ABB IRB 140 Product Manual

ROBOTICS

Product manual

IRB 140

Trace back information:

Workspace R18-2 version a18

Checked in 2018-11-20

Skribenta version 5.3.012

Product manual

IRB 140 type C

IRB 140T type C

IRB 140-6/0.8 type C

IRB 140T-6/0.8 type C

IRC5

Document ID: 3HAC027400-001

Revision: V

© Copyright 2004-2018 ABB. All rights reserved.

Specifications subject to change without notice.

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.

Keep for future reference.

Additional copies of this manual may be obtained from ABB.

Original instructions.



ABB AB, Robotics

Robotics and Motion

Se-721 68 Västerås

Sweden

Table of contents


Overview of this manual ...................................................................................................................

Product documentation ....................................................................................................................

How to read the product manual ......................................................................................................

9

14

16

1 Safety

1.1

General safety information ..................................................................................

1.1.1

Limitation of liability .................................................................................

1.1.2

Protective stop and emergency stop ...........................................................

1.2

Safety actions ...................................................................................................

1.2.1

Fire extinguishing ....................................................................................

1.2.2

Emergency release of the robot axes ..........................................................

1.2.3

Make sure that the main power has been switched off ....................................

1.3

Safety risks ......................................................................................................

1.3.1

Safety risks during installation and service work on robots ..............................

1.3.2

Moving robots are potentially lethal ............................................................

1.3.3

First test run may cause injury or damage ....................................................

1.3.4

Work inside the working range of the robot ..................................................

1.3.5

Enabling device and hold-to-run functionality ...............................................

1.3.6

Risks associated with live electric parts .......................................................

1.3.7

The unit is sensitive to ESD .......................................................................

1.3.8

Hot parts may cause burns .......................................................................

1.3.9

Safety risks related to pneumatic/hydraulic systems ......................................

1.3.10 Brake testing ..........................................................................................

1.3.11 Safety risks during handling of batteries ......................................................

1.3.12 Safety risks during work with gearbox lubricants (oil or grease) .......................

1.4

Safety signals and symbols .................................................................................

1.4.1

Safety signals in the manual ......................................................................

1.4.2

Safety symbols on product labels ...............................................................

17

28

29

31

32

23

25

26

27

20

21

22

23

17

17

19

20

33

34

35

36

38

38

40

2 Installation and commissioning

2.1

Introduction ......................................................................................................

2.2

Unpacking .......................................................................................................

2.2.1

Pre-installation procedure .........................................................................

2.2.2

Working range, IRB 140 ............................................................................

2.2.3

Risk of tipping/stability .............................................................................

2.3

On-site installation ............................................................................................

2.3.1

Lifting the manipulator with lifting slings ......................................................

2.3.2

Lifting and turning the manipulator ............................................................

2.3.3

Manually releasing the brakes ...................................................................

2.3.4

Orienting and securing the manipulator .......................................................

2.3.5

Fitting equipment on manipulator ...............................................................

2.3.6

Loads ....................................................................................................

2.3.7

Setting the system parameters for a suspended or tilted robot .........................

2.3.8

Bolt pattern ............................................................................................

2.3.9

Installation of signal lamp (option) ..............................................................

2.4

Restricting the working range ..............................................................................

2.4.1

Restricting the working range ....................................................................

2.5

Electrical connections ........................................................................................

2.5.1

Grounding and bonding point on manipulator ...............................................

2.5.2

Customer connections on manipulator ........................................................

2.6

Start of robot in cold environments ......................................................................

47

66

71

73

74

59

62

63

65

74

75

75

76

78

54

55

55

56

47

48

48

52

3 Maintenance

3.1

Introduction ......................................................................................................

3.2

Maintenance schedules ......................................................................................

3.2.1

Specification of maintenance intervals ........................................................

79

79

80

80

Product manual - IRB 140

3HAC027400-001 Revision: V

5



3.2.2

Maintenance schedule .............................................................................

3.3

Inspection activities ...........................................................................................

3.3.1

Inspection, damper axes 2, 3 and 5 .............................................................

3.3.2

Inspecting the robot cabling .....................................................................

3.3.3

Inspection, timing belts ............................................................................

3.3.4

Inspecting oil level gearbox axis 1 ..............................................................

3.3.5


3.3.6


3.3.7


3.3.8

Inspecting oil level gearbox axes 5-6 ...........................................................

3.3.9

Inspecting information labels .....................................................................

3.4

Cleaning activities .............................................................................................

3.4.1

Cleaning the IRB 140 type C ......................................................................

3.5

Changing/ replacing activities ..............................................................................

3.5.1

Type of lubrication in gearboxes ................................................................

3.5.2

Changing the oil in axes 5 and 6 gearboxes .................................................

95

98

101

104

106

106

109

109

110

81

83

83

85

86

89

92

4 Repair 113

4.1

Introduction ......................................................................................................

4.2

General procedures ...........................................................................................

4.2.1

Mounting instructions for bearings .............................................................

4.2.2

Mounting instructions for seals ..................................................................

4.2.3

Cut the paint or surface on the robot before replacing parts ............................

4.3

Complete robot .................................................................................................

4.3.1

Replacement of cable harness ...................................................................

4.3.2

Replacement of complete upper arm ...........................................................

4.3.3

Replacement of complete lower arm ...........................................................

4.3.4

Replacement of base ...............................................................................

4.4

Upper arm .......................................................................................................

4.4.1

Replacing the wrist unit, IRB 1600 ..............................................................

4.4.2

Replacing the damper, axis 3 .....................................................................

4.4.3

Replacement of damper, axis 5 ..................................................................

4.4.4

Replacement of cover, arm housing ............................................................

4.5

Lower arm .......................................................................................................

4.5.1

Replacement of lower arm cover and gasket ................................................

4.5.2

Replacing the damper, axis 2 .....................................................................

4.6

Frame and base ................................................................................................

4.6.1

Replacement of cover, console ..................................................................

4.6.2

Replacement of console ...........................................................................

4.6.3

Replacing the serial measurement unit and the battery pack ...........................

4.6.4

Replacement of control cable ....................................................................

4.7

Motors ............................................................................................................

4.7.1

Replacement of motor, axis 1 ....................................................................

4.7.2

Replacement of motor, axis 2 ....................................................................

4.7.3

Replacement of motor and timing belt, axis 3 ...............................................

4.7.4

Replacement of motor, axis 4, IRB 1600 ......................................................

4.7.5

Replacement of motor and timing belt, axes 5 or 6 ........................................

4.7.6

Adjustments and measurements ................................................................

4.7.6.1 Measuring the gear play, axis 5 ......................................................

4.7.6.2 Measuring the gear play, axis 6 ......................................................

4.8

Gearboxes .......................................................................................................

4.8.1

Replacement of gearbox, axes 1-2 and damper, axis 1 ...................................

4.8.2

Service work on gearbox, axis 4 .................................................................

177

181

186

192

197

203

203

205

153

157

159

159

162

167

173

177

207

207

213

134

138

142

142

146

148

150

153

113

114

114

116

118

120

120

128

5 Calibration information 215

5.1

When to calibrate .............................................................................................

5.2

Calibration methods ...........................................................................................

5.3

Synchronization marks and synchronization position for axes ...................................

5.4

Calibration movement directions for all axes ..........................................................

215

216

218

219

6 Product manual - IRB 140




5.5

Updating revolution counters ...............................................................................

5.6

Checking the synchronization position ..................................................................

220

224

6 Decommissioning 225

6.1

Environmental information ..................................................................................

6.2

Scrapping of robot .............................................................................................

225

227

7 Robot description 229

7.1

Type C of IRB 140 .............................................................................................

229

8 Reference information 231

8.1

Introduction ......................................................................................................

8.2

Applicable standards .........................................................................................

8.3

Unit conversion .................................................................................................

8.4

Screw joints ....................................................................................................

8.5

Weight specifications .........................................................................................

8.6

Standard tools ..................................................................................................

8.7

Special tools ....................................................................................................

8.8

Performing a leak-down test ................................................................................

8.9

Lifting accessories and lifting instructions ..............................................................

231

232

234

235

238

239

240

241

242

9 Spare part lists 243

9.1

Spare part lists and illustrations ...........................................................................

243

10 Circuit diagram 245

10.1 Circuit diagrams ................................................................................................

245

Index 247




7

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Overview of this manual


About this manual

This manual contains instructions for:

• mechanical and electrical installation of the robot

• maintenance of the robot

• mechanical and electrical repair of the robot.

Usage

Who should read this manual?

This manual is intended for:

• installation personnel

• maintenance personnel

• repair personnel.

Prerequisites

This manual should be used during:

• installation, from lifting the robot to its work site and securing it to the foundation to making it ready for operation

• maintenance work

• repair work and calibration.

Maintenance/repair/installation personnel working with an ABB Robot must:

• be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work.

Product manual scope

The manual covers covers all variants and designs of the IRB 140 type C. Some variants and designs may have been removed from the business offer and are no longer available for purchase.

Organization of chapters

The manual is organized in the following chapters:

Chapter

Safety, service

Contents

Safety information that must be read through before performing any installation or service work on robot. Contains general safety aspects as well as more specific information about how to avoid personal injuries and damage to the product.

Required information about lifting and installation of the robot.

Installation and commissioning

Maintenance

Repair

Step-by-step procedures that describe how to perform maintenance of the robot. Based on a maintenance schedule that may be used in the work of planning periodical maintenance.

Step-by-step procedures that describe how to perform repair activities of the robot. Based on available spare parts.



Continues on next page

9



Continued

References

Revisions

Chapter

Calibration information

Decommissioning

Reference information

Contents

Procedures that does not require specific calibration equipment.

General information about calibration.

Environmental information about the robot and its components.

Useful information when performing installation, maintenance or repair work. Includes lists of necessary tools, additional documents, safety standards, etc.

Spare parts and exploded views

Complete spare part list and complete list of robot components, shown in exploded views.

Circuit diagram References to the circuit diagrams for the robot.

Reference

Circuit diagram - IRB 140 type C

Operating manual - General safety information i

Product manual - IRC5

IRC5 with main computer DSQC 639.

Product manual - IRC5

IRC5 with main computer DSQC1000.

Product specification - IRB 140

Document ID

3HAC6816-3

3HAC031045-001

3HAC021313-001

3HAC047136-001

Product manual, spare parts - IRB 140

Operating manual - IRC5 with FlexPendant

Operating manual - Calibration Pendulum

3HAC041346-001

3HAC049099-001

3HAC050941-001

3HAC16578-1

Operating manual - Service Information System

Technical reference manual - Lubrication in gearboxes

3HAC050944-001

3HAC042927-001

Technical reference manual - RAPID Instructions, Functions and

Data types

3HAC050917-001 i

Application manual - CalibWare Field 5.0

3HAC030421-001

This manual contains all safety instructions from the product manuals for the manipulators and the controllers.

A

B

-

Revision

C

Description

First edition, see also

Type C of IRB 140 on page 229

.

IRB 140-6/0.8 and IRB 140T-6/0.8 added.

Clean Room added.

Changes made in:

• Prerequisites in section Overview

• Oil change in section Maintenance

Content updated in section:

• Making robot ready for operation, Clean room , Additional installation procedure .






Continued

Revision

D

E

F

G

H

J

Description

Content updated in section:

• Repair , exchange of parts on Clean room robots

• Maintenance , Cleaning of robot

• Maintenance schedule : Interval for replacement of battery pack changed.

• Section What is an emergency stop?

added to chapter Safety .

Content updated in sections:

• Article numbers added or replaced in sections

Replacement of complete upper arm on page 128 ,

Replacement of complete lower arm on page 134 ,

Replacement of gearbox, axes 1-2 and damper, axis 1 on page 207

, and

Type C of IRB 140 on page 229

.

Content updated in sections:

• Required equipment updated in

Replacement of motor and timing belt, axis 3 on page 186 .

• Spare part list updated regarding Foundry Plus cable guard and new wrist.

• Circuit diagrams are not included in this document but delivered as separate files. See

Circuit diagram on page 245

.

• List of standards updated, see

Applicable standards on page 232 .

• Sealing compound updated in

Cut the paint or surface on the robot before replacing parts on page 118

.

• Decommissioning chapter added.

The chapter Safety updated with:

• Updated safety signal graphics for the levels Danger and Warning , see

Safety signals in the manual on page 38 .

• New safety labels on the manipulators, see

Safety symbols on product labels on page 40 .

• Revised terminology: robot replaced with manipulator .

This revision includes the following additions:

• New section,

Restricting the working range on page 74 .

•

Lifting and turning the manipulator on page 56

.

This revision includes the following updates:

• Corrected amount of oil in axes 3, 5, and 6, see Amount of oil.

• Updates in chapter Calibration .


• Corrected article number for VK cover, see

Replacement of complete upper arm on page 128

and

Replacement of motor and timing belt, axes 5 or 6 on page 197 .


• A new block, about general illustrations, added in section

How to read the product manual on page 16

.

• The option Foundry Plus Cable Guard is removed.

• Some general tightening torques have been changed/added, see updated values in

Screw joints on page 235 .

• The figure of the base is updated in concerned sections.

• Added

Safety risks during handling of batteries on page 35

.





11


Continued

M

N

P

Q

Revision

K

L

R

S

Description


• Information regarding disassembly of Clean Room robots added to concerned repair instructions.

• Changed the instruction for how to fit the o-ring of the axis-4 motor when refitting the motor, see

Replacement of motor, axis 4, IRB

1600 on page 192

.

• Added figures that show an alternative layout inside the base, see

Replacing the serial measurement unit and the battery pack on page 167 .

• All data about type of lubrication in gearboxes is moved from the manual to a separate lubrication manual, see

Type and amount of oil in gearboxes on page 109 .

• Corrected article number for battery pack.

• A new SMB unit and battery is introduced, with longer battery lifetime.


• Added information about risks when scrapping a decommissioned robot, see

Scrapping of robot on page 227

.

• Spare parts and exploded views are not included in this document but delivered as a separate document. See Spare part lists Product manual, spare parts - IRB 140 .


• Minor corrections.


• Updated section

Setting the system parameters for a suspended or tilted robot on page 66 .

• Turning disk fixture is removed from special tools for Levelmeter calibration.


• Removed note in Installation of signal lamp.

Published in release R16.2. The following updates are done in this revision:

• Added a procedure for how to lift and rotate the robot, see

Lifting and turning the manipulator on page 56

.

• Section Amount of oil is removed from the manual, since the data has been moved to the separate lubrication manual, see

Type and amount of oil in gearboxes on page 109

.

Published in release R17.1. The following updates are done in this revision:

• Added a procedure for how inspect the oil level, see

Inspection activities on page 83

.

Published in release R17.2. The following updates are made in this revision:

• Information about coupled axes in

Updating revolution counters on page 220

.

• Information about minimum resonance frequency added.

• Updated list of applicable standards.

• Updated inspection of oil level.

• Information about grounding point added, see

Grounding and bonding point on manipulator on page 75

.

• Section

Start of robot in cold environments on page 78

added.


12





Continued

U

V

Revision

T

Description


• Added sections in

General procedures on page 114

• Safety section restructured.

• Information about myABB Business Portal added.

• Added Nickel in Environmental information.


• Added section for inspection of labels in maintenance chapter.


• Reference updated.




13

Product documentation


Categories for user documentation from ABB Robotics

The user documentation from ABB Robotics is divided into a number of categories.

This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.

All documents can be found via myABB Business Portal, www.myportal.abb.com

.

Product manuals

Manipulators, controllers, DressPack/SpotPack, and most other hardware is delivered with a Product manual that generally contains:

• Safety information.

• Installation and commissioning (descriptions of mechanical installation or electrical connections).

• Maintenance (descriptions of all required preventive maintenance procedures including intervals and expected life time of parts).

• Repair (descriptions of all recommended repair procedures including spare parts).

• Calibration.

• Decommissioning.

• Reference information (safety standards, unit conversions, screw joints, lists of tools).

• Spare parts list with corresponding figures (or references to separate spare parts lists).

• References to circuit diagrams.

Technical reference manuals

The technical reference manuals describe reference information for robotics products, for example lubrication, the RAPID language, and system parameters.

Application manuals

Specific applications (for example software or hardware options) are described in

Application manuals . An application manual can describe one or several applications.

An application manual generally contains information about:

• The purpose of the application (what it does and when it is useful).

• What is included (for example cables, I/O boards, RAPID instructions, system parameters, software).

• How to install included or required hardware.

• How to use the application.

• Examples of how to use the application.


14





Continued

Operating manuals

The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters.




15

How to read the product manual

How to read the product manual

Reading the procedures

The procedures contain references to figures, tools, material, and so on. The references are read as described below.

References to figures

The procedures often include references to components or attachment points located on the manipulator/controller. The components or attachment points are marked with italic text in the procedures and completed with a reference to the figure where the current component or attachment point is shown.

The denomination in the procedure for the component or attachment point corresponds to the denomination in the referenced figure.

The table below shows an example of a reference to a figure from a step in a procedure.

8.

Action

Remove the rear attachment screws, gearbox.

Note/Illustration

Shown in the figure Location of gearbox on page xx .

References to required equipment

The procedures often include references to equipment (spare parts, tools, etc.) required for the different actions in the procedure. The equipment is marked with italic text in the procedures and completed with a reference to the section where the equipment is listed with further information, that is article number and dimensions.

The designation in the procedure for the component or attachment point corresponds to the designation in the referenced list.

The table below shows an example of a reference to a list of required equipment from a step in a procedure.

3.

Action

Fit a new sealing, axis 2 to the gearbox.


Art. no. is specified in Required equipment on page xx.

Safety information

The manual includes a separate safety chapter that must be read through before proceeding with any service or installation procedures. All procedures also include specific safety information when dangerous steps are to be performed.

Read more in the chapter

Safety on page 17

.

Illustrations

The robot is illustrated with general figures that does not take painting or protection type in consideration.

Likewise, certain work methods or general information that is valid for several robot models, can be illustrated with illustrations that show a different robot model than the one that is described in the current manual.




1 Safety

1.1.1 Limitation of liability

1 Safety

1.1 General safety information

1.1.1 Limitation of liability

Limitation of liability

Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with.

The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment that can influence the safety of the entire system.

In particular, liability cannot be accepted if injury/damage has been caused for any of the following reasons:

• Use of the robot in other ways than intended.

• Incorrect operation or maintenance.

• Operation of the robot when the safety devices are defective, not in their intended location or in any other way not working.

• When instructions for operation and maintenance are not followed.

• Non-authorized design modifications made in or around the robot.

• Repairs carried out by in-experienced or non-qualified personnel.

• Foreign objects.

• Force majeure.

Nation/region specific regulations

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.

To be observed by the supplier of the complete system

The integrator is responsible that the safety devices necessary to protect people working with the robot system are designed and installed correctly.

When integrating the robot with external devices and machines:

• 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.





17

1 Safety

1.1.1 Limitation of liability

Continued

The integrator of the final application is required to perform an assessment of the hazards and risks (HRA).

Note

The integrator is responsible for the safety of the final application.

Safe access

The robot system shall be designed to allow safe access to all areas where intervention is necessary during operation, adjustment, and maintenance.

Where it is necessary to perform tasks within the safeguarded space there shall be safe and adequate access to the task locations.

Safety zones, which must 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.

A safety fence is recommended to ensure safeguarded space. Sufficient space must be provided around the manipulator to protect those working with or on it from hazards such as crushing.

The fence or enclosure must be dimensioned 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 the section

Robot motion in the Product specification ).

Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot.

Safe handling

Users shall not be exposed to hazards, including slipping, tripping, and falling hazards.

It must be possible to safely turn off tools, such as milling cutters, etc. Make sure that guards remain closed until the cutters stop rotating.

It should be possible to release parts by manual operation (valves).

Safe design

Emergency stop buttons must be positioned in easily accessible places so that the robot can be stopped quickly. If any of the buttons do not stop all the robot workcell motion, each emergency stop button must be marked, if more than one is provided, to indicate its designated safety function.

Grippers/end effectors must be designed so that they do not drop work pieces/tools in the event of a power failure or a disturbance to the controller.

Unauthorized modifications of the originally delivered robot are prohibited. Without the consent of ABB, it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength of the robot could be affected.

18




1 Safety

1.1.2 Protective stop and emergency stop

1.1.2 Protective stop and emergency stop

Overview

The protective stops and emergency stops are described in the product manual for the controller.




19

1 Safety

1.2.1 Fire extinguishing

1.2 Safety actions

1.2.1 Fire extinguishing

Note

Use a CARBON DIOXIDE (CO

2

) extinguisher in the event of a fire in the manipulator or controller.

20




1 Safety

1.2.2 Emergency release of the robot axes

1.2.2 Emergency release of the robot axes

Description

In an emergency situation, the brakes on a robot axis can be released manually by pushing a brake release button.

How to release the brakes is described in the section:

•

Manually releasing the brakes on page 59 .

The robot may be moved manually on smaller robot models, but larger models may require using an overhead crane or similar equipment.

Increased injury

Before releasing the brakes, make sure that the weight of the robot does not increase the pressure on the trapped person, further increasing any injury.

DANGER

When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways.

Make sure no personnel is near or beneath the robot.




21

1 Safety

1.2.3 Make sure that the main power has been switched off

1.2.3 Make sure that the main power has been switched off

Description

Working with high voltage is potentially lethal. Persons subjected to high voltage may suffer cardiac arrest, burn injuries, or other severe injuries. To avoid these personal injuries, switch off the main power on the controller before proceeding work.

Note

Switch off all main power switches in a MultiMove system.

22




1 Safety

1.3.1 Safety risks during installation and service work on robots

1.3 Safety risks

1.3.1 Safety risks during installation and service work on robots

Requirements on personnel

Only persons who know the robot and are trained in the operation and handling of the robot are allowed to maintain the robot. Persons who are under the influence of alcohol, drugs or any other intoxicating substances are not allowed to install, maintain, repair, or use the robot.

• Those in charge of operations must make sure that safety instructions are available for the installation in question.

• Those who install or service/maintain the robot must have the appropriate training for the equipment in question and in any safety matters associated with it.

• Personnel should be trained on responding to emergency or abnormal situations.

General risks during installation and service

The instructions in the product manual must always be followed.

Never turn the power on to the robot before it is properly fixed and bolted to its foundation/support.

Make sure that no one else can turn on the power to the controller and robot while you are working with the system. A good method is to always lock the main switch on the controller cabinet with a safety lock.

