ABB Robotics Sensor Module (DSQC 256A) Alt # 3HAB2211

ABB Robotics Sensor Module (DSQC 256A) Alt # 3HAB2211
Advant 800xA | Advant OCS | Bailey Infi 90
Bailey Net 90 | Contronic | Master | Procontic
Procontrol | Taylor MOD 30 and Mod 300
Distributed Control Systems
for Industrial Automation
ABB
Product PDF
Presented by – DCScenter.com
For Product Needs:
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Call:
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http://www.DCScenter.com
Product manual
Articulated robot
Note! This PDF includes the two parts; Procedures and
Reference information, but is presented as one single file!
If delivered as a printed manual, however, the Product manual
is divided and published in two separate parts!
IRB 2400/L
IRB 2400/10
IRB 2400/16
M2000, M2000A, M2004
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Product manual
IRB 2400/L
IRB 2400/10
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IRB 2400/16
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M2000
M2004
M2004
Document ID: 3HAC 022031-001
Revision: B
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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.
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In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB’s written
permission, and contents thereof must not be imparted to a third party nor be used for
any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
© Copyright 2004 ABB All right reserved.
ABB Automation Technologies AB
Robotics
SE-721 68 Västerås
Sweden
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Safety
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1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.1 Safety in the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.2 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2.1 Safety risks during installation and service work on robot . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2.2 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.2.3 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.2.4 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.2.2.5 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2.3 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.3.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.3.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.3.3 Emergency release of the robot’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.3.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.2.3.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.3.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.3.7 Work inside the manipulator's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.2.3.8 Translate the information on safety and information labels . . . . . . . . . . . . . . . . . . . . . . . 29
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1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.3.2 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.3.3 DANGER - First test run may cause injury or damage! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.3.4 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.3.5 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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2 Installation and commissioning
37
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.2.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.2.2 Working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.3 On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.3.1 Lifting robot with lifting slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.3.2 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.3.3 Orienting and securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.3.4 Suspended mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.3.5 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.4 Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.4.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.4.3 Mechanically restricting the working range of axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.4.4 Installation of limit switch, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.5.1 Connectors on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.5.2 Robot cabling and connection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3 Maintenance
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3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Table of Contents
3.2 Maintenace schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.3 Changing activites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.3.1 Oil in gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.3.2 Oil change, gearbox axes 5-6 (wrist unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.3.3 Replacement of SMB battery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4 Repair
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4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.2.2 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.2.3 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.3 Complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.3.1 Replacement of cable unit, axes 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.3.2 Replacement of cable harness, axes 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
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4.4 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.4.1 Replacement of wrist IRB 2400/10/16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.4.2 Replacement of wrist IRB 2400L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.4.3 Replacement of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.5 Lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
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4.5.1 Replacement of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.5.2 Replacement of tie rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.6 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.6.1 Replacement of SMB unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.6.2 Replacement of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.6.3 Replacement of parallel arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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4.7 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.7.1 Replacement of motor, axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.7.2 Replacement of motor, axis 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.7.3 Replacement of motor, axis 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.7.4 Replacement of motors, axes 4-6, IRB 2400L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.7.5 Replacement of motors, axes 4-6, IRB 2400/10/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.8 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.8.1 Replacement of gearbox, axis 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.8.2 Replacement of drive shaft unit, IRB 2400L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
5 Calibration information
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Calibration movement directions for all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
6 Reference information
169
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
6.2 Applicable safety standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
6.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
6.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
6.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
6.6 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
6.7 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
6.8 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
7 Spare parts and exploded views
179
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
7.2 Spare parts - base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
7.3 Spare parts - lower arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
7.4 Spare parts - upper arm, IRB 2400/10/16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
7.5 Spare parts - upper arm, IRB 2400/L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
7.6 Spare parts - drive unit, IRB 2400/L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
7.7 Spare parts - customer cable, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
7.8 Spare parts - limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
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8 Circuit diagram
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8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Index
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Table of Contents
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Overview
Overview
About this manual
This manual contains instructions for
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mechanical and electrical installation of the robot
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maintenance of the robot
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mechanical and electrical repair of the robot.
Usage
This manual should be used during
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installation, from lifting the robot to its work site and securing it to the foundation to
making it ready for operation
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maintenance work
•
repair work.
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Who should read this manual?
This manual is intended for:
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installation personnel
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maintenance personnel
•
repair personnel.
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Prerequisites
The reader should...
•
be a trained maintenance/repair craftsman
•
have the required knowledge of mechanical and electrical installation/repair/
maintenance work.
Organization of chapters
The manual is organized in the following chapters:
Chapter
Contents
Safety, service
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.
Installation and commissioning
Required information about lifting and installation of the robot.
Maintenance
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.
Repair
Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.
Calibration information
Procedures that does not require specific calibration equipment.
Decommissioning
Environmental information about the robot and its components.
Continues on next page
3HAC 022031-001 Revision: B
7
Overview
Continued
References
Procedures in this product manual contain references to the following manuals:
Document name
Document ID
Product specification - IRB 2400
3HAC9112-1
Product manual - IRC5
3HAC021313-001
Product manual - S4Cplus M2000
3HAC021333-001
Product manual - S4Cplus M2000A
3HAC022419-001
Operating manual - IRC5 with FlexPendant
3HAC16590-1
User’s guide - S4Cplus
3HAC7793-1
Operating manual - Service Information System
3HAC025709-001
Operating manual - Calibration Pendulum
3HAC16578-1
Operating manual - Levelmeter Calibration
3HAC022907-001
Technical reference manual - System parameters
3HAC17076-1
M2000/M2000A
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3HAC021395-001
M2004
Application manual - External axes
3HAC9299-1
M2000
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Document name
CalibWare 2.0 Users Guide (M2000)
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Revision Description
-
Document ID
3HAC16090-1
First edition.
