlash is excessive, replace the plain
bearings as described in Repairs chapter section 6.3.4.
Interval 4,000 h or 2 Years
If necessary, replace the parts as described in Repairs chapter.
Type of grease:
Mobilgrease FM 102 (see 5.2.6)
Optimol Obeen UF 2 (see 5.2.6)
5.2.4
Vacuum System
Use only unlubricated air.
Interval 500 h
Empty air filter <3> and check the position of the clamps <4> for the hose.
The correct position for the outer clamps is 150 mm from joints.
Check that the air supply is dry and clean. Particle size must not exceed 5 µm!
Interval 4,000 h or 2 Years
Replace pneumatic valves <16>. The service life of the valves is 4x107 cycles.
Article number for:
Air filter:
3HAC 3718-1
Pneumatic valve unit:
3HAC 8030-4, PIAB
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63
Maintenance
5.2.5
Bar System
The wear on the wear rings depends on the payload, cycle, environment, and
lubrication.
Interval 500 hrs or 1 year.
Check wear rings <5>. Listen for screeching. If necessary apply grease.
Type of grease:
Mobilgrease FM 102
Optimol Obeen UF 2
Volume:
0.5 ml
Interval 4,000 hrs or 2 Years
Check surface of tube <10> for cracks or damages.
Check the distance between the wear ring holders <11>.
Normal dimension should be 126 mm. If distance is less than 124 mm, the ring is
worn out and must be replaced, see Figure 37.
If necessary, replace parts as described in Chapter 6, Repairs in this manual.
126 mm
Figure 37 Wear Ring Holder Distance
5.2.6
Substitute greases
Robots installed in application that not requires FDA approwed grease can use greases
stated below as substitute (the grease should be of type NLGI 2):
Type of grease:
Mobilgrease SpecialMobilegrease XHP
222
Olista Longtime 2Optimol Longlife PD 2
5.2.7
Joint Balls
Check surface of joint balls <13, 14> for cracks or burrs. If necessary replace the part
as described in Chapter 6, Repairs in this manual.
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Product Manual
Maintenance
5.2.8
Upper Arms
Check the surface of tube <12>, no cracks.
If necessary exchange the part as described in Chapter 6, Repairs in this manual.
5.2.9
Hoses
Interval 500 hrs
Check the entire hose <6> so that there are no folds or surface damage.
If necessary exchange the part as described in Chapter 6, Repairs in this manual.
5.2.10 Spring Units
Check the roller <7> for wear.
If necessary exchange the part as described in Chapter 6, Repairs in this manual.
5.2.11 Movable Plate with Swivel
Check the axis rotation joint <15> so that the rotation is smooth.
If necessary, replace the part as described in Chapter 6, Repairs in this manual.
5.2.12 Gearboxes, Axes 1-3
Interval 4,000 h or 2 Years
Check for backlash in outgoing shafts <17>. Total backlash should be < ±0.0167o
(1 minute of arc).
If necessary exchange the part as described in Chapter 6, Repairs in this manual.
Interval 12,000 hrs or 3 Years
Oil should only be changed after the first 12,000 h.
Change the oil as follows.
Type of oil:
Mobil DTE FM 220
Volume:
0.9l (per gearbox)
Drain the Gearbox, alt. No. 1:
• Unscrew base cover.
Product Manual
65
Maintenance
• Remove oil plugs (see Figure 38).
Motor/gear box for axis 4
must be removed
Oil plug (3x)
Serial measurement
board must be removed
Figure 38 Location of Oil Plugs.
• Suck up the oil with a smooth hose.
• The oil is filled through the plug holes, with specified volume.
• Mount base cover.
Drain the Gearbox, alt. No. 2:
• Remove the transmission cover and arms.
• The oil is drained through the lower drain plug <18> holes (see Figure 39).
• The oil is filled through the upper plug holes, with specified volume.
• Mount transmission cover and arms.
• Calibrate axes 1-3, as described in Repairs chapter, section in this manual.
5.2.13 Manipulator Fan
Interval 30,000 hrs or 5 Years
Check roller bearings.
If necessary, replace the part as described Chapter 6, Repairs in this manual.
66
Product Manual
Maintenance
5.2.14 Location of Maintenance Points
16
19
5, 11 (12x)
12 (3x)
13
3
4 (2x)
14
6
1
7
10
8
2 (2x)
9 (2x)
Upper oil plug
15
Lower oil plug, 18
17
Figure 39 Maintenance Points.
Product Manual
67
Maintenance
5.2.15 Changing the Battery in the Measuring System
The robot is delivered with a 3-cell lithium battery. The lithium battery of primary
type, needs no charging. For this reason there is a blocking diode, which prevents
charging from the serial measurement board.
The battery to be replaced is located under the cover in the base box.
(See Figure 40).
• Set the robot to the MOTORS OFF operating mode. (This means that it will not
have to be coarse-calibrated after the change.)
• Loosen the battery terminals from the serial measuring board and cut the clasps
that keep the battery unit in place.
• Install a new battery with two clasps and connect the terminals to the serial
measuring board.
Used batteries must never be thrown away! They must be handled as hazardous waste!
