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Note

Action

Standard robots

xx1400000544

Remove the screws holding the brake.

2

Paint robots

xx1600000640

xx1400000545

Pull out the brake.

3

Push the new brake in place.

4

Safety the brake with the screws.

5

38

Product manual - FlexPendant Retractable Cable

3HAC048816-001 Revision: B

© Copyright 2015-2016 ABB. All rights reserved.

4 Repair

4.1 Replacing the brake

Continued

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Summary of Contents for FlexPendant

Page 1: ...Product manual FlexPendant Retractable Cable ...

Page 2: ...Trace back information Workspace Main version a182 Checked in 2016 10 06 Skribenta version 4 6 320 ...

Page 3: ...Product manual FlexPendant Retractable Cable Document ID 3HAC048816 001 Revision B Copyright 2015 2016 ABB All rights reserved ...

Page 4: ...r 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 Additional copies of this manual may be obtained from ABB The original language for this publication is English Any ...

Page 5: ...acket for standard robots 21 2 2 Installing the bracket for paint robots 23 2 3 Connecting the cables 31 3 Maintenance 31 3 1 Maintenance schedule and expected component life 32 3 2 Inspecting the complete FlexPendant Retractable Cable 35 3 3 Cleaning the complete FlexPendant Retractable Cable 37 4 Repair 37 4 1 Replacing the brake 39 4 2 Replacing the cable stopper 41 5 Spare parts 43 Index Produ...

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Page 7: ...ce 3HAC031045 001 Operating manual General safety information i 3HAC050941 001 Operating manual IRC5 with FlexPendant 3HNA008861 001 Product Manual IRC5P 3HAC7793 1 User s guide S4Cplus BaseWare OS 4 0 3HAC5784 1 User s guide S4C BaseWare OS 3 2 i This manual contains all safety instructions from the product manuals for the manipulators and the controllers Revisions Description Revision First edit...

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Page 9: ...structions from the product manuals for the robots and the controllers The robot system shall be designed and constructed in such a way as 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 Users shall not be ex...

Page 10: ...4Cplus BaseWare OS 4 0 Changing operating modes Operating modes Operating manual IRC5 with FlexPend ant Operator s Manual IRC5P Installation and commissioning Product manual for the robot Restricting the working space 10 Product manual FlexPendant Retractable Cable 3HAC048816 001 Revision B Copyright 2015 2016 ABB All rights reserved 1 Safety 1 1 Safety in the robot system Continued ...

Page 11: ... 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 ...

Page 12: ...ere is a risk of the robot being damaged To be observed by the supplier of the complete system 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 ...

Page 13: ...abling Description Safety risk CAUTION The cable packages are sensitive to mechan ical damage Handle the cable packages and the connectors with care in order to avoid damage Cable packages are sensitive to mechanical damage Product manual FlexPendant Retractable Cable 13 3HAC048816 001 Revision B Copyright 2015 2016 ABB All rights reserved 1 Safety 1 2 Safety risks during installation and service ...

Page 14: ... if the valid regulations are followed All work must be performed by qualified personnel on machine robot system in deadlock in an isolated state disconnected from power supply and protected against reconnection Voltage related risks S4C and S4Cplus controller A danger of high voltage is associated with for example the following parts Be aware of stored electrical energy DC link in the controller ...

Page 15: ... 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 robot A danger of high voltage is associated with the robot in The power supply for the motors up to 800 VDC The user connections for tools or other parts of the installation max 230 VAC V...

Page 16: ...y to ensure that they are not damaged and are operating cor rectly Use a wrist strap 1 The mat must be grounded through a current limit ing resistor Use an ESD protective floor mat 2 The mat should provide a controlled discharge of static voltages and must be grounded Use a dissipative table mat 3 Location of wrist strap button The wrist strap is located on the left side on the inside of the contr...

Page 17: ...jogging device 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 bring the jogging device with him her This is to prevent anyone else from taking control of the robot with...

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Page 19: ...Note The retractable cable unit must be installed vertically with the cable outlet at the top and the connection cable to the controller pointing down see figure xx1300002384 Required equipment Note Equipment Retractable cable unit 3 pieces Attachment screws and washers The screw holes in the bracket has a diameter of 8 mm ABB recommends using M8 socket head cap screws and wide flat washers Screws...

