ABB IRB 1400 Product Manual

Product manual
Articulated robot
IRB 1400
M2004
Product manual
3HAC021111-001
Revision: B
Articulated robot
IRB 1400
M2000
M2004
The information in this manual is subject to change without notice and should not be construed
as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in
this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be construed
as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from use of
this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
©Copyright 2004-2008 ABB All right reserved.
ABB AB
Robotics Products
SE-721 68 Västerås
Sweden
Table of Contents
0.0.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
0.0.2 Product documentation, M2000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
0.0.3 Product documentation, M2004. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1: Safety, service
13
1.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.1.1 Safety, service - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.1.2 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.1.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2: Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.1 Safety risks related to gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.2 Safety risks related to tools/workpieces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.3 Safety risks related to pneumatic/hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.2.4 Safety risks during operational disturbances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2.5 Safety risks during installation and service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.6 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.3: Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.3.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.3.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.3.3 Emergency release of the manipulator's arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.3.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.3.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.3.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.3.7 Work inside the manipulator's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.3.8 Signal lamp (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2: Installation and commissioning
31
2.0.1 Transporting and Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.0.2 Stability / Risk of Tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.0.3 System CD ROM and Diskette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.0.4 Transport Locking Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.1: On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.1.1 Lifting the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.1.2 Turning the Manipulator (Inverted Suspension Application) . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.1.3 Assembling the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.1.4 Suspended Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.1.5 Stress Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.1.6 Amount of Space required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.1.7 Manually engaging the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.1.8 Restricting the Working Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.1.9 Mounting Holes for Equipment on the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.1.10 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.2: Customer connections on manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.2.1 Air supply and signals for extra equipment to upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.2.2 Connection of Extra Equipment to the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3: Maintenance
51
3.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.0.2 Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.1: Instructions for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.1.1 Oil in gears 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.1.2 Greasing axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.1.3 Lubricating spring brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.1.4 Changing the battery in the measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.1.5 Checking the mechanical stop, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3
Table of Contents
4: Repair
59
4.1: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.1.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.1.2 Instructions for reading the following sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.1.3 Caution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.1.4 Fitting new Bearings and Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.1.5 Instructions for tightening Screw Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.1.6 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.1.7 Checking for play in gearboxes and wrist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.2: Axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.2.1 Changing the motor of axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.2.2 Changing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.2.3 Position indicator in axis 1 (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.2.4 Replacing the mechanical stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.3: Axis 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.3.1 Changing the motor of axis 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.3.2 Changing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.3.3 Dismantling the lower arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.3.4 Changing the bearings in the upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.3.5 Dismantling the balancing springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.4: Axis 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.4.1 Changing the motor of axis 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.4.2 Changing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.4.3 Dismantling the parallel arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.4.4 Changing the tie rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.4.5 Dismantling the complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.5: Axis 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.5.1 Changing the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.5.2 Changing the intermediate gear including sealing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.5.3 Dismantling the drive gear on the tubular shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.5.4 Dismantling the tubular shaft and changing bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.6: Cabling and serial measuring board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.6.1 Changing serial measuring boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.6.2 Changing the cabling in axes 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.6.3 Changing the cabling in axes 4, 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.7: The wrist and axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.7.1 Dismantling the wrist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.7.2 Dismantling the complete drive mechanism of axes 5 and 6. . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.7.3 Changing the motor or driving belt of axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.7.4 Measuring play in axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.8: Motor units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.8.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5: Calibration, M2000
99
5.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.1: Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.1.1 How to calibrate the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.1.2 Calibration, prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.2: Reference information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.2.1 Calibration scales and correct axis position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.2.2 Directions for all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.2.3 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4
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5.2.4 Positions and directions of sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.2.5 Initialization of Levelmeter 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.3: Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.3.1 Calibration axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.3.2 Calibration, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
5.3.3 Calibration, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5.3.4 Calibration, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.3.5 Calibration, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.3.6 Calibration, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5.3.7 Fine calibration procedure on TPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
5.3.8 Resetting of Levelmeter 2000 and sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
5.3.9 Updating the revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5.4: After calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.4.1 Post calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
6: Calibration information
131
6.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
6.0.2 Calibration methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
6.0.3 Calibration scales and correct axis position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
6.0.4 Calibration movement directions for all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
6.0.5 Updating revolution counters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
6.0.6 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
7: Alternative calibration
141
7.0.1 Alternative calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
7.0.2 Alternative calibrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
7.0.3 New calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
7.0.4 New calibration offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
7.0.5 Retrieving offset values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
8: Reference information, IRB 1400
147
8.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
8.0.2 Applicable Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
8.0.3 Unit conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
8.0.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
8.0.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
8.0.6 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
8.0.7 Standard toolkit, IRB 1400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
8.0.8 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
8.0.9 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
9: Spare part list
159
9.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
9.0.2 Manipulator complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
9.0.3 Arm housing, complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
9.0.4 Drive unit, axes 5-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
9.0.5 Serial measurement unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
10: Foldouts
167
10.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
11: Circuit diagram
169
11.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
11.0.2 Sheet 101 List of contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
11.0.3 Sheet 102 Connection point location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
11.0.4 Sheet 103 Serial measurement board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
5
Table of Contents
11.0.5 Sheet 104 Motor axes 1 - 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
11.0.6 Sheet 105 Feedback axes 1 - 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
11.0.7 Sheet 106 Motor axes 4 - 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
11.0.8 Sheet 107 Feedback axes 4 - 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
11.0.9 Sheet 108 Customer connection (Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
11.0.10 Sheet 109 Integrated wirefeed cabling (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
11.0.11 Sheet 110 Position indicator axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
11.0.12 Sheet 111 External connections (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
6
0.0.1 Overview
0.0.1 Overview
About this
manual
Usage
Who should read
this manual?
This manual contains instructions for
•
mechanical and electrical installation of the manipulator
•
maintenance of the manipulator
•
mechanical and electrical repair of the manipulator.
This manual should be used during
•
installation, from lifting the manipulator to its work site and securing it to the foundation
to making it ready for operation
•
maintenance work
•
repair work and calibration.
This manual is intended for:
•
installation personnel
•
maintenance personnel
•
repair personnel.
Prerequisites
A maintenance/repair/ installation craftsman working with an ABB Robot must:
•
Organization of
chapters
be trained by ABB and have the required knowledge of mechanical and electrical
installation/repair/maintenance work.
The manual is organized in the following chapters:
Chapter
Contents
Safety, service
Safety information
Installation and commissioning
Information about installation of the manipulator.
Maintenance
Information about maintenance work, including maintenance schedules.
Repair
Information about repair work.
Calibration
Information about calibration of the manipulator.
Decommissioning
Environmental information about the manipulator.
Reference
Document Id
References
3HAC021111-001 Revision: B
7
0.0.1 Overview
Revisions
Revision
Description
-
First edition.
Replaces previous product manual 3HAC 7617-1
Changes made in the material from the previous manuals:
• Model M2004 implemented.
A
Yaskawa motors included.
B
Changes made in:
• Prerequisites in section Owerview
• Oil change in section Maintenance
8
3HAC021111-001 Revision: B
0.0.2 Product documentation, M2000
0.0.2 Product documentation, M2000
General
The complete product documentation kit for the M2000 robot system, including controller,
manipulator and any hardware option, consists of the manuals listed below:
Hardware
manuals
All hardware, manipulators and controller cabinets, will be delivered with a Product manual
that is divided into two parts:
Product manual, procedures
•
Safety information
•
Installation and commissioning (descriptions of mechanical installation, electrical connections and loading system software)
•
Maintenance (descriptions of all required preventive maintenance procedures including periodicity)
•
Repair (descriptions of all recommended repair procedures including spare parts)
•
Additional procedures, if any (calibration, decommissioning).
Product manual, reference information
Software manuals
•
Reference information (article numbers for documentation refered to in Product manual, procedures, lists of tools, safety standards)
•
Part list
•
Foldouts or exploded views
•
Circuit diagrams.
The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during operation.
A complete listing of all available software manuals is available from ABB.
Hardware option
manual
Each hardware option is supplied with its own documentation. Each document set contains
the types of information specified below:
•
Installation information
•
Repair information
•
Maintenance information
In addition, spare part information is supplied for the entire option.
3HAC021111-001 Revision: B
9
0.0.2 Product documentation, M2000
10
3HAC021111-001 Revision: B
0.0.3 Product documentation, M2004
0.0.3 Product documentation, M2004
General
The robot documentation may be divided into a number of categories. This listing is based on
the type of information contained within the documents, regardless of whether the products
are standard or optional. This means that any one delivery of robot products will not contain
all documents listed, but only some of them.
However, all documents listed may be ordered from ABB. The documents listed are valid for
M2004 robot systems.
Hardware
manuals
All hardware, manipulators and controller cabinets, will be delivered with a Product manual
that is divided into two parts:
Product manual, procedures
•
Safety information
•
Installation and commissioning (descriptions of mechanical installation, electrical connections and loading system software)
•
Maintenance (descriptions of all required preventive maintenance procedures including periodicity)
•
Repair (descriptions of all recommended repair procedures including spare parts)
•
Additional procedures, if any (calibration, decommissioning).
Product manual, reference information
RobotWare
manuals
•
Reference information (article numbers for documentation refered to in Product manual, procedures, lists of tools, safety standards)
•
Part list
•
Foldouts or exploded views
•
Circuit diagrams.
The following manuals describe the robot software in general and contain reference information about it:
•
Application
manuals
RAPID Overview : An overview of the RAPID programming language.
•
RAPID reference manual part 1 : Description of all RAPID instructions.
•
RAPID reference manual part 2 : Description of all RAPID functions and data types.
•
Technical reference manual - System parameters : Description of system parameters and configuration workflows.
Specific applications (e.g. software or hardware options) are described in Application manuals . An application manual can describe one or several applications.
An application manual generally contains information about:
•
The purpose of the application (what does it do and when is it useful)
•
What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)
•
How to use the application
•
Examples of how to use the application
3HAC021111-001 Revision: B
11
0.0.3 Product documentation, M2004
Operating
Manuals
Miscellaneous
This group of manuals is aimed at those having first hand operational contact with the robot,
i.e. production cell operators, programmers and trouble shooters, and include:
•
Operating Manual - IRC5 with FlexPendant
•
Operating Manual - RobotStudioOnline
•
Trouble shooting Manual for the controller and manipulator
A number of manuals provide generic descriptions of the robot and robot system. These
include:
•
12
Robot fundamentals (describing the fundamental aspects, functions, concept and
similar, of a robot system to provide a basic understanding of the robot system)
3HAC021111-001 Revision: B
1 Safety, service
1.0.1 Introduction
1: Safety, service
1.0.1 Introduction
Definitions
This chapter details safety information for service personnel i.e. personnel performing installation, repair and maintenance work.
Sections
The chapter "Safety, service" is divided into the following sections:
1. General information contains lists of:
• Safety, service -general
• Limitation of liability
• Referenced documents
2. Safety risks lists dangers relevant when servicing the robot system. The dangers
are split into different categories:
• Safety risks related to gripper/end effector
• Safety risks related to tools/workpieces
• Safety risks related to pneumatic/hydraulic systems
• Safety risks during operational disturbances
• Safety risks during installation and service
• Risks associated with live electric parts
3. Safety actions details actions which may be taken to remedy or avoid dangers.
• Safety fence dimensions
• Fire extinguishing
• Emergency release of the manipulator´s arm
• Brake testing
• Risk of disabling function "Reduced speed 250 mm/s"
• Safe use of the Teach Pendant Unit enabling device
• Work inside the manipulator´s working range
• Signal lamp (optional)
3HAC021111-001 Revision: B
13
1 Safety, service
1.1.1 Safety, service - General
1.1: General information
1.1.1 Safety, service - General
Validity and
responsibility
The information does not cover how to design, install and operate a complete system, nor
does it cover all peripheral equipment, which can influence the safety of the total system. To
protect personnel, the complete system must be designed and installed in accordance with the
safety requirements set forth in the standards and regulations of the country where the robot
is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable safety laws
and regulations in the country concerned are observed and that the safety devices necessary
to protect people working with the robot system have been designed and installed correctly.
Personnel working with robots must be familiar with the operation and handling of the industrial robot, described in the applicable documents, e.g. User's Guide and Product Manual.
Connection of
external safety
devices
Apart from the built-in safety functions, the robot is also supplied with an interface for the
connection of external safety devices. Via this interface, an external safety function can interact with other machines and peripheral equipment. This means that control signals can act on
safety signals received from the peripheral equipment as well as from the robot.
In the Product Manual - Installation and Commissioning, instructions are provided for connecting safety devices between the robot and the peripheral equipment.
14
3HAC021111-001 Revision: B
1 Safety, service
1.1.2 Limitation of Liability
1.1.2 Limitation of Liability
General
Any information given in this information product regarding safety, must not be construed as
a warranty by ABB that the industrial robot will not cause injury or damage even if all safety
instructions have been complied with.
3HAC021111-001 Revision: B
15
1 Safety, service
1.1.3 Related information
1.1.3 Related information
General
The list below specifies documents which contain useful information:
Documents
Type of information
Detailed in document
Section
Installation of safety devices
Product manual for the manipulator Installation and commissioning
Changing robot modes
User’s Guide
Start-up
Restricting the working space Product manual for the manipulator Installation and commissioning
16
3HAC021111-001 Revision: B
1 Safety, service
1.2.1 Safety risks related to gripper
1.2: Safety risks
1.2.1 Safety risks related to gripper
CAUTION!
Ensure that a gripper is prevented from dropping a workpiece, if such is used.
3HAC021111-001 Revision: B
17
1 Safety, service
1.2.2 Safety risks related to tools/workpieces
1.2.2 Safety risks related to tools/workpieces
Safe handling
It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that guards
remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
18
Grippers/end effectors must be designed so that they retain workpieces in the event of a power
failure or a disturbance of the controller.
3HAC021111-001 Revision: B
1 Safety, service
1.2.3 Safety risks related to pneumatic/hydraulic systems
1.2.3 Safety risks related to pneumatic/hydraulic systems
General
Residual energy
Safe design
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.
3HAC021111-001 Revision: B
19
1 Safety, service
1.2.4 Safety risks during operational disturbances
1.2.4 Safety risks during operational disturbances
General
Qualified personnel
Extraordinary
risks
20
•
The industrial robot is a flexible tool which can be used in many different industrial
applications.
•
All work must be carried out professionally and in accordance with the applicable
safety regulations.
•
Care must be taken at all times.
•
Remedial action must only be carried out by qualified personnel who are familiar with
the entire installation as well as the special risks associated with its different parts.
If the working process is interrupted, extra care must be taken due to risks other than those
associated with regular operation. Such an interruption may have to be rectified manually.
3HAC021111-001 Revision: B
1 Safety, service
1.2.5 Safety risks during installation and service
1.2.5 Safety risks during installation and service
General risks
during installation and service
Nation/region
specific regulations
Non-voltage
related risks
To be observed
by the supplier of
the complete
system
•
The instructions in the Product Manual - Installation and Commissioning must always
be followed.
•
Emergency stop buttons must be positioned in easily accessible places so that the
robot can be stopped quickly.
•
Those in charge of operations must make sure that safety instructions are available
for the installation in question.
•
Those who install the robot must have the appropriate training for the robot system in
question and in any safety matters associated with it.
To prevent injuries and damage during the installation of the robot system, the regulations
applicable in the country concerned and the instructions of ABB Robotics must be complied
with.
•
Safety zones, which have to be crossed before admittance, must be set up in front of
the robot's working space. Light beams or sensitive mats are suitable devices.
•
Turntables or the like should be used to keep the operator out of the robot's working
space.
•
The axes are affected by the force of gravity when the brakes are released. In addition
to the risk of being hit by moving robot parts, you run the risk of being crushed by the
parallel arm.
•
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 heat energy in the controller.
•
Never use the robot as a ladder, i.e. do not climb on the robot motors or other parts
during service work. There is a serious risk of slipping because of the high temperature of the motors or oil spills that can occur on the robot.
•
The supplier of the complete system must ensure that all circuits used in the safety
function are interlocked in accordance with the applicable standards for that function.
•
The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner, in accordance with the applicable standards for the emergency stop function.
3HAC021111-001 Revision: B
21
1 Safety, service
1.2.6 Risks associated with live electric parts
1.2.6 Risks associated with live electric parts
Voltage related
risks, general
Voltage related
risks, controller
•
Although troubleshooting may, on occasion, have to be carried out while the power
supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
•
The mains supply to the robot must be connected in such a way that it can be turned
off outside the robot’s working space.
A danger of high voltage is associated with the following parts:
•
Be aware of stored electrical energy (DC link) in the controller.
•
Units inside the controller, e.g. I/O modules, can be supplied with power from an external source.
•
The mains supply/mains switch
•
The power unit
•
The power supply unit for the computer system (230 VAC)
•
The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
•
The drive unit (700 VDC)
•
The service outlets (115/230 VAC)
•
The power supply unit for tools, or special power supply units for the machining process
•
The external voltage connected to the control cabinet remains live even when the
robot is disconnected from the mains.
•
Additional connections
Voltage related
risks, manipulator
A danger of high voltage is associated with the manipulator in:
Voltage related
risks, tools,
material handling
devices, etc
Tools, material handling devices, etc., may be live even if the robot system is in the OFF
position. Power supply cables which are in motion during the working process may be damaged.
22
•
The power supply for the motors (up to 800 VDC)
•
The user connections for tools or other parts of the installation (max. 230 VAC, see
Installation and Commissioning Manual)
3HAC021111-001 Revision: B
1 Safety, service
1.3.1 Safety fence dimensions
1.3: Safety actions
1.3.1 Safety fence dimensions
General
Install a safety cell around the robot to ensure safe robot installation and operation.
Dimensioning
Dimension the fence or enclosure to enable it to withstand the force created if the load being
handled by the robot is dropped or released at maximum speed. Determine the maximum
speed from the maximum velocities of the robot axes and from the position at which the robot
is working in the work cell (see Product Specification - Description, Robot Motion).
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating
tool or other device fitted to the manipulator.
3HAC021111-001 Revision: B
23
1 Safety, service
1.3.2 Fire extinguishing
1.3.2 Fire extinguishing
NOTE!
Use a CARBON DIOXIDE (CO 2 ) extinguisher in the event of a fire in the robot (manipulator or controller)!
24
3HAC021111-001 Revision: B
1 Safety, service
1.3.3 Emergency release of the manipulator's arm
1.3.3 Emergency release of the manipulator's arm
Description
In an emergency situation, any of the manipulator's axes may be released manually by pushing the brake release buttons on the manipulator or on an optional external brake release unit.
How to release the brakes is detailed in section Manually releasing the brakes in the Product
manual for the manipulator.
The manipulator arm may be moved manually on smaller robot models, but larger models
may require using an overhead crane or similar.
Increased injury
Before releasing the brakes, make sure that the weight of the arms does not increase the
pressure on the trapped person, further increasing any injury!
3HAC021111-001 Revision: B
25
1 Safety, service
1.3.4 Brake testing
1.3.4 Brake testing
When to test
During operation the holding brakes of each axis motor wear normally. A test may be performed to determine whether the brake can still perform its function.
