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ABB IRB 6600 - 175/2.55, User Manual

The ABB IRB 6600 - 175/2.55 is a state-of-the-art industrial robot that enhances productivity and efficiency. To maximize user operation, a comprehensive and detailed User Manual is available for download, completely free of charge, from our website. Equip yourself with the necessary knowledge and skills to fully utilize this remarkable product.

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3 Repair activities, manipulator

3.1.1 Removal of cable harness

24

A

3HAC 16247-1

Section 3.1: Complete manipulator 

3.1.1 Removal of cable harness 

Location com-
plete cable har-
ness 

The cable harness is located throughout the manipulator as shown in the figure below. 

xx0200000210 

A 

Connector at manipulator base, R1.MP and R1.SMB 

B 

Connectors at motor 1; R2.FB1 and R2.MP1 

C 

Connectors at motor 2; R2.FB2 and R2.MP2 

D 

Connectors at serial measurement board; R1.SMB1-3, R1.SMB4-6, R1.SMB1.7, 
R2.FB7 and R2.SMB. Battery connector X3 R1.G and R2.G. Connectors at brake 
release unit X8, X9 and X10. 

E 

Connectors at motor 3; R2.FB3 and R2.MP3 and for signal lamp R2.H1 and R2.H2 

F 

Connectors at motor 4; R2.FB4 and R2.MP4 

G 

Connectors at cable harness separation; R2.M5/6 

H 

Connectors at cable harness division, inside of upper arm tube; R3.FB5 and R3.MP5. 
Connectors at motor 5; R4.FB5 and R4.MP5. 

J 

Connectors at motor 6; R3.FB6 and R3.MP6 

K 

Rear cover plate 

L 

Connector R1.MP 

M 

Connector R1.SMB 

N 

Connection of earth cable 

O 

Velcro strap that secures the cable harness to the arm house 

A

B

C

D

E

F

G

H

J

K

O

L

M

N

Summary of Contents for IRB 6600 - 175/2.55

Page 1: ... Product Manual Industrial Robot IRB 6600 225 2 55 IRB 6600 175 2 8 IRB 6600 175 2 55 IRB 6650 200 2 75 IRB 6650 125 3 2 M2000A ...

Page 2: ......

Page 3: ...Product Specification 3HAC 14064 1 M2000 Rev 2 IRB 6600 175 2 55 IRB 6600 225 2 55 IRB 6600 175 2 8 IRB 6650 125 3 2 IRB 6650 200 2 75 ...

Page 4: ...cument or of the software and hardware described in this document This document and parts thereof must not be reproduced or copied without ABB Automation Technology Products AB Robotics 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 document may be obtained from ABB ...

Page 5: ... axis 5 centre line down movement 24 Mounting equipment 25 Holes for mounting extra equipment 26 1 5 Maintenance and Troubleshooting 30 1 6 Robot Motion 31 Performance according to ISO 9283 34 Velocity 34 1 7 Cooling fan for axis 1 3 motor option 113 115 34 1 8 SpotPack and DressPack 35 Description of DressPack 37 Description of Water and Air unit 39 Description of Power Unit 40 1 9 Description of...

Page 6: ...Product Specification IRB 6600 2 Product Specification IRB 6600 M2000 ...

Page 7: ...unlikely event of an accident but also robot tools peripheral equipment and the robot itself The robot is equipped with the operating system BaseWare OS BaseWare OS controls every aspect of the robot like motion control development and execution of application programs communication etc See Product Specification S4Cplus For additional functionality the robot can be equipped with optional software ...

Page 8: ... Handling capacity Reach Manipulator weight IRB 6600 175 2 55 1700 kg IRB 6600 225 2 55 1700 kg IRB 6600 175 2 8 1700 kg IRB 6650 125 3 2 1725 kg IRB 6650 200 2 75 1700 kg Airborne noise level The sound pressure level outside 73 dB A Leq acc to the working space Machinery directive 98 37 EEC Power consumption at max load ISO Cube 2 6 kW Normal robot movements 3 8 kW Prefix Description Mounting Flo...

Page 9: ...the manipulator from the side and above dimensions in mm Allow 200 mm behind the manipulator foot for cables 6600 400 2 55 1142 IRB 6600 2 55 1392 IRB 6600 2 8 R 580 R 690 with fork lift 1592 IRB 6650 3 2 IRB 6650 2 75 2445 IRB 6650 2240 IRB 6600 IRB 6600 1280 IRB 6650 ...

Page 10: ...formation system gathers information about the robot s usage and by that determines how hard the robot has been used The usage is characterised by the speed the rotation angles and the load of every axis With this data collection the service interval of every individual robot of this generation can be predicted optimising and planning ahead service activities The collection data is available via t...

Page 11: ...ly Stabilised Path ESP The load and inertia of the tool have a significant effect on the path performance of a robot The Process Robot Generation is equipped with a system to electronically stabilise the robot s path in order to achieve the best path performance This has an influence while accelerating and braking and consequently stabilises the path during all motion operations with a compromise ...

Page 12: ...plies with category 3 of EN 954 1 Safety of machinery safety related parts of control systems Part 1 Selecting the operating mode The robot can be operated either manually or automatically In manual mode the robot can only be operated via the teach pendant i e not by any external equipment Reduced speed In manual mode the speed is limited to a maximum of 250 mm s 600 inch min The speed limitation ...

Page 13: ...f Hold to run control Hold to run meansthatyoumustdepressthestartbuttoninordertomovetherobot When the button is released the robot will stop The hold to run function makes program testing safer Fire safety Both the manipulator and control system comply with UL s Underwriters Laboratory tough requirements for fire safety Safety lamp option As an option the robot can be equipped with a safety lamp m...

Page 14: ...en a mains voltage other than 400 475V is selected Operating requirements Protection standards Standard and Foundry Manipulator IP67 Cleanroom standards Cleanroom class 100 for manipulator according to DIN EN ISO 14644 Cleanrooms and associated controlled environments US Federal Standard 209 e Air clean classes Explosive environments The robot must not be located or operated in an explosive enviro...

Page 15: ... Product Specification IRB 6600 M2000 11 Figure 3 Hole configuration dimensions in mm 88 0 3 Recommended screws for fastening M24 x 120 8 8 with 4 mm flat washer Torque value 775 Nm the manipulator to a base plate ...

Page 16: ...on 12 Product Specification IRB 6600 M2000 Figure 4 Option Base plate dimensions in mm 1 A A A B B C C D 1 5 0 1 A A A 50 10 o 1 5 o 3 7 5 o B B C C D 522 5 Two guiding pins required dimensions see Figure 5 325 ...

Page 17: ...e 6 At different arm load payload and moment of inertia the load diagram will be changed For an accurate load diagram please use the calculation program ABBLoad for 6600 on inside abb com atrm click on Products Robots IRB 6600 or http www abb com roboticspartner click on Product range Robots IRB 6600 Figure 6 Centre of gravity for 50 kg extra load at arm housing dimensions i mm Protected from corr...

Page 18: ...75 2 55 Figure 7 Maximum permitted load mounted on the robot tool flange at different positions centre of gravity 0 00 0 10 0 20 0 30 0 40 0 50 0 60 0 70 0 80 0 00 0 10 0 20 0 30 0 40 0 50 L distance m Z distance m 185 kg 180 kg 175 kg 150 kg 135 kg 120 kg 100 kg 80 kg 0 10 200 mm ...

Page 19: ... Wrist 10o J0 15 kgm2 For wrist down 0o deviation from the vertical line Max load 215 kg Zmax 0 310m and Lmax 0 133m IRB 6600 175 2 55 Armload 50kg 0 0 0 2 0 4 0 6 0 8 1 0 1 2 1 4 0 0 0 2 0 4 0 6 0 8 1 0 1 2 1 4 Load diagram Vertical Wrist 10 150 kg 210 kg 100 kg 200 mm 0 20 0 40 0 20 0 40 0 60 0 60 0 80 0 80 1 00 1 00 1 20 1 20 1 40 1 40 L distance m Z distance m 1 00 0 60 Pay load 10o 10o Z Vert...

Page 20: ...re 9 Maximum permitted load mounted on the robot tool flange at different positions centre of gravity 0 00 0 10 0 20 0 30 0 40 0 50 0 60 0 70 0 80 0 90 0 00 0 10 0 20 0 30 0 40 0 50 0 60 L distance m Z distance m 175 kg 150 kg 120 kg 100 kg 200 kg 215 kg 225 kg 230 kg 220 kg 0 10 200 mm 0 20 ...

Page 21: ...tions centre of gravity at Vertical Wrist 10o For wrist down 0o deviation from the vertical line Max load 270 kg Zmax 0 359m and Lmax 0 124m IRB 6600 225 2 55 Armload 50kg 0 00 0 20 0 40 0 60 0 80 1 00 1 20 1 40 1 60 0 00 0 20 0 40 0 60 0 80 1 00 1 20 1 40 L distance m Z distance m Load diagram Vertical Wrist 10 100 kg 200 mm 150 kg 200 kg 235 kg 260 kg Pay load 10o 10o Z L Vertical wrist ...

Page 22: ...1 Maximum permitted load mounted on the robot tool flange at different positions centre of gravity 0 00 0 10 0 20 0 30 0 40 0 50 0 60 0 70 0 80 0 90 1 00 1 10 0 00 0 10 0 20 0 30 0 40 0 50 0 60 0 70 L distance m Z distance m 80 kg 100 kg 120 kg 150 kg 170 kg 175 kg 180 kg 185 kg 0 10 0 20 200 mm ...

Page 23: ...robot tool flange at different positions centre of gravity at Vertical Wrist 10o For wrist down 0o deviation from the vertical line Max load 215 kg Zmax 0 382m and Lmax 0 116m 0 00 0 20 0 40 0 60 0 80 1 00 1 20 0 00 0 20 0 40 0 60 0 80 1 00 1 20 1 40 L distance m Z distance m 170 kg 200 mm 125 kg 190 kg 210 kg 100 kg Pay load 10o 10o Z L Vertical wrist ...

Page 24: ...e 13 Maximum permitted load mounted on the robot tool flange at different positions centre of gravity 0 00 0 10 0 20 0 30 0 40 0 50 0 60 0 70 0 80 0 90 1 00 1 10 0 00 0 10 0 20 0 30 0 40 0 50 0 60 0 70 200 mm 0 20 L distance m Z distance m 100 kg 110 kg 115 kg 120 kg 125 kg 130 kg 80 kg 90 kg ...

Page 25: ...l Wrist 10o For wrist down 0o deviation from the vertical line Max load 150 kg Zmax 0 462m and Lmax 0 156m IRB 6650 125 3 20 Armload 50kg 0 0 0 2 0 4 0 6 0 8 1 0 1 2 1 4 1 6 0 0 0 2 0 4 0 6 0 8 1 0 1 2 1 4 1 6 Load diagram Vertical Wrist 10 0 20 0 40 0 60 0 80 1 00 1 20 1 60 1 40 1 60 0 20 0 40 0 80 1 20 1 40 1 00 0 60 150 kg Pay load 10o 10o Z L 135 kg 120 kg 110 kg 100 kg 200 mm L distance m Z d...

Page 26: ...gure 15 Maximum permitted load mounted on the robot tool flange at different positions centre of gravity 0 00 0 10 0 20 0 30 0 40 0 50 0 60 0 70 0 80 0 90 0 00 0 10 0 20 0 30 0 40 0 50 0 60 100 kg 200 mm 0 10 L distance m Z distance m 120 kg 135 kg 150 kg 175 kg 195 kg 200 kg 205 kg 210 kg ...

Page 27: ...t Vertical Wrist 10o For wrist down 0o deviation from the vertical line Max load 245 kg Zmax 0 345m and Lmax 0 098m IRB 6650 200 2 75 Armload 50kg 0 0 0 2 0 4 0 6 0 8 1 0 1 2 1 4 0 0 0 2 0 4 0 6 0 8 1 0 1 2 1 4 Load diagram Vertical Wrist 10 0 20 0 40 0 60 0 80 1 00 1 20 1 40 0 20 0 40 0 80 1 20 1 40 1 00 0 60 L distance m Z distance m Pay load 10o 10o Z L 235 kg 210 kg 175 kg 125 kg 100 kg Vertic...

Page 28: ...17 Moment of inertia when full movement of axis 5 Limited axis 5 centre line down Axis 5 Maximum moment of inertia Ja5 Load Z 0 200 2 L2 J0L 275kgm2 for 225 2 55 175 2 8 125 3 2 and 200 2 75 215 kgm2 for 175 2 55 Axis 6 Maximum moment of inertia Ja6 Load L2 J0Z 250 kgm2 for 225 2 55 175 2 8 125 3 2 and 200 2 75 195 kgm2 for 175 2 55 Figure 18 Moment of inertia when axis 5 centre line down Z X Cent...

Page 29: ...extra load on upper arm housing plus the maximum handling weight See Figure 19 M1 50 kg with distance a 500 mm centre of gravity in axis 3 extension Figure 19 Permitted extra load on upper arm Frame Hip Load Permitted extra load on frame is JH 200 kgm2 Recommended position see Figure 20 JH JH0 M4 R2 where JH0 is the moment of inertia of the equipment R is the radius m from the centre of axis 1 M4 ...

Page 30: ...Holes for mounting see Figure 21 and Figure 22 When mounting on the frame all the four holes 2x2 16 on one side must be used Holes for mounting extra equipment Figure 21 Holes for mounting extra equipment on the upper and the lower arm and the frame dimensions in mm 400 IRB 6600 520 IRB 6600 500 IRB 6650 725 IRB 6650 ...

Page 31: ...Description Product Specification IRB 6600 M2000 27 Figure 22 Holes for mounting of extra load on the upper arm dimensions in mm ...

Page 32: ...Product Specification IRB 6600 M2000 Figure 23 Robot tool flange dimensions in mm 12 H7 Depth 15 A R 1 6 0 04 A A B 15 A A 2 0 02 CD A B IRB 6600 175 2 55 100 H7 Depth 8 min 99 160 M12 11x B B 0 2 A B 0 02 A 30 o 12x ...

Page 33: ...6600 M2000 29 Figure 24 Robot tool flange dimensions in mm IRB 6600 225 2 55 15 A A 1 6 0 02 C D A B IRB 6600 175 2 8 IRB 6650 125 3 2 IRB 6650 125 3 2 12 H7 Depth 15 A 1 2 1 6 0 04 A A B B 0 02 A 160 M12 11x B B 0 2 A B 100 H7 Depth 8 min ...

Page 34: ... used Oil is used for the gear boxes The cabling is routed for longevity and in the unlikely event of a failure its modular design makes it easy to change The following maintenance is required Changing filter for the transformer drive unit cooling every year Changing batteries every third year The maintenance intervals depend on the use of the robot For detailed information on maintenance procedur...

Page 35: ...ation motion 180o to 180o Axis 2 Arm motion 85o to 65o Axis 3 Arm motion 70o to 180o Axis 4 Wrist motion 300o to 300o Axis 5 Bend motion 120o to 120o Axis 6 Turn motion 300o to 300o Figure 25 The extreme positions of the robot arm specified at the wrist centre dimensions in mm IRB 6600 175 2 55 IRB 6600 225 2 55 ...

Page 36: ...Description 32 Product Specification IRB 6600 M2000 Figure 26 The extreme positions of the robot arm specified at the wrist centre dimensions in mm IRB 6600 175 2 8 ...

Page 37: ...6600 M2000 33 Figure 27 The extreme positions of the robot arm specified at the wrist centre dimensions in mm Figure 28 The extreme positions of the robot arm specified at the wrist centre dimensions in mm IRB 6650 125 3 2 IRB 6650 200 2 75 ...

Page 38: ...150 s 5 120 s 120 s 6 190 s 235 s 1 7 Cooling fan for axis 1 3 motor option 113 115 A motor of the robot needs a fan to avoid overheating if the avarage speed over time exceeds the value given in Table 1 The maximum allowed avarage speed is depending on the load The average speed can be calculated with the following formula The maximum allowed average speed for axis 1 3 at the maximum ambient temp...

Page 39: ...uch as compressed air cooling water and electrical power SpotPack IRB6600 6650 can be delivered in three standard versions developed for three different applications SpotPack IRB6600 6650 Type S is designed for transformer guns carried by the robot manipulator SpotPack IRB6600 6650 Type HS is designed for transformer guns mounted on a pedestal SpotPack IRB6600 6650 Type H is designed for material ...

Page 40: ...ess are in different combinations described as DressPack The DressPack for upper and lower arm harness contains signals process media water and air and power feeding for Spotwelding power for customer use The floor harness for DressPack contains customer signals To form a complete SpotPack also a Water and Air unit with hoses Power unit with power cable and signal cables between these units are re...

Page 41: ...andling application has the following specification and capacity Quad twisted under separate screen Can also be used for very sinsitive signals Table 2 Type Pcs Area Allowed capacity Customer Power CP Utility Power Protective Earth 2 2 1 0 5 mm2 1 0 mm2 500 VAC 5 A rms 500 VAC Customer Signals CS Signals twisted pair Signals twisted pair and separate shielded 19 4 0 23 mm2 0 23 mm2 50 VAC DC 1 A r...

Page 42: ... Power CP Servo motor power Utility Power Protective Earth 3 2 2 1 1 5 mm2 0 5 mm2 1 5 mm2 600 VAC 12 A rms 500 VAC 5 A rms 500 VAC Customer Signals CS Signals twisted pair Signals twisted pair and separate shielded 19 4 0 23 mm2 0 23 mm2 50 VAC DC 1 A rms 50 VAC DC 1 A rms Customer Bus CBus Bus signals Bus signals Bus signals Bus utility signals 2 2 4 4 0 18 mm2 0 18 mm2 0 18 mm2 0 23 mm2 Profibu...

Page 43: ...g applications Max air pressure 16 bar 230 PSI max water pressure 10 bar 145 PSI Parker Pushlock reference 3C382 15 8BK brass version Plugged at delivery to be used for tip dresser or other equipment Fitting 1 2 BSP 1 5 Signals for water and air unit Electrical connections to robot I O board are made via the splitbox on the water and air unit Total 6 x M12 connections 4 pins are available The numb...

Page 44: ...sic versions are available Type S for Spotwelding with robot handled gun and Type HS for Spotwelding with pedestal gun Incoming power connection made by customer For incoming power recommendations see Installation and Maintenance manual 150 A rms at 20 C 68F ambient temp and 120 A rms at 50 C 122F ambient temp The connector type at the power unit is Han compact HD insert Protection class for the p...

Page 45: ... Digital 24 VDC I O 16 inputs 16 outputs Option 251 Internal connection of I O Option 206 Internal connection of safety signals Option 553 SpotWare software option for pneumatic guns SpotPack Type H standard requires no general robot options 1 9 1 Required options for SpotPack IRB 6600 6650 different types with servo gun To enable the spot welding function package SpotPack IRB 6600 6650 to run wit...