The length of life of the Lithium Battery
The battery is used as a back-up when the robot system is switched off. Hence the life
of a lithium battery depends on how frequently the power to the system is switched off
and also if the environment temperature is higher than recommended operating
temperature.
The length of life of the lithium battery varies from 12 - 36 months, depending on
current situations. An alert is given on the TPU when the battery is nearly discharged
and must then be replaced within a month.
Battery
Figure 40 The Battery is located Inside the Base Box.
Lithium battery available:
- A 3-cell battery, art. No. 3HAB 9999-1
68
Product Manual
Maintenance
Voltage of batteries, measured at power off:
Tabell 12
Lithium
Min.
Max.
7.0 V
12.0 V
The battery is replaced as described in the first paragraph of this section.
Product Manual
69
Maintenance
5.3
Cleaning of Robot
The manipulator is tested to fulfil IP55 (Standard) and IP 67 (Wash Down, Stainless
Wash Down) according to IEC 529.
The test is performed under the following conditions:
IP55
The capping is sprayed with water from all possible angles with a nozzle.
- Nozzle inside diameter: 6,3 mm.
- Water flow: 12,5 l/min. ± 5%.
- Water pressure to be adjusted to achive the specified delivery rate.
- Test time / m² of the capping area: 1 min.
- Shortest test time: 3 min.
- Distance from the nozzle to the capping: approx. 3 m.
IP67
The capping is lowered into water to fulfil the following conditions.
- The water surface should be min. 150 mm above the highest part of the
capping.
- The lowest part of the capping should be at least 1 m below the water surface.
- The length of the test should be at least 30 min.
- The water temperature should not deviate more than 5°C from the
temperature of the material. This requirement could be changed by the
technical committee in question if the test is to be done when the material is
powered or in motion.
5.3.1
Standard Cleaning
The standard version of IRB 340 is not manufactured for wash down applications and
should only be cleaned by wiping off the dirt and dust using a dry or moistened cloth.
5.3.2
Wash Down Cleaning
Note! This applies for IRB 340 SA, and IRB 340 SAS, Wash Down version.
70
1.
Flush with water max. 60°C, low pressure, see Figure 41 for sensitive points.
2.
Foam with “P3-Topax 12” with a concentration of approximately 3% depending
on the type of dirt. The water temperature should be 40-60°C. The solvent should
be applied to the whole external surface.
3.
Wait about 15 minutes so the solvent takes effect. To retain effective cleaning properties, ensure that the solvent does not dry on the surface.
4.
Flush thoroughly with water.
Product Manual
Maintenance
5.
Apply the disinfectant, we recommend “P3-Topax 99”. Time, concentration, and
water temperature are chosen to reach the desired effect.
- Concentration = 1-2%
- Temperature = 10-40°C
- Time approx. 20 min.
6.
Flush thoroughly with water. Sealings and joints should be lubricated after
cleaning, for good functionality.
Be careful flushing sealings.
After cleaning bearing races and
“swivel cup” sealing, lubricate them
with provision classified grease.
Due to the risk of damaging the roller
bearing do not clean with any detergent
when the “swivel cup” is removed. Only
use a moistened cloth.
Figure 41 Sensitive Points
Product Manual
71
Maintenance
72
Product Manual
Repairs
6
6.1
Repairs
General Description
IRB 340 are avalailable in the following versions:
Table 13
Pay load
Standard
WashDown
WashDown
Stainless
1 kg
IRB 340
IRB 340 SA
IRB 340 SAS
2 kg
IRB 340/2
IRB 340 SA/2
IRB 340 SAS/2
The industrial robot system IRB 340 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 for longevity. 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.
Product Manual
73
Repairs
The Mechanical System is available in six version. All versions are equipped with 4
axes, enabling the flexible robot motions.
Axis 1
Axis 3
Axis 4
Axis 2
TCP
Figure 42 The Robot Axes and Working Space.
Axis No. 1, 2 and 3 moves the end effector parallel with the working surface.
Axis No. 4 is a telescopic shaft that rotates the tool.
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 Button should be connected as indicated in Chapter, Installation
and Commissioning, (See Product Manual for S4Cplus or IRC5) to enable
movements of the axes. See also Section 4.2.5 Manually engaging the Brakes in this
manual.
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 manual must be complied with at all times.
6.1.1
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. Re-calibration 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 Section 6.8
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Product Manual
Repairs
Calibration.
IMPORTANT! 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 as described in this chapter, Section 6.8.2 Checking the Calibration Position. If a calibration fault is discovered, the robot must be re-calibrated as
described in Section 6.8 Calibration.
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.
Foldouts. In the Spare Parts chapter which can be found in the “Reference
Information” part 2 of this manual, there are a number of foldouts 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 foldouts. The foldouts are referred to in the Manual text within “arrow heads”
(< >) as exploded view numbers. Where reference is made to foldouts, other than
those specified in the paragraph title, the foldout number is included in the item
number reference, for example <5/19> or <10:2/5>, the digit(s) before the stroke
referring to the foldout number.
Numbers in brackets ( ) refer to figures in the text.
The foldouts also include information such as article number, designation and relevant
data.
N.B. 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.
6.1.2
Caution
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.
6.1.3
Mounting Instructions for Bearings and Seals
Bearing Rings
1.
Let a 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.