Make sure that no one else can turn on the power to the controller and robot while you are working with the system. A good method is to remove the power cable to the controller.

If the robot is installed at a height, hanging, or other than standing directly on the floor, there may be additional risks than those for a robot standing directly on the floor.

Energy stored in the robot for the purpose of counterbalancing certain axes may be released if the robot, or parts thereof, are dismantled.

Never use the robot as a ladder, which means, do not climb on the controller, motors, or other parts during service work. There is a risk of slipping because of the high temperature of the motors and oil spills that can occur on the robot. There is also a risk of the robot being damaged.

To avoid damaging the product, make sure that there are no loose screws, turnings, or other parts inside the product after work has been performed.

Safety risks during operational disturbances

Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts.




23


1 Safety

1.3.1 Safety risks during installation and service work on robots

Continued

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.

Spare parts and special equipment

ABB does not supply spare parts and special equipment which have not been tested and approved by ABB. The installation and/or use of such products could negatively affect the structural properties of the robot and as a result of that affect the active or passive safety operation. ABB is not liable for damages caused by the use of non-original spare parts and special equipment. ABB is not liable for damages or injuries caused by unauthorized modifications to the robot.

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. An external safety function can interact with other machines and peripheral equipment via this interface. This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot.

Personal protective equipment

Always use suitable personal protective equipment, based on the risk assessment for the installation.

Allergenic material

See

Environmental information on page 225

for specification of allergenic materials in the product, if any.

24




1 Safety

1.3.2 Moving robots are potentially lethal

1.3.2 Moving robots are potentially lethal

Description

Any moving robot is a potentially lethal machine.

When running, the robot may perform unexpected and sometimes irrational movements. Moreover, all movements are performed with great force and may seriously injure any personnel and/or damage any piece of equipment located within the working range of the robot.

Safe handling

1

2

3

Action Note

Before attempting to run the robot, make sure all emergency stop equipment is correctly installed and connected.

Emergency stop equipment such as gates, tread mats, light curtains, etc.

Usually the hold-to-run function is active only in manual full speed mode. To increase safety it is also possible to activate hold-to-run for manual reduced speed with a system parameter.

The hold-to-run function is used in manual mode, not in automatic mode.

How to use the hold-to-run function is described in section How to use the hold-torun function in the Operating manual - IRC5 with FlexPendant .

Make sure no personnel are present within the working range of the robot before pressing the start button.




25

1 Safety

1.3.3 First test run may cause injury or damage

1.3.3 First test run may cause injury or damage

Description

After installation and performing service activities, there are several safety risks to take into consideration before the first test run.

Safe handling

Use this procedure when performing the first test run after installation, maintenance, or repair.

DANGER

Running the robot without fulfilling the following aspects, may involve a risk of injury and cause severe damage to the robot.

1

2

3

4

5

6

7

Action

Remove all tools and foreign objects from the robot and its working area.

Verify that the robot is properly secured to its position by all screws, before it is powered up.

Verify that any safety equipment installed to secure the position or restrict the robot motion during service activity is removed.

Verify that the fixture and work piece are well secured, if applicable.

Install all safety equipment properly.

Make sure all personnel are standing at a safe distance from the robot, and is out of its reach behind safety fences, or similar.

If maintenance or repair has been done, pay special attention to the function of the part that was serviced.

Collision risks

CAUTION

When programming the movements of the robot, always identify potential collision risks before the first test run.

26




1 Safety

1.3.4 Work inside the working range of the robot

1.3.4 Work inside the working range of the robot

WARNING

If work must be carried out within the work area of the robot, then the following points must be observed:

• The operating mode selector on the controller must be in the manual mode position to render the three-position enabling device operational and to block operation from a computer link or remote control panel.

• The maximum speed of the robot is limited to 250 mm/s when the operating mode selector is in the position Manual mode with reduced speed . This should be the normal position when entering the working space.

The position Manual mode with full speed (100%) may only be used by trained personnel who are aware of the risks that this entails.

Manual mode with full speed (100%) is not available in USA or Canada.

• Pay attention to the rotating axes of the robot. Keep away from axes to not get entangled with hair or clothing. Also, be aware of any danger that may be caused by rotating tools or other devices mounted on the robot or inside the cell.

• Keep clear of moving parts so that limbs, hands, or fingers do not get trapped or crushed by the robot.

• To prevent anyone else from taking control of the robot, always put a safety lock on the cell door and bring the three-position enabling device with you when entering the working space.

WARNING

NEVER , under any circumstances, stay beneath any of the robot's axes! There is always a risk that the robot will move unexpectedly when robot axes are moved using the three-position enabling device or during other work inside the working range of the robot.




27

1 Safety

1.3.5 Enabling device and hold-to-run functionality

1.3.5 Enabling device and hold-to-run functionality

Three-position enabling device

The three-position enabling device is a manually operated, constant pressure push-button which, when continuously activated in one position only, allows potentially hazardous functions but does not initiate them. In any other position, hazardous functions are stopped safely.

The three-position enabling device is of a specific type where you must press the push-button only half-way to activate it. In the fully in and fully out positions, operating the robot is impossible.

Note

The three-position enabling device is a push-button located on the teach pendant which, when pressed halfway in, switches the system to MOTORS ON. When the enabling device is released or pushed all the way in, the manipulator switches to the MOTORS OFF state.

To ensure safe use of the teach pendant, the following must be implemented:

• The enabling device must never be rendered inoperational 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.

• Anyone entering the working space of the robot must always hold the teach pendant. This is to prevent anyone else from taking control of the robot without his/her knowledge.

Hold-to-run function

The hold-to-run function allows movement when a button connected to the function is actuated manually and immediately stops any movement when released. The hold-to-run function can only be used in manual mode.

How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant .

28




1 Safety

1.3.6 Risks associated with live electric parts

1.3.6 Risks associated with live electric parts

Voltage related risks, general

Work on the electrical equipment of the robot must be performed by a qualified electrician in accordance with electrical regulations.

Although troubleshooting may, on occasion, need to be carried out while the power supply is turned on, the robot must be turned off (by setting the main switch to

OFF) when repairing faults, disconnecting electric leads, and disconnecting or connecting units.

The main supply to the robot must be connected in such a way that it can be turned off from outside the working space of the robot.

Make sure that no one else can turn on the power to the controller and robot while you are working with the system. A good method is to always lock the main switch on the controller cabinet with a safety lock.

The necessary protection for the electrical equipment and robot during installation, commissioning, and maintenance is guaranteed if the valid regulations are followed.

Voltage related risks, IRC5 controller

A danger of high voltage is associated with, for example, the following parts:

• Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in the controller.

• Units such as I/O modules, can be supplied with power from an external source.

• The main supply/main switch

• The transformers

• The power unit

• The control power supply (230 VAC)

• The rectifier unit (262/400-480 VAC and 400/700 VDC. Note: capacitors!)

• The drive unit (400/700 VDC)

• The drive system power supply (230 VAC)

• The service outlets (115/230 VAC)

• The customer power supply (230 VAC)

• The power supply unit for additional tools, or special power supply units for the machining process.

• The external voltage connected to the controller remains live even when the robot is disconnected from the mains.

• Additional connections.

Voltage related risks, manipulator

A danger of low voltage is associated with the manipulator in:

• The power supply for the motors (up to 800 VDC).

• The user connections for tools or other parts of the installation (max. 230

VAC).




29


1 Safety

1.3.6 Risks associated with live electric parts

Continued

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.

30




1 Safety

1.3.7 The unit is sensitive to ESD

1.3.7 The unit is sensitive to ESD

Description

ESD (electrostatic discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not grounded may potentially transfer high static charges. This discharge may destroy sensitive electronics.

Safe handling

1

2

3

Action Note

Use a wrist strap. The wrist strap button is located inside the controller.

Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly.

• Product manual - IRC5

• Product manual - IRC5 Compact

• Product manual - IRC5 Panel Mounted

Controller

Use an ESD protective floor mat.

Use a dissipative table mat.

The mat must be grounded through a current-limiting resistor.

The mat should provide a controlled discharge of static voltages and must be grounded.




31

1 Safety

1.3.8 Hot parts may cause burns

1.3.8 Hot parts may cause burns

Description

During normal operation, many parts become hot. Touching these may cause burns.

There is also a risk of fire if flammable materials are put on hot surfaces.

Safe handling

Always use your hand, at some distance, to feel if heat is radiating from the potentially hot component before actually touching it.

Wait until the potentially hot component has cooled if it is to be removed or handled in any other way.

Do not put anything on hot metal surfaces, e.g. paper or plastic.

32




1 Safety

1.3.9 Safety risks related to pneumatic/hydraulic systems

1.3.9 Safety risks related to pneumatic/hydraulic systems

General

Special safety regulations apply to pneumatic and hydraulic systems.

Note

All components that remain pressurized after separating the machine from the power supply must be provided with clearly visible drain facilities and a warning sign that indicates the need for pressure relief before adjustments or performing any maintenance on the robot system.

Residual energy

Residual energy can be present in these systems. After shutdown, particular care must be taken.

The pressure must be released in the complete pneumatic or hydraulic systems before starting to repair them.

Work on hydraulic equipment may only be performed by persons with special knowledge and experience of hydraulics.

All pipes, hoses, and connections have to be inspected regularly for leaks and damage. Damage must be repaired immediately.

Splashed oil may cause injury or fire.

Safe design

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.




33

1 Safety

1.3.10 Brake testing

1.3.10 Brake testing

When to test

During operation, the holding brake of each axis normally wears down. A test can be performed to determine whether the brake can still perform its function.

How to test

The function of the holding brake of each axis motor may be verified as described below:

1 Run each robot axis to a position where the combined weight of the robot arm and any load is maximized (maximum static load).

2 Switch the motor to the MOTORS OFF.

3 Inspect and verify that the axis maintains its position.

If the robot does not change position as the motors are switched off, then the brake function is adequate.

34




1 Safety

1.3.11 Safety risks during handling of batteries

1.3.11 Safety risks during handling of batteries

Description

Under normal conditions of use, the electrode materials and liquid electrolyte in the batteries are not exposed to the outside, provided the battery integrity is maintained and seals remain intact.

There is a risk of exposure only in case of abuse (mechanical, thermal, electrical) which leads to the activation of safety valves and/or the rupture of the battery container. Electrolyte leakage, electrode materials reaction with moisture/water or battery vent/explosion/fire may follow, depending upon the circumstances.

Note

Appropriate disposal regulations must be observed.

Safe handling

Use safety glasses when handling the batteries.

In the event of leakage, wear rubber gloves and chemical apron.

In the event of fire, use self-contained breathing apparatus.

Do not short circuit, recharge, puncture, incinerate, crush, immerse, force discharge or expose to temperatures above the declared operating temperature range of the product. Risk of fire or explosion.

Operating temperatures are listed in

Pre-installation procedure on page 48

.




35

1 Safety

1.3.12 Safety risks during work with gearbox lubricants (oil or grease)

1.3.12 Safety risks during work with gearbox lubricants (oil or grease)

Description

When handling gearbox lubricants, there is a risk of both personal injury and product damage occurring. The following safety information must be regarded before performing any work with lubricants in the gearboxes.

Note

When handling oil, grease, or other chemical substances the safety information of the manufacturer must be observed.

Note

When aggressive media is handled, an appropriate skin protection must be provided. Gloves and goggles are recommended.

Note

Appropriate disposal regulations must be observed.

Note

Take special care when handling hot lubricants.

Safe handling

Warning Description Elimination/Action

Changing and draining gearbox oil or grease may require handling hot lubricant heated up to

90 °C.

Make sure that protective gear like goggles and gloves are always worn during this activity.

Hot oil or grease

When working with gearbox lubricant there is a risk of an allergic reaction.

Make sure that protective gear like goggles and gloves are always worn.

Allergic reaction

Possible pressure build-up in gearbox

When opening the oil or grease plug, there may be pressure present in the gearbox, causing lubricant to spray from the opening.

Open the plug carefully and keep away from the opening. Do not overfill the gearbox when filling.


36




1 Safety

1.3.12 Safety risks during work with gearbox lubricants (oil or grease)

Continued

Warning

Do not overfill

Specified amount depends on drained volume

Description Elimination/Action

Overfilling of gearbox lubricant can lead to internal over-pressure inside the gearbox which in turn may:

• damage seals and gaskets

• completely press out seals and gaskets

• prevent the robot from moving freely.

Make sure not to overfill the gearbox when filling it with oil or grease.

After filling, verify that the level is correct.

The specified amount of oil or grease is based on the total volume of the gearbox. When changing the lubricant, the amount refilled may differ from the specified amount, depending on how much has previously been drained from the gearbox.

After filling, verify that the level is correct.

Contaminated oil in gear boxes

When draining the oil make sure that as much oil as possible is drained from the gearbox. The reason for this is to drain as much oil sludge and metal chips as possible from the gearbox.

The magnetic oil plugs will take care of any remaining metal chips.




37

1 Safety

1.4.1 Safety signals in the manual

1.4 Safety signals and symbols

1.4.1 Safety signals in the manual

Introduction to safety signals

This section specifies all safety signals used in the user manuals. Each signal consists of:

• A caption specifying the danger level (DANGER, WARNING, or CAUTION) and the type of danger.

• A brief description of what will happen if the the danger is not eliminated.

• Instruction about how to eliminate danger to simplify doing the work.

Danger levels

The table below defines the captions specifying the danger levels used throughout this manual.

Symbol Designation

DANGER

WARNING

ELECTRICAL

SHOCK

Significance

Warns that an accident will occur if the instructions are not followed, resulting in a serious or fatal injury and/or severe damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height, and so on.

Warns that an accident may occur if the instructions are not followed that can lead to serious injury, possibly fatal, and/or great damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height, etc.

Warns for electrical hazards which could result in severe personal injury or death.

CAUTION Warns that an accident may occur if the instructions are not followed that can result in injury and/or damage to the product. It also applies to warnings of risks that include burns, eye injury, skin injury, hearing damage, crushing or slipping, tripping, impact, fall from height, etc. Furthermore, it applies to warnings that include function requirements when fitting and removing equipment where there is a risk of damaging the product or causing a breakdown.

ELECTROSTATIC

DISCHARGE (ESD)

Warns for electrostatic hazards which could result in severe damage to the product.


38




Symbol Designation

NOTE

1 Safety

1.4.1 Safety signals in the manual

Continued

Significance

Describes important facts and conditions.

TIP Describes where to find additional information or how to do an operation in an easier way.




39

1 Safety

1.4.2 Safety symbols on product labels

1.4.2 Safety symbols on product labels

Introduction to labels

This section describes safety symbols used on labels (stickers) on the product.

Symbols are used in combinations on the labels, describing each specific warning.

The descriptions in this section are generic, the labels can contain additional information such as values.

Note

The safety and health symbols on the labels on the product must be observed.

Additional safety information given by the system builder or integrator must also be observed.

Types of labels

Both the manipulator and the controller are marked with several safety and information labels, containing important information about the product. The information is useful for all personnel handling the robot, for example during installation, service, or operation.

The safety labels are language independent, they only use graphics. See

Symbols on safety labels on page 40

.

The information labels can contain information in text (English, German, and

French).

Symbols on safety labels

Symbol xx0900000812 xx0900000811

Description

Warning!

Warns that an accident may occur if the instructions are not followed that can lead to serious injury, possibly fatal, and/or great damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height, etc.

Caution!

Warns that an accident may occur if the instructions are not followed that can result in injury and/or damage to the product.

It also applies to warnings of risks that include burns, eye injury, skin injury, hearing damage, crushing or slipping, tripping, impact, fall from height, etc. Furthermore, it applies to warnings that include function requirements when fitting and removing equipment where there is a risk of damaging the product or causing a breakdown.

Prohibition

Used in combinations with other symbols.

xx0900000839





Symbol xx0900000813

1 Safety


Continued

Description

See user documentation

Read user documentation for details.

Which manual to read is defined by the symbol:

• No text: Product manual .

• EPS: Application manual - Electronic Position Switches .

Before disassemble, see product manual xx0900000816

Do not disassemble

Disassembling this part can cause injury.

xx0900000815

Extended rotation

This axis has extended rotation (working area) compared to standard.

xx0900000814 xx0900000808

Brake release

Pressing this button will release the brakes. This means that the robot arm can fall down.





41

1 Safety


Continued

Symbol Description

Tip risk when loosening bolts

The robot can tip over if the bolts are not securely fastened.

xx0900000810 xx1500002402

Crush

Risk of crush injuries.

xx0900000817


42




Symbol

1 Safety


Continued

Description

Heat

Risk of heat that can cause burns. (Both signs are used) xx0900000818

!

xx1300001087

1 xx0900000819

3

4

5

2

6

Moving robot

The robot can move unexpectedly.

xx1000001141

2

4

3

1 xx1500002616





43

1 Safety


Continued

Symbol Description

Brake release buttons xx0900000820 xx1000001140 xx0900000821

Lifting bolt

Chain sling with shortener xx1000001242

Lifting of robot xx0900000822

Oil

Can be used in combination with prohibition if oil is not allowed.

xx0900000823

Mechanical stop xx0900000824


44




1 Safety


Continued

Description

No mechanical stop

Symbol xx1000001144 xx0900000825

Stored energy

Warns that this part contains stored energy.

Used in combination with Do not disassemble symbol.

Pressure

Warns that this part is pressurized. Usually contains additional text with the pressure level.

xx0900000826

Shut off with handle

Use the power switch on the controller.

xx0900000827

Do not step

Warns that stepping on these parts can cause damage to the parts.

xx1400002648




45



2.1 Introduction


2.1 Introduction

General

This chapter contains assembly instructions and information for installing the IRB

140 type C at the working site.

More detailed technical data can be found in the Product specification for the IRB

140 type C, such as:

• Load diagram

• Permitted extra loads (equipment), if any

• Location of extra loads (equipment), if any.


Before any installation work is commenced, it is extremely important that all safety information is observed.

There are general safety aspects that must be read through, as well as more specific safety information that describes the danger and safety risks when performing the procedures. Read the chapter

Safety on page 17

before performing any installation work.

Note

If the IRB 140 type C is connected to power, always make sure that the robot is connected to protective earth before starting any installation work.

For more information see:





47


2.2.1 Pre-installation procedure

2.2 Unpacking

2.2.1 Pre-installation procedure

Introduction

This section is intended for use when unpacking and installing the robot for the first time. It also contains information useful during later re-installation of the robot.

Prerequisites for installation personnel

Installation personnel working with an ABB product must:

• be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work

• conform to all national and local codes.

Checking the pre-requisites for installation

1

2

3

Action

Make a visual inspection of the packaging and make sure that nothing is damaged.

Remove the packaging.

Check for any visible transport damage.

Note

Stop unpacking and contact ABB if transport damages are found.

4

5

6

7

8

9

10

11

Clean the unit with a lint-free cloth, if necessary.

Make sure that the lifting accessory used (if required) is suitable to handle the weight of the robot as specified in:

Weight, robot on page 48

If the robot is not installed directly, it must be stored as described in:

Storage conditions, robot on page 51

Make sure that the expected operating environment of the robot conforms to the specifications as described in:

Operating conditions, robot on page 51

Before taking the robot to its installation site, make sure that the site conforms to:

•

Loads on foundation, robot on page 49

•

Protection classes, robot on page 51

•

Requirements, foundation on page 50

Before moving the robot, please observe the stability of the robot:

Risk of tipping/stability on page 54

When these prerequisites are met, the robot can be taken to its installation site as described in section:

On-site installation on page 55

Install required equipment, if any.

•

Installation of signal lamp (option) on page 73

Weight, robot

The table shows the weight of the robot.

Robot model

IRB 140 type C

Weight

100 kg


48






Continued

Note

The weight does not include tools and other equipment fitted on the robot.

Loads on foundation, robot

The illustration shows the directions of the robots stress forces.

The directions are valid for all floor mounted, suspended and inverted robots.

T xy

F z

F xy

T z xx1100000521

F xy

F z

T xy

T z

Force in any direction in the XY plane

Force in the Z plane

Bending torque in any direction in the XY plane

Bending torque in the Z plane

The table shows the various forces and torques working on the robot during different kinds of operation.

Note

These forces and torques are extreme values that are rarely encountered during operation. The values also never reach their maximum at the same time!

WARNING

The robot installation is restricted to the mounting options given in following load table(s).

Floor mounted

Force

Force xy



Endurance load (in operation)

± 1020 N


Max. load (emergency stop)

± 2000 N


49



Continued

Force

Force z

Torque xy

Torque z


- 1000 ± 620 N

± 700 Nm

± 250 Nm


- 1000 ± 1250 N

± 1500 Nm

± 470 Nm

Wall mounted

Force

Force xy

Force z

Torque xy

Torque z


± 1750 N

± 850 N

± 1020 Nm

± 250 Nm


± 2800 N

± 1600 N

± 1710 Nm

± 485 Nm

Suspended

Force

Force xy

Force z

Torque xy

Torque z


± 1020 N

+ 1000 ± 620 N

± 700 Nm

± 250 Nm


± 2000 N

+ 1000 ± 1250 N

± 1500 Nm

± 470 Nm

Requirements, foundation

The table shows the requirements for the foundation where the weight of the installed robot is included:

Requirement

Flatness of foundation surface

Maximum tilt

Minimum resonance frequency

Value

0.5 mm

Note

Flat foundations give better repeatability of the resolver calibration compared to original settings on delivery from ABB.

The value for levelness aims at the circumstance of the anchoring points in the robot base.

In order to compensate for an uneven surface, the robot can be recalibrated during installation.

If resolver/encoder calibration is changed this will influence the absolute accuracy.

5°

22 Hz

Note

It may affect the manipulator lifetime to have a lower resonance frequency than recommended.

The value is recommended for optimal performance.

Due to foundation stiffness, consider robot mass including equipment.

i

For information about compensating for foundation flexibility, see Application manual - Controller software IRC5 , section Motion Process Mode .

i

The minimum resonance frequency given should be interpreted as the frequency of the robot mass/inertia, robot assumed stiff, when a foundation translational/torsional elasticity is added, i.e., the stiffness of the pedestal where the robot is mounted. The minimum resonance frequency should not be interpreted as the resonance frequency of the building, floor etc. For example, if the equivalent mass of the floor is very high, it will not affect robot movement, even if the frequency is well below the stated 25 Hz. The robot should be mounted as rigid as possibly to the floor.