Page 46: ...Option 702 Stationary Gun Option 686 689 Connection of servo gun 7 30 m Option 625 SpotWare Servo software option for servo guns replaces option 553 The option 561 Servo Tool Control could be an alternative to 625 if the application software is designed by the customer Option 561 is not used in the SpotPack as this is intended to be a ready to use package ...

Page 47: ... and very high requirements The cable and hose package has a 1000 mm free length at axis 6 for connection to a spot welding gun or a gripper A tension arm unit keeps hose package in the right position for the robot arm movement approved for the SpotPack An arm protection will prevent wear on the protective hose and on the robot itself Please note that when the robot is operating some multiply axis...

Page 48: ...lly general configurations for the process cable package is specified With this as a base the details of the application signals and media are added Option 056 Connection to manipulator No floor cables for the DressPack are chosen The connector at the base for interfacing is specified in installation and maintenance manual Terminal connections could be found in the circuit diagrams Option 057 Conn...

Page 49: ... The type of bus are defined by choice of floor cabling see also option 057 Option 2204 Material Handling axis 1 to axis 3 The Lower arm harness for the Material Handling has been chosen This includes the process cable package as well as brackets connectors etc to form a complete dressing package from manipulator base until connectors on axis 3 Depending on the choice above the process cable packa...

Page 50: ... axis 6 under option 2205 Table 7 Type Pcs at Terminal Pcs at Connection point Allowed capacity Customer Power CP Utility Power Protective earth 2 2 1 2 2 1 500 VAC 5 A rms 500 VAC Customer Signals CS Signals twisted pair Signals twisted pair and separate shielded 19 4 19 4 50 VAC 1 A rms 50 VAC 1 A rms Table 8 Type Pcs at Terminal Pcs at Connection point Allowed capacity Customer Power CP Utility...

Page 51: ...ng on the earlier choice see option 2204 the process cable package will have different content For content see Table 6 Table 7 Table 8 Table 9 and Table 10 The connector type at the manipulator base at axis 3 and axis 6 is specified in the Installation and maintenance manual Table 9 Type Pcs at Terminal Pcs atConnection point Allowed capacity Customer Power CP Utility Power Protective earth 2 2 1 ...

Page 52: ... of the content are common These common parts for Spot Welding application are shown in table 11 below Unique parts for different option combinations are showed in Table 12 Table 13 Table 14 Table 15 and Table 16 Table for common content Spot Welding with option 2063 2064 At manipulator base or axis 6 150 A rms at 20 C 68F ambient temp 120 A rms at 50 C 122F ambient temp 135 A rms at 20 C 68F ambi...

Page 53: ...able 12 Type Pcs at Terminal Pcs at Connection point Allowed capacity Customer Power CP Utility Power Protective earth 2 2 1 2 2 1 500 VAC 5 A rms 500 VAC Customer Signals CS Signals twisted pair Signals twisted pair and separate shielded 19 4 19 4 50 VAC 1 A rms 50 VAC 1 A rms Table 13 Type Pcs at Terminal Pcs at Connection point Allowed capacity Customer Power CP Servo motor Power Utility Power ...

Page 54: ...ction point Allowed capacity Customer Power CP Utility Power Protective earth 2 2 1 2 2 1 500 VAC 5 A rms 500 VAC Customer Bus CBus Bus signals Bus signals Signals twisted pair Utility signals 4 4 2 2 4 4 CAN DeviceNet spec 50 VAC 1 A rms 50 VAC 1 A rms 50 VAC 1 A rms Table 15 Type Pcs at Terminal Pcs at Connection point Allowed capacity Customer Power CP Utility Power Protective arth 2 2 1 2 2 1 ...

Page 55: ... 3 At axis 6 with free end Option 2070 Connection kit Axis 6 robot side SW The process cable package from manipulator base to axis 6 option 2200 ends with free end for media and for weld power cable If this option is chosen a kit for connections will be supplied This has to be assembled by the customer when hoses and power cable has been cut to required length The kit contains 4 Hose fittings Park...

Page 56: ...The welding timer includes control program which gives possibility to program different weld sequence The programming is normally done on a PC that is connected directly to the welding timer The interface between the robot system and the welding timer is handled via a digital signal interface Example of signals are weld start weld ready weld program choice and error Also cross connections of inter...

Page 57: ...ear of the power unit This forces air on the cooling surface for the thyristor or MFDC converter For the MFDC converter this is mandatory For the AC thyristor the need of the forced air cooling depends on the load and the ambient temperature For further information see separate manuals for the Bosch equipment Option 2092 Earth fault protection This option adds an earth fault protection to the circ...

Page 58: ... and air unit is the connection point for cooling water and compressed air to the spot welding gun All standard features and options are the same for types S and HS Water and air unit is not included for type H The standard water and air unit is mounted at the base of the robot The standard water and air unit consists of four main assemblies Water in circuit Water return circuit Air supply circuit...

Page 59: ... off valve and an Parker Puchlock 33482 8 8BK fitting for hose hose assembled by customer From this point the water is led to the factory water system Air supply circuit The air supply circuit provides the robot and option proportional valve with air supply The air supply circuit started with a Parker Puchlock 39C82 15 8BK fitting hose assembled by customer Manually operated shut off valve to vent...

Page 60: ...between air supply circuit and manipulator base PROC 1 1 2 hose between water in circuit and manipulator base PROC 2 1 2 hose between water return circuit and manipulator base PROC 3 Option 2175 Water and Air unit type HS The basic water and air unit for type HS is equipped for a pedestal stationary gun and with the following components Water in circuit Water return circuit Air supply circuit Spli...

Page 61: ... 2193 This option means that the flow switch and the flow control valve with visible flow indication is replaced by the digital flow meter and a flow control valve without visible flow indication not required as adjustments could be seen on the digital flow meter The digital flow meter gives the following advantages compared to flow switch The biggest advantage is that the flow switch is mechanica...

Page 62: ...ed compressed air circuits An analogue signal 0 10V controls the proportional valve and the air pressure is in the range of 0 12 bar Option 2183 Cable to split box 7m This option includes floor cable of 7 m length for signals to the split box sitting on the water and air unit This cable is connect to the Power unit option 2087 2088 with a modular harting Han Compact with insert type HD The cable e...

Page 63: ...harness to get the signals to axis 6 660 Connection to cabinet cable length CAN DeviceNet 7m Specifies floor cable length and type of bus Example 2 SpotPack for SpotWelding with pneumatic gun and parallel interface Option no Name Note General options 122 No upper cover on robot control cabinet 201 1pc Digital 24 VDC I O 16 inputs 16 outputs 251 Internal connection of I O 206 Internal connection of...

Page 64: ... of I O 206 Internal connection of safety signals Servo gun options 381 Drive unit type DDU V 702 Robot Gun 681 Connection of servo gun 7m 625 SpotWare Servo software option for servo guns DressPack and SpotPack options 057 Connection to cabinet Includes floor cables with signals to terminals inside controller 2063 Communication Parallel communication 2200 SpotWelding to axis 6 Lower arm and Upper...

Page 65: ... Servo software option for servo guns DressPack and SpotPack options 057 Connection to cabinet Includes floor cables with signals to terminals inside controller 2064 Communication Bus communication 2200 SpotWelding to axis 6 Lower arm and Upper arm harness to get the signals to axis 6 670 Connection to cabinet cable length Interbus 7m Specifies floor cable length with Interbus interface 248 Interb...

Page 66: ...tion below 1 11 1 Stationary Gun SG Figure 32 Configuration of Stationary Gun Options according to Table 17 are required to complete the delivery For further details see corresponding Product Specification Table 17 Option Description Product Spec 381 DDU in a separate box and cable to cabinet S4Cplus 686 689 Cables 7 30m between DDU and SG S4Cplus 701 Cables inside the manipulator and manipulator ...

Page 67: ...t Specification Table 18 Option Description Product Spec 381 DDU in a separate box and cable to cabinet S4Cplus 697 699 Extended cables 7 30m between DDU and RG S4Cplus 702 Cabling inside the controller and the manipulator S4Cplus 2063 Parallel communication including Servo IRB 6600 625 Software SpotWare Servo RobotWare Options M1 M2 D1 D2 CB1 option 702 options 697 699 options 2063 option 381 DDU...

Page 68: ...n Table 19 Option Description Product Spec 382 DDU in separate box and cable to the cabinet S4Cplus 686 689 Cables 7 30m between DDU and SG S4Cplus 697 699 Extended cables 7 30m between DDU and RG S4Cplus 703 SMB box with cabling S4Cplus 2063 Parallel communication inclusive of Servo IRB 6600 625 Software SpotWare Servo RobotWare Options M1 M2 D1 D2 CB1 M1 M2 D1 D2 CB2 M7C1B1 CFG SMB option 703 op...

Page 69: ...ry For further details see corresponding Product Specification Table 20 Option Description Product Spec 382 DDU in separate box and cable to the cabinet S4Cplus 686 689 Cables 7 30m between DDU and SGs S4Cplus 704 SMB box with cablings S4Cplus 625 Software SpotWare Servo RobotWare Options M1 M2 D1 D2 CB1 M1 M2 D1 D2 CB2 M7C1B1 CFG option 382 options 686 689 SMB options 641 644 option 704 SG 1 SG 2...

Page 70: ... cables to the control cabinet are included in the IRBT 6003S delivery Table 21 Option Description Product Spec 382 DDU in separate box and cable to the cabinet S4Cplus 686 689 Cables 7 30m between DDU and SG S4Cplus 705 Cable between the cabinet and TM and cable between TM and SG S4Cplus Incl in TM delivery SMB box with cablings Cable between DDU and TM IRBT 6003S 625 Software SpotWare Servo Robo...

Page 71: ...ncluded in the IRBT 6003S delivery Table 22 Option Description Product Spec 382 DDU in a separate box and cable to the cabinet S4Cplus 697 699 Extended cables 7 30m between DDU and RG S4Cplus 706 Cable between the cabinet and TM and between SMB and the manipulator S4Cplus 2063 Parallel communication inclusive of Servo IRB 6600 Incl in TM delivery SMB box with cablings Cable between DDU and TM IRBT...

Page 72: ...tions according to Table 23 below are required to complete the delivery For further details see corresponding Product Specification Table 23 Option Description Product Spec 383 DDU in a separate box and cable to the cabinet S4Cplus 2204 or 2200 Cable from manipulator foot to SMB 7 axis IRB 6600 TM delivery Cable between DDU and TM IRBT 6003S M1 M2 D1 D2 CB1 M1 M2 D1 D2 CB2 M7C1B1 CFG option 383 op...

Page 73: ...Robot adapted for foundry or other harsh environments The robot has the FoundryPlus protection which means that the whole manipulator is steam washable The excellent corrosion protection is obtained by a special coating The connectors are designed for severe environment and bearings gears and other sensitive parts are highly protected PROCESS CABLE PACKAGE For more information see chapter 1 9 2 Dr...

Page 74: ...ling from base to axis 3 and Material Handling fromaxis 3 to axis 6 Figure 40 Spot Welding from base to axis 3 and Spot Welding from axis 3 to axis 6 Communication 2063 Parallel Includes customer power CP customer signals CS and Air for MH process cable package Includes CP CS Air and two Media hoses for SW process cable package 2064 Bus Includes CP CS Air and CAN DeviceNet or Interbus for MH proce...

Page 75: ...s on the foot Figure 42 Location of MH connections on axis 3 Figure 43 Location of SW connections on the base R1 SW1 R3 FB7 R1 MP R1 SMB R1 SW2 3 R1 PROC1 R1 CP CS 1 x 1 2 R2 CP CS R2 PROC1 1 x 1 2 R2 MP 5 6 R1 SW1 R1 MP R1 SMB R1 SW2 3 R1 PROC1 3 3 x 1 2 R1 CP CS R1 WELD 3 x 35mm2 Ext Media SW option 2065 R3 FB7 ...

Page 76: ...665 7m 676 661 671 666 15m 678 663 673 668 30m Robot Servo Gun Extended Stationary Servo Gun 699 686 7m 697 687 15m 698 689 30m EQUIPMENT 691 Safety lamp A safety lamp with an orange fixed light can be mounted on the manipulator The lamp is active in MOTORS ON mode The safety lamp is required on a UL UR approved robot 092 Fork lift device Lifting device on the manipulator for fork lift handling No...

Page 77: ...option 113 115 Not for protection Foundry 115 Cooling fan for axis 3 motor IP 54 For in use recommendations see 1 7 Cooling fan for axis 1 3 motor option 113 115 See Figure 44 Not for protection Foundry 088 Upper arm covers Included in protection Foundry See Figure 45 Figure 44 Cooling fan for axis 1 motor and axis 3 motor Figure 45 Upper arm covers Option 115 Option 113 Option 088 ...

Page 78: ...astening bolts to the gear box are larger and the bolts are insulated from the tool flange see Figure 46 Note The Insulated tool flange option can be ordered in combination with the Absolute Accuracy option and the robot will then be factory calibrated When the Insulated tool flange is mounted after the robot delivery the robot must be re calibrated for absolute accuracy Figure 46 Insulated tool f...

Page 79: ...ach with two independent switches and cams For axis 1 it is possible to mount a second set of position switches doubling the number of redundant zones to six Each position zone consists of two switches mechanically operated by separate cams Each switch has one normally open and one normally closed contact See Product Specification S4Cplus The design and components fulfill the demands to be used as...

Page 80: ...ra mechanical stops Axis 1 7 5 degrees 061 Four stops two which allow the working range to be restricted in increments of 15o and two stops of 7 5o 062 Axis 1 15 degrees Two stops which allow the working range to be restricted in increments of 15o 063 Axis 2 Six stops which allow the working range to be restricted in increments of 15o at both end positions Each stop decreases the motion by 15o 064...

Page 81: ...ater and Air Fore more information see chapter 1 9 4 Water and Air Unit 2174 Water and Air unit type S 2175 Water and Air unit type HS 2177 Second water return 2192 Digital flow meter one water return 2193 Digital flow meter two water returns 2179 Pressure switch and regulator for air 2181 Electrical proportional valve for air Cable to split box 2183 7m 2184 15m 2185 30m ...

Page 82: ...Specification of Variants and Options 78 Product Specification IRB 6600 M2000 ...

Page 83: ...ification RobotWare Options Robot Peripherals Track Motion Tool System Motor Units Spot welding system for transformer gun Tools Brake release box Includes six brake release buttons and 24V battery unit which can be connected to R1 BU on the manipulator frame The brake release box can be ordered from ABB Automation Technology Products Robotics department S Calibration Cube This calibration tool ca...

Page 84: ...Accessories 80 Product Specification IRB 6600 M2000 ...

Page 85: ... 30 manipulator colour 69 mechanical interface 28 29 motion 31 mounting extra equipment 25 robot 10 mounting flange 28 29 N noise level 4 O operating requirements 10 options 69 overspeed protection 7 P Passive Safety System 7 payload 10 position switches 8 10 75 protection 69 protection standards 10 R range of movement 31 reduced speed 8 Robot Gun 63 Robot Gun and Track Motion 67 Robot Peripherals...

Page 86: ...Index 82 Product Specification IRB 6600 M2000 T temperature 10 troubleshooting 30 Twin Stationary Guns 65 V variants 69 W weight 4 working space restricting 7 10 76 Z zone switches 8 ...

Page 87: ... 14 Program management 14 Editing programs 15 Testing programs 15 1 7 Automatic Operation 15 1 8 The RAPID Language and Environment 16 1 9 Exception handling 17 1 10 Maintenance and Troubleshooting 17 1 11 Robot Motion 18 Motion concepts 18 Coordinate systems 18 Stationary TCP 20 Program execution 20 Jogging 20 Singularity handling 20 Motion Supervision 20 External axes 21 Big Inertia 21 Soft Serv...

Page 88: ...Product Specification S4Cplus 2 Product Specification S4Cplus M2000 BaseWare OS 4 0 System signals 27 1 14 Communication 29 2 Specification of Variants and Options 31 3 Index 51 ...

Page 89: ... BaseWare OS operating system which includes all basic functions for operation and programming Controller weight 250 kg Controller volume 950 x 800 x 620 mm Airborne noise level The sound pressure level outside 70 dB A Leq acc to the working space Machinery directive 98 37 EEC Figure 1 The controller is specifically designed to control robots which means that optimal performance and functionality ...

Page 90: ...gure 2 View of the controller from the front from above and from the side dimensions in mm 200 950 980 500 500 820 Lifting points Castor wheels Option 126 800 250 Extended cover Option 123 Cabinet extension Option 124 for forklift 200 Air distance to wall 800 623 71 52 ...

Page 91: ...ety system based on a two channel circuit which is monitored continuously If any component fails theelectricalpowersuppliedtothemotorsshutsoffandthebrakesengage Safety category 3 Malfunction of a single component such as a sticking relay will be detected at the next MOTOR OFF MOTOR ON operation MOTOR ON is then prevented and the faulty section is indicated This complies with category 3 of EN 954 1...

Page 92: ...ormal program stop with no deviation from the programmed path After approx 1 second the power supplied to the motors shuts off Collision detection In case an unexpected mechanical disturbance like a collision electrode sticking etc occurs the robot will stop and slightly back off from its stop position Restricting the working space The movement of each axis can be restricted using software limits ...

Page 93: ...ion including the complete programming language is in English or if preferred some other major language Available languages see options on page 35 Display Displays all information during programming to change programs etc 16 text lines with 40 characters per line Motion keys Select the type of movement when jogging Navigation keys Used to move the cursor within a window on the display and enter da...

Page 94: ...obot is taken to the MOTORS OFF state Joystick The joystick is used to jog move the robot manually e g when programming the robot Emergency stop button The robot stops immediately when the button is pressed in Figure 4 Window for manual operation of input and output signals Using the joystick the robot can be manually jogged moved The user determines the speed of this movement large deflections of...

Page 95: ...d indicating lamp Duty time counter The robot is not calibrated or the revolution counters Slow flashing light 1 Hz Note The motors have been switched off Indicates the operating time for the manipulator released brakes Operating mode selector Automatic mode Manual mode at reduced speed 100 Manual mode at full speed Running production Programming and setup Max speed 250 mm s 600 inches min Optiona...

Page 96: ...dant can be mounted externally i e separated from the cabinet The robot can then be controlled from there The robot can be remotely controlled from a computer PLC or from a customer s panel using serial communication or digital system signals For more information on how to operate the robot see the User s Guide ...

Page 97: ...anent code for booting a release area of 20 MB where all the code for a specific release is stored a system specific data area of 10 MB where all the run time specific data including the user program for a system is stored at backup a user mass memory area which can be used for storing RAPID programs data logs etc The flash disk is used for backup i e when a power failure occurs or at power off al...