Replaces previous manuals:
• Installation and Commssioning Manual
• Maintenance Manual
• Repair Manual, part 1
• Repair Manual, part 2.
Changes made in the material from the previous manuals:
• Model M2004 implemented.
A
•
•
•
Chapter“ Calibration” replaced with chapter “Calibration information”.
Safety chapter rewritten.
Section Document references is completed with article numbers for
calibration manuals.
B
•
Sections are restructured into Replacement procedures, instead of
removal/refitting procedures.
Procedure for refitting the motor of axis 1 is completed.
Correction made in Protection classes on page 39.
Various corrections due to technical revisions etc.
•
•
•
8
M2004
Application manual - Additional axes and stand
alone controller
Additional document references
Revisions
Note
3HAC 022031-001 Revision: B
How to read the product manual
How to read the product manual
Reading the procedures
The procedures contain references to figures, tools, material etc. The references are read as
described below.
References to figures
The procedures often include references to components or attachment points located on the
robot/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.
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Action
8.
Remove the rear attachment screws, gearbox.
References to required equipment
Note/Illustration
Shown in the figure Location of
gearbox on page xx.
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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, i.e. article number, dimension.
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The denomination in the procedure for the component or attachment point corresponds to the
denomination 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
Note/Illustration
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 chapter Safety on page 13.
3HAC 022031-001 Revision: B
9
Product documentation, M2000/M2000A
Product documentation, M2000/M2000A
General
The complete product documentation kit for the M2000 robot system, including controller,
robot and any hardware option, consists of the manuals listed below:
Product manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
is divided into two parts:
Product manual, procedures
•
Safety information
•
Installation and commissioning (descriptions of mechanical installation, electrical
connections and loading system software)
•
Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
•
Repair (descriptions of all recommended repair procedures including spare parts)
•
Additional procedures, if any (calibration, decommissioning)
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Product manual, reference information
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Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
•
Part list
•
Foldouts or exploded views
•
Circuit diagrams
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The product manual published as a PDF consists of only one file where the two parts are
presented together, as one Product manual.
Software manuals
The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during
operation.
A complete listing of all available software manuals is available from ABB.
Controller hardware option manual
Each hardware option for the controller is supplied with its own documentation. Each
document set contains the types of information specified below:
•
Installation information
•
Repair information
•
Maintenance information
In addition, spare part information is supplied for the entire option.
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3HAC 022031-001 Revision: B
Product documentation, M2004
Product documentation, M2004
General
The robot documentation may be divided into a number of categories. This listing is based on
the type of information contained within the documents, regardless of whether the products
are standard or optional. This means that any given delivery of robot products will not contain
all documents listed, only the ones pertaining to the equipment delivered.
However, all documents listed may be ordered from ABB. The documents listed are valid for
M2004 robot systems.
Product manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
is divided into two parts:
Product manual, procedures
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•
Safety information
•
Installation and commissioning (descriptions of mechanical installation, electrical
connections and loading system software)
•
Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
•
Repair (descriptions of all recommended repair procedures including spare parts)
•
Additional procedures, if any (calibration, decommissioning)
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Product manual, reference information
•
Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
•
Part list
•
Foldouts or exploded views
•
Circuit diagrams
The product manual published as a PDF consists of only one file where the two parts are
presented together, as one Product manual.
RobotWare manuals
The following manuals describe the robot software in general and contain relevant reference
information:
•
RAPID Overview: An overview of the RAPID programming language.
•
RAPID reference manual : Description of all RAPID instructions.
•
Technical reference manual - System parameters: Description of system
parameters and configuration workflows.
Continues on next page
3HAC 022031-001 Revision: B
11
Product documentation, M2004
Continued
Application manuals
Specific applications (e.g. software or hardware options) are described in Application
manuals. An application manual can describe one or several applications.
An application manual generally contains information about:
•
The purpose of the application (what it does and when it is useful)
•
What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)
•
How to use the application
•
Examples of how to use the application
Operating manuals
This group of manuals is aimed at those having first hand operational contact with the robot,
i.e. production cell operators, programmers and trouble shooters. The group of manuals
includes:
•
Getting started - IRC5 and RobotStudio Online
•
Operating manual - IRC5 with FlexPendant
•
Operating manual - RobotStudio Online
•
Trouble shooting manual for the controller and robot
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1 Safety
1.1. Introduction
1 Safety
1.1. Introduction
Overview
The safety information in this manual is divided in two categories:
•
general safety aspects, important to attend to before performing any service work on
the robot. These are applicable for all service work and are found in section General
safety information on page 14.
•
specific safety information, pointed out in the procedure at the moment of the danger.
How to avoid and eliminate the danger is either detailed directly in the procedure, or
further detailed in separate instructions, found in section Safety related instructions on
page 30.
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13
1 Safety
1.2.1. Safety in the robot system
1.2 General safety information
1.2.1. Safety in the robot system
Validity and responsibility
The information does not cover how to design, install and operate a complete system, nor
does it cover all peripheral equipment, which can influence the safety of the total system. To
protect personnel, the complete system must be designed and installed in accordance with the
safety requirements set forth in the standards and regulations of the country where the robot
is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable safety laws
and regulations in the country concerned are observed and that the safety devices necessary
to protect people working with the robot system are designed and installed correctly.
Personnel working with robots must be familiar with the operation and handling of the
industrial robot, described in the applicable documents, e.g. User’s guide - S4Cplus (M2000)
/ Operating manual - IRC5 with FlexPendant (M2004) and Product manual.