3. The bearing must be greased after fitting. The main reason for this is the
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Repairs
requirement for cleanliness and a minimum of wear.
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.
Seals
1.
The most common cause of leakage is incorrect fitting.
Rotating Seals
2. The sealing surfaces should be protected during transport and mounting.
3. The seal should be kept in the original wrappings or be well protected.
4.
Sealing surfaces must be inspected before mounting. If scratches or damage are
found, that may result in future leakage, the seal must be replaced.
5. 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.
6.
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. The rubber coated external diameter
must also be greased.
7.
The fitting of seals and gears must be carried out on clean workbenches.
8. Mount the seal correctly. If it is misaligned, there is a risk of leakage due to the
pumping effect.
9. Always mount the seal with a mounting tool. Never hammer directly on the seal,
as this may result in leakage.
10. Use a protective sleeve for the sealing lip during mounting, when sliding over
threads, key ways, etc.
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Repairs
Flange Seals and Static Seals
11. 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).
12. 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.
13. The surfaces must be properly cleaned in accordance with ABB’s
recommendations.
14. Distribute the sealing compound evenly over the surface, preferably with a brush.
15. Tighten the screws evenly when fastening the flange joint.
O-rings
16. Check the O-ring grooves. The grooves must be geometrically correct and free
from pores and contamination.
17. Check the O-ring with regard to surface defects, burrs, shape accuracy, etc.
18. Ensure that the correct O-ring size is used.
19. Tighten the screws evenly when assembling.
20. Defective O-rings and O-ring grooves must not be used.
21. Fitting defective parts will result in leakage. Grease the O-ring with lubricant
before mounting.
6.1.4
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.
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Repairs
Screws treated with Gleitmo (lubricated)
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 fastening 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 be
lubricated between the washer and the head of the screw.
Screws must be tightened with a torque-wrench.
Screw Joints locked with Loctite
When Loctite is used in screw joints, always follow recommendations from Loctite,
regarding the time it takes for a joint locked with Loctite to harden before the
equipment can be used.
Disassembly of Joints locked with Loctite
When dissassembling a screw joint locked with Loctite, heat up the screw joint to
approximately 100°C before dismounting. Follow recommendations from Loctite!
6.1.5
Tightening Torques
Collar Screw
Tabell 14
Tightening torque - Nm
Dimension
Class 8.8
Coated with zinc, dry
M6
9.0
Torx Screw
Tabell 15
Tightening torque - Nm
78
Dimension
Class 8.8
Gleitmo 610
Molycote 1000
M6
7.0
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Repairs
Screws with Hexagon Socket Head
Tabell 16
Tightening torque - Nm
Dimension
Class 8.8
Molycote 1000
Gleitmo 610
M4
Class 12.9
Molycote 1000
Gleitmo 610
Class 8.8
Oil
Loctite
2.8
M6
7
M8
17
M 10
33
11
Special Screws
Tabell 17
Tightening torque - Nm
6.1.6
Dimension
Loctite
Location
M8
11.0
Ball joints
M12
20
Swivel
M12
18
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! The play in the brake disk does not affect the robot motion or accuracy.
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Repairs
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6.2
6.2.1
Axis 1, 2 and 3
Replacing Motor/Gearbox Unit
Refer to foldout Nos. 3 and 4.
Dismounting
1. Remove the parallel arms according to this chapter 6.5.1.
2.
Dismount the upper arms according to Section 6.2.3 Replacing the Upper Arm in
this chapter.
3. Dismount telescopic shaft according to Section 6.3.3 Replacing the Telescopic
Shaft.
4.
Remove flange cover <3/16>.
5. Dismount the transmission cover <10>.
6. Unscrew screws <4/38> for the base cover <4/33>.
7. Disconnect the cable for the fan, contact R4.FAN, and the manipulator cables.
8. Remove the base cover.
9. Disconnect the motor cabling.
If motor/gearbox for axis 3 is to be dismounted axis 4 must be dismounted first
(see this chapter, Section 6.3.1 Replacing Motor/Gearbox Unit).
If motor/gearbox for axis 2 is to be dismounted axis 4 and the serial
measurement board must be removed first (see this chapter, Section 6.3.1
Replacing Motor/Gearbox Unit and Section 6.6.2 Replacing the Serial
Measurement Board).
10. Unscrew screws <3/5> and remove the motor/gearbox unit.
Mounting
11. Place the motor/gearbox in position, 2 guide pins.
12. Mount the unit with screws <3/5> and washers <3/4>. Tightening torque 33 Nm.
13. Connect the motor cabling.
14. Remount the transmission cover <3/10> with screws >3/9>, torque 9 Nm.
15. Remount flange cover <3/16> and telescopic shaft.
16. Connect the cable for the fan, R4.FAN.
17. Tighten screws <4/38> for the base cover <4/33> with torque 14 Nm.
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81
18. Mount the upper arm according to 6.2.3 in this chapter.
19. Mount the parallel arms according to Section 6.5.1 Replacing Parallel Arms in
this chapter.