Page 98: ...potWare option will reduce memory significantly i e down to about 4 8 MB depending on the number of simultaneous welding guns 1 5 Installation The controller is delivered with a standard configuration for the corresponding manipulator and can be operated immediately after installation Its configuration is displayed in plain language and can easily be changed using the teach pendant Operating requi...

Page 99: ...en the power is switched on EM stop sequence Action taken at an emergency stop Main start sequence Action taken when the program is starting from the beginning Program start sequence Action taken at program start Program stop sequence Action taken at program stop Change program sequence Action taken when a new program is loaded Working space Working space limitations External axes Number type comm...

Page 100: ...ned see Figure 7 as a stop point i e the robot reaches the programmed position or a fly by point i e the robot passes close to the programmed position The size of the deviation is defined independently for the TCP the tool orientation and the external axes Figure 7 The fly by point reduces the cycle time since the robot does not have to stop at the programmed point The path is speed independent Th...

Page 101: ...modifying numeric values To prevent unauthorised personnel from making program changes passwords can be used Testing programs Several helpful functions can be used when testing programs For example it is possible to start from any instruction execute an incomplete program run a single cycle execute forward backward step by step simulate wait conditions temporarily reduce the speed change a positio...

Page 102: ...e value prior to the power failure 1 8 The RAPID Language and Environment The RAPID language is a well balanced combination of simplicity flexibility and powerfulness It contains the following concepts Hierarchical and modular program structure to support structured programming and reuse Routines can be Functions or Procedures Local or global data and routines Data typing including structured and ...

Page 103: ...s a supervision of temperature fans and battery health The robot has several functions to provide efficient diagnostics and error reports It performs a self test when power on is set Computer status LEDs and console serial channel for fault tracing support Errors are indicated by a message displayed in plain language The message includes the reason for the fault and suggests recovery action Faults...

Page 104: ... handling fragile parts The number of adjustments that have to be made to achieve the shortest possible cycle time is minimized TrueMoveTM The TrueMoveTM concept means that the programmed path is followed regardless of the speed or operating mode even after an emergency stop a safeguarded stop a process stop a program stop or a power failure This very accurate path and speed is based on advanced d...

Page 105: ...n of a fixture or workpiece manipulator The object coordinate system specifies how a workpiece is positioned in a fixture or workpiece manipulator The coordinate systems can be programmed by specifying numeric values or jogging the robot through a number of positions the tool does not have to be removed Each position is specified in object coordinates with respect to the tool s position and orient...

Page 106: ...then be modified in order to adjust the motion to the location of the part Jogging The robot can be manually operated in any one of the following ways Axis by axis i e one axis at a time Linearly i e the TCP moves in a linear path relative to one of the coordinate systems mentioned above Reoriented around the TCP It is possible to select the step size for incremental jogging Incremental jogging ca...

Page 107: ...t motion can be simultaneously coordinated with for example a linear robot carrier and a work piece positioner A mechanical unit can be activated or deactivated to make it safe when for example manually changing a workpiece located on the unit In order to reduce investment costs any axes that do not have to be active at the same time can share the same drive unit An external axis is an AC motor IR...

Page 108: ...binet as shown in Figure 10 External axes for robot types IRB 6600 and IRB 7600 The drive units for all external axes must be located in a separate cabinet as shown in Figure 10 Figure 10 Outline diagram external axes SMB Not supplied on delivery Not supplied on delivery SMB Measurement System 1 Measurement System 2 ABB Drives Drive System 2 Multiple External Axes Single External Axes Motor channe...

Page 109: ...puts and outputs Gateway slave for Allen Bradley Remote I O Gateway slave for Interbus Slave Gateway slave for Profibus DP Slave S4Cplus with the option I O Plus can be configured for fieldbus units from other suppliers For more details see the Product Specification RobotWare Options The inputs and outputs can be configured to suit your installation Each signal and unit can be given a name e g gri...

Page 110: ...le effect on the robot motion i e if a limited number of instructions are executed in the trap routine Background programs for monitoring signals for example can be run in parallel with the actual robot program Requires Multitasking option see Product Specification RobotWare Manual functions are available to List all the signal values Create your own list of your most important signals Manually ch...

Page 111: ...nal External1 1 The digital signals are supplied in groups each group having 8 inputs or outputs Digital I O 120 VAC 320 25x 16 16 Internal External Analog I O 355 22x 4 3 1 Internal AD Combi I O 327 23x 16 16 2 Internal External1 Relay I O 332 26x 16 16 Internal External1 Allen Bradley Remote I O Slave 350 241 1282 2 To calculate the number of logical signals add 2 status signals for Allen Bradle...

Page 112: ...to 35 V Rated voltage 24 V DC Logical voltage levels 1 18 to 34 V 0 7 V Output current max 0 5 A Potential difference max 500 V Time delays hardware 1 ms software 2 ms Time variations 2 ms Relay outputs option 205 Single pole relays with one make contact normally open Rated voltage 24 V DC 120 VAC Voltage range 19 to 35 V DC 24 to 140 V AC Output current max 2 A Potential difference max 500V Time ...

Page 113: ...1 mV 14 bits Accuracy 0 2 of input signal Analog outputs option 202 VoltageOutput voltage 10 V Load impedance min 2 kohm Resolution 2 44 mV 12 bits CurrentOutput current 4 20 mA Load impedance min 800 ohm Resolution 4 88 µA 12 bits Accuracy 0 2 of output signal Analog outputs option 203 Output voltage galvanically isolated 0 to 10 V Load impedance min 2 kohm Resolution 2 44 mV 12 bits Accuracy 25 ...

Page 114: ...ops program when the program cycle is ready Stops program after current instruction Executes trap routine without affecting status of stopped regular program1 Loads and starts program from the beginning1 Resets error Resets emergency stop System reset Analog output TCP speed signal 1 Program can be decided when configuring the robot For more information on system signals see User s Guide System Pa...

Page 115: ...thernet channels and both can be used at 10 Mbit s or 100 Mbit s The communication speed is set automatically Figure 12 Point to point communication The communication includes TCP IP with intensive network configuration possibilities like DNS DHCP etc including multiple gateway Network file system accesses using FTP NFS client and FTP server Control and or monitoring of controllers with RAP protoc...

Page 116: ...Description 30 Product Specification S4Cplus M2000 BaseWare OS 4 0 ...

Page 117: ...tates and Canada UL UL CSA means certification of complete product and UR UL recognized Component means certification of component or not complete product Safety lamp 691 Door interlock 145 or 142 Operating mode selector standard 2 modes 193 are mandatory Not with Cabinet height 950 mm no cover 122 Cabinet height 1200 mm 123 Cabinet height 1750 mm 124 Cabinet variant Prepared for Arcitec 112 Mains...

Page 118: ... when cabinet extension is mounted on top of the cabinet after delivery Not with Door interlock 145 or UL 695 or UR 696 123 Standard cabinet with 250 mm extension The height of the cover increases the available space for external equipment that can be mounted inside the cabinet Not with UL 695 124 Standard cabinet with 800 mm extension The extension is mounted on top of the standard cabinet There ...

Page 119: ...aration All necessary cabling including flange connectors sealing strips screws etc is supplied External enclosure is not supplied 183 External mounted in a box See Figure 16 Figure 15 Required preparation of external panel enclosure all dimensions in mm 184 224 180 140 193 196 70 62 45o External panel enclosure not supplied M8 x4 Connection to Holes for flange Holes for operator s panel Holes for...

Page 120: ...193 Standard 2 modes manual and automatic 191 Standard 3 modes manual manual full speed and automatic Does not comply with UL and UR safety standards CONTROLLER COOLING 472 Ambient temperature up to 45oC 113oF Standard design The computer unit is provided with a passive heat exchanger cooling fins on the rear part of the box 473 Ambient temperature up to 52oC 125oF The computer unit is provided wi...

Page 121: ...optional operator s panel cable must be included in the limitation 607 20 m MAINS VOLTAGE The control system can be connected to a rated voltage of between 200 V and 600 V 3 phase and protective earthing A voltage fluctuation of 10 to 15 is permissible 151 200V 152 220V 153 400V 154 440V 155 475V 156 500V 157 525V 158 600V For all robots except for IRB 6600 7600 the voltage range must be specified...

Page 122: ...ctor 133 32 A 380 415 V 3p N PE see Figure 18 Not with Flange disconnector 142 or UL UR 695 696 Not available for IRB 6600 7600 134 Connection via an industrial Harting 6HSB connector in accordance with DIN 41640 35 A 600 V 6p PE see Figure 19 Cannot be combined with Flange disconnector 142 Figure 19 DIN male connector MAINS SWITCH 141 Rotary switch 40 A in accordance with the standard in section ...

Page 123: ...tary switch 40 A to the two contactors in the AC power supply for the drive system The handle can be locked by a padlock e g in an off position 145 Door interlock for rotary switch Included in the options UL CSA UR 695 696 and Servo disconnector 144 147 Circuit breaker for rotary switch A 16A option 163 and 164 or 25A option 162 circuit breaker for short circuit protection of mains cables in the c...

Page 124: ...ol D sub Ph 5 Pol CAN 1 3 X7 MS NS X8 DSQC 504 CAN 1 X1 I O COMPUTER 25 Pol D sub DB 44 X13 POWER SUPPLY FCI Male 15 Pol FCI Female 15 Pol CAN 2 Test Ph 5 Pol NS MS GS2 X6 CONTROL PANEL X9 BASE CONN UNIT X7 TEACH PENDANT 1 1 1 DSQC 509 X2 X1 GS1 ES2 ES1 NS MS EN POWER UNIT POWER CONTROL RL2 RL1 1 X5 1 X8 WARNING ANY EXTERNAL EQUIPMENT REMOVE JUMPERS BEFORE CONNECTING AS2 AS1 CONNECTIONS X4 X3 CUST...

Page 125: ...in two versions one for up to two I O units and one for up to four I O units The versions are selected to match the number of ordered I O units By this option it is possible to get the four unit version even if less than three I O units are ordered SAFETY SIGNALS 206 Internal connection The signals are connected directly to screw terminals in the upper part of the cabinet see Figure 20 207 Externa...

Page 126: ...d by the master part of the DSQC512 529 unit The slave part of the DSQC512 529 unit is normally controlled by an external master on a separate Interbus network This network is a different one than the network hold ing the I O units for the master part of the board The slave part is a digital in and out put I O unit with up to 160 digital in and 160 digital out signals Two variants are available 24...

Page 127: ...Encoder interface unit for conveyor tracking DSQC 377 Only available for IRB 140 and IRB 340 required for PickMaster 4 0 Physically similar to option 344 EXTERNAL I O UNITS I O units can be delivered separately The units can then be mounted outside the cabinet or in the cabinet extension These are connected in a chain to a connector CAN 3 or CAN 2 see Figure 20 in the upper part of the cabinet Con...

Page 128: ...he cabinet Male connector is also supplied 391 Drive unit C The drive unit is part of the DC link Recommended motor type see Figure 23 Not available for IRB 640 392 Drive unit T The drive unit is part of the DC link Recommended motor type see Figure 23 Not available for IRB 640 6400R 397 Drive unit U The drive unit is part of the DC link Recommended motor types see Figure 23 Not available for IRB ...

Page 129: ...400R 6400S 395 Drive unit C GT A combination of 391 and 393 Not available for IRB 4400 640 6400R 6400S 365 Trackmotion A special wiring for the three motor combination 394 IRB 140 1400 2400 only to be used when axis 7 is intended for an ABB Trackmotion The drive unit in the DC link and the Trackmotion measurement board is then connected to the robot axes computer 1 while the drive unit and the mea...

Page 130: ... option is a combination of 701 and 702 A distributed drive unit DDU controls the SG motor The cabling between the SG SMB and the controller is selected in the option range 686 689 and the cabling between the RG SMB and the controller is selected in the option range 681 684 Drive unit options 397 for the RG and 380 for the SG are required IRB 6600 7600 The option includes cabling inside the contro...

Page 131: ...mounted close to the manipulator foot Dimensions and mounting information can be found in the product Specification Motor Unit Drive unit 382 DDU VW must be selected 705 SG and Track Motion T IRB 6400R The option is a combination of 701 and a track motion IRBT 6002S controlled by a distributed drive unit The cabling between the SG SMB and the controller is selected in the option range 686 689 Driv...

Page 132: ... a 1 5m resolver cable for the RG to be connected to the Track Motion mounted SMB box Drive unit 382 DDU VW must be selected EXTERNAL AXES MEASUREMENT BOARD not available for IRB 340 IRB 6400PE The resolvers can be connected to a serial measurement board outside the controller 387 Serial measurement board as separate unit EXTERNAL AXES SEPARATE CABINET not available for IRB 340 IRB 6400PE An exter...

Page 133: ...C5 and a drive unit VW The box has 4 keyholes on the back of the encapsulation for fastening Connection cabling length 5m to the controller is included The DDU VW is operated from an additional axis computer included in the option while the DDU V and W are operated from the basic robot axes computer The options also include appropriate cabling inside the manipulator for different resolver configur...

Page 134: ...nance purposes The maximum load permitted is 500 VA max 100 W can be installed inside the cabinet 411 120 V in accordance with American standard single socket Harvey Hubble 412 230 V mains outlet in accordance with DIN VDE 0620 single socket suitable for EU countries POWER SUPPLY to the service outlet 431 Connection from the main transformer The voltage is switched on off by the mains switch on th...

Page 135: ...ecification S4Cplus M2000 BaseWare OS 4 0 49 will not deteriorate at higher temperatures but there will be an increase in the number of reading writing problems as the temperature increases Extended mass memory 310 Flash disc 128 Mb Standard is 64 Mb ...

Page 136: ...Specification of Variants and Options 50 Product Specification S4Cplus M2000 BaseWare OS 4 0 ...

Page 137: ...gnals 23 26 display 7 distributed I O 25 E editing position 15 programs 15 emergency stop 6 7 emergency stop button 8 enabling device 5 8 display 7 Encoder interface unit 25 41 event routine 16 explosive environments 12 extended memory 11 external axes 21 external panel 33 F fire safety 6 flash disk memory 11 fly by point 14 function keys 7 H hold to run 8 hold to run control 6 humidity 12 I I O u...

Page 138: ...ecution 20 programming 14 19 position fixed I O 24 power supply 12 production window 15 Profibus 39 Profibus DP Slave 23 25 41 program editing 15 testing 15 programming 13 protection standards 12 Q QuickMove 18 R RAPID Language 16 reduced speed 5 S safe manual movements 6 safeguarded space stop 6 delayed 6 safety 5 safety lamp 6 serial communication 29 service 17 service outlets 48 signal data 26 ...

Page 139: ...Index Product Specification S4Cplus M2000 BaseWare OS 4 0 53 V variants 31 vibration 12 volume 3 W window keys 7 windows 7 working space restricting 6 world coordinate system 19 ...

Page 140: ...Index 54 Product Specification S4Cplus M2000 BaseWare OS 4 0 ...

Page 141: ...Product Specification RobotWare Options 3HAC 9218 1 Rev 2 BaseWare OS 4 0 ...

Page 142: ...r of the software and hardware described in this document This document and parts thereof must not be reproduced or copied without ABB Automation Technol ogy Products AB Robotics 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 document may be obtained from ABB Automatio...

Page 143: ...iscrete Application 22 540 Conveyor Tracking 23 533 Electronically Linked Motors 24 547 Sensor Synchronization 25 539 Sensor Interface 26 561 Servo Tool Control 27 631 Servo Tool Change 29 535 RAP Communication 31 543 Ethernet Services 32 534 FactoryWare Interface 33 271 Interbus Configuration Tool 34 270 Profibus DP Configuration Tool 35 538 I O Plus 36 3 ProcessWare 37 551 ArcWare 37 552 ArcWare...

Page 144: ...Product Specification RobotWare Options 2 Product Specification RobotWare Options for BaseWare OS 4 0 ...

Page 145: ...are family BaseWare OS provides all the necessary features for fundamental robot programming and operation It is an inherent part of the robot but can be provided separately for upgrading purposes For the description of BaseWare OS see Product Specification S4Cplus BaseWare Options These products are options that run on top of BaseWare OS of the robot They represent functionality for robot users t...

Page 146: ...Introduction 4 Product Specification RobotWare Options for BaseWare OS 4 0 ...

Page 147: ... Applications Any application where Absolute Accuracy is needed to facilitate Exchangeability of robots Off line programming with minimum touch up On line programming with accurate linear movement as well as accurate reorientation of tool Re use of programs between applications Controller algorithms Inherent mechanical tolerances and deflection due to load in the robot structure decrease the robot...

Page 148: ...oint based jogging External axes Track motion Any feature not listed in Absolute Accuracy is active in For joint based motions switching to the jogging window and selecting a cartesian jog mode Linear Reorient will show the correct absolute coordinates Similarly creation of a robtarget at a point taught by joint based motion will be absolutely accurate Requirements Each Absolute Accuracy robot is ...

Page 149: ...ely three minutes The starting point of the identification motion pattern can be chosen by the user so that collisions are avoided The accuracy achieved is normally better than 5 Collision Detection Abnormal torque levels on any robot axis not external axes are detected and will cause the robot to stop quickly and thereafter back off to relieve forces between the robot and environment Tuning is no...

Page 150: ...tion LidCode 8 Product Specification RobotWare Options for BaseWare OS 4 0 ParIdPosValid Checking that the current position is OK for identification LoadId Performing identification MechUnitLoad Definition of payload for external mechanical units ...

Page 151: ...play and input fields defined by Their position and size Their type display input Their display format integer decimal binary hexadecimal text A possible boundary with minimum and maximum limits Example of a user defined screen The represent the fields Advanced Display functions The user defined screens run independently of the RAPID programs Some events occur on a screen new screen displayed menu...

Page 152: ...rithmetical div or logical AND OR NOT XOR operations on the data read Comparing data read and carrying out a command or not depending on the comparison result Displaying a different screen Capacities The user screens can be grouped in a screen package file under a specific name Up to 8 packages can be loaded at the same time A certain amount of memory approx 50 kbytes is reserved for loading these...

Page 153: ...his operator dialogue into a background task the operator can specify input data for the next work cycle without having to stop the robot The robot is controlling a piece of external equipment in parallel with the normal program execution Performance When the various processes are programmed in the correct way no performance problems will normally occur When the priorities for the various processe...

Page 154: ...motion with multi axis manipulators Coordinated motion with multi axis manipulators or robot carriers gantries requires the Advanced Motion option Note that simultaneous coordination with several single axis manipulators e g track motion and workpiece manipulator does not require Advanced Motion Note There is a built in general method for defining the geometry for a manipulator comprising two rota...