How to test
The function of each axis' motor holding brakes may be checked as detailed below:
1. Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized (max. static load).
2. Switch the motor to the MOTORS OFF position with the Operating mode selector
on the controller.
3. Check that the axis maintains its position.
If the manipulator does not change position as the motors are switched off, then the brake
function is adequate.
26
3HAC021111-001 Revision: B
1 Safety, service
1.3.5 Risk of disabling function "Reduced speed 250 mm/s"
1.3.5 Risk of disabling function "Reduced speed 250 mm/s"
Note!
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.
3HAC021111-001 Revision: B
27
1 Safety, service
1.3.6 Safe use of the Teach Pendant Unit
1.3.6 Safe use of the Teach Pendant Unit
NOTE!
The enabling device is a push button located on the side of the Teach Pendant Unit (TPU)
which, when pressed halfway in, takes the system to MOTORS ON. When the enabling
device is released or pushed all the way in, the robot is taken to the MOTORS OFF state.
To ensure safe use of the Teach Pendant Unit, the following must be implemented:
The enabling device must never be rendered inoperative in any way.
During programming and testing, the enabling device must be released as soon as there is no
need for the robot to move.
The programmer must always bring the Teach Pendant Unit with him/her, when entering the
robot's working space. This is to prevent anyone else taking control over the robot without
the programmer knowing.
28
3HAC021111-001 Revision: B
1 Safety, service
1.3.7 Work inside the manipulator's working range
1.3.7 Work inside the manipulator's working range
Warning!
If work must be carried out within the robot’s work envelope, the following points must be
observed:
- The operating mode selector on the controller must be in the manual mode position to render
the enabling device operative and to block operation from a computer link or remote control
panel.
- The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in position < 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.
- Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in order
not to get entangled with hair or clothing. Also be aware of any danger that may be caused by
rotating tools or other devices mounted on the manipulator or inside the cell.
- Test the motor brake on each axis, according to section Brake testing on page 26.
3HAC021111-001 Revision: B
29
1 Safety, service
1.3.8 Signal lamp (optional)
1.3.8 Signal lamp (optional)
Description
A signal lamp with an yellow fixed light can be mounted on the manipulator, as a safety
device. The signal lamp is required on an UL/UR approved robot.
Function
The lamp is active in MOTORS ON mode.
Further
information
Further information about the MOTORS ON/MOTORS OFF mode may be found in the chapter Description, Control System in the Product manual for the controller.
30
3HAC021111-001 Revision: B
2 Installation and commissioning
2.0.1 Transporting and Unpacking
2: Installation and commissioning
2.0.1 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.
Operating
conditions
Storage
conditions
Parameter
Value
Ambient temperature
+5º to +45º
Relative humidity
Max. 95% at constant temperature
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 and +55°C.
When air transport is used, the robot must be located in a pressure-equalized area.
Weight
The net weight of the manipulator is approximately: 225 kg
3HAC021111-001 Revision: B
31
2 Installation and commissioning
2.0.2 Stability / Risk of Tipping
2.0.2 Stability / Risk of Tipping
When the manipulator is not fastened to the floor and standing still, the manipulator is not
stable in the whole working area. When the arms are moved, care must be taken so that the
centre of gravity is not displaced, as this could cause the manipulator to tip over.
32
3HAC021111-001 Revision: B
2 Installation and commissioning
2.0.3 System CD ROM and Diskette
2.0.3 System CD ROM and Diskette
The system CD ROM and the manipulator parameter disk are delivered with the robot system.
See section RobotWare CD-ROM in the Product manual for the controller.
Art. no. for the manual is detailed in section Document references in the Product manual,
reference information.
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2 Installation and commissioning
2.0.4 Transport Locking Device
2.0.4 Transport Locking Device
At delivery, axis 2 (= lower arm) is equipped with a transport locking device (see figure
below).
Remove the transport locking device before operating the robot.
Transport locking
device
Transport Locking Device, Axis 2.
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2 Installation and commissioning
2.1.1 Lifting the Manipulator
2.1: On-site installation
2.1.1 Lifting the Manipulator
The best way to lift the manipulator is to use lifting straps and a traverse crane. Attach the
straps to the special eye bolts on the gear boxes for axes 2 and 3 (see figure below). The lifting
strap dimensions must comply with the applicable standards for lifting.
Never walk under a suspended load.
Lifting eye
IRB 1400H
Lifting eye
IRB 1400
Lifting the Manipulators using a Traverse Crane.
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2 Installation and commissioning
2.1.2 Turning the Manipulator (Inverted Suspension Application)
2.1.2 Turning the Manipulator (Inverted Suspension Application)
N.B! Only possible with IRB 1400H.
A special tool is recommended when the manipulator is to be turned for inverted mounting
(ABB article number 3HAB 3397-1).
The tool is attached to the outsides of the gearboxes for axes 2 and 3 using six (M8x25) bolts
and washers. Tightening torque 25 Nm.
The manipulator is lifted with a fork lift or a crane (see figure below).
Note also the positions of the arm system.
(Fork lift)
Appr. R=860
M8x25 (x3) on both sides
Tool 3HAB 3397-1
Appr. R=580
Turning the Manipulator.
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2 Installation and commissioning
2.1.3 Assembling the robot
2.1.3 Assembling the robot
Manipulator
The manipulator must be mounted on a level surface with the same hole layout as shown in
Figure . The levelness requirement of the surface is as follows:
0.5
.
38
20
35
∅ 18,5
455
245
210
∅ 35 H8
400
200
∅ 18.5 H7
Bolting down the Manipulator.
The manipulator is bolted down by means of three M16 bolts.
Suitable bolts
M16 8.8
Tightening torque
190 Nm
Two guide sleeves, ABB art. no. 2151 0024-169, can be fitted to the two rear bolt holes, to
allow the same robot to be re-mounted without having to re-adjust the program.
When bolting a mounting plate or frame to a concrete floor, follow the general instructions
for expansion-shell bolts. The screw joint must be able to withstand the stress loads defined
in this chapter, Section 2.1.5 Stress Forces.
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2 Installation and commissioning
2.1.4 Suspended Mounting
2.1.4 Suspended Mounting
The method for mounting the manipulator in a suspended position is basically the same as for
floor mounting.
With inverted installation, make sure that the gantry or corresponding structure is rigid
enough to prevent unacceptable vibrations and deflections, so that optimum performance can be achieved.
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2 Installation and commissioning
2.1.5 Stress Forces
2.1.5 Stress Forces
Stiffness
The stiffness of the foundation must be designed to minimize the influence on the dynamic
behaviour of the robot.
TuneServo can be used for adapting the robot tuning to a non-optimal foundation.
IRB 1400 and IRB
1400H
Force
Endurance load (in operation) Max. load (emergency stop)
Fxy
± 1500 N
± 2000 N
Fz (upright)
2800 ± 500 N
2800 ± 700 N
Fz (suspended)
-2800 ± 800 N
-2800 ± 1000 N
Torque
Endurance load (in operation) Max. load (emergency stop)
Mxy
± 1800 Nm
± 2000 Nm
Mz
± 400 Nm
± 500 Nm
Fxy and Mxy are vectors that can have any direction in the xy plane.
X
Z
The Directions of the Stress Forces.
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2 Installation and commissioning
2.1.6 Amount of Space required
2.1.6 Amount of Space required
The amount of working space required to operate the manipulator is illustrated in the figures
below. The working range for axis 1 is +/- 170°.
NB! There are no software or mechanical limits for the working space under the base of
the manipulator.
Manipulator
1793
1195
50
150
511
1008
1444
1282
733
254
150
1051
150
770
1127
1221
1645
Axis 1 +145o
-135o
Axis 1 ± 170o
The Amount of working Space required for the Manipulator.
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2 Installation and commissioning
2.1.7 Manually engaging the brakes
2.1.7 Manually engaging the brakes
All axes are equipped with holding brakes. If the positions of the manipulator axes are 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
contact at the base of the manipulator (see figure below).
Note! Be careful not to interchange the 24V and 0V pins! If they are mixed up, damage
can be caused to electrical components.
+24 V B8
0 V C10
Connection of External Voltage to enable Engagement of the Brakes.
External power must be connected according to Figure . Incorrectly connected power
can release all brakes, causing simultaneously movement of all axes.
When the controller or the voltage supply is connected as illustrated above, the brakes can be
engaged using the push-button on the manipulator, see Figure .
WARNING: Be very careful when engaging the brakes. The axes become activated very
quickly and may cause damage or injury.
Brake release button
Location of the Brake Release Button.
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2 Installation and commissioning
2.1.8 Restricting the Working Space
2.1.8 Restricting the Working Space
When installing the manipulator, make sure that it can move freely within its entire working
space. If there is a risk that it may collide with other objects, its working space should be
limited, both mechanically and using software. Installation of an optional extra stop for the
main axes 1, 2 and 3 is described below.
Limiting the working space using software is described in the System Parameters in the
User’s Guide.
Axis 1
The range of rotation for axis 1 can be limited mechanically by fitting extra stop lugs to the
base, see Figure .
Instructions for necessary machining and mounting are supplied with the kit.
NB! The original stop lug must never be removed.
Extra stop lug for axis 1
Mechanically limiting Axis 1.
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2 Installation and commissioning
2.1.8 Restricting the Working Space
Axis 2
The working range of axis 2 can be limited mechanically by fitting extra stop lugs to the under
arm (see Figure ). The lugs limit the arm movements in intervals of 20°. (20° = 1 lug, 40° =
2 lugs, etc.)
Instructions for doing this are supplied with the kit.
Under arm
Extra stop lugs
Mechanically limiting Axis 2.
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2 Installation and commissioning
2.1.8 Restricting the Working Space
Axis 3
The working range of axis 3 can be limited mechanically by fitting a stop lug under the
parallel arm (see Figure ). Axis 3 is limited upwards to 0 or -10 degrees above the horizontal
plane.
Instructions for doing this are supplied with the kit.
Extra stop lug
Extra Stop Lug for limiting Axis 3.
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2 Installation and commissioning
2.1.9 Mounting Holes for Equipment on the Manipulator
2.1.9 Mounting Holes for Equipment on the Manipulator
NB! Never drill a hole in the manipulator without first consulting ABB.
A
A
135
Mounting holes
for equipment
M8 (2x)
Depth 16
IRB 1400H
120
120
IRB 1400
135
Mounting holes
for equipment
M8 (2x)
Depth 16
A
Mounting holes
for equipment, both sides
M8 (3x), R=75
Depth 16
A
120o(3x)
15o
Mounting Holes for Customer Equipment.
C
D=6 H7
∅ 0.05 B
M6 (4x)
∅ 0.3 C
10
B
D=12
R 20
D=50 h8
A
D=25 H8
45o
A
90o (4x)
2
4
0.06 B
A-A
The mechanical Interface (Mounting Flange).
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2 Installation and commissioning
2.1.10 Loads
2.1.10 Loads
Regarding load diagram, permitted extra loads (equipment) and locations of extra loads
(equipment), see the Product Specification for IRB 1400. The loads must also be defined in
the soft ware, see User’s Guide.
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2 Installation and commissioning
2.2.1 Air supply and signals for extra equipment to upper arm
2.2: Customer connections on manipulator
2.2.1 Air supply and signals for extra equipment to upper arm
Option 041
Hose for compressed air is integrated into the manipulator. There is an inlet at the base and
an outlet on the upper arm housing. Connections: R1/4” in the upper arm housing and at the
base. Max. 8 bar. Inner hose diameter: 6.5 mm.
For connection of extra equipment on the manipulator, there are cables integrated into the
manipulator’s cabling.
Option 042
Number of signals
12 signals, 49V, 500 mA
Connector on upper arm:
FCI 12-pin UT001412SHT
Connector on robot base:
FCI 12-pin UT001412PHT
Control cabling to arc welding wire-feeder is integrated into the manipulator’s cabling.
Control signals
Number of signals:
16 signals, 49V, 500 mA
Connector on upper arm housing:
FCI 23-pin UTG61823PN
Connector on robot base:
FCI 23-pin UT001823SHT
Power signals
Number of signals:
12 signals, 300V, 4A
Connector on upper arm housing:
FCI 12-pin socket UTG61412SN
Connector on robot base:
FCI 12-pin UT001412PHT
This option (042) is not available for IRB 1400H.
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2 Installation and commissioning
2.2.1 Air supply and signals for extra equipment to upper arm
R1.CS
Air (only option 041)
R2.CP (only option 042)
R2.CS
Air (only option 041)
R2.CP (only option 042)
Location of Customer Connections.
To connect power and signal conductors to the manipulator base and to the upper arm
connectors, the following parts are recommended:
• ABB’s recommended contact set, for connector R2.CS, has Art. No. 3HAC 12583-1.
•
ABB’s recommended contact set, for connector R1.CS, has Art. No. 3HAC 12493-1.
The complete contact set (option) contains:
• Pins for cable area 0.13 - 0.25 mm2
•
Shrinking hose bottled shaped
•
Shrinking hose, angled,
•
which corresponds to item 4, 5, 6, 7, 8 and 9 according to Figure .
9
Customer side
4, 5
Manipulator side
1, 3
8
6
2
7
FCI Connector
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2 Installation and commissioning
2.2.2 Connection of Extra Equipment to the Manipulator
2.2.2 Connection of Extra Equipment to the Manipulator
Technical data for customer connections.
Signals
Conductor resistance
< 3 ohm, 0.154 mm2
Max. voltage
50 V AC/DC
Max. current
250 mA
Connections on
Upper Arm
R2.CS
Customer Connections on Upper Arm.
Signal
Name
Customer Contact
Customer Terminal on Upper Arm, R2
Controller (optional)
Customer Contact on
Manipulator Base
(Cable not supplied)
CSA
XT5.1
R2.CS.A
R1.CS.A
CSB
XT5.2
R2.CS.B
R1.CS.B
CSC
XT5.3
R2.CS.C
R1.CS.C
CSD
XT5.4
R2.CS.D
R1.CS.D
CSE
XT5.5
R2.CS.E
R1.CS.E
CSF
XT5.6
R2.CS.F
R1.CS.F
CSG
XT5.7
R2.CS.G
R1.CS.G
CSH
XT5.8
R2.CS.H
R1.CS.H
CSJ
XT5.9
R2.CS.J
R1.CS.J
CSK
XT5.10
R2.CS.K
R1.CS.K
CSL
XT5.11
R2.CS.L
R1.CS.L
CSM
XT5.12
R2.CS.M
R1.CS.M
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2 Installation and commissioning
2.2.2 Connection of Extra Equipment to the Manipulator
Connection of
Signal Lamp on
Upper Arm
(Option)
R3.H1 +
R3.H2 -
Signal lamp
Location of Signal Lamp.
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3 Maintenance
3.0.1 Introduction
3: Maintenance
3.0.1 Introduction
The robot is designed to be able to work under very demanding circumstances with a minimum of maintenance. Nevertheless, certain routine checks and preventative maintenance
must be carried out at given periodical intervals, see 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 joint and cable bushings are really airtight so that dust and
dirt are not sucked into the cabinet.
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3 Maintenance
3.0.2 Maintenance Intervals
3.0.2 Maintenance Intervals
Equipment
Check Check
twice/ once/
year
year
Mechanical stop
axis 1
X1
Cabling
X2
Maintenance
Maintenance
every 2000 hrs every 4000 hrs
or 6 months
or 1 year
Gears axis 1-4
Lubrication of
spring brackets
Maintenance
free
X
Lubrication of
gears axis 5-6
X
3 years3
Replacement of
accumulator for
measuring system
52
Others
1)
Check that the “mechanical stop” is not bent.
2)
Inspect all visible cabling. Change if damaged.
3)
See section Changing the battery in the measuring system on page 56.
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3 Maintenance
3.1.1 Oil in gears 1-4
3.1: Instructions for maintenance
3.1.1 Oil in gears 1-4
The gearboxes are lubricated for life.
ABB’s oil, Mobil Gear 600 XP 320 art. No. 1171 2016-604, corresponds to:
Oil volume (BP),
floor-mounted
robot
BP: Energol GR-XP 320
Castrol: Alpha SP 320
Esso: Spartan EP 320
Klüber: Lamora 320
Optimol: Optigear 320
Shell: Omala Oil 320
Texaco: Meropa 320
Statoil: Loaway EP
Gearbox
Volume
Axis 1
2,000 ml
Axis 2 and 3
1,700 ml
Axis 4
30 ml
Gearbox
Volume
Axis 1
2,700 ml
Axis 2 and 3
1,700 ml
Axis 4
30 ml
Oil volume (BP),
suspended robot
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3 Maintenance
3.1.2 Greasing axes 5 and 6
3.1.2 Greasing axes 5 and 6
Grease is pressed through the 3 nipples (1), see Figure . The tip nozzle of the greasing gun
should be of type Orion 1015063, or equivalent.
Volume: 2 ml (0.00053 US gallon)
(1)
Greasing Positions for Axes 5 and 6.
Type of grease: ABB’s art. No. 3HAB 3537-1, corresponds to:
Shell Alvania WR2
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3 Maintenance
3.1.3 Lubricating spring brackets
3.1.3 Lubricating spring brackets
There are four lubrication places, located over and under the two balancing springs.
Type of grease: ABB’s art. No. 3HAA 1001-294, corresponds to:
Optimol PDO
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3 Maintenance
3.1.4 Changing the battery in the measuring system
3.1.4 Changing the battery in the measuring system
The battery to be replaced is located inside the base under the flange cover (see Figure ).
The robot is delivered with a rechargeable Nickel-Cadmium (Ni-Cd) battery with article
number 4944 026-4.
The battery must never be just thrown away; it must always be handled as hazardous waste.
•
Set the robot to the MOTORS OFF operating mode. (This means that it will not
have to be coarse-calibrated after changing the battery.)
•
Remove the flange cover. All connections on the flange cover, except for the signal
contact for the serial link, R1.SMB, can be disconnected.
•
Remove one of the screws and loosen the two other screws holding the serial
measurement board. Push the unit to the side and remove it backwards. All
cables and contacts must remain intact. Note the ESD-protection (ESD = Electrostatic Discharge).
•
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.
•
Refit the serial measurement board, flange cover and connections.
•
The Ni-Cd battery takes 36 hours to recharge; the mains supply must be switched
on during this time.
Flange cover
The Battery is located Inside the Base under the Flange Cover.
Alternative
Battery
As an alternative to the Ni-Cd battery a lithium battery of primary type can be installed. The
lithium battery needs no charging and has for that reason a blocking diode which prevents
charging from the serial measurement board.
The benefit with a lithium 10.8 V battery is the lifetime, which can be up to 5 years in service,
compare with the Ni-Cd battery’s maximum life time of 3 years in service.
Two lithium batteries exists:
•
A 3-cell battery, art.No. 3HAB 9999-1
•
A 6-cell battery, art.No. 3HAB 9999-2
The life time of the lithium battery depends on how frequently the user switches off the
power. The estimated max. life time in years for the different lithium batteries and the recommended exchange interval is shown below:
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3 Maintenance
3.1.4 Changing the battery in the measuring system
User type
Exchange 3-cell
Exchange 6-cell
1. Vacation (4 weeks) power off
Every 5 years
Every 5 years1
2. Weekend power off + user type 1
Every 2 years
Every 4 years
3. Nightly power off + user type 1 and 2
Every year
Every 2 years
1)
Because of material aging, the maximum life in service is 5 years.