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Connection of external safety devices
Apart from the built-in safety functions, the robot is also supplied with an interface for the
connection of external safety devices. Via this interface, an external safety function can
interact with other machines and peripheral equipment. This means that control signals can
act on safety signals received from the peripheral equipment as well as from the robot.
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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.
Related information
14
Type of information
Detailed in document
Section
Installation of safety
devices
Product manual for the robot
Installation and commissioning
Changing operating
modes
User’s guide - S4Cplus (RobotWare 4.0) Start-up
Operating manual - IRC5 with
Operating modes
FlexPendant (RobotWare 5.0)
Restricting the working
space
Product manual for the robot
Installation and commissioning
3HAC 022031-001 Revision: B
1 Safety
1.2.2.1. Safety risks during installation and service work on robot
1.2.2. Safety risks
1.2.2.1. Safety risks during installation and service work on robot
Overview
This section includes information of general safety risks to be considered when performing
installation and service work on the robot.
General risks during installation and service
•
The instructions in the Product Manual - Installation and Commissioning must always
be followed.
•
Emergency stop buttons must be positioned in easily accessible places so that the robot
can be stopped quickly.
•
Those in charge of operations must make sure that safety instructions are available for
the installation in question.
•
Those who install the robot must have the appropriate training for the robot system in
question and in any safety matters associated with it.
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Nation/region specific regulations
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To prevent injuries and damage during the installation of the robot system, the regulations
applicable in the country concerned and the instructions of ABB Robotics must be complied
with.
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Non-voltage related risks
•
Safety zones, which have to be crossed before admittance, must be set up in front of
the robot’s working space. Light beams or sensitive mats are suitable devices.
•
Turntables or the like should be used to keep the operator out of the robot’s working
space.
•
The axes are affected by the force of gravity when the brakes are released. In addition
to the risk of being hit by moving robot parts, you run the risk of being crushed by the
parallel arm.
•
Energy, stored in the robot for the purpose of counterbalancing certain axes, may be
released if the robot, or parts thereof, are dismantled.
•
When dismantling/assembling mechanical units, watch out for falling objects.
•
Be aware of stored heat energy in the controller.
•
Never use the robot as a ladder, i.e. do not climb on the robot motors or other part
during service work. There is a serious risk of slipping because of the high temperature
of the motors or oil spills that can occur on the robot.
To be observed by the supplier of the complete system
•
The supplier of the complete system must ensure that all circuits used in the safety
function are interlocked in accordance with the applicable standards for that function.
•
The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance with the
applicable standards for the emergency stop function.
Continues on next page
3HAC 022031-001 Revision: B
15
1 Safety
1.2.2.1. Safety risks during installation and service work on robot
Continued
Complete robot
Safety risk
Description
Hot components!
Caution!
Motors and gears are HOT after running the robot!
Touching the motors and gears may result in burns!
Removed parts may result in
collapse of robot!
Warning!
Take any necessary measures to ensure that the robot
does not collapse as parts are removed, e.g. secure the
lower arm with fixtures if removing motor, axis 2.
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Cabling
Safety risk
Description
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Cable packs are sensitive to
mechanical damage!
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Caution!
The cable packs are sensitive to mechanical damage!
They must be handled with care, especially the
connectors, in order to avoid damaging them!
Gearboxes and motors
Safety risk
Description
Gears may be damaged if
excessive force is used!
Caution!
Whenever parting/mating motor and gearbox, the gears
may be damaged if excessive force is used!
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3HAC 022031-001 Revision: B
1 Safety
1.2.2.2. Safety risks related to tools/workpieces
1.2.2.2. Safety risks related to tools/workpieces
Safe handling
It must be possible to safely turn off tools, such as milling cutters, etc. Make sure that guards
remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
Grippers/end effectors must be designed so that they retain workpieces in the event of a power
failure or a disturbance of the controller.
CAUTION!
Ensure that a gripper is prevented from dropping a workpiece, if such is used.
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17
1 Safety
1.2.2.3. Safety risks related to pneumatic/hydraulic systems
1.2.2.3. Safety risks related to pneumatic/hydraulic systems
General
Special safety regulations apply to pneumatic and hydraulic systems.
Residual energy
•
Residual energy may be present in these systems. After shutdown, particular care must
be taken.
•
The pressure in pneumatic and hydraulic systems must be released before starting to
repair them.
•
Gravity may cause any parts or objects held by these systems to drop.
•
Dump valves should be used in case of emergency.
•
Shot bolts should be used to prevent tools, etc., from falling due to gravity.
Safe design
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3HAC 022031-001 Revision: B
1 Safety
1.2.2.4. Safety risks during operational disturbances
1.2.2.4. Safety risks during operational disturbances
General
•
The industrial robot is a flexible tool which can be used in many different industrial
applications.
•
All work must be carried out professionally and in accordance with the applicable
safety regulations.
•
Care must be taken at all times.
•
Corrective maintenance must only be carried out by qualified personnel who are
familiar with the entire installation as well as the special risks associated with its
different parts.
Qualified personnel
Extraordinary risks
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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.
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3HAC 022031-001 Revision: B
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1 Safety
1.2.2.5. Risks associated with live electric parts
1.2.2.5. Risks associated with live electric parts
Voltage related risks, general
•
Although troubleshooting may, on occasion, have to be carried out while the power
supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
•
The mains supply to the robot must be connected in such a way that it can be turned
off outside the robot’s working space.
Voltage related risks, controller S4Cplus
A danger of high voltage is associated with the following parts:
•
Be aware of stored electrical energy (DC link) in the controller.