Page 20: ... the FlexPendant Retractable Cable bracket in place and secure it with the screws 2 Limitation Do not install the FlexPendant Retractable Cable when a robot system is equipped with any of the following options 733 3 External panel 733 4 External panel small box 734 1 Panel cable 15 m 734 3 Panel cable 30 m 734 5 Panel cable 7 m 20 Product manual FlexPendant Retractable Cable 3HAC048816 001 Revisio...

Page 21: ...ith the cable outlet at the top and the connection cable to the controller pointing down see figure xx1600000629 CAUTION The retractable cable unit must be installed outside the paint booth The grounding cable must be connected Required equipment Note Equipment Retractable cable unit 2 pieces Attachment screws and washers The screw holes in the bracket has a diameter of 8 mm ABB recommends using M...

Page 22: ...ake holes for the bracket screws 1 Continue with connecting the cables see Connecting the cables on page 23 Hold the FlexPendant Retractable Cable bracket in place and secure it with the screws 2 22 Product manual FlexPendant Retractable Cable 3HAC048816 001 Revision B Copyright 2015 2016 ABB All rights reserved 2 Installation 2 2 Installing the bracket for paint robots Continued ...

Page 23: ...ontroller and the retractable cable unit WARNING The emergency stop button and the three position enabling device must be verified after the replacement This requires that the power is turned on Safety the area before the verification Connecting the connection cable Use this procedure to connect the connection cable between the controller and the retractable cable unit Note Action Disconnect the F...

Page 24: ... cable 2 xx1300002543 Push the tab fasteners and pull out the con nectors Connector Black Dish RJ45 Connector 3 Push the connectors for the retractable cable in place 4 xx1300002544 Put the strain relief in the recess 5 Put the housing cover in place 6 Tighten the screws Continues on next page 24 Product manual FlexPendant Retractable Cable 3HAC048816 001 Revision B Copyright 2015 2016 ABB All rig...

Page 25: ...riginal cable Note Action xx1600000631 Remove the screws on the back cover of the FlexPendant using a torx screw driver 1 xx1600000632 Pull the front cover out of the back cover and remove the connector between them 2 xx1600000633 Remove the cable nut of the back cover 3 Continues on next page Product manual FlexPendant Retractable Cable 25 3HAC048816 001 Revision B Copyright 2015 2016 ABB All rig...

Page 26: ... careful when pulling out the cables the space is limited 5 Connect the retractable cable Note Action xx1600000636 Push the teach pendant cables into the cable hole of the back cover 1 xx1600000637 Install the cable ring 2 Continues on next page 26 Product manual FlexPendant Retractable Cable 3HAC048816 001 Revision B Copyright 2015 2016 ABB All rights reserved 2 Installation 2 3 Connecting the ca...

Page 27: ...xx1600000632 Connect the cable between the front cover and the back cover 5 xx1600000631 Tighten the screws on the back cover using a torx screw driver 6 Tightening torque 0 6 Nm Continues on next page Product manual FlexPendant Retractable Cable 27 3HAC048816 001 Revision B Copyright 2015 2016 ABB All rights reserved 2 Installation 2 3 Connecting the cables Continued ...

Page 28: ...inal cable Note Action Remove the back housing cover of the teach pendant 1 See position E in the figure Disconnect the cable from the back cover 2 See position C in the figure Remove the grounding screw and clamp 3 See positions A and B in the figure Remove the screw clamp and plastic straps that attach the teach pendant cable 4 Continues on next page 28 Product manual FlexPendant Retractable Cab...

Page 29: ...gure Disconnect the main cable connector 7 Connecting the retractable cable CAUTION The color code of the wires in the retractable cable B do not match the colors of the original wires A xx1400000543 Wire color Color code Yellow YE Brown BN Green GN White WH Continues on next page Product manual FlexPendant Retractable Cable 29 3HAC048816 001 Revision B Copyright 2015 2016 ABB All rights reserved ...

Page 30: ...nd tighten the screw 4 See position A in the figure Put the retractable cable in position and at tach the clamps and screws 5 Adjust the length of the cable and put the gasket into the slot 6 See position B in the figure Safety the cable and wires with plastic straps 7 See position E in the figure Connect the connector of the teach pendant back cover 8 Put the housing cover in place Make sure that...