Voltage of batteries, measured at power off:
Min.
Max.
Ni-Cd
7.0 V
8.7 V
Lithium
7.0 V
-
Exchange of the battery is done according to the beginning of this section.
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3 Maintenance
3.1.5 Checking the mechanical stop, axis 1
3.1.5 Checking the mechanical stop, axis 1
Check regularly, as follows:
•
That the stop pin is not bent.
If the stop pin is bent, it must be replaced by a new one. See section Replacing the mechanical
stop on page 71.
The article number of the pin is 3HAB 3258-1.
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4 Repair
4.1.1 General description
4: Repair
4.1: General information
4.1.1 General description
The industrial robot system comprises two separate units: the control cabinet and the manipulator. The IRB 1400 is also available in a suspended version, IRB 1400H. Servicing the
mechanical unit is described in the following sections. Servicing the manipulator is described
in this manual.
When service on the IRB1400H is contemplated, a decision must be made in each particular
case whether the work can be carried out with the manipulator suspended or whether it must
be removed and the work done on the floor.
Lifting and turning the manipulator is described in section Lifting the Manipulator on page
35.
When servicing the manipulator, it is helpful to service the following parts separately:
• The Electrical System
•
The Motor Units
•
The Mechanical System
The Electrical System is routed through the entire manipulator and is made up of two main
cabling systems; the power cabling and signal cabling. The power cabling feeds the motor
units of the manipulator axes. The signal cabling feeds the various control parameters, such
as axis positions, motor revs, etc.
The AC Motor Units provide the motive power for the various manipulator axes by means of
gears. Mechanical brakes, electrically released, lock the motor units when the robot is inoperative for more than 3 minutes during both automatic and manual operation.
The manipulator has 6 axes which makes its movements very flexible.
Axis 1 rotates the manipulator. Axis 2 provides the lower arm’s reciprocating motion. The
lower arm, together with the parallel arm and the parallel bracket, forms a parallelogram
relative to the upper arm. The parallel bracket is mounted on bearings in the parallel arm and
in the upper arm.
Axis 3 raises the upper arm of the manipulator. Axis 4, located on the side of the upper arm,
rotates the upper arm. The wrist is bolted to the tip of the upper arm and includes axes 5 and
6. These axes form a cross and their motors are located at the rear of the upper arm.
Axis 5 is used to tilt and axis 6 to turn. A connection is supplied for various customer tools
on the tip of the wrist in the turn disc. The tool (or manipulator) can be pneumatically controlled by means of an external air supply (optional extra). The signals to/from the tool can
be supplied via internal customer connections (optional extras).
Note that the control cabinet must be switched off during all maintenance work on the manipulator. The accumulator power supply must always be disconnected before performing any
work on the manipulator measurement system (measurement boards, cabling, resolver unit).
When any type of maintenance work is carried out, the calibration position of the manipulator
must be checked before the robot is returned to the operational mode.
Take special care when manually operating the brakes. Make sure also that the safety instructions described in this manual are followed when starting to operate the robot.
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4 Repair
4.1.2 Instructions for reading the following sections
4.1.2 Instructions for reading the following sections
The subsequent sections describe the type of on-site maintenance that can be performed by
the customer’s own maintenance staff. Some maintenance jobs require special experience or
specific tools and are therefore not described in this manual. These jobs involve replacing the
faulty module or component on-site. The faulty component is then transported to ABB for
service.
Calibration
The robot must be re-calibrated when a mechanical unit or part of one is replaced, when the
motor and feedback unit is disconnected, when a resolver error occurs, or when the power
supply between a measurement board and resolver is interrupted. This procedure is described
in detail in section Calibration information on page 131.
Any work on the robot signal cabling may cause the robot to move to the wrong positions.
After performing such work, the calibration position of the robot must be checked as
described in section Calibration information on page 131.
Tools
Two types of tools are required for the various maintenance jobs. It may be necessary to use
conventional tools, such as sockets and ratchet spanners, etc., or special tools, depending on
the type of servicing. Conventional tools are not discussed in this manual, since it is assumed
that maintenance staff have sufficient basic technical competence. Maintenance jobs which
require the use of special tools are, on the other hand, described in this manual.
Foldouts
The chapter on spare parts comes with a number of foldouts which illustrate the parts of the
robot. These foldouts are provided in order to make it easier for you to quickly identify both
the type of service required and the make-up of the various parts and components. The item
numbers of the parts are also shown on the foldouts.
In the subsequent sections, these numbers are referred to in angle brackets < >. If a reference
is made to a foldout, other than that specified in the paragraph title, the foldout’s number is
included in the numeric reference to its item number; for example:
<5/19> or <10:2/5>. The digit(s) before the stroke refer to the foldout number.
The foldouts also include other information such as the article number, designation and
related data.
NB! This manual is not considered as a substitute for a proper training course. The information in the following chapters should be used only after an appropriate course has been completed.
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4 Repair
4.1.3 Caution
4.1.3 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 anybody is allowed to enter
its working space.
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4 Repair
4.1.4 Fitting new Bearings and Seals
4.1.4 Fitting new Bearings and Seals
Bearings
1. Do not unwrap new bearings until just before assembly, in order to prevent dust
and grit getting into the bearing.
2. Make sure that all parts of the bearing are free from burr dust, grinding dust and
any other contamination. Cast parts must be free from foundry sand.
3. Bearing rings, races and roller parts must not under any circumstances be subjected to direct impact. The roller parts must not be subjected to any pressure that
is created during the assembly.
Tapered Bearings
1. The bearing should be tightened gradually until the recommended pre-tensioning
is attained.
2. The roller parts must be rotated a specified number of turns both before
pre-tensioning and during pre-tensioning.
3. The above procedure must be carried out to enable the roller parts to slot into the
correct position with respect to the racer flange.
4. It is important to position the bearings correctly, because this directly affects the
service life of the bearing.
Greasing
Bearings
1. Bearings must be greased after they are fitted. Extreme cleanliness is necessary
throughout. High quality lubricating grease, such as Shell Alvania WR2
(ABB’s art. No. 3537-1), should be used.
2. Grooved ball bearings should be greased on both sides.
3. Tapered roller bearings and axial needle bearings should be greased when they
are split.
4. Normally the bearings should not be completely filled with grease. However, if
there is space on both sides of the bearing, it can be filled completely with grease
when it is fitted, as surplus grease will be released from the bearing on start up.
5. 70-80% of the available volume of the bearing must be filled with grease during
operation.
6. Make sure that the grease is handled and stored correctly, to avoid contamination.
Seals
The most common cause of leakage is incorrect mounting.
Rotating Seals
1. The seal surfaces must be protected during transportation and assembly.
2. The seals must either be kept in their original packages or be protected well.
3. The seal surfaces must be inspected before mounting. If the seal is scratched or
damaged in such a way that it may cause leakage in the future, it must be
replaced.
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4 Repair
4.1.4 Fitting new Bearings and Seals
4. The seal must also be checked before it is fitted to ensure that:
5. The seal edge is not damaged (feel the edge with your finger nail),
6. The correct type of seal is used (has a cut-off edge),
7. There is no other damage.
8. Grease the seal just before it is fitted – not too early as otherwise dirt and foreign
particles may stick to the seal. The space between the dust tongue and sealing
lip should 2/3-filled with grease of type Shell Alvania WR2 (ABB’s art. No. 35371). The rubber coated external diameter must also be greased.
9. Seals and gears must be fitted on clean workbenches.
10.Fit the seal correctly. If it is fitted incorrectly, it may start to leak when pumping
starts.
11.Always use an assembling tool to fit the seal. Never hammer directly on the seal
because this will cause it to leak.
12.Use a protective sleeve on the sealing edge during assembly, when sliding over
threads, key-ways, etc.
Flange Seals and
Static Seals
1. Check the flange surfaces. The surface must be even and have no pores. The
evenness can be easily checked using a gauge on the fitted joint (without sealing
compound).
2. The surfaces must be even and free from burr dust (caused by incorrect machining). If the flange surfaces are defective, they must not be used as they will cause
leakage.
3. The surfaces must be cleaned properly in the manner recommended by ABB.
4. Distribute the sealing compound evenly over the surface, preferably using a
brush.
5. Tighten the screws evenly around the flange joint.
6. Make sure that the joint is not subjected to loading until the sealing compound has
attained the hardness specified in the materials specification.
O-rings
1. Check the O-ring grooves. The grooves must be geometrically correct, without
pores and free of dust and grime.
2. Check the O-ring for surface defects and burrs, and check that it has the correct
shape, etc.
3. Make sure the correct O-ring size is used.
4. Tighten the screws evenly.
5. Defective O-rings and O-ring grooves must not be used.
6. If any of the parts fitted are defective, they will cause leakage. Grease the O-ring
with Shell Alvania WR2 (ABB’s art. No. 3537-1) before fitting it.
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4.1.5 Instructions for tightening Screw Joints
4.1.5 Instructions for tightening Screw Joints
General
It is extremely important that all screw joints are tightened using the correct torque.
Application
The following tightening torques must be used, unless otherwise specified in the text, for all
screw joints made of metallic materials.
The instructions do not apply to screw joints made of soft or brittle materials.
For screws with a property class higher than 8.8, the same specifications as for class 8.8. are
applicable, unless otherwise stated.
Screws treated
with Gleitmo
All screws in the manipulator that are tightened to a specified torque are treated with Gleitmo.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should
be used.
Screws treated with Gleitmo can be unscrewed and screwed in again 3-4 times before the slip
coating disappears. Screws can also be treated with Molycote 1000.
When screwing in new screws without Gleitmo, these should first be lubricated with Molycote 1000 and then tightened to the specified torque.
Assembly
Screw threads sized M8 or larger should preferably be lubricated with oil. Molycote 1000
should only be used when specified in the text.
Screws sized M8 or larger should be tightened with a torque wrench, if possible.
Screws sized M6 or smaller may be tightened to the correct torque by personnel with sufficient mechanical training, without using torque measurement tools.
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4.1.6 Tightening Torques
4.1.6 Tightening Torques
Screws with
slotted or cross
recessed head,
property class 4.8
Screws with
hexagon socket
head, property
class 8.8
Dimension
Tightening Torque Nm
Without Oil
M2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
Dimension
Tightening Torque Nm
Tightening Torque Nm
Without Oil
With Oil
M3
1
1
M4
2
2
M5
5.5
4
M6
10
9
M8
24
22
M10
48
45
M12
83
78
M16
200
190
M20
410
400
M24
750
740
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4.1.7 Checking for play in gearboxes and wrist
4.1.7 Checking for play in gearboxes and wrist
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.
The play in the brake disk does not affect the robot motion or accuracy.
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4.2.1 Changing the motor of axis 1
4.2: Axis 1
4.2.1 Changing the motor of axis 1
See foldouts 1 and 5 (6 for IRB 1400H) in the list of spare parts.
The motor and the drive gear constitute one unit.
NOTE!
There are two different types of motors, (Elmo and Yaskawa) The different motors are not
compatible. Make sure to replace with correct model!
To dismantle
1. Remove the cover of the motor.
2. Loosen connectors R4.MP1 and R4.FB1.
3. Remove the connection box by unscrewing <5/160>.
4. Note the position of the motor before removing it.
5. Loosen the motor by unscrewing <1/10>.
To assemble
1. Check that the assembly surfaces are clean and the motor unscratched.
2. Release the brake, apply 24V DC to terminals 7 and 8 in the 4.MP1 connector.
3. Install the motor, tighten screws <1/10> using a torque of approximately 2 Nm.
Note the position of the motor!
4. Adjust the motor in relation to the gear in the gearbox.
5. Screw the 3HAB 1201-1 crank tool into the end of the motor shaft.
6. Make sure there is very small play by turning axis 1 at least 45o.
7. Tighten screws <1/10> using a torque of 8.3 Nm ±10%.
8. Connect the cabling.
9. Calibrate the robot as specified in section Calibration information on page 131.
Tightening torque
The motor attaching screws, item10:8.3 Nm ±10%
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4.2.2 Changing the gearbox
4.2.2 Changing the gearbox
Axis 1 gearbox is of the conventional type, manufactured with a high degree of precision and,
together with the gearboxes for axes 2 and 3, forms a complete unit.
The gearbox is not normally serviced or adjusted.
Note! If the gearbox on any of the axes 1, 2 or 3 is changed, the whole unit must
be changed.
See foldout 1 (6 for IRB 1400H) in the list of spare parts.
To dismantle
1. Remove the motors in axes 1, 2 and 3 as described in section Changing the motor
of axis 1 on page 67, section Changing the motor of axis 2 on page 72 and section
Changing the motor of axis 3 on page 77.
2. Remove the cabling and serial measuring boards according to section Changing
the cabling in axes 1, 2 and 3 on page 91 and section Changing serial measuring
boards on page 90.
3. Remove the tie rod as described in this chapter, section Changing the tie rod on
page 80.
4. Remove the parallel arm according to section Dismantling the parallel arm on
page 79.
5. Remove the balancing springs in accordance with section Dismantling the balancing springs on page 76 (not valid for IRB 1400H).
6. Dismantle the upper arm as described in section Dismantling the complete upper
arm on page 81.
7. Dismantle the lower arm according to section Dismantling the lower arm on page
74.
8. Place the remaining parts of the manipulator upside-down on a table or similar
surface and remove the bottom plate <1/5>. See Figure .
Make sure that the foot is stable.
How to Position the Foot when dismantling Axes 1, 2 and 3.
9. Undo screws <1/4>.
10.Separate the base from the gear unit.
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4.2.2 Changing the gearbox
To assemble
1. Place a new gear unit on the table.
2. Raise the base.
3. Screw in the screws <1/4> together with their washers <1/3>. Tighten using a
torque of 68 Nm ±10%.
4. Replace the bottom plate <1/5> using screws <1/7>.
5. Turn the foot.
6. Replace the lower arm as described in section Dismantling the lower arm on page
74.
7. Replace the parallel arm according to section Dismantling the parallel arm on
page 79.
8. Replace the upper arm as described in section Dismantling the complete upper
arm on page 81.
9. Replace the cabling in accordance with section Changing the cabling in axes 1, 2
and 3 on page 91 and section Changing serial measuring boards on page 90.
10.Replace the tie rod as described in section Changing the tie rod on page 80.
11.Replace the balancingd springs according to section Dismantling the balancing
springs on page 76 (not valid for IRB 1400H).
12.Calibrate the robot as described in section Calibration information on page 131.
Tightening
Torque
Screwed joint of base/gear unit, item <4>:68 Nm ±10%
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4.2.3 Position indicator in axis 1 (optional)
4.2.3 Position indicator in axis 1 (optional)
See foldouts 3 and 4 (6 for IRB 1400H) in the list of spare parts.
To dismantle
1. Remove the flange plate <4/138>.
2. Loosen the connector R1.LS.
3. Dismantle the two limit switches <3/174>.
4. Loosen the cables from the switches.
5. Remove the cabling through the base.
To assemble
70
1. Assemble in the reverse order.
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4.2.4 Replacing the mechanical stop
4.2.4 Replacing the mechanical stop
See foldout 1 in the list of spare parts.
If the stop pins are bent, they must be replaced.
Remove the old stop pin.
68 ± 1
Fit the new pin as illustrated in Figure below.
Loctite 242 or 243
Fit the new Pin as illustrated.
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4.3.1 Changing the motor of axis 2
4.3: Axis 2
4.3.1 Changing the motor of axis 2
See foldouts 1 and 5 (6 for IRB 1400H) in the list of spare parts.
The motor and the drive gear constitute one unit.
NOTE!
There are two different types of motors, (Elmo and Yaskawa) The different motors are not
compatible. Make sure to replace with correct model!
To dismantle
Lock the arm system before dismantling the motor; the brake is located in the motor.
1. Remove the cover of the motor.
2. Loosen connectors R3.MP2 and R3.FB2.
3. Remove the connection box by unscrewing <5/160>.
4. Note the position of the motor before removing it.
5. Loosen the motor by unscrewing <1/10>. N.B! The oil will start to run out.
To assemble
1. Check that the assembly surfaces are clean and the motor unscratched.
2. Release the brake, apply 24 V DC to terminals 7 and 8 on the R3.MP2 connector.
3. Install the motor, tighten screws <1/10> to a torque of approximately 2 Nm.
Note the position of the motor!
4. Adjust the motor in relation to the drive in the gearbox.
5. Screw the 3HAB 1201-1 crank tool into the end of the motor shaft.
6. Make sure there is no play.
7. Tighten screws <1/10> to a torque of 8.3 Nm ±10%.
8. Fill with oil. See section Oil in gears 1-4 on page 53.
9. Connect the cabling.
10.Calibrate the robot as specified in section Calibration information on page 131.
Tightening torque
72
The motor’s fixing screws, item10: 8.3 Nm ±10%
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4.3.2 Changing the gearbox
4.3.2 Changing the gearbox
Axis 2 gearbox is of a conventional type, manufactured with a high degree of precision and,
together with the gearbox for axes 1 and 3, forms a complete unit.
The gearbox is not normally serviced or adjusted.
Note! If the gearbox of any of the axes 1, 2 or 3 needs to be changed, the whole unit must be
changed.
See foldout 1 in the list of spare parts.
To dismantle
See section Changing the gearbox on page 68.
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4.3.3 Dismantling the lower arm
4.3.3 Dismantling the lower arm
See foldouts 1 (6 for IRB 1400H) in the list of spare parts.
To dismantle
1. Remove the balancing springs as described in section Dismantling the balancing
springs on page 76 (not valid for IRB 1400H).
2. Remove the cabling down to axis 1 according to section Cabling and serial measuring board on page 90.
3. Dismantle the upper arm as specified in section Dismantling the complete upper
arm on page 81.
4. Attach the crane to the lower arm.
5. Remove the parallel arm in accordance with section Dismantling the parallel arm
on page 79.
6. Loosen screws <1/13>.
7. Remove the lower arm.
To assemble
1. Transfer the damping element and calibration marking to the new lower arm.
2. Lift the lower arm into position.
3. Fix the lower arm to gear 2 using screws <1/13> and tighten them to a torque of
68 Nm ±10%.
To prevent clicking during operation of the robot, grease the bearing seating of the parallel
arm in the lower arm.
4. Replace the parallel arm as described in section Dismantling the parallel arm on
page 79.
5. Replace the upper arm as specified in section Dismantling the complete upper
arm on page 81.
6. Replace the balancing springs in accordance with section Dismantling the balancing springs on page 76 (not valid for IRB 1400H).
7. Replace the cabling as described in section Cabling and serial measuring board
on page 90.
8. Calibrate the robot according to section Calibration information on page 131.
Tightening torque
74
Screwed joint of lower arm/gear 2, item <13>:68 Nm ±10%
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4.3.4 Changing the bearings in the upper arm
4.3.4 Changing the bearings in the upper arm
See foldout 1 (6 for IRB 1400H) in the list of spare parts.
To dismantle
1. Loosen the upper bracket of the tie rod as described in section Changing the tie
rod on page 80.