Continued

Disturbances from other machinery will affect the robot and the tool accuracy. The robot has resonance frequencies in the region 10 – 20 Hz and disturbances in this region will be amplified, although somewhat damped by the servo control. This might be a problem, depending on the requirements from the applications. If this is a problem, the robot needs to be isolated from the environment.

Storage conditions, robot

The table shows the allowed storage conditions for the robot:

Parameter

Minimum ambient temperature

Maximum ambient temperature

Maximum ambient temperature (less than 24 hrs)

Maximum ambient humidity

Value

-25° C

+55° C

+70° C

95% at constant temperature

(gaseous only)

Operating conditions, robot

The table shows the allowed operating conditions for the robot:

Parameter

Minimum ambient temperature

Maximum ambient temperature

Maximum ambient humidity

Value

+45° C

+5° C

95% at constant temperature

Protection classes, robot

The table shows the available protection types of the robot, with the corresponding protection class.

Protection type

Manipulator, protection type Standard

Manipulator, protection type Foundry Plus

Manipulator, protection type Clean Room

Manipulator, protection type Wash

Protection class

IP 67

IP 67

IP 67

IP 67




51


2.2.2 Working range, IRB 140

2.2.2 Working range, IRB 140

Working range axis 2 -3

The illustration below shows the unrestricted working range axis 2-3.

6

7

4

5

8

0

1

2

3 xx0200000058

Pos.

255

-480

1

218

-670

Position at wrist centre

X Z

450 712

70

314

765

1092

421

99

-119

23

596

558

352

Angle (degrees)

Axis 2

0°

0°

0°

+110°

+110°

-90°

-90°

+110°

-90°

Axis 3

0°

-90°

+50°

-90°

+4°

-150°

+50°

-230°

-90°


52





2.2.2 Working range, IRB 140

Continued

Working range axis 1

The illustrations below shows the unrestricted working range of axis 1.

xx0200000061




53


2.2.3 Risk of tipping/stability

2.2.3 Risk of tipping/stability

Risk of tipping

If the robot is not fastened to the foundation while moving the arm, the robot is not stable in the whole working area. Moving the arm will displace the center of gravity, which may cause the robot to tip over.

The shipping position is the most stable position.

Do not change the robot position before securing it to the foundation!

WARNING

The robot is likely to be mechanically unstable if not secured to the foundation.

54





2.3.1 Lifting the manipulator with lifting slings

2.3 On-site installation

2.3.1 Lifting the manipulator with lifting slings

Introduction

This section details how to lift the manipulator using lifting slings.

Equipment

Sling line for manipulator

Sling line for control cable

Note

Length: 2 m. Load: 500 kg.

Illustration xx0200000084

1

2

3



Sling line for control cable

How to lift the manipulator

1 Adjust the manipulator to lifting position according to the illustration.

2 Put one sling line around each leg on the lower arm (positions 1 and 2).

3 Use another sling line to secure the lifting of the control cable (position 3).



55



2.3.2 Lifting and turning the manipulator

2.3.2 Lifting and turning the manipulator

Required equipment

Equipment

Lifting slings -

Article number Note

2 pcs

Length: 2 m.

Lifting capacity: 1,000 kg (too narrow slings risk to damage the sealings on the axis-2 shaft).

Overhead crane or fork lift -

Lifting slings attached to the robot

The figure shows lifting slings attached to the robot, rigged as choker hitches, for lifting and turning the robot for installation on a wall or inverted.

WARNING

The robot will tip forward when lifting it off the ground.

xx1600000347


56






Continued

Lifting and turning the robot

The procedure details how to lift and turn the robot for installation on a wall or inverted.

1

2

Action

Move axis-2 to approximately -20º and axis-3 to approximately +50º.

Remaining axes can be positioned as suitable, depending on equipment installed on the robot.

Rig the lifting sling as a choker hitch by passing the lifting sling around the axis-2 gearbox, underneath the axis-2 damper, then through itself, then attaching it to the overhead crane or fork lift.

The figure shows the principle of a choker hitch.

Note

3 xx1400000730

If necessary, use an extra lifting sling to lengthen the reach between the sling and the overhead crane/fork lift.

To facilitate the installation of the slings, the axis-

2 damper can be removed temporarily.

xx1600000348

Rig the lifting sling as a choker hitch by passing the lifting sling around the lower arm shaft, then through itself, then attaching it to the overhead crane or fork lift.

If necessary, use an extra lifting sling to lengthen the reach between the sling and the overhead crane/fork lift.

4

5

Loosen the robot from the foundation.

CAUTION

The IRB 140 type C robot weighs 100 kg.

All lifting accessories used must be sized accordingly!

xx1600000347





57



Continued

6

Action Note

Lift the robot while holding touch of the robot with your hands in order to carefully tip it forward.

Keep tipping the robot forward until it hangs either horizontally or completely inverted.

The figure shows the robot rotated

180º.

WARNING

The robot will tip forward when lifting it off the ground.

7 Secure the robot at its working site on the wall or inverted according to

Orienting and securing the manipulator on page 62

.

Reinstall the axis-2 damper, if removed.

xx1600000544

58





2.3.3 Manually releasing the brakes

2.3.3 Manually releasing the brakes

General

The section below details how to release the holding brakes of each axis' motor.

This may be done in one of three ways:

• using the brake release unit when the robot is connected to the controller.

• using the brake release unit when the robot is disconnected from the controller, but connected to an external power supply at the connector R1.MP.

• using an external voltage supply directly on the motor connector.

Using the brake release unit when the robot is connected to the controller

Use this procedure to release the holding brakes with the internal brake release unit.

1

Action

The brake release button (A) is located at the base of the robot.

Note

2

3

DANGER

When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways!

Make sure no personnel is near or beneath the robot arm!

Release the holding brakes by pushing the brake release button.

The brake will function again as soon as the button is released.

xx0200000069





59



Continued

Using the brake release unit with an external power supply

This section details how to release the holding brakes with the internal brake release unit using an external voltage supply. This is done if the robot is not connected to the controller.

1

Action Note

DANGER

Incorrect connections, such as supplying power to the wrong pin, may cause all brakes to be released simultaneously!

Also, be careful not to interchange the

24V and 0V pins. If they are mixed up, damage can be caused to a resistor diode and to the system board.

2 Connect an external power supply to connector XP1.

3 Push the brake release button to release the holding brakes, according to the previous procedure.

xx0200000071

Supply:

• A: B16 24V DC

• B: B14 0V


60






Continued

Using external power supply

This section details how to release the holding brakes using an external voltage supply. If the positions of the robot axes are to be changed without connecting the controller, an external voltage supply (24 V DC) must be connected to enable the brake release buttons on the robot.

1

Action

Remove the screws and dismount the cover on the back of the robot base.


2

3

Locate the R1.MP4-6 connector and disconnect.

Connect an external power supply to release the holding brake on all axis.

xx0200000072

• A: 13 0V

• B: 15 24V DC




61


2.3.4 Orienting and securing the manipulator

2.3.4 Orienting and securing the manipulator

General

This section details how to orient and secure the manipulator to the foundation in order to safely run the robot.

Bolting requirements

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 section

Loads on foundation, robot on page 49

.

Note

When the robot is to be mounted in a tilted or a suspended position, the guide sleeves must be used to secure the bolted joint.

Attachment screws

The table below specifies the type of securing screws and washers to be used for securing the robot to the base plate/foundation.

Suitable screws, lightly lubricated:

Quality

Suitable washer:

Tightening torque:

M12

Quality 8.8

Thickness: 2.5 mm

Outer diameter: 24 mm

Inner diameter: 13.4 mm

85 Nm

Hole configuration and cross section

The bolt pattern requirements are shown in section

Bolt pattern on page 71 .

Guide sleeves

Two guide sleeves can be fitted to the two rear bolt holes to allow the same robot to be remounted without re-adjusting the program.

Equipment

Guide sleeves

Art. no.

3HAC 9519-1

62





2.3.5 Fitting equipment on manipulator

2.3.5 Fitting equipment on manipulator

General

The manipulator features mounting holes for additional equipment.

In addition to the stock mounting holes, extra mounting holes may be added on the manipulator under certain conditions. These special conditions are specified in the Product specification - IRB 140 .

Note

All equipment and cables used on the robot, must be designed and fitted not to damage the robot and/or its parts.

Illustration, holes on upper arm

The illustration below shows the stock holes available for fitting extra equipment on the upper arm.

xx0600003263





63


2.3.5 Fitting equipment on manipulator

Continued

Illustration, holes on mounting flange

The illustration below shows the stock holes available for fitting equipment on the mounting flange.

xx0200000063

Fastener quality

When fitting tools on the turning disk, use only screws with quality 12.9. When fitting equipment on other places, standard screws with quality 8.8 can be used.

64





2.3.6 Loads

2.3.6 Loads

Introduction

Any loads mounted on the manipulator must be defined correctly and carefully

(with regard to the position of the center of gravity and inertia factor) to avoid jolting movements and overloading the motors. If this is not done correctly operation stops can occur.

References

Load diagrams, permitted extra loads (equipment) and their positions as specified in the product specification. The loads must also be defined in the software as detailed in Operating manual - IRC5 with FlexPendant .

Brake performance

Manipulator motor brake performance depends on any loads attached. For further information about brake performance, please contact ABB.




65


2.3.7 Setting the system parameters for a suspended or tilted robot

2.3.7 Setting the system parameters for a suspended or tilted robot

General

The robot is configured for mounting parallel to the floor, without tilting, on delivery.

The method for mounting the robot in a suspended (upside down) or tilted position is basically the same as for floor mounting, but the system parameters that describe the mounting angle (how the robot is oriented relative to the gravity) must be re-defined.

Note

With suspended 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.

Note

The allowed mounting positions are described in the product specification for the robot. The requirements on the foundation are described in

Requirements, foundation on page 50

.

System parameters

Note

The mounting angle must be configured correctly in the system parameters so that the robot system can control the movements in the best possible way. An incorrect definition of the mounting angle will result in:

• Overloading the mechanical structure.

• Lower path performance and path accuracy.

• Some functions will not work properly, for example Load Identification and

Collision detection .

Gravity Beta

If the robot is mounted upside down or on a wall (rotated around the y-axis), then the robot base frame and the system parameter Gravity Beta must be redefined.

Gravity Beta should then be π (+3.141593) if the robot is mounted upside down

(suspended), or ±π/2 (±1.570796) if mounted on a wall.

The Gravity Beta is a positive rotation direction around the y-axis in the base coordinate system. The value is set in radians.

Gravity Alpha

If the robot is mounted on a wall (rotated around the x-axis), then the robot base frame and the system parameter Gravity Alpha must be redefined. The value of

Gravity Alpha should then be ±π/2 (±1.570796).







Continued

The Gravity Alpha is a positive rotation direction around the x-axis in the base coordinate system. The value is set in radians.

Note

The system parameter Gravity Alpha is not supported for all robot types. It is not supported for IRB 140, IRB 1410, IRB 1600ID, IRB 2400, IRB 4400, IRB 6400R,

IRB 6400 (except for IRB 6400 200/2.5 and IRB 6400 200/2.8), IRB 6600, IRB

6650, IRB 6650S and IRB 7600 (except for IRB 7600 325/3.1).

If the robot does not support Gravity Alpha , then use Gravity Beta along with the recalibration of axis 1 to define the rotation of the robot around the x-axis.

Note

The parameter is supported for all robots on track when the system parameter

7 axes high performance motion is set, see Technical reference manual - System parameters .

Gamma Rotation

Gamma Rotation defines the orientation of the robot foot on the travel carriage

(track motion).

Mounting angles and values

The parameter Gravity Beta (or Gravity Alpha ) specifies the mounting angle of the robot in radians. It is calculated in the following way.

Gravity Beta = A° x 3.141593/180 = B radians

, where

A is the mounting angle in degrees and B is the mounting angle in radians.

Example of position

Floor mounted

Wall mounting

Suspended mounting

Mounting angle (A°)

0°

90°

180°

Gravity Beta

0.000000 (Default)

1.570796

3.141593





67



Continued

Examples of mounting angles tilted around the Y axis ( Gravity Beta ) xx0200000066


68






Continued

Examples of mounting angles tilted around the X axis ( Gravity Alpha )

The following illustration shows the IRB 120, but the same principle applies for all robots.

xx1500000532

3

4

Pos

1

2

Mounting angle

0° (Floor mounted)

45° (Tilted)

90° (Wall)

-90° (Wall)

Gravity Alpha

0

0.785398

1.570796

-1.570796

Note

For suspended robots (180°), it is recommended to use Gravity Beta instead of

Gravity Alpha .





69



Continued

Defining the parameter in the IRC5 software

The value of the system parameters that define the mounting angle must be redefined when changing the mounting angle of the robot. The parameters belong to the type Robot , in the topic Motion .

How to calculate a new value is detailed in

Mounting angles and values on page 67 .

The system parameters are described in Technical reference manual - System parameters .

The system parameters are redefined in the Configuration Editor , in RobotStudio or on the FlexPendant.

70





2.3.8 Bolt pattern

2.3.8 Bolt pattern

Hole configuration

The illustration below shows the hole configuration used when securing the manipulator:

A

A A

Z

Ø13

Ø 0,6 A

B B xx0200000085





71


2.3.8 Bolt pattern

Continued

Cross section, guide sleeve hole

The illustration below shows the cross section of the guide sleeve holes: xx0200000086

A-A

72





2.3.9 Installation of signal lamp (option)

2.3.9 Installation of signal lamp (option)

Signal lamp

See the assembly instruction delivered with the signal lamp.




73


2.4.1 Restricting the working range

2.4 Restricting the working range

2.4.1 Restricting the working range

Introduction

When installing the manipulator, make sure that it can move freely within its entire working space. If there is a risk that it can collide with other objects, its working space should be limited.

WARNING

The working space can only be limited using software, for this reason the limited area cannot be classified as a safe zone. All work within this zone is prohibited.

System parameters

The system parameters that must be changed ( Upper joint bound and Lower joint bound ) are described in Technical reference manual - System parameters .

Limiting devices

Examples of limiting devices are listed below.

1 Light curtains.

2 Tread mats.

3 Other similar devices.

4 Software.

74





2.5.1 Grounding and bonding point on manipulator

2.5 Electrical connections

2.5.1 Grounding and bonding point on manipulator

Location of grounding/bonding point

There is a grounding/bonding point on the manipulator base. The grounding/bonding point is used for potential equalizing between control cabinet, manipulator and any peripheral devices.

xx1700000974




75


2.5.2 Customer connections on manipulator

2.5.2 Customer connections on manipulator

General

For connection of extra equipment on the manipulator there are cables integrated into the manipulator's cabling. There are both air and electrical connectors on the manipulator.

Connections xx0200000074

Connections

For air on base / upper arm

Signal connector on upper arm

Description

R1/4" Max. 8 bar/hose inner diameter: 6.5 mm

FCI UT 071412SH44N connector

Number of signals: 12 signals, 49V, 500mA


76





2.5.2 Customer connections on manipulator

Continued

Recommended parts

To connect power and signal conductors to the upper arm connector, the following parts are recommended xx0200000132

ABB’s recommended contact set, for connector R2.CS (3HAC 12497-1) contains:

• Multipole connector 12 pin

• Adapter Tin plated 12 pin

• Pins for cable area 0.25-0.5 mm

2

• Pins for cable area 0.5-1.5 mm

2

• Shrinking hose, bootled shaped

• Shrinking hose angled

The connection set is delivered in a plastic bag also containing a Technical and assembly instruction.




77


2.6 Start of robot in cold environments

2.6 Start of robot in cold environments

Introduction

This section describes how to start the robot in a cold environment if it is not starting the normal way.

Problems with starting the robot

Event message from Motion Supervision

Use this procedure if an event message indicates a problem with Motion supervision at start-up. More information about Motion Supervision is found in Technical reference manual - System parameters .

1

2

3

Action

Turn off Motion Supervision.

Start the robot.

When the robot has reached normal working temperature, the Motion Supervision can be turned on again.

Note

Robot stopping with other event message

Use this procedure if the robot is not starting.

1

Action

Start the robot with its normal program but with reduced speed.

Note

The speed can be regulated with the

RAPID instruction VelSet .

Adjusting the speed and acceleration during warm-up

Depending on how cold the environment is and what program is being used, the speed might need to be ramped up until reached maximum. The table shows examples of how to adjust the speed:

Work cycles

3 Work cycles

5 Work cycles

5 Work cycles

5 Work cycles

More than 5 Work cycles

AccSet

20, 20

40, 40

60, 60

100, 100

100, 100

Speed/velocity v100 (100 mm/s) v400 (400 mm/s) v600 (600 mm/s) v1000 (1000 mm/s)

Max.

If the program consists of large wrist movements, it is possible that the reorientation velocity, which is always high in predefined velocities, needs to be included in the ramping up.

78




3 Maintenance

3.1 Introduction

3 Maintenance


Structure of this chapter

This chapter describes all the maintenance activities recommended for the IRB

140 type C.

It is based on the maintenance schedule found at the beginning of the chapter.

The schedule contains information about required maintenance activities including intervals, and refers to procedures for the activities.

Each procedure contains all the information required to perform the activity, including required tools and materials.

The procedures are gathered in different sections and divided according to the maintenance activity.


Observe all safety information before conducting any service work.

There are general safety aspects that must be read through, as well as more specific safety information that describes the danger and safety risks when performing the procedures. Read the chapter

Safety on page 17

before performing any service work.

Note

If the IRB 140 type C is connected to power, always make sure that the IRB 140 type C is connected to protective earth before starting any maintenance work.






79

3 Maintenance

3.2.1 Specification of maintenance intervals

3.2 Maintenance schedules

3.2.1 Specification of maintenance intervals

Introduction

The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the IRB 140 type C:

• Calendar time: specified in months regardless of whether the system is running or not.

• Operating time: specified in operating hours. More frequent running means more frequent maintenance activities.

• SIS: specified by the robot's SIS (Service Information System). A typical value is given for a typical work cycle, but the value will differ depending on how hard each part is run. The SIS used in M2004 is further described in the

Operating manual - Service Information System .

80




3 Maintenance

3.2.2 Maintenance schedule

3.2.2 Maintenance schedule

General

The robot, consisting of robot and controller cabinet, must be maintained regularly to ensure its function. The maintenance activities and their respective intervals are specified in the table below.

Non-predictable situations also give rise to inspections of the robot. Any damages must be attended to immediately!

The inspection intervals do not specify the life of each component.

Activities and intervals, standard equipment

The sections referred to in the table can be found in the different chapters for every maintenance activity.

The table below specifies the required maintenance activities and intervals:

Equipment Interval Detailed in section: Maintenance activity

Inspection

Inspection

Robot Regularly

i

For Clean Room robots:

Daily

Damper, axes 2-3 Regularly i

Check for abnormal wear or contamination

Inspection

Inspection

Inspection

Inspection

Changing

Changing

Replacement

Cable harnesses Regularly

i

Timing belts

Oil

36 mths

12 mths

Information labels 12 months

Gearbox 5, oil

Gearbox 6, oil

36 months

36 months

Battery pack, measurement system of type

RMU101 or

RMU102 (3-pole battery contact)

36 months or battery low alert ii

Inspection, damper axes

2, 3 and 5 on page 83

Inspecting the robot cabling on page 85

Inspection, timing belts on page 86

Inspection activities on page 83

Replace any damaged, missing or unreadable labels.

Replace any damaged, missing or unreadable labels.

Inspecting information labels on page 104

Changing the oil in axes

5 and 6 gearboxes on page 110



Replacing the serial measurement unit and the battery pack on page 167




81


3 Maintenance

3.2.2 Maintenance schedule

Continued

Maintenance activity

Equipment Interval Detailed in section:

Replacement Battery pack, measurement system with 2pole battery contact, e.g.

DSQC633A

Battery low alert iii

Complete robot Regularly

i


Cleaning

Cleaning the IRB 140 type

C on page 106

i ii iii

"Regularly" implies that the activity is to be performed regularly, but the actual interval may not be specified by the robot manufacturer. The interval depends on the operation cycle of the robot, its working environment and movement pattern. Generally, the more contaminated environment, the shorter intervals. The more demanding movement pattern (sharper bending cable harness), the shorter intervals.

The battery low alert (38213 Battery charge low ) is displayed when the battery needs to be replaced.

The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned on until the battery is to be replaced.

See the replacement instruction for more details.

The battery low alert (38213 Battery charge low ) is displayed when remaining backup capacity

(robot powered off) is less than 2 months. The typical lifetime of a new battery is 36 months if the robot is powered off 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime can be extended with a battery shutdown service routine. See Operating manual - IRC5 with

FlexPendant for instructions.

82




3 Maintenance

3.3.1 Inspection, damper axes 2, 3 and 5

3.3 Inspection activities

3.3.1 Inspection, damper axes 2, 3 and 5

Location of dampers

The figure below shows the location of all the dampers to be inspected.

xx0200000426

A Damper, axis 2 xx0200000427

A Damper, axis 3





83

3 Maintenance

3.3.1 Inspection, damper axes 2, 3 and 5

Continued


Equipment

Standard toolkit -

Art. no.

Note

Content is defined in section

Standard tools on page 239 .

CAUTION

Always cut the paint with a knife and grind the paint edge when disassembling parts. See


.

Inspection, dampers

The procedure below details how to inspect the dampers.

Action Note

1

DANGER

Turn off all:

• electric power supply

• hydraulic pressure supply

• air pressure supply to the robot, before entering the robot working area.

2

3

4

Check all dampers for damage, such as cracks or existing impressions that are larger than 1 mm.

Shown in the figure

Location of dampers on page 83 .

Check attachment screws for deformation.

If any damage is detected, the damper must be replaced with a new one!

Replacement is detailed in sections:

•

Replacing the damper, axis

2 on page 157

•

Replacing the damper, axis

3 on page 146

•

Replacement of damper, axis 5 on page 148 .

84




3 Maintenance

3.3.2 Inspecting the robot cabling

3.3.2 Inspecting the robot cabling

Introduction

CAUTION

Always read the specific instructions if the robot has protection type Clean Room, before doing any repair work, see


Location of robot cabling

The robot cabling comprises the cabling between the robot and controller cabinet as well as the externally visible cabling around motors 1 and 2.

A more detailed view of the components and its position may be found in chapter

Spare part lists on page 243

.

Required tools and equipment

Visual inspection, no tools are required.

Other tools and procedures may be required if the spare part needs to be replaced.

These are specified in the replacement procedure.

