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4 Repair

4.4.2 Changing the gearbox

3HAC021111-001 Revision: B

4.4.2 Changing the gearbox

Axis 3’s gearbox is of a conventional type, manufactured with a high degree of precision and,

together with the gearbox for axes 1 and 2, forms a complete unit.

The gearbox is not normally serviced are adjusted.

Note! If the gearbox of any of the axes 1, 2 or 3 needs to be changed,the whole unit must be
changed.

See foldout 1 in the list of spare parts.

To dismantle

See this chapter, section Changing the gearbox on page 73.

Summary of Contents for IRB 1400

Page 1: ...Product manual Articulated robot IRB 1400 M2004 ...

Page 2: ......

Page 3: ...Product manual 3HAC021111 001 Revision B Articulated robot IRB 1400 M2000 M2004 ...

Page 4: ...s 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 per mission and contents thereof must not be imparted to a third party nor be used for any unau thorized purpose Contravention will be prosecute...

Page 5: ...nipulator s working range 29 1 3 8 Signal lamp optional 30 2 Installation and commissioning 31 2 0 1 Transporting and Unpacking 31 2 0 2 Stability Risk of Tipping 32 2 0 3 System CD ROM and Diskette 33 2 0 4 Transport Locking Device 34 2 1 On site installation 35 2 1 1 Lifting the Manipulator 35 2 1 2 Turning the Manipulator Inverted Suspension Application 36 2 1 3 Assembling the robot 37 2 1 4 Su...

Page 6: ...anging the tie rod 80 4 4 5 Dismantling the complete upper arm 81 4 5 Axis 4 84 4 5 1 Changing the motor 84 4 5 2 Changing the intermediate gear including sealing 85 4 5 3 Dismantling the drive gear on the tubular shaft 87 4 5 4 Dismantling the tubular shaft and changing bearings 89 4 6 Cabling and serial measuring board 90 4 6 1 Changing serial measuring boards 90 4 6 2 Changing the cabling in ax...

Page 7: ...libration position 138 7 Alternative calibration 141 7 0 1 Alternative calibration position 141 7 0 2 Alternative calibrating 142 7 0 3 New calibration position 143 7 0 4 New calibration offset 144 7 0 5 Retrieving offset values 145 8 Reference information IRB 1400 147 8 0 1 Introduction 147 8 0 2 Applicable Safety Standards 148 8 0 3 Unit conversion 149 8 0 4 Screw joints 150 8 0 5 Weight specifi...

Page 8: ...s 1 3 175 11 0 7 Sheet 106 Motor axes 4 6 176 11 0 8 Sheet 107 Feedback axes 4 6 177 11 0 9 Sheet 108 Customer connection Option 178 11 0 10 Sheet 109 Integrated wirefeed cabling Option 179 11 0 11 Sheet 110 Position indicator axis 1 180 11 0 12 Sheet 111 External connections Option 181 ...

Page 9: ... personnel maintenance personnel repair personnel Prerequisites A maintenance repair installation craftsman working with an ABB Robot must be trained by ABB and have the required knowledge of mechanical and electrical installation repair maintenance work Organization of chapters The manual is organized in the following chapters References Chapter Contents Safety service Safety information Installa...

Page 10: ... Description First edition Replaces previous product manual 3HAC 7617 1 Changes made in the material from the previous manuals Model M2004 implemented A Yaskawa motors included B Changes made in Prerequisites in section Owerview Oil change in section Maintenance ...

Page 11: ...l recommended repair procedures including spare parts Additional procedures if any calibration decommissioning Product manual reference information Reference information article numbers for documentation refered to in Product man ual procedures lists of tools safety standards Part list Foldouts or exploded views Circuit diagrams Softwaremanuals The software documentation consists of a wide range o...

Page 12: ...0 0 2 Product documentation M2000 10 3HAC021111 001 Revision B ...

Page 13: ...ures including spare parts Additional procedures if any calibration decommissioning Product manual reference information Reference information article numbers for documentation refered to in Product man ual procedures lists of tools safety standards Part list Foldouts or exploded views Circuit diagrams RobotWare manuals The following manuals describe the robot software in general and contain refer...

Page 14: ...rouble shooters and include Operating Manual IRC5 with FlexPendant Operating Manual RobotStudioOnline Trouble shooting Manual for the controller and manipulator Miscellaneous A number of manuals provide generic descriptions of the robot and robot system These include Robot fundamentals describing the fundamental aspects functions concept and similar of a robot system to provide a basic understandi...

Page 15: ...the robot system The dangers are split into different categories Safety risks related to gripper end effector Safety risks related to tools workpieces Safety risks related to pneumatic hydraulic systems Safety risks during operational disturbances Safety risks during installation and service Risks associated with live electric parts 3 Safety actions details actions which may be taken to remedy or ...

Page 16: ...re observed and that the safety devices necessary to protect people working with the robot system have been designed and installed correctly Personnel working with robots must be familiar with the operation and handling of the indus trial robot described in the applicable documents e g User s Guide and Product Manual Connection of external safety devices Apart from the built in safety functions th...

Page 17: ...on B 15 1 1 2 Limitation of Liability General Any information given in this information product regarding safety must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions have been complied with ...

Page 18: ...uments which contain useful information Documents Type of information Detailed in document Section Installation of safety devices Product manual for the manipulator Installation and com missioning Changing robot modes User s Guide Start up Restricting the working space Product manual for the manipulator Installation and com missioning ...

Page 19: ...rvice 1 2 1 Safety risks related to gripper 3HAC021111 001 Revision B 17 1 2 Safety risks 1 2 1 Safety risks related to gripper CAUTION Ensure that a gripper is prevented from dropping a workpiece if such is used ...

Page 20: ...It must be possible to turn off tools such as milling cutters etc safely Make sure that guards remain closed until the cutters stop rotating It should be possible to release parts by manual operation valves Safe design Grippers end effectors must be designed so that they retain workpieces in the event of a power failure or a disturbance of the controller ...

Page 21: ...aulic systems Residual energy Residual energy may be present in these systems so after shutdown particular care must be taken The pressure in pneumatic and hydraulic systems must be released before starting to repair them 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 fr...

Page 22: ...ionally and in accordance with the applicable safety regulations Care must be taken at all times Qualified per sonnel Remedial action must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts Extraordinary risks If the working process is interrupted extra care must be taken due to risks other than ...

Page 23: ...ive 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 release...

Page 24: ...power from an exter nal 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 pro cess The external voltage connected to the control cabinet remains live ...

Page 25: ...losure 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 malfunctio...

Page 26: ...1 Safety service 1 3 2 Fire extinguishing 24 3HAC021111 001 Revision B 1 3 2 Fire extinguishing NOTE Use a CARBON DIOXIDE CO 2 extinguisher in the event of a fire in the robot manipula tor or controller ...

Page 27: ...the manipulator or on an optional external brake release unit How to release the brakes is detailed in section Manually releasing the brakes in the Product manual for the manipulator The manipulator arm may be moved manually on smaller robot models but larger models may require using an overhead crane or similar Increased injury Before releasing the brakes make sure that the weight of the arms doe...

Page 28: ... The function of each axis motor holding brakes may be checked as detailed below 1 Run each manipulator axis to a position where the combined weight of the manip ulator 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...

Page 29: ...peed 250 mm s 3HAC021111 001 Revision B 27 1 3 5 Risk of disabling function Reduced speed 250 mm s Note Do not change Transm gear ratio or other kinematic parameters from the Teach Pendant Unit or a PC This will affect the safety function Reduced speed 250 mm s ...

Page 30: ...hed 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 e...