2. Unscrew screws <13> which hold the parallel arm to gear 3.
3. Remove the bearings from the parallel arm.
To assemble
1. Fit new bearings to the parallel arm.
2. Replace the parallel arm using screws <13> and tighten to a torque of 68 Nm
±10%.
3. Attach the upper bracket of the tie rod as specified in section Changing the tie rod
on page 80.
4. Calibrate the robot according to section Calibration information on page 131.
Tightening torque
Screwed joint of parallel arm/gear 3, pos. <13>:68 Nm ±10%
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4.3.5 Dismantling the balancing springs
4.3.5 Dismantling the balancing springs
See foldouts 1 and 2 in the list of spare parts.
Note! Not valid for IRB 1400H.
To dismantle
1. Place the lower arm in a vertical position.
2. Loosen the locking nut <1/76>.
3. Release the spring using tool 3HAB 1214-6 and undo screw <1/13> at the same
time.
If the tool 3HAB 1214-6 is not available, but there are two persons, then the spring can be
released manually.
4. Unscrew <2/65> in the upper bracket of the spring.
5. Remove the springs.
To assemble
1. Before installing new springs, make sure that the distance between the attachment points is correct, see Figure . Lock the link heads using Loctite 242 or 243.
C C 377
Distance between the Attachment Points.
2. Lubricate the link heads with grease.
3. Attach the springs to the top bracket using screws <2/65> and tighten to a torque
of 39 Nm ±10%.
4. Pull the springs down using tool 3HAB 1214-6 and attach screws <1/13>, together
with lifting lug <1/23> and washer <1/17>.
5. Attach the locking nut <1/76>.
Tightening torque
76
Screws of upper bracket, position <65>:39 Nm ±10%.
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4.4.1 Changing the motor of axis 3
4.4: Axis 3
4.4.1 Changing the motor of axis 3
See foldouts 1 and 5 (6 for IRB 1400H) in the list of spare parts.
The motor and the drive gear constitute one unit.
NOTE!
There are two different types of motors, (Elmo and Yaskawa) The different motors are not
compatible. Make sure to replace with correct model!
To dismantle
1. Remove the cover of the motor.
2. Loosen connectors R5.MP3 and R5.FB3.
3. Remove the connection box by unscrewing <5/160>.
4. Note the position of the motor before removing it.
5. Loosen the motor by unscrewing <1/10>. N.B! The oil will start to run out.
To assemble
1. Check that the assembly surfaces are clean and the motor unscratched.
2. Release the brake, apply 24 V d.c. to terminals 7 and 8 on the 4.MP1 connector.
3. Install the motor, tighten screws <1/10> to a torque of approximately 2 Nm.
Note the position of the motor!
4. Adjust the motor in relation to the drive in the gearbox.
5. Screw the 3HAB 1201-1 crank tool into the end of the motor shaft.
6. Make sure there is no play.
7. Tighten screws <1/10> to a torque of 8.3 Nm ±10%.
8. Fill with oil. See section Oil in gears 1-4 on page 53.
9. Connect the cabling.
10.Calibrate the robot as specified in section Calibration information on page 131.
Tightening torque
The motor’s fixing screws, item 10:8.3 Nm ±10%
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4.4.2 Changing the gearbox
4.4.2 Changing the gearbox
Axis 3’s gearbox is of a conventional type, manufactured with a high degree of precision and,
together with the gearbox for axes 1 and 2, forms a complete unit.
The gearbox is not normally serviced are adjusted.
Note! If the gearbox of any of the axes 1, 2 or 3 needs to be changed,the whole unit must be
changed.
See foldout 1 in the list of spare parts.
To dismantle
78
See this chapter, section Changing the gearbox on page 73.
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4.4.3 Dismantling the parallel arm
4.4.3 Dismantling the parallel arm
See foldout 1 (6 for IRB 1400H) in the list of spare parts.
To dismantle
1. Loosen the upper bracket of the tie rod as described in this chapter, section
Changing the tie rod on page 80.
2. Unscrew screws <13> which fix the parallel arm to gear 3.
3. Remove the bearings from the parallel arm.
To assemble
1. Fit the bearings on the parallel arm.
2. Replace the parallel arm using screws <13> and tighten to a torque of
68 Nm ±10%.
3. Attach the upper bracket of the tie rod according to section Changing the tie rod
on page 80.
4. Calibrate the robot as specified in section Calibration information on page 131.
Tightening torque
Screwed joint of parallel arm/gear 3, item <13>:68 Nm ±10%
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4.4.4 Changing the tie rod
4.4.4 Changing the tie rod
See foldout 2 in the list of spare parts.
To dismantle
Lock the upper arm in a horizontal position with the help of a crane or similar.
1. Unscrew screw <74>.
2. Undo the two screws for fixing the cabling bracket of the upper arm housing.
Fold back the cabling bracket.
3. Screw the screw <74> back into the shaft <71>.
4. Carefully knock the shaft out.
5. Remove housing <72>.
6. Unscrew <70> on the lower bracket.
7. Carefully tap the rod off the shaft.
8. Change the bearings.
To assemble
1. Fit bearings on the parallel arm.
2. Make sure you replace the rod the correct way up. See foldout 1 (1:1).
3. Install grommets: (3 x) <68> and (1 x) <75>.
Note! The grommet <75> is bevelled and must be inserted the right way up in the lower
bearing.
4. Place the lower bearing of the tie rod on the parallel arm.
5. Screw in screw <70> and its washer <69>. Lock using Loctite 242 or 243.
6. Replace shaft <71>. N.B! Do not forget the sleeve <72>.
7. Mount washer <73> and tighten the shaft using a temporary screw, M8x35.
8. Replace this screw by screw <74> and mount the cable bearer <163>.
Lock using Loctite 242 or 243.
80
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4.4.5 Dismantling the complete upper arm
4.4.5 Dismantling the complete upper arm
See foldout 2 in the list of spare parts.
To dismantle
Attach a crane to the upper arm.
1. Unscrew the upper bracket of the tie rod as specified in section Changing the tie
rod on page 80.
2. Loosen the connectors of the motors of axes 4, 5 and 6.
3. Disconnect the connection box from the motors.
4. Detach the balancing springs as described in section Dismantling the balancing
springs on page 76 (not valid for IRB 1400H).
5. Undo the KM nuts <64>.
6. Remove washers <63> and shims <61-62> on the same side as axis 3.
7. Attach the withdrawing tool 3HAB 1259-1 and pull the axes off.
To assemble
1. Raise the upper arm into assembly position.
2. Install shaft spindles <59> (both sides), use two temporary screws M10x90.
3. Insert bearings <60> (both sides) using tool 3HAB 1200-1 and screws <65>.
4. Detach the tool and tighten the screws once more, only to prevent rotation of the
axis when the KM nut is tightened.
N.B! Assemble the same side as axis 2 first.
5. Mount two washers <63> and calibration washer <50>.
6. Tighten using the KM nut <64>.
7. Attach the measuring instrument 3HAB 1205-1 to the shaft spindle on axis 3.
N.B! If measuring instrument 3HAB 1205-1 is not available, you can use a micrometer
thickness gauge.
8. Hold the tool against the shoulder of the shaft spindle and measure the
dimension “A”. See Figure .
(If you are not using the measuring instrument, tighten using the KM nut and,
before measuring with the micrometer thickness gauge, then undo it again.)
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4.4.5 Dismantling the complete upper arm
Measuring the Shim Thickness when preloading the Bearing.
9. Make a note of the dimension “A”. Fit one washer <63> and shims <61-62>, and
using the micrometer, measure the thickness so that the total thickness is
0.10 - 0.20 mm more than the noted dimension “A”. This will result in a preloading
of the bearing of 0.10 - 0.20 mm.
10.Fit the shims and washer and tighten the KM nut <64>.
11.Replace the upper attachment of the tie rod as specified in section Changing the
tie rod on page 80.
12.Replace the balancing springs as described in section Dismantling the balancing
springs on page 76 (not valid for IRB 1400H).
13.Reconnect the connection boxes and the cabling.
14.Calibrate the robot in accordance with section Calibration information on page
131.
15.Undo the KM-nut on the axis 2 side, just to be able to adjust the calibration
washer <50>.
16.If the old armhouse is mounted, adjust the calibration washer according to the
punch mark. If the armhouse is new adjust the washer according to Figure and
make new punch marks for axes 3 and 4, according to section Calibration scales,
IRB 1400 on page 134.
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4.4.5 Dismantling the complete upper arm
105o
Calibration Mark for Axis 3.
Tools pressing
tool for bearings:
3HAB 1200-1
Measuring instrument:
3HAB 1205-1
Withdrawing tool for shaft spindles:
3HAB 1259-1
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4.5.1 Changing the motor
4.5: Axis 4
4.5.1 Changing the motor
See foldouts 5 and 8 in the list of spare parts.
The motor and the drive gear constitute one unit.
Position the arm system in such a way that the motor of axis 4 points upwards.
NOTE!
There are two different types of motors, (Elmo and Yaskawa) The different motors are not
compatible. Make sure to replace with correct model!
To dismantle
1. Remove the cover of the motor.
2. Loosen connectors R3.MP4 and R3.FB4.
3. Remove the connection box by unscrewing <5/160>.
4. Note the position of the motor before removing it.
5. Loosen the motor by unscrewing <8/23>.
To assemble
1. Check that the assembly surfaces are clean and the motor unscratched.
2. Put O-ring <8/21> on the motor.
3. Release the brake, apply 24 V DC to terminals 7 and 8 on the R3.MP4 connector.
4. Install the motor, tighten screws <8/23> to a torque of approximately 2 Nm.
Note the position of the motor!
5. Adjust the position of the motor in relation to the drive in the gearbox.
6. Screw the 3HAB 1201-1 crank tool into the end of the motor shaft.
7. Make sure there is a small clearance.
8. Unscrew one screw at a time, apply Loctite 242 or 243 and tighten to a torque of
4.1 Nm ±10%.
9. Connect the cabling.
10.Calibrate the robot as specified in section Calibration information on page 131.
Tightening torque
The motor’s fixing screws, item <23>:4.1 Nm ±10%
Tool
Crank tool for checking the play:
84
3HAB 1201-1
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4.5.2 Changing the intermediate gear including sealing
4.5.2 Changing the intermediate gear including sealing
See foldout 8 in the list of spare parts.
To dismantle
1. Dismantle the wrist as described in section Dismantling the wrist on page 94.
2. Dismantle the drive mechanism according to section Dismantling the complete
drive mechanism of axes 5 and 6 on page 95.
3. Dismantle the motor of axis 4 as specified in section Changing the motor on page
84.
4. Remove the cover <25>.
5. Undo screws <18> fixing the large drive gear <17> and dismantle it.
N.B! Put the shims in a safe place.
6. Undo screws <12>.
7. Push the intermediate gear out of the arm housing.
To assemble
1. Grease the seating of the arm housing to provide radial sealing.
2. Push the gear unit down into the arm housing.
3. Screw in screws <12> together with their washers <13> and pull the gear down.
4. Mount the drive gear <17> using screws <18> and tighten to a torque of
8.3 Nm ±10%.
N.B! Do not forget to insert shims <14, 15, 16> under the drive gear.
5. Tighten screws <12> to a torque of approximately 5 Nm.
6. Bend the pinion towards the large drive gear and then rotate it around the tubular
shaft a couple of times so that the clearance in the gears can adjust itself in relation to the highest point of the large drive gear.
7. Then tighten screws <12> to a torque of 20 Nm ±10%.
8. Check the clearance in relation to the tightening torque.
9. Replace the cover <25> using screws <26>. Use a drop of Loctite 242 or 243.
10.Position the manipulator so that the tubular shaft points upwards.
11.Fill (30 ml) oil into the gear of axis 4. See section Oil in gears 1-4 on page 53.
12.Install the motor of axis 4 in accordance with section Changing the motor on page
84.
13.Install drive mechanism <28> as described in section Dismantling the complete
drive mechanism of axes 5 and 6 on page 95.
14.Replace the wrist in accordance with section Dismantling the wrist on page 94.
15.Calibrate the robot as specified in section Calibration information on page 131.
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4 Repair
4.5.2 Changing the intermediate gear including sealing
Tightening torque
86
Screws for the large drive gear, item <18>:
8.3 Nm ±10%
Screws for the intermediate gear of axis 4, item <12>:
20 Nm ±10%
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4.5.3 Dismantling the drive gear on the tubular shaft
4.5.3 Dismantling the drive gear on the tubular shaft
See foldout 8 in the list of spare parts.
To dismantle
1. Dismantle the wrist as described in section Dismantling the wrist on page 94.
2. Dismantle the drive mechanism in accordance with section Dismantling the complete drive mechanism of axes 5 and 6 on page 95.
3. Dismantle the motor of axis 4 as specified in section Changing the motor on page
84.
4. Remove the cover <25>.
5. Unscrew screws <12> that hold the intermediate gear in place.
6. Unscrew screws <18> that hold the large drive gear <17> and then dismantle it.
N.B! Put the shims from under the drive gear in a safe place.
To assemble
Shim between drive gear <17> and the rear bearing <3>.
Shim thickness = B - A + 0.05 mm, see Figure .
Measuring the Shim Thickness of the Drive Gear of Axis 4.
1. Install the drive gear using screws <18> and tighten to a torque of 8.3 Nm ±10%.
N.B! Do not forget the shims.
2. Screw screw <19> and 2 washers <20> into the drive gear. Lock using Loctite 242
or 243.
3. Mount the intermediate gear according to section Changing the intermediate gear
including sealing on page 85.
4. Lubricate the drive gear with grease (30 g).
5. Install the motor of axis 4 as described in section Changing the motor on page 84.
6. Replace the cover <25> using screws <26>. Lock using a drop of Loctite 242 or
243.
3HAC021111-001 Revision: B
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4 Repair
4.5.3 Dismantling the drive gear on the tubular shaft
7. Mount the drive mechanism as specified in section Dismantling the complete
drive mechanism of axes 5 and 6 on page 95.
8. Mount the wrist according to section Dismantling the wrist on page 94.
9. Calibrate the robot as specified in section Calibration information on page 131.
Tightening torque
88
Screws of drive gear, item <18>:8.3 Nm ±10%
3HAC021111-001 Revision: B
4 Repair
4.5.4 Dismantling the tubular shaft and changing bearings
4.5.4 Dismantling the tubular shaft and changing bearings
See foldout 8 in the list of spare parts.
To dismantle
1. Dismantle the drive gear as described in section Dismantling the drive gear on the
tubular shaft on page 87.
2. Push out the tubular shaft.
To assemble
1. Fit a new bearing <3> on the tubular shaft using tool 6896 134-V.
2. Push the tube into the housing of the upper arm.
3. Insert the rear bearing <3> using tool 6896 134-JB.
4. Mount the drive gear in accordance with section Dismantling the drive gear on the
tubular shaft on page 87.
5. Calibrate the robot as specified in section Calibration information on page 131.
Tools
Pressing tool for front bearing:6896 134-V
Pressing tool for rear bearing:6896 134-JB
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89
4 Repair
4.6.1 Changing serial measuring boards
4.6: Cabling and serial measuring board
4.6.1 Changing serial measuring boards
See foldout 4 in the list of spare parts.
To dismantle
1. Remove flange plate <138>.
2. Cut tie around bundle <144>.
3. Unscrew the serial measuring board <135> using screws <7>.
4. Remove the board and loosen the contacts.
To assemble
90
1. Assemble in the reverse order.
3HAC021111-001 Revision: B
4 Repair
4.6.2 Changing the cabling in axes 1, 2 and 3
4.6.2 Changing the cabling in axes 1, 2 and 3
See foldouts 3 and 4 (7 for IRB 1400H) in the list of spare parts.
To dismantle
1. Remove the cover of the motors.
2. Remove the flange plate <4/138>.
3. Loosen connectors R1.MP, R2.FB1-3.
4. Cut tie around bundle and detach the cable brackets.
5. Detach the cable guides <3/104 and 105> and undo screws <3/149>.
6. Loosen the connectors in the motors.
7. Disconnect the connection boxes in the motors.
8. Feed the cabling up through the middle of axis 1.
To assemble
1. Assemble in the reverse order.
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4 Repair
4.6.3 Changing the cabling in axes 4, 5 and 6
4.6.3 Changing the cabling in axes 4, 5 and 6
See foldouts 2, 3 and 4 (6 for IRB 1400H) in the list of spare parts.
To dismantle
1. Remove the cover of the motors.
2. Remove the flange plate <4/138>.
3. Loosen connectors R2.MP4-6 and R2.FB4-6, including customer connector
R1.CS (if there is one) and the air hose.
4. Detach the cable guides <3/104, 105>.
5. Loosen the cable brackets <3/149> between gears 2 and 3 and cut the tie around
them.
6. Feed the cabling and air hose up through axis 1.
7. Loosen the cable bracket on the lower arm and undo screws <3/147>.
8. Undo screw <2/74> which fixes the shaft of the tie rod.
9. Disconnect the connection boxes in the motors.
10.Loosen the remaining cable brackets and remove the cabling.
To assemble
92
1. Assemble in the reverse order.
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4 Repair
4.6.3 Changing the cabling in axes 4, 5 and 6
4.7: The wrist and axes 5 and 6
The wrist, which includes axes 5 and 6, is a complete unit, comprising drive units and gears.
It is of such a complex design that it is not normally serviced on-site, but should be sent to
ABB to be serviced.
ABB recommends its customers to carry out only the following servicing and repair work on
the wrist.
•
Grease the wrist according to the table in section Maintenance Intervals on page
52.
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4 Repair
4.7.1 Dismantling the wrist
4.7.1 Dismantling the wrist
See foldouts 1 (6 for IRB 1400H) and 9 in the list of spare parts.
To dismantle
1. Remove the 2 plastic plugs on the rear of the wrist.
2. Release the brake in axes 5 and 6.
3. Rotate axes 5 and 6 so that you can see screws <9/15> in the clamping sleeve
through the hole.
4. Disconnect the clamping sleeve.
5. Undo screws <1/53> and remove the wrist.
To assemble
1. Mount the wrist, tighten screws <1/53> to a torque of 8.3 Nm ±10%.
Note! The grease nipple on the tilt house should be pointing against the base
when the axis 4 is in the calibration position.
2. Screw the clamping sleeves together using screws <9/15>.
3. Replace the plastic plugs.
4. Calibrate the robot as described in section Calibration information on page 131.
Tightening torque
94
Screwed joint of wrist/tubular shaft, item <1/53>:8.3 Nm ±10%
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4 Repair
4.7.2 Dismantling the complete drive mechanism of axes 5 and 6
4.7.2 Dismantling the complete drive mechanism of axes 5 and 6
See foldouts 8 and 9 in the list of spare parts.
To dismantle
1. Dismantle the wrist according to section Dismantling the wrist on page 94.
2. Loosen the connectors on the motors of axes 5 and 6.
3. Undo screws <8/29>.
4. Squeeze the drive shafts (<9/1>) together at the tip of the tubular shaft, in order
that they can pass through the tube.
5. Pull out the complete drive mechanism of axes 5 and 6.
To assemble
1. Install the drive mechanism in the tubular shaft.
2. Tighten screws <8/29> to a torque of 8.3 Nm ±10%.
3. Insert the cabling.
4. Mount the wrist as described in section Dismantling the wrist on page 94.
Tightening torque
Screwed joint of the drive mechanism, item <8/29>:8.3 Nm ±10%
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4 Repair
4.7.3 Changing the motor or driving belt of axes 5 and 6
4.7.3 Changing the motor or driving belt of axes 5 and 6
See foldout 9 in the list of spare parts.