20. Calibrate the robot as specified in this chapter, Section 6.8 Calibration.
Tightening Torque
Screw joint motor unit/base box, item <3/5>:33 Nm
Screw joint base cover/base box, item <4/38>:14 Nm
Screws for transmission cover, item <3/10>: 9 Nm
6.2.2
Exchange of Motor or Gearbox
Motor
1. Remove the transmission cover according to this chapter, 6.2.1.
2.
Drain the gearbox according to Section 5.2.12 Gearboxes, Axes 1-3 in this
chapter.
3.
Unscrew the three screws (1) holding to motor to the gearbox (see Figure 43).
1
Figure 43 Motor and Gearbox Axes 1-3.
4.
82
Remove the motor.
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5.
Mount O-ring (2) onto the motor flange (see Figure 44).
1
3
2
Figure 44 Mounting of Motor Axes 1-3.
6.
Insert the new motor, do not tighten the screws (1).
7. Remount the upper arm temporarily, to be used to feel the backlash.
8. Push the motor gently downwards with help of a screw driver at the same time as
you feel for the backlash by moving the upper arm back and forward.
9. Tighten the screws (1) with torque 11 Nm.
10. Check through the upper oil level hole that gear wheel (3) is axially movable
(see Figure 44).
11. Fill the gearbox with oil according to Section 5.2.12 Gearboxes, Axes 1-3 in this
chapter.
12. Remount transmission cover according to 6.2.1 in this chapter.
13. Calibrate the robot as specified in this chapter, Section 6.8 Calibration.
Gearbox
14. Dismount the motor/gear unit according to this chapter, 6.2.1.
15. Follow points 2. to 11. above.
16. Remount the unit (motor/gearbox) according to this chapter, 6.2.1.
17. Calibrate the robot as specified in this chapter, Section 6.8 Calibration.
6.2.3
Replacing the Upper Arm
Refer to foldout No. 1 and 3.
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83
Dismounting
1.
Unscrew screws <3/19>.
2.
Remove the flange cover/flange axis 1-3 <3/16>.
3.
Remove the parallel arms <1/1> according to this chapter, Section 6.5.1
Replacing Parallel Arms in this chapter.
4.
Remove the VK-cover <3/42>. Knock a screw driver or similar through the
VK-cover and bend it out. A new cover must be mounted back.
5.
Unscrew screws <3/41>.
6.
Pull the upper arm <3/40> out.
Mounting
7.
Mount the flange cover/flange axis 1-3 <3/16> onto the upper arm shaft. Make
sure that the sealing ring <3/17> is in the right position on the shaft.
NOTE! Flange axis 1-3 art.no. 3HAC021118-001 is designed to work as a
mechanical stop on the upper arm. This flange shall only be mounted on upper arm
art.no. 3HAC021121-001! It shall not be used on upper arm art.no. 3HAC2078-1! On
this upper arm, use flange cover art.no. 3HAC4250-1.
8. Place the upper arm <3/40> in position, on the guide pin.
9.
Tighten screws <3/41> with torque 11 Nm.
10. Tighten screws <3/19> with torque 9 Nm.
11. Remount the parallel arms according to this chapter, Section 6.5.1 Replacing
Parallel Arms in this chapter.
Tightening Torque
Screw joint upper arm/gearbox, item <3/41>:7 Nm
Screw joint flange cover/gearbox, item <3/19>:9 Nm
6.2.4
Replacement of Joint Balls
Refer to foldout No. 1.
Dismounting
1.
Remove the parallel arms according to this chapter, Section 6.5.1 Replacing
Parallel Arms in this chapter.
2.
Unscrew the joint balls <6> in the upper arm.
Mounting
3. Mount new joint balls, torque 11 Nm. Use Loctite 243.
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4. Mount parallel arm system according to this chapter, Section 6.5.1 Replacing
Parallel Arms.
Tightening Torque
Joint balls/upper arm, item <6>:11 Nm
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6.3
6.3.1
Axis 4
Replacing Motor/Gearbox Unit
Refer to foldout numbers. 1, 3 and 4.
Dismounting
1.
Remove base cover <4/33>, screws <4/38>.
2.
Disconnect the cable for the fan, contact R4.FAN, and the manipulator cables.
3.
Disconnect the motor connectors, R3.FB4 and R3.MP4.
4.
Loosen the set screw <1/12> at the upper coupling on the telescopic shaft.
5.
Unscrew screws <3/24>.
6.
Remove the motor/gearbox <4/22>.
Mounting
7.
Mount motor and gearbox with screws <3/24>, tightening torque 9 Nm.
8.
Remount the telescopic shaft, lock with set screw <1/12> and Loctite 243,
tightening torque 4 Nm.
9.
Connect the cables to the motor.
10. Connect the cabling and mount cover <4/33> with screws <4/38>, tightening
torque 14 Nm.
11. Calibrate the robot as specified in this chapter, Section 6.8 Calibration.
Tightening Torque
Screw joint motor/basebox, item <3/24>:9 Nm
Screw joint base cover/basebox, item <4/38>:14 Nm
6.3.2
Exchange of Motor or Gearbox
Motor
1.
Remove motor/gearbox unit according to this chapter, Section 6.3.1 Replacing
Motor/Gearbox Unit.
2.
Knock a screw driver or similar through the VK-cover (2) and bend it out. A new
cover must be mounted (see Figure 45).
3.
Pour out the oil.
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87
4.