Page 31: ...trol panel The robot s speed is limited to max 250 mm s when the operating mode selector is in posi tion 250 mm s This should be the normal position when entering the working space The position 100 full speed may only be used by trained personnel who are aware of the risks that this entails Pay attention to the rotating axes of the manipulator Keep a distance to the axes in order not to get entang...

Page 32: ...w fixed light can be mounted on the manipulator as a safety device The signal lamp is required on an UL UR approved robot Function The lamp is active in MOTORS ON mode Further information Further information about the MOTORS ON MOTORS OFF mode may be found in the chap ter Description Control System in the Product manual for the controller ...

Page 33: ...installation personnel and should conform to all national and local codes When you have unpacked the robot check that it has not been damaged during trans port or while unpacking Operating conditions Storage conditions If the equipment is not going to be installed straight away it must be stored in a dry area at an ambient temperature between 25 C and 55 C When air transport is used the robot must...

Page 34: ... 2 0 2 Stability Risk of Tipping When the manipulator is not fastened to the floor and standing still the manipulator is not stable in the whole working area When the arms are moved care must be taken so that the centre of gravity is not displaced as this could cause the manipulator to tip over ...

Page 35: ...0 3 System CD ROM and Diskette The system CD ROM and the manipulator parameter disk are delivered with the robot system See section RobotWare CD ROM in the Product manual for the controller Art no for the manual is detailed in section Document references in the Product manual reference information ...

Page 36: ... 3HAC021111 001 Revision B 2 0 4 Transport Locking Device At delivery axis 2 lower arm is equipped with a transport locking device see figure below Remove the transport locking device before operating the robot Transport Locking Device Axis 2 Transport locking device ...

Page 37: ...ft the manipulator is to use lifting straps and a traverse crane Attach the straps to the special eye bolts on the gear boxes for axes 2 and 3 see figure below The lifting strap dimensions must comply with the applicable standards for lifting Never walk under a suspended load Lifting the Manipulators using a Traverse Crane IRB 1400H IRB 1400 Lifting eye Lifting eye ...

Page 38: ...recommended when the manipulator is to be turned for inverted mounting ABB article number 3HAB 3397 1 The tool is attached to the outsides of the gearboxes for axes 2 and 3 using six M8x25 bolts and washers Tightening torque 25 Nm The manipulator is lifted with a fork lift or a crane see figure below Note also the positions of the arm system Turning the Manipulator Fork lift M8x25 x3 on both sides...

Page 39: ...lted down by means of three M16 bolts Two guide sleeves ABB art no 2151 0024 169 can be fitted to the two rear bolt holes to allow the same robot to be re mounted without having to re adjust the program When bolting a mounting plate or frame to a concrete floor follow the general instructions for expansion shell bolts The screw joint must be able to withstand the stress loads defined in this chapt...

Page 40: ...unting The method for mounting the manipulator in a suspended position is basically the same as for floor mounting With inverted installation make sure that the gantry or corresponding structure is rigid enough to prevent unacceptable vibrations and deflections so that optimum perfor mance can be achieved ...

Page 41: ...n be used for adapting the robot tuning to a non optimal foundation IRB 1400 and IRB 1400H Fxy and Mxy are vectors that can have any direction in the xy plane The Directions of the Stress Forces Force Endurance load in operation Max load emergency stop Fxy 1500 N 2000 N Fz upright 2800 500 N 2800 700 N Fz suspended 2800 800 N 2800 1000 N Torque Endurance load in operation Max load emergency stop M...

Page 42: ...rate the manipulator is illustrated in the figures below The working range for axis 1 is 170 NB There are no software or mechanical limits for the working space under the base of the manipulator Manipulator The Amount of working Space required for the Manipulator 1051 150 254 1282 733 1645 770 1127 1221 150 Axis 1 170o Axis 1 145o 135o 1195 1008 1444 150 511 1793 50 ...

Page 43: ...eful not to interchange the 24V and 0V pins If they are mixed up damage can be caused to electrical components Connection of External Voltage to enable Engagement of the Brakes External power must be connected according to Figure Incorrectly connected power can release all brakes causing simultaneously movement of all axes When the controller or the voltage supply is connected as illustrated above...

Page 44: ...ited both mechanically and using software Installation of an optional extra stop for the main axes 1 2 and 3 is described below Limiting the working space using software is described in the System Parameters in the User s Guide Axis 1 The range of rotation for axis 1 can be limited mechanically by fitting extra stop lugs to the base see Figure Instructions for necessary machining and mounting are ...

Page 45: ...xis 2 The working range of axis 2 can be limited mechanically by fitting extra stop lugs to the under arm see Figure The lugs limit the arm movements in intervals of 20 20 1 lug 40 2 lugs etc Instructions for doing this are supplied with the kit Mechanically limiting Axis 2 Under arm Extra stop lugs ...

Page 46: ... B Axis 3 The working range of axis 3 can be limited mechanically by fitting a stop lug under the parallel arm see Figure Axis 3 is limited upwards to 0 or 10 degrees above the horizontal plane Instructions for doing this are supplied with the kit Extra Stop Lug for limiting Axis 3 Extra stop lug ...

Page 47: ...ulator without first consulting ABB Mounting Holes for Customer Equipment The mechanical Interface Mounting Flange 135 Mounting holes for equipment M8 2x Depth 16 120 A A Mounting holes for equipment both sides M8 3x R 75 Depth 16 15o 120o 3x IRB 1400 120 135 for equipment Depth 16 Mounting holes M8 2x A A IRB 1400H D 25 D 50 H8 h8 45o D 6 H7 M6 4x R 20 A A 4 10 A A 2 0 05 0 3 B C B 0 06 B 4x 90o ...

Page 48: ...s 46 3HAC021111 001 Revision B 2 1 10 Loads Regarding load diagram permitted extra loads equipment and locations of extra loads equipment see the Product Specification for IRB 1400 The loads must also be defined in the soft ware see User s Guide ...

Page 49: ...ra equipment on the manipulator there are cables integrated into the manipulator s cabling Option 042 Control cabling to arc welding wire feeder is integrated into the manipulator s cabling This option 042 is not available for IRB 1400H Number of signals 12 signals 49V 500 mA Connector on upper arm FCI 12 pin UT001412SHT Connector on robot base FCI 12 pin UT001412PHT Control signals Number of sign...

Page 50: ... s recommended contact set for connector R2 CS has Art No 3HAC 12583 1 ABB s recommended contact set for connector R1 CS has Art No 3HAC 12493 1 The complete contact set option contains Pins for cable area 0 13 0 25 mm2 Shrinking hose bottled shaped Shrinking hose angled which corresponds to item 4 5 6 7 8 and 9 according to Figure FCI Connector R2 CS R1 CS Air only option 041 R2 CP only option 04...

Page 51: ...154 mm2 Max voltage 50 V AC DC Max current 250 mA Signal Name Customer Terminal Controller optional Customer Contact on Upper Arm R2 Customer Contact on Manipulator Base Cable not supplied CSA XT5 1 R2 CS A R1 CS A CSB XT5 2 R2 CS B R1 CS B CSC XT5 3 R2 CS C R1 CS C CSD XT5 4 R2 CS D R1 CS D CSE XT5 5 R2 CS E R1 CS E CSF XT5 6 R2 CS F R1 CS F CSG XT5 7 R2 CS G R1 CS G CSH XT5 8 R2 CS H R1 CS H CSJ...

Page 52: ...stallation and commissioning 2 2 2 Connection of Extra Equipment to the Manipulator 50 3HAC021111 001 Revision B Connection of Signal Lamp on Upper Arm Option Location of Signal Lamp Signal lamp R3 H1 R3 H2 ...