Inspection, robot cabling

Use this procedure to inspect the robot cabling.

Action

1

DANGER

Turn off all:

• electric power supply to the robot

• hydraulic pressure supply to the robot

• air pressure supply to the robot

Before entering the robot working area.

2

3

Note

Visually inspect:

• the control cabling between the robot and control cabinet

• the cabling to motors 1 and 2.

Look for abrasions, cuts or crush damages.

Replace the cabling if wear or damage is detected.

This is detailed in section

Replacement of cable harness on page 120 .




3 Maintenance

3.3.3 Inspection, timing belts

3.3.3 Inspection, timing belts

Location of timing belts

Axes 3, 5 and 6 are fitted with timing belts. These are located as shown in the figures below.



.

xx0200000448

G Timing belt, axis 3


86




3 Maintenance


Continued xx0600003261

R

U

Timing belt, axis 6

Timing belt, axis 5


Equipment, etc.

Standard toolkit

Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.

Art. no.

3HAC020812-001

Note


Standard tools on page 239

.

These procedures include references to the tools required.





87

3 Maintenance


Continued

Inspection

The procedure below details how to inspect the timing belts.

WARNING

1

2

3

Please observe the following before commencing any repair work on the manipulator:

• Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them!

• Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot!

• When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures.

Action Note

Gain access to each belt by removing covers, etc.

These procedures are detailed in sections

Replacement of motor and timing belt, axis 3 on page 186

and

Replacement of motor and timing belt, axes 5 or 6 on page 197

.

Check each belt for damage.

Check each belt for tension.

If the belt tension is not correct, it should be adjusted.

Replace the timing belts if found defective as detailed in sections


and

Replacement of motor and timing belt, axes 5 or

6 on page 197

.

The belt tension should be:

• Axis 3: F = 35-60 N

• Axis 5: F = 35-60 N

• Axis 6: F = 35-60 N

88 xx0200000474

Belt tension adjustment is detailed in sections


and


.




3 Maintenance

3.3.4 Inspecting oil level gearbox axis 1

3.3.4 Inspecting oil level gearbox axis 1

Location of oil plugs

The oil plug axis 1 gearbox is located as shown in the figure.

A xx1700000416

A Oil plug, filling, draining, inspection


Equipment

Oil plug sealing washer, gearbox

Lubrication oil

Standard toolkit

Note

3HAC029646-001

See section

Type of lubrication in gearboxes on page 109

.



.

Other tools and procedures may be required.

See references to these procedures in the step-by-step instructions below.





89


3 Maintenance


Continued

CAUTION



.

Inspecting oil level

Use this procedure to inspect the oil level in the axis 1 gearbox.

1

Note

The suspended manipulator must be taken down and secured standing on the floor for inspection.

Action Note

WARNING

Handling gearbox oil involves several safety risks. Before proceeding, please read the safety information in the section

Safety risks during work with gearbox lubricants (oil or grease) on page 36

.

2

DANGER

Turn off all:




3

CAUTION

The gearbox can contain an excess of pressure that can be hazardous. Open the oil plug carefully in order to let out the excess pressure.


90




3 Maintenance


Continued

4

Action

Measure the oil level at the oil plug hole.

Required oil level:

• 34 ±5 mm below the upper edge of the oil plug hole.

Note

Note

Position the axis according to illustration before measuring the oil level.

A

B xx1700000422

A

B

The upper edge of the oil plug hole

Oil level

5

6

Add oil if required.

Refit the oil plug, filling.

Note

Before refitting the oil plug in the gearbox, always replace the oil plug sealing washer with a new one. If not there is a risk of leakage.

See Technical reference manual - Lubrication in gearboxes

Tightening torque:

• 10 Nm

7 Seal and paint the joints that have been opened. Also repair possible damages of the special Foundry Prime paint coat of the robot. See


.

Note

After all repair work, wipe the robot free from particles with spirit on a lint free cloth.




91

3 Maintenance





A xx1700000417



Equipment


Lubrication oil

Note

3HAC029646-001

See section


.

Standard toolkit Content is defined in section


.





92

CAUTION



.




3 Maintenance


Continued



Note

1


Action Note

WARNING



.

2

DANGER

Turn off all:




3

CAUTION






93

3 Maintenance


Continued

4

Action


Required oil level:

• 125 -25 mm below the lower edge of the oil plug hole.

A

Note

Note

B

If it is not possible to measure the oil level, drain all oil out and refill with initial amount according to Technical reference manual.

• Remove the motor.

See

Removal, motor axis 2 on page 182 .

• Refill oil in the gearbox.

See Technical reference manual - Lubrication in gearboxes .

• Refit the motor.

See

Refitting, motor axis 2 on page 184 .

xx1700000570

A

B

The lower edge of the oil plug hole

Oil level

5

6

Note




Note


See, Technical reference manual - Lubrication in gearboxes .

Tightening torque:

• 10 Nm



.

Note


94




3 Maintenance





A xx1700000418



Equipment


Lubrication oil

Note

3HAC029646-001

See section


.



.




CAUTION



.





95

3 Maintenance


Continued



Note

1


Action Note

WARNING



.

2

DANGER

Turn off all:




3

CAUTION


4 Measure the oil level at the oil plug hole.

Required oil level:

• 148 ±5 mm below the upper edge of the oil plug hole.

A

B

Note


xx1700000571

A The upper edge of the oil plug hole

B Oil level

5 Add oil if required.



96




3 Maintenance


Continued

6

Action


Note


Note

Tightening torque:

• 10 Nm



.

Note





97

3 Maintenance





A xx1700000419



Equipment


Lubrication oil

Note

3HAC029646-001

See section


.



.




CAUTION



.


98




3 Maintenance


Continued



Note

1

If the surroundings prohibits an inspection of the manipulator in a suspended position, then the manipulator must be taken down and secured standing on the floor.

Action Note

WARNING



.

2

DANGER

Turn off all:




3

CAUTION






99

3 Maintenance


Continued

4

Action


Required oil level:

• 15 ±3 mm below the upper edge of oil plug hole.

Note

Note


A

B xx1700000421

A The upper edge of the oil plug hole

B Oil level

5

6



Note



Tightening torque:

• 10 Nm



.

Note


100




3 Maintenance

3.3.8 Inspecting oil level gearbox axes 5-6

3.3.8 Inspecting oil level gearbox axes 5-6


The oil plug axis 5-6 gearbox is located as shown in the figure.

A

B xx1700000420

A

B

Oil plug, filling, draining, inspection

Oil plug, ventilation hole


Equipment


Lubrication oil

Note

3HAC029646-001

See section


.



.




CAUTION



.





101

3 Maintenance


Continued


Use this procedure to inspect the oil level in the axis 5-6 gearbox.

Note

1

If the surroundings prohibits an inspection of the manipulator in a suspended position, then the manipulator must be taken down and secured standing on the floor.

Action Note

WARNING



.

2

DANGER

Turn off all:




3

CAUTION


4 Measure the oil level at the oil plug hole.

Required oil level:

• 23 ±3 mm below the lower edge of the oil plug hole.

A

B

Note


xx1700000572

A The lower edge of the oil plug hole

B Oil Level

5 Add oil if required.






3 Maintenance


Continued

6

Action


Note


Note

Tightening torque:

• 10 Nm



.

Note





103

3 Maintenance

3.3.9 Inspecting information labels

3.3.9 Inspecting information labels

Location of information labels

The figure shows the location of the information labels to be inspected.

A



A

PLUS



H

G

1

C C

H

G

2

H

WARNING

ACHTUNG

VARNING

ATTENTION



A A



F

H

D

L

LIFTING OF ROBOT

HEBEN DES ROBOT

LEVAGE DU ROBOT

WEIGHT

GEWICHT

POIDS

E

WARNING

ACHTUNG

ATTENTION

J

H

F

K

B

H

H

J

K

L xx1800001184

D

E

F

G1

A

B

C

G2

ABB logotype

Warning label - Brake release

Warning label - heat (2 pcs)

Rating label (located inside the base)

Calibration label

Lifting instruction label

Foundry or CleanRoom logotype, if applicable. Location is valid if option lamp unit is selected.

Foundry or CleanRoom logotype, if applicable. Location is valid if option lamp unit is not selected.

Warning label - Electricity (symbol of flash) (6 pcs)

UL/UR label

Information sign - AbsAcc

Label - battery

D


Equipment

Labels

Spare part number

See

Spare part lists on page 243 .

Note

F





3 Maintenance

3.3.9 Inspecting information labels

Continued

Inspecting labels

Use this procedure to inspect the labels on the robot.

Action Note

1

DANGER

Turn off all:




2 Check all labels.

See the figure in

Location of information labels on page 104

.

3 Replace any missing or damaged labels.




105

3 Maintenance

3.4.1 Cleaning the IRB 140 type C

3.4 Cleaning activities

3.4.1 Cleaning the IRB 140 type C

WARNING

Turn off all electrical power supplies to the manipulator before entering its work space.

General

To secure high uptime it is important that the IRB 140 type C is cleaned regularly.

The frequency of cleaning depends on the environment in which the product works.

Different cleaning methods are allowed depending on the type of protection of the

IRB 140 type C.

Note

Always verify the protection type of the robot before cleaning.

Special cleaning considerations

This section specifies some special considerations when cleaning the robot.

• Always use cleaning equipment as specified. Any other cleaning equipment may shorten the life of the robot.

• Always check that all protective covers are fitted to the robot before cleaning.

• Never point the water jet at connectors, joints, sealings, or gaskets.

• Do not use compressed air to clean the robot.

• Never use solvents that are not approved by ABB to clean the robot.

• Do not spray from a distance closer than 0.4 m.

• Do not remove any covers or other protective devices before cleaning the robot.

Cleaning methods

The following table defines what cleaning methods are allowed depending on the protection type.

Protection type

Standard

Cleaning method

Vacuum cleaner

Wipe with cloth Rinse with water

Yes Yes. With light cleaning detergent.

Yes. It is highly recommended that the water contains a rust-prevention solution and that the manipulator is dried afterwards.

High pressure water or steam

No





3 Maintenance


Continued i ii

Protection type

Wash

Cleaning method

Vacuum cleaner

Foundry Plus Yes

Yes

Wipe with cloth

Yes. With light cleaning detergent or spirit.

Yes. With light cleaning detergent or spirit.

Rinse with water

Yes. It is highly recommended that the water contains a rust-prevention solution.

Yes. It is highly recommended that the water contains a rust-prevention solution.

Clean room Yes Yes. With light cleaning detergent, spirit or isopropyl alcohol.

No

Perform according to section

Cleaning with water and steam on page 107 .

Perform according to section

Cleaning with water and steam on page 107 .

High pressure water or steam

Yes i

.

It is highly recommended that the water and steam contains rust preventive, without cleaning detergents.

Yes ii

.

It is highly recommended that the water and steam contains rust preventive, without cleaning detergents.

No

Cleaning with water and steam

Instructions for rinsing with water

ABB robots with protection types Standard , Foundry Plus , Wash , or Foundry Prime can be cleaned by rinsing with water (water cleaner).

1

The following list defines the prerequisites:

• Maximum water pressure at the nozzle: 700 kN/m

2

(7 bar)

I

I

• Fan jet nozzle should be used, min. 45° spread

• Minimum distance from nozzle to encapsulation: 0.4 meters

• Maximum flow: 20 liters/min

I

Typical tap water pressure and flow

Instructions for steam or high pressure water cleaning

ABB robots with protection types Foundry Plus , Wash , or Foundry Prime can be cleaned using a steam cleaner or high pressure water cleaner.

2

The following list defines the prerequisites:

• Maximum water pressure at the nozzle: 2500 kN/m

2

(25 bar)

• Fan jet nozzle should be used, min. 45° spread

• Minimum distance from nozzle to encapsulation: 0.4 meters

• Maximum water temperature: 80° C

1

2

See

Cleaning methods on page 106

for exceptions.

See

Cleaning methods on page 106

for exceptions.





107

3 Maintenance


Continued

Cables

Movable cables need to be able to move freely:

• Remove waste material, such as sand, dust and chips, if it prevents cable movement.

• Clean the cables if they have a crusty surface, for example from dry release agents.

108




3 Maintenance

3.5.1 Type of lubrication in gearboxes

3.5 Changing/ replacing activities

3.5.1 Type of lubrication in gearboxes

Introduction

This section describes where to find information about the type of lubrication , article number and the amount of lubrication in the specific gearbox. It also describes the equipment needed when working with lubrication.

Type and amount of oil in gearboxes

Information about the type of lubrication , article number as well as the amount in the specific gearbox can be found in Technical reference manual - Lubrication in gearboxes available for registered users on myABB Business Portal, www.myportal.abb.com

.

Before starting any inspection, maintenance, or changing activities of lubrication, always contact the local ABB Service organization for more information.

For ABB personnel: Always check ABB Library for the latest revision of the manual

Technical reference manual - Lubrication in gearboxes , in order to always get the latest information of updates about lubrication in gearboxes. A new revision will be published on ABB Library immediately after updates.

Location of gearboxes

The figure shows the location of the gearboxes.

Equipment

Equipment

Oil dispenser

Nipple for quick connect fitting, with o-ring

Note

Includes pump with outlet pipe.

Use the suggested dispenser or a similar one:

• Orion OriCan article number 22590

(pneumatic)




109

3 Maintenance

3.5.2 Changing the oil in axes 5 and 6 gearboxes

3.5.2 Changing the oil in axes 5 and 6 gearboxes


The gearboxes for axes 5 and 6 are located in the wrist unit as shown in the figure below.



.

xx0600002846

A

B

Oil plug, draining and filling

Oil plug, vent hole


Equipment, etc.

Lubricating oil

Note

Information about the oil is found in Technical reference manual - Lubrication in gearboxes .

See


Oil collecting vessel

Standard toolkit

The capacity of the vessel must be sufficient to take the complete amount of oil.





CAUTION



.


110




3 Maintenance


Continued

Draining, wrist unit

The procedure below details how to drain oil from the gearboxes in the wrist unit.

Action Note/Illustration

1

DANGER

Turn off all:




2

WARNING


Safety risks during work with gearbox lubricants (oil or grease) on page 36 .

3 Position the robot as shown in the figure to the right:

• upper arm: upwards for a standing robot

• axis 4: 180º, to a position where the oil plug (A), faces downwards.

Note!

The total amount of oil will not be drained.

There will remain approximately 50 ml in the wrist unit.

The capacity of the vessel must be sufficient to take the complete amount of oil.

4

5 xx0500001434

A Oil plug, draining and filling

The position for an inverted robot is the opposite!

Remove the both oil plugs .

Both oil plugs must be removed in order to drain the wrist unit properly.

Shown in the figure

Location of oil plugs on page 110

.

Refit the oil plug, vent hole.





111

3 Maintenance


Continued

Filling oil, wrist unit

The procedure below details how to fill oil in the gearboxes in the wrist unit.


1

DANGER

Turn off all:




2

WARNING


Safety risks during work with gearbox lubricants (oil or grease) on page 36 .

3

4

Remove the oil plug, draining and filling.

Shown in the figure

Location of oil plugs on page 110 !

Position the robot as shown in the figure to the right:

• upper arm: downwards for a standing robot

• axis 4: 90º, to a position where the oil plug (A), faces upwards.

Fill oil in the wrist unit through the oil plug.

Where to find type of oil and total amount is detailed in


112 xx0500001435

• A: Oil plug, draining and filling

The position for an inverted robot is the opposite.

5 Refit the oil plug.




4 Repair

4.1 Introduction

4 Repair


Structure of this chapter

This chapter describes all repair activities recommended for the IRB 140 type C and any external unit.

It is made up of separate procedures, each describing a specific repair activity.

Each procedure contains all the information required to perform the activity, for example spare parts numbers, required special tools, and materials.

WARNING

Repair activities not described in this chapter must only be carried out by ABB.

Otherwise damage to the mechanics and electronics may occur.


The details of the equipment required to perform a specific repair activity are listed in the respective procedures.

The details of equipment are also available in different lists in the chapter

Reference information on page 231

.


There are general safety information and specific safety information. The specific safety information describes the danger and safety risks while performing specific steps in a procedure. Make sure to read through the chapter

Safety on page 17

before commencing any service work.

Note

If the IRB 140 type C is connected to power, always make sure that the IRB 140 type C is connected to earth before starting any repair work.






113

4 Repair

4.2.1 Mounting instructions for bearings

4.2 General procedures

4.2.1 Mounting instructions for bearings

General

This section describes how to mount and grease different types of bearings on the robot.

Equipment

Equipment, etc.

Grease

Article number

3HAB3537-1

Note

Used to grease the bearings, if not specified otherwise.

Assembly of all bearings

Attend to the following instructions while mounting a bearing on the robot.

1

2

3

Action

To avoid contamination, let a new bearing remain in its wrapping until it is time for fitting.

Ensure that the parts included in the bearing fitting are free from burrs, grinding waste, and other contamination. Cast components must be free of foundry sand.

Bearing rings, inner rings, and roller elements must not be subjected to direct impact. The roller elements must not be exposed to any stresses during the assembly work.

Note

Assembly of tapered bearings

Follow the preceding instructions for the assembly of the bearings when mounting a tapered bearing on the robot.

In addition to those instructions, the following procedure must be carried out to enable the roller elements to adjust to the correct position against the race flange.

1

Action

Tension the bearing gradually until the recommended pre-tension is achieved.

Note

Note

The roller elements must be rotated a specified number of turns before pretensioning is carried out and also rotated during the pre-tensioning sequence.

2 Make sure the bearing is properly aligned as this will directly affect the durability of the bearing.

Greasing of bearings

Note

This instruction is not valid for solid oil bearings.





4 Repair

4.2.1 Mounting instructions for bearings

Continued

The bearings must be greased after assembly according to the following instructions:

• The bearings must not be completely filled with grease. However, if space is available beside the bearing fitting, the bearing may be totally filled with grease when mounted, as excessive grease will be pressed out from the bearing when the robot is started.

• During operation, the bearing should be filled to 70-80% of the available volume.

• Ensure that grease is handled and stored properly to avoid contamination.

Grease the different types of bearings as following description:

• Grooved ball bearings must be filled with grease from both sides.

• Tapered roller bearings and axial needle bearings must be greased in the split condition.




115

4 Repair

4.2.2 Mounting instructions for seals

4.2.2 Mounting instructions for seals

General

This section describes how to mount different types of seals.

Equipment

Equipment, etc.

Grease

Article number

3HAB3537-1

Note

Used to lubricate the seals.

Rotating seals

The procedure below describes how to fit rotating seals.

CAUTION

Please observe the following before commencing any assembly of seals:

• Protect the sealing surfaces during transport and mounting.

• Keep the seal in its original wrappings or protect it well before actual mounting.

• The fitting of seals and gears must be carried out on clean workbenches.

• Use a protective sleeve for the sealing lip during mounting, when sliding over threads, keyways, etc.

1

2

3

4

5

Action

Check the seal to ensure that:

• The seal is of the correct type (provided with cutting edge).

• There is no damage to the sealing edge (feel with a fingernail).

Inspect the sealing surface before mounting. If scratches or damage are found, the seal must be replaced since it may result in future leakage.

Note

Lubricate the seal with grease just before fitting. (Not too early - there is a risk of dirt and foreign particles adhering to the seal.)

Fill 2/3 of the space between the dust tongue and sealing lip with grease. The rubber coated external diameter must also be greased, unless otherwise specified.

Article number is specified in

Equipment on page 116 .

Mount the seal correctly with a mounting tool.

Never hammer directly on the seal as this may result in leakage.

Make sure no grease left on the robot surface.


116




4 Repair

4.2.2 Mounting instructions for seals

Continued

Flange seals and static seals

The following procedure describes how to fit flange seals and static seals.

1

2

3

4

Action

Check the flange surfaces. They must be even and free from pores.

It is easy to check flatness using a gauge on the fastened joint (without sealing compound).

If the flange surfaces are defective, the parts may not be used because leakage could occur.

Clean the surfaces properly in accordance with the recommendations of ABB.

Distribute the sealing compound evenly over the surface, preferably with a brush.

Tighten the screws evenly when fastening the flange joint.

O-rings

The following procedure describes how to fit o-rings.

1

2

3

4

5

6

Action Note

Ensure that the correct o-ring size is used.

Check the o-ring for surface defects, burrs, shape accuracy, or deformation.

Check the o-ring grooves.

The grooves must be geometrically correct and should be free of pores and contamination.

Defective o-rings may not be used.

Lubricate the o-ring with grease.

Defective o-rings, including damaged or deformed o-rings, may not be used.

Tighten the screws evenly while assembling.

Make sure that no grease is left on the robot surface.




117

4 Repair

4.2.3 Cut the paint or surface on the robot before replacing parts

4.2.3 Cut the paint or surface on the robot before replacing parts

General

Follow the procedures in this section whenever breaking the paint of the robot during replacement of parts.

When replacing parts on a robot with protection type Clean Room, it is important to make sure that after the replacement, no particles will be emitted from the joint between the structure and the new part, and that the easy cleaned surface is retained.


Equipment

Sealing compound

Tooling pin

Cleaning agent

Knife

Spare parts

Lint free cloth

Touch up paint Clean Room,

White

3HAC036639-001

Touch up paint Standard/Foundry

Plus, ABB Orange

3HAC037052-001

Note

Sikaflex 521 FC. Color white.

Width 6-9 mm, made of wood.

Ethanol

Removing

1

Action

Cut the paint with a knife in the joint between the part that will be removed and the structure, to avoid that the paint cracks.

Description

Refitting

2 Carefully grind the paint edge that is left on the structure to a smooth surface.

xx0900000121

1

2

Action

Before the parts are refitted, clean the joint so that it is free from oil and grease.

Place the tooling pin in hot water.

Description

Use ethanol on a lint free cloth.





4 Repair

4.2.3 Cut the paint or surface on the robot before replacing parts

Continued

3

Action

Seal all refitted joints with Sikaflex 521FC.

Description

4 Use the tooling pin to even out the surface of the Sikaflex seal.

xx0900000122 xx0900000125

5

6

Wait 15 minutes.

Use Touch up paint Clean Room, white to paint the joint.

Sikaflex 521FC skin dry time (15 minutes).

3HAC036639-001

Note

Always read the instruction in the product data sheet in the paint repair kit for Clean

Room.

Note





119

4 Repair

4.3.1 Replacement of cable harness

4.3 Complete robot

4.3.1 Replacement of cable harness

Location of cable harness

The cable harness runs from the base to the motors of axes 3-6.