Unscrew screws (1) and remove the motor.
Loctite 243
2
1
6
3+Loctite 243
5
Motor pinion
4
Sealing ring
Figure 45 Motor/Gear Unit Axis 4.
5.
Open screw (3) a bit and wind the gear (5) down.
6.
Mount O-ring (4) in the gear house.
7.
Mount the motor with screws (1), tightening torque 9 Nm.
8.
Rotate gear (5) upwards so that there is no play between the gears.
9.
Ensure that the gear is kept absolutely still. Apply Loctite 243 and tighten the
screw (3), torque 9 Nm.
10. Check the play again.
11. Apply Loctite 243 to lock the shaft (see Figure 45).
12. Calibrate the robot as specified in this chapter, Section 6.8 Calibration.
13. Fill the gearbox with oil to the centre of the motor pinion (see Figure 45).
14. Unscrew screws (6) so that the sealing ring does not pop out when mounting the
VK cover (2)
Note! Do not forget to carry out No. 15 and 16 below.
15. Mount the new VK cover (2).
16. Mount screws (6).
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Product Manual
Tightening Torque
Screw joint motor/gearbox, item (1)9 Nm
Locking screw, item (3)9 Nm
6.3.3
Replacing the Telescopic Shaft
Refer to foldout numbers 1 and 3.
Dismounting
1.
Lift up the seal ring (v-ring) and unscrew the lower set screw <1/12>.
2.
Unscrew the upper set screw <1/12>, see Figure 46.
3.
Push the shaft together and remove it.
Set Screws
Figure 46 Set Screws
Mounting
The set screws for the telescopic shaft must be tightened as described below,
otherwise there is a risk of the shaft becoming loose and damaging the arms and
causing personal injuries.
4.
Tighten set screws <1/12> with torque 4 Nm. Use Loctite 243.
5.
Press the seal ring back in place.
Note! Do not press the seal down too hard because this will cause heavy wear,
see Figure 47.
6.
Product Manual
Calibrate axis 4 as described in this chapter, Section 6.8 Calibration.
89
Push against
chamfer (9 mm)
Figure 47 Seal Ring.
6.3.4
Replacing the Plain Bearings, Washdown and Stainless Versions
Note!
The following procedure of replacing the plain bearings, is not
recommended to
be performed by others than ABB. It
requires special skills and special tools.
90
1.
Remove the telescopic shaft as described in this chapter, Section 6.3.3 Replacing
the Telescopic Shaft.
2.
Unscrew the nuts (1) gently (see Figure 48).
3.
Before dismounting the components, heat them up to at least 150°C. This will
make it easier to disassemble parts locked with Loctite.
4.
Disassemble the components apart.
5.
Remove the three plain bearings in each bearing holder (see Figure 48).
6.
Replace with new plain bearings. Ensure that the small notch is located so it fits in
the hole.
7.
Before applying adhesive, clean the parts with Loctite 7063 Super Clean and let it
dry.
8.
Apply Loctite 7649 Activator and let it dry.
Product Manual
9.
Apply Loctite 620.
10. Assemble the parts of the telescopic shaft. Torque 4 Nm. Check that the bars are
parallel. The orientation of universal joints are crucial. Joints must be “in-line”!
Notify that this is controlled when mounting shaft-pivots D11 and D12. The M5
hole on these must be perpendicularly mounted!
11. Check that the movement of the telescopic shaft is smooth along its whole length.
12. Remount the telescopic shaft as described in this chapter, Section 6.3.3 Replacing
the Telescopic Shaft.
1
1
Plain bearing
Hole with notch
Figure 48 Plain Bearings, Wash Down and StainlessVersion.
Tightening Torque
Nuts, telescopic shaft, item (1):4 Nm
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6.4
6.4.1
Movable Plate with Swivel
Dismounting Movable Plate
Refer to foldout No. 1
Dismounting
1.
Remove the lower end of the telescopic shaft as described in this chapter,
Section 6.3.3.
2.
Pull the parallel arms apart by hand or use tool 3HAC 6194-1, and remove the
plate.
Mounting
6.4.2
3.
Mount the movable plate by pulling the parallel arms apart by hand or use tool
3HAC 6194-1.
4.
Mount the lower end of the telescopic shaft according to this chapter,
Section 6.3.3.
Replacement of Joint Balls
Refer to foldout No. 1.
Dismounting
1.
Dismount movable plate according to Section 6.4.1 above.
2.
Unscrew joint balls <6>.
Mounting
3.
Mount new joint balls, torque 11 Nm. Use Loctite 243.
4.
Mount movable plate according to Section 6.4.1 above.
Tightening Torque
Joint balls/movable plate, item <6>:11 ±1 Nm
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6.5
6.5.1
Parallel Arm System
Replacing Parallel Arms
Refer to foldout No. 1.
Dismounting
1.
Remove the vacuum hose from the arm system.
2.
Use tool 3HAC 6194-1 (or by hand), and pull the arms apart in both ends
(see Figure 49).
Figure 49 Parallel Arms with Spring Units.
3.
Remove the arms.
Mounting
4.
6.5.2
Mount in reversed order.
Replacing the Spring Unit
Refer to foldout No. 1.
Dismounting
1.