Page 53: ...s and preventative maintenance must be carried out at given periodical intervals see the table below The exterior of the robot should be cleaned as required Use a vacuum cleaner or wipe it with a cloth Compressed air and harsh solvents that can damage the sealing joints bearings lacquer or cabling must not be used Check that the sealing joint and cable bushings are really airtight so that dust and...

Page 54: ...ed 3 See section Changing the battery in the measuring system on page 56 Equipment Check twice year Check once year Maintenance every 2000 hrs or 6 months Maintenance every 4000 hrs or 1 year Others Mechanical stop axis 1 X1 Cabling X2 Gears axis 1 4 Maintenance free Lubrication of spring brackets X Lubrication of gears axis 5 6 X Replacement of accumulator for measuring sys tem 3 years3 ...

Page 55: ...20 art No 1171 2016 604 corresponds to Oil volume BP floor mounted robot Oil volume BP suspended robot BP Energol GR XP 320 Castrol Alpha SP 320 Esso Spartan EP 320 Klüber Lamora 320 Optimol Optigear 320 Shell Omala Oil 320 Texaco Meropa 320 Statoil Loaway EP Gearbox Volume Axis 1 2 000 ml Axis 2 and 3 1 700 ml Axis 4 30 ml Gearbox Volume Axis 1 2 700 ml Axis 2 and 3 1 700 ml Axis 4 30 ml ...

Page 56: ...axes 5 and 6 Grease is pressed through the 3 nipples 1 see Figure The tip nozzle of the greasing gun should be of type Orion 1015063 or equivalent Volume 2 ml 0 00053 US gallon Greasing Positions for Axes 5 and 6 Type of grease ABB s art No 3HAB 3537 1 corresponds to Shell Alvania WR2 1 ...

Page 57: ...g spring brackets 3HAC021111 001 Revision B 55 3 1 3 Lubricating spring brackets There are four lubrication places located over and under the two balancing springs Type of grease ABB s art No 3HAA 1001 294 corresponds to Optimol PDO ...

Page 58: ...ls from the serial measuring board and cut the clasps that keep the battery unit in place Install a new battery with two clasps and connect the terminals to the serial mea suring board Refit the serial measurement board flange cover and connections The Ni Cd battery takes 36 hours to recharge the mains supply must be switched on during this time The Battery is located Inside the Base under the Fla...

Page 59: ...f batteries measured at power off Exchange of the battery is done according to the beginning of this section User type Exchange 3 cell Exchange 6 cell 1 Vacation 4 weeks power off Every 5 years Every 5 years1 2 Weekend power off user type 1 Every 2 years Every 4 years 3 Nightly power off user type 1 and 2 Every year Every 2 years Min Max Ni Cd 7 0 V 8 7 V Lithium 7 0 V ...

Page 60: ...1 001 Revision B 3 1 5 Checking the mechanical stop axis 1 Check regularly as follows That the stop pin is not bent If the stop pin is bent it must be replaced by a new one See section Replacing the mechanical stop on page 71 The article number of the pin is 3HAB 3258 1 ...

Page 61: ... both automatic and manual operation The manipulator has 6 axes which makes its movements very flexible Axis 1 rotates the manipulator Axis 2 provides the lower arm s reciprocating motion The lower arm together with the parallel arm and the parallel bracket forms a parallelogram relative to the upper arm The parallel bracket is mounted on bearings in the parallel arm and in the upper arm Axis 3 ra...

Page 62: ...ntenance jobs It may be necessary to use conventional tools such as sockets and ratchet spanners etc or special tools depending on the type of servicing Conventional tools are not discussed in this manual since it is assumed that maintenance staff have sufficient basic technical competence Maintenance jobs which require the use of special tools are on the other hand described in this manual Foldou...

Page 63: ...several parts which are too heavy to lift manually As these parts must be moved with precision during any maintenance and repair work it is important to have a suitable lifting device available The robot should always be switched to MOTORS OFF before anybody is allowed to enter its working space ...

Page 64: ...directly affects the service life of the bearing Greasing Bearings 1 Bearings must be greased after they are fitted Extreme cleanliness is necessary throughout High quality lubricating grease such as Shell Alvania WR2 ABB s art No 3537 1 should be used 2 Grooved ball bearings should be greased on both sides 3 Tapered roller bearings and axial needle bearings should be greased when they are split 4...

Page 65: ...ic Seals 1 Check the flange surfaces The surface must be even and have no pores The evenness can be easily checked using a gauge on the fitted joint without sealing compound 2 The surfaces must be even and free from burr dust caused by incorrect machin ing If the flange surfaces are defective they must not be used as they will cause leakage 3 The surfaces must be cleaned properly in the manner rec...

Page 66: ... that are tightened to a specified torque are treated with Gleitmo When handling screws treated with Gleitmo protective gloves of nitrile rubber type should be used Screws treated with Gleitmo can be unscrewed and screwed in again 3 4 times before the slip coating disappears Screws can also be treated with Molycote 1000 When screwing in new screws without Gleitmo these should first be lubricated w...

Page 67: ...d head property class 4 8 Screws with hexagon socket head property class 8 8 Dimension Tightening Torque Nm Without Oil M2 5 0 25 M3 0 5 M4 1 2 M5 2 5 M6 5 0 Dimension Tightening Torque Nm Tightening Torque Nm Without Oil With Oil M3 1 1 M4 2 2 M5 5 5 4 M6 10 9 M8 24 22 M10 48 45 M12 83 78 M16 200 190 M20 410 400 M24 750 740 ...

Page 68: ...e engaged some play can be felt The play that can be felt is between the brake disk and the motor shaft not in the gearbox itself This is because the rotating brake disk is connected to the motor shaft by splines This is why the brakes must be disengaged before testing for play in the gearboxes and wrist The brakes are disengaged by pressing the enable button on the teach pendant The play in the b...

Page 69: ...or before removing it 5 Loosen the motor by unscrewing 1 10 To assemble 1 Check that the assembly surfaces are clean and the motor unscratched 2 Release the brake apply 24V DC to terminals 7 and 8 in the 4 MP1 connector 3 Install the motor tighten screws 1 10 using a torque of approximately 2 Nm Note the position of the motor 4 Adjust the motor in relation to the gear in the gearbox 5 Screw the 3H...

Page 70: ...ng boards according to section Changing the cabling in axes 1 2 and 3 on page 91 and section Changing serial measuring boards on page 90 3 Remove the tie rod as described in this chapter section Changing the tie rod on page 80 4 Remove the parallel arm according to section Dismantling the parallel arm on page 79 5 Remove the balancing springs in accordance with section Dismantling the bal ancing s...

Page 71: ...ng the parallel arm on page 79 8 Replace the upper arm as described in section Dismantling the complete upper arm on page 81 9 Replace the cabling in accordance with section Changing the cabling in axes 1 2 and 3 on page 91 and section Changing serial measuring boards on page 90 10 Replace the tie rod as described in section Changing the tie rod on page 80 11 Replace the balancingd springs accordi...

Page 72: ...xis 1 optional See foldouts 3 and 4 6 for IRB 1400H in the list of spare parts To dismantle 1 Remove the flange plate 4 138 2 Loosen the connector R1 LS 3 Dismantle the two limit switches 3 174 4 Loosen the cables from the switches 5 Remove the cabling through the base To assemble 1 Assemble in the reverse order ...

Page 73: ...evision B 71 4 2 4 Replacing the mechanical stop See foldout 1 in the list of spare parts If the stop pins are bent they must be replaced Remove the old stop pin Fit the new pin as illustrated in Figure below Fit the new Pin as illustrated Loctite 242 or 243 68 1 ...