To dismantle
1. Dismantle the wrist as described in section Dismantling the wrist on page 94.
2. Dismantle the drive mechanism according to section Dismantling the complete
drive mechanism of axes 5 and 6 on page 95.
3. Undo screws <9> and remove the appropriate motor.
4. If the driving belt is to be changed, both motors must be removed.
5. Undo screws <9> and remove plate <7>.
To assemble
1. Install the driving belts.
2. Mount the plate <7> using screws <9>.
NOTE!
Do not forget the nuts of the motors.
3. Install the motors.
NOTE!
There are two different types of motors, (Elmo and Yaskawa) The different motors are not
compatible. Make sure to replace with correct model!
4. Push the motors in sideways to tension the belts. Use tool 3HAA 7601-050.
Tighten screws <9> to a torque of 4.1 Nm.
5. Rotate the drive shafts. Check the tension on the belt.
6. Install the drive mechanism as described in section Dismantling the complete
drive mechanism of axes 5 and 6 on page 95.
7. Mount the wrist according to section Dismantling the wrist on page 94.
8. Calibrate the robot as specified in section Calibration information on page 131.
Tightening torque
Screws for motors and plate, item <9>:4.1 Nm.
Tool
To adjust the belt tension:
96
3HAA 7601-050
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4 Repair
4.7.4 Measuring play in axes 5 and 6
4.7.4 Measuring play in axes 5 and 6
Axis 5
Axis 4 shall be turned 90o. The maximum accepted play in axis 5 is 4.7 arc.minutes when
loading axis 5 with a moment of 4.8 Nm in one direction, unloading to 0.24 Nm and start
measuring the play, loading in the other direction with 4.8 Nm unloading to 0.24 Nm and
reading the play. This correspond to play of 0.27 mm on a radius of 200 mm when the load is
F=40 N and 2 N on radius 120 mm. See Figure .
120
35
F
200
Measuring Play in Axis 5.
Axis 6
The maximum accepted play in axis 6 is 12.8 arc.minutes when loading axis 6 with a moment
of 4.2 Nm in one direction, unloading to 0.2 Nm and start measuring the play, loading in the
other direction with 4.2 Nm unloading to 0.2 Nm and reading the play. This correspond to a
play of 0.37 mm on a radius of 100 mm when the load is F=42 N and 2 N. See Figure .
100
F
Measuring Play in Axis 6.
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97
4 Repair
4.8.1 General
4.8: Motor units
4.8.1 General
General
Each axis (6 axes) of the manipulator has its own motor unit, and is regarded as one complete
unit, comprising:
•
A synchronous motor
•
A brake (built into the motor)
•
A feedback device.
Description
The power and signal cables are run to the respective motor from the cable connector points
on the manipulator. The cables are connected to the motor units by connectors.
The drive shaft of the electric motor forms a part of the gearbox of the manipulator axis. A
brake, operated electromagnetically, is mounted on the rear end of the motor shaft and a
pinion is mounted on its drive end. The brake releases when power is supplied to the electromagnets.
The commutation value of the motors is: 1.570800.
NOTE!
There is a feedback device mounted on each motor unit. The device is installed by the supplier
of the motor and should never be removed from the motor. The motor need never be commutated.
98
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5 Calibration, M2000
5.0.1 Introduction
5: Calibration, M2000
5.0.1 Introduction
Calibration
methods
This chapter details how to calibrate the robot with the Wyler calibration equipment, using
Levelmeter 2000, when the robot is part of an M2000 robot system (S4Cplus controller).
The robot can also be calibrated with the Calibration Pendulum equipment, as detailed in the
Calibration Pendulum Instruction, enclosed with the Pendulum toolkit.
When to calibrate
The system must be calibrated if any of the below occurs.
Changed resolver
values
Calibrate the measurement system carefully as detailed in section Calibration on page 110 if
any of the resolver values have changed. This may occur when parts affecting the calibration
position are replaced on the robot.
Contents of the
revolution
counter memory
are lost
Calibrate the system roughly as detailed in section Updating the revolution counters on page
127 if the contents of the revolution counter memory are lost. This may occur when:
•
the battery is discharged
•
a resolver error occurs
•
the signal between a resolver and measurement board is interrupted
•
a robot axis is moved with the control system disconnected
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5 Calibration, M2000
5.1.1 How to calibrate the robot system
5.1: Overview
5.1.1 How to calibrate the robot system
General
This section provides an overview of the procedures to perform when calibrating the robot
system. Many of the steps in this overview are detailed in other sections to which references
are given.
Method -Wyler
Calibration
The calibration procedure with Wyler equipment may be performed with either one or two
sensors. The procedure detailed here is performed with only one sensor and may be described
as checking an pre-adjusted sensor, trying to obtain the same measurement value on every
axis as when adjusted at the reference plane.
All article numbers of relevant equipment are specified in their instructions respectively.
Overview,
calibration
Step
Additional
information
100
Action
Note
1.
Check that all required hardware is available for calibrating the robot.
Required hardware is specified in the
calibrating procedures for each axis.
2.
Manually run the robot axes to a position
close to the correct calibration position.
Use the calibration scales fitted to
each robot axis to locate this position.
These are shown in the section Calibration scales and correct axis position on page 102.
3.
Initialize the Levelmeter.
Detailed in section Initialization of
Levelmeter 2000 on page 108.
4.
Start the calibration procedure on the TPU. Detailed in section Fine calibration
procedure on TPU on page 122.
5.
Calibrate each axis.
Detailed in each axis' calibration
instruction.
6.
Verify that the calibration was successfully
carried out.
Detailed in section Post calibration
procedure on page 129.
In addition to the basic calibration procedure detailed above, a number of calibration related
actions may be performed:
Action
Detailed in section:
How to update the robot revolution counter without performing a
complete calibration.
Updating the revolution
counters on page 127
How to manually check the current calibration position.
Checking the calibration
position on page 105
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5 Calibration, M2000
5.1.2 Calibration, prerequisites
5.1.2 Calibration, prerequisites
Peripheral
equipment
The robot must be free from any peripheral equipment during calibration. Fitted tools and
similar will cause erroneous calibration positions.
Calibration order
The axes must be adjusted in increasing sequence, i.e. 1 - 2 - 3 - 4 - 5 - 6.
Location of
sensors
The positions where the calibration sensor and reference sensor should be fitted during calibration, are specified in Positions and directions of sensor on page 106.
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5 Calibration, M2000
5.2.1 Calibration scales and correct axis position
5.2: Reference information
5.2.1 Calibration scales and correct axis position
Introduction
This section specifies the calibration scale positions and/or correct axis position for all robot
models.
Safety
information
Read the safety information below.
If work must be carried out within the robot’s work envelope, the following points must be
observed:
The operating mode selector on the controller must be in the manual mode position to render
the enabling device operative and to block operation from a computer link or remote control
panel.
The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in position
< 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.
Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in order not
to get entangled with hair or clothing. Also be aware of any danger that may be caused by
rotating tools or other devices mounted on the manipulator or inside the cell.
Test the motor brake on each axis, according to section Brake testing .
102
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5 Calibration, M2000
5.2.1 Calibration scales and correct axis position
Calibration
scales, IRB 1400
The illustration below shows the calibration scale positions:
en0200000272
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103
5 Calibration, M2000
5.2.2 Directions for all axes
5.2.2 Directions for all axes
Calibration
movement
directions
When calibrating, the axis must consistently be run towards the calibration position in the
same direction, in order to avoid position errors caused by backlash in gears etc. Positive
directions are shown in the figure below.
This is normally handled by the robot calibration software.
Note! The figure shows an IRB 7600, but the positive direction is the same for all robots!
6+
4+
5+
3+
2+
1+
xx0200000089
104
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5 Calibration, M2000
5.2.3 Checking the calibration position
5.2.3 Checking the calibration position
General
Using the
program
CALxxxx in the
system software
Using the
Jogging window
on the teach
pendant
Check the calibration position before beginning any programming of the robot system. This
may be done in one of two ways:
•
Using the program CALxxxx in the system software (xxxx signifying the robot type;
IRB xxxx)
•
Using the Jogging window on the teach pendant
Step
Action
1.
Run the program \SYSTEM\UTILITY\SERVICE\CALIBRAT\CALxxxx in the system and follow the instructions displayed on the teach
pendant.
2.
Switch to MOTORS OFF when the robot stops.
Check that the calibration marks for that particular axis align correctly. If they do not, update the
revolution counters.
3.
Check that resolver offset values in the system
parameters match those on the parameter disk
delivered with the robot or those established
when calibrating the robot (after a repair, etc).
Step
Action
Button
Calibration marks are shown in
section Calibration scales and
correct axis position on page
102.
Detailed in section Updating the
revolution counters on page 127.
Illustration
1.
Open the Jogging window.
2.
Choose running axis-by-axis.
3.
Manually run the robot axis to a position where
the resolver offset value read, is equal to zero.
4.
Check that the calibration marks for that particu- Shown in section Calibration
lar axis align correctly. If they do not, update the scales and correct axis position
revolution counters !
on page 102.
Detailed in section Updating the
revolution counters on page
127.
xx0100000195
xx0100000196
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105
5 Calibration, M2000
5.2.4 Positions and directions of sensor
5.2.4 Positions and directions of sensor
General
This section details the mounting positions and directions for the
•
reference sensor
•
calibration sensor
When calibrating an axis with only one sensor, the sensor must first be positioned at the base
of the manipulator in order to create reference values. This is further detailed in section Resetting of Levelmeter 2000 and sensor on page 124. These reference values are then used to
calibrate the axes of the manipulator.
The reference sensor and the calibration sensor is consequently the same sensor used at different locations.
When using the sensor as a reference at the base, it is fitted to a sensor fixture together with
a sensor plate, as shown in the figure below. The sensor has different directions, depending
on which axis is calibrated. The directions are shown in the figure below.
Calibration and
reference sensor
position
The sensor is positioned and aligned on the axes as shown in the figures below.
xx0400001019
106
A
View from above Axis 2
B
View from above Axis 6
C
View from above Axis 5
3HAC021111-001 Revision: B
5 Calibration, M2000
5.2.4 Positions and directions of sensor
D
Axis 4
E
Axis 3
F
Direction for sensor at reference plane, axis 2, 3 and 5
G
Direction for sensor at reference plane, axis 4 and 6
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107
5 Calibration, M2000
5.2.5 Initialization of Levelmeter 2000
5.2.5 Initialization of Levelmeter 2000
Overview
Whenever Levelmeter 2000 is used for calibrating the robot, the equipment must first be
initialized as detailed in this section.
Shown below is an outline of how to initialize the Levelmeter 2000. Detailed procedures are
given further down.
1. Select the correct filter type, as detailed in Select filter type on page 108.
2. Set the measuring unit, as detailed in Measuring units on page 109.
3. Install sensor, as detailed in Installation of sensor on page 109.
4. Calibrate the robot, as detailed in the instruction for each axis respectively, in the section Calibration on page 110!
Levelmeter 2000
The Levelmeter 2000 is shown for reference below:
+
00 0 0 0 0 0 0 0 0 0
° oo
GON
Port/Sensor
A°o o
"1/12"
mRAD
"1/10"
mm/m
"/REL"
DEG
mm/REL
A
50
A
B
B AT T
LE VE LM ET ER 2000
+
O N /M O D E
Z E R O S E LE C T
E N TE R
C
S E N D /E S C
H O LD
W YL ER
A
B
OUT
xx0200000083
A
Measuring unit
B
Selection pointer
C
Sensor connection
Select filter type
Step
108
Action
Info/Illustration
1.
Press ON/MODE until the dot flashes under FIL- Shown in the figure Levelmeter
TER .
2000 on page 108!
2.
Press ENTER.
3.
The standard filter type no. 5 flashes.
Default setting is filter type 5.
3HAC021111-001 Revision: B
5 Calibration, M2000
5.2.5 Initialization of Levelmeter 2000
Step
4.
Action
Info/Illustration
If type 5 does not flash, press ZERO/SELECT to
select filter type 5 and press ENTER .
Measuring units
Step
Action
Info/Illustration
1.
Press ON/MODE until the dot flashes under UNIT . Shown in the figure Levelmeter 2000 on page 108!
2.
Press ENTER.
3.
Press ZERO/SELECT until mm/m flashes.
Two decimals (0.00) are shown on the display
4.
Press ENTER.
Installation of
sensor
Step
Result
Action
Info/Illustration
1.
Connect the sensor to the Sensor connection point. Shown in the figure Levelmeter 2000 on page 108!
2.
Press ON/MODE .
3.
Press ON/MODE until the dot flashes under SENSOR .
4.
Press ENTER.
5.
Press ZERO/SELECT until a flashing "A" is shown.
6.
Press ENTER.
Wait until the "A" flashes again.
7.
Press ENTER.
The Levelmeter 2000 is now initialized and ready for service.
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109
5 Calibration, M2000
5.3.1 Calibration axis 1
5.3: Calibration
5.3.1 Calibration axis 1
Location of axis 1
The axis 1 is located as shown in the figure below
The special calibration equipment is fitted to the base of the manipulator as shown in the
figure below.
xx0400001018
A
Guide oin ini gearbox
B
Calibration tool
C
Measuring pin, axis 1
Required
equipment
110
Equipment, etc.
Art. no.
Note
Isopropanol
1177 1012-208
Used to clean the reference surface
Calibration tool axis1
3HAB 1378-1
Measuring pin
6808 001-GR
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5 Calibration, M2000
5.3.1 Calibration axis 1
Calibration, axis 1
The procedure below details how to calibrate axis 1
NOTE!
Make sure the sensors and sensor positions on the manipulator are clean and free from metallic materials!
Step
Action
1.
Move the robot to its calibration position corresponding to the calibration scales.
2.
Remove the cover plate on the reference surface
on the base of the manipulator.
3.
Clean the surface with etanol and deburr it.
4.
Fit the calibration tool, axis 1 on the guide pin
underneath the gearbox.
5.
Release the brakes and move the manipulator
manually so that the measuring pin can be
placed in the guide hole on the base.
6.
Update axis 1 only , using the TPU.
7.
Remove the calibration tool for axis 1.
8.
Refit the cover plate to the reference surface on
the base of the manipulator, if no other calibration
is to be performed.
3HAC021111-001 Revision: B
Info/Illustration
Described in Fine calibration
procedure on TPU on page 122.
111
5 Calibration, M2000
5.3.2 Calibration, axis 2
5.3.2 Calibration, axis 2
General
This section details how to perform the actual fine calibration of axis 2 using the Wyler calibration equipment.
Required
equipment
Equipment
Art. no.
Note
Levelmeter 2000 cali6369 901-347
bration kit with one sensor
Includes one sensor.
Sensor plate
3HAC 0392-1
One sensor plate is required for each sensor!
Angle bracket
6808 0011-LP
For calibration sensor on manipulator lower arm.
Isopropanol
1177 1012-108
For cleaning the attachment points.
Other tools and procedures may be required.
See references to these
procedures in the stepby-step instructions
below.
These procedures include references to the tools
required.
TIP!
Lock the axes previous to the one calibrated to minimize the risk of accidentally moving other
axes! In case of accidental movement of previous axes, the calibration procedure must be
restarted from the moved axis and continued in increasing sequence!
Procedure
Step
112
Action
Illustration
1.
Reset the levelmeter and the sensor for cal- Detailed in section Resetting of Levelibration of axis 2.
meter 2000 and sensor on page 124.
2.
Clean the calibration surface with isopropanol.
Art. no. is specified in Required equipment on page 112!
3.
Fit the angle bracket on the lower arm.
Adjust the angle of the bracket to make it
level.
Art. no. is specified in Required equipment on page 112!
4.
Fit the calibration sensor together with the
Shown in section Positions and direcsensor plate on the angle bracket on axis 2. tions of sensor on page 106!
Carefully tighten the securing screws with
approximately same tightening torque that
used at the reference plane!
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5 Calibration, M2000
5.3.2 Calibration, axis 2
Step
5.
Action
Illustration
Manually run axis 2 in with the joystick to the Correct measurement on the levelcorrect position as indicated by the levelme- meter:
ter.
0 ±0.40 mm/m
Tip!
Reduce the jogging velocity in order to easily
position the axis as close to zero as possible!
6.
Update only axis 2.
7.
Remove the sensor.
8.
Refit the cover plate on the calibration surface on the manipulator lower arm. Refit also
the cover plate on the reference surface at
the base if no further calibration is performed.
9.
Check the calibration according to section
Post calibration procedure on page 129 or
continue with calibration of next axis.
3HAC021111-001 Revision: B
Detailed in section Fine calibration
procedure on TPU on page 122.
113
5 Calibration, M2000
5.3.3 Calibration, axis 3
5.3.3 Calibration, axis 3
General
This section details how to perform the actual fine calibration of axis 3 using the Wyler calibration equipment.
Required
equipment
Equipment
Art. no.
Info
Levelmeter 2000 calibration kit with one sensor
6369 901-347
Includes one sensor.
Sensor plate
3HAC 0392-1
One sensor plate is required for each sensor.
Turning disk fixture
6808 0011-GU
For fitting the calibration sensor plate to the
sync adapter.
Isopropanol
1177 1012-108
For cleaning the attachment points.
Other tools and procedures may be required.
See references to these
procedures in the step-bystep instructions below.
These procedures include references to the
tools required.
TIP!
Lock the axes previous to the one calibrated to minimize the risk of accidentally moving other
axes! In case of accidental movement of previous axes, the calibration procedure must be
restarted from the moved axis and continued in increasing sequence!
Procedure
Step
114
Action
Illustration/Info
1.
Clean the manipulator turning disk with isopro- Art. no. is specified in Required
panol.
equipment on page 114!
2.
Fit the sync adapter to the turning disk.
Fit the turning disk fixture (incl. guide pin) on
the turning disk.
3.
Turn the tool clockwise against the pin at the
same time as the screws are tightened.
4.
Run the program \SYSTEM\UTILITY\SERVICE\CALIBRAT\CALxxxx (xxxx=robot model,
e.g. 7600) in the system and select Calib:
CAL3.
The robot moves to the position for calibration
of axis 3.
5.
Reset the levelmeter with correct orientation of Detailed in section Resetting of
the sensor for calibration of axis 3.
Levelmeter 2000 and sensor on
page 124.
Art. no. is specified in Required
equipment on page 114!
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5 Calibration, M2000
5.3.3 Calibration, axis 3
Step
Action
Illustration/Info
6.
Fit the calibration sensor unit (sensor and
plate) on the turning disk fixture.
Carefully tighten the securing screws with
approximately same tightening torque that
used at the reference plane.
Shown in the section Positions
and directions of sensor on page
106!
7.
Manually run axis 3 in with the joystick to the
Correct measurement on the levcorrect position as indicated by the levelmeter. elmeter:
0 ±0.40 mm/m
Tip!
Reduce the jogging velocity in order to easily
position the axis as close to zero as possible!
8.
Update only axis 3.
9.
Remove the sensor.
10.