•
Units inside the controller, e.g. I/O modules, can be supplied with power from an
external source.
•
The mains supply/mains switch
•
The power unit
•
The power supply unit for the computer system (230 VAC)
•
The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
•
The drive unit (700 VDC)
•
The service outlets (115/230 VAC)
•
The power supply unit for tools, or special power supply units for the machining
process.
•
The external voltage connected to the control cabinet remains live even when the robot
is disconnected from the mains.
•
Additional connections
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3HAC 022031-001 Revision: B
1 Safety
1.2.2.5. Risks associated with live electric parts
Continued
Voltage related risks, controller IRC5
A danger of high voltage is associated with the following parts:
•
Be aware of stored electrical energy (DC link, Ultra Cap unit) in the controller.
•
Units inside the controller, e.g. I/O modules, can be supplied with power from an
external source.
•
The mains supply/mains switch
•
The transformers
•
The power unit
•
The control power supply (230 VAC)
•
The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
•
The drive unit (700 VDC)
•
The drive system power supply (230 VAC)
•
The service outlets (115/230 VAC)
•
The customer power supply (230 VAC)
•
The power supply unit for tools, or special power supply units for the machining
process.
•
The external voltage connected to the control cabinet remains live even when the robot
is disconnected from the mains.
•
Additional connections.
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Voltage related risks, robot
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A danger of high voltage is associated with the robot in:
•
The power supply for the motors (up to 800 VDC).
•
The user connections for tools or other parts of the installation (max. 230 VAC, see
chapter Installation and commissioning in the Product manual).
Voltage related risks, tools, material handling devices, etc
Tools, material handling devices, etc., may be live even if the robot system is in the OFF
position. Power supply cables which are in motion during the working process may be
damaged.
3HAC 022031-001 Revision: B
21
1 Safety
1.2.3.1. Safety fence dimensions
1.2.3. Safety actions
1.2.3.1. Safety fence dimensions
General
Install a safety cell around the robot to ensure safe robot installation and operation.
Dimensioning
Dimension the fence or enclosure to enable it to withstand the force created if the load being
handled by the robot is dropped or released at maximum speed. Determine the maximum
speed from the maximum velocities of the robot axes and from the position at which the robot
is working in the work cell (see Product Specification - Description, Robot Motion).
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating
tool or other device fitted to the manipulator.
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1 Safety
1.2.3.2. Fire extinguishing
1.2.3.2. Fire extinguishing
NOTE!
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot (manipulator
or controller)!
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23
1 Safety
1.2.3.3. Emergency release of the robot’s arm
1.2.3.3. Emergency release of the robot’s arm
Description
In an emergency situation, any of the robot’s axes may be released manually by pushing the
brake release buttons on the robot.
How to release the brakes is detailed in section:
•
Manually releasing the brakes on page 43.
The robot arm may be moved manually on smaller robot models, but larger models may
require using an overhead crane or similar.
Increased injury
Before releasing the brakes, make sure that the weight of the arms does not increase the
pressure on the trapped person, further increasing any injury!
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3HAC 022031-001 Revision: B
1 Safety
1.2.3.4. Brake testing
1.2.3.4. Brake testing
When to test
During operation the holding brake of each axis motor wear normally. A test may be
performed to determine whether the brake can still perform its function.
How to test
The function of the holding brake of each axis motor may be checked as detailed below:
1. Run each manipulator axis to a position where the combined weight of the manipulator
arm and any load is maximized (max. static load).
2. Switch the motor to the MOTORS OFF position with the Operating mode selector on the
controller.
3. Check that the axis maintains its position.
If the manipulator does not change position as the motors are switched off, then the brake
function is adequate.
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25
1 Safety
1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s"
1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s"
NOTE!
Do not change "Transm gear ratio" or other kinematic parameters from the Teach Pendant
Unit or a PC. This will affect the safety function Reduced speed 250 mm/s.
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1 Safety
1.2.3.6. Safe use of the Teach Pendant Unit
1.2.3.6. Safe use of the Teach Pendant Unit
NOTE!
The enabling device is a push button located on the side of the Teach Pendant Unit (TPU)
which, when pressed halfway in, takes the system to MOTORS ON. When the enabling
device is released or pushed all the way in, the robot is taken to the MOTORS OFF state.
To ensure safe use of the Teach Pendant Unit, the following must be implemented:
•
The enabling device must never be rendered inoperative in any way.
•
During programming and testing, the enabling device must be released as soon as
there is no need for the robot to move.
•
The programmer must always bring the Teach Pendant Unit with him/her, when
entering the robot’s working space. This is to prevent anyone else taking control of the
robot without the programmer knowing.
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27
1 Safety
1.2.3.7. Work inside the manipulator’s working range
1.2.3.7. Work inside the manipulator’s working range
WARNING!
If work must be carried out within the robot’s work envelope, the following points must be
observed:
•
The operating mode selector on the controller must be in the manual mode position to
render the enabling device operative and to block operation from a computer link or
remote control panel.
•
The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in
position "manual mode with reduced speed". This should be the normal position when
entering the working space. The position "manual mode with full speed (100%)" may
only be used by trained personnel who are aware of the risks that this entails.
•
Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in
order not to get entangled with hair or clothing. Also be aware of any danger that may
be caused by rotating tools or other devices mounted on the manipulator or inside the
cell.
•
Test the motor brake on each axis, according to section Brake testing on page 25.
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1 Safety
1.2.3.8. Translate the information on safety and information labels
1.2.3.8. Translate the information on safety and information labels
Labels on the product
Both the robot and the controller are marked with several safety and information labels,
containing important information about the product. The information is useful for all
personnel handling the robot system, eg. during installation, service or operation.