Page 74: ...osition of the motor before removing it 5 Loosen the motor by unscrewing 1 10 N B The oil will start to run out To assemble 1 Check that the assembly surfaces are clean and the motor unscratched 2 Release the brake apply 24 V DC to terminals 7 and 8 on the R3 MP2 connector 3 Install the motor tighten screws 1 10 to a torque of approximately 2 Nm Note the position of the motor 4 Adjust the motor in...

Page 75: ... with a high degree of precision and together with the gearbox for axes 1 and 3 forms a complete unit The gearbox is not normally serviced or adjusted Note If the gearbox of any of the axes 1 2 or 3 needs to be changed the whole unit must be changed See foldout 1 in the list of spare parts To dismantle See section Changing the gearbox on page 68 ...

Page 76: ...ssemble 1 Transfer the damping element and calibration marking to the new lower arm 2 Lift the lower arm into position 3 Fix the lower arm to gear 2 using screws 1 13 and tighten them to a torque of 68 Nm 10 To prevent clicking during operation of the robot grease the bearing seating of the parallel arm in the lower arm 4 Replace the parallel arm as described in section Dismantling the parallel ar...

Page 77: ... page 80 2 Unscrew screws 13 which hold the parallel arm to gear 3 3 Remove the bearings from the parallel arm To assemble 1 Fit new bearings to the parallel arm 2 Replace the parallel arm using screws 13 and tighten to a torque of 68 Nm 10 3 Attach the upper bracket of the tie rod as specified in section Changing the tie rod on page 80 4 Calibrate the robot according to section Calibration inform...

Page 78: ... be released manually 4 Unscrew 2 65 in the upper bracket of the spring 5 Remove the springs To assemble 1 Before installing new springs make sure that the distance between the attach ment points is correct see Figure Lock the link heads using Loctite 242 or 243 Distance between the Attachment Points 2 Lubricate the link heads with grease 3 Attach the springs to the top bracket using screws 2 65 a...

Page 79: ...Loosen the motor by unscrewing 1 10 N B The oil will start to run out To assemble 1 Check that the assembly surfaces are clean and the motor unscratched 2 Release the brake apply 24 V d c to terminals 7 and 8 on the 4 MP1 connector 3 Install the motor tighten screws 1 10 to a torque of approximately 2 Nm Note the position of the motor 4 Adjust the motor in relation to the drive in the gearbox 5 Sc...

Page 80: ...a high degree of precision and together with the gearbox for axes 1 and 2 forms a complete unit The gearbox is not normally serviced are adjusted Note If the gearbox of any of the axes 1 2 or 3 needs to be changed the whole unit must be changed See foldout 1 in the list of spare parts To dismantle See this chapter section Changing the gearbox on page 73 ...

Page 81: ...ge 80 2 Unscrew screws 13 which fix the parallel arm to gear 3 3 Remove the bearings from the parallel arm To assemble 1 Fit the bearings on the parallel arm 2 Replace the parallel arm using screws 13 and tighten to a torque of 68 Nm 10 3 Attach the upper bracket of the tie rod according to section Changing the tie rod on page 80 4 Calibrate the robot as specified in section Calibration informatio...

Page 82: ... the lower bracket 7 Carefully tap the rod off the shaft 8 Change the bearings To assemble 1 Fit bearings on the parallel arm 2 Make sure you replace the rod the correct way up See foldout 1 1 1 3 Install grommets 3 x 68 and 1 x 75 Note The grommet 75 is bevelled and must be inserted the right way up in the lower bearing 4 Place the lower bearing of the tie rod on the parallel arm 5 Screw in screw...

Page 83: ...l the axes off To assemble 1 Raise the upper arm into assembly position 2 Install shaft spindles 59 both sides use two temporary screws M10x90 3 Insert bearings 60 both sides using tool 3HAB 1200 1 and screws 65 4 Detach the tool and tighten the screws once more only to prevent rotation of the axis when the KM nut is tightened N B Assemble the same side as axis 2 first 5 Mount two washers 63 and c...

Page 84: ...of the tie rod as specified in section Changing the tie rod on page 80 12 Replace the balancing springs as described in section Dismantling the balancing springs on page 76 not valid for IRB 1400H 13 Reconnect the connection boxes and the cabling 14 Calibrate the robot in accordance with section Calibration information on page 131 15 Undo the KM nut on the axis 2 side just to be able to adjust the...

Page 85: ...mantling the complete upper arm 3HAC021111 001 Revision B 83 Calibration Mark for Axis 3 Tools pressing tool for bearings 3HAB 1200 1 105o Measuring instrument 3HAB 1205 1 Withdrawing tool for shaft spindles 3HAB 1259 1 ...

Page 86: ... motor by unscrewing 8 23 To assemble 1 Check that the assembly surfaces are clean and the motor unscratched 2 Put O ring 8 21 on the motor 3 Release the brake apply 24 V DC to terminals 7 and 8 on the R3 MP4 connector 4 Install the motor tighten screws 8 23 to a torque of approximately 2 Nm Note the position of the motor 5 Adjust the position of the motor in relation to the drive in the gearbox 6...

Page 87: ...r 17 using screws 18 and tighten to a torque of 8 3 Nm 10 N B Do not forget to insert shims 14 15 16 under the drive gear 5 Tighten screws 12 to a torque of approximately 5 Nm 6 Bend the pinion towards the large drive gear and then rotate it around the tubular shaft a couple of times so that the clearance in the gears can adjust itself in rela tion to the highest point of the large drive gear 7 Th...

Page 88: ...4 5 2 Changing the intermediate gear including sealing 86 3HAC021111 001 Revision B Tightening torque Screws for the large drive gear item 18 8 3 Nm 10 Screws for the intermediate gear of axis 4 item 12 20 Nm 10 ...

Page 89: ...crews 18 that hold the large drive gear 17 and then dismantle it N B Put the shims from under the drive gear in a safe place To assemble Shim between drive gear 17 and the rear bearing 3 Shim thickness B A 0 05 mm see Figure Measuring the Shim Thickness of the Drive Gear of Axis 4 1 Install the drive gear using screws 18 and tighten to a torque of 8 3 Nm 10 N B Do not forget the shims 2 Screw scre...

Page 90: ...mechanism as specified in section Dismantling the complete drive mechanism of axes 5 and 6 on page 95 8 Mount the wrist according to section Dismantling the wrist on page 94 9 Calibrate the robot as specified in section Calibration information on page 131 Tightening torque Screws of drive gear item 18 8 3 Nm 10 ...

Page 91: ...aft on page 87 2 Push out the tubular shaft To assemble 1 Fit a new bearing 3 on the tubular shaft using tool 6896 134 V 2 Push the tube into the housing of the upper arm 3 Insert the rear bearing 3 using tool 6896 134 JB 4 Mount the drive gear in accordance with section Dismantling the drive gear on the tubular shaft on page 87 5 Calibrate the robot as specified in section Calibration information...

Page 92: ...asuring board 4 6 1 Changing serial measuring boards See foldout 4 in the list of spare parts To dismantle 1 Remove flange plate 138 2 Cut tie around bundle 144 3 Unscrew the serial measuring board 135 using screws 7 4 Remove the board and loosen the contacts To assemble 1 Assemble in the reverse order ...

Page 93: ...ntle 1 Remove the cover of the motors 2 Remove the flange plate 4 138 3 Loosen connectors R1 MP R2 FB1 3 4 Cut tie around bundle and detach the cable brackets 5 Detach the cable guides 3 104 and 105 and undo screws 3 149 6 Loosen the connectors in the motors 7 Disconnect the connection boxes in the motors 8 Feed the cabling up through the middle of axis 1 To assemble 1 Assemble in the reverse orde...