Page 155: ...s a friction effect typically in the form of approximately 0 5 mm bumps can be noted Advanced Motion offers a possibility of compensating for these frictional effects Typically a 0 5 mm bump can be reduced to about 0 1 mm This however requires careful tuning of the friction level see User s Guide for tuning procedure Note that even with careful tuning there is no guarantee that perfect paths can a...

Page 156: ...other peripheral equipment e g a PC bar code reader or another robot Information is transferred via an RS232 or RS485 serial channel Examples of applications Printout of production statistics on a printer connected to the robot Reading part numbers from a bar code reader with a serial interface Transferring data between the robot and a PC The transfer is controlled entirely from the robot s work p...

Page 157: ...e DispenseWare Fixed position IO check The value of an input output signal digital analog or group can be checked at a certain distance before or after a programmed position The signal will then be checked at the same place every time irrespective of the robot s speed The distance can also be specified as a certain time max 500 ms before the programmed position The data being checked is compared w...

Page 158: ...ut and after that enters only when the corresponding output from the other robot is reset Movements in interrupt routines and error handlers This function makes it possible to temporarily interrupt a movement which is in progress and then start a new movement which is independent of the first one The robot stores information about the original movement path which allows it to be resumed later Exam...

Page 159: ...rial channel or file ReadAnyBin Read data from a binary serial channel or file ReadStrBin Read a string from a binary serial channel or file ClearIOBuff Clear input buffer of a serial channel WZBoxDef Define a box shaped world zone WZCylDef Define a cylinder shaped world zone WZLimSup Activate world zone limit supervision WZSphDef Define a sphere shaped world zone WZDOSet Activate world zone to se...

Page 160: ...ions 18 Product Specification RobotWare Options for BaseWare OS 4 0 MoveJSync Position fix procedure call during joint movement ISignalAI Interrupts from analog input signal ISignalAO Interrupts from analog output signal ...

Page 161: ...il concerning the kernel i e all general language elements which are not used to control robot or other equipment In addition to this the manual includes descriptions on Built in Routines Built in Data Objects Built in Objects Intertask Objects Text Files Storage allocation for RAPID objects Bit Functions This is a package for handling i e setting reading and clearing individual bits in a byte The...

Page 162: ...ossible to create your own data types like a record definition AliasIO Instruction used to define a signal of any type with an alias alternative name The instruction can be used to make generic modules work together with site specific I O without changing the program code ArgName Function used inside a routine to get the name of a data object which is referenced as argument in the call of the rout...

Page 163: ...tput value proportional to the actual TCP speed Note that this instruction must be used in combination with a TriggL C J instruction see 530 Advanced Functions StepBwdPath Instruction used to move backward on its path in a RESTART event routine TriggStopProc Generation of restart data at program stop or emergency stop File Operation Functions The package includes instructions and functions to work...

Page 164: ... 537 Developer s Function 22 Product Specification RobotWare Options for BaseWare OS 4 0 FileSize Get the size of a file FSSize Get the size of a file system ...

Page 165: ...with execution of up to 4 parallel processes Specialized process for monitoring of external process devices like spot welding controllers Supports encapsulation of the process and motion in shell routines provided to the end user The Advanced Functions option is included in DAP Application Creation of software for advanced applications with a discrete behaviour such as spot welding drilling measur...

Page 166: ... object queue which can be manipulated by RAPID instructions It is possible to define a start window in which an object must be before track ing can start A maximum tracking distance may be specified If the robot is mounted on a parallel track motion then the system can be con figured such that the track will follow the conveyor and maintain the relative position to the conveyor Tracking of a conv...

Page 167: ...shafts Arm Motor position available on the TPU Possibility to activate deactivate link during process Automatic calibration at startup Application Gantry machines to replace mechanical driving shafts Requirements There are no software or hardware requirements for this option Performance When jogging the electronically linked motors will follow the master motor Calibration running follower motors i...

Page 168: ...cToSensor combined with movement instructions fine points or corner zones Note that hardware components for measuring the sensor output are needed for this function The same hardware as for Conveyor Tracking is used encoder and canbus boards Please refer to the Product Specification for your robot Features Up to 4 sensors robot On the fly activation Valid for any type of movement RAPID access to s...

Page 169: ...g functionality when combined with option Advanced Motion based on using the contour tracking path correction functionality Application In any application where it is wanted to read control a sensor during execution and to react on changes in certain data like path offset or process supervisory data thus making adaptive seam tracking and process control possible Requirements External sensors commu...

Page 170: ...ple code package Application Spot Welding with Servo Guns The option provides advanced control functionality for Servo Guns Communication with Weld timers and other process control functionality needs to be implemented outside this option For a total spot welding package please refer to the option SpotWare Servo Performance The tool is configured as an external axis which ensures optimal performan...

Page 171: ...efined force and thickness STOpen Open a Servo Tool STCalib Calibrate a Servo Tool STTune Tune motion parameters for a Servo Tool STTuneReset Reset tuned motion parameters STIsClosed Test if a Servo Tool is closed STIsOpen Test if a Servo Tool is open STCalcTorque Calculate the motor torque for a Servo Tool STCalcForce Calculate the programmable force for a Servo Tool ...

Page 172: ...ned for different reach and weld forces equipped with different brands and sizes of servo motors may be held and operated by a robot switching from one servo gun to another Servo Tool Change can be used as an independent option or as an addition to the SpotWare Servo or Servo Toool Control options Requirements Servo Tool Change requires a mechanical wrist interface a Tool Changer A MOC service par...

Page 173: ... saved and restored next time the axis is activated Note The motor position must not change more than half a motor revolution when the axis is disconnected In SpotWare Servo there is a calibration routine which handles larger position changes RAPID instructions included in this option There are no specific RAPID instructions included in this option ...

Page 174: ... superior computer where none of the WebWare products are used It includes the same functionality described for the option Factory Ware Interface It also works for the WebWare products There is no difference from the FactoryWare Interface except that the price is higher Note that both FactoryWare Interface and RAP Communication can be installed simultaneously ...

Page 175: ...disk of the PC This is done by a manual command from the teach pendant or an instruction in the program If the option RAP Communication or FactoryWare Interface is used it can also be done by a command from the PC without using the ramdisk as intermediate storage Several robots are connected to a PC via Ethernet The control program and the user programs for all the robots are stored on the PC A so...

Page 176: ...nsfer files to from the robot Read the robot status Read and write data Read and write output signals Read input signals Read error messages Change robot mode Read logs RAP communication is available both for serial links and network as illustrated by the figure below Examples of applications Production is controlled from a superior computer Information about the robot status is displayed by the c...

Page 177: ...271 Interbus Configuration Tool The Interbus Configuration Tool is used to configure the communication channels of the DSQC 512 board See I O Interfaces in the S4Cplus Product Specification The tool consists of standard PC software The tool creates a bus configuration which is used by the controller ...

Page 178: ... is used to configure the master channel of the Profibus DP DSQC 510 board See I O Interfaces in the S4Cplus Product Specification The tool consists of standard PC software The tool creates a bus configuration which is used in the robot controller Note This tool is NOT needed for configuration and use of other channels than the master channel of the DSQC 510 board ...

Page 179: ...the units Configuration data for the units is included In I O Plus there is also support for a so called Welder This is a project specific spot welding timer and is not intended for general use In addition to the above units the I O Plus Generic Driver also opens up the possibility to use other digital I O units that conform with the DeviceNet specification ABB does not assume any responsibility f...

Page 180: ...troller uses parallel signals but a serial interface is also available Advanced process control Voltage wire feed rate and other process data can be controlled individually for each weld or part of a weld The process data can be changed at the start and finish of a welding process in such a way that the best process result is achieved Testing the program When testing a program welding weaving or w...

Page 181: ...ns gas on or off Wire feed on off Turns wire feed on or off Wire feed direction Feeds wire forward backward Weld error Weld error Error information Digital outputs for error identification Weld program number Parallel port for selection of program number or 3 bit pulse port for selection of program number or Serial CAN Devicenet communication Digital inputs Description Arc OK Arc established start...

Page 182: ...nt for monitoring and supervision Current Weld current measurement for monitoring and supervision RAPID instructions included in this option ArcL Arc welding with linear movement ArcC Arc welding with circular movement ArcKill Aborts the process and is intended to be used in error handlers ArcRefresh Updates the weld references to new values ...

Page 183: ...ons This functionality is also a part of option Advanced Motion see this option for more information Adaptive process control for e g sensors like LaserTrak and Serial Weld Guide systems The sensor can for instance provide the robot system with changes in the shape of the seam These values can then be used to adapt the process parameters like voltage or wire feed to the current shape See option Se...

Page 184: ...rol not only the robot program but also the set up configuration and programming of the power source Thus the robot teach pendant will be used for programming and tuning both the robot and the power source The package also includes a special aid for easy welding programming i e the synergic function This means that there is a pre programmed relationsship between the wire feed rate and all other da...

Page 185: ...erface is also available for some type of weld timers It should be noted that the SpotWare options are general and can be extensively customized They have a default ready to use functionality directly after install but it is intended that some configuration data RAPID data and RAPID routines has to be changed during the customizing SpotWare features Some examples of useful functions are given belo...

Page 186: ...environment A number of predefined parameters are also available to shape the behaviour of the SpotWare instructions Programming principles Both the robot movement and the control of the spot weld equipment are embedded in the basic spot weld instructions SpotL and SpotJ The spot welding process is specified by Spotdata spot weld process data Gundata spot weld equipment data The system modules SWU...

Page 187: ... they come to a well defined process stop For example the welding processes will carry on and finish the welds and open the guns although the program has been stopped during the weld phase For well defined points in the welding sequence calls to user routines offer adaptations to the plant environment A number of predefined parameters are also available to shape the behaviour of the SpotWare instr...

Page 188: ...cesses Move the TCP along a linear path and perform spot welding with 1 4 gun equipments at the end position SpotMJ Control the motion gun closure opening and 1 4 welding processes Move the TCP along a non linear path and perform spot weld ing with 1 4 gun equipments at the end position Spot welding data Data type Used to define spotmdata The spot weld process gunmdata The spot weld equipment ...

Page 189: ...be extensively customized They have a default ready to use functionality directly after install but it is intended that some configuration data RAPID data and RAPID routines has to be changed during the customizing SpotWare Servo features The SpotWare Servo package contains the following features Fast and accurate positioning using the unique QuickMove and TrueMove concept Gun pre closing i e havi...

Page 190: ...h the weld and open the gun although the program has been stopped during the weld phase For well defined points in the welding sequence and movements calls to user routines offer adaptations to the plant environment A number of predefined parameters are also available to shape the behaviour of the SpotWare instructions Programming principles Both the robot movement and the control of the spot weld...

Page 191: ...perform a spot welding at the end position SetForce Close the gun a predefined time then open the gun CalibL Calibrate the gun during linear movement to the programmed position CalibJ Calibrate the gun during non linear movement to the programmed position Calibrate Calibrate the gun in current position without movement STTune Tune motion parameters for the servo gun STTuneReset Reset tuned motion ...

Page 192: ...ped then the weld processes and supervision will continue until they come to a well defined process stop For example the welding processes will carry on and finish the weld and open the guns although the program has been stopped during the weld phase Programming principles Both the robot movement and the control of the spot weld equipments are embedded in the basic spot weld instructions SpotL and...

Page 193: ...tion gun closure opening and 1 2 welding processes Move the TCP along a linear path and perform spot welding with 1 2 gun equipments at the end position SpotMJ Control the motion gun closure opening and 1 2 welding processes Move the TCP along a non linear path and perform spot welding with 1 2 gun equipments at the end position ...

Page 194: ...guns Speed proportional or constant analog outputs Up to five different guns can be handled simultaneously controlled by 1 5 digital output signals for gun on off control and 1 2 analog output signals for flow control Four different gun equipment each controlled by 1 5 digital output signals and 1 2 analog output signals can be handled in the same program Possibility to use different anticipated t...

Page 195: ...ing purposes See Predefined Data and Programs System Module DPUSER The I O configuration See System Parameters DispenseWare Dispensing instructions Instruction Used to DispL Move the TCP along a linear path and perform dispensing with the given data DispC Move the TCP along a circular path and perform dispensing with the given data Dispensing data Data type Used to define beaddata Dispensing data ...

Page 196: ...d external equipment In order to minimize commissioning time PalletWare is equipped with a standardized set of modules referred to as the Standard Package Add On Advanced users can replace these modules with their own if special customizing is needed PalletWare is also delivered with template user routines that handles the most common solutions PalletWare offers a standardized interface where to c...

Page 197: ... Define tooldata if the tool does not match the templates Check the set up in the configuration module PAL_CFG Define teach work objects to the stations Define teach robtarget with tool in zero orientation Create and load pallet cycles with PalletWizard In addition to this PalletWare offers a great deal of customizing possibilities for advanced users e g Using tools with suction cups or mechanical...

Page 198: ...composition and the pallet cycles Automatic pick and place definition Automatic calculating of grip zones to be used for the tool Software based collision detection Library of predefined patterns Several different pallet cycles can be combined into a production cycle and saved into a file which can be downloaded to the robot At the robot the operator can then select what specific pallet cycle to r...

Page 199: ...DispenseWare 51 E electronically linked motors 24 error handler movement 16 Ethernet Services 32 F file read and write 14 33 fixed position output 15 procedure call 15 Friction Compensation 13 FTP 32 I I O Plus 36 independent movement 13 input or output signals interrupts 17 Interbus Configuration Tool 34 interrupt routine movement 16 interrupts from analog input or output signals 17 L Load Identi...

Page 200: ...e OS 4 0 Reset the work area 12 S Sensor Interface 26 Sensor Synchronization 25 serial channel 14 Servo Tool Change 29 Servo Tool Control 27 SpotWare Servo 46 SpotWare Servo Plus 49 T transfer data 14 33 file 33 program 33 W World Zones 16 write data 14 file 14 ...

Page 201: ...Installation Manual IRB 6600 6650 M2000A 3HAC 16245 1 Revision A ...

Page 202: ...rom 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 2002 ABB All rights res...

Page 203: ...rk inside the manipulator s working range 15 Chapter 2 Reference information 17 2 0 1 Introduction 17 Section 2 1 Reference information 18 2 1 1 Applicable Safety Standards 18 2 1 2 Screw joints 19 2 1 3 Weight specifications 21 2 1 4 Standard toolkit 22 2 1 5 Special tools 23 2 1 6 Performing a leak down test 25 2 1 7 Lifting equipment and lifting instructions 26 Chapter 3 Unpacking 27 3 0 1 Pre ...

Page 204: ... 3 Customer connections on manipulator 88 5 3 1 Signal connections SpotWelding Specification 88 5 3 2 Signal connections Material Handling Specification 89 Section 5 4 Customer connections on controller 90 5 4 1 The MOTORS ON MOTORS OFF circuit 90 5 4 2 External customer connections on panel X1 X4 95 5 4 3 Connection of external safety relay 98 Section 5 5 Supplies 100 5 5 1 External 24V supply 10...

Page 205: ...e in the robot controller mass storage memory 171 9 0 4 Preparation of S4Cplus software to be installed 172 9 0 5 Handling mass memory storage capacity 173 Chapter 10 Calibration 175 Section 10 1 General 175 10 1 1 Types of calibration procedures 175 10 1 2 How to calibrate the robot system 176 10 1 3 Calibration prerequisites 178 10 1 4 Calibration pendulum kit contents 179 Section 10 2 Prelimina...

Page 206: ...Table of Contents iv 3HAC 16245 1 Chapter 11 Decommissioning 205 11 0 1 Balancing device IRB 7600 and IRB 6600 6650 205 ...

Page 207: ... manual is intended for installation personnel on the installation site Prerequisites The reader should have the required knowledge of mechanical as well as electrical installation work Organization of Chapters The information product is organized in the following chapters References Chapter Contents 1 Safety Service 2 Reference Information 3 Unpacking 4 On site Installation 5 Electrical connectio...

Page 208: ...ion Description First edition A Various corrections in text and in figures due to reconstruc tions new options etc Manual completed with references to pagenumbers and numbering of sections manipulator sections Manual completed with version IRB 6650 ...

Page 209: ...ons for all manipulator details considered spare parts Remove Refitting instructions for all controller cabinet details considered spare parts If there is any model specific information Maintenance Manual The Maintenance Manual contains the following information Safety Service Reference Information Maintenance schedules Instructions for all maintenance activities specified in the maintenance sched...

Page 210: ...l Each hardware option is supplied with its own documentation Each document set contains the types of information specified above Installation information Repair information Maintenance information In addition spare part information is supplied for the complete option ...

Page 211: ...rvicing the robot system The dan gers 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 r...

Page 212: ...ction 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 inter act with other machines and peripheral equipment This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot In the...

Page 213: ...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 from falling due to gravity 1 2 4 Safety risks during operational disturbances Gene...

Page 214: ...y stored in the robot for the purpose of counterbalancing certain axes may be released if the robot or parts thereof is dismantled When dismantling assembling mechanical units watch out for falling objects Be aware of stored heat energy in the controller Never use the robot as a ladder i e do not climb on the robot motors or other parts during service work There is a serious risk of slipping becau...

Page 215: ... machining pro cess The external voltage connected to the control cabinet remains live even when the robot is disconnected from the mains Additional connections Voltage related risks manipula tor A danger of high voltage is associated with the manipulator in The power supply for the motors up to 800 VDC The user connections for tools or other parts of the installation max 230 VAC see Installation ...

Page 216: ...eased manually by push ing the brake release buttons on the manipulator or on an optional external brake release unit How to release the brakes is detailed in section Manually releasing the brakes 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 o...

Page 217: ...t Unit with him her when entering the robot s working space This is to prevent anyone else taking control over the robot without the programmer knowing 1 3 7 Work inside the manipulator s working range 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 ena...

Page 218: ...1 Safety service 1 3 7 Work inside the manipulator s working range 16 A 3HAC 16245 1 ...

Page 219: ...ion 2 0 1 Introduction 3HAC 16245 1 A 17 Chapter 2 Reference information 2 0 1 Introduction General This chapter presents generic pieces of information complementing the more specific infor mation in the following chapters ...

Page 220: ...sessment ANSI RIA 15 06 1999 Industrial robots safety requirements DIN 19258 Interbus S International Standard Standards robot cell The following standards are applicable when the robot is part of a robot cell EN 953 Fixed and moveable guards EN 811 Safety distances to prevent danger zones being reached by the lower limbs EN 349 Minimum gaps to avoid crushing of parts of the human body EN 294 Safe...

Page 221: ... void any warranty and may potentially cause serious damage or injury Gleitmo treated screws Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint Screws treated with Gleitmo may be reused 3 4 times before the coating disappears After this the screw must be discarded and replaced with a new one When handling screws treated with Gleitmo protective gloves of n...