Check the calibration according to section Post
calibration procedure on page 129 or continue
with calibration of next axis.
11.
Refit the cover plate on the reference surface
on the base if no further calibration is performed.
3HAC021111-001 Revision: B
Detailed in section Fine calibration
procedure on TPU on page 122.
115
5 Calibration, M2000
5.3.4 Calibration, axis 4
5.3.4 Calibration, axis 4
General
This section details how to perform the actual fine calibration of axis 4 using the Wyler calibration equipment.
Required
equipment
Equipment
Art. no.
Info
Levelmeter 2000 calibra- 6369 901-347
tion kit with one sensor
Includes one sensor.
Sensor plate
3HAC 0392-1
One sensor plate is required for each sensor.
Turning disk fixture
6808 0011-GU
For fitting the calibration sensor plate to the
sync adapter.
Isopropanol
1177 1012-108
For cleaning the attachment points.
Other tools and procedures may be required.
See references to these
procedures in the stepby-step instructions
below.
These procedures include references to the
tools required.
TIP!
Lock the axes previous to the one calibrated to minimize the risk of accidentally moving other
axes! In case of accidental movement of previous axes, the calibration procedure must be
restarted from the moved axis and continued in increasing sequence!
Procedure
Step
116
Action
Illustration
1.
Clean the manipulator turning disk with isopropanol . Art. no. is specified in
Required equipment on
page 116!
2.
Fit the sync adapter to the turning disk.
Fit the turning disk fixture (incl. pin) on the turning
disk.
3.
Turn the tool clockwise against the pin at the same
time as the screws are tightened.
4.
Run the program \SYSTEM\UTILITY\SERVICE\CALIBRAT\CALxxxx (xxxx=robot model, e.g. 7600) in the
system and select Calib: CAL4A.
The robot moves to the position for calibration of axis
4.
5.
Reset the levelmeter with correct orientation of the
sensor for calibration of axis 4.
Art. no. is specified in
Required equipment on
page 116!
Detailed in section Resetting of Levelmeter 2000 and
sensor on page 124.
3HAC021111-001 Revision: B
5 Calibration, M2000
5.3.4 Calibration, axis 4
Step
Action
Illustration
6.
Fit the calibration sensor unit (sensor and plate) on Shown in the section Posithe turning disk fixture.
tions and directions of sensor on page 106!
Carefully tighten the securing screws with approximately same tightening torque that used at the reference plane.
7.
Manually run axis 4 in with the joystick to the correct Correct measurement on
position as indicated by the levelmeter.
the levelmeter:
0 ±0.80 mm/m
Tip!
Reduce the jogging velocity in order to easily position
the axis as close to zero as possible!
8.
Update only axis 4.
9.
Remove the sensor.
10.
Select Calib: CAL4B.
The axis 4 moves 90º, to a correct position.
11.
Update only axis 4.
12.
Check the calibration according to section Post calibration procedure on page 129 or continue with calibration of next axis.
13.
Refit the cover plate on the reference surface at the
base if no further calibration is performed.
3HAC021111-001 Revision: B
Detailed in section Fine calibration procedure on TPU
on page 122.
Detailed in section Fine calibration procedure on TPU
on page 122.
117
5 Calibration, M2000
5.3.5 Calibration, axis 5
5.3.5 Calibration, axis 5
General
This section details how to perform the actual fine calibration of axis 5 using the Wyler calibration equipment.
Required
equipment
Equipment
Art. no.
Info
Levelmeter 2000 cali6369 901-347
bration kit with one sensor
Sensor plate
3HAC 0392-1
One sensor plate is required for each sensor.
Turning disk fixture
6808 0011-GU
For fitting the calibration sensor plate to the sync
adapter.
Isopropanol
1177 1012-108
For cleaning the attachment points.
Other tools and procedures may be required.
See references to these
procedures in the stepby-step instructions
below.
These procedures include references to the
tools required.
TIP!
Lock the axes previous to the one calibrated to minimize the risk of accidentally moving other
axes! In case of accidental movement of previous axes, the calibration procedure must be
restarted from the moved axis and continued in increasing sequence!
Procedure
Step
118
Action
Illustration
1.
Clean the manipulator turning disk with isopropanol . Art. no. is specified in
Required equipment on
page 118!
2.
Fit the sync adapter to the turning disk.
Fit the turning disk fixture (incl. pin) on the turning
disk.
3.
Turn the tool clockwise against the pin at the same
time as the screws are tightened.
4.
Run the program \SYSTEM\UTILITY\SERVICE\CALIBRAT\CALxxxx (xxxx=robot model, e.g.
7600) in the system and select Calib: CAL5.
The robot will now move to the position for calibration
of axis 5.
5.
Reset the levelmeter with correct orientation of the
sensor for calibration of axis 5.
Art. no. is specified in
Required equipment on
page 118!
Detailed in section Resetting of Levelmeter 2000 and
sensor on page 124.
3HAC021111-001 Revision: B
5 Calibration, M2000
5.3.5 Calibration, axis 5
Step
Action
Illustration
6.
Fit the calibration sensor on the turning disk fixture. Shown in the section Positions and directions of senCarefully tighten the securing screws with approximately same tightening torque that used at the refer- sor on page 106!
ence plane.
7.
Manually run axis 5 in with the joystick to the correct Correct measurement on
position as indicated by the levelmeter.
the levelmeter:
0 ±0.80 mm/m
Tip!
Reduce the jogging velocity in order to easily position
the axis as close to zero as possible!
8.
Update only axis 5.
9.
Remove the sensor.
10.
Check the calibration according to section Post calibration procedure on page 129 or continue with calibration of next axis.
11.
Refit the cover plate on the reference surface at the
base if no further calibration is performed.
3HAC021111-001 Revision: B
Detailed in section Fine calibration procedure on TPU
on page 122.
119
5 Calibration, M2000
5.3.6 Calibration, axis 6
5.3.6 Calibration, axis 6
General
This section details how to perform the actual fine calibration of axis 6 using the Wyler calibration equipment.
Required
equipment
Equipment
Art. no.
Info
Levelmeter 2000 calibra- 6369 901-347
tion kit with one sensor
Sensor plate
3HAC 0392-1
One sensor plate is required for each sensor.
Turning disk fixture
6808 0011-GU
For fitting the calibration sensor plate to the
sync adapter.
Isopropanol
1177 1012-108
For cleaning the attachment points.
Other tools and procedures may be required.
See references to these
procedures in the stepby-step instructions
below.
These procedures include references to the
tools required.
TIP!
Lock the axes previous to the one calibrated to minimize the risk of accidentally moving other
axes! In case of accidental movement of previous axes, the calibration procedure must be
restarted from the moved axis and continued in increasing sequence!
Procedure
Step
Action
Illustration
1.
Calibrate axis 5.
Detailed in section Calibration, axis 5 on page 118.
2.
Reset the levelmeter with correct orientation of the Detailed in section Resetting
sensor for calibration of axis 6.
of Levelmeter 2000 and sensor on page 124.
3.
Fit the calibration sensor unit (sensor and plate) on Shown in section Positions
the turning disk fixture.
and directions of sensor on
Carefully tighten the securing screws with approxi- page 106!
mately same tightening torque that used at the reference plane.
4.
Manually run axis 6 in with the joystick to the correct Correct measurement on the
position as indicated by the levelmeter.
levelmeter:
0 ±0.80 mm/m
Tip!
Reduce the jogging velocity in order to easily position the axis as close to zero as possible!
120
3HAC021111-001 Revision: B
5 Calibration, M2000
5.3.6 Calibration, axis 6
Step
Action
Illustration
5.
Update only axis 6.
Detailed in section Fine calibration procedure on TPU on
page 122.
6.
Remove the sensor.
7.
Check the calibration according to section Post calibration procedure on page 129.
8.
Refit the cover plate on the reference surface at the
base.
3HAC021111-001 Revision: B
121
5 Calibration, M2000
5.3.7 Fine calibration procedure on TPU
5.3.7 Fine calibration procedure on TPU
General
This section details how to use the Teach Pendant Unit (TPU) when performing a fine calibration of the robot. The method of fitting the calibration equipment to each axis is detailed
in the calibration instruction for the axis.
Procedure
Step
1.
Action
Note/Illustration
Press the button "Miscellaneous".
xx0100000194
2.
Select the Service window by pressing ENTER.
xx0100000200
3.
Select Calibration
from the View menu.
The Calibration window
appears.
If multiple units are connected to the robot, they
will be listed in the window.
xx0100000201
The calibration status can be any of the following:
• Synchronized: all axes are calibrated and their
positions are known. The unit is ready for use.
122
•
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
detailed in section Updating the revolution
counters on page 127.
•
Not calibrated: one (or more) of the axes is NOT
fine-calibrated. This axis, or these axes, must
therefore be fine-calibrated as detailed below
and in the calibration instructions for each axis.
3HAC021111-001 Revision: B
5 Calibration, M2000
5.3.7 Fine calibration procedure on TPU
Step
4.
Action
Note/Illustration
Select the desired unit and
choose Fine Calibrate from the Calib
menu. A Warning window
appears.
xx0100000203
5.
Move the desired robot
axis according to the calibration procedure for current axis. These
procedures are found in
section Calibration on
page 110.
Press OK. The Fine Calibrate window appears.
6.
Select the desired axis
and press Incl to
include it (it will be marked
with an x) or press All to
select all axes.
7.
Press OK when all axes
that are to be updated are
marked with an x.
CANCEL returns to the
Calibration window.
8.
Press OK again to confirm and start the update.
CANCEL returns to the
Fine Calibration window.
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.
xx0100000204
3HAC021111-001 Revision: B
123
5 Calibration, M2000
5.3.8 Resetting of Levelmeter 2000 and sensor
5.3.8 Resetting of Levelmeter 2000 and sensor
General
The equipment must first be reset before calibrating each axis.
This section details how to reset the Levelmeter 2000 and make the one sensor ready for
calibration.
Levelmeter 2000
The Levelmeter 2000 is shown for reference below:
+
00 0 0 0 0 0 0 0 0 0
° oo
GON
Port/Sensor
A°o o
"1/12"
mRAD
"1/10"
mm/m
"/REL"
A
DEG
mm/REL
A
50
B
B AT T
LE VE LM ET ER 2000
+
O N /M O D E
Z E R O S E LE C T
E N TE R
C
S E N D /E S C
H O LD
W YL ER
A
B
OUT
xx0200000083
Sensor mounted
on fixture
A
Measuring unit
B
Selection pointer
C
Sensor connection
When using the sensor as a reference sensor it is fitted to the sensor fixture, together with a
sensor plate, as shown below.
See the section Positions and directions of sensor on page 106 for actual positioning and
orientation of the fixture and the sensor, since the direction of the sensor differs depending on
which axis is calibrated.
A
X
Y
B
C
xx0100000207
124
3HAC021111-001 Revision: B
5 Calibration, M2000
5.3.8 Resetting of Levelmeter 2000 and sensor
A
Reference sensor, fitted to the sensor plate (actual direction differs)
B
Sensor fixture, fitted on manipulator base
C
Attachment screws, sensor plate
Required
equipment
Equipment
Art. no.
Note
Levelmeter, one sensor
6369 901-347
Includes one sensor.
Sensor plate
3HAC 0392-1
Sensor fixture
6808 0011-GM
Isopropanol
1177 1012-108
For cleaning the sensor fixture.
Note!
Always secure the sensor to the sensor fixture using screws and with approximately the same
torque each time!
Note!
Always fit the sensor in the same direction when resetting it as when performing the calibration for each axis!
Note!
Always reset the sensor when using it in a new direction!
Resetting
Step
Action
Info/Illustration
1.
If the sensor and the sensor plate are separate, Art. no. is specified in Required
fit them together by first cleaning the attachment equipment on page 125.
area on the sensor plate with isopropanol and
then fitting the sensor to it.
Handle the sensor plate and the sensor as a
complete unit when fitting it to and moving it
between the reference point and the different
axes.
2.
Make sure the Levelmeter is initialized according
to section Initialization of Levelmeter 2000 on
page 108.
3.
Remove the cover plate on the reference surface Shown in the section Positions
on the manipulator base.
and directions of sensor on
page 106.
4.
Clean the area where the sensor fixture is fitted
with isopropanol .
5.
Fit the sensor fixture on the reference surface on Art. no. is specified in Required
the manipulator base.
equipment on page 125!
Orientation is specified in section Positions and directions of
sensor on page 106!
3HAC021111-001 Revision: B
125
5 Calibration, M2000
5.3.8 Resetting of Levelmeter 2000 and sensor
Step
Result
126
Action
Info/Illustration
6.
Clean the sensor plate attachment area on the
fixture with isopropanol.
7.
Fit the sensor unit (sensor plate and sensor) on
to the sensor fixture and connect the sensor to
the Levelmeter 2000.
Correct direction is shown in
Positions and directions of sensor on page 106.
Connection is shown in the figure Sensor mounted on fixture
on page 124.
8.
Press ON/MODE on the Levelmeter 2000 until
the dot flashes under REL ZERO .
Shown in the figure Levelmeter
2000 on page 124!
9.
Press ENTER.
10.
Wait until + or - flashes.
11.
Press HOLD .
12.
Wait until + or - flashes.
13.
Press ENTER.
The Levelmeter 2000 and the one sensor is now reset and ready for service. When moving
the sensor and the sensor plate to different axes, move it as a complete unit.
3HAC021111-001 Revision: B
5 Calibration, M2000
5.3.9 Updating the revolution counters
5.3.9 Updating the revolution counters
Manually running
the manipulator
to the calibration
position
This section details the first step when updating the revolution counter; manually running the
manipulator to the calibration position.
Step
Storing the
revolution
counter setting
Action
Illustration
1.
Select axis-by-axis motion mode.
2.
Press the enabling device on the teach pendant Shown in section Calibration
and, using the joystick, move the robot manually scales and correct axis position
so that the calibration marks lie within the toler- on page 102.
ance zone.
3.
Note that axis 6 does not have any mechanical
stop and can thus be calibrated at the wrong
faceplate revolution. Do not operate axis 6 manually before the robot has been calibrated.
4.
When all axes are positioned as above, store the
revolution counter settings using the Teach Pendant Unit as detailed below:
This section details the second step when updating the revolution counter; storing the revolution counter setting.
CAUTION!
If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, which
in turn may cause damage or injury!
Check the calibration very carefully after each update!
Step
1.
Action
Illustration
Press the button "Miscellaneous".
xx0100000194
2.
Select the Service window by pressing ENTER.
3.
Select Calibration from
the View menu.
The Calibration window
appears.
If there is more than one unit
connected to the robot, they
will be listed in the window.
xx0100000200
xx0100000201
3HAC021111-001 Revision: B
127
5 Calibration, M2000
5.3.9 Updating the revolution counters
Step
4.
Action
Illustration
Select the desired unit and
choose Rev Counter
Update from the Calib
menu.
The Revolution Counter
Update window appears.
xx0100000202
128
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.
Press OK when all axes
that are to be updated are
marked with an x.
CANCEL returns to the Calibration window.
7.
Press OK again to confirm
and start the update.
CANCEL returns to the
Revolution Counter Update
window.
8.
At this point, it is recomNot required.
mended that the revolution
counter values are saved to
a diskette.
9.
Recheck the calibration
position.
Detailed in section Checking the calibration position
on page 105.
3HAC021111-001 Revision: B
5 Calibration, M2000
5.4.1 Post calibration procedure
5.4: After calibration
5.4.1 Post calibration procedure
General
Perform the following procedure after calibrating any manipulator axes. The procedure is
intended to verify that all calibration positions are correct.
Procedure
Step
Action
Illustration
1.
Run the calibration home position program twice. .
Do not change the position of the manipulator
axes after running the program!
2.
Check the calibration positions.
Detailed in section Calibration
If the axes are outside the tolerance, start the cal- on page 110.
ibration procedure from the beginning, in increasing sequence of the axes.
3.
Repeat the check as above.
4.
Adjust the calibration marks when the calibration Shown in section Calibration
is done.
scales and correct axis position on page 102.
5.
The system parameters will be saved to the storage memory at power off.
6.
Change the values on a new label and stick it on
top of the label located
• underneath the flange plate on the base.
7.
Remove any calibration equipment from the
manipulator.
3HAC021111-001 Revision: B
129
5 Calibration, M2000
5.4.1 Post calibration procedure
130
3HAC021111-001 Revision: B
6 Calibration information
6.0.1 Introduction
6: Calibration information
6.0.1 Introduction
General
This chapter includes general information about different calibration methods and also details
procedures that do not require specific calibration equipment.
When the robot system must be recalibrated, it is done according to documentation enclosed
with the calibration tools.
When to calibrate
The system must be calibrated if any of the below occurs.
The resolver values are changed
If resolver values are changed, the robot must be recalibrated using the calibration methods
supplied from ABB. Calibrate the robot carefully with standard calibration. The different
methods are briefly described in section Calibration methods on page 133, and further
detailed in separate Calibration manuals.
If the robot has Absolute Accuracy calibration, it is also recommended but not always needed
to be calibrated for new Absolute Accuracy.
The resolver values will change when parts affecting the calibration position are replaced on
the robot, e.g. motors, wrist or part of transmission.
Contents of the
revolution
counter memory
are lost
If the contents of the revolution counter memory are lost, the counters must be updated as
detailed in section Updating revolution counters on page 136. This will occur when:
• the battery is discharged
• a resolver error occurs
• the signal between a resolver and measurement board is interrupted
• a robot axis is moved with the control system disconnected
The revolution counters must also be updated after the robot and controller are connected at
the first installation.
The robot is
rebuilt
If the robot has been rebuilt, e.g. after a crash or when the robot has been changed for other
reachability, it needs to be recalibrated for new resolver values.
If the robot has Absolute Accuracy calibration, it needs to be calibrated for new Absolute
Accuracy.
3HAC021111-001 Revision: B
131
6 Calibration information
6.0.2 Calibration methods
6.0.2 Calibration methods
Overview
This section specifies the different types of calibration and the calibration methods that are
supplied from ABB.
Types of calibration
Type of
calibration
Description
Calibration method
Standard calibration
The calibrated robot is positioned at home
position, i.e. the axes positions (angles) are
set to 0º.
Standard calibration data is found in the file
calib.cfg, supplied with the robot at delivery.
The file identifies the correct resolver/motor
position corresponding to the robot home position.
From deliveries together with RobotWare 5.0.5
and higher, the data will instead be found on
the SMB (serial measurement board) in the
robot, and not in a separate file.
Calibration Pendulum
(standard method)
or
Levelmeter calibration
(alternative method)
Absolute Accuracy
calibration
(optional)
Based on standard calibration, and besides
CalibWare
positioning the robot at home position, the
Absolute Accuracy calibration also compensates for:
mechanical tolerances in the robot structure
deflection due to load.
Absolute Accuracy calibration focuses on
positioning accuracy in the Cartesian coordinate system for the robot.
Absolute Accuracy data is found in the file
absacc.cfg, supplied with the robot at delivery.
The file replaces the calib.cfg file and identifies
motor positions as well as absacc-compensation parameters.
From deliveries together with RobotWare 5.0.6
and higher, the data will instead be found on
the SMB (serial measurement board) in the
robot, and not in a separate file.