Page 94: ...6 including customer connector R1 CS if there is one and the air hose 4 Detach the cable guides 3 104 105 5 Loosen the cable brackets 3 149 between gears 2 and 3 and cut the tie around them 6 Feed the cabling and air hose up through axis 1 7 Loosen the cable bracket on the lower arm and undo screws 3 147 8 Undo screw 2 74 which fixes the shaft of the tie rod 9 Disconnect the connection boxes in th...

Page 95: ... 6 is a complete unit comprising drive units and gears It is of such a complex design that it is not normally serviced on site but should be sent to ABB to be serviced ABB recommends its customers to carry out only the following servicing and repair work on the wrist Grease the wrist according to the table in section Maintenance Intervals on page 52 ...

Page 96: ...eeve through the hole 4 Disconnect the clamping sleeve 5 Undo screws 1 53 and remove the wrist To assemble 1 Mount the wrist tighten screws 1 53 to a torque of 8 3 Nm 10 Note The grease nipple on the tilt house should be pointing against the base when the axis 4 is in the calibration position 2 Screw the clamping sleeves together using screws 9 15 3 Replace the plastic plugs 4 Calibrate the robot ...

Page 97: ... connectors on the motors of axes 5 and 6 3 Undo screws 8 29 4 Squeeze the drive shafts 9 1 together at the tip of the tubular shaft in order that they can pass through the tube 5 Pull out the complete drive mechanism of axes 5 and 6 To assemble 1 Install the drive mechanism in the tubular shaft 2 Tighten screws 8 29 to a torque of 8 3 Nm 10 3 Insert the cabling 4 Mount the wrist as described in s...

Page 98: ...lts 2 Mount the plate 7 using screws 9 NOTE Do not forget the nuts of the motors 3 Install the motors NOTE There are two different types of motors Elmo and Yaskawa The different motors are not compatible Make sure to replace with correct model 4 Push the motors in sideways to tension the belts Use tool 3HAA 7601 050 Tighten screws 9 to a torque of 4 1 Nm 5 Rotate the drive shafts Check the tension...

Page 99: ...24 Nm and reading the play This correspond to play of 0 27 mm on a radius of 200 mm when the load is F 40 N and 2 N on radius 120 mm See Figure Measuring Play in Axis 5 Axis 6 The maximum accepted play in axis 6 is 12 8 arc minutes when loading axis 6 with a moment of 4 2 Nm in one direction unloading to 0 2 Nm and start measuring the play loading in the other direction with 4 2 Nm unloading to 0 ...

Page 100: ...ulator The cables are connected to the motor units by connectors The drive shaft of the electric motor forms a part of the gearbox of the manipulator axis A brake operated electromagnetically is mounted on the rear end of the motor shaft and a pinion is mounted on its drive end The brake releases when power is supplied to the electro magnets The commutation value of the motors is 1 570800 NOTE The...

Page 101: ...must be calibrated if any of the below occurs Changed resolver values Calibrate the measurement system carefully as detailed in section Calibration on page 110 if any of the resolver values have changed This may occur when parts affecting the calibration position are replaced on the robot Contents of the revolution counter memory are lost Calibrate the system roughly as detailed in section Updatin...

Page 102: ... related actions may be performed Step Action Note 1 Check that all required hardware is avail able for calibrating the robot Required hardware is specified in the calibrating procedures for each axis 2 Manually run the robot axes to a position close to the correct calibration position Use the calibration scales fitted to each robot axis to locate this position These are shown in the section Cali ...

Page 103: ...ipheral equipment during calibration Fitted tools and similar will cause erroneous calibration positions Calibration order The axes must be adjusted in increasing sequence i e 1 2 3 4 5 6 Location of sensors The positions where the calibration sensor and reference sensor should be fitted during cali bration are specified in Positions and directions of sensor on page 106 ...

Page 104: ...ition to render the enabling device operative and to block operation from a computer link or remote control panel The robot s speed is limited to max 250 mm s when the operating mode selector is in position 250 mm s This should be the normal position when entering the working space The posi tion 100 full speed may only be used by trained personnel who are aware of the risks that this entails Pay a...

Page 105: ...5 Calibration M2000 5 2 1 Calibration scales and correct axis position 3HAC021111 001 Revision B 103 Calibration scales IRB 1400 The illustration below shows the calibration scale positions en0200000272 ...

Page 106: ... must consistently be run towards the calibration position in the same direction in order to avoid position errors caused by backlash in gears etc Positive directions are shown in the figure below This is normally handled by the robot calibration software Note The figure shows an IRB 7600 but the positive direction is the same for all robots xx0200000089 2 4 6 3 1 5 ...

Page 107: ...n marks for that particu lar axis align correctly If they do not update the revolution counters Calibration marks are shown in section Calibration scales and correct axis position on page 102 Detailed in section Updating the revolution counters on page 127 3 Check that resolver offset values in the system parameters match those on the parameter disk delivered with the robot or those established wh...

Page 108: ...r on page 124 These reference values are then used to calibrate the axes of the manipulator The reference sensor and the calibration sensor is consequently the same sensor used at dif ferent locations When using the sensor as a reference at the base it is fitted to a sensor fixture together with a sensor plate as shown in the figure below The sensor has different directions depending on which axis...

Page 109: ...tion M2000 5 2 4 Positions and directions of sensor 3HAC021111 001 Revision B 107 D Axis 4 E Axis 3 F Direction for sensor at reference plane axis 2 3 and 5 G Direction for sensor at reference plane axis 4 and 6 ...

Page 110: ...etailed in Installation of sensor on page 109 4 Calibrate the robot as detailed in the instruction for each axis respectively in the sec tion Calibration on page 110 Levelmeter 2000 The Levelmeter 2000 is shown for reference below xx0200000083 Select filter type A Measuring unit B Selection pointer C Sensor connection Z E R O S E LE C T H O L D S E N D E S C E N T E R O N M O D E W YL ER L E V E L...

Page 111: ...tration 1 Press ON MODE until the dot flashes under UNIT Shown in the figure Level meter 2000 on page 108 2 Press ENTER 3 Press ZERO SELECT until mm m flashes Two decimals 0 00 are shown on the display 4 Press ENTER Step Action Info Illustration 1 Connect the sensor to the Sensor connection point Shown in the figure Level meter 2000 on page 108 2 Press ON MODE 3 Press ON MODE until the dot flashes...

Page 112: ...n the figure below The special calibration equipment is fitted to the base of the manipulator as shown in the figure below xx0400001018 Required equipment A Guide oin ini gearbox B Calibration tool C Measuring pin axis 1 Equipment etc Art no Note Isopropanol 1177 1012 208 Used to clean the reference surface Calibration tool axis1 3HAB 1378 1 Measuring pin 6808 001 GR ...

Page 113: ...move the cover plate on the reference surface on the base of the manipulator 3 Clean the surface with etanol and deburr it 4 Fit the calibration tool axis 1 on the guide pin underneath the gearbox 5 Release the brakes and move the manipulator manually so that the measuring pin can be placed in the guide hole on the base 6 Update axis 1 only using the TPU Described in Fine calibration procedure on ...

Page 114: ...pulator lower arm Isopropanol 1177 1012 108 For cleaning the attachment points Other tools and proce dures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Step Action Illustration 1 Reset the levelmeter and the sensor for cal ibration of axis 2 Detailed in section Resetting of Level meter 2000 and s...

Page 115: ...easurement on the level meter 0 0 40 mm m 6 Update only axis 2 Detailed in section Fine calibration procedure on TPU on page 122 7 Remove the sensor 8 Refit the cover plate on the calibration sur face on the manipulator lower arm Refit also the cover plate on the reference surface at the base if no further calibration is per formed 9 Check the calibration according to section Post calibration proc...