Page 222: ... dry Screws with hexagon socket head lubricated Dimension Tightening torque Nm Class 4 8 dry M2 5 0 25 M3 0 5 M4 1 2 M5 2 5 M6 5 0 Dimension Tightening torque Nm Class 8 8 dry Tightening torque Nm Class 10 9 dry Tightening torque Nm Class 12 9 dry M5 6 M6 10 M8 24 34 40 M10 47 67 80 M12 82 115 140 M16 200 290 340 Dimension Tightening torque Nm Class 10 9 Tightening torque Nm Class 12 9 M8 28 34 M1...

Page 223: ...onents exceeding 22 kg 50 lbs are high lighted in this way ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg to avoid inflicting injury A wide range of lifting tools and devices is avail able for each manipulator model Example Below is an example of how a weight specification is presented The motor weighs 65 kg All lifting equipment used must be dim...

Page 224: ...lkit and defined in the table below In this way the tools required are the sum of the Standard Toolkit and any tools listed in the instruction Contents standard toolkit 3HAC 15571 1 Qty Tool Rem 1 Ring open end spanner 8 19mm 1 Socket head cap 5 17mm 1 Torx socket no 20 60 1 Box spanner set 1 Torque wrench 10 100Nm 1 Torque wrench 75 400Nm 1 Ratchet head for torque wrench 1 2 2 Hexagon headed scre...

Page 225: ...olts M16 x 80 for Mech stop ax 3 2 3HAB 3409 89 Cal tool a a 68080011 GM Calibration bracket a 3HAC 13908 9 Calibration tool ax1 a a 3HAC 13908 4 CalPen Calibration Pendulum 1 1 3HAC 15716 1 Extension 300mm for bits 1 2 1 1 3HAC 12342 1 Fixture lower arm 1 3HAC 13659 1 Fixture lower arm 1 3HAC 13660 1 Gearbox crank 1 3HAC 16488 1 Guide pins M12 x 150 2 3HAC 13056 2 Guide pins M12 x 200 2 3HAC 1305...

Page 226: ...motor ax 2 3 4 1 1 3HAC 15534 1 Lifting tool wrist unit 1 3HAC 13605 1 Lifting tool wrist unit 1 3HAC 12734 1 Measuring pin a 3HAC 13908 5 Mech stop ax 3 2 3HAC 12708 1 Mech stop ax 3 2 3HAC 12708 2 Press tool ax 2 bearing 1 3HAC 13527 1 Press tool ax 2 bearing 1 3HAC 13453 1 Press tool ax 2 shaft 1 1 3HAC 13452 1 Press tool balancing device shaft 1 1 3HAC 17129 1 Press tool balancing device 1 1 3...

Page 227: ...cluded in the leakdown tester kit Art no specified above 3 Apply compressed air and raise the pressure with the knob until the correct value is shown on the manometer 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 signifi cantly colder or warmer than the gearbox to be tested a...

Page 228: ...ctivities require different pieces of lifting equipment which are specified in each activity instruction However how to use each piece of lifting equipment is not detailed in the activity instruction 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 229: ...r as specified in Weight manipulator on page 27 4 If the manipulator is not to be installed directly it must be stored as described in Storage conditions manipulator on page 28 5 Make sure the expected operating environment of the manipulator conforms to the specifications as described in Operating conditions manipulator on page 28 6 Before taking the manipulator to its installation site make sure...

Page 230: ... condi tions manipula tor The table below shows the allowed operating conditions for the manipulator Force Endurance load in operation Max load at emergency stop Force xy 10 1 kN 20 7 kN Force z 18 0 13 8 kN 18 0 22 4 kN Torque xy 27 6 kNm 50 6 kNm Torque z 7 4 kNm 14 4 kNm Requirement Value Note Min levelity 0 5 mm Max tilt 5 The limit for the maximum payload on the manipulator is reduced if the ...

Page 231: ...king 3 0 1 Pre installation procedure 3HAC 16245 1 A 29 Protection classes manipu lator The table below shows the protection class of the manipulator Equipment Protection class Manipulator IRB 6600 6650 IP 67 ...

Page 232: ... 2 55 30 A 3HAC 16245 1 3 0 2 Working range IRB 6600 175 2 55 and IRB 6600 225 2 55 Illustration The illustration below shows the unrestricted working range of IRB 6600 175 2 55 and IRB 6600 225 2 55 xx0200000025 IRB 6600 175 2 55 IRB 6600 225 2 55 903 1119 1814 2550 ...

Page 233: ...ing range IRB 6600 175 2 8 3HAC 16245 1 A 31 3 0 3 Working range IRB 6600 175 2 8 Illustration The illustration below shows the unrestricted working range of IRB 6600 175 2 8 xx0200000026 IRB 6600 175 2 8 1004 1324 2061 2800 ...

Page 234: ...3 0 4 Working range IRB 6650 125 3 2 32 A 3HAC 16245 1 3 0 4 Working range IRB 6650 125 3 2 Illustration The illustration below shows the unrestricted working range of IRB 6650 125 3 2 xx0200000338 IRB 6650 125 3 2 ...

Page 235: ...0 5 Working range IRB 6650 200 2 75 3HAC 16245 1 A 33 3 0 5 Working range IRB 6650 200 2 75 Illustration The illustration below shows the unrestricted working range of IRB 6650 200 2 75 xx0200000339 RB 6650 200 2 75 ...

Page 236: ...g area Moving the arms will displace the centre of gravity which may cause the manipulator to tip over DO NOT change the manipulator position before securing it to the foundation Stabililty The figure below shows the manipulator in its shipping position which also is its most stable position xx0100000103 1 DO NOT change the manipulator position before securing it to its foundation The shipping pos...

Page 237: ...4 On site Installation 3HAC 16245 1 A 35 Chapter 4 On site Installation ...

Page 238: ...own in the figure below are different depending on the design of the frame This means that the fork lift sets are unique for one type of frame they are in other words not compatible Except for the shorter distance between the attachment holes the later design of the frame also includes an extra oil plug located as shown in the figure below xx0200000386 Required equip ment 1 Frame version without o...

Page 239: ...C 0604 2 The figure below shows how to attach the fork lift set 3HAC 0604 2 to the manipulator xx0100000102 Standard toolkit 3HAC15557 1 The contents are defined in section Stan dard toolkit on page 18 Equipment etc Art no Note A Securing screws 2x4 pcs B Fork lift pockets 2 pcs C Spacer 2 pcs A B C ...

Page 240: ...or using the fork lift ONLY The IRB 6600 6650 manipulator weighs 1725 kg All lifting equipment used must be dimen sioned accordingly The IRB 7600 manipulator weighs 2550 kg All lifting equipment used must be dimensioned accordingly The shorter fork lift pocket weighs 22 kg while the longer version weighs 60 kg Use a suitable lifting device to avoid injury to personnel A Fork lift pocket 2 pcs diff...

Page 241: ...ad is permitted on the manipulator xx0200000387 When using fork lift set 3HAC 0604 1 a load is permitted on the manipulator 2 Fit the two spacers to the manipulator and secure Shown in the figures Illustration 3HAC 0604 2 on page 37 or Illustration 3HAC 0604 1 on page 38 3 Secure the fork lift pocket horizontally to the spacers with four washers and securing screws Notice the tightening torques Al...

Page 242: ...econd fork lift pocket on the other side of the manipulator with securing screws Shown in figure Illustration 3HAC 0604 2 on page 37 or Illustration 3HAC 0604 1 on page 38 4 pcs M16x60 tightening torque 60 Nm 12 Nm not oil lubricated screws Make sure the original screws are always used or replacements of equivalent quality M16 quality 12 9 6 Double check that the pockets are properly secured to th...

Page 243: ...for lifting of robot IRB 6600 10 700 725 50 3x Chain sling with shortener 4250kg 0 47m 0 54m 0 76m 3x Anschlagketten mit Verkürzer 4250kg 0 47m 0 54m 0 76m 3x Chaîne avec crochet raccourcisseur 4250kg 0 47m 0 54m 0 76m Roundsling 2000kg Do not strech Rundschlingen 2000kg Nicht gespannt Élingue ronde 2000k g Ne doivent pasetre sous tension m L IFT ING OF R OBOT HE BE N DE S ROBOT E RS L E VAGE DU R...

Page 244: ...w to lift the complete manipulator with lifting slings Note the recommended manipulator position shown in the following figure and in the instruc tion Attempting to lift a manipulator in any other position may result in the manipulator tipping over causing severe damage or injury xx0200000153 A Load hook B Swivelling lifting eyes 4 pcs C Shortening hook D Chain E M12 lifting eye F Lifting device s...

Page 245: ... Equipment Art no Lifting device manipulator 3HAC 15607 1 includes instruction 3HAC 15971 2 for how to use the lifting device Step Action Note 1 Run the overhead crane to a position above the manipulator 2 Make sure the manipulator is positioned as shown in the figure on the right If it is not position it that way Release the brakes if required as detailed in Manually releasing the brakes on page ...

Page 246: ...r is connected or that power is supplied to the R1 MP connector on manipulator base 0V on pin 12 and 24V on pin 11 IRB 7600 External brake release unit using push buttons on an external brake release unit This does NOT require the controller to be connected The external unit is used when there are no push buttons on the manipulator Supplying power on the wrong pins may cause all brakes on the mani...

Page 247: ...below shows the unit located at the base xx0200000375 Illustration IRB 7600 frame The internal brake release unit on the IRB 7600 is located either at the base or at the frame The figure below shows the unit located at the frame xx0200000376 Internal brake release unit with push buttons located on the manipulator base Internal brake release unit with push buttons located on the manipulator frame 6...

Page 248: ...e release unit in order to release the manipulator s holding brakes xx0100000104 Step Action Info Illustration 1 The internal brake release unit is equipped with six buttons for controlling the axes brakes The buttons are numbered according to the num bers of the axes The buttons are located according to one of the figures Illustration IRB 6600 6650 on page 44 Illustration IRB 7600 base on page 45...

Page 249: ...xternal brake release unit only IRB 7600 When releasing the holding brakes the manipulator axes may move very quickly and some times in unexpected ways Make sure no personnel is near the manipulator arm A Rear connector plate B Connector R1 MP C Connector R1 BU D External brake release unit E Connect to R1 BU A B D E C Equipment Art no External brake release unit 3HAC 12987 1 Step Action Info Illu...

Page 250: ...nnectors on page 47 3 Connect the external brake release unit to connector R1 BU Art no specified in section Required equipment on page 47 Shown in Illustration IRB 7600 exter nal brake release unit connectors on page 47 4 Release the holding brake of each manipu lator axis by pressing the respective button on the external brake release unit 5 Disconnect the external brake release unit 6 Refit the...

Page 251: ...e plate Equipment Spare part no Art no Note Standard toolkit 3HAC 15571 1 The contents are defined in section Standard toolkit on page 18 Lifting eye M16 3HAC 14457 4 Use three lifting eyes For lifting the base plate Lifting slings Use three slings Length approx 2 m A Attachment holes for lifting eyes x3 A Step Action Info Illustration 1 Fit lifting eyes in the three lifting holes Shown in the fig...

Page 252: ... plate 50 A 3HAC 16245 1 4 1 6 Securing the base plate General This section details how to secure the base plate Base plate dimensions xx0100000105 480 540 2x 321 2x 503 2x 453 2x 247 2x 90 2x 90 2x 273 2x 407 2x 451 2x 182 455 A A B B D A A B B D ...

Page 253: ...Note Base plate 3HAC 12937 7 Includes all required guide sleeves screws and washers A drawing of the base plate itself may be ordered from ABB Robotics Guide sleeves 2 pcs between guide plate and manipulator 3HAC 12937 3 Included in Base plate 3HAC 12937 7 Standard toolkit 3HAC 15571 1 The contents are defined in section Standard toolkit on page 18 Other tools and proce dures may be required See r...

Page 254: ...ing the three grooves in the base plate Shown in Base plate grooves and holes on page 51 3 Lift the base plate to its mounting position Detailed in Lifting the base plate on page 49 4 Use the base plate as a template and drill 16 attachment holes as required by the selected bolt dimension If possible observe the recommenda tions specified in the table above ABB does not assume any responsibility f...

Page 255: ...650 uses 8 attachment bolts Illustration manipulator fitted to base plate The illustration below shows the IRB 7600 manipulator base fitted to the base plate The IRB 6600 6650 manipulator base does not have the attachment holes A 4 pcs xx0100000107 Attachment screws The table below specifies the type of securing screws and washers to be used for securing the manipulator to the base plate foundatio...

Page 256: ...he manipulator to the vicinity of its installation location 3 Fit two guide sleeves to the guide sleeve holes in the base plate Shown in Base plate grooves and holes on page 51 Note that one of the guide sleeve holes is elongated 4 Guide the manipulator gently using two M24 screws while lowering it into its mounting position Make sure the manipulator base is cor rectly fitted onto the guide sleeve...

Page 257: ...Hole configura tion IRB 7600 The illustration below shows the hole configuration used when securing the manipulator IRB 7600 xx0300000046 Cross section guide sleeve hole The illustration below shows the cross section of the guide sleeve holes xx0100000109 4 x 10 4 x 1 5 4 x 7 5 4 x 3 7 5 ...

Page 258: ...itions mounting holes may be added on the manipulator Illustration fitting extra equipment on lower arm The illustration below shows the mounting holes available for fitting extra equipment on the lower arm Make sure not to damage the manipulator cabling on the inside of the lower arm when fitting extra equipment Always use the appropriate attachment screws xx0200000195 Illustration fitting extra ...

Page 259: ...ing equipment on manipulator 3HAC 16245 1 A 57 Illustration fitting extra equipment on frame The illustration below shows the mounting holes available for fitting extra equipment on the frame xx0200000198 1195 790 75 45 200 240 4x M16 ...

Page 260: ...ations below show the mounting holes available for fitting equipment on the mounting flange There are two different versions of the mounting flange as shown in illus trations below xx0200000197 Mounting flange for robot version 225 2 55 175 2 8 125 3 2 and 200 2 75 Ø12 H7 Depth 15 Ø 160 15 A A B B B B A A 30 11x Ø100 H7Depth 8 min ...

Page 261: ...7 Fastener quality When fitting tools on the mounting flange see the figures above use only screws with qual ity 12 9 When fitting other equipment standard screws with quality 8 8 can be used Mounting flange for robot version 175 2 55 A 15 Ø12 H7 Depth 15 30 12 x B B A Ø160 Ø100H7 Depth 8min ...

Page 262: ...and overloading the motors If this is not done correctly operational stops may result 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 Stop time and braking distances Manipulator motor brake performance depends on any loads attached For further informa t...

Page 263: ...e risk of collisions The following axes may be restricted Axis 1 hardware mechanical stop and software signal from adjustable position switch Axis 2 hardware mechanical stop and software signal from adjustable position switch Axis 3 hardware mechanical stop and software signal from adjustable position switch This section describes the utilization of the mechanical stops and the position switches ...

Page 264: ...graduation in both directions Mechanical stops axis 1 The illustration below shows the mounting position of the mechanical stops on axis 1 xx0300000049 Required equip ment A Additional mechanical stop B Fixed mechanical stop A B Equipment etc Spare part no Art no Note 7 5 mechanical stop for axis 1 3HAC 11076 1 Includes attachment screws 15 mechanical stop for axis 1 3HAC 11076 2 Includes attachme...

Page 265: ...closed with the product The addititonal mechanical stop must be replaced after a hard collision if the mechanical stop has been deformed Step Action Note Illustration 1 Mount the additional mechanical stop on the frame according to the figure Mechanical stops axis 1 on page 62 Tightening torque 115 Nm 2 The software working range limitations must be amended to correspond to the changes in the mech...

Page 266: ...ws the mounting position of the mechanical stops on axis 2 xx0300000047 Required equip ment A Additional mechanical stops B Fixed mechanical stop A B Equipment etc Spare part no Art no Note Mechanical stop set axis 2 IRB 6600 6650 3HAC13787 1 Includes six stops 3HAC 13786 1 each one restricting the work ing range by 15 Includes attachment screws Mechanical stop set axis 2 IRB 7600 3HAC11077 1 Incl...

Page 267: ... the product The addititonal mechanical stop must be replaced after a hard collision if the mechanical stop has been deformed Step Action Note Illustration 1 Mount and tighten the additional stops in a row starting from the fixed stop Tightening torque 115 Nm Shown in the figure Mechanical stops axis 2 on page 64 2 The software working range limitations must be amended to correspond to the changes...

Page 268: ...ops on axis 3 xx0300000048 Required equip ment A Additional mechanical stops B Fixed mechanical stop A B Equipment etc Spare part no Art no Note Mechanical stop set axis 3 IRB 6600 6650 3HAC 13128 1 Includes six stops one with 80 restriction 3HAC 12708 3 use when limitation angle 80 and five with 20 3HAC 12708 1 Includes attachment screws Mechanical stop set axis 3 IRB 7600 3HAC 13128 3 Includes s...

Page 269: ... the product The addititonal mechanical stop must be replaced after a hard collision if the mechanical stop has been deformed Step Action Note Illustration 1 Mount and tighten the additional stops in a row starting from the fixed stop Shown in the figure Mechanical stops axis 3 on page 66 Tightening torque 115 Nm 2 The software working range limitations must be amended to correspond to the changes...

Page 270: ...n delivery In this case the cams must still be fitted and locked by the user For axis 1 the cover for the cams must also be fitted As kits to be completely fitted to the manipulator and adjusted by the user Axis 1 The illustration below shows the position switch for axis 1 xx0100000158 Description Art no Position switch axis 1 complete 3HAC 14118 1 Position switch axis 2 complete 3HAC 15710 1 Posi...

Page 271: ...ation 4 2 5 Position switches 3HAC 16245 1 A 69 Axis 2 The illustration below shows the position switch for axis 2 xx0100000159 A Position switch axis 2 B Cam C Set screw cam cam stop E Rail F Rail Attachment B E A C F ...

Page 272: ... be connected to different points on the robot system R1 SW1 at the manipulator base Customer connection kit is recommended Also see Customer Connection Kit R1 SW2 3 at the manipulator base Customer connection kit is recommended Also see Customer Connection Kit XT8 screw terminal in the controller cabinet A Position switch axis 3 B Cam C Set screw cam cam stop E Rail F Rail attachment C A B E F Pa...

Page 273: ...rp knife and rubber ham mer or similar 2 Cut the edge of the cam edge to max 30 Shown in Illustration cutting the cam on page 72 If the angle is larger this may dam age the position switch 3 Cut the part of the cam running in the profile to 90 Also see Illustration cutting the cam on page 72 below 4 Make sure the ends of the profile are cham fered to enable the cam to run through the pro file 5 Fi...

Page 274: ...n site Installation 4 2 5 Position switches 72 A 3HAC 16245 1 Illustration cut ting the cam The illustration below show how to cut the position switch cam xx0100000114 A Remove the gray section 90 o 30 o A ...