Translation possibilities
The labels fitted to the product contain space for adding a fourth language underneath the
three standard languages (English, German and French).
Add a local language to the label by:
•
using a transparent sticker over the standard label with text added in a fourth language.
Drawings detailing the design (text, figure, dimensions) of the standard labels can be
ordered from ABB. Notice that each label is identified according to the article number
located in the lower corner of the label.
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Example of transparent sticker
The figure below shows the location of the free space on one of the labels on the robot, where
the fourth language can be added. The figure also shows a transparent sticker, containing the
text in Swedish.
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3HAC 022031-001 Revision: B
Free space for adding a fourth language
29
1 Safety
1.3.1. Safety signals, general
1.3 Safety related instructions
1.3.1. Safety signals, general
General
This section specifies all dangers that may arise from performing the work detailed in the
manual. Each danger is detailed in its own section consisting of:
•
A caption specifying the danger level (DANGER, WARNING or CAUTION) and the
type of danger.
•
A brief description of what will happen if the operator/service personnel do not
eliminate the danger.
•
An instruction of how to eliminate the danger to facilitate performing the activity at
hand.
Danger levels
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The table below defines the captions specifying the danger levels used throughout this
manual.
Symbol
Designation
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danger
Signification
DANGER
Warns that an accident will occur if the instructions
are not followed, resulting in a serious or fatal injury
and/or severe damage to the product. It applies to
warnings that apply to danger with, for example,
contact with high voltage electrical units, explosion
or fire risk, risk of poisonous gases, risk of crushing,
impact, fall from height etc.
WARNING
Warns that an accident may occur if the instructions
are not followed, that can lead to serious injury,
possibly fatal, and/or great damage to the product. It
applies to warnings that apply to danger with, for
example, contact with high voltage electrical units,
explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height etc.
ELECTRICAL
SHOCK
The electrocution or electrical shock symbol
indicates electrical hazards which could result in
severe personal injury or death.
CAUTION
Warns that an accident may occur if the instructions
are not followed, that can result in injury and/or
damage to the product. It also applies to warnings of
risks that include burns, eye injury, skin injury,
hearing damage, crushing or slipping, tripping,
impact, fall from height etc. Furthermore, it applies to
warnings that include function requirements when
fitting and removing equipment, where there is a risk
of damaging the product or causing a breakdown.
warning
Electrical shock
caution
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3HAC 022031-001 Revision: B
1 Safety
1.3.1. Safety signals, general
Continued
Symbol
Designation
Signification
ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates
DISCHARGE (ESD) electrostatic hazards which could result in severe
damage to the product.
Electrostatic discharge
(ESD)
NOTE
Note symbols alert you to important facts and
conditions.
TIP
Tip symbols direct you to specific instructions, where
to find additional information or how to perform a
certain operation in an easier way.
Note
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1 Safety
1.3.2. DANGER - Moving manipulators are potentially lethal!
1.3.2. DANGER - Moving manipulators are potentially lethal!
Description
Any moving manipulator is a potentially lethal machine.
When running the manipulator, it may perform unexpected and sometimes irrational
movements. However, all movements are performed with great force and may seriously
injure any personnel and/or damage any piece of equipment located within the manipulator
working range.
Elimination
Action
Note/Illustration
1. Before attempting to run the manipulator,
Emergency stop equipment such as gates,
make sure all emergency stop equipment is tread mats, light curtains, etc.
correctly installed and connected.
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2. If possible, use the hold-to-run button
whenever possible.
The hold-to-run button is used in manual
mode, not in automatic mode.
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How to use the hold-to-run control in
RobotWare 5.0 is detailed in section How
to use the hold-to-run function in the
Operating manual - IRC5 with FlexPendant.
How to use the hold-to-run control in
RobotWare 4.0 is detailed in section The
Teach Pendant unit in the User’s Guide.
3. Make sure no personnel are present within
the manipulator working range before
pressing the start button.
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1 Safety
1.3.3. DANGER - First test run may cause injury or damage!
1.3.3. DANGER - First test run may cause injury or damage!
Description
Since performing a service activity often requires disassembly of the robot there are several
safety risks to take into consideration before the first test run.
Elimination
Follow the procedure below when performing the first test run after a service activity (repair,
installation or maintenance):
Action
1. Remove all service tools and foreign objects from the robot and its working area!
2. Install all safety equipment properly!
3. Make sure all personnel are standing at a safe distance from the robot, i.e. out of its
reach behind safety fences, etc!
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4. Pay special attention to the function of the part previously serviced!
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1 Safety
1.3.4. WARNING - The unit is sensitive to ESD!
1.3.4. WARNING - The unit is sensitive to ESD!
Description
ESD (electro static discharge) is the transfer of electrical static charge between two bodies at
different potentials, either through direct contact or through an induced electrical field. When
handling parts or their containers, personnel not grounded may potentially transfer high static
charges. This discharge may destroy sensitive electronics.
Elimination
Action
Note
1. Use a wrist strap
Wrist straps must be tested frequently to ensure
that they are not damaged and are operating
correctly.
2. Use an ESD protective floor mat.
The mat must be grounded through a currentlimiting resistor.
3. Use a dissipative table mat.
The mat should provide a controlled discharge of
static voltages and must be grounded.
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1 Safety
1.3.5. WARNING - Safety risks during work with gearbox oil
1.3.5. WARNING - Safety risks during work with gearbox oil
Description
When handling the gearbox oil, there are several dangers to both personal injuries and product
damages! Following safety information must be regarded before performing any work with
the oil in the gearboxes!