Remove the affected arm system according to Section 6.5.1 above.
2.
Push the bar as shown in Figure 50.
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95
Rollers (x4)
Figure 50 Removing the Spring Unit.
3.
Take out the rollers (see Figure 50).
4.
Remove the spring unit.
5.
Both sides identical.
Mounting
6.5.3
6.
Place the spring unit in position.
7.
Mount the rollers onto the pin (see Figure 50).
8.
Pull the arm backwards into position.
9.
Mount back the arm system according to Section 6.5.1 above.
Exchange of Wear Rings
Refer to foldout No. 1
Dismounting
1.
Remove the parallel arm according to Section 6.5.1 above.
2.
Insert a screw driver, and bend carefully the wear ring out (see Figure 51).
Mounting
3.
96
Place a new wear ring into the joint socket (see Figure 51).
Product Manual
4.
Place the arm bar in dolly 3HAC 4182-1.
5.
Put drifter 3HAC 4184-1 into the wear ring and knock it gently down to its
position.
6.
Apply grease according to Maintenance chapter in this manual.
Drifter 3HAC 4184-1
Wear ring
Dolly 3HAC 4182-1
Figure 51 Exchange of Wear Rings.
7.
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Mount the parallel arms according to Section 6.5.1 above.
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6.6
6.6.1
Cabling
Dismounting the Complete Cabling
Refer to foldout No. 5.
Dismounting
1.
Remove the base cover according to first points in this chapter, Section 6.3.1
Replacing Motor/Gearbox Unit.
2.
Make a note or small drawing of the location of the cabling.
3.
Cut all the straps holding the cabling.
4.
Disconnect all contacts.
5.
Dismount the transmission cover according to the first points in this chapter,
Section 6.2.2 Exchange of Motor or Gearbox.
6.
Disconnect the cables for the warning lamp and brake release button.
Mounting
7.
In reversed order.
Note!
Make sure that no cables are in the marked area according to foldout 5.
See Foldouts in “Reference Information”.
6.6.2
Replacing the Serial Measurement Board
Refer to foldout numbers 4 and 5.
Note!
When working with the serial measurement board it is important that a wrist
strap is used, to avoid ESD faults.
Dismounting
1.
Remove base cover <4/33>, screws <4/38>.
2.
Disconnect the cable for the fan, contact R4.FAN, and the manipulator cables.
3.
Disconnect the contacts connected to the board.
4.
Loosen the screws holding the board and remove it.
Mounting
5.
Product Manual
Mount in reversed order.
99
6.6.3
Replacing Pushbutton Unit and Warning Lamp
Refer to foldout numbers 3 and 5.
Dismounting
1.
Remove the parallel arm system according to this chapter, Section 6.5 Parallel
Arm System.
2.
Remove the upper arms according to this chapter, Section 6.2.3 Replacing the
Upper Arm.
3.
Dismount the transmission cover <3/10>, screws <3/59>.
4.
Disconnect and unscrew the push button or lamp unit.
Mounting
5.
6.6.4
Mount in reversed order.
Replacing the Fan
Refer to foldout No. 4.
Dismounting
1.
Remove the ventilation connection <46>, screws <19>.
2.
Remove the base cover <33>, screws <38>.
3.
Remove the fan cover <37>, screws <60>.
4.
Disconnect the cable <35>, R4.FAN.
5.
Unscrew screws <36> and remove the fan <34>.
Note! One of the screws <36> is hidden under the ventilation gasket.
Mounting
6.
100
Mount in reversed order.
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6.7
6.7.1
Vacuum System
Dismounting Ejector Unit
Refer to foldout numbers 1 and 6.
Dismounting
1.
Disconnect the air supply, vacuum hoses and signal cable.
2.
Loosen the air filter plate <6/2>, screws <6/8>.
3.
Unscrew screw <1/19>.
4.
Lift out the ejector unit <6/1>.
Mounting
5.
6.7.2
Mount in reversed order.
Exchange of Hoses
Dismount and mount according to foldout No. 6.
1.
Open straps <12>.
2.
Pull the hose out from the swivel
3.
Pull the hose out from the air filter.
4.
Mount a new hose on the swivel.
5.
Fix the hose, do not tighten, against the three clamps <11> on the parallel arm.
6.
Twist the hose and mount it on the air filter.
7.
Then adjust the hose according to foldout no. 6.
8.
Tighten the straps.
9.
Make a small program (low velocity) and check that the hose runs freely.
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6.8
6.8.1
Calibration
General
The robot measurement system consists of one feedback unit for each axis and a
measurement board that continuously keeps track of the current robot position.
The measurement board memory has a battery backup.
If any of the resolver values has been changed, the measurement system must be
carefully calibrated (as described in Section 6.8.4 Fine Calibration). This can happen
when:
- Parts affecting the calibration position have been replaced on the robot.
The system needs to be roughly calibrated (as described in Section 6.8.5 Updating
Revolution Counter) if the contents of the revolution counter memory are lost. This
may happen when:
- The battery is empty.
- A resolver error occurs.
- The signal between a resolver and measurement board is interrupted.
- A robot axis has been moved with the control system disconnected.
6.8.2
Checking the Calibration Position
Before any programming of the robot system can begin, a check of the calibration
position must be made. There are two ways to check the calibration position.