Page 275: ...on 4 3 On site installation controller cabinet 4 3 1 Lifting the controller cabinet Lifting device Use the four lifting devices on the cabinet or a fork lift when lifting the controller cabinet S4Cplus M2000A as shown below xx0100000153 A Min 60 when lifting with straps B Fork lift 60 ...

Page 276: ...quired installation space control cabinet Dimensions The figure below shows the required installation space for the S4Cplus M2000A control cab inet xx0100000156 Dimensions The figure below shows the bolt pattern for the S4Cplus M2000A control cabinet xx0100000157 A Min distance from wall A A 400 720 ...

Page 277: ...5 Electrical connections 3HAC 16245 1 A 75 Chapter 5 Electrical connections ...

Page 278: ...el XS78 Safety signals external connections XS77 X7 DeviceNet LAN XTDF Mains connection X24VE VS External axes IBS Position switches XS41 Manipulator cables XS58 XS2 Ext contr panel Cable category Description Manipulator cables Handles power supply to and control of the manipulator s motors as well as feedback from the serial measurement board Position switch cables option Handles supply to and fe...

Page 279: ...m the drive units in the control cabinet to the manip ulator motors XP1 R1 MP Manipulator cable signals Transfers resolver data from the serial measurement board and power supply to the SMB XP2 R1 SMB Cable Article number Manipulator cable power 7 m 3HAC 11818 1 Manipulator cable power 15 m 3HAC 11818 2 Manipulator cable power 30 m 3HAC 11818 4 Cable Article number Manipulator cable signal shielde...

Page 280: ...nection point cabinet Connection point manipulator Fieldbus cable CAN 7 m 3HAC 13173 1 XT XP5 1 XT XP6 XS6 R1 CP CS Fieldbus cable CAN 15 m 3HAC 13173 2 XT XP5 1 XT XP6 XS6 R1 CP CS Fieldbus cable CAN 30 m 3HAC 13173 4 XT XP5 1 XT XP6 XS6 R1 CP CS Fieldbus cable Profibus 7 m 3HAC 13174 1 XT XP5 1 XT XP6 DP M R1 CP CS Fieldbus cable Profibus 15 m 3HAC 13174 2 XT XP5 1 XT XP6 DP M R1 CP CS Fieldbus ...

Page 281: ...cting the manipulator to the control cabinet specifies which cables to use and to which connectors these are to be connected in order to to connect the controller to the manipulator Connections to the cabinet All control cabinet connectors are shown in the figure below xx0100000247 The connections on the manipulator are located on the rear of the robot base A Manipulator cable Power B Manipulator ...

Page 282: ...s in accordance with the rated power and line voltage see rating plate on the controller Connections to the mains switch Also see the Circuit Diagram The instruction below details how to make all required connections to the mains switch xx0100000248 A Connector Q1 L1 L2 L3 B Cable gland C Protective Earth connection PE Step Action Info Illustration 1 Remove the left cover plate under the top lid 2...

Page 283: ...lied option 132 134 xx0100000162 4 Connect phase 1 to L1 Not dependent on phase sequence 2 to L2 3 to L3 0 to XT26 N line neutral is needed only for option 432 and protective earth to theprotective earth connection Shown in the figure above NOTE Max conductor size is 6 mm2 AWG 10 Tighten to a torque of 2 3 2 5 Nm Retighten after approx 1 week 5 Snap the breaker on to the knob again and check that ...

Page 284: ...es when selecting and laying cable Signals from different classes must not be mixed Signals Power Signals Supplies external motors and brakes Control signals Digital operating and data signals digital I O safety stops etc Measuring signals Analog measuring and control signals resolver and analog I O Data communication signals Gateway Field bus connection computer link ...

Page 285: ...et for dis tributingI Ounits Thin cable according to DeviceNet specification release 1 2 must be used e g ABB article no 3HAB 8277 1 The cable is shielded and has four conductors two for electronic supply and two for signal transmission Note that a separate cable for supply of I O loads is required Allen Bradley Remote I O Cables according to Allen Bradley specification e g Blue hose should be use...

Page 286: ...ross the coil Varistors give shorter turn off times Neutralising the coils lengthens the life of the switches that control them Clamping with a diode The diode should be be dimensioned for the same current as the relay coil and a voltage of twice the supply voltage xx0100000163 Clamping with a varistor The varistor should be be dimensioned for the same current as the relay coil and a voltage of tw...

Page 287: ... 3HAC 16245 1 A 85 5 2 4 Connection types General I O external emergency stops safety stops etc can be supplied on screw connections or as industrial connectors Connections Designation Connection type X T Screw terminal XP Pin male XS Sockets female ...

Page 288: ...ctions will be found in the circuit diagram Service Man ual Installation The installation should comply with the IP54 NEMA 12 protective standard 1 Bend unused conductors backwards and attach them to the cable using a clasp or similar To prevent interference ensure that unused conductors are not connected at the other end of the cable antenna effect In environments with much interference disconnec...

Page 289: ...Making the con nection The section below details how to crimp cable connections to pins 1 Using a special crimp tool crimp a pin or socket on to each non insulated conduc tor When two conductors are be connected to the same pin or socket both of them must be crimped into the same pin or socket A maximum of two conductors may be crimped into the same pin or socket 2 Snap the pin into the connector ...

Page 290: ... information Servo motor power 3 600 VAC 12A rms min 1 5 mm 2 Utility power 4 600 VAC 5A rms min 0 5 mm 2 Protective earth 1 min 1 5 mm 2 Signals 20 50 VAC DC 1A rms min AWG 24 tw pairs Sensitive signals 10 50 VAC DC 1A rms min AWG 24 tw pairs extra screening Bus signals 2 Profibus 12 Mbit s spec Bus signals 2 CAN DeviceNet spec Bus signals 4 Interbus spec Bus utility signals 4 50 VAC DC 1A rms mi...

Page 291: ...ROC Further information See Circuit Diagram in the Repairs Manual part 2 for further information Servo motor power 3 600 VAC 12A rms min 1 5 mm 2 Utility power 4 600 VAC 5A rms min 0 5 mm 2 Protective earth 1 min 1 5 mm 2 Signals 20 50 VAC DC 1A rms min AWG 24 tw pairs Sensitive signals 10 50 VAC DC 1A rms min AWG 24 tw pairs extra screening Bus signals 2 Profibus 12 Mbit s spec Bus signals 2 CAN ...

Page 292: ... circuit monitors all safety related equipment and switches If any of the switches is opened the MOTORS ON MOTORS OFF circuit switches the power to the motors off As long as the two chains are not identical the robot will remain in MOTORS OFF mode A ES emergency stop B LS Limit switch C Solid state switches D Contactor E Mains F Drive unit G Second chain interlock H GS general mode safeguarded spa...

Page 293: ...10 and 0V X1 X2 10 is displayed When ext supply X1 X2 3 is connected to ext 24V and X1 X2 8 is connected to ext 0V dotted lines Technical data per chain Limit switch Load 300 mV Max voltage drop 1 V External connectors Load 10 mA Max voltage drop 4 V GS AS load at 24 V 25 mA GS AS closed 1 18 V GS AS open 0 5 V External supply of GS AS Max 35 VDC Min 35 VDC Max potential in relation to the cabinet...

Page 294: ...or 48 VDC ES1 and ES2 max output current 120 VAC 4 A 48 VDC L R 50 mA 24 VDC L R 2 A 24 VDC R load 8 A External supply of ES relay Min 22 V between terminals X1 9 8 and X2 9 8 respectively Rated current per chain 40 mA Max potential in relation to the cabinet earthing and other signal groups 300 V Signal class Control signals 24V 24V 0V 0V 1 4 X1 10 X1 3 X1 9 X1 7 X1 8 X1 1 X1 2 24V A B C D D X1 6...

Page 295: ...he diagram below shows the connection of terminals for customer use xx0100000197 A K1 Motor on off 1 B K1 Motor on off 2 Technical data Max voltage 48 VDC Max current 4 A Max potential in relation to the cabinet earthing and other signal groups 300 V Signal class Control signals A B X3 2 X4 2 1 1 A Auto 1 B MAN1 C 100 Option D Auto 2 E MAN2 F 100 Option Technical data Max voltage 48 VDC Max curren...

Page 296: ...ion of terminals for customer use xx0100000199 Max potential in relation to the cabinet earthing and other signal groups 300 V Signal class Control signals Technical data A K3 Brake Technical data Max voltage 48 VDC Max current 4 A Max potential in relation to the cabinet earthing and other signal groups 300 V Signal class Control signals X4 5 6 A ...

Page 297: ...er to the Circuit Diagram grey field Jumper WARNING REMOVE JUMPERS BEFORE CONNECTING ANY EXTERNAL EQUIPMENT Signal Terminal number Comment ES1 out A 1 Emergency stop out chain 1 ES1 out B 2 Emergency stop out chain 1 ES1 top 3 Top of emergency stop chain 1 24 V panel 4 24 V emergency stop chain 1 and run chain 1 Run ch1 top 5 Top of run chain 1 ES1 internal 6 Internal signal from emergency stop re...

Page 298: ...y stop chain 2 ES2 bottom 9 Bottom of emergency stop chain 2 24 V panel 10 24 V emergency stop chain 1 and run chain 2 Ext LIM2 A 11 External limit switch chain 2 Ext LIM2 B 12 External limit switch chain 2 Signal Terminal number Comment Signal Terminal number Comment Ext MON 1 A 1 Motor contactor 1 Ext MON 1 B 2 Motor contactor 1 0 V 3 External contactor 1 0 V CONT1 4 External contactor 1 5 No co...

Page 299: ... X4 3HAC 16245 1 A 97 0 V 7 0 V to auto stop AS and general stop GS GS2 8 General stop minus chain 2 AS2 9 Auto stop minus chain 2 GS2 10 General stop plus chain 2 AS2 11 Auto stop plus chain 2 24 V panel 12 24 V to auto stop and general stop Signal Terminal number Comment ...

Page 300: ...rnal equipment if external relays are used The figure below shows two examples of how to connect the external safety relays Connection examples xx0100000246 A Panel unit B Relays with positive action C Robot 1 D Robot 2 E External supply F ES emergency stop out G Safety relay K2 K1 X3 4 X3 3 X3 1 X3 2 X4 1 X4 2 X4 3 X4 4 0 V CONT 1 Ext MON 1 Ext MON 2 24 V CONT 2 24 V 0 V A B AS GS AS GS E E F F G...

Page 301: ...5 Electrical connections 5 4 3 Connection of external safety relay 3HAC 16245 1 A 99 H To other equipment J Safety gate K Cell ES emergency stop ...

Page 302: ...ther or not the robot has power on for example When there is a risk that major interference can be carried over into the internal 24V supply How to connect the external sup ply The external supply neutral wire must be connected to the chassis such that the maximum permitted potential difference in the chassis earth is not exceeded For example a neutral wire can be connected to the chassis earth of...

Page 303: ...ges 24 VDC supply for internal and external use 24 VDC supply available at XT 31 24V I O available for customer connections at XT 31 is shown in the figure in Connections to screw terminals Voltage 24 0 26 4V Ripple Max 0 2V Permitted customer load Max 7A Current limit 13 5 0A XT 31 2 24 V through a 2 A fuse XT 31 1 for own fuses XT 31 4 0 V connected to cabinet structure ...

Page 304: ...rom the rest of the controller voltages 115 230 VAC sup ply for internal and external use 115 230 VAC sup ply available at XT 21 115 VAC 230 VAC available for customer connections at XT 21 is shown in the figure in Connection to screw terminals Voltage 115 VAC or 230 VAC Permitted customer load Max 500 VA Fuse size 115 V 6 3 A Fuse size 230 V 3 15 A FU2 201 230 VAC FU1 202 115 VAC N 203 N connecte...

Page 305: ...s of whether any I O units are used or not CAN 1 1 is con nected to socket X15 on the Base connector unit see Connection of the CAN bus CAN 1 2 If CAN 1 2 is not used a terminating resistor must be connected to the X6 socket exceptional case see below A Base connector unit E Termination of last unit B CAN bus F 120 ohm 1 0 25 W metal film resistor C Control cabinet G See figure in section CAN 2 be...

Page 306: ...d in the end of any CAN chain but somewhere between the end points of the chain then no terminating resistor should be mounted in CAN 1 3 This is in accordance with the basic rule i e the CAN chain should be terminated in both end points Termination resistors in CAN bus The CAN chain must be terminated with terminating resistors in each end If CAN 1 2 for example is not connected in the end of any...

Page 307: ...nnection of the CAN bus 3HAC 16245 1 A 105 The illustration below shows CAN connections on base connector unit xx0100000243 A X6 CAN 1 2 external I O B X7 CAN 1 3 external I O C X8 CAN 2 external I O D X15 CAN 1 1 internal I O A B C D ...

Page 308: ...onnected to pin 2 Phoenix connector located on the Interbus S card s front panel marked 24V Technical data Also see the Interbus S specification Further informa tion For setup parameters see User s Guide System Parameters Topic Controller Also see the Circuit Diagram Unit ID Unit ID to be entered in the Interbus S master is 3 The length code depends on the selected data Width between 1 and 4 Layou...

Page 309: ...plug on the interconnection cable connected to the OUT connector of each unit The link informs the Interbus S unit that more units are connected further out in the chain The last unit in the chain does not have a cable connected and therefore no link Connections X5 DeviceNet con nectors See DeviceNet Connectors Connections connector X20 Interbus S IN The figure below shows the pin configuration of...

Page 310: ...Layout DSQC 352 above The figure and table below show the location and significance of the the LEDs on the board NC 5 Not connected TPDO1 N 6 Communication line TPDO1 N TPDI1 N 7 Communication line TPDI1 N NC 8 Not connected NC 9 Not connected Signal name X20 pin Function Signal name X21 pin Function TPDO2 1 Communication line TPDO2 TPDI2 2 Communication line TPDI2 GND 3 Ground connection NC 4 Not...

Page 311: ...iption CAN Tx CAN Rx Green red See section CAN bus status LED description POWER 5 VDC Green Lit when both 5 VDC supplies are within limits and no reset is active RBDA Red Lit when this Interbus S station is last in the Interbus S net work If it is not which is required check parameter setup BA Green Lit when Interbus S is active If there is no light check network nodes and connections RC Green Lit...

Page 312: ...on Standard DIN E 19245 part 3 Further information For setup parameters see User s Guide System Parameters Topic I O Signals Also see the Circuit diagram Layout DSQC 352 The figure below show the layout of the DSQC 352 board xx0100000223 Communication concept The Profibus DP system is able to communicate with a number of external devices depend ing on the number of process words occupied by each u...

Page 313: ...bus S IN Connections connector X3 The figure below shows the pin configuration of the connector xx0100000221 The table below show the connections to connector X3 A Master PLC B Robot 1 word 1 8 C Robot 1 word 9 16 D Robot 2 word 17 24 E 256 inputs 256 outputs F 128 inputs 128 outputs Signal name X20 pin Function Shield 1 Cable screen NC 2 Not connected RxD TxD P 3 Receive Transmit data P Control P...

Page 314: ...ction Designation Color Description Profibus active Green Lit when the node is communicating with the master If there is no light check system messages in robot and in Profibus net NS MS Green red See section CAN bus status LED description CAN Tx CAN Rx Green red See section CAN bus status LED description POWER 24 VDC Green Indicates that a supply voltage is present and has a level above 12 VDC If...

Page 315: ...an be installed inside the controller Normally a distributed I O unit is placed outside the controller Connection The maximum total length of the distributed I O cable is 100 m from one end of the chain to the other end The controller can be one of the end points or be placed somewhere in the middle of the chain Parameter setup For setup parameters see User s Guide section System Parameters Topic ...

Page 316: ...ional digital unit Technical data See Product Specification for Controller S4Cplus Allowed types of digital sensors The table below shows the allowed types of digtal sensors to be used and their signal levels respectively Sensor type Signal level Digital one bit sensor High 1 Low 0 Digital two bit sensor High 01 No signal 00 Low 10 Error status 11 stop program running ...

Page 317: ...upply voltage is required a bridge connection can be made to an optional digital input The supervision instruction must be written in the RAPID program This is described in the User s Guide The table below show the connections to connector X1 No of inputs 16 divided into two groups of 8 galvanically isolated from each other No of outputs 16 divided into two groups of 8 galvanically isolated from e...

Page 318: ...d output Out ch 7 7 Optically isolated output Out ch 8 8 Optically isolated output 0 V for outputs 1 8 9 Optically isolated output 24 V for outputs 1 8 10 Unit function Signal name X1 pin Unit function Signal name X2 pin Optically isolated output Out ch 9 1 Optically isolated output Out ch 10 2 Optically isolated output Out ch 11 3 Optically isolated output Out ch 12 4 Optically isolated output Ou...

Page 319: ...n setting the input When connecting outputs sensitive to pre oscillation current a series resistor 100 W may be used Unit function Signal name X4 pin Optically isolated input In ch 9 1 Optically isolated input In ch 10 2 Optically isolated input In ch 11 3 Optically isolated input In ch 12 4 Optically isolated input In ch 13 5 Optically isolated input In ch 14 6 Optically isolated input In ch 15 7...

Page 320: ...tions connector X1 If supervision of the supply voltage is required a bridge connection can be made to an optional digital input The supervision instruction must be written in the RAPID program This is described in the User s Guide The table below show the connections to connector X1 No of digital inputs 16 divided into two groups of 8 galvanically isolated from each other No of digital outputs 16...

Page 321: ...solated output Out ch 8 8 Optically isolated output 0 V for outputs 1 8 9 Optically isolated output 24 V for outputs 1 8 10 Unit function Signal name X2 pin Optically isolated output Out ch 9 1 Optically isolated output Out ch 10 2 Optically isolated output Out ch 11 3 Optically isolated output Out ch 12 4 Optically isolated output Out ch 13 5 Optically isolated output Out ch 14 6 Optically isolat...

Page 322: ...n current a series resistor 100 W may be used Unit function Signal name X4 pin Optically isolated input In ch 9 1 Optically isolated input In ch 10 2 Optically isolated input In ch 11 3 Optically isolated input In ch 12 4 Optically isolated input In ch 13 5 Optically isolated input In ch 14 6 Optically isolated input In ch 15 7 Optically isolated input In ch 16 8 Optically isolated input 0 V for i...

Page 323: ...r setup parameters see User s Guide System Parameters Topic Controller Also see the Circuit Diagram Layout DSQC 355 The figure below show the layout of the DSQC 355 board xx0100000238 No of analog inputs 4 10 V 10 V No of analog outputs 3 10 V 10 V 1 4 20 mA No of analog outputs 2 galvanically isolated from the controller electronics Supply voltage 24 VDC X3 Not used X5 DeviceNet input and ID conn...