Page 116: ...apter Isopropanol 1177 1012 108 For cleaning the attachment points Other tools and proce dures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Step Action Illustration Info 1 Clean the manipulator turning disk with isopro panol Art no is specified in Required equipment on page 114 2 Fit the sync ada...

Page 117: ...tick to the correct position as indicated by the levelmeter Tip Reduce the jogging velocity in order to easily position the axis as close to zero as possible Correct measurement on the lev elmeter 0 0 40 mm m 8 Update only axis 3 Detailed in section Fine calibration procedure on TPU on page 122 9 Remove the sensor 10 Check the calibration according to section Post calibration procedure on page 129...

Page 118: ...nc adapter Isopropanol 1177 1012 108 For cleaning the attachment points Other tools and proce dures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Step Action Illustration 1 Clean the manipulator turning disk with isopropanol Art no is specified in Required equipment on page 116 2 Fit the sync adap...

Page 119: ...e jogging velocity in order to easily position the axis as close to zero as possible Correct measurement on the levelmeter 0 0 80 mm m 8 Update only axis 4 Detailed in section Fine cal ibration procedure on TPU on page 122 9 Remove the sensor 10 Select Calib CAL4B The axis 4 moves 90º to a correct position 11 Update only axis 4 Detailed in section Fine cal ibration procedure on TPU on page 122 12 ...

Page 120: ...opropanol 1177 1012 108 For cleaning the attachment points Other tools and proce dures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Step Action Illustration 1 Clean the manipulator turning disk with isopropanol Art no is specified in Required equipment on page 118 2 Fit the sync adapter to the tu...

Page 121: ... the correct position as indicated by the levelmeter Tip Reduce the jogging velocity in order to easily position the axis as close to zero as possible Correct measurement on the levelmeter 0 0 80 mm m 8 Update only axis 5 Detailed in section Fine cali bration procedure on TPU on page 122 9 Remove the sensor 10 Check the calibration according to section Post cali bration procedure on page 129 or co...

Page 122: ...108 For cleaning the attachment points Other tools and proce dures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Step Action Illustration 1 Calibrate axis 5 Detailed in section Calibra tion axis 5 on page 118 2 Reset the levelmeter with correct orientation of the sensor for calibration of axis 6 D...

Page 123: ... Update only axis 6 Detailed in section Fine cali bration procedure on TPU on page 122 6 Remove the sensor 7 Check the calibration according to section Post cal ibration procedure on page 129 8 Refit the cover plate on the reference surface at the base Step Action Illustration ...

Page 124: ...ibration from the View menu The Calibration window appears If multiple units are con nected to the robot they will be listed in the win dow xx0100000201 The calibration status can be any of the following Synchronized all axes are calibrated and their positions are known The unit is ready for use Revolution Counter not updated all axes are fine calibrated but one or more of the axes has a counter t...

Page 125: ... window appears xx0100000204 6 Select the desired axis and press Incl to include it it will be marked with an x or press All to select all axes 7 Press OK when all axes that are to be updated are marked with an x CANCEL returns to the Calibration window 8 Press OK again to con firm and start the update CANCEL returns to the Fine Calibration window An alert box is displayed during calibration The S...

Page 126: ...en using the sensor as a reference sensor it is fitted to the sensor fixture together with a sensor plate as shown below See the section Positions and directions of sensor on page 106 for actual positioning and orientation of the fixture and the sensor since the direction of the sensor differs depending on which axis is calibrated xx0100000207 A Measuring unit B Selection pointer C Sensor connecti...

Page 127: ...or fixture Step Action Info Illustration 1 If the sensor and the sensor plate are separate fit them together by first cleaning the attachment area on the sensor plate with isopropanol and then fitting the sensor to it Handle the sensor plate and the sensor as a complete unit when fitting it to and moving it between the reference point and the different axes Art no is specified in Required equipmen...

Page 128: ... isopropanol 7 Fit the sensor unit sensor plate and sensor on to the sensor fixture and connect the sensor to the Levelmeter 2000 Correct direction is shown in Positions and directions of sen sor on page 106 Connection is shown in the fig ure Sensor mounted on fixture on page 124 8 Press ON MODE on the Levelmeter 2000 until the dot flashes under REL ZERO Shown in the figure Levelmeter 2000 on page...

Page 129: ...stration 1 Select axis by axis motion mode 2 Press the enabling device on the teach pendant and using the joystick move the robot manually so that the calibration marks lie within the toler ance zone Shown in section Calibration scales and correct axis position on page 102 3 Note that axis 6 does not have any mechanical stop and can thus be calibrated at the wrong faceplate revolution Do not opera...

Page 130: ...ked with an x or press All to select all axes 6 Press OK when all axes that are to be updated are marked with an x CANCEL returns to the Cal ibration window 7 Press OK again to confirm and start the update CANCEL returns to the Revolution Counter Update window 8 At this point it is recom mended that the revolution counter values are saved to a diskette Not required 9 Recheck the calibration positi...

Page 131: ...ter running the program 2 Check the calibration positions If the axes are outside the tolerance start the cal ibration procedure from the beginning in increas ing sequence of the axes Detailed in section Calibration on page 110 3 Repeat the check as above 4 Adjust the calibration marks when the calibration is done Shown in section Calibration scales and correct axis posi tion on page 102 5 The sys...

Page 132: ...5 Calibration M2000 5 4 1 Post calibration procedure 130 3HAC021111 001 Revision B ...

Page 133: ...ccuracy calibration it is also recommended but not always needed to be calibrated for new Absolute Accuracy The resolver values will change when parts affecting the calibration position are replaced on the robot e g motors wrist or part of transmission Contents of the revolution counter memory are lost If the contents of the revolution counter memory are lost the counters must be updated as detail...

Page 134: ...m standard method or Levelmeter calibration alternative method Absolute Accuracy calibration optional Based on standard calibration and besides positioning the robot at home position the Absolute Accuracy calibration also compen sates for mechanical tolerances in the robot structure deflection due to load Absolute Accuracy calibration focuses on positioning accuracy in the Cartesian coordi nate sy...

Page 135: ...anical 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 there fore not recommended The calibration equipment for Levelmeter Calibration is ordered as separate parts for each robot and the operating manual for Levelmeter Calibration is enclosed with the Levelmeter 2000 CalibWare Abso ...

Page 136: ...1 Revision B 6 0 3 Calibration scales and correct axis position Introduction This section specifies the calibration scale positions and or correct axis position for all robot models Calibration scales IRB 1400 The illustration below shows the calibration scale positions on IRB 1400 en0200000272 ...

Page 137: ... position in the same direction in order to avoid position errors caused by backlash in gears etc Positive directions are shown in the figure below This is normally handled by the robot calibration software Calibration movement direc tions 6 axes NOTE The figure shows an IRB 7600 but the positive direction is the same for all 6 axis robots except the positive direction of axis 3 for IRB 6400R whic...

Page 138: ...econd step when updating the revolution counter storing the rev olution counter setting with the FlexPendant RobotWare 5 0 Action Note Select axis by axis motion mode Jog the robot to place the calibration marks within the tolerance zone IRB 140 1400 2400 4400 6600ID 6650ID Axes 5 and 6 must be positioned together Shown in section Calibration scales IRB 1400 on page 134 When all axes are positione...

Page 139: ...icking in the box to the left Tapping Select all to update all axes Then tap Update A dialog box is displayed warning that the updating operation cannot be undone Tap Update to proceed with updating the revolution counters Tap Cancel to cancel updating the revolution counters Tapping Update updates the ticked revolution counters and removes the tick from the list of axes If a revolution counter is...