A. Using the program CAL340 in the system software:
1.
Run the program \ SYSTEM \ UTILITY \ SERVICE \ CALIBRAT \ CAL340 in
the system and follow the instructions displayed on the teach pendant.
2.
When the robot stops, switch to MOTORS OFF. Check that the calibration marks
for each axis are at the same level, see Figure 57. If they are not, the setting of the
revolution counters must be repeated.
3.
Check resolver offset values in system parameters.
B. Using the Jogging window on the teach pendant:
Open the Jogging window
2.
Using the joystick, move the robot so that the read-out of the position is equal
to -13.19°.
3.
Check that the calibration marks for each axis are at the same level, see Figure 57.
If they are not, the setting of the revolution counters must be repeated.
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and choose running axis-by-axis
1
2
1.
.
103
6.8.3
Fine Calibration Procedure on the Teach Pendant
1.
Press
and select the Service window (see Figure 52) by pressing
7
4
1
1
2
P1
8
5
2
0
.
9
6
3
P2
P3
Figure 52 The Misc. Window Key from which the Service Window can be chosen.
2.
Choose Calibration from the View menu.
The calibration window (see Figure 53) appears.
If there is more than one unit connected to the robot,
they will be listed in the window.
The calibration status can be any of the following:
- Synchronised
All axes are calibrated and their positions are
known. The unit is ready for use.
Figure 53 Calibra-
- Revolution Counter not updated
All axes are fine-calibrated but one (or more) of the axes has a counter that is
NOT updated. This axis, or these axes, must therefore be updated as described
in Section 6.8.5 Updating Revolution Counter.
- Not calibrated
One (or more) of the axes is NOT fine-calibrated. This axis, or these axes,
must therefore be fine-calibrated as described in Section 6.8.4 Fine Calibration.
3.
Select the desired unit and choose Fine
Calibrate from the Calib menu. A Warning
window (see Figure 54) appears.
4.
Place the manipulator in its calibration position
and press OK. The Fine Calibrate window (see
Figure 55) appears.
5.
Select the desired axis and press Incl to
include it (it will be marked with an x) or press
All to select all axes.
6.
When all axes that are to be updated are marked
with an x, press OK.
Cancel returns to the Calibration window (see
104
Figure 54 Fine
Calibra-
Figure 55 Fine
Product Manual
Figure 53 Calibration Window).
7.
Press
OK again to confirm and start the update.
Cancel returns to the Fine Calibrate window (Figure 54).
An alert box is displayed during calibration. The Status window appears when the fine
calibration is complete. The revolution counters are always updated at the same time
as the calibration is performed.
6.8.4
Fine Calibration
Adjust the axes in increasing sequence, that is, 1 - 2 - 3 - 4, and one at the time.
Axis 1, 2 and 3.
See Figure 56.
1.
Select the MOTORS OFF mode.
2.
Remove the bar system according to this chapter, Section 6.5 Parallel Arm System.
3.
Remove cover (see Figure 56).
4.
Mount calibration tool art. No. 3HAC 9596-1. Do NOT tighten the screw!
5.
Release the brakes and push the upper arm towards the tool.
6.
Position the tool correctly and tighten the screw.
7.
Release the brakes again and push the upper arm very gently against the tool.
8.
When joint ball reaches tool apply the brake.
9.
The upper arm is now in calibration position.
10. Update only axis 1, as described in Section 6.8.3 Fine Calibration Procedure on
the Teach Pendant.
11. Continue with the other two remaining axes in the same way, follow point 3 - 10.
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105
F
D
E
H
G
A
B
C
Figure 56 Calibration Positions for Axes 1-3.
Table 18
Components in Figure 15
A
Tool 3HAC 9596-1
B
Joint ball
C
Upper arm
D
Nut
E
Pin
F
Correct angle = -13,19º
G
Cover
H
Label
Axis 4
1.
106
Mount the bar system according to this chapter, Section 6.5 Parallel Arm System
and axis 4 according to this chapter, Section 6.3 Axis 4.
Product Manual
2.
Run axis 4 with the joystick so that the calibration marks is in line, see Figure 57.
3.
Update only axis 4, as described in Section 6.8.3 Fine Calibration Procedure on
the Teach Pendant.
4.
Check the calibration position as described in Section 6.8.2 Checking the Calibration Position.
5.
The system parameters will be saved to the storage memory at power off.
6.
Change the values on the label, located in the base box under the plate for the
manipulator cables (see Figure 56).
Axis 1, 2 and 3
The pin should be
inside the nut
Nut
Pin
Axis 4
Marks should be
in line.
Mark
Figure 57 Calibration Marks on the Manipulator.
6.8.5
Updating Revolution Counter
When starting up a new robot, you may receive a message telling you that the
manipulator is not synchronised. The message appears in the form of an error code on
the teach pendant. If you receive such a message, the revolution counter of the
manipulator must be updated using the calibration marks on the manipulator. See
Figure 57.
Examples of when the revolution counter must be updated:
- When the battery unit (on the manipulator) is empty.
- When there has been a resolver error.
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107
- When the signal between the resolver and the measuring system board has
been interrupted.