Page 324: ...rrent when setting the input Connect a resistor 100 W in series when connecting outputs sensitive to pre oscillation current Signal name X7 pin Explanation ANOUT_ 1 Analog output 1 10 V 10 V ANOUT_ 2 Analog output 2 10 V 10 V ANOUT_ 3 Analog output 3 10 V 10 V ANOUT_ 4 Analog output 4 4 20 mA Not used 5 Not used 6 Not used 7 Not used 8 Not used 9 Not used 10 Not used 11 Not used 12 Not used 13 Not...

Page 325: ...ANIN_3 3 Analog input 3 10 V 10 V ANIN_4 4 Analog input 4 10 V 10 V Not used 5 Not used 6 Not used 7 Not used 8 Not used 9 Not used 10 Not used 11 Not used 12 Not used 13 Not used 14 Not used 15 Not used 16 24 V out 17 24 VDC supply 24 V out 18 24 VDC supply 24 V out 19 24 VDC supply 24 V out 20 24 VDC supply 24 V out 21 24 VDC supply 24 V out 22 24 VDC supply 24 V out 23 24 VDC supply 24 V out 24...

Page 326: ...lor Description NS MS Green red See section 4 1 RS232 Rx Green Indicates the state of the RS232 Rx line LED is active when receiving data If there is no light check communication line and connections RS232 Tx Green Indicates the state of the RS232 Tx line LED is active when transceiving data If there is no light when transmission is expected check error messages and check also system boards in rac...

Page 327: ...rature decoding QDEC to determine position and direction One digital input external start signal conveyor synchronisation point Technical data Also see Product Specification for controller S4Cplus Further informa tion User reference Description Conveyor Tracking For setup parameters see User s Guide Sys tem Parameters Topic Controller Also see the Circuit Diagram Layout DSQC 354 The figure below s...

Page 328: ...upply AB 0 V I O or external supply AC Encoder AD Sync switch AE 10 16 not used AF Encoder unit AG Galvanic isolation 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Opto Opto Opto Opto Opto Opto B A 24 VDC 24 VDC 0V 0V AA AB AC AD AE AF AG Signal name X20 pin Explanation 24 VDC 1 24 VDC supply 0 V 2 0 V ENC 3 Encoder 24 VDC ENC 4 Encoder 0 VDC ENC_A 5 Encoder phase A ENC_B 6 Encoder phase B DIGIN 7 Synchr...

Page 329: ...bles and connectors If power is applied to the unit but it does not work replace the unit NS MS Green red See section CAN bus status LED description CAN Tx CAN Rx Green red See section CAN bus status LED description ENC 1A 1B Green Indicates phase 1 and 2 from encoder Flashes at each Encoder pulse At frequencies higher than a few Hz flashing can no longer be observed light will appear weaker If th...

Page 330: ... used for external start signal conveyor synchronisation point If there is no light there is an error due to one or more of the following reasons Faulty power supply for input circuit internal or external Faulty limit switch photocell etc Short circuit or broken wire in external wiring or con nectors Defective input circuit on board Designation Color Description ...

Page 331: ...er provides 32 inputs and 32 outputs and a rack will subsequently provide 128 inputs and 128 outputs A rack may also be shared by 2 3 or 4 robots Each of these robots will then have the same rack address but different starting quarters must be specified Illustration The following illustration shows a block diagram of the Allen Bradley system where Robot 1 uses a full rack while robot 2 and robot 3...

Page 332: ...ignals Also see Circuit Diagram Connection The RIO unit should be connected to an Allen Bradley PLC using a screened two conductor cable Layout DSQC 350 The figure below show the layout of the DSQC 350 board xx0100000226 Connections connector X8 The figure below shows the pin configuration of the connector xx0100000221 No of digital inputs Unit is programmable for 32 64 96 or 128 digital inputs No...

Page 333: ...of and provided by ABB Flexible Automation Bus status LEDs The figure and table below show the location and significance of the the LEDs on the board The designations refer to LEDs shown in the figure in section Layout DSQC 350 above Signal name X8 pin Function LINE1 blue 1 Remote I O in LINE2 clear 2 Remote I O in Shield 3 Remote I O in Cabinet ground 4 Remote I O in Signal name X9 pin Function B...

Page 334: ...ation If there is no light check network cables and connections Also check that PLC is operational Flashing green indicates that communication is established but the INIT_COMPLETE bit is not set in NA chip or config uration rack size etc does not match configuration set in PLC If LED keeps flashing continuously check setup Designation Color Description ...

Page 335: ... was formerly referred to as SIO2 For temporary use MC CONSOLE RS 232 115 kb s This was formerly referred to as Com1 Further information For setup parameters see User s Guide System Parameters Topic I O Signals Circuit Diagram Location in the cabinet see figure in section Connection to screw terminals Technical data See Product Specification for controller S4Cplus Separate documentation is include...

Page 336: ...n configuration of the connector xx0100000220 The table below shows the connections to connector X9 Signal Pin Description DCD 1 Data carrier Detect RX 2 Receive Data TX 3 Transmit Data DTR 4 Data Terminal Ready GND 5 Signal Ground DSR 6 Data Set Ready RTS 7 Request To Send CTS 8 Clear To Send RI 9 Ring Indicator NC 10 Not Connected COM2 Signal name X10 pin 1 RxD Receive Data 2 TxD Transmit Data 3...

Page 337: ...emporary use e g connection of laptop PC The table below shows the signals on the MC CONSOLE RS232 RxD Receive Data 3 RxD N Receive data N 4 0 V 5 DATA Data Signals in Half Duplex Mode 6 DATA N Data Signals in Half Duplex Mode N 7 DCLK Data Transmission Clock 8 DCLK N Data Transmission Clock N 9 COM3 Signal name X9 socket A External computer Signal Pin Description RX 2 Receive Data TX 3 Transmit D...

Page 338: ...ned in IEEE 802 3 10 100 BASE T Maximum node to node distance 100 meter The main computer board has no termination for a cable shield The cable shield must be grounded at the cabinet wall with a cable gland 10BASE T is a point to point net connected via a HUB see the figure above The figure below shows the main computer board front A External computer B Controller Robot 1 C Controller Robot 2 Sign...

Page 339: ...e outlet on cabinet front behind service hatch on the controller The figure below shows how to connect a laptop to the service outlet xx0100000215 For setup parameters see User s Guide System Parameters Topic I O Signals Also see the Circuit Diagram Separate documentation is included when the option Ethernet services is ordered X1 LAN PWR HDD STATUS X2 1 8 Ethernet ...

Page 340: ...ousing which satisfies protection class IP 54 in accordance with IEC 144 and IEC 529 The following figure shows the main dimensions of the external operator s panel xx0100000214 A Holes for operator s panel B Holes for flange C Required depth 200 mm D External panel enclosure option E Holes for teach pendant unit TPU holder F Teach pendant unit TPU connector G Connection to the controller 184 200 ...

Page 341: ...ment is as specified 6 The operating mode selector on the operator s panel is in the Manual mode posi tion 7 When external safety devices are used check that these have been connected or that the following circuits in either XS3 connector on the outside left cabinet wall or X1 X4 screw terminals on the panel unit are strapped Device XS3 Panel unit External limit switches A5 A6 B5 B6 X1 3 4 X2 3 4 ...

Page 342: ...nuously in order to fully charge the batteries for the serial measurement board It takes approx 4 hours to fully charge a computer system battery 8 After having checked the above verify that the start stop and mode selection including the key lock switches control devices work as intended each axis moves and is restricted as intended emergency stop and safety stop where included circuits and devic...

Page 343: ...ur system the RobInstall tool must be used to install the controller software The RobIn stall tool is included on the RobotWare CD ROM see section RobotWare CD ROM The RobInstall tool can be used both for creation of the controller software and for downloading it to the controller system Types of software loading xx0100000192 When downloading the controller software can be transferred to the contr...

Page 344: ...m named Boot Image This basic program must always be in the storage memory At start up of the controller with out any controller software installed Boot Image will start and ask the operator for controller software installation instructions If the controller software is already installed and a warm start is performed Boot Image is not used The installed controller software can be deleted by cold s...

Page 345: ...FTP client will start and guide you through the installation Please read the Readme file for information about license regulations Contents Description 1 RobInstall A PC tool used to create and install the controller operating system in the robot control system 2 Documentation On line documentation for the RobInstall application and the Controller Operating System Package 3 Controller OS Package C...

Page 346: ...existing system download a system to the controller using the Ethernet connection create Boot Disks to transfer the system to the Controller Concept Means System pack This is the RobotWare Controller Operating System Package for S4Cplus including all options even if they are not ordered and acti vated Key This is a text string or a special file with the text string which is used to define and open...

Page 347: ...7 Installation of controller software 7 0 3 Installing new Robot Controller Software with RobInstall 3HAC 16245 1 A 145 3 The RobInstall start window will open xx0100000185 Step Action Illustration Info ...

Page 348: ...bot Controller system as shown in the figure xx0100000179 3 Enter a name for the new control ler system Select a saving loca tion or use the default directory normally Program Files ABB Robotics system see the figure below position 1 xx0100000180 4 Enter the RobotWare key or add from file If added from a file files with the extension kxt should be used see the figure above posi tion 2 5 Press OK T...

Page 349: ... the last figure in section Setting up the system or click on Additional Keys in the menu to the left xx0100000182 2 Enter the key string for the selected option and press Add Key to list or pressAdd key from file to select a key string file 3 To remove additional keys select the key in the Included Additional Keys list and press Remove Key 4 Press Finish to create the control ler system or press ...

Page 350: ...the Loaded Additional Parameters list and press Remove 6 Press Finish to create the control ler system or press Next to con tinue to Options see section Change options or system pack revision Step Action Illustration Info Step Action Illustration Info 1 To change the option configura tion press Next in the screen shown in the figure below or click on Options in the menu to the left xx0100000184 2 ...

Page 351: ... 149 4 If you want the system to start up in query mode put a mark in the query mode selection square For further details of the query mode see section Start in Query Mode 5 Press Finish to create the control ler system or press Next to view the current configuration Step Action Illustration Info ...

Page 352: ... system in the system list and press OK see the figure above Please note that a pop up menu can be shown by clicking right mouse button With this menu Copy Rename or Delete can be selected for the marked system xx0100000190 3 The window displaying the cur rent configuration of the system will be shown Follow the instructions in sections Add or remove external options Add or remove additional syste...

Page 353: ...roller If using a direct connection between PC and IOC service outlet on controller below Download Robot Control ler System below Network Intranet connection with fixed IP addresses If using Network Intranet con nection with fixed IP addresses below Download Robot Control ler System below Network Intranet connection with DHCP Dynamic Host Configuration Protocol If using Network Intranet con nectio...

Page 354: ...that the robot controller displays the Start Window on the Teach Pendant Unit see section Start window Step Action Illustration Info 1 Make sure that the Network protocol is set for TCP IP properties 2 Change the TCP IP Properties in accordance with the values to be used for IP address Subnet mask and Gate way 3 Perform a X START see section x START or C START see section C start on the S4Cplus co...

Page 355: ... password if required by the robot controller as in the figure below position 2 xx0100000177 4 Test the connection by pressing Test Connection and press OK if a connection is established 5 Select a system in the list on the left and press OK as in the figure below Please note that it is possi ble to select another system pool than the shown one in such case be sure to select the system pool direct...

Page 356: ...roller displays the Start Window on the Teach Pendant Unit see section Start Window an optional floppy disk drive is installed in the robot controller Create Boot Diskettes from RobInstall Step Action Illustration Info 1 Press Create Boot Disk as in the figure below xx0100000173 2 Select a system in the list on the left and press OK as in the figure below RobInstall will now create an image file a...

Page 357: ...of controller software 7 0 7 Transfer Robot Controller System using floppy disks 3HAC 16245 1 A 155 5 Use the finished floppy disks to boot your system as described in section Boot Disks Step Action Illustration Info ...

Page 358: ...obInstall for new programs and optional products press Preferences as shown in the figure See also chapter System Directory Structure xx0100000186 2 To select another media pool see section Media Pool in the PC press Select Media Pool as shown in the figure position 1 xx0100000187 3 To add a new system package or option package to the media pool press Import Program as shown in the figure position...

Page 359: ... is a basic program which is used to start up the system from scratch Purpose of the program This program is already installed in the controller at delivery and is used to restart the system load the system from boot disks or network connections set or check network settings choose a system from the mass storage memory ...

Page 360: ... you can choose to do one of the following Restart the system Reboot The BootImage will be re executed used to apply changes in the system settings see section Reboot Load a system from diskettes Boot Disks See section 4 4 Set the network settings Network Settings Set network settings for Main Computer or check how to configure your PC see section Network Settings Choose a system from the mass sto...

Page 361: ...eboot Window When is it shown The Reboot window will be displayed if any of the system settings are changed or when Reboot is pressed in the Start window as shown in the figure below xx0100000169 Button Function YES Restarts the system NO Returns to the start window ...

Page 362: ...to create boot disks Information on how to create boot disks from RobInstall can be found in section Create Boot Diskettes from Robinstall Load the system Step Action Illustration Info 1 Insert the correct diskette in the floppy disk drive and press OK If the diskette is alright the system will be loaded CANCEL removes all previously loaded data and returns to the Start window as shown in the fig ...

Page 363: ...asked to reboot the system 4 Press YES to make the new setting take effect NONE will after the system is rebooted remove the IP settings CANCEL returns to the Start window as shown in the figure in section Start Win dow without changing any settings Parameter Type Description MAC ID Node identification The Main Computer s ethernet address Current IP Node identification The Main Computer s current ...

Page 364: ...ing OK returns to the Start window as shown in the figure in section Start Win dow Parameter Description IP service setting The IP Address for the I O Computer IP Required to configure your PC s network settings for communication between RobInstall and the I O Computer Subnet mask Required to configure your PC s network settings for communication between RobInstall and the I O Computer Gateway Req...

Page 365: ...igure in section Start Window xx0100000171 How to select system The window shows all systems installed on the controller mass storage memory CANCEL returns to the Start window as shown in the figure in section Start Win dow Step Action Illustration Info 1 Select by moving the X to a desired system and press OK The system will reboot with the new system and then present the Welcome window as shown ...

Page 366: ...memory and then execute the BootImage to present the Start window Any system stored in the mass stor age memory may then be selected as described in section Select System When performing an X Start all stored system data will be restored similar to performing a warm start Step Action Illustration Info 1 Press the button Miscellaneous and select Service win dow or System Parameter window Miscellane...

Page 367: ...em can be selected if available in the mass storage memory see section Select System or a new system can be down loaded and started see section Transfer Robot Controller System using Ethernet connection or Trans fer Robot Controller System using floppy disks Do not touch any key joystick enable device or emergency stop during the cold start until the Start window is shown as in the figure in secti...

Page 368: ...8 Robot controller 8 0 8 How to perform a Restart 166 A 3HAC 16245 1 3 Enter the numbers 1_3_4_6_7_9 the fifth function key changes to C START 4 Press C START Step Action Illustration Info ...

Page 369: ... Query Mode pushbutton Query In Query Mode you can on top of the things in Easy Query select DC link change Robot type within the same family and for IRB 7600 select balancing unit see section Query Mode Easy Query Mode If Easy Query was chosen as start up query mode the following steps will be required to start the system Query Mode If Query Mode was chosen as start up query mode the following st...

Page 370: ...sed on the unit inside the controller then use the table below to find out the configuration ID for that DC link 4 Select xxxx model Choose Robot model type within in the same family e g 1400 6400 etc If there are more than three options press pushbutton SCAN to view them 5 Install xxx See section Easy Query Mode step 3 Step Action Illustration info ...

Page 371: ... the Preference window see section Robinstall Preferences xx0200000156 Naming conventions Each package is stored in a directory the name of which is an article number ending with the sub number and with the revision number as shown in the table above All the system packs and option packs in one media pool must have the correct revision numbers in their directory names Thus a later revision can be ...

Page 372: ...ct System window File system requirements The system directory must hold these files and directories to allow software installation key id encrypted key file for the actual controller program id file with paths to selected programs in the media pool A syspar directory containing cfg files to be included in the software installation pro cedure All system parameter files included when creating a sys...

Page 373: ...a for all system data e g at power break This means that at warm start in addition to restoring the operating system from the control system package all system data is restored from this directory and reloaded into the working mem ory Never change these directories Never delete or change the bin or BootRom sys directories in the root directory If this is done the controller cannot be restarted and...

Page 374: ...e copied from the media pool and concatenated into one target file that also holds the key id and the syspar directory This may then be downloaded to the control ler via Ethernet or a set of diskettes The target file is temporarily stored in the system directory before downloading or creating diskettes Media pool S ystem pool S ystem Pack in 3haxbbbb 1 nn signature no Ext Option in 3haxcccc 1 nn r...

Page 375: ... dosFsShow There should always be at least 25 Mb free disk space on the controller mass storage memory before attempting to download a new system For information on how to increase storage capacity see below Increasing storage capacity If the capacity of the mass storage memory is less than 25 Mb when a new controller system is to be downloaded storage memory must be released by removing old syste...

Page 376: ...9 System directory structure 9 0 5 Handling mass memory storage capacity 174 A 3HAC 16245 1 ...

Page 377: ... changed This may occur when parts affecting the calibration position have been replaced on the robot Calibrate the system roughly as detailed in section Updating the revolution counter on page 183 if the contents of the revolution counter memory are lost This may occur when the battery is discharged a resolver error occurs the signal between a resolver and measurement board is interrupted a robot...

Page 378: ...ired hardware is specified in the calibrating procedures for each axis 3 Connect the calibration equipment to the robot controller and initialize it Specified in Initialization of calibration pendulum on page 186 4 Manually run the robot axes to be cali brated to a position close to the correct cal ibration position Use the calibration scales fitted to each robot axis to locate this position 5 Sta...

Page 379: ...eck the current calibration position Checking the calibration position on page 181 An alternative calibration position for axis 1 may be defined Alternative calibration position on page 199 How to perform the alternative calibration Alternative calibrating on page 200 How to change to a new offset value for the alternative calibration position New calibration offset axis 1 on page 202 How to retri...

Page 380: ... must be adjusted in increasing sequence i e 1 2 3 4 5 6 Calibration move ment direction When calibrating the axis must consistently be run towards the calibration position in the same direction in order to avoid position errors caused by backlash in gears etc Positive directions are shown in the figure below This is normally handled by the robot calibration software NOTE The figure shows an IRB 7...

Page 381: ...ibration pendulum 3HAC 4540 1 1 Turning disk adapter 3HAC 16423 1 May be turned both ways to fit IRB 140 IRB 1400 IRB 2400 and IRB 4400 Includes all guide pins and attachment screws Also see illustration below 1 Adapter turning disk 3HAC 14034 1 Fits IRB 6600 and IRB 7600 Includes all guide pins and attachment screws Also see illustration below 4 Batteries For battery supply of Leveltronic NT 41 1...