Warnings and elimination
Warning
Description
Elimination / Action
Changing and draining
Make sure that protective gear
gearbox oil may require
like goggles and gloves are
handling hot oil of up to 90 °C! always worn during this activity.
-
Hot oil!
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When opening the oil plug,
Open oil plug carefully and keep
there may be pressure present away from the opening. Do not
in the gearbox, causing oil to overfill the gearbox when filling.
spray from the opening!
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Possible pressure build
up in gearbox!
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Do not overfill!
-
Overfilling of gearbox oil can
lead to internal over-pressure
inside the gearbox which in
turn may:
• damage seals and
gaskets
• completely press out
seals and gaskets
• prevent the manipulator
from moving freely.
Make sure not to overfill the
gearbox when filling with oil!
After filling, check the correct oil
level.
Mixing types of oil may cause
severe damage to the
gearbox!
When filling gearbox oil, do not
mix different types of oil unless
specified in the instruction.
Always use the type of oil
specified by the manufacturer!
Do not mix types of oil!
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1 Safety
1.3.5. WARNING - Safety risks during work with gearbox oil
Continued
Warning
Description
Elimination / Action
Warm oil drains quicker than
cold oil.
When changing gearbox oil, first
run the robot for a time to heat
up the oil.
-
Heat up the oil!
-
Specified amount
depends on drained
volume!
The specified amount of oil is After refilling, check the oil level.
based on the total volume of
the gearbox. When changing
the oil, the amount of refilled oil
may differ from the specified
amount, depending on how
much oil has previously been
drained from the gearbox.
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2 Installation and commissioning
2.1. Introduction
2 Installation and commissioning
2.1. Introduction
General
This chapter contains information for installing the robot to the working site.
More detailed technical data, such as load diagram, permitted extra loads (equipment) and
location of extra loads (equipment), may be found in the Product Specification for the robot.
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2 Installation and commissioning
2.2.1. Pre-installation procedure
2.2 Unpacking
2.2.1. Pre-installation procedure
General
These instructions are to be used when unpacking and installing the robot for the first time.
They also contain information useful later during re-installation of the robot.
Checking the pre-requisites for installation
The check-list below details what must be observed before proceeding with the actual
installation of the robot:
1. Make sure only qualified installation personnel conforming to all national and local codes
are allowed to perform the installation.
2. Make sure the robot is not damaged, by visually inspecting it.
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3. Make sure the lifting device to be used is fit to handle the weight of the robot as specified
in Weight, robot on page 38.
4. If the robot is not to be installed directly, it must be stored according to the specifications
in Storage conditions on page 39.
5. Make sure the appointed operating environment of the robot conforms to the
specifications outlined in Operating conditions on page 39.
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6. Before taking the robot to the installation site, make sure the site conforms to Loads on
foundation on page 38, Requirements, foundation on page 39 and Protection classes on
page 39.
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7. When these prerequisites are met, the robot may be taken to its installation site as
described in Lifting robot with lifting slings on page 42.
Weight, robot
Robot model
Weight
IRB 2400
380 kg
Loads on foundation
The table below shows the different forces and torques working on the robot during various
kinds of operation.
Note! These forces and torques are extreme values that are rarely encountered during
operation. The values also never simultaneously reach their maximum!
IRB 2400 -10, -16
Forces and torques
Endurance load
(operation)
Max. load (emergency
stop)
Force xy (upright/suspended)
± 2000 N
± 2600 N
Force z (upright)
4100 ± 1400 N
4100 ± 1900 N
Forze z (suspended)
- 4100 ± 1400 N
- 4100 ± 1900 N
Torque Mxy
± 3400 Nm
± 4000 Nm
Torque Mz
± 550 Nm
± 900 Nm
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2.2.1. Pre-installation procedure
Continued
IRB 2400 - L
Forces and torques
Endurance load
(operation)
Max. load (emergency
stop)
Force xy
± 1700 N
± 2100 N
Force z, upright
4100 ± 1100 N
4100 ± 1400 N
Force z, suspended
- 4100 ± 1100 N
- 4100 ± 1400 N
Torque Mxy
± 3000 Nm
± 3400 Nm
Torque Mz
± 450 Nm
± 900 Nm
Requirements, foundation
The table below shows the requirements for the foundation where the weight of the installed
robot is included:
Requirement
Value
Min. levelity
0.5 mm
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Max. tilt
5°
Min. resonance frequency
Storage conditions
30 Hz
The table below shows the allowed storage conditions for the robot:
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Parameter
Min. ambient temperature, storage
Max. ambient temperature, storage
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Value
-25° C
+55° C
Max. ambient temperature, storage (less than 24 hrs) +70° C
Max. ambient humidity, storage
Operating conditions
Max. 95% at constant temperature
The table below shows the allowed operating conditions for the robot and controller:
Parameter
Value
Min. ambient temperature
+5° C
Max. ambient temperature
+45° C
Max. ambient humidity
Max. 95% at constant temperature
Protection classes
The table below shows the protection class of the main parts of the robot system:
Equipment
Protection class
Robot IRB 2400 (Foundry, Wash)
IP 67
Robot IRB 2400 (Standard, CleanRoom)
IP 54
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2 Installation and commissioning
2.2.2. Working range
2.2.2. Working range
Working range
This section specifies the working areas of the robot models.
IRB 2400/L
The working area is the same for both floor and inverted (suspended). Positions are located
at wrist center.
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xx0200000159
Pos.