Page 140: ...u Create the following program MoveAbsJ 0 0 0 0 0 0 9E9 9E9 9E9 9E9 9E9 9E 9 NoEOffs v1000 z50 Tool0 Run the program in manual mode Check that the calibration marks for the axes align correctly If they do not update the revolution counters The calibration marks are shown in section Calibration scales IRB 1400 on page 134 How to update the revolution counters is detailed in section Updating revolut...

Page 141: ...6 Calibration information 6 0 6 Checking the calibration position 3HAC021111 001 Revision B 139 ...

Page 142: ......

Page 143: ...on instruc tions detailed for each axis are intended for calibration position 0 i e the normal position Calibration instructions for alternative positions are detailed in Alternative calibrating on page 128 Illustration The illustration shows the available calibrating positions of a suspended robot xx0400001020 A Calibration program Normal calibration position 0 axes 2 and 3 B Calibration program ...

Page 144: ...ormal position and check the calibration marks for each axis 4 Run the calibration program again and select the desired cal ibration position Hanging as shown in Alternative calibra tion position on page 127 5 Change to the new calibration offset as detailed in New cal ibration offset on page 130 6 Note the new calibration offset on the label located under the flange plate on the base The new cali...

Page 145: ...uring definition of a new calibration position Step Action Illustration 1 Press the Miscellaneous button xx0100000194 2 Select the System parameters window by pressing ENTER xx0100000200 3 Select Manipulator from the Topics menu 4 Select Arm from the Types menu 5 Select axes 2 and 3 6 Change Cal pos to 1 570796 7 The angle is measured in radians as shown in Alternative calibration position on page...

Page 146: ...ation offset for axis 1 during definition of a new calibration position Step Action Illustration 1 Press the Miscellaneous button xx0100000194 2 Select the Service window by press ing ENTER xx0100000200 3 Select Calibration from the View menu The calibration window appears xx0100000201 4 Select Calibrate from the Calib menu 5 Select axes 2 and 3 6 Confirm by pressing OK twice ...

Page 147: ...ns when retrieving new offset values for axis 1 during definition of a new calibration position Step Action Illustration 1 Press the Micellaneous button xx0100000194 2 Select the system parameters window by pressing ENTER xx0100000200 3 Select Motor from the Types menu 4 Select axes 2 and 3 and press ENTETR xx0100000200 5 Note the cal offset value ...

Page 148: ...7 Alternative calibration 7 0 5 Retrieving offset values 146 3HAC021111 001 Revision B ...

Page 149: ...B 1400 8 0 1 Introduction 3HAC021111 001 Revision B 147 8 Reference information IRB 1400 8 0 1 Introduction General This chapter includes general information complementing the more specific information in the following chapters ...

Page 150: ...rrounding the robot cell ISO DIS 11161 Industrial automation systems safety of integrated manufacturing systems Basic requirements prEN 999 1995 Standards robot cell The following standards are applicable when the robot is part of a robot cell IEN 294 Safety of machinery Safety distance to prevent danger zones being reached by the upper limbs EN 349 Safety of machinery Minimum gaps to avoid crushi...

Page 151: ...evision B 149 8 0 3 Unit conversion Converter table Use the table below to convert units used in this manual Quantity Units Length 1 m 3 28 ft 39 37 in Weight 1 kg 2 21 lb Pressure 1 bar 100 kPa 14 5 psi Force 1 N 0 738 lbf Moment 1 Nm 0 738 lbf tn Volume 1 L 0 264 US gal ...

Page 152: ...crews 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 Screwslubricated in other ways Screws lubricated with...

Page 153: ...joint by hand and never use pneumatical tools Use the correct tightening technique i e do not jerk Tighten the screw in a slow flowing motion Maximum allowed total deviation from the specified value is 10 The table below specify the recommended standard tightening torque for oil lubricated screws with slotted or cross recess head screws The table below specify the recommended standard tightening t...

Page 154: ... the recommended standard tightening torque for water and air con nectors when one or both connectors are made of brass Dimension Tightening torque Nm Class 10 9 Molycote lubricated Tightening torque Nm Class 12 9 Molycote lubricated M8 28 34 M10 55 66 M12 96 115 M16 235 280 Dimension Tightening torque Nm Nominal Tightening torque Nm Min Tightening torque Nm Max 1 8 12 8 15 1 4 15 10 20 3 8 20 15 ...

Page 155: ...ified All components exceeding 22 kg 50 lbs are high lighted in this way To avoid injury ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg A wide range of lifting tools and devices are available for each manipulator model Example Below is an example of how a weight specification is presented CAUTION The motor weighs 32 kg All lifting equipment used ...

Page 156: ...als for all controller models The part number 001 is the English version Operators manual The operators manual contains instructions for daily operation of robot systems The table below specifies the article numbers of the operators manuals for different robot systems Additional docu mentaion Document name Document ID Product specification 3HAC 9376 1 Document name Document ID Product manual S4Cpl...

Page 157: ...aintenance and installation instructions contain lists of tools required to perform the specified activity All special tools i e all tools that are not considered stan dard as defined below are listed in their instructions respectively This way the tools required are the sum of the Standard Toolkit and any tools listed in the instruction Contents Tool Rem ...

Page 158: ...ncluded in the leakdown tester kit Art no is specified above 3 Apply compressed air and raise the pressure with the knob until the correct value is shown on the manom eter Recommended value 0 2 0 25 bar 20 25 kPa 4 Disconnect the compressed air supply 5 Wait for approx 8 10 minutes No pressure loss must be detected If the compressed air is sig nificantly colder or warmer than the gearbox to be tes...

Page 159: ...air and maintenance activities require different pieces of lifting equipment which are specified in each procedure The use of each piece of lifting equipment is not detailed in the activity procedure but in the instruction delivered with each piece of lifting equipment This implies that the instructions delivered with the lifting equipment should be stored for later reference ...

Page 160: ...8 Reference information IRB 1400 8 0 9 Lifting equipment and lifting instructions 158 3HAC021111 001 Revision B ...

Page 161: ...0 1 Introduction 3HAC021111 001 Revision B 159 9 Spare part list 9 0 1 Introduction Item number refers to item number on the foldouts Article numbers marked with bold text are specially designed as spare parts painted etc ...

Page 162: ... 12 Screw 3HAB 3402 24 Gleitmo 610 M6x16 8 8 11 1 Lower arm 3HAB 3682 1 Standard 11 1 Lower arm 3HAB 3281 1 Hanging 12 2 Damper 3HAB 3257 1 13 16 Spring washer 2154 2033 10 10 5x23x2 5 FZM 14 6 Screw 3HAB 3409 51 Gleitmo 610 M10x30 12 9 15 1 Parallel arm 3HAB 3126 1 Standard 15 1 Parallel arm 3HAB 3282 1 Hanging 16 1 Ball bearing 2213 253 12 61821 2RS1 17 8 Screw 3HAB 3409 57 Gleitmo 610 M10x60 12...

Page 163: ...07 1 50 1 Sync marker 3HAB 3747 1 51 1 Upper arm 3HAB 3379 1 See 1 2 52 1 Wrist 3HAB 3388 1 53 6 Screw 3HAB 3402 25 Gleitmo 610 MC6S M6x20 54 6 Washer 9ADA 312 6 6 4x12x1 6 55 2 Cover 3HAA 2362 1 56 2 Protection plug 2522 2101 5 57 2 Spring 3HAB 3263 1 58 4 Rod end bearing 3HAA 2301 12 KM 10 59 2 Shaft 3HAB 3265 1 60 2 Ball bearing 2213 6950 206 6206 2RS1 61 3 Shims 2159 167 70 T 0 3 62 3 Shims 21...