Page 31: ...3 months FlexPendant Retractable Cable Inspection 3 months Brake Inspection 6 months Removable carter Inspection 12 months Grounding cable Inspection 12 months Cable stopper handle Inspection When neededi FlexPendant Retractable Cable Cleaning When neededi Brushes Cleaning When neededi Cable Cleaning Every month Cleaning roller Cleaning and replacement i The interval depends on the working environ...

Page 32: ...able or the guarantee is not valid Inspection for standard robots Use the following procedure to inspect the complete FlexPendant Retractable Cable Note Action xx1300002384 Make sure that the holding screw of the bracket is tight 1 Examine the connectors and cabling to make sure they are securely attached and that the cabling is not damaged 2 Examine the integrity of all the external plastic eleme...

Page 33: ...ble retracts Examine that the entire cable length is retracted slowly 3 Pull out cable and release it Stop the re traction to make sure that the stop device is working 4 Repeat 4 times 7 Examine that there is sealing glue on all locking screws Do not remove the glue 8 Inspection for paint robots Use the following procedure to inspect the complete FlexPendant Retractable Cable Note Action xx1600000...

Page 34: ...table cable to make sure that the stop device is working that is that the cable stays pulled out There should be a click clack sound while pulling out the cable 2 Pull out the entire retractable cable and release it so the cable retracts Examine that the entire cable length is retracted slowly 3 Pull out cable and release it Stop the re traction to make sure that the stop device is working 4 Repea...

Page 35: ... Cable using a soft cloth and water or a mild cleaning agent 2 xx1400000781 Clean the brushes with a vacuum cleaner 3 Do s and don ts The section below specifies some special considerations when cleaning the FlexPendant Retractable Cable Always Always use ESD protection Always use cleaning equipment as specified above Any other cleaning equipment may shorten the life of paintwork rust inhibitors s...

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Page 37: ...n be damaged if the retraction is so strong that the operator loses his grip xx1300002383 Replacing the brake Use this procedure to replace the brake on the FlexPendant Retractable Cable Note Action Retract the cable so that all cable is inside the housing 1 Continues on next page Product manual FlexPendant Retractable Cable 37 3HAC048816 001 Revision B Copyright 2015 2016 ABB All rights reserved ...

Page 38: ...int robots xx1600000640 xx1400000545 Pull out the brake 3 Push the new brake in place 4 Safety the brake with the screws 5 38 Product manual FlexPendant Retractable Cable 3HAC048816 001 Revision B Copyright 2015 2016 ABB All rights reserved 4 Repair 4 1 Replacing the brake Continued ...

Page 39: ...rocedure to replace the cable stopper on the FlexPendant Retractable Cable Note Action Retract the cable leaving approximately 50 cm pulled out to make the cable stopper easily ac cessible 1 Remove the screws holding the cable stopper 2 Pull the pieces apart and remove the cable stop per 3 Assemble the new cable stopper around the cable 4 Safety the cable stopper with the screws 5 Product manual F...

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Page 41: ...bots Description Spare part number Part 3HAC049831 001 Cable stopper 10 meters Small version 3HAC049832 001 Brake 20 meters Large version 3HAC049832 002 Brake Spare parts for paint robots Description Spare part number Part 3HNA026564 001 Cable stopper handle 3HNA026568 001 Brake 3HNA026565 001 Cover A B 3HNA026566 001 Cleaning roller blue 3HNA026567 001 Cleaning roller red Product manual FlexPenda...

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Page 43: ...maintenance schedule 31 P pedestal installed on pedestal 12 protective equipment 11 protective wear 11 R responsibility and validity 9 retractable cable connecting IRC5 24 connecting IRC5P 25 connecting S4C S4C 28 S safety ESD 16 robot system 9 service 9 wrist strap 16 safety risk electric parts 14 installation 11 service work 11 voltage 14 safety zones 11 screws installing bracket for paint robot...

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Page 46: ... 344 400 ABB AS Robotics Discrete Automation and Motion Nordlysvegen 7 N 4340 BRYNE Norway Box 265 N 4349 BRYNE Norway Telephone 47 51489000 ABB Engineering Shanghai Ltd No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 www abb com robotics 3HAC048816 001 Rev B en ...

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