X
Z
Angle axis 2
Angle axis 3
0
970
1620
0
0
1
404
2298
0
-60
2
602
745
0
65
3
1577
-246
110
-60
4
400
-403
110
24.5
5
-1611
623
-100
-60
6
-115
1088
-100
65
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2.2.2. Working range
Continued
IRB 2400/10, /16
The working area is the same for both floor and inverted (suspended). Positions are located
at wrist center.
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Angle axis 2
Angle axis 3
0
0
2041
0
-60
541
693
0
65
1351
-118
110
-60
4
400
-302
110
18.3
5
-1350
624
-100
-60
6
-53
1036
-100
65
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Pos.
X
Z
0
855
1455
360
1
2
3
Positions in the working range
The table below specifies the positions inside the working range, shown in the figure above.
Position in figure
Position (mm)
Angles (º)
X
Z
Axis 2
Axis 3
1
870
1139
0
0
2
510
1246
-28
-17
3
446
722
-28
31
4
515
218
60
119
5
607
-73
85
119
6
1506
210
85
26
7
1313
1148
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2 Installation and commissioning
2.3.1. Lifting robot with lifting slings
2.3 On-site installation
2.3.1. Lifting robot with lifting slings
General
This section details how to lift the robot using lifting slings.
Required equipment
Equipment
Note
Sling line Type: KDBK 7-8.
Length: 2 m. Load at 90°: 380 kg.
Illustration, attachment of lifting slings
The figure below shows how to attach the lifting slings to the robot.
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xx0200000164
Lifting of robot
Action
1. Move the robot to the lifting position shown in
the figure above.
Note
If necessary, release the brakes as
detailed in section Manually
releasing the brakes on page 43.
2. Attach the straps to the special eye bolts on the
gearboxes for axes 2 and 3.
3. Lift the robot carefully.
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2 Installation and commissioning
2.3.2. Manually releasing the brakes
2.3.2. Manually releasing the brakes
General
The holding brakes of each axis’ motor are of an electromechanical type and are released
when voltage is applied. This section details how to release the brakes, using the internal
brake release unit, in order to enable the axes to move manually.
The brake of each motor can also be released by connecting an external voltage supply
directly on the motor connector, see the circuit diagram or the repair procedures for each
motor (section Motors on page 118).
Releasing the brakes using the brake release unit
The procedure below details how to release the holding brakes using the internal brake release
unit.
Action
Note/Illustration
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1.
DANGER!
When releasing the holding brakes, the robot
axes may move very quickly and sometimes in
unexpected ways! Make sure no personnel is
near the robot arm!
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2. If the robot is not connected to the controller,
power must be supplied to the connector
R1.MP.
Detailed in section Supplying power
to connector R1.MP on page 44.
3. The internal brake release unit is located at the
base of the robot and equipped with buttons
for controlling the holding brakes for each axis
separately. The buttons are numbered
according to the numbers of the axes.
To release the brake on a particular robot axis,
push the corresponding button on the internal
brake release panel and keep it depressed.
The brake will function again as soon as the
button is released.
xx0600002697
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2 Installation and commissioning
2.3.2. Manually releasing the brakes
Continued
Supplying power to connector R1.MP
If the robot is not connected to the controller, power must be supplied to connector R1.MP in
the robot base in order to enable the brake release unit on the robot.
Action
Note/Illustration
1.
CAUTION!
Be careful not to interchange the 24 VDC 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
R1.MP, at the robot base.
Supply:
• +24 V on pin B8
• 0 V on pin C10
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xx0200000167
3. Release the brakes with the brake release unit as
detailed in the previous procedure.
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2.3.3. Orienting and securing the robot
2.3.3. Orienting and securing the robot
General
This section details how to orient and secure the robot to the foundation in order to safely run
the robot. The requirements for the foundations are shown in the tables and figures below.
Bolting requirements
When bolting a base plate or the base 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 on page 38.
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
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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
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Suitable washer:
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Tightening torque:
Hole configuration
M16 x 50
Quality 8.8
Thickness: 3 mm
Outer diameter: 30 mm
Inner diameter: 17 mm
190 Nm
The figure below shows the hole configuration of the robot base, used when securing the
robot. Cross section is shown in the following figure.
xx0200000181
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2 Installation and commissioning
2.3.3. Orienting and securing the robot
Continued
Cross section, guide sleeve hole
The figure below shows the cross section of the guide sleeve holes (from previous figure):
xx0200000182
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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
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2 Installation and commissioning
2.3.4. Suspended mounting
2.3.4. Suspended mounting
General
The robot can be mounted in a suspended position. This section details how to turn the robot.
Turning the robot
1. Use the special tool for inverted mounting, see following figure.
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xx0200000212
A
Lifting beam
B
Fork lift
-
Inverted mounting tool 3HAC 8961-1
2. Seal the eight holes in the bottom plate with plastic plugs, see following figure.
xx0200000215
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Plastic plugs (x8)
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2 Installation and commissioning
2.3.5. Loads
2.3.5. Loads
General
Any loads mounted on the robot must be defined correctly and carefully (with regard to the
position of center of gravity and inertia factor) in order to avoid jolting movements and
overloading the motors.
CAUTION!
Incorrect defined loads may result in operational stops or major damage in bearings.
References
Load diagrams, permitted extra loads (equipment) and their positions are specified in the
Product Specification. The loads must also be defined in the software as detailed in User’s
Guide (RobotWare 4.0), or Operating manual (RobotWare 5.0).
Stop time and braking distances
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Robot motor brake performance depends on any loads attached. For further information about
brake performance, please contact ABB.
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2.4.1. Introduction
2.4 Restricting the working range
2.4.1. Introduction
General
When installing the robot, make sure that it can move freely within its entire working space.