.


Equipment, etc.

Cable harness

Standard toolkit



Circuit diagram

Spare part no.

3HAC 7370-1

Art. no.

3HAC020812-001

Note

Standard and Foundry versions

Clean room version

Includes cabling:

• Cable harness, power axis 1-3

• Cable harness, power axis 4-6

• Cable harness, signals axis 1-3

• Cable harness, signals axis 4-6

• Cable harness, customer connections



.


3HAC 6816-3 See chapter


.


120




4 Repair


Continued

Removal, cable harness

The procedure below details how to remove the cable harness.

WARNING

Please observe the following before doing any repair work on the manipulator:

• Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

• Turn off all electric power, hydraulic, and pneumatic pressure supplies to the robot!

• Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, for example secure the lower arm with fixtures if removing motor, axis 2.

CAUTION

1

The cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them!


CAUTION



.

2

3

Remove the serial measurement board.

Disconnect connectors in the manipulator base.

Detailed in section


xx0300000090

Connectors:

• A: R1.MP1-3

• B: R1.CS

• C: Air hose

• D: R1.MP4-6





121

4 Repair


Continued

4

Action

Remove the cable holder by unscrewing its attachment screws.


5

6

7

8 xx0300000091

• A: Cable holder

• B: Attachment screws

• C: Cable securing screws

Remove the cables from the cable holder by unscrewing the cable securing screws.

See figure above!

Remove the cover, arm housing .

Remove the lower arm cover .

Detailed in section

Replacement of cover, arm housing on page 150 .

Detailed in section

Replacement of lower arm cover and gasket on page 153 .

Gently knock out the VK cover .

Detailed in section

Removing the VK cover on page 131 .


122




4 Repair


Continued

9

Action

Disconnect connectors in the rear of the upper arm.


10

11 xx0300000092

Connectors:

• A: R2.CS

• B: Pressurized air connection

• C: R3.FB4

• D: R3.FB5

• E: R3.FB6

• F: R3.MP5

• G: R3.MP4

• H: R3.MP6

Parts:

• J: Shield

Remove the shield by unscrewing its attachment screws.

See figure above!

Cut any cable ties securing the cabling inside the lower arm.





123

4 Repair


Continued

12

Action

Disconnect the connectors inside the lower arm.

Note/Illustration xx0200000449

• G: Connectors R3.MP3 and R3.FB3

13

14

Pull the cables out of the upper arm.

Remove the cover, console .

15

16

17

Detailed in section

Replacement of cover, console on page 159

.

Disconnect the connectors inside the console and undo the cable holders.

Connectors:

• R3.MP1

• R3.MP2

• R3.FB1

• R3.FB2

Gently pull the cabling from the base up through the console.

Gently pull the cabling out of the lower arm.


124




4 Repair


Continued

Refitting, cable harness

The procedure below details how to refit the cable harness.

WARNING


• - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears!

• - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

• - Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.

CAUTION


1

2

3

Action

Refit in reverse order to what is detailed above.

Detailed below are some recommendations on how to route the cables.

Clean the joints that have been opened. See



Cable distribution in the cable holder in the manipulator base.

xx0300000093

Cables:

• A: Signal

• B: Signal

• C: Customer signal

• D: Power cable, axes 4-6

• E: Pressurized air supply

• F: Power cable, axes 1-3





125

4 Repair


Continued

4

Action

Cable layout in the lower arm.

Note/Illustration xx0200000449

• A: Cable ties

• B: Pressurized air hose

• C: Power cables, axes 4, 5 and 6

• D: Customer cables, signal

• E: Signal cables, axes 4, 5 and 6

• F: Signal cable, axis 3



126




4 Repair


Continued

5

Action

Cable holder in the upper arm.


6 Seal and paint the joints that have been opened. See


xx0300000094

Cables:

• A: Customer signal

• B: Signal

• C: Pressurized air supply

• D: Power cables

Note

After all repair work, wipe the Clean

Room robot free from particles with spirit on a lint free cloth.




127

4 Repair

4.3.2 Replacement of complete upper arm

4.3.2 Replacement of complete upper arm

Location of upper arm

The upper arm is located on top of the manipulator as shown in the figure below.



.

xx0200000446

H

J

F

G

C

D

A

B

E

Cover, armhousing

Attachment screws, cover armhousing, (4 pcs)

CS-connector

Pressurized air connector

VK cover

Cable guide

Attachment screws, cable guide

Attachment screws, upper arm (6 pcs)

Sealing ring


128




4 Repair


Continued


Equipment

Upper arm

Sealing ring

VK cover

Gasket upper arm cover

Standard toolkit

Special socket



Spare part no.

See


Art. no.

3HAB3732-13

Note

Includes all required sealings and gaskets.

To be replaced if damaged only.

Included in the upper arm assembly.

3HAA2166-13

3HAC7867-1

-

3HAC020812-001 Content is defined in section


.

For fitting the CS-connector.


WARNING





Removal, upper arm

The procedure below details how to remove the complete upper arm.

Action Note

1

CAUTION



.

2

3

Run the manipulator arm to a horizontal position.

Remove all brackets securing any exterior cabling to the upper arm by unscrewing their attachment screws respectively.




129


4 Repair


Continued

4

5

Action Note

Remove the rear cover armhousing by unscrewing its four attachment screws .

Shown in the figure

Location of upper arm on page 128 !

DO NOT under any circumstance unscrew the six screws on top of the lower arm! Doing so will cause the manipulator to require a complete rebuild!

6

7

8 xx0300000101

Disconnect all cables to/from motors 4-6.

• A: DO NOT touch these screws! (NOTE! Only two screws shown!)

Connectors

• R3.MP4

• R3.MP5

• R3.MP6

• R3.FB4

• R3.FB5

• R3.FB6

Disconnect any connector from the CS-connector.

Shown in the figure


Use a special socket to remove the CS-connector from the housing and pull it into the upper arm assembly.

Shown in the figure


Art. no. specified in section

Required equipment on page 129 !

9

10

11

Remove the housing and pull it into the upper arm assembly.

Remove the arm joint.

pressurized air connector

VK-cover from the from the upper arm/lower

Shown in the figure




Shown in the figure


Detailed in section

Removing the

VK cover on page 131 .

Remove the cable guide by unscrewing its two attachment screws .

Shown in the figure


12

13

Gently pull all cables and hoses out.

Remove the upper arm by unscrewing its six attachment screws .

Shown in the figure


14 Lift the upper arm and place it on a secure surface.





4 Repair


Continued

Removing the VK cover

The procedure below details how to remove the VK cover from the upper arm.

xx0200000433

A

B

C

D

Lower arm

Lower arm cover gasket

Cover l. arm, spare (without lamp unit)

Cover l. arm, spare (with lamp unit)

1

2

3

Action

Remove the lower arm cover by unscrewing its attachment screws.

Note

Tap the VK cover with a long blunt edged bar through the hole in the lower arm to press it out.

Make sure to press the circumference of the VK cover evenly to avoid damaging it.

Shown in the figure in section


If the VK cover is damaged, it must be replaced on refitting.

Specified in section

Replacement of complete upper arm on page 128 .





131

4 Repair


Continued

Refitting

The procedure below details how to refit the complete upper arm.

1

2

Action



Note

Check the sealing ring to see whether it is damaged.

Replace if it is damaged!

Shown in the figure




3

4

5

6

7

8

9

10

11

12

Lift the upper arm into position.

Secure the upper arm with its six attachment screws .

Shown in the figure


Tightening torque: 35 Nm ± 3 Nm

Gently pull all cables and hoses through the hole in the upper arm.

Reconnect all connectors to motors 4-6.

Refit the cable guide with its two attachment screws .

Connectors

• R3.MP4

• R3.MP5

• R3.MP6

• R3.FB4

• R3.FB5

• R3.FB6

Shown in the figure


Pull the pressurized air connector through the housing and secure it into fitting in the upper arm assembly.

Shown in the figure


Pull the CS-connector through the housing and secure it into the fitting in the upper arm assembly.

Use a special socket to secure it.

Shown in the figure




Reconnect any connector previously connected externally to the CS connector.

Fit a new VK-cover to the upper arm/lower arm joint.

Gently knock it into position.

Shown in the figure




Use a plastic mallet or similar.

Refit the rear cover armhousing with its four attachment screws .

Shown in the figure


13 Refit any brackets securing any exterior cabling to the upper arm with their attachment screws respectively.


132




4 Repair


Continued

14

Action

Seal and paint the joints that have been opened. See


Note

Note


15 Recalibrate the robot.

Calibration is detailed in a separate calibration manual enclosed with the calibration tools.

General calibration information is included in section

Calibration information on page 215

.

DANGER

When performing the first test run after a service activity (repair, installation or maintenance), it is vital that:

• all the service tools and other foreign objects are removed from the manipulator!

• all normal safety equipment is installed properly, e.g. FlexPendant enabling device.

• all personnel are standing at a safe distance from the manipulator, i.e. out of its reach behind safety fences, etc.

• special attention is paid to the function of the part that has been serviced.




133

4 Repair

4.3.3 Replacement of complete lower arm

4.3.3 Replacement of complete lower arm

Location of lower arm

The lower arm is located between upper arm and frame as shown in the figure below.



.

xx0200000469

A Lower arm


Equipment

Lower arm, spare

Spare part no.

3HAC034935-001

Art. no.


134

Note


Includes all required bearings, oil and VK cover.




4 Repair


Continued

Equipment

Lower arm, spare

Standard toolkit

Lifting device for lower arm

Special socket


See references to these procedures in the stepby-step instructions below.

Spare part no.

3HAC034937-001

Art. no.

Note

Clean room versions

Includes all required bearings, oil and VK cover.



Lifting capacity >16 kg

For fitting the CS-connector


Removal, lower arm

The procedure below details how to remove the complete lower arm.

WARNING

1





Action Information

CAUTION



.

2 Remove the console.

Detailed in section

Replacement of console on page 162 .





135

4 Repair


Continued

3

Action


Information

4 Remove the VK cover by pressing a screwdriver, or similar, through it and pulling.

xx0300000101

Parts:

• A: DO NOT touch these screws! (Note! Only

2 screws are shown.)

5

6 xx0300000097

Parts:

• A: Washer

• B: Lower arm attachment screws (10 pcs)

• C: VK cover

Unscrew the lower arm attachment screws .

Also remove the washer.

Shown in the figure above!

Raise the lifting device to remove the lower arm.

Refitting, lower arm

The procedure below details how to refit the complete lower arm.

1

2

Action



Fit the lifting device and lift the lower arm into position.

Note





3

Action

Fit the lower arm to gearbox, axis

2, and secure it with its attachment screws and washers.

Note

4 Repair


Continued

4

5

6 xx0300000097

Parts:

• A: Washer

• B: Lower arm attachment screws (10 pcs)

• C: VK cover



Fit a new VK cover by gently tapping it into position.

Refit the console.

Detailed in section

Replacement of console on page 162 .



Note




General Calibration information is included in section,





137

4 Repair

4.3.4 Replacement of base

4.3.4 Replacement of base

Location of base

The base is located at the bottom of the robot as shown in the figure below.

A more detailed view of the components and its position may be found in Spare part lists and exploded views .

xx0200000423

D

E

F

A

B

C

Base

Bottom plate

Attachment screws, bottom plate (26 pcs)

Attachment screws and washers, gearbox/base (10 pcs each)

Damper, axis 1

Washer


Equipment

Base, spare

Base, spare

Spare part no.

For spare part number, see:

•


.


•


.

Art. no.

Note

Standard and Foundry versions.

Includes parallel pin 3HAC

3785-2.

Clean room versions.

Includes parallel pin 3HAC

3785-2.





4 Repair


Continued

Equipment

Lifting slings

Locking liquid

Grease

Isopropanol

Standard toolkit

Spare part no.

-

-

Art. no.

3HAB3537-1

Note

Loctite 574

For sealing the base to the gearbox 1-2.

For lubricating the V-ring.

For cleaning the mating surfaces.



.


Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.

CAUTION



.

Removal, base

The procedure below details how to remove the base from the robot.

Action Note

1

DANGER

Turn off all:




2

CAUTION


Cut the paint or surface on the robot before replacing parts on page 118 .

3

4

Remove the axis 1 and 2 motors.

Remove the cable harness.

Detailed in sections:

•

Replacement of motor, axis 1 on page 177

•


Detailed in section

Replacement of cable harness on page 120

.




139


4 Repair


Continued

5

6

7

8

9

10

11

12

Action

Remove the serial measurement unit.

Remove the complete upper arm.

Remove the complete lower arm.

Detailed in section

Replacement of complete lower arm on page 134 .

Unfasten the base from the installation site by removing the attachment bolts from the foundation.

Fit the lifting slings to the robot, lift it and place it with the side of the lower arm downwards on a work bench.

Remove the bottom plate .

Shown in the figure

Location of base on page 138

.

Secure the weight of the base and remove the gearbox/base attachment screws and washer .

Shown in the figure

Location of base on page 138

.

Separate the base from the gearbox unit.

Note

Detailed in section


.

Detailed in section


Refitting, base

6

7

The procedure below details how to refit the base to the robot.

Action Note

1

DANGER

Turn off all:




2

3

4

5

8

9



Place the robot with the side of the lower arm downwards on a workbench.

Clean the mating surfaces between the base and the gearbox unit with isopropanol.

Lubricate the mating surface on the base with

Loctite 574.

Lift the base to mounting position.

Secure the base to the gearbox unit with the gearbox/base attachment screws and washer.

Shown in the figure

Location of base on page 138 .

Tightening torque: 35 Nm ± 3Nm

Refit the bottom plate and secure it with its attachment screws .

Shown in the figure

Location of base on page 138 .

Turn the robot to stand upright.





4 Repair


Continued

10

11

12

13

14

15

Action

Secure the base to the foundation.

Refit the complete lower arm.

Refit the complete upper arm.

Refit motors 1 and 2.

Refit the serial measurement unit.

Refit the cable harness.

Note

Attachment bolt and tightening torque are specified in section

Attachment screws on page 62

Detailed in section


Detailed in section


.

Detailed in sections


and


respectively.

Detailed in section


.

Detailed in section


.



Note



Pendulum Calibration is described in

Operating manual - Calibration Pendulum , enclosed with the calibration tools.


Calibration information on page 215 .

18

DANGER

Make sure all safety requirements are met when performing the first test run. These are further detailed in the section

First test run may cause injury or damage on page 26

.




141

4 Repair

4.4.1 Replacing the wrist unit, IRB 1600

4.4 Upper arm

4.4.1 Replacing the wrist unit, IRB 1600

Location of wrist unit

The wrist unit is located in the frontmost part of the upper arm.

A more detailed view of the components and its position may be found in Spare parts - Spare part lists and exploded views .

xx0600002847

A

B

C

Attachment screws, wrist unit (3 pcs)

Oil plug (only one shown)

Wrist unit


Equipment, etc.

Wrist Standard/Foundry

Spare part no.

Art. no.

Wrist unit (CR) 3HAC 026569-003

Note

Standard and Foundry versions.

O-ring sealing plate not included!

Note ! The wrist, standard/Foundry is not interchangeable with art. no. 3HAC 10475-1!

Clean room versions

O-ring sealing plate not included!





4 Repair


Continued

Equipment, etc.

O-ring sealing plate

Spare part no.

Grease

Standard toolkit

Arm

Other tools and procedures may be required. See references to these procedures in the stepby-step instructions below.

Art. no.

Note

Must be replaced.

Note ! The o-ring sealing plate is not interchangeable with art.no.

3HAC 7191-1!

-

3HAC 3537-1 For lubricating the o-ring sealing plate.



3HAC 9037-1 For adjusting the gear play, motor/pinion.


CAUTION



.

Removal, wrist unit

The procedure below details how to remove the complete wrist unit.

Action Note

1

DANGER

Turn off all:




2

CAUTION

Always cut the paint with a knife and grind the paint edge when disassembling parts.

See


3

4

Drain the oil from the wrist unit.

Remove the wrist unit by unscrewing its three attachment screws.

Detailed in section

Changing the oil in axes 5 and 6 gearboxes on page 110

.


Location of wrist unit on page 142 .





143

4 Repair


Continued

Refitting, wrist unit

The procedure below details how to refit the complete wrist unit.

1

2

Action

Clean the joints that have been opened.

See


Note

Move the robot to a position where the upper arm is vertical.

3

DANGER

Turn off all:




4

5

6

7

8

Lightly lubricate the o-ring sealingplate with grease .

Art. no. is specified in section

Required equipment on page 142 .

In order to release the brake, connect the 24 VDC power supply to motors:

Connect to connector R3.MP5 or 6:

• +: pin 7

• -: pin 8

Fit the o-ring sealingplate and the wrist unit to the upper arm with the attachment screws, but do not tighten them.

Do not tighten its attachment screws!

Use a new o-ring! Spare part no. is specified in

Required equipment on page 142

.

Fit the arm to the rear of the motor.



Manually push the wrist to adjust the wrist in relation to the gear in the gearbox.

The gear play must be checked according to subsections

Measuring the gear play, axis 5 on page 203

and


9 xx0200000445

A Wrist unit, axes 5 and 6 gears

B Drive shafts from motors, axes 5 and

6 gears

C Adjustment direction

D Gear play

Tighten the wrist unit attachment screws.

Tightening torque: 28 Nm.





4 Repair


Continued

10

Action

Check the gear play by moving axes 5 and 6 by hand.

11

12

Perform a leak-down test.

Refill the wrist unit with oil.

Note

The gear play should be as decribed in subsection


and

Measuring the gear play, axis

6 on page 205

to pass the test.

Detailed in section

Performing a leak-down test on page 241

.

Detailed in section



.



Note


14 Recalibrate the robot!

Pendulum Calibration is described in Operating manual - Calibration Pendulum , enclosed with the calibration tools.



15

DANGER

Make sure all safety requirements are met when performing the first test run.

These are further detailed in the section

First test run may cause injury or damage on page 26 .




145

4 Repair

4.4.2 Replacing the damper, axis 3

4.4.2 Replacing the damper, axis 3

Location of damper, axis 3

A more detailed view of the components and its position may be found in Spare part lists and exploded views .

xx0200000427

A Damper, axis 3


Equipment, etc.

Damper, axis 3

Standard toolkit

Art. no.

3HAC 7881-1

Note



CAUTION



.

Removing the damper axis 3

Use this procedure to remove the damper.

1

Action

Run the robot to a position where it is best to enable access to the access 3 damper.

Note

Shown in the figure

Location of damper, axis 3 on page 146 .


146




4 Repair


Continued

Action

2

DANGER

Turn off all:




Note

3 Remove the damper by gently prying it from the cast tab.

Refitting the damper axis 3

Use this procedure to refit the damper.

1

Action

Run the robot to a position where it is best to enable access to the location where the axis 3 damper is fitted.

2

DANGER

Note

Shown in the figure


Turn off all:




3 Refit the damper by gently pressing it onto the cast tab on the upper arm.

4

DANGER






147

4 Repair

4.4.3 Replacement of damper, axis 5

4.4.3 Replacement of damper, axis 5


The damper, axis 5, is located as shown in the figure below!

xx0600002806

A

B

Damper, axis 5

Recess


Equipment, etc.

Damper, axis 5

Standard toolkit

Spare part no.

3HAB 8964-1

Note



.

CAUTION



.

Removal, damper axis 5

The procedure below details how to remove the damper, axis 5.

1

Action Note

Run the robot to a position that enables the end of the damper to be pushed into the recess in the wrist unit.

Shown in the figure



148




4 Repair

4.4.3 Replacement of damper, axis 5

Continued

Action

2

3

4

DANGER

Turn off all:




Unhook the end of the damper, and push it into the recess.

Manually move the wrist (robot axis 5) away from the damper to pull it out.

Note

Refitting, damper axis 5

The procedure below details how to refit the damper, axis 5.

Action Note

1

DANGER

2

3

4

5

Turn off all:




Push the end of the damper into the gap between the wrist unit and upper arm.

Manually move the wrist (robot axis 5) in order to pull the damper into position.

Fold out the damper hooks to secure it in position.

Make sure the damper is turned the correct way!

DANGER






149

4 Repair

4.4.4 Replacement of cover, arm housing

4.4.4 Replacement of cover, arm housing

Location of cover, armhousing

The cover, armhousing is located on the rear of the upper arm as shown in the figure below.



.

xx0200000464

A

B

C

Cover, arm housing

Attachment screws, cover, armhousing

Gasket, upper arm cover


Equipment, etc.

Cover, arm housing

Cover, arm housing

Gasket, upper arm cover

Standard toolkit



Spare part. no.

3HAC 10473-1

3HAC 10473-3

Art. no.

Note

Standard and Foundry version

Includes gasket 3HAC

7867-1

Clean Room versions


7867-1

3HAC 7867-1




CAUTION


150



.




4 Repair


Continued

Removal

Refitting

The procedure below details how to remove the cover, armhousing.

WARNING

1





Action Note

CAUTION



.

2

3

Manually, run the robot to a position that enables access to the rear of the upper arm.

Remove the cover, armhousing by unscrewing its attachment screws .

Shown in the figure

Location of cover, armhousing on page 150 .

NOTE! Do not damage the gasket inside the cover!

The procedure below details how to refit cover, armhousing.

WARNING





1

Action



Note




151


4 Repair


Continued

2

3

4

5

Action

Manually, run the robot to a position that enables access to the rear of the upper arm.

Note

Shown in the figure


Make sure the gasket inside the cover, arm housing has not been damaged.

Replace if damaged.

Shown in the figure


Secure the cover, arm housing to the upper arm with its attachment screws.



Note


152




4 Repair

4.5.1 Replacement of lower arm cover and gasket

4.5 Lower arm

4.5.1 Replacement of lower arm cover and gasket

Location of lower arm cover and gasket

The lower arm cover and gasket are located as shown in the figure below.

A more detailed view of the components and its position may be found in section


.

xx0200000433

A

B

Lower arm

Gasket lower-arm cover





153

4 Repair


Continued

C

D

Cover l. arm, spare (without lamp unit)

Cover l. arm, spare (with lamp unit)


Equipment, etc.

Lower arm

Cover, lover arm, spare,

Std/F

Spare part no.


•


3HAC 10471-1

Art. no.