A robot calibrated with AbsAcc has a sticker
next to the identification plate of the robot.
To regain 100% Absolute Accuracy performance, the robot must be recalibrated for
Absolute Accuracy!
xx0400001197
132
3HAC021111-001 Revision: B
6 Calibration information
6.0.2 Calibration methods
Calibration
methods
Each calibration method is detailed in a separate manual. Below is a brief description of the
methods available.
Calibration Pendulum - standard
method
Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB
6400R, IRB 640, IRB 1400H and IRB 4400S) and is also the most accurate method for the
standard type of calibration. It is the recommended method in order to achieve proper performance.
Two different routines are available for the Calibration Pendulum method:
• Calibration Pendulum II
• Reference Calibration.
The calibration equipment for Calibration Pendulum is delivered as a complete toolkit,
including the operating manual for Calibration Pendulum, which describes the method and
the different routines further.
Levelmeter Calibration - alternative method
Levelmeter Calibration is referred to as the alternative method for calibration of ABB robots,
because of the less accurate values obtained during calibration. The method uses the same
principles as Calibration Pendulum but does not have as good of mechanical tolerances to the
toolkit parts as the standard method with Calibration Pendulum.
This method may, after calibration, require modifications in the robot program, and is therefore not recommended.
The calibration equipment for Levelmeter Calibration is ordered as separate parts for each
robot and the operating manual for Levelmeter Calibration is enclosed with the Levelmeter
2000.
CalibWare - Absolute Accuracy calibration
In order to achieve a good positioning in the Cartesian coordinate system, Absolute Accuracy
is used as a TCP calibration. The tool CalibWare guides through the calibration process and
calculates new compensation parameters. This is detailed further in the manual CalibWare 2.0
Users Guide (M2000).
If a service operation is done to a robot with Absolute Accuracy, a new absolute accuracy
calibration is required in order to establish full performance. For most cases after motor and
transmission replacements that do not include taking apart the robot structure, standard calibration is sufficient. Standard calibration also supports wrist exchange.
References
Article numbers for the calibration tools are listed in section Special tools in part 2 of the
Product manual. A calibration manual is enclosed with the calibration tools.
The article numbers for the operating manuals for calibration are also listed in section xx.
3HAC021111-001 Revision: B
133
6 Calibration information
6.0.3 Calibration scales and correct axis position
6.0.3 Calibration scales and correct axis position
Introduction
This section specifies the calibration scale positions and/or correct axis position for all robot
models.
Calibration
scales, IRB 1400
The illustration below shows the calibration scale positions on IRB 1400:
en0200000272
134
3HAC021111-001 Revision: B
6 Calibration information
6.0.4 Calibration movement directions for all axes
6.0.4 Calibration movement directions for all axes
Overview
When calibrating, the axis must consistently be run towards the calibration position in the
same direction, in order to avoid position errors caused by backlash in gears etc. Positive
directions are shown in the figure below.
This is normally handled by the robot calibration software.
Calibration
movement directions, 6 axes
NOTE!
The figure shows an IRB 7600, but the positive direction is the same for all 6-axis robots,
except the positive direction of axis 3 for IRB 6400R which is in the opposite direction!
xx0200000089
3HAC021111-001 Revision: B
135
6 Calibration information
6.0.5 Updating revolution counters
6.0.5 Updating revolution counters
General
This section details how to perform a rough calibration of each robot axis, i.e. updating the
revolution counter value for each axis, using the pendant.
Step 1 - Manually
running the robot
to the calibration
position
This procedure details the first step when updating the revolution counter; manually running
the robot to the calibration position.
Action
Note
Select axis-by-axis motion mode.
Step 2 - Storing
the revolution
counter setting
with the FlexPendant
Jog the robot to place the calibration marks
within the tolerance zone.
IRB 140, 1400, 2400, 4400, 6600ID/
6650ID: Axes 5 and 6 must be positioned
together!
Shown in section Calibration scales, IRB
1400 on page 134.
When all axes are positioned, store the
revolution counter settings.
Detailed in sections:
Step 2 - Storing the revolution counter setting with the FlexPendant on page 136
(RobotWare 5.0).
This procedure details the second step when updating the revolution counter; storing the revolution counter setting with the FlexPendant (RobotWare 5.0).
Action
On the ABB menu, tap Calibration.
All mechanical units connected to the system are shown along with their calibration
status.
Tap the mechanical unit in question.
A screen is displayed: tap Rev. Counters.
en0400000771
136
3HAC021111-001 Revision: B
6 Calibration information
6.0.5 Updating revolution counters
Action
Tap Update Revolution Counters....
A dialog box is displayed, warning that updating the revolution counters may change
programmed robot positions:
Tap Yes to update the revolution counters.
Tap No to cancel updating the revolution counters.
Tapping Yes displays the axis selection window.
Select the axis to have its revolution counter updated by:
Ticking in the box to the left
Tapping Select all to update all axes.
Then tap Update.
A dialog box is displayed, warning that the updating operation cannot be undone:
Tap Update to proceed with updating the revolution counters.
Tap Cancel to cancel updating the revolution counters.
Tapping Update updates the ticked revolution counters and removes the tick from the
list of axes.
If a revolution counter is incorrectly updated, it will cause incorrect robot positioning,
which in turn may cause damage or injury!
Check the calibration position very carefully after each update.
See section Checking the calibration position on page 138.
3HAC021111-001 Revision: B
137
6 Calibration information
6.0.6 Checking the calibration position
6.0.6 Checking the calibration position
General
Check the calibration position before beginning any programming of the robot system. This
may be done in one of two ways:
• Using a MoveAbsJ instruction with argument zero on all axes.
• Using the Jogging window on the teach pendant.
Using a
MoveAbsJ
instruction on the
FlexPendant,
IRC5
This section describes how to create a program, which runs all the robot axes to their zero
position.
Action
Note
On ABB menu tap Program Editor.
Create a new program.
Use MoveAbsJ in the Motion&Proc menu.
Create the following program: MoveAbsJ
[[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E
9]]\NoEOffs, v1000, z50, Tool0
Run the program in manual mode.
Check that the calibration marks for the axes align
correctly. If they do not, update the revolution
counters!
Using the
Jogging window
on the FlexPendant, IRC5
The calibration marks are shown
in section Calibration scales,
IRB 1400 on page 134.
How to update the revolution
counters is detailed in section
Updating revolution counters on
page 136.
This section describes how to jog the robot to all axes zero position.
Action
Note
Tap Jogging in the ABB menu.
Tap Motion mode to choose group of axes to jog.
Tap axes 1-3 to jog axes 1, 2 or 3.
Manually run the robots axes to a position where the axis
position value read on the FlexPendant, is equal to zero.
Check that the calibration marks for the axes align correctly. If they do not, update the revolution counters!
138
The calibration marks are
shown in section Calibration
scales, IRB 1400 on page
134.
How to update the counters
is detailed in section Updating revolution counters on
page 136.
3HAC021111-001 Revision: B
6 Calibration information
6.0.6 Checking the calibration position
3HAC021111-001 Revision: B
139
7 Alternative calibration
7.0.1 Alternative calibration position
7: Alternative calibration
7.0.1 Alternative calibration position
General
The manipulator may be calibrated in alternative positions. The regular calibration instructions detailed for each axis are intended for calibration position 0, i.e. the normal position
Calibration instructions for alternative positions are detailed in Alternative calibrating on
page 128.
Illustration
The illustration shows the available calibrating positions of a suspended robot.
xx0400001020
A
Calibration program Normal, calibration position 0 (axes 2 and 3)
B
Calibration program Hanging, calibration position -1.570796 (axes 2 and 3)
3HAC021111-001 Revision: B
141
7 Alternative calibration
7.0.2 Alternative calibrating
7.0.2 Alternative calibrating
General
The manipulator may be calibrated in any of three positions, shown in Alternative calibration
position on page 127.
Procedure
Step
142
Action
Illustration
1.
Calibrate the robot in position 0 for all axes.
Set an alternative calibration position before installation if the
final installation makes it impossible to reach the calibration
0 position.
2.
Run the calibration program CALxxx in the system\SYSTEM\UTILITY\SERVICE\CALIBRAT\. (xxx = robot version,
e.g. CAL1400)
3.
Select Normal position, and check the calibration marks for
each axis.
4.
Run the calibration program again and select the desired calibration position (Hanging) as shown in Alternative calibration position on page 127.
5.
Change to the new calibration offset, as detailed in New calibration offset on page 130.
6.
Note the new calibration offset on the label, located under the
flange plate on the base.The new calibration offset values
can be found as detailed in Retrieving offset values on page
131.
7.
Change to the new calibration position as detailed in New
calibration position on page 129.
8.
Restart the robot by selecting Restart from the File menu.
9.
Mark the new calibration positions for axes 2 and 3, with the
punch marker.
10.
The system parameters will be saved to the storage memory
at power off.
3HAC021111-001 Revision: B
7 Alternative calibration
7.0.3 New calibration position
7.0.3 New calibration position
Procedure
Use these instructions to change to a new calibration position for axis 1 during definition of
a new calibration position.
Step
Action
1.
Press the "Miscellaneous" button
2.
Select the System parameters window by pressing ENTER.
Illustration
xx0100000194
xx0100000200
3.
Select Manipulator from the Topics menu.
4.
Select Arm from the Types menu.
5.
Select axes 2 and 3.
6.
Change Cal pos to -1.570796.
7.
The angle is measured in radians as shown in Alternative calibration
position on page 127.
3HAC021111-001 Revision: B
143
7 Alternative calibration
7.0.4 New calibration offset
7.0.4 New calibration offset
Procedure
Use these instructions when changing to a new calibration offset for axis 1 during definition
of a new calibration position.
Step
1.
Action
Illustration
Press the "Miscellaneous" button.
xx0100000194
2.
Select the Service window by pressing ENTER.
xx0100000200
3.
Select Calibration from the View
menu. The calibration window
appears.
xx0100000201
144
4.
Select Calibrate from the Calib
menu.
5.
Select axes 2 and 3.
6.
Confirm by pressing OK twice.
3HAC021111-001 Revision: B
7 Alternative calibration
7.0.5 Retrieving offset values
7.0.5 Retrieving offset values
Procedure
Use these instructions when retrieving new offset values for axis 1 during definition of a new
calibration position.
Step
Action
1.
Press the “Micellaneous” button.
2.
Select the system parameters window by pressing
ENTER.
3.
Select Motor from the Types menu.
4.
Select axes 2 and 3, and press ENTETR.
Illustration
xx0100000194
xx0100000200
xx0100000200
5.
3HAC021111-001 Revision: B
Note the cal offset value.
145
7 Alternative calibration
7.0.5 Retrieving offset values
146
3HAC021111-001 Revision: B
8 Reference information, IRB 1400
8.0.1 Introduction
8: Reference information, IRB 1400
8.0.1 Introduction
General
This chapter includes general information, complementing the more specific information in
the following chapters.
3HAC021111-001 Revision: B
147
8 Reference information, IRB 1400
8.0.2 Applicable Safety Standards
8.0.2 Applicable Safety Standards
Standards,
general
Standards, safety
fence
Standards, robot
cell
148
The robot is designed in accordance with the requirements of:
•
EN ISO 10218-1 : 2006, Robots for industrial environments - Safety requirements Part 1 Robot
•
ANSI/RIA 15.06-1999
•
ISO/DIS 11161, Industrial automation systems - safety of integrated manufacturing
systems - Basic requirements
•
DIN 19258 - Interbus-S, International Standard
The following standards are applicable to the safety fence surrounding the robot cell:
•
ISO/DIS 11161, Industrial automation systems - safety of integrated manufacturing
systems - Basic requirements
•
prEN 999:1995
The following standards are applicable when the robot is part of a robot cell:
•
IEN 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 - Interlocking device associated with guards principles
for design and selection.
3HAC021111-001 Revision: B
8 Reference information, IRB 1400
8.0.3 Unit conversion
8.0.3 Unit conversion
Converter table
Use the table below to convert units used in this manual.
Quantity
Units
Length
1m
3.28 ft
Weight
1 kg
2.21 lb
Pressure
1 bar
100 kPa
Force
1N
0.738 lbf
Moment
1 Nm
0.738 lbf-tn
Volume
1L
0.264 US gal
3HAC021111-001 Revision: B
39.37 in
14.5 psi
149
8 Reference information, IRB 1400
8.0.4 Screw joints
8.0.4 Screw joints
General
This section details how to tighten the various types of screw joints on the robot and the
controller.
The instructions and torque values are valid for screw joints comprised of metallic materials
and do not apply to soft or brittle materials.
UNBRAKO
screws
UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It
features special surface treatment (Gleitmo as described below), and is extremely resistant to
fatigue.
Whenever used, this is specified in the instructions and in such cases no other type of
replacement screw is allowed! Using other types of screws will void any warranty and may
potentially cause serious damage or injury!
Gleitmo treated
screws
Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.
Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After
this the screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should
be used.
Screws lubricated
in other ways
Screws lubricated with Molycote 1000 should only be used when specified in the repair,
maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1. Apply lubricant to the screw thread.
2. Apply lubricant between the plain washer and screw head.
3. Tighten to the torque specified in section Tightening torque below. Screw dimensions
of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or
smaller may be tightened without a torque wrench if this is done by trained and
qualified personnel.
150
Lubricant
Art. no.
Molycote 1000 (molybdenum disulphide grease)
1171 2016-618
3HAC021111-001 Revision: B
8 Reference information, IRB 1400
8.0.4 Screw joints
Tightening torque
Before tightening any screw, note the following:
•
Determine whether a standard tightening torque or special torque is to be applied. The
standard torques are specified in the tables below. Any special torques are specified in
the Repair, Maintenance or Installation procedure description. Any special torque
specified overrides the standard value.
•
Use the correct tightening torque for each type of screw joint.
•
Only use correctly calibrated torque keys.
•
Always tighten the joint by hand, and never use pneumatical tools
•
Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a slow,
flowing motion.
•
Maximum allowed total deviation from the specified value is 10%!
The table below specify the recommended standard tightening torque for oil-lubricated
screws with slotted or cross-recess head screws.
Dimension
Tightening torque (Nm)
Class 4.8, oil-lubricated
M2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
The table below specify the recommended standard tightening torque for oil-lubricated
screws with Allen head screws.
Dimension
Tightening torque
(Nm)
Class 8.8, oillubricated
Tightening torque
(Nm)
Class 10.9, oillubricated
Tightening torque
(Nm)
Class 12.9, oillubricated
M5
6
-
-
M6
10
-
-
M8
24
34
40
M10
47
67
80
M12
82
115
140
M16
200
290
340
3HAC021111-001 Revision: B
151
8 Reference information, IRB 1400
8.0.4 Screw joints
The table below specify the recommended standard tightening torque for Molycote-lubricated screws with Allen head screws.
Dimension
Tightening torque (Nm)
Tightening torque (Nm)
Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M8
28
34
M10
55
66
M12
96
115
M16
235
280
The table below specify the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass.
152
Dimension
Tightening torque
Nm - Nominal
Tightening torque
Nm - Min.
Tightening torque
Nm - Max.
1/8
12
8
15
1/4
15
10
20
3/8
20
15
25
1/2
40
30
50
3/4
70
55
90
3HAC021111-001 Revision: B
8 Reference information, IRB 1400
8.0.5 Weight specifications
8.0.5 Weight specifications
Definition
In all repair and maintenance procedures, weights of the components handled are sometimes
specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.
To avoid injury, ABB recommends the use of lifting equipment when handling components
with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for
each manipulator model.
Example
Below is an example of how a weight specification is presented:
CAUTION!
The motor weighs 32 kg! All lifting equipment used must be sized accordingly!
3HAC021111-001 Revision: B
153
8 Reference information, IRB 1400
8.0.6 Document references
8.0.6 Document references
General
The contents of this manual may include references to additional documentation necessary to
perform certain procedures. This section specifies the article numbers for the referenced documentation.
Product specification, robot
The product specification includes generic technical data. The specification listed below is
the English version.
Product manuals,
controller
Operators manual
Document name
Document ID
Product specification
3HAC 9376-1
The product manuals include information about installation and service activities. The table
below specifies the article numbers of the product manuals for all controller models. The part
number -001 is the English version.
Document name
Document ID
Product manual, S4Cplus M2000
3HAC 021333-001
Product manual, S4Cplus M2000A
3HAC 021128-001
Product manual, IRC5 M2004
3HAC 021313-001
The operators manual contains instructions for daily operation of robot systems. The table
below specifies the article numbers of the operators manuals for different robot systems.
Document name
Document ID
Note
User’s guide (S4Cplus)
3HAC 7793-1
Contains instructions for daily operation
of S4Cplus based robot systems.
Operator’s manual (IRC5)
3HAC 16590-1
Additional documentaion
154
Document name
Document ID
Note
Calibration Pendulum Instruction
3HAC 16578-1
Enclosed with the Calibration Pendulum Toolkit.
External axes
3HAC 9299-1
3HAC021111-001 Revision: B
8 Reference information, IRB 1400
8.0.7 Standard toolkit, IRB 1400
8.0.7 Standard toolkit, IRB 1400
General
All service (repair, maintenance and installation) instructions contain lists of tools required
to perform the specified activity. All special tools, i.e. all tools that are not considered standard as defined below, are listed in their instructions respectively.
This way, the tools required are the sum of the Standard Toolkit and any tools listed in the
instruction.
Contents
Tool
3HAC021111-001 Revision: B
Rem.
155
8 Reference information, IRB 1400
8.0.8 Performing a leak-down test
8.0.8 Performing a leak-down test
General
After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil
must be tested. This is done in a leak-down test.
Required equipment
Equipment, etc.
Art. no.
Leakdown tester
3HAC 0207-1
Leak detection spray
-
Note
Procedure
Step
156
Action
Note/Illustration
1.
Finish the refitting procedure of the motor or gear in
question.
2.
Remove the topmost oil plug on the gear in question,
and replace it with the leakdown tester .
Adapters may be required, which are included in the
leakdown tester kit.
3.
Apply compressed air, and raise the pressure with the Recommended value: 0.2 knob until the correct value is shown on the manom- 0.25 bar (20 - 25 kPa)
eter.
4.
Disconnect the compressed air supply.
5.
Wait for approx. 8-10 minutes. No pressure loss must If the compressed air is sigbe detected.
nificantly colder or warmer
than the gearbox to be
tested, a slight pressure
increase or decrease
respectively may occur. This
is quite normal.
6.
Was any pressure drop evident?
Localize the leak as detailed below.
Remove the leakdown tester, and refit the oil plug.
The test is complete.
7.
Spray suspected leak areas with leak detection
spray .
Bubbles indicate a leak.
8.
When the leak has been localized: take the necessary measures to correct the leak.
Art. no. is specified above!
Art. no. is specified above!
3HAC021111-001 Revision: B
8 Reference information, IRB 1400
8.0.9 Lifting equipment and lifting instructions
8.0.9 Lifting equipment and lifting instructions
General
Many repair and maintenance activities require different pieces of lifting equipment, which
are specified in each procedure.
The use of each piece of lifting equipment is not detailed in the activity procedure, but in
the instruction delivered with each piece of lifting equipment.
This implies that the instructions delivered with the lifting equipment should be stored for
later reference.