Page 164: ... unit axes 4 6 3HAC 1858 1 Option 041 hanging 107 1 Cable unit axes 4 6 3HAC 2072 1 Option 042 standard 109 2 Bracket axes 5 6 3HAB 3230 1 110 1 Clamp 2166 2018 2 D 11 111 1 Clamp 2166 2018 8 D 6 117 3 Cover axes 1 3 3HAC 4337 1 119 3 Gasket 3HAC 4419 1 122 1 Cover axis 4 3HAC 4350 1 Not option 691 122 1 Lamp unit 3HAC 2743 1 Option 691 124 3 Gasket 3HAC 4429 1 127 1 Cover axes 5 6 3HAC 4405 1 130...

Page 165: ...0 1 Option 075 173 2 Bushing 2166 2421 2 Option 075 174 2 Limit switch 3HAA 2496 1 Option 075 175 1 Protective hood 3HAB 9344 1 Option 042 176 2 Dust cap 5217 649 9 Option 041 or 042 177 1 Dust cap 5217 649 9 Option 075 179 1 Sealing liquid 1269 0014 412 Loctite 542 option 041 180 1 Coupling 3HAB 3333 20 Option 041 181 2 Cable gland 2672 063 3 Pr 18 6 option 075 182 2 Rubber washer 2452 398 2 Pr 1...

Page 166: ...2 T 0 1 16 1 Spacer 2159 167 63 T 0 5 17 1 Gear wheel 3HAB 3210 1 18 6 Screw 3HAB 3402 24 Gleitmo 610 MC6S M6x16 19 2 Screw 9ADA 183 22 MC6S M6x10 20 7 Plain washer 9ADA 312 6 6 4x12x1 6 21 1 O ring 2152 2011 414 D 44 2x3 22 1 Motor complete axis 4 3HAC 11864 1 Elmo 22 1 Motor complete axis 4 3HAC 021740 001 Yaskawa 23 4 Screw 9ADA 183 14 MC6S M5x16 24 1 Nut 9ADA 267 6 M6 25 1 Cover 3HAB 3266 1 26...

Page 167: ... locate the item numbers Item Qty Name Art no Remark 1 1 Driving shaft 5 6 3HAC 11305 1 2 2 Motor unit axes 5 6 3HAC 11865 1 Elmo 2 2 Motor unit axes 5 6 3HAC 021741 001 Yaskawa 3 1 Motor end barrier 3HAA 2504 1 4 8 Nut 9ADA 267 5 M5 5 10 Screw 3HAB 3402 14 Gleitmo 610 MC6S M5x16 6 10 Plain washer 9ADA 312 5 5 3x10x1 7 2 Timing belt 3HAA 2393 1 ...

Page 168: ... Serial mea surement unit See foldout 10 to locate the item numbers Item Qty Name Art no Remark 3 1 Battery 4944 026 4 4 4 Straps outdoor 2166 2055 6 L 368 mm 5 1 Serial measurement board 3HAC021905 001 DSQC 633 7 1 Signal cable 3HAB 3774 1 8 2 Straps outdoor 2166 2055 3 L 186 mm 9 1 Label 2940 1413 1 38x19 ...

Page 169: ...1 Introduction 3HAC021111 001 Revision B 167 10 Foldouts 10 0 1 Introduction Overview This chapter includes foldouts with illustrations of the robot The item numbers are specified in chapter Spare part list on page 159 ...

Page 170: ...10 Foldouts 10 0 1 Introduction 168 3HAC021111 001 Revision B ...

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Page 181: ...11 Circuit diagram 11 0 1 Introduction 169 3HAC021111 001 Revision B 11 Circuit diagram 11 0 1 Introduction Overview This chapter includes the complete circuit diagram for the robot ...

Page 182: ...11 Circuit diagram 11 0 1 Introduction 170 3HAC021111 001 Revision B ...

Page 183: ...11 Circuit diagram 11 0 2 Sheet 101 List of contents 3HAC021111 001 Revision B 171 11 0 2 Sheet 101 List of contents ...

Page 184: ...11 Circuit diagram 11 0 3 Sheet 102 Connection point location 3HAC021111 001 Revision B 172 11 0 3 Sheet 102 Connection point location ...

Page 185: ...11 Circuit diagram 11 0 4 Sheet 103 Serial measurement board 3HAC021111 001 Revision B 173 11 0 4 Sheet 103 Serial measurement board ...

Page 186: ...11 Circuit diagram 11 0 5 Sheet 104 Motor axes 1 3 3HAC021111 001 Revision B 174 11 0 5 Sheet 104 Motor axes 1 3 ...

Page 187: ...11 Circuit diagram 11 0 6 Sheet 105 Feedback axes 1 3 3HAC021111 001 Revision B 175 11 0 6 Sheet 105 Feedback axes 1 3 ...

Page 188: ...1 3 2 U W V MU6 6 7 8 5 B PTC W 3 R3 MP4 1 2 U V 7 8 B MU4 5 6 PTC 1 2 3 6 9 12 4 7 10 R1 MP4 6 PTC 34 11 8 PE PE R S T R S T R S T M4R M4S M4T M6R M6S M6T M5R M5S M5T PTC 111 R1 MP4 6 111 5 BRPB R S1 3 R1 BU 104 13 14 15 2 1 BU 3 4 BU BU BU BU BU BU 15 14 13 GNYE 17 16 12 8 7 6 2 1 5 4 3 9 GNYE PTC 46 10 BU BU PTC 65 1 R1 H1 112 11 R3 H2 1 R3 H1 1 BRAKE REL 0V BRAKE BRAKE REL 0V BRAKE ...

Page 189: ...11 Circuit diagram 11 0 8 Sheet 107 Feedback axes 4 6 3HAC021111 001 Revision B 177 11 0 8 Sheet 107 Feedback axes 4 6 ...

Page 190: ...11 Circuit diagram 11 0 9 Sheet 108 Customer connection Option 3HAC021111 001 Revision B 178 11 0 9 Sheet 108 Customer connection Option ...

Page 191: ...g Option CSA CSJ CSB CSC CSD CSE CSF CSG CSH CSP CSK CSL CSM CSN CSR CSS GY WH VT WH BU WH GN WH YE WH OG WH RD WH BN WH S R N M L H K P G F J E D C B A S R N M L H K P G F J E D C B A M L J K F G H C E B D A CPM CPL CPJ CPK CPF CPG CPH CPC CPE CPB CPD CPA CPD CPA M L J K F G H C E B D A 4 5 6 7 8 9 10 11 12 13 14 15 16 17 R2 CS R1 CS R1 CP R2 CP ...

Page 192: ...11 Circuit diagram 11 0 11 Sheet 110 Position indicator axis 1 3HAC021111 001 Revision B 180 11 0 11 Sheet 110 Position indicator axis 1 ...

Page 193: ...11 Circuit diagram 11 0 12 Sheet 111 External connections Option 3HAC021111 001 Revision B 181 11 0 12 Sheet 111 External connections Option ...

Page 194: ...11 Circuit diagram 11 0 12 Sheet 111 External connections Option 182 3HAC021111 001 Revision B ...

Page 195: ... 138 jogging to FlexPendant 138 scales 134 calibration Absolute Accuracy 133 CalibWare 132 D direction of axes 135 F FlexPendant jogging to calibration position 138 MoveAbsJ instruction 138 updating revolution counters 136 L Levelmeter calibration 133 M MoveAbsJ instruction FlexPendant 138 N negative directions axes 135 P position robot 134 positive directions axes 135 R Revolution counters 127 re...

Page 196: ...Index 184 ...

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Page 198: ...ABB AB Robotics Products S 721 68 VÄSTERÅS SWEDEN Telephone 46 0 21 344000 Telefax 46 0 21 132592 3HAC021111 001 Revision A en ...

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