Note

Cover, lower arm, spare, CR 3HAC 10471-3


No lamp unit included


7869-1

Clean room versions

No lamp unit included


7869-1

Gasket lower-arm cover

Isopropanol

Standard toolkit


3HAC 7869-1

1177 1012-208

3HAC020812-001

For cleaning sealing surfaces



.


CAUTION



.

Removal, lower arm cover and gasket

The procedure below details how to remove the lower arm cover and gasket.

WARNING


154








4 Repair


Continued

Action Note

1

CAUTION



.

2

3

4

Remove the lower arm cover by unscrewing its attachment screws.

Shown in the figure

Location of lower arm cover and gasket on page 153 .

If the gasket is to be replaced, proceed below!

Use a knife to gently remove the old gasket from the cover.

Clean the sealing surface with isopropanol , making sure it is completely clean and free from scratches and burrs.



Refitting, lower arm cover and gasket

The procedure below details how to refit the lower arm cover and gasket.

WARNING


• - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears!

• - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

• - Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.

1

2

3

4

Action



Note

If the Gasket lower-arm cover is to be replaced, proceed below. If not, see further down!

Shown in the figure

Location of lower arm cover and gasket on page 153

.

Remove the protective backing from the self-adhesive gasket and fit it onto the cover sealing surface.

Make absolutely sure it is correctly located!

Refit the lower arm cover with its attachment screws.

Shown in the figure

Location of lower arm cover and gasket on page 153

.





155

4 Repair


Continued

5

Action



Note

Note


156




4 Repair


4.5.2 Replacing the damper, axis 2




.

xx0200000426

A Damper, axis 2


Equipment, etc.

Damper, axis 2

Standard toolkit


-

Art. no.

3HAC 7880-1

Note



.


CAUTION



.





157

4 Repair


Continued

Removing the damper

Use this procedure to remove the damper.

Action

1

Note

CAUTION


See


2 Run the robot to a position where it is best to enable access to the attachment screw of the damper.

3

DANGER

Turn off all:




4 Remove the damper by unscrewing the attachment screw and washer.

Refitting the damper

Use this procedure to refit the damper.

1

Action

Run the robot to a position where it is best to enable access to the attachment screw of the damper.

Note

2

DANGER

Turn off all:




3 Secure the damper with the attachment screw and washer.

1 pc: M6 x 16.

4

DANGER






4 Repair

4.6.1 Replacement of cover, console

4.6 Frame and base

4.6.1 Replacement of cover, console

Location of cover, console

The cover, console is located on top of the console as shown in the figure below.



.

xx0200000462

A

B

C

D

Cover, console

Attachment screws, cover, console (4 pcs)

Gasket

Console


Equipment, etc.

Cover, console, spare

Spare part. no.

3HAC 10472-1

Art. no.

Cover, console, spare 3HAC 10472-3

Gasket, cover console 3HAC 7868-1

Note



7868-1

Clean Room versions


7868-1




159


4 Repair


Continued

Equipment, etc.

Standard toolkit



Spare part. no.

Art. no.

3HAC020812-001

Note



.


Removal

The procedure below details how to remove the cover, console.

WARNING





Action

1

CAUTION



Note

2

3

Manually, run the robot to a position that enables access to the top of the console .

Shown in the figure

Location of cover, console on page 159 .

Remove the cover, console by unscrewing its attachment screws .

NOTE! Do not damage the gasket inside the cover!


160




Refitting

4 Repair


Continued

The procedure below details how to refit cover, console.

WARNING

1

2

3

4

5





Action



Note

Manually, run the robot to a position that enables access to the top of the console .

Shown in the figure

Location of cover, console on page 159

.

Make sure the gasket inside the cover, console has not been damaged.

Replace if damaged.

Shown in the figure

Location of cover, console on page 159

.

Secure the cover, console to the console with its attachment screws.



Note





161

4 Repair

4.6.2 Replacement of console

4.6.2 Replacement of console

Location of console

The console is located on top of gearbox, axes 1-2 as shown in the figure below.



.

xx0200000462

A

B

C

D

Cover, console

Attachment screws, cover, console (4 pcs)

Gasket

Console


Equipment, etc.

Console, spare

Console, spare

Standard toolkit


Spare part. no.

3HAC 10478-1

3HAC 10478-3

Art. no.

Note


Clean Room versions








Removal

4 Repair


Continued

CAUTION



.

The procedure below details how to remove the cover, console.

WARNING





Action

1

CAUTION


See


.


2

3

4



Remove the complete upper arm.

Detailed in section


Detailed in section


Detailed in section


.





163

4 Repair


Continued

5

Action



6 Remove the motor of axis 3.

xx0300000101

Parts:

• A: DO NOT touch these screws! (Note! Only two screws shown!)

Detailed in section


7

8

Attach the lifting device to the lower arm.

Remove the bearing hub by unscrewing its attachment screws.

9 Remove the console by unscrewing its attachment screws .

xx0300000096

Parts:

• A: Console

• B: Bearing hub

• C: Bearing hub attachment screws (6 pcs)

• D: Console attachment screws (10 pcs)

• E: Washers (10 pcs)



164




Refitting

4 Repair


Continued

The procedure below details how to refit cover, console.

WARNING





1

2

Action



Refit the console and secure it with its attachment screws and washers.


3

4

5 xx0300000096

Parts:

• A: Console

• B: Bearing hub

• C: Bearing hub attachment screws (6 pcs)

• D: Console attachment screws (10 pcs)

• E: Washers (10 pcs)


Refit the bearing hub and secure it with its attachment screws .



Refit the complete upper arm.

Refit motor 3 and timing belt.

Detailed in section


Detailed in section





165


4 Repair


Continued

6

7

8


Refit the serial measurement board.

Detailed in section



Detailed in section


.



Note






.

166




4 Repair

4.6.3 Replacing the serial measurement unit and the battery pack

4.6.3 Replacing the serial measurement unit and the battery pack

Note

The battery low alert (38213 Battery charge low ) is displayed when the battery needs to be replaced. The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned on until the battery is to be replaced.

For an SMB board with 3-pole battery contact (RMU101 3HAC044168-001 or

RMU102 3HAC043904-001), the lifetime of a new battery is typically 36 months.

For an SMB board with 2-pole battery contact, the typical lifetime of a new battery is 36 months if the robot is powered off 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime can be extended for longer production breaks with a battery shutdown service routine. See Operating manual - IRC5 with

FlexPendant for instructions.

WARNING

See instructions for batteries,

Safety risks during handling of batteries on page 35

.

Location of serial measurement unit and battery pack

The serial measurement unit and battery pack are located inside the manipulator base as shown in the figure below (different layouts are shown).

DSQC 633A xx1200000831

A

B

C

Battery pack with 2-pole battery contact

Serial measurement board (SMB), DSQC 633A

SMB attachment screws (2 pcs)





167

4 Repair


Continued

RMU101 xx1300000279

A

B

C

Battery pack RMU with 3-pole battery contact

Serial measurement board (SMB), RMU 101

Attachment screws (2 pcs)


All spare parts are listed in Spare parts in Product manual, spare parts - IRB

1600/1660 .

Note

There are different variants of SMB units and batteries. The variant with the

3-pole battery contact has longer lifetime for the battery.

It is important that the SMB unit uses the correct battery. Make sure to order the correct spare parts. Do not replace the battery contact!

Equipment, etc.

Serial measurement unit

Battery pack

Cable tie

Gasket base-cover

Standard toolkit, IRB 140

Note

See Spare parts in Product manual, spare parts - IRB 1600/1660 .

See Spare parts in Product manual, spare parts - IRB 1600/1660 .

Indoors

Replace only if required!



.




Circuit diagram See chapter


.





4 Repair


Continued

Removal

The procedure below details how to remove the serial measurement unit and battery pack.

WARNING





DANGER

Follow these instruction to prevent the unit to be damaged from ESD:

• The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to electrostatic voltages.

• Before handling, make sure you are grounded through a special ESD wrist bracelet or similar.

CAUTION

This component is classified as hazardous waste and must be disposed of accordingly!

If in doubt of the correct disposal procedure, please contact your local environmental authority!

CAUTION

1


Action Note

CAUTION



2 Set the robot system to MOTORS OFF state.

This will simplify calibration of the robot after replacement since no coarse calibration will be required.




169


4 Repair


Continued

3

Action

Remove the rear cable cover from the base of the robot by unscrewing its attachment screws.

Note

Refitting

4

5

6

7 xx1200000830

Remove the serial measurement unit by unscrewing its attachment screws .

The removal is simplified by pushing the unit to the side and then pulling it backwards.

Shown in the figure

Location of serial measurement unit and battery pack on page 167 !

If only the battery is to be replaced, disconnect the cables to the battery only!

Disconnect all connectors from the serial measurement unit.

Connectors

• R2.SMB

• R2.FB1-3

• R2.FB4-6

• R2.G

Lift the board out.

If the battery pack is to be replaced, proceed below!

Cut the cable tie and disconnect the battery connector to remove the battery pack.

Battery includes protection circuits. Replace it only with the specified spare part in the refitting instruction or with an ABB approved eqvivalent.

Shown in the figure


The procedure below details how to refit the serial measurement unit and battery pack.

WARNING






170




4 Repair


Continued

DANGER

Follow these instruction to prevent the unit to be damaged from ESD:

• The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to electrostatic voltages.

• Before handling, make sure you are grounded through a special ESD wrist bracelet or similar.

CAUTION

This component is classified as Hazardous waste and must be disposed of accordingly!

If in doubt of the correct disposal procedure, please contact your local environmental authority!

CAUTION

1

2

3

4

5

6

7


Action



Connect the new battery pack to the serial measurement unit and secure it with a cable tie.

Note

Reconnect all connectors to the unit.

Connectors

• R2.SMB

• R2.FB1-3

• R2.FB4-6

• R2.G

Place the serial measurement unit in position inside the manipulator base and secure it with its four attachment screws .

Shown in the figure


Make sure the gasket sealing the rear cable cover has not been damaged.

Replace the gasket if required.

Shown in the figure




Making sure all cables are correctly located behind the rear cable cover , refit it into position.

Make sure no cables or other equipment fitted behind the cover get pinched by the cover.

Shown in the figure


Secure the rear cable cover to the base of the robot with its attachment screws .

Shown in the figure






171

4 Repair


Continued

8

9

Action

Seal and paint the joints that have been opened.

See


Note

Note


Recalibrate the robot!




.

172




4 Repair

4.6.4 Replacement of control cable

4.6.4 Replacement of control cable

Location of control cable

The control cable is located on the rear of the manipulator base as shown in the figure below.



.

xx0200000467

A

B

C

Gasket, base-cover

Attachment screws and washers (9 pcs each), control cable

Control cable, spare


Equipment, etc.





Spare part. no.

3HAC 10476-1

Art. no.

3HAC 10477-1

3HAC 11331-1

3HAC 13090-1

Note

3 m


Cover gasket included

7 m



15 m



22 m






173


4 Repair


Continued

Equipment, etc.







Standard toolkit



Spare part. no.

3HAC 13089-1

3HAC 10476-4

3HAC 10477-2

3HAC 11331-2

3HAC 13090-2

3HAC 13089-2

Art. no.

Note

30 m



3 m

Clean Room versions


7 m

Clean Room versions


15 m

Clean Room versions


22 m

Clean Room versions


30 m

Clean Room versions




.


Removal

The procedure below details how to remove the control cable.

WARNING






174




4 Repair


Continued

2

3

1

4

Action Note

CAUTION



Make sure the robot system has been switched off, and that no power is supplied to the manipulator.

Remove the Control cable, spare by unscrewing its attachment screws.

Shown in the figure

Location of control cable on page 173 .

Make sure the gasket does not get damaged!

Disconnect connectors inside the manipulator base.

5

6

Pull the cable out of the manipulator base.

Disconnect the connectors from the control cabinet.

xx0300000090

Connectors:

• A: R1.MP1-3

• B: R1.CS

• C: Air hose

• D: R1.MP4-6

Refitting

The procedure below details how to refit control cable.

WARNING








175


4 Repair


Continued

1

2

3

Action


See


Note

Place the control cable on the floor with the manipulator base cover close to the manipulator.

Shown in the figure

Location of control cable on page 173

.

Connect the connectors inside the manipulators base.

4

5

6 xx0300000090

Connectors:

• A: R1.MP1-3

• B: R1.CS

• C: Air hose

• D: R1.MP4-6

Fit a new gasket when refitting the cover.

Included in the spare part

Fit the cover onto the manipulator base and secure it with its attachment screws .

Shown in the figure

Location of control cable on page 173

.



Note


176




4 Repair

4.7.1 Replacement of motor, axis 1

4.7 Motors

4.7.1 Replacement of motor, axis 1

Location of motor axis 1

The motor axis 1 is located on the rear of the manipulator as shown in the figure below:



.

xx0200000407

C

D

A

B

E

Motor, axis 1

Cover for connector access

Motor attachment screws (4 pcs)

Cable gland attachment screws (4 pcs)

Console


Equipment, etc.

Rot. ac motor with pinion

O-ring

Grease

Standard toolkit

Arm

Art no.


•


.

21522012-426

Note

Must be replaced when replacing motor!

Included in the spare parts motor kits

3HAB3537-1

3HAC020812-001

3HAC9037-1

Used to lubricate the o-ring



For adjusting the gear play, motor/pinion




177


4 Repair


Continued

Equipment, etc.

Power supply


Circuit diagram

Art no.

Removal

Note

24 VDC, max. 1,5 A

For releasing the brakes


See chapter


.

The procedure below details how to remove motor, axis 1.

CAUTION

If the manipulator normally works in an inverted position, it must be removed from this position and placed on the floor before the work detailed in this instruction may be carried out!

WARNING





Note

1

Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used!

Action Note

CAUTION



.

2 Remove the cover for connector access on top of the motor by unscrewing its four attachment screws.

Shown in the figure

Location of motor axis 1 on page 177

.

Detailed in section

Replacement of cover, console on page 159

.





4 Repair


Continued

3

4

5

6

7

8

9

Action

Disconnect the motor 1 connectors inside the console.

Note

Connectors:

• R3.MP1

• R3.FB1

Cut any cable ties and remove any brackets securing the cables.

Remove the cable gland by removing its attachment screws , and pull the cables out from the console.

Shown in the figure


.

In order to release the brakes, connect the 24 VDC power supply:

Connect to connector R3.MP1

• +: pin 7

• -: pin 8

Remove the motor by unscrewing its four attachment screws and plain washers.

Shown in the figure


.

Lift the motor to get the pinion away from the gear and disconnect the brake release voltage.

Remove the motor by gently lifting it straight up.

Refitting

The procedure below details how to refit motor, axis 1.

WARNING





Note

1

2

3

4


Action



Note

Make sure the mating surfaces on the motor and the gearbox are clean and free from burrs.

Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate the oring with grease .



.

In order to release the brake, connect the 24 VDC power supply:


• +: pin 7

• -: pin 8




179


4 Repair


Continued

5

6

7

8

9

10

11

12

13

14

Action

Fit the motor, making sure the motor pinion is properly mated to gearbox 1.

Note

Make sure the motor is turned the right way, i.e. connections rearwards.

Make sure the motor pinion does not get damaged!

Tightening torque: approx 2 Nm Fit the motor with four attachment screws and plain washers.

Fit the Arm to the end of the motor shaft.



.

Adjust the motor in relation to the gear in the gearbox.

Use the Arm tool to wiggle the motor shaft back and forth to feel the play.

There should be a barely noticable gear play.

Tighten the motor attachment screws.

Tightening torque: approx 11 Nm ±

1 Nm

Disconnect the brake release voltage.

Make sure the cable gland gasket has not been damaged. Replace, if it has.



.

Push the cables into the console, and refit the cable gland with its attachment screws.

Perform a leak-down test .

Detailed in section

Performing a leak-down test on page 241 .


See


Note






.

180




4 Repair


4.7.2 Replacement of motor, axis 2


The motor axis 2 is located on the front of the robot as shown in the figure.



.

xx0200000408

C

D

A

B

E

Motor, axis 2

Cover for connector access

Motor attachment screws (4 pcs)

Cable gland attachment screws (4 pcs)

Console


Equipment, etc.


O-ring

Locking liquid

Isopropanol

Standard toolkit

Rotation tool, motor

Power supply

-

-

Art. no.


•


21522012-426

Note

Must be replaced when replacing motor.

Loctite 574

For cleaning mating surfaces.



-

3HAC9037-1 For adjusting the gear play, motor/pinion

24 VDC, 1.5 A.

For releasing the brakes.





181

4 Repair


Continued

Equipment, etc.


Circuit diagram -

Art. no.

Note


See chapter

Circuit diagram on page 245 .

CAUTION



.

Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.

Depending on which routine is chosen, action might be required prior to beginning the repair work of the robot, see the table.

1

Action Note

Decide which calibration routine to use for calibrating the robot.

• Reference calibration. External cable packages (DressPack) and tools can stay fitted on the robot.

• Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot.

If the robot is to be calibrated with reference calibration:

Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values.

Find previous reference values for the axis or create new reference values. These values are to be used after the repair procedure is completed, for calibration of the robot.

If no previous reference values exist, and no new reference values can be created, then reference calibration is not possible.

Creating new values requires possibility to move the robot.

Read more about reference calibration for

Pendulum Calibration in Operating manual - Calibration Pendulum .

If the robot is to be calibrated with fine calibration:

Remove all external cable packages

(DressPack) and tools from the robot.

Removal, motor axis 2

The procedure below details how to remove the axis 2 motor.

1

Action

Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure.

Note


182




4 Repair


Continued

Action Note

2

DANGER

Turn off all:




3

CAUTION



.

4

5

6

7

Remove the cover for connector access on top of the motor by unscrewing its four attachment screws.

Shown in the figure


.

Disconnect the motor connectors inside the console.

Connectors:

• R3.MP2

• R3.FB2

Cut any cable ties and remove any brackets or clamps securing the cables.

Remove the cable gland by removing its attachment screws , and pull the cables out from the console.

Shown in the figure


.

8

9

DANGER

Secure the weight of the lower arm properly before releasing the brakes of motor, axis 2!

When releasing the holding brakes of the motor, the lower arm will be movable and may fall down!

In order to release the brakes, connect the 24 VDC power supply to the motor.


• +: pin 7

• -: pin 8

10

WARNING

Oil will be running out of the motor attachment hole when removing the motor! It may also be hot! Take any necessary measures to collect the oil.

11

12

13

14

Remove the motor by unscrewing its four attachment screws and plain washers.

Shown in the figure


.

Remove the motor by gently pulling it out, making sure the motor pinion does not get damaged while moving it away from the gear.


Remove any remaining oil from the gearbox by siphoning it off.




183


4 Repair


Continued

Refitting, motor axis 2

The procedure below details how to refit the axis 2 motor.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

Action



Note

Make sure the mating surfaces on the motor and the gearbox are clean and free from burrs.

If necessary, clean the surfaces with isopropanol.

Replace the o-ring if damaged.

1 Apply enough Loctite 574 to the motor groove.

2 Refit the o-ring . Make sure the o-ring on the circumference of the motor is seated properly.



In order to release the brakes, connect the 24

VDC power supply to the motor.

Connect to connector R3.MP2:

• +: pin 7

• -: pin 8

Remove the motor cover from top of the motor.

Shown in the figure


.

Fit the rotation tool to the end of the motor shaft.



Fit the motor, making sure the motor pinion is properly mated to gearbox 2.

Use the rotation tool to rotate the motor pinion, when mating it to the gear.

Make sure the motor is turned the right way, i.e. connections rearwards.

Make sure the motor pinion does not get damaged!

Secure the motor with four attachment screws and plain washers, but do not tighten yet.

Tightening torque: approx 2 Nm.


Use the rotation tool to wiggle the motor shaft back and forth to feel the play. Tap with a plastic mallet.


Refit the motor cover to the top of the motor.

Be careful not to damage the cables!

Tighten the motor attachment screws.

Tightening torque: approx 11 Nm ±

1 Nm


Make sure the cable gland cover gasket has not been damaged. Replace if it has.



Push the cables into the console, and refit the cable gland with its attachment screws.

Refit all cable ties and brackets.


Refill the gearbox with oil.

Detailed in section

Performing a leak-down test on page 241

.






4 Repair


Continued

18

Action


See


Note

Note



20

DANGER



.

Pendulum Calibration is described in Operating manual - Calibration

Pendulum , enclosed with the calibration tools.






185

4 Repair

4.7.3 Replacement of motor and timing belt, axis 3

4.7.3 Replacement of motor and timing belt, axis 3


The motor axis 3 is located behind the lower arm cover on the right hand side of the manipulator as shown in the figure below.

For a more detailed view of the components and its position, see


xx0200000448

F

G

D

E

A

B

C

Lower arm cover

Attachment screws, lower arm cover (13 pcs)

Belt shield

Motor 3

Attachment screws, belt shield (3 pcs)

Attachment screws, motor 3 (4 pcs)

Belt


186




4 Repair


Continued


Equipment, etc.

Spare part no.

Rotating AC motor with pinion

3HAC7866-1

3HAC021756-001

Timing belt

Standard toolkit

Art. no.

3HAC6793-1

3HAC020812-001



Circuit diagram

Note



.


See chapter


Removing the motor, axis 3

Use this procedure to remove the motor, axis 3.

WARNING





Note


Action Note

1

CAUTION



.

2

3

Remove any equipment hindering access to the lower arm cover .



.

Remove the lower arm cover by unscrewing its attachment screws .



.




187


4 Repair


Continued

4

Action

Cut the cable ties to simplify accessing the motor.

Note

5 Disconnect motor connectors.

xx0200000449

• A: Cable ties







Connectors:

• R3.MP3

• R3.FB3

• R3.H1 (if Safety lamp is fitted)

• R3.H2 (if Safety lamp is fitted)


188




4 Repair


Continued

6

Action

DO NOT under any circumstance unscrew the three screws securing the belt wheel! Doing so will cause the manipulator to require a complete rebuild!

Note

7 xx0300000102

Parts:

• DO NOT touch these screws! (3 pcs)

Remove the belt shield by unscrewing its two attachment screws .



.

8

9

10

Remove the remaining motor attachment screws .

Remove the belt.



.


axis 3 on page 186

.

Location of motor

Remove the motor .



.

Refitting the motor, axis 3

Use this procedure to refit the motor, axis 3.

WARNING





1

2

Action


See


Note

Make sure the mating surfaces on the motor and the lower arm are clean and free from burrs.




189


4 Repair


Continued

3

4

Action

Fit the motor in the lower arm.

Fit the belt .