3HAC021111-001 Revision: B
157
8 Reference information, IRB 1400
8.0.9 Lifting equipment and lifting instructions
158
3HAC021111-001 Revision: B
9 Spare part list
9.0.1 Introduction
9: Spare part list
9.0.1 Introduction
Item number refers to item number on the foldouts. Article numbers marked with bold text
are specially designed as spare parts (painted etc.).
3HAC021111-001 Revision: B
159
9 Spare part list
9.0.2 Manipulator complete
9.0.2 Manipulator complete
Manipulator
complete
160
See foldouts 1, 2, 3, 4 and 5 to locate the item numbers.
Item Qty
Name
Art. no.
Remark
1
1
Foot
3HAB 3443-1
2
1
Gears, axes 1-3
3HAB 3272-1
3
6
Plain washer
9ADA 312-9
13x24x2.5
4
6
Screw
3HAB 3402-67
Gleitmo 610 M12x40
8.8
5
1
Bottom plate
3HAB 9418-1
6
1
Gasket, bott. plate
3HAB 3347-1
7
4
Screw
2121 2172-228
M5x12
8
3
O-ring
2152 2012-428
79.5x3
9
1
Motor unit axis 1
3HAC 021458-001
Elmo, Gear box
Stephan Werke
9
1
Motor unit axis 1
3HAC 1618-1
Elmo, Gear box Sampingranaggi
9
1
Motor unit axis 1
3HAC 021963-001
Yaskawa
10
12
Screw
3HAB 3402-24
Gleitmo 610
M6x16 8.8
11
1
Lower arm
3HAB 3682-1
Standard
11
1
Lower arm
3HAB 3281-1
Hanging
12
2
Damper
3HAB 3257-1
13
16
Spring washer
2154 2033-10
10.5x23x2.5 FZM
14
6
Screw
3HAB 3409-51
Gleitmo 610
M10x30 12.9
15
1
Parallel arm
3HAB 3126-1
Standard
15
1
Parallel arm
3HAB 3282-1
Hanging
16
1
Ball bearing
2213 253-12
61821-2RS1
17
8
Screw
3HAB 3409-57
Gleitmo 610
M10x60 12.9
9
1
Motor unit axis 2
3HAC 021458-001
Elmo, Gear box
Stephan Werke
9
1
Motor unit axis 2
3HAB 3378-1
IRB1400 H, Elmo, Gear
box Stephan Werke
9
1
Motor unit axis 2
3HAC 1618-1
Elmo, Gear box Sampingranaggi
9
1
Motor unit axis 2
3HAC 1619-1
IRB1400 H, Elmo, Gear
box Sampingranaggi
9
1
Motor unit axis 2
3HAC 021963-001
Yaskawa
9
1
Motor unit axis 2
3HAC 021964-001
IRB1400 H, Yaskawa
18
1
Motor unit axis 3
3HAC 021458-001
Elmo, Gear box
Stephan Werke
3HAC021111-001 Revision: B
9 Spare part list
9.0.2 Manipulator complete
Item Qty
Name
Art. no.
Remark
18
1
Motor unit axis 3
3HAC 1618-1
Elmo, Gear box Sampingranaggi
18
1
Motor unit axis 3
3HAC 021963-001
Yaskawa
23
2
Lifting eye
2179 090-25
26
2
Sync.marker
3HAB 3296-1
27
1
Stop pin
3HAB 3258-1
28
2
Cushion axis 3
3HAB 3254-1
29
5400 ml
Oil
1171 2016-604
Floor mounted
29
6100 ml
Oil
1171 2016-604
Hanging
30
1g
Grease
3HAB 3537-1
31
1 ml
Grease
3HAB 1001-294
32
1 ml
Loctite 243
3HAB 7116-1
34
1 ml
Loctite 601
1269 0014-407
35
6
Protective hood
2522 2101-9
D=12-13.9 Hanging
36
1
Sealing strip
1854 1909-4
L=1.3 m Hanging
38
1
Loctite 577
1269 1907-1
50
1
Sync. marker
3HAB 3747-1
51
1
Upper arm
3HAB 3379-1
52
1
Wrist
3HAB 3388-1
53
6
Screw
3HAB 3402-25
Gleitmo 610
MC6S, M6x20
54
6
Washer
9ADA 312-6
6.4x12x1.6
55
2
Cover
3HAA 2362-1
56
2
Protection plug
2522 2101-5
57
2
Spring
3HAB 3263-1
58
4
Rod end bearing
3HAA 2301-12
59
2
Shaft
3HAB 3265-1
60
2
Ball bearing
2213 6950-206
6206-2RS1
61
3
Shims
2159 167-70
T=0.3
62
3
Shims
2159 167-71
T=0.1
63
3
Spacer
3HAB 3262-1
64
2
Lock nut
2126 2851-105
KM-5, M25x1.5
65
2
Screw
3HAB 3409-61
Gleitmo
610M10x90 12.9
Stand.
65
2
Screw
3HAB 3409-60
Gleitmo 610
M10x80 12.9
Hanging
66
1
Parallel bar
3HAB 3031-1
Standard
66
1
Parallel bar
3HAB 3283-1
Hanging
67
2
Spherical roller bear.
3HAA 2167-13
22205
68
3
Sealing washer
3HAB 3768-1
L=1200
69
1
Washer
3HAB 3260-1
70
1
Screw
2121 2852-449
3HAC021111-001 Revision: B
Kit
Optimol
See 1.2
KM-10
SKRF, M8x16
161
9 Spare part list
9.0.2 Manipulator complete
162
Item Qty
Name
Art. no.
Remark
71
1
Shaft
3HAB 3256-1
72
1
Spacer
3HAB 3264-1
73
1
Washer
3HAA 2355-11
74
1
Screw
9ADA 183-36
75
1
Sealing washer
3HAB 3767-1
76
2
Nut
9ADA 267-8
101
1
Bracket
3HAB 3225-1
102
1
Bracket
3HAB 9387-1
103
1
Spring
3HAB 3291-1
104
1
Cable guide
3HAB 3298-1
105
2
Holder for cable guide
3HAB 3299-1
106
1
Cable unit axes 1-3
3HAB 8440-1
107
1
Cable unit axes 4-6
3HAC 1855-1
Option 040
+ standard
107
1
Cable unit axes 4-6
3HAC 1856-1
Option 041
+ standard
107
1
Cable unit axes 4-6
3HAC 1857-1
Option 040
+ hanging
107
1
Cable unit axes 4-6
3HAC 1858-1
Option 041
+ hanging
107
1
Cable unit axes 4-6
3HAC 2072-1
Option 042
+ standard
109
2
Bracket, axes 5-6
3HAB 3230-1
110
1
Clamp
2166 2018-2
D=11
111
1
Clamp
2166 2018-8
D=6
117
3
Cover, axes 1-3
3HAC 4337-1
119
3
Gasket
3HAC 4419-1
122
1
Cover, axis 4
3HAC 4350-1
Not option 691
122
1
Lamp unit
3HAC 2743-1
Option 691
124
3
Gasket
3HAC 4429-1
127
1
Cover, axes 5-6
3HAC 4405-1
130
1
Battery unit
4944 026-4
135
1
SMB with bracket
3HAB3700-1
136
1
Signal cable SMB
3HAB 3774-1
137
1
Gasket
3HAB 3348-1
138
1
Bracket
3HAC 2037-1
139
1
Earth symbol
3HAB 5617-1
140
2
Clamp
2166 2018-7
D=5
144
12
Straps (outdoor)
2166 2055-3
L=186 mm
145
4
Straps (outdoor)
2166 2055-6
L=386 mm
147
6
Tapping screw
9ADA 624-47
M5x25
148
4
Screw
9ADA 183-22
M6x10
149
8
Screw
9ADA 183-11
M5x8
M5x140
MC6S, M8x20
M10
3HAC021111-001 Revision: B
9 Spare part list
9.0.2 Manipulator complete
Item Qty
Name
Art. no.
Remark
150
4
Tapping screw
2121 2477-291
M4x12
151
1
Bracket
SK 616 013-F
152
1
Actuator
1SFA616100R1006
154
1
Protective cover
1SFA616920R8010
156
1
Sealing
3HAB 3293-1
159
11
Straps (outdoor)
2166 2055-1
L=92 mm
160
46
Tapping screw
9ADA 624-44
M5x12
161
1
Dust cap
5217 649-9
12p. FCI
162
1
Gasket
2152 0363-3
12p. FCI
163
1
Cable guide
3HAB 3328-1
164
1
Profile
1866 1903-1
L=100
165
1
Tape
1169 9198-301
L=200
167
7
Screw
9ADA 129-45
M5x16
170
2
Protective hood
2522 2101-8
D=11.1 - 13
Black
Option 041
171
12
Nut
172
1
Cable pos. indicator axis HAB 3310-1
1
Option 075
173
2
Bushing
2166 2421-2
Option 075
174
2
Limit switch
3HAA 2496-1
Option 075
175
1
Protective hood
3HAB 9344-1
Option 042
176
2
Dust cap
5217 649-9
Option 041 or 042
177
1
Dust cap
5217 649-9
Option 075
179
1
Sealing liquid
1269 0014-412
Loctite 542, option 041
180
1
Coupling
3HAB 3333-20
Option 041
181
2
Cable gland
2672 063-3
Pr 18.6, option 075
182
2
Rubber washer
2452 398-2
Pr 18.6, option 075
184
1
Protective hood
2522 726-3
D=7.6-9.3, option 059
186
1
Protective hood
2522 2101-9
D=12-13.9
187
2
Protective hood
2522 2101-9
D=12-13.9
188
1
Cover
3HAB 9343-1
189
3
Adaptor power cabling
3HAC 2809-1
190
16
Screw
9ADA 629-22
M3x6
192
4
Screw
9ADA 629-22
M3x6
193
4
Nut
9ADA 267-6
M6
194
1
Gasket
3HAB 7195-1
196
1
Cover plate
3HAC 2056-1
Option 041
197
1
Dust cap
3HAA 1001-630
Option 042
3HAC021111-001 Revision: B
9ADA 290-1
M5
163
9 Spare part list
9.0.3 Arm housing, complete
9.0.3 Arm housing, complete
Arm housing,
complete
164
See foldout 6 to locate the item numbers.
Item
Qty
Name
Art. no.
Remark
1
1
Tubular shaft
3HAB 3270-1
2
1
Back-up ring
3HAB 6354-1
3
2
Ball bearing
2213 253-12
4
1
Housing axis 4
3HAB 3201-1
5
1
Intermediate gear
3HAB 3380-1
12
2
Screw
3HAB 3402-38
MC6S, M8x30
13
2
Washer
9ADA 312-7
8.4x16x1.6
14
2
Spacer
2159 167-61
T=0.05
15
4
Spacer
2159 167-62
T=0.1
16
1
Spacer
2159 167-63
T=0.5
17
1
Gear wheel
3HAB 3210-1
18
6
Screw
3HAB 3402-24
Gleitmo 610
MC6S, M6x16
19
2
Screw
9ADA 183-22
MC6S, M6x10
20
7
Plain washer
9ADA 312-6
6.4x12x1.6
21
1
O-ring
2152 2011-414
D=44,2x3
22
1
Motor complete axis 4
3HAC 11864-1
Elmo
22
1
Motor complete axis 4
3HAC 021740-001
Yaskawa
23
4
Screw
9ADA 183-14
MC6S, M5x16
24
1
Nut
9ADA 267-6
M6
25
1
Cover
3HAB 3266-1
26
7
Screw
9ADA 183-13
MC6S, M5x12
28
1
Drive unit axes 5-6
3HAC 6082-2
See foldout 9
29
4
Screw
3HAB 3402-30
Gleitmo 610
MC6S, M6x45
32
2
Plug
2216 264-14
33
1
Grease
3HAB 3532-1
1g
35
1
Loctite 243
1269 0014-410
1 ml
36
1
Oil
1171 2016-604
1 ml
37
1
Loctite 638
1269 0014-413
1 ml
61821-2RS1
3HAC021111-001 Revision: B
9 Spare part list
9.0.4 Drive unit, axes 5-6
9.0.4 Drive unit, axes 5-6
Drive unit, axes 56
See foldouts 7, 8 and 9 to locate the item numbers.
Item
Qty
Name
Art. no.
Remark
1
1
Driving shaft, 5-6
3HAC 11305-1
2
2
Motor unit, axes 5 - 6
3HAC 11865-1
Elmo
2
2
Motor unit, axes 5 - 6
3HAC 021741-001
Yaskawa
3
1
Motor end barrier
3HAA 2504-1
4
8
Nut
9ADA 267-5
M5
5
10
Screw
3HAB 3402-14
Gleitmo 610
MC6S, M5x16
6
10
Plain washer
9ADA 312-5
7
2
Timing belt
3HAA 2393-1
3HAC021111-001 Revision: B
5.3x10x1
165
9 Spare part list
9.0.5 Serial measurement unit
9.0.5 Serial measurement unit
Serial measurement unit
166
See foldout 10 to locate the item numbers.
Item
Qty
Name
Art. no.
Remark
3
1
Battery
4944 026-4
4
4
Straps, outdoor
2166 2055-6
5
1
Serial measurement board
3HAC021905-001 DSQC 633
7
1
Signal cable
3HAB 3774-1
8
2
Straps, outdoor
2166 2055-3
L=186 mm
9
1
Label
2940 1413-1
38x19
L=368 mm
3HAC021111-001 Revision: B
10 Foldouts
10.0.1 Introduction
10: Foldouts
10.0.1 Introduction
Overview
This chapter includes foldouts with illustrations of the robot. The item numbers are specified
in chapter Spare part list on page 159.
3HAC021111-001 Revision: B
167
10 Foldouts
10.0.1 Introduction
168
3HAC021111-001 Revision: B
11 Circuit diagram
11.0.1 Introduction
11: Circuit diagram
11.0.1 Introduction
Overview
This chapter includes the complete circuit diagram for the robot.
169
3HAC021111-001 Revision: B
11 Circuit diagram
11.0.1 Introduction
170
3HAC021111-001 Revision: B
11 Circuit diagram
11.0.2 Sheet 101 List of contents
11.0.2 Sheet 101 List of contents
3HAC021111-001 Revision: B
171
11 Circuit diagram
11.0.3 Sheet 102 Connection point location
11.0.3 Sheet 102 Connection point location
3HAC021111-001 Revision: B
172
11 Circuit diagram
11.0.4 Sheet 103 Serial measurement board
11.0.4 Sheet 103 Serial measurement board
3HAC021111-001 Revision: B
173
11 Circuit diagram
11.0.5 Sheet 104 Motor axes 1 - 3
11.0.5 Sheet 104 Motor axes 1 - 3
3HAC021111-001 Revision: B
174
11 Circuit diagram
11.0.6 Sheet 105 Feedback axes 1 - 3
11.0.6 Sheet 105 Feedback axes 1 - 3
3HAC021111-001 Revision: B
175
3HAC021111-001 Revision: B
111
15
14
3
S1
PE
11
4
7
10
BRPB
4
R
BU
BU
13
1
BU
BU
BU
BU
BU
104
R1.BU
3
2
5
6
9
12
8
R1.H1
1
R1.MP4-6
112
111
PE
R1.MP4-6
1
2
3
PTC
M5R
M5S
M5T
BRAKE REL.
0V BRAKE
M6R
M6S
M6T
PTC 34
0V BRAKE
BRAKE REL.
M4R
M4S
M4T
M
10
BU
R4.MP6
1
2
3
MU6
GNYE
9
3
5
4
11
R3.H1:1
R
5
6
7
8
R4.MP5
1
2
3
MU5
BU PTC 65
6
5
7
LED-LAMP;
OPTION
PTC
B
3
8
R3.H2:1
R (U)
S (V )
T (W)
1
PTC 46
6
5
8
7
R3.MP4
1
2
3
2
7
6
8
12
17
16
GNYE
15
14
13
MU4
S (V )
T (W)
R ( U)
R ( U)
S (V )
T (W)
B
M
B
M
PTC
3
PTC
3
11 Circuit diagram
11.0.7 Sheet 106 Motor axes 4 - 6
11.0.7 Sheet 106 Motor axes 4 - 6
176
11 Circuit diagram
11.0.8 Sheet 107 Feedback axes 4 - 6
11.0.8 Sheet 107 Feedback axes 4 - 6
3HAC021111-001 Revision: B
177
11 Circuit diagram
11.0.9 Sheet 108 Customer connection (Option)
11.0.9 Sheet 108 Customer connection (Option)
3HAC021111-001 Revision: B
178
YE
WH
RD
WH
BN
WH
6
7
8
9
10
11
12
13
14
CSB
CSC
CSD
CSE
CSF
CSG
CSH
CSP
CSK
CSL
CSM
CSN
CSR
CSS
CPM
CPL
CPJ
CPK
CPF
CPG
CPH
CPC
CPE
CPB
B
C
D
E
F
G
H
P
K
3HAC021111-001 Revision: B
L
M
N
R
S
R1.CP
M
L
J
K
F
G
H
C
E
B
16
CPD
CPA
D
A
17
15
CPD
CPA
5
4
WH
OG
WH
GN
WH
BU
WH
A
D
B
C
E
H
G
F
K
J
L
R2.CP
M
S
R
N
M
L
K
P
H
G
F
E
D
C
B
J
WH
CSJ
J
VT
R2.CS
A
GY
CSA
R1.CS
A
11 Circuit diagram
11.0.10 Sheet 109 Integrated wirefeed cabling (Option)
11.0.10 Sheet 109 Integrated wirefeed cabling (Option)
179
11 Circuit diagram
11.0.11 Sheet 110 Position indicator axis 1
11.0.11 Sheet 110 Position indicator axis 1
3HAC021111-001 Revision: B
180
11 Circuit diagram
11.0.12 Sheet 111 External connections (Option)
11.0.12 Sheet 111 External connections (Option)
3HAC021111-001 Revision: B
181
11 Circuit diagram
11.0.12 Sheet 111 External connections (Option)
182
3HAC021111-001 Revision: B
Index
A
robot position, 134
Absolute Accuracy, calibration, 133
S
C
scales on robot, 134
sync marks, 134
calibrating
roughly, 136
calibration
Absolute Accuracy type, 132
alternative method, 133
Calibration Pendulum, 133
Levelmeter calibration, 133
marks/scales, 134
rough, 136
standard method, 133
standard type, 132
when to calibrate, 131
calibration manuals, 133
Calibration Pendulum, 133
Calibration position, 127
calibration position, 136
checking, 138
jogging to, FlexPendant, 138
scales, 134
calibration, Absolute Accuracy, 133
CalibWare, 132
U
Updating revolution counters, 127
updating revolution counters, 136
D
direction of axes, 135
F
FlexPendant
jogging to calibration position, 138
MoveAbsJ instruction, 138
updating revolution counters, 136
L
Levelmeter calibration, 133
M
MoveAbsJ instruction
FlexPendant, 138
N
negative directions, axes, 135
P
position, robot, 134
positive directions, axes, 135
R
Revolution counters, 127
revolution counters
storing on FlexPendant, 136
updating, 136
183
Index
184
3HAC021111-001, Revision A, en
ABB AB
Robotics Products
S-721 68 VÄSTERÅS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax:
+46 (0) 21 132592