If there is a risk that it may collide with other objects, its working space should be limited.
The working range of the following axes may be restricted:
•
Axis 1, hardware (mechanical stop and position switch)
•
Axis 2, hardware (mechanical stop).
•
Axis 3, hardware (limit switch)
This section describes how to install hardware that restricts the working range.
Notice that adjustments must also be made in the software. References to software manuals
are given in the following installation procedures.
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2.4.2. Mechanically restricting the working range of axis 1
2.4.2. Mechanically restricting the working range of axis 1
Restrictions in the working range
The working range of axis 1 can be restricted within the area from 50º to 140º as shown in the
figure below. The restrictions are made by fitting two extra stops to the robot base.
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Location of the mechanical stop, axis 1
The extra mechanical stop is fitted to the robot base as shown in the figure below.
Note! The stop must only be mounted in the direction shown below!
xx0200000205
1
Stop, axis 1, removable
2
Plain washer
3
Hex socket head cap screw
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2.4.2. Mechanically restricting the working range of axis 1
Continued
Required equipment
Equipment
Art. no.
Stop, axis 1
3HAB 7298-1 Includes:
• removable stop (2 pcs)
• plain washers (4 pcs)
• hex socket head cap screw (4
pcs, M12x30)
• drill template (1 pc)
User’s guide - S4Cplus (RobotWare 4.0)
Technical reference manual - System
parameters (RobotWare 5.0)
Note
Art. no. is specified in section
References on page 8.
Fitting, mechanical stop axis 1
The procedure below details how to fit a mechanical stop to the robot base.
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Action
Note
1. Decide where to fit the extra mechanical
stops, according to the figure Location of
where to drill holes for extra stops on page 52.
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2. Make a copy of the drill template, enclosed
with the mechanical stop.
The template is also shown in the figure
Drill template on page 54 in scale 1:1.
3. Use the template to mark the center of the two Place the template edge edge with the
holes on each stop.
robot base, as shown in the figure
Location of where to drill holes for extra
stops on page 52.
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4. Drill the holes through, Ø 10.2. Cut threads,
M12.
5. Fit the stops to the robot base, but without
tightening the screws.
Note! The stops must be mounted in
correct direction, as shown in the figure
Location of where to drill holes for extra
stops on page 52.
6. Turn axis 1 manually and check the working
range between the stops.
If necessary; correct the angle of
impact.
7. Tighten the screws.
8. The software working range limitations must
be re-defined to correspond to the changes in
the mechanical limitations of the working
range.
How to define the range of movement in
RobotWare 4.0 is detailed in User’s
guide - S4Cplus, chapter System
Parameters - topic Manipulator.
The system parameters that must be
changed in RobotWare 5.0 (Upper joint
bound and Lower joint bound) are
further detailed in Technical reference
manual - System parameters.
9.
WARNING!
If the mechanical stop is deformed after a
hard collision, it must be replaced!
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2 Installation and commissioning
2.4.2. Mechanically restricting the working range of axis 1
Continued
Location of where to drill holes for extra stops
The figure below shows the drill pattern used when drilling for mechanical stops on axis 1.
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xx0200000206
A
Maximum working range, axis 1
B
Minimum working range, axis 1
C
Drilling pattern enclosed with the mechanical stop.
D
This mounting direction only
*
The minimum and maximum measurement between the mechanical stops. The
difference between the measurement and the minimum and maximum working
range is 2 x 4º, which corresponds to the width of the stop pin (at the frame).
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2.4.2. Mechanically restricting the working range of axis 1
Continued
Hidden stiffening ribs and forbidden drilling sector
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xx0600002647
C
Drilling not allowed inside this sector!
D
Center lines for the hidden stiffening ribs
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2 Installation and commissioning
2.4.2. Mechanically restricting the working range of axis 1
Continued
Drill template
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2.4.3. Mechanically restricting the working range of axis 2
2.4.3. Mechanically restricting the working range of axis 2
General
The range of rotation for axis 2 can be limited mechanically by fitting extra stops on the lower
arm.
Restrictions in working range
The figure below shows the mechanical stops available. The number of items that are needed
for different working ranges are specified in the following table.
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xx0200000208
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Working range
Qty. item 1
Qty. item 2
Qty. item 3
+110° / -100°
-
-
-
+110° / -70°
1
2
2
+110° / -40°
2
2
4
+80° / -100°
1
2
2
+80° / -70°
2
2
4
+80° / -40°
3
2
6
+50° / -100°
2
2
4
+50° / -70°
3
2
6
+50° / -40°
4
2
8
+20° / -100°
3
2
6
+20° / -70°
4
2
8
+20° / -40°
5
2
10
Required equipment
Equipment
Art. no.
Stop, axis 2
3HAC 2624-1
Note
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2 Installation and commissioning
2.4.3. Mechanically restricting the working range of axis 2
Continued
Equipment
Art. no.
Note
User’s guide - S4Cplus (RobotWare 4.0)
Technical reference manual - System
parameters (RobotWare 5.0)
Art. no. is specified in section
References on page 8.
Standard toolkit
The contents are defined in section
Standard toolkit on page 176, in part
2 of the Product manual.
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2.4.4. Installation of limit switch, axis 3
2.4.4. Installation of limit switch, axis 3
General
The working range of axis 3 can be limited by fitting an electrical switch on the gearbox axis
3, which senses the position via a cam.
Mounting of eletrical stop
Following illustration shows howe to fit the electrical stop.
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2.5.1. Connectors on robot
2.5 Electrical connections
2.5.1. Connectors on robot
Connectors on the robot
The figure below shows all connections of the robot cabling, including the customer
connections.
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