- When one of the manipulator axes has been manually moved, while the controller is disconnected.
If the resolver values must be calibrated, this is described in Section 6.8.4 Fine
Calibration.
Working in the robot work cell is dangerous.
Press the enabling device on the teach pendant and, using the joystick, move the robot
manually so that the calibration marks lie within the tolerance zone (see Figure 57).
When all axes have been positioned as above, the revolution counter settings are
stored using the Teach Pendant Unit, as follows:
1.
Press
and select the Service window (see Figure 52) by pressing
7
8
9
4
1
5
2
0
6
3
1
2
P1
.
P2
P3
Figure 58 The Misc. Window Key from which the Service Window can be chosen.
2.
Choose Calibration from the View menu.
The calibration window (see Figure 59) appears.
If there is more than one unit connected to the robot,
they will be listed in the window.
Figure 59 Calibra-
3.
Select the desired unit and choose Rev.
Counter Update from the Calib menu. The
Revolution Counter Update window (see
Figure 60) appears.
4.
Select the desired axis and press Incl to
include it (it will be marked with an x) or press
All to select all axes.
5.
When all axes that are to be updated are marked with an x, press
Figure 60 Revolution
OK.
CANCEL returns to the Calibration window (Figure 59 Calibration Window).
6.
Press
OK again to confirm and start the update.
CANCEL returns to the Revolution Counter Update window (Figure 60).
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Product Manual
If a revolution counter is incorrectly updated, it will cause incorrect positioning.
Thus, check the calibration very carefully after each update. Incorrect updating
can damage the robot system or injure someone.
7.
6.8.6
Check the calibration as described in Section 6.8.2 Checking the Calibration Position.
Calibration Equipment
Axis 1 -3
Product Manual
3HAC 9596-1
Sync fixture for axis 1, 2 and 3
109
110
Product Manual
6.9
Corrective action in case of a collision
If a collision occurs with the robot, please inspect the following parts!
6.9.1
6.9.2
Overview
1.
Due to the fact that mechanical problems have occurred during manually moving
and/or crashing with the manipulator, there are some things that has to be taken in
consideration when performing service. If not, both manipulator and peripheral
equipment, such as conveyors, may be affected.
2.
Parts needed in case of a collision, are specified in the Spare Parts list for the
manipulator. They are specially designed as Spare parts for Collision Maintenance. Under “Remark” the quantity of these parts are written in bold and underlined. Ex. Qty. 6. See also, Spare Parts 1.6 Collision Maintenance Parts in
“Reference Information”.
Telescopic Shaft
1.
Verify that the 6 bars of the telescopic shaft are parallel.
2.
If they appear to be twisted, remove the telescopic shaft from the robot by loosening the setscrews.
3.
Use a heat gun to loosen the setscrews. They are locked with Loctite 243.
4.
Loosen the nuts and reset the bars back to being parallel.
5.
Retighten the nuts.
6.
Check that there is a smooth operation of the bars all the way, after each nut has
been tightened.
7.
If the bars are bent and adjustment isn´t possible, replace the telescopic shaft!
8.
After replacing the telescopic shaft, apply Loctite 243 to the setscrews.
9.
Tighten the setscrews to a torque of 4 Nm.
10. Wait 3 hours for the loctite to dry, before running the robot!
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111
6.9.3
6.9.4
6.9.5
112
Spring Units
1.
Check that the six spring units are OK.
2.
Make sure that the forks not are bent.
3.
If the forks not are absolutely straight, there is risk that the rollers are falling out.
4.
The forks has to be lined up, in order to complete the parallel shape.
5.
Make certain that the screws on each side are tight. If not, tighten them to the specification in the manual.
6.
Secure the screws with Loctite 243.
Rollers
1.
Check that all rollers are in place (24 pcs) and that they not are broken in any way.
2.
Apply new grease on the axis. Use Mobile FM 102.
3.
Check that each roller is pushed in the correct position on the fork.
Bars
1.
Inspect the bars. Look for signs of any damage after a crash.
2.
Look for loose hoses.
3.
Look for anything else that may have damaged the bars.
Product Manual
4.
6.9.6
6.9.7
Check and regrease the wear rings.
Joint Balls
1.
Check the joint balls for damage.
2.
Change them if they show any sign of damage.
Universal Joints
1.
Verify that the universal joints are running smoothly and that there is no damage.
2.
If there is any obliqueness in the universal joint, replace it.
3.
If the ball bearings are in a bad condition, replace the universal joint.
4.
Remember to heat the screw to approximately 100 degrees Celsius (212 F) at dismantling.
5.
Assemble the sealing ring (V-ring) against the ledge on the universal joint. See
Product Manual
113
Repairs chapter for more information!
114
Product Manual
6.10
Special Tools List
The need for special tools has been reduced to a minimum. When tools are needed for
dismounting/mounting work, a description is given in that section.
During the ordinary service training courses arranged by ABB, detailed descriptions
of the tools are given together with their use.
Tabell 19
Calibration
Calibration fixture
3HAC 9596-1
Arm system
Product Manual
Tool for mounting the parallel arms
3HAC 6194-1
Drifter for mounting wear rings
3HAC 4184-1
Dolly for joint socket when inserting new wear rings
3HAC 4182-1
115
116
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