Note

5

6

7

8

9

10



.

Tighten the two motor attachment screws slightly, but not completely.

Adjust the position of the motor in such a way that the correct belt tension is achieved.

Correct belt tension F=35 - 60 N

DO NOT adjust the belt tension using the intermediate wheel securing screws.

Fit the belt shield and secure it with the two remaining screws.

Tightening torque: 4 Nm ± 0.5 Nm

Tighten the last motor attachment screws.


Refit the cabling as shown.


190 xx0200000449

• A: Cable ties










4 Repair


Continued

11

Action



Note

Note









191

4 Repair

4.7.4 Replacement of motor, axis 4, IRB 1600

4.7.4 Replacement of motor, axis 4, IRB 1600

Location of motor

The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below.



.

xx0600003262

A

B

C

Attachment screws, motor 4 (3 pcs)

Motor, axis 4

O-ring


Equipment, etc.

Spare part no.

Rot. ac motor with pinion For spare part number, see:

•


O-ring

Art. no.

Grease

Standard toolkit

Power supply

Rotation tool, motor

Note

Does not include the o-ring!

3HAC3772-24

3HAB3537-1

-

3HAC020812-

001

3HAC9037-1

Must be replaced when replacing motor!

Used for lubricating the oring.



24 VDC, max. 1,5 A.

For releasing the brakes.

For adjusting the gear play.





4 Repair


Continued

Equipment, etc.



Circuit diagram

Spare part no.

Art. no.

Note


See chapter


.

Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.

Depending on which routine is chosen, action might be required prior to beginning the repair work of the robot, see the table.

1

Action

Decide which calibration routine to use for calibrating the robot.

• Reference calibration. External cable packages (DressPack) and tools can stay fitted on the robot.

• Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot.

Note

If the robot is to be calibrated with reference calibration:

Find previous reference values for the axis or create new reference values. These values are to be used after the repair procedure is completed, for calibration of the robot.

If no previous reference values exist, and no new reference values can be created, then reference calibration is not possible.

Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values.

Creating new values requires possibility to move the robot.

Read more about reference calibration for

Pendulum Calibration in Operating manual - Calibration Pendulum .

If the robot is to be calibrated with fine calibration:

Remove all external cable packages

(DressPack) and tools from the robot.

CAUTION



.

Removal, motor axis 4

The procedure below details how to remove the motor, axis 4.

1

Action

Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure.

Note





193

4 Repair


Continued

Action Note

2

DANGER

Turn off all:




3

CAUTION



.

4

5

6

7

8

9

10

Manually move the robot to a position where the upper arm points straight down.

Remove the motors for axes 5 and 6.

This will enable the motor 4 to be removed without draining the oil in the gearbox.

Detailed in section

Replacement of motor and timing belt, axes 5 or

6 on page 197

.

In order to release the brakes, connect the 24 VDC power supply to the motor.


• +: pin 7

• -: pin 8

Remove the motor, axis 4 by unscrewing the motor attachment screws .

Shown in the figure

Location of motor on page 192

.

Lift the motor to get the pinion away from the gear and disconnect the brake release voltage.

Remove the motor by gently lifting it out.

Make sure the motor pinion is not damaged!

Remove the o-ring from the arm housing.

Refitting, motor axis 4

The procedure below details how to refit the motor, axis 4.

1

2

Action



Note

Clean the mating surfaces on the motor and the gearbox.

Shown in the figure

Location of motor on page 192 .


194




4 Repair


Continued

3

Action

Lightly lubricate a new o-ring (A) and put it in the bottom of the machined hole of the arm housing.

Note



.

A xx1200000823

4

5

6

7

8

9

10

11

In order to release the brakes, connect the 24

VDC power supply to the motor.


• +: pin 7

• -: pin 8

Fit the motor with the attachment screws, compressing the o-ring in axial direction.

Until the motor shaft is adjusted to the gear, as described in following steps, only tighten the screws lightly.

Shown in the figure

on page 192 .

Location of motor

Tightening torque: approx. 2 Nm.

Fit the rotational tool to the end of the motor shaft.



.


Use the arm tool to wiggle the motor shaft back and forth to feel the play.


Tighten the motor attachment screws .

Shown in the figure

Location of motor on page 192 .

Tightening torque: 6 Nm ± 0.6 Nm.

Refit motors 5 and 6.


Detailed in section


.

Detailed in section

Performing a leakdown test on page 241 .



Note





195


4 Repair


Continued

12

Action

Recalibrate the robot!

13

DANGER



.

Note

Pendulum Calibration is described in

Operating manual - Calibration Pendulum , enclosed with the calibration tools.



196




4 Repair

4.7.5 Replacement of motor and timing belt, axes 5 or 6

4.7.5 Replacement of motor and timing belt, axes 5 or 6

Location of motor and timing belt, axes 5 or 6

The motor and timing belt axes 5 or 6 are located in the rear of the upper arm as shown in the figure below.



.

xx0600003261

E

F

G

H

J

A

B

C

D

Lower arm cover

Attachment screws, lower arm cover

Cover, armhousing

Attachment screws, cover armhousing (4 pcs)

VK cover

Pressurized air hose (on front of upper arm)

CS connector

Cable guide

Attachment screws, cable guide





197

4 Repair


Continued

Y

Z

U

V

W

X

N

R

S

K

L

M

Belt shield

Attachment screws, belt shield

Motor attachment screws, 4 pcs per motor

Attachment screws, motor console

Timing belt, axis 6

Pulley, axis 6

Timing belt, axis 5

Pulley, axis 5

Motor console, ax. 5-6

Motor, axis 4

Motor, axis 5

Motor, axis 6


Equipment, etc.


Timing belt

VK cover

Standard toolkit

Special socket 30 mm


Circuit diagram

Sonic Tension Meter

Spare part no.

3HAC021757-001

Rot. ac motor with pinion 3HAC021758-001

3HAC6779-1

Art. no.

Note

Axis 4

Standard, Clean room and Foundry versions

Axes 5 and 6

Standard, Clean room and Foundry versions

Axes 5 and 6

3HAA2166-13



.

For fitting the CS-connector


3HAC6816-3 See chapter


Model 505C


198




4 Repair


Continued

Removal

The procedure below details how to remove motor, axis 5 or 6.

WARNING





3

4

5

6

7

Note

1


Action Note

CAUTION


See


2 Run the robot to a position where the upper arm is close to horizontal

Remove the lower arm cover by unscrewing its attachment screws .


Location of motor and timing belt, axes 5 or 6 on page 197

!

Remove the rear cover armhousing by unscrewing its four attachment screws .



!

Disconnect all cables to/from motors 4-6.

Disconnect any connector from the CSconnector.

Connectors:

• R3.MP4

• R3.MP5

• R3.MP6

• R3.FB4

• R3.FB5

• R3.FB6



!

Use a special socket to remove the CSconnector from the housing and pull it into the upper arm assembly.



!






199


4 Repair


Continued

8

9

10

11

12

13

14

15

16

Action Note

Remove the pressurized air connector from the housing and pull it into the upper arm assembly.



!



!

Remove the VK-cover arm/lower arm joint.

from the upper Shown in the figure in section


!

Detailed in section

Removing the VK cover on page 131

.

Remove the cable guide by unscrewing its two attachment screws .



!

Gently pull the cables out of the upper arm.

Remove the belt shield by unscrewing its attachment screws .



!

Loosen the motor attachment screws .



!

Remove the axis 6.

Remove the axis 5.

pulley pulley and and belt belt from motor, from motor,



!



!

Remove the motor console, ax. 5-6 by unscrewing its attachment screws .



!

Refitting

The procedure below details how to refit motor, axis 5.

WARNING






200

Note





4 Repair


Continued

7

8

1

2

3

4

5

6

9

10

11

12

13

14

15

Action



Note

Make sure the mating surfaces on the motor and the console are clean and free from burrs.

Fit the motors in the motor console without tightening the attachment screws.



!

Fit the motor console in the upper arm housing. Secure with its attachment screws .



!


Fit timingbelt , axis 5.



!

Tighten the motor attachment screws to enable the motor to be shifted slightly.

This will facilitate adjustment of the belt tension.

Adjust the belt tension axis 5.


Secure the motor with its attachment screws including the ones in the motor console.


Fit timing belt , axis 6.



!

Repeat the belt adjustment procedure detailed above for the remaining motor axis 6.


Secure the motor with its attachment screws.


Fit the belt shield with its attachment screws.



!


Pull the pressurized air connector through the housing and secure it into fitting in the upper arm assembly.


of motor and timing belt, axes 5 or 6 on page 197

!

Location



Pull the CS-connector through the housing and secure it into the fitting in the upper arm assembly.

Use a special socket to secure it.



!



Reconnect any connector to the CS-connector.



!





201

4 Repair


Continued

16

17

18

19

20

21

22

Action

Reconnect all cables to/from motors 4-6.

Note

Connectors

• R3.MP4

• R3.MP5

• R3.MP6

• R3.FB4

• R3.FB5

• R3.FB6

Refit the cable guide with its two attachment screws .



!

Fit a new VK-cover to the upper arm/lower arm joint.

Gently knock it into position.



!



Use a plastic mallet or similar.

Refit the rear cover armhousing with its four attachment screws .



!

Refit any brackets securing any exterior cabling to the upper arm with their attachment screws respectively.



Note


Recalibrate the robot.




202




4 Repair

4.7.6.1 Measuring the gear play, axis 5

4.7.6 Adjustments and measurements

4.7.6.1 Measuring the gear play, axis 5

General

After reassembly due to repair work or any other reason, the gear play must be checked to ensure the repetition accuracy of the robot positioning. The procedure for axis 5 is detailed below.

Certain measurement tools must be fashioned to enable measuring. The dimensions of these are specified.


Equipment, etc.

Standard toolkit

Arm

Measurement dial with magnetic base

Power supply


Art no.

3HAC020812-001

3HAC 9037-1

Note




Measuring accuracy 0.01mm

24 VDC, max. 1.5 A



WARNING





Measurement

The procedure below details how to measure the gear play for axis 5.

1

Action

Manually, turn axis 4 90°.

Note





203

4 Repair


Continued

2

Action

Fit the dial fitting arm and dial to the manipulator turning disk as shown in the figure.

Apply the 40 N load as shown.

Note

3

4

Remove the load and read

Value 1 .

Apply 40 N load as shown.

xx0200000457

5

6

7 xx0200000458


Value 2 .

Calculate the gear play value.

Gear play value = value 1 - value 2

Determine whether or not the value is OK.

OK < 0.18 mm (4.1 arc minutes)

204




4 Repair


4.7.6.2 Measuring the gear play, axis 6

General

After reassembly due to repair work or any other reason, the gear play must be checked to ensure the repetition accuracy of the robot positioning. The procedure for axis 6 is detailed below.

Certain measurement tools must be fashioned to enable measuring. The dimensions of these are specified.


Equipment, etc.

Standard toolkit

Arm

Measurement dial with magnetic base

Power supply


Art no.

3HAC020812-001

3HAC 9037-1

Note




Measuring accuracy 0.01 mm

24 VDC, max. 1.5 A



WARNING





Measurement

The procedure below details how to measure the gear play for axis 6.

1

Action

Manually, turn axis 4 90°.

Note





205

4 Repair


Continued

2

Action

Fit the dial fitting arm and dial to the manipulator turning disk as shown in the figure.

Apply the 40 N load as shown.

Note

3

4


Value 1 .

Apply 40 N load as shown.

xx0200000460

5

6

7 xx0200000461


Value 2 .

Calculate the gear play value.

Gear play value = value 1 - value 2

Determine whether or not the value is OK.

OK < 0.30 mm (10.3 arc minutes)

206




4 Repair

4.8.1 Replacement of gearbox, axes 1-2 and damper, axis 1

4.8 Gearboxes

4.8.1 Replacement of gearbox, axes 1-2 and damper, axis 1

Location of gearbox unit, axes 1-2

The gearboxes of axes 1 and 2 are located as shown in the figure below. Note that both gearboxes, 1 and 2, are a single unit!

The damper, axis 1, is shown in the figure in the procedure!



.

xx0200000422

A Gearbox unit, axes 1-2


Equipment

Gearbox, axis 1 and 2

Damper, axis 1

Isopropanol

Flange sealing

Locking liquid

Sealing ring

Lifting slings

Standard toolkit

-

-

Art. no.

Note


•


Includes:

• gearbox

• all required lubricant

• all o-rings and sealing rings.

-

3HAC7527-1

12340011-116

3HAC6965-1

For cleaning the mating surfaces before fitting.

2 ml

Loctite 574

Replace only when damaged!






207


4 Repair


Continued

Equipment

Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.

Art. no.

Illustration, base

Note


xx0200000423

E

F

C

D

A

B

Base

Bottom plate

Attachment screws, bottom plate (26 pcs)

Attachment screws and washers, gearbox/base (10 pcs each)

Damper, axis 1

Washer

CAUTION



.


208




4 Repair


Continued

Removal, gearbox unit axes 1-2

The procedure below details how to remove the complete gearbox unit, axes 1-2.

Action Note

1

DANGER

Turn off all:




2

CAUTION



.

3

4

5

6

7

8

9

10

11

Remove the oil plug and drain all oil from gearbox axis 1 using a drain pump.

Remove the oil plug and drain all oil from gearbox axis 2 using a drain pump.

Remove the motor, axis 2.

Detailed in section


.

Remove the motor, axis 1.



Remove the upper arm.

Detailed in section


.

Detailed in section


.

Detailed in section


Remove the lower arm.

Detailed in section


Detailed in section


Unfasten the base from the installation site by removing the attachment bolts from the foundation.

12

CAUTION

The gearbox unit weighs 30 kg.


13 Fit the lifting slings to the base/gearbox unit and place it with the lower arm side downwards, on top of a suitable workbench.




209


4 Repair


Continued

14

15

16

17

Action Note

Remove the bottom plate by unscrewing its 26 attachment screws.

Shown in the figure

Illustration, base on page 208 .

Secure the weight of the base with lifting slings.

Remove the gearbox/base attachment screws and washer .

Shown in the figure


Separate the base from the gearbox unit.

Removal of damper, axis 1

The procedure below details how to remove the damper, axis 1.

1

Action

Open the base of the robot.

Note

Detailed in section

Removal, gearbox unit axes 1-

2 on page 209

.

2 Remove the damper, axis 1.

Refitting of damper, axis 1

The procedure below details how to refit the damper, axis 1.

1

2

Action

Fit the damper, axis 1 .

Proceed with assembling the robot.

Note

Shown in the figure

Refitting, gearbox unit axes 1-2 on page 210

.

Detailed in section

Refitting, gearbox unit axes 1-2 on page 210

.

Refitting, gearbox unit axes 1-2

The procedure below details how to refit the complete gearbox unit, axes 1-2.

Action Note

1

DANGER

Turn off all:




2

3

CAUTION

The gearbox unit weighs 30 kg.



See






4 Repair


Continued

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

Action

Place the gearbox unit with the lower arm side downwards on a suitable workbench.

Clean the mating surfaces of the base and of the gearbox unit with isopropanol.

Fit a small amount of Loctite 574 on the mating surface in the gearbox unit.

Note

Shown in the figure


Fit the base to the gearbox unit and secure it with the attachment screws and the washer.

Shown in the figure


20 pcs, tightening torque: 35 Nm ± 3 Nm.

Refit the bottom plate and secure it with its attachment screws .

Shown in the figure

Location of gearbox unit, axes 1-2 on page 207

.

Fit the lifting slings to the base/gearbox unit, turn it right side up and move it to the installation site.

Secure the base to the foundation Attachment bolts and the tightening torque are specified in section

Attachment screws on page 62

Refit the lower arm.

Detailed in section


Refit the upper arm.

Refit the serial measurement board.


Refit the motors, axes 1 and 2.


Fill the two gearboxes with oil.

Detailed in section


.

Detailed in section


.

Detailed in section


Detailed in sections:

•


•

Refitting, motor axis 2 on page 184 .

Detailed in section

Performing a leakdown test on page 241

.




Note



Pendulum Calibration is described in Operating manual - Calibration Pendulum , enclosed with the calibration tools.






211


4 Repair


Continued

Action

20

DANGER



Note

212




4 Repair

4.8.2 Service work on gearbox, axis 4

4.8.2 Service work on gearbox, axis 4

General

The gearbox, axis 4, is intended to run without requiring any repairs or maintenance work. This implies that it must under no circumstances be opened or serviced.

If it requires replacement, the complete upper arm is to be replaced. This procedure is detailed in section


.




213


5 Calibration information

5.1 When to calibrate


5.1 When to calibrate

When to calibrate

The system must be calibrated if any of the following situations occur.

The resolver values are changed

If resolver values are changed, the robot must be recalibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration, according to information in this manual.

If the robot has absolute accuracy calibration, it is also recommended, but not always necessary to calibrate for new absolute accuracy.

The resolver values will change when parts affecting the calibration position are replaced on the robot, for example motors or parts of the transmission.

The revolution counter memory is lost

If the revolution counter memory is lost, the counters must be updated. See

Updating revolution counters on page 220

. 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 is rebuilt, for example, after a crash or when the reach ability of a robot is changed, 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.




215


5.2 Calibration methods

5.2 Calibration methods

Overview

This section specifies the different types of calibration and the calibration methods that are supplied by ABB.

Types of calibration

Type of calibration Description Calibration method

Standard calibration The calibrated robot is positioned at calibration position.

Standard calibration data is found on the SMB

(serial measurement board) or EIB in the robot.

For robots with RobotWare 5.04 or older, the calibration data is delivered in a file, calib.cfg, supplied with the robot at delivery. The file identifies the correct resolver/motor position corresponding to the robot home position.

Calibration Pendulum

Levelmeter calibration

(alternative method)

Absolute accuracy calibration (optional)

Based on standard calibration, and besides positioning the robot at synchronization 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 calibration data is found on the SMB (serial measurement board) in the robot.

For robots with RobotWare 5.05 or older, the absolute accuracy calibration data is delivered in a file, absacc.cfg, supplied with the robot at delivery. The file replaces the calib.cfg file and identifies motor positions as well as absolute accuracy compensation parameters.

A robot calibrated with absolute accuracy 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!

CalibWare xx0400001197

Brief description of calibration methods

Calibration Pendulum method

Calibration Pendulum is a standard calibration method for calibration of all ABB robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S).






5.2 Calibration methods

Continued

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 - 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 (Levelmeter 2000) for levelmeter calibration is ordered as separate parts for each robot, and includes the Operating manual - Levelmeter

Calibration , which describes the method and the different routines further.

CalibWare - Absolute Accuracy calibration

To achieve a good positioning in the Cartesian coordinate system, Absolute

Accuracy calibration is used as a TCP calibration. The CalibWare tool guides through the calibration process and calculates new compensation parameters.

This is further detailed in the Application manual - CalibWare Field 5.0

.

If a service operation is done to a robot with the option 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 the section

Special tools on page 240

.

The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including the Operating manual - Calibration Pendulum , which describes the method and the different routines further.




217


5.3 Synchronization marks and synchronization position for axes

5.3 Synchronization marks and synchronization position for axes

Introduction

This section shows the position of the synchronization marks and the synchronization position for each axis.

Synchronization marks, IRB 140

The illustration below shows the calibration scale positions on the robot.

218 xx0200000157





5.4 Calibration movement directions for all axes

5.4 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 and so on. Positive directions are shown in the graphic below.

Calibration service routines will handle the calibration movements automatically and these might be different from the positive directions shown below.

Manual movement directions, 6 axes

Note!

The graphic shows an IRB 7600. 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




219


5.5 Updating revolution counters

5.5 Updating revolution counters

Introduction

This section describes how to do a rough calibration of each manipulator axis by updating the revolution counter for each axis, using the FlexPendant.

Coupled axes

When updating the revolution counters for a coupled axis, also the axis it is coupled to needs to be at its synchronization position for the update to be correct; i.e. axis

4 needs to be in synchronization position when updating axis 5 and 6.

With reversed coupled joints, the relationship is the opposite, i.e. axis 4 needs to be in synchronization position to update axis 3.

Coupled axes

Axis 4, 5, 6

Axis 5, 6

Axis 4, 3 x x x x x x x x x x x x x

Step 1 - Manually running the manipulator to the synchronization position

Use this procedure to manually run the manipulator to the synchronization position.

1

2

3

Action Note

Select axis-by-axis motion mode.

Jog the manipulator to align the synchronization marks.

IRB 140, 1400, 2400, 4400, 6600ID/6650ID,

6640ID: Axes 5 and 6 must be positioned together!

See

Synchronization marks and synchronization position for axes on page 218 .

When all axes are positioned, update the revolution counter.

Step 2 - Updating the revolution counter with the FlexPendant on page 221 .

Correct calibration position of axis 4 and 6

When jogging the manipulator to synchronization position, it is extremely important to make sure that axes 4 and 6 of the following mentioned manipulators are positioned correctly. The axes can be calibrated at the wrong turn, resulting in an incorrect manipulator calibration.

Make sure the axes are positioned according to the correct calibration values, not only according to the synchronization marks. The correct values are found on a label, located either on the lower arm, underneath the flange plate on the base or on the frame.







Continued

At delivery the manipulator is in the correct position, do NOT rotate axis 4 or 6 at power up before the revolution counters are updated.

If one of the following mentioned axes are rotated one or more turns from its calibration position before updating the revolution counter, the correct calibration position will be lost due to non-integer gear ratio. This affects the following manipulators:

Manipulator variant

IRB 140

Axis 4

Yes

Axis 6

Yes

If the synchronization marks seem to be wrong (even if the motor calibration data is correct), try to rotate the axis one turn, update the revolution counter and check the synchronization marks again (try both directions, if needed).

Step 2 - Updating the revolution counter with the FlexPendant

Use this procedure to update the revolution counter with the FlexPendant (IRC5).

1

Action

On the ABB menu, tap Calibration .

xx1500000942





221



Continued

2

Action

All mechanical units connected to the system are shown with their calibration status.

Tap the mechanical unit in question.

xx1500000943

3 A screen is displayed, tap Rev. Counters .

en0400000771


222






Continued

4

5

6

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 selected revolution counters and removes the tick from the list of axes.

7

CAUTION

If a revolution counter is incorrectly updated, it will cause incorrect manipulator positioning, which in turn may cause damage or injury!

Check the synchronization position very carefully after each update. See

Checking the synchronization position on page 224

.




223


5.6 Checking the synchronization position

5.6 Checking the synchronization position

Introduction

Check the synchronization position of the robot before beginning any programming of the robot system. This may be done:

• Using a MoveAbsJ instruction with argument zero on all axes.

• Using the Jogging window on the FlexPendant.

Using a MoveAbsJ instruction

Use this procedure to create a program that runs all the robot axes to their synchronization position.

1

2

3

4

Action

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],

[9E9,9E9,9E9,9E9,9E9,9E9]]

\NoEOffs, v1000, fine, tool0

Note

5

6

Run the program in manual mode.

Check that the synchronization marks for the axes align correctly. If they do not, update the revolution counters.

See

Synchronization marks and synchronization position for axes on page 218

and

Updating revolution counters on page 220 .

Using the jogging window

Use this procedure to jog the robot to the synchronization position of all axes.

1

2

3

4

5

Action

On the ABB menu, tap Jogging .

Note

Tap Motion mode to select group of axes to jog.

Tap to select the axis to jog, axis 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 synchronization marks for the axes align correctly. If they do not, update the revolution counters.

See

Synchronization marks and synchronization position for axes on page 218

and

Updating revolution counters on page 220 .

224




6 Decommissioning

6.1 Environmental information


6.1 Environmental information

Symbol

The following symbol indicates that the product must not be disposed of as common garbage. Handle each product according to local regulations for the respective content (see table below).

xx1800000058

Hazardous material

The table specifies some of the materials in the product and their respective use throughout the product.

Dispose components properly according to local regulations to prevent health or environmental hazards.

Material

Batteries, NiCad or Lithium

Copper

Cast iron/nodular iron

Steel

Neodymium

Plastic/rubber

Oil, grease

Aluminium

Nickel

Example application

Serial measurement board

Cables, motors

Base, lower arm, upper arm

Gears, screws, base frame, and so on.

Brakes, motors

Cables, connectors, drive belts, and so on.

Gearboxes

Covers, synchronization brackets

Turning disc (foundry)

Oil and grease

Where possible, arrange for oil and grease to be recycled. Dispose of via an authorized person/contractor in accordance with local regulations. Do not dispose of oil and grease near lakes, ponds, ditches, down drains, or onto soil. Incineration must be carried out under controlled conditions in accordance with local regulations.




225



6.1 Environmental information

Continued

Also note that:

• Spills can form a film on water surfaces causing damage to organisms.

Oxygen transfer could also be impaired.

• Spillage can penetrate the soil causing ground water contamination.

226





6.2 Scrapping of robot

6.2 Scrapping of robot

Important when scrapping the robot

DANGER

When a robot is disassembled while being scrapped, it is very important to remember the following before disassembling starts, in order to prevent injuries:

• Always remove all batteries. If a battery is exposed to heat, for example from a blow torch, it will explode.

• Always remove all oil/grease in gearboxes. If exposed to heat, for example from a blow torch, the oil/grease will catch fire.

• When motors are removed from the robot, the robot will collapse if it is not properly supported before the motor is removed.




227


7 Robot description

7.1 Type C of IRB 140

7 Robot description

7.1 Type C of IRB 140

Type C new upper arm and wrist

Type C of IRB 140 has a new upper arm, complete and a new wrist unit. As a result of this, the following parts differ from earlier versions:

• Upper arm, complete

• Wrist unit

• O-ring sealing plate

How to know which type the robot is?

The robots using RobotWare version 5.07.01 or newer have the new upper arm.

Use this procedure to check which RobotWare version is installed:

1 On the FlexPendant ABB menu, tap System Info .

2 Tap System properties . The RobotWare version is displayed on the right side.

Contact ABB if you are unsure of the type.

Which parts are interchangeable and which are not?

The following parts are not interchangeable:

• The wrist unit with spare part no. 3HAC026569-001 is not interchangeable with spare part no. 3HAC10475-1.

• The o-ring sealing plate with spare part no. 3HAC025420-001 is not interchangeable with spare part no. 3HAC 7191-1.




229


8 Reference information

8.1 Introduction



General

This chapter includes general information, complementing the more specific information in the different procedures in the manual.




231


8.2 Applicable standards

8.2 Applicable standards

Note

The listed standards are valid at the time of the release of this document. Phased out or replaced standards are removed from the list when needed.

Standards, EN ISO

The product is designed in accordance with the requirements of:

Standard

EN ISO 12100:2010

EN ISO 13849-1:2015

EN ISO 13850:2015

EN ISO 10218-1:2011

ISO 9787:2013

ISO 9283:1998

Description

Safety of machinery - General principles for design - Risk assessment and risk reduction

Safety of machinery, safety related parts of control systems -

Part 1: General principles for design

Safety of machinery - Emergency stop - Principles for design

Robots for industrial environments - Safety requirements -Part

1 Robot

Robots and robotic devices -- Coordinate systems and motion nomenclatures

Manipulating industrial robots, performance criteria, and related test methods

Classification of air cleanliness

Ergonomics of the thermal environment - Part 1

EMC, Generic emission

EN ISO 14644-1:2015 i

EN ISO 13732-1:2008

EN 61000-6-4:2007 +

A1:2011

IEC 61000-6-4:2006 +

A1:2010

(option 129-1)

EN 61000-6-2:2005

IEC 61000-6-2:2005

EN IEC 60974-1:2012 ii

EN IEC 60974-10:2014

ii

EMC, Generic immunity

Arc welding equipment - Part 1: Welding power sources

Arc welding equipment - Part 10: EMC requirements

EN IEC 60204-1:2006 Safety of machinery - Electrical equipment of machines - Part

1 General requirements i ii

IEC 60529:1989 + A2:2013 Degrees of protection provided by enclosures (IP code)

Only robots with protection Clean Room.

Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.

European standards

Standard

EN 614-1:2006 + A1:2009

EN 574:1996 + A1:2008

Description

Safety of machinery - Ergonomic design principles - Part 1:

Terminology and general principles

Safety of machinery - Two-hand control devices - Functional aspects - Principles for design






8.2 Applicable standards

Continued

Other standards

Standard

ANSI/RIA R15.06

ANSI/UL 1740

CAN/CSA Z 434-14

Description

Safety requirements for industrial robots and robot systems

Safety standard for robots and robotic equipment

Industrial robots and robot Systems - General safety requirements




233


8.3 Unit conversion

8.3 Unit conversion

Converter table

Use the following table to convert units used in this manual.

Quantity

Length

Weight

Weight

Pressure

Force

Moment

Volume

Units

1 m

1 kg

1 g

1 bar

1 N

1 Nm

1 L

3.28 ft.

2.21 lb.

0.035 ounces

100 kPa

0.225 lbf

0.738 lbf-ft

0.264 US gal

39.37 in

14.5 psi

234





8.4 Screw joints

8.4 Screw joints

General

This section describes how to tighten the various types of screw joints on the IRB

140 type C.

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 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.

Lubricant

Molycote 1000 (molybdenum disulphide grease)

Article number

3HAC042472-001

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 following tables. Any special torques are specified in the repair, maintenance or installation procedure descriptions.

Any special torque specified overrides the standard torque!

• Use the correct tightening torque for each type of screw joint.

• Only use correctly calibrated torque keys.




235



8.4 Screw joints

Continued

• Always tighten the joint by hand, and never use pneumatic tools.

• Use the correct tightening technique , that is do not jerk. Tighten the screw in a slow, flowing motion.

• Maximum allowed total deviation from the specified value is 10% !

Oil-lubricated screws with slotted or cross-recess head screws

The following table specifies the recommended standard tightening torque for oil-lubricated screws with slotted or cross-recess head screws.

Note

A special torque specified in the repair, maintenance or installation procedure overrides the standard torque.

Oil-lubricated screws with allen head screws

The following table specifies the recommended standard tightening torque for oil-lubricated screws with allen head screws.

Note


Dimension

M5

M6

M8

M10

M12

M16

M20

M24

10

24

47

82

Tightening torque (Nm)

Class 8.8, oil-lubricated

Tightening torque (Nm) Tightening torque (Nm)



6 -

-

34

67

115

-

40

80

140

200

400

680

290

560

960

340

670

1150

Lubricated screws (Molycote, Gleitmo or equivalent) with allen head screws

The following table specifies the recommended standard tightening torque for screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head screws.

Note


Dimension Tightening torque (Nm)

Class 10.9, lubricated i

28 M8


236


Class 12.9, lubricated

i

35





8.4 Screw joints

Continued

Dimension Tightening torque (Nm)

Class 10.9, lubricated i


Class 12.9, lubricated

i

M10

M12

M16

55

96

235

70

120

280

M20 460 550 i

M24 790 950

Lubricated with Molycote 1000, Gleitmo 603 or equivalent

Water and air connectors

The following table specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass .

Note


1/8

1/4

3/8

1/2

3/4

Dimension

15

20

40

70

Tightening torque Nm -

Nominal


Min.


Max.

12 8 15

10

15

30

55

20

25

50

90




237


8.5 Weight specifications

8.5 Weight specifications

Definition

In installation, repair, and maintenance procedures, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are highlighted in this way.

To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.

Example

Following is an example of a weight specification in a procedure:

Action Note

CAUTION

The robot weighs 100 kg.

All lifting accessories used must be sized accordingly.

238





8.6 Standard tools

8.6 Standard tools

General

Contents, standard toolkit

1

1

1

1

1

1

1

1

1

1

Qty

1

1

All service (repairs, maintenance, and installation) procedures contains lists of tools required to perform the specified activity.

All special tools required are listed directly in the procedures while all the tools that are considered standard are gathered in the standard toolkit and defined in the following table.

This way, the tools required are the sum of the standard toolkit and any tools listed in the instruction.

Tool

Ring-open-end spanner 8-19 mm

Socket head cap 2.5-17 mm

Torx socket no: 20-60

Torque wrench 10-100 Nm

Small screwdriver

Plastic mallet

Ratchet head for torque wrench 1/2"

Socket head cap no: 5, socket 1/2" bit L 20 mm



Small cutting plier

T-handle with ball head




239


8.7 Special tools

8.7 Special tools

General

All service instructions contain lists of tools required to perform the specified activity. The required tools are a sum of standard tools, defined in the section


, and of special tools, listed directly in the instructions and also gathered in this section.

Calibration equipment, Levelmeter (alternative method)

The following table specifies the calibration equipment required when calibrating the robot with the alternative method, Levelmeter Calibration.

Note Description

Angle bracket

Calibration bracket

Calibration tool ax1

Levelmeter 2000 kit

Measuring pin

Sensor fixture

Sensor plate

Sync. adapter

Art. no.

68080011-LP

3HAC13908-9

3HAC13908-4

6369901-347

3HAC13908-5

68080011-GM

3HAC0392-1

3HAC13908-1

Includes one sensor.

Calibration equipment, Calibration Pendulum

The following table specifies the calibration equipment needed when calibrating the robot with the Calibration Pendulum method.

Description

Calibration Pendulum toolkit

Art. no.

3HAC15716-1

Note

Complete kit that also includes operating manual.

240





8.8 Performing a leak-down test

8.8 Performing a leak-down test

When to perform a leak-down test

After refitting any motor and gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test.


Equipment, etc.

Leak-down tester

Leak detection spray -

-

Article number Note

Performing a leak-down test

1

2

3

Action

Finish the refitting procedure of the motor or gear in question.

Note

Remove the upper oil plug on the gear and replace it with the leak-down tester.

Regulators, which are included in the leak-down test, may be required.

Use caution, apply compressed air and raise the pressure with the knob until the correct value is shown on the manometer.

Correct value:

0.2-0.25 bar (20-25 kPa)

CAUTION

The pressure must under no circumstance be higher than 0.25 bar (20-25 kPa). Also during the time when the pressure is raised.

4

5

6

7

8

Disconnect the compressed air supply.

Wait for approximately 8-10 minutes and make sure that no pressure loss occurs.

If the compressed air is significantly colder or warmer than the gearbox to be tested, a slight pressure increase or decrease may occur. This is quite normal.

If any pressure drop occurred, then localize the leak as described in step

7 .

If no pressure drop occurred, then remove the leakdown tester and refit the oil plug. The test is complete.

Spray any suspected leak areas with the leak detection spray. Bubbles indicate a leak.

When the leak has been localized, take the necessary measures to correct the leak.





8.9 Lifting accessories and lifting instructions

8.9 Lifting accessories and lifting instructions

General

Many repair and maintenance activities require different pieces of lifting accessories, which are specified in each procedure.

The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting accessories.

This implies that the instructions delivered with the lifting accessories should be stored for later reference.

242




9 Spare part lists

9.1 Spare part lists and illustrations

9 Spare part lists

9.1 Spare part lists and illustrations

Location

Spare parts and exploded views are not included in the manual but delivered as a separate document for registered users on myABB Business Portal, www.myportal.abb.com

.




243


10 Circuit diagram

10.1 Circuit diagrams


10.1 Circuit diagrams

Overview

The circuit diagrams are not included in this manual, but are available for registered users on myABB Business Portal, www.myportal.abb.com

.

See the article numbers in the tables below.

Controllers

Product

Circuit diagram - IRC5

Circuit diagram - IRC5 Compact

Article numbers for circuit diagrams

3HAC024480-011

3HAC049406-003

Circuit diagram - IRC5 Panel Mounted Controller

3HAC026871-020

Circuit diagram - Euromap 3HAC024120-004

Circuit diagram - Spot welding cabinet 3HAC057185-001

Robots

Product

Circuit diagram - IRB 120

Circuit diagram - IRB 140 type C








Circuit diagram - IRB 1600/1660




Circuit diagram - IRB 4400/4450S


Circuit diagram - IRB 6400RF

Circuit diagram - IRB 6600 type A

Circuit diagram - IRB 6600 type B




3HAC031408-003

3HAC6816-3

3HAC025611-001

3HAC028647-009

3HAC036446-005

3HAC025691-001

3HAC025691-001

3HAC046307-003

3HAC2800-3

3HAC021351-003

3HAC039498-007

3HAC6670-3

3HAC029570-007

3HAC9821-1

3HAC029038-003

3HAC8935-1

3HAC13347-1

3HAC025744-001

3HAC13347-1

3HAC025744-001


245



10.1 Circuit diagrams

Continued

Product


Circuit diagram - IRB 6620 / IRB 6620LX


Circuit diagram - IRB 6650S




Circuit diagram - Product.ProductName

Circuit diagram - IRB 910SC


3HAC025090-001

3HAC025090-001

3HAC025744-001

3HAC13347-1

3HAC025744-001

3HAC025744-001

3HAC029940-001

3HAC043446-005

3HAC13347-1

3HAC025744-001

3HAC050778-003

3HAC056159-002

246




Index

Index

A

Absolute Accuracy, calibration, 217

aluminum

disposal, 225

ambient humidity

operation, 51 storage, 51

ambient temperature


assembly instructions, 47

assessment of hazards and risks, 18

B base

brake release buttons, 59

replacing, 138

screws, tightening torque, 140

spare part number, 138

batteries

disposal, 225

handling, 35

battery

replacing, 167

battery pack

replacing, interval, 81

battery shutdown

service routine, 167

brake release unit

releasing the brakes, 59

brakes

testing function, 34

brakes, releasing

external power supply to connector R1.MP, 60

manually, 59

power supply to motor axis 2, 183

power supply to motor axis 4, 194

C

cabinet lock, 23, 29

calibrating

roughly, 220

calibration

Absolute Accuracy type, 216

alternative method, 217

Levelmeter calibration, 217

rough, 220

standard type, 216

when to calibrate, 215

calibration, Absolute Accuracy, 217 calibration manuals, 217

calibration marks, 218

calibration position

jogging to, 224

scales, 218 calibration scales, 218

CalibWare, 216

carbon dioxide extinguisher, 20

cast iron

disposal, 225

cleaning, 106

climbing on robot, 23

Cold environments, 78

connection




external safety devices, 24

copper

disposal, 225

cracks, damper, 84

D

damage, damper, 84

damper, axis 2, 83

attachment screw, 158

replacing, 157 spare part number, 157

damper, axis 3

inspection, 83


damper, axis 5

inspection, 83


danger levels, 38

direction of axes, 219

E

enabling device, 28

environmental information, 225

ESD

damage elimination, 31 sensitive equipment, 31

external safety devices, 24

F figures


power supply to connector R1.MP, 60

fire extinguishing, 20

FlexPendant

jogging to calibration position, 224

MoveAbsJ instruction, 224

updating revolution counters, 221

foundation

requirements, 50

frame


G gearbox, axes 1-2


gearboxes

location of, 109

gearboxes, axes 5 and 6

oil change, 110

Gravity Alpha, 67

Gravity Beta, 66

grease

disposal, 225

H hanging

installed hanging, 23

hazardous material, 225

height

installed at a height, 23

hold-to-run, 28

HRA, 18

humidity

247

Index


I illustrations


power supply to connector R1.MP, 60

inspecting

robot cabling, 85

inspection, 83

instructions for assembly, 47

integrator responsibility, 17

inverted installation, 56

L labels

robot, 40

leak-down test, 241

Levelmeter calibration, 217

lifting accessory, 238

lifting and turning the robot, 56

limitation of liability, 17

Lithium

disposal, 225

loads on foundation, 49

lubrication

amount in gearboxes, 109 type of lubrication, 109

M magnesium

disposal, 225

motor axis 2

brake release with power supply, 183


tightening torque, 184

motor axis 4

brake release with power supply, 194

replace, 192



MoveAbsJ instruction, 224

N

nation specific regulations, 17

negative directions, axes, 219

neodymium

disposal, 225

NiCad

disposal, 225

nodular iron

disposal, 225

O oil

amount in gearboxes, 109

disposal, 225

type of oil, 109

oil change

gearbox axes 5 and 6, 110

safety risks, 36

wrist unit, 110

operating conditions, 51

P pedestal

248

installed on pedestal, 23

plastic

disposal, 225

position, robot

when draining wrist unit, 111

when filling oil in wrist unit, 112

positive directions, axes, 219

product standards, 232

protection classes, 51 protection type, 51

protective equipment, 24 protective wear, 24

push button unit

releasing the brakes, 59

R

region specific regulations, 17

release brakes, 21

releasing brakes

external power supply to connector R1.MP, 60

manually, 59

requirements on foundation, 50

responsibility and validity, 17

restricting

working range, 74

revolution counters

storing on FlexPendant, 221

updating, 220

risk of tipping, 54

robot

labels, 40

protection class, 51 protection types, 51

symbols, 40

robot cabling

inspecting, 85

robot position

when draining wrist unit, 111

when filling oil in wrist unit, 112

rubber

disposal, 225

S safety

brake testing, 34

ESD, 31

fire extinguishing, 20

moving robots, 25

release robot axes, 21

signals, 38 signals in manual, 38 symbols, 38

symbols on robot, 40

test run, 26

working range, 27

safety fence, 18

safety risk

electric parts, 29

hot parts, 32

hydraulic system, 33

installation, 23

oil change, 36

operational disturbance, 23

pneumatic system, 33

service work, 23

voltage, 29

safety signals




in manual, 38

safety standards, 232

safety zones, 18

scales on robot, 218

screw joints, 235

signals

safety, 38

SMB

replacing, 167

SMB battery

extension of lifetime, 167 replacing, 167

special tools, 240

speed

adjusting, 78

stability, 54

standards, 232

ANSI, 233

CAN, 233

EN, 232

EN IEC, 232

EN ISO, 232

start of robot in cold environments, 78

steel

disposal, 225

storage conditions, 51

suspended mounting, 66

symbols

safety, 38

synchronization position, 220

sync marks, 218

system integrator requirements, 17

system parameter

Gravity Alpha, 67

Gravity Beta, 66

T temperatures


testing

brakes, 34

three-position enabling device, 28

tightening torques, attachment screws

base-gearbox unit, 140

motor axis 2, 184

motor axis 4, 195

wrist unit, 144

tools

calibration equipment, Levelmeter, 240

Calibration Pendulum, 240 for service, 240

rotational tool, article number, 192

torques on foundation, 49

U

updating revolution counters, 220

V

validity and responsibility, 17

velocity

adjusting, 78

VK-covers, spare part number

at base, 138

W

wall mounted, 56

wall mounting, 66

weight, 48

gearbox 1, 209–210

robot, 57, 238

working range

restricting, 74

wrist unit

oil change, 110

replacing, 142



Z zero position

checking, 224

Index




249

ABB AB, Robotics

Robotics and Motion

S-721 68 VÄSTERÅS, Sweden

Telephone +46 (0) 21 344 400

ABB AS, Robotics


Nordlysvegen 7, N-4340 BRYNE, Norway

Box 265, N-4349 BRYNE, Norway

Telephone: +47 22 87 2000

ABB Engineering (Shanghai) Ltd.

Robotics and Motion

No. 4528 Kangxin Highway

PuDong District

SHANGHAI 201319, China

Telephone: +86 21 6105 6666

ABB Inc.


1250 Brown Road

Auburn Hills, MI 48326

USA

Telephone: +1 248 391 9000 abb.com/robotics



ABB IRB 140 Product Manual 252 Pages

ABB IRB 140 Product Manual

Product manual

Product manual

IRB 140 type C

IRB 140T type C

IRB 140-6/0.8 type C

IRB 140T-6/0.8 type C

Table of contents

Overview of this manual

Product documentation

How to read the product manual

1 Safety

2 Installation and commissioning

3 Maintenance

4 Repair

5 Calibration information

6 Decommissioning

7 Robot description

8 Reference information

9 Spare part lists

10 Circuit diagram

Index

Related manuals

Table of contents

ABB IRB 140 Product Manual 252 Pages

ABB IRB 140 Product Manual

Product manual

Product manual

IRB 140 type C

IRB 140T type C

IRB 140-6/0.8 type C

IRB 140T-6/0.8 type C

Table of contents

Overview of this manual

Product documentation

How to read the product manual

1 Safety

2 Installation and commissioning

3 Maintenance

4 Repair

5 Calibration information

6 Decommissioning

7 Robot description

8 Reference information

9 Spare part lists

10 Circuit diagram

Index

Related manuals

ABB

IRB 140T-6/0.8

ABB

IRB 140T type C

ABB Robotics

IRB 120

ABB

IRB 1300

ABB

IRB 2400/10

ABB

IRB 4400/60

ABB

IRB1410

ABB

IRB 360-6/1600

ABB

IRB 6650S-90/3.9

ABB

IRB 6620LX

ABB

IRB 6660 - 100/3.3

ABB

IRB 6620

Table of contents