Page 382: ...n turn ing disk adapter May be turned both ways to fit IRB 140 IRB 1400 IRB 2400 and IRB 4400 xx0200000276 Illustration adapter turning disk Fits IRB 6600 and IRB 7600 xx0200000278 A Guide pin 8 mm B Guide pin 6 mm C Screw M10 D Screw M6 A Locating shaft B Hand wheel C Turning disk robot ...

Page 383: ...he system soft ware Step Action Button 1 Run the program SYSTEM UTILITY SER VICE CALIBRAT CALxxxx in the system and fol low the instructions displayed on the teach pendant 2 Switch to MOTORS OFF when the robot stops Check that the calibration marks for that particular axis align correctly If they do not update the rev olution counters Calibration marks shown in Calibration scales on page 194 Detai...

Page 384: ... xx0100000195 2 Choose running axis by axis xx0100000196 3 Manually run the robot axis to a position where the resolver offset value read is equal to zero 4 Check that the calibration marks for that par ticular axis align correctly If they do not update the revolution counters Shown in Calibration scales on page 194 Detailed in Updating the revolution counter on page 183 ...

Page 385: ...ect 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 calibra tion marks lie within the tolerance zone Shown in Calibration scales on page 194 3 Note that axis 6 does not have any mechanical stop and can thus be calibrated at the wrong faceplate revolution Do not operate axis 6 manually before the robot has been cal...

Page 386: ...e View menu The Calibration window appears xx0100000201 4 Select the desired unit and choose Rev Counter Update from the Calib menu The Revolution Counter Update window appears xx0100000202 5 Select the desired axis and press Incl to include it it will be marked with an x or press All to select all axes 6 Press OK when all axes that are to be updated are marked with an x CANCEL returns to the Cali...

Page 387: ...on on the TPU xx0300000009 2 Select Special and then Call service rou tine 3 Start the program Calpendulum rutin 4 Select the required calibration procedure by pressing START xx0200000188 5 Enter the value for your choice of which robot axes to calibrate Press OK xx0200000190 Default value All axes In this example axis 1 was selected 6 Press 0 to acknowledge the selection made Press OK 7 Proceed t...

Page 388: ...nsor B here C Connect SIO 1 in controller here D Selection pointer E Measuring unit ZERO SELECT HOLD SEND ESC ENTER ON MODE WYLER LEVELMETER 2000 BA TT A 50 Port Sensor oo A oo mm m REL mRAD 1 10 1 12 DEG mm REL GON 0000000 00000 A B OUT A B C C D Step Action Info Illustration 1 Make sure the Levelmeter 2000 has reached normal operating temperature before connecting it to any thing Also switch the...

Page 389: ...s long as they differ from each other Detailed in the documentation supplied by sensor manufacturer Found in the calibration kit box Step Action Info Illustration 1 Connect the sensor to the Sensor connection points Marked A and B Shown in the figure in section General on page 186 2 Press ON MODE 3 Press ON MODE until the dot flashes under SEN SOR 4 Press ENTER 5 Press ZERO SELECT arrows until a f...

Page 390: ...tion sensors on all robot systems using the Calibration Pendulum method Additional information on calibration alternative calibration positions etc may be found in the Installation Manual Reference sensor The illustrations below show the mounting position and direction for the reference sensor IRB 6600 IRB 7600 xx0200000183 A Calibration pendulum in reference sensor position NOTE The pendulum is o...

Page 391: ... Axis 1 The illustrations below show the mounting position and direction for the calibration sensor axis 1 IRB 6600 IRB 7600 xx0200000177 A Calibration pendulum NOTE The pendulum is only fitted in one position at a time B Calibration pendulum attachment screw C Locating pin A B C ...

Page 392: ...alibration sensor mounting positions 190 A 3HAC 16245 1 Axis 2 The illustrations below show the mounting position and direction for the calibration sensor axis 2 IRB 6600 IRB 7600 xx0200000178 A Calibration pendulum axis 2 A ...

Page 393: ...he IRB 7600 2 3 500 version requires a slightly different sensor mounting position than the other versions the sensor being turned 90 This is shown in the following figure xx0300000016 Any special considerations to be taken when calibrating this robot version is detailed in sec tion Calibrating axes 3 4 IRB 7600 2 3 500 on page 197 A Calibration sensor axis 3 NOTE The pendulum is only fitted in on...

Page 394: ... The IRB 7600 2 3 500 version requires a slightly different sensor mounting position than the other versions the sensor being turned 90 This is shown in the figure below xx0300000016 Any special considerations to be taken when calibrating this robot version is detailed in sec tion Calibrating axes 3 4 IRB 7600 2 3 500 on page 197 A Calibration sensor axis 4 NOTE The pendulum is only fitted in one ...

Page 395: ...6600 IRB 7600 xx0200000180 Axis 6 The illustrations below show the mounting position and direction for the calibration sensor axis 6 IRB 6600 IRB 7600 xx0200000180 A Calibration sensor axis 5 NOTE The pendulum is only fitted in one position at a time B Adapter turning disk A B A Calibration sensor axis 6 NOTE The pendulum is only fitted in one position at a time B Adapter turning disk A B ...

Page 396: ...n scale positions for all robot models IRB 6600 The illustration below show the calibration scale positions xx0200000176 IRB 7600 The illustration below show the calibration scale positions xx0100000198 A Sync scale axis 1 B Sync scale axes 2 5 C Sync scale axis 6 C B A A Sync scale axis 1 B Sync scale axes 2 5 C Sync scale axis 6 C B A ...

Page 397: ...ts IRB 6600 and IRB 7600 Included in the complete set Isopropanol 1177 1012 208 For cleaning the sensor attachment points Step Action Illustration 1 Run the robot manually to the calibration position of the axis to be calibrated 2 Make a rough calibration Detailed in Updating the revolution counter on page 183 3 Turn the calibration equipment on to allow it to reach operating temperature and stabi...

Page 398: ...itting the calibration pendulum for axes 1 3 Fitting the pendulum to the turning disk requires an adapter included in the complete set NOTE that there are two adapters Article number specified in section General on page 195 The way of handling the calibration program prior to the actual calibra tion of each axis is detailed in Cali bration procedure on TPU on page 185 9 Click OK A number of menus ...

Page 399: ...ed This applies to calibrating axes 3 and 4 of the IRB 7600 2 3 500 only xx0300000020 Procedure A Cable holder attachment point A Step Action Info Illustration 1 Remove any cable holders by unscrew ing their respective attachment screws Shown in the figure in section General on page 197 This is to facilitate fitting the calibration sensor 2 Perform the calibration procedure as with any other versi...

Page 400: ...o not change the position of the manipulator axes after running the program Detailed in Checking the calibra tion position on page 181 2 Check all calibration positions Detailed in Checking the calibra tion position on page 181 3 Repeat the check as above 4 Adjust the calibration marks when the calibra tion is done Shown in Calibration scales on page 194 5 The system parameters will be saved to th...

Page 401: ...calibration instructions detailed for each axis are intended for calibration position 0 i e the normal position Calibration instructions for positions Right 1 and Left 2 are detailed in Alternative calibrating on page 200 Illustration The illustration shows the three available calibrating positions xx0100000258 A Calibration position 2 90 left 1 570796 B Calibration position 0 C Calibration positi...

Page 402: ... for each axis 4 Run the calibration program again and select the desired calibra tion position Left or Right as shown in Alternative calibration position on page 199 5 Change to the new calibration offset for axis 1 as detailed in New calibration offset axis 1 on page 202 6 Note the new calibration offset on the label located on the frame to the left of motor axis 1 remove the cover between axes ...

Page 403: ...ibration 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 axis 1 6 Change Cal pos to 1 570796 or 1 570796 depending on the selected calibration position The angle is measured in radians as shown in Alternative calibr...

Page 404: ...fset 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 pressing ENTER xx0100000200 3 Select Calibration from the View menu The calibration window appears xx0100000201 4 Select Calibrate from the Calib menu 5 Select axis 1 no other axes 6 Confirm by pressing OK twice ...

Page 405: ...retrieving new offset values for axis 1 during 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 Motor from the Types menu 4 Select axis 1 and press ENTER xx0100000200 5 Note the Cal offset value ...

Page 406: ...10 Calibration 10 5 5 Retrieving offset values 204 A 3HAC 16245 1 ...

Page 407: ...mple attempting to open the balancing device is potentially lethal Procedure The instruction below details how to cut open the balancing device housing and removing the tension in the coil springs before opening the device Equipment etc Spare part no Art no Note Standard toolkit 3HAC 15571 1 The contents are defined in section Standard toolkit on page 22 Cutting torch For opening housing and cut t...

Page 408: ...side the housing as specified below Outer spring cut at least five 5 coils Middle spring cut at least four 4 coils Inner spring cut at least four 4 coils Use a cutting torch 5 After double checking the number of coils cut remove the end cover of the balanc ing device 6 Dismantle the balancing device and sort its parts for the recycling plant Step Action Info Illustration 450 500 mm 450 500 mm 450 ...

Page 409: ... Repair Manual part 1 Industrial Robot IRB 6600 225 2 55 IRB 6600 175 2 8 IRB 6600 175 2 55 IRB 6650 200 2 75 IRB 6650 125 3 2 M2000A ...

Page 410: ......

Page 411: ...Repair Manual part 1 IRB 6600 6650 M2000A 3HAC 16247 1 Revision A ...

Page 412: ...rom 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 2003 ABB All rights res...

Page 413: ... use of the Teach Pendant Unit 11 1 3 7 Work inside the manipulator s working range 11 Chapter 2 Reference information 13 2 0 1 Introduction 13 Section 2 1 Reference information 14 2 1 1 Applicable Safety Standards 14 2 1 2 Screw joints 15 2 1 3 Weight specifications 17 2 1 4 Standard toolkit 18 2 1 5 Special tools IRB 6600 6650 7600 19 2 1 6 Performing a leak down test 21 2 1 7 Lifting equipment ...

Page 414: ...3 6 5 Removal of gearbox axis 3 142 3 6 6 Refitting of gearbox axis 3 145 3 6 7 Removal of gearbox axis 6 149 3 6 8 Refitting of gearbox axis 6 151 Chapter 4 Repair activities controller cabinet 155 4 0 1 Introduction 155 Section 4 1 Complete controller cabinet 156 4 1 1 Replacement of battery unit controller 156 4 1 2 Replacement of I O and gateway units 158 4 1 3 Replacement of bleeder resistor ...

Page 415: ...25 3 2 200 2 75 3HAC 8114 5 190 5 1 11 Material set manipulator 3HAC 13263 1 194 5 1 12 Mtrl set ax 1 2 3HAC 13264 1 195 5 1 13 Mtrl set balancing device 3HAC 13265 1 198 5 1 14 Arm extension set 250 mm 3HAC 12311 4 199 5 1 15 Arm extension set 450 mm 3HAC 12311 5 199 Chapter 6 Appendix 2 Foldouts 201 6 0 1 Introduction 201 6 0 2 Base incl Frame 203 6 0 3 Frame Lower arm 1 205 6 0 4 Frame Lower ar...

Page 416: ...Table of Contents iv 3HAC 16247 1 ...

Page 417: ...d knowledge of mechanical repair work OR have the required knowledge of electrical repair work Organization of Chapters The information product is organized in the following chapters References Revisions Chapter Contents 1 Safety 2 Reference information 3 Manipulator 4 Controller 6 Appendix Reference Document Id Circuit Diagrams Manipulator 3HAC 13347 1 Circuit Diagrams Controller 3HAC 14189 2 Rev...

Page 418: ...0 0 1 Overview 2 A 3HAC 16247 1 ...

Page 419: ...ons for all manipulator details considered spare parts Remove Refitting instructions for all controller cabinet details considered spare parts If there is any model specific information Maintenance Manual The Maintenance Manual contains the following information Safety Service Reference Information Maintenance schedules Instructions for all maintenance activities specified in the maintenance sched...

Page 420: ...l Each hardware option is supplied with its own documentation Each document set contains the types of information specified above Installation information Repair information Maintenance information In addition spare part information is supplied for the complete option ...

Page 421: ...rvicing the robot system The dan gers 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 r...

Page 422: ...ction 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 inter act with other machines and peripheral equipment This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot In the...

Page 423: ...fter 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 from falling due to gravity 1 2 4 Safety risks during operational disturbances Gener...

Page 424: ...y stored in the robot for the purpose of counterbalancing certain axes may be released if the robot or parts thereof is dismantled When dismantling assembling mechanical units watch out for falling objects Be aware of stored heat energy in the controller Never use the robot as a ladder i e do not climb on the robot motors or other parts during service work There is a serious risk of slipping becau...

Page 425: ... machining pro cess The external voltage connected to the control cabinet remains live even when the robot is disconnected from the mains Additional connections Voltage related risks manipula tor A danger of high voltage is associated with the manipulator in The power supply for the motors up to 800 VDC The user connections for tools or other parts of the installation max 230 VAC see Installation ...

Page 426: ...eased manually by push ing the brake release buttons on the manipulator or on an optional external brake release unit How to release the brakes is detailed in section Manually releasing the brakes 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 o...

Page 427: ...t Unit with him her when entering the robot s working space This is to prevent anyone else taking control over the robot without the programmer knowing 1 3 7 Work inside the manipulator s working range 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 ena...

Page 428: ...1 Safety service 1 3 7 Work inside the manipulator s working range 12 A 3HAC 16247 1 ...

Page 429: ...ion 2 0 1 Introduction 3HAC 16247 1 A 13 Chapter 2 Reference information 2 0 1 Introduction General This chapter presents generic pieces of information complementing the more specific infor mation in the following chapters ...

Page 430: ...sessment ANSI RIA 15 06 1999 Industrial robots safety requirements DIN 19258 Interbus S International Standard Standards robot cell The following standards are applicable when the robot is part of a robot cell EN 953 Fixed and moveable guards EN 811 Safety distances to prevent danger zones being reached by the lower limbs EN 349 Minimum gaps to avoid crushing of parts of the human body EN 294 Safe...

Page 431: ... void any warranty and may potentially cause serious damage or injury Gleitmo treated screws Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint Screws treated with Gleitmo may be reused 3 4 times before the coating disappears After this the screw must be discarded and replaced with a new one When handling screws treated with Gleitmo protective gloves of n...

Page 432: ... dry Screws with hexagon socket head lubricated Dimension Tightening torque Nm Class 4 8 dry M2 5 0 25 M3 0 5 M4 1 2 M5 2 5 M6 5 0 Dimension Tightening torque Nm Class 8 8 dry Tightening torque Nm Class 10 9 dry Tightening torque Nm Class 12 9 dry M5 6 M6 10 M8 24 34 40 M10 47 67 80 M12 82 115 140 M16 200 290 340 Dimension Tightening torque Nm Class 10 9 Tightening torque Nm Class 12 9 M8 28 34 M1...

Page 433: ...onents exceeding 22 kg 50 lbs are high lighted in this way ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg to avoid inflicting injury A wide range of lifting tools and devices is avail able for each manipulator model Example Below is an example of how a weight specification is presented The motor weighs 65 kg All lifting equipment used must be dim...

Page 434: ...t and defined in the table below In this way the tools required are the sum of the Standard Toolkit and any tools listed in the instruction Contents standard toolkit 3HAC 15571 1 Qty Art no Tool Rem 1 Ring open end spanner 8 19mm 1 Socket head cap 5 17mm 1 Torx socket no 20 60 1 Box spanner set 1 Torque wrench 10 100Nm 1 Torque wrench 75 400Nm 1 Ratchet head for torque wrench 1 2 2 Hexagon headed ...

Page 435: ... for Mech stop axis 3 2 3HAB 3409 86 Bolts M16 x 80 for Mech stop axis 3 2 3HAB 3409 89 Cal tool a a 68080011 GM Calibration bracket a 3HAC 13908 9 Calibration tool ax1 a a 3HAC 13908 4 CalPen Calibration Pendulum 1 1 3HAC 15716 1 Extension 300mm for bits 1 2 1 1 3HAC 12342 1 Fixture lower arm 1 3HAC 13659 1 Fixture lower arm 1 3HAC 13660 1 Gearbox crank 1 3HAC 16488 1 Guide pins M12 x 150 2 3HAC ...

Page 436: ... 1 3HAC 14459 1 Lifting tool motor ax 2 3 4 1 1 3HAC 15534 1 Lifting tool wrist unit 1 3HAC 13605 1 Lifting tool wrist unit 1 3HAC 12734 1 Measuring pin a 3HAC 13908 5 Mech stop ax 3 2 3HAC 12708 1 Mech stop ax 3 2 3HAC 12708 2 Press tool ax 2 bearing 1 3HAC 13527 1 Press tool ax 2 bearing 1 3HAC 13453 1 Press tool ax 2 shaft 1 1 3HAC 13452 1 Press tool balancing device shaft 1 1 3HAC 17129 1 Pres...

Page 437: ...included in the leakdown tester kit Art no specified above 3 Apply compressed air and raise the pres sure with the knob until the correct value is shown on the manometer 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 significantly colder or warmer than the gearbox to be tested...

Page 438: ...ctivities require different pieces of lifting equipment which are specified in each activity instruction However how to use each piece of lifting equipment is not detailed in the activity instruction 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 439: ...r It is made up of separate units each detailing a specific repair activity e g Removal or Refit ting of a certain component on the manipulator Each unit contains all information required to perform the activity e g spare parts numbers required special tools and materials The chapter is divided into Removal refitting instructions for all the spare parts on the manipulator Remaining instructions fo...

Page 440: ...t board R1 SMB1 3 R1 SMB4 6 R1 SMB1 7 R2 FB7 and R2 SMB Battery connector X3 R1 G and R2 G Connectors at brake release unit X8 X9 and X10 E Connectors at motor 3 R2 FB3 and R2 MP3 and for signal lamp R2 H1 and R2 H2 F Connectors at motor 4 R2 FB4 and R2 MP4 G Connectors at cable harness separation R2 M5 6 H Connectors at cable harness division inside of upper arm tube R3 FB5 and R3 MP5 Connectors ...

Page 441: ... Art no Note Circuit Diagram 3HAC 13347 1 Included in Repair Manual part 2 Standard toolkit 3HAC 15571 1 The contents are defined in section Standard toolkit on page 18 Other tools and proce dures may be required See references to these procedures in the step by step instruc tions below These procedures include ref erences to the tools required Step Action Note Illustration 1 In order to facilitat...

Page 442: ...chment screws and the velcro strap Note Different manipulator versions are fitted with different plate versions Make sure the correct one is used to avoid cable failure 11 Remove the bracket securing the cables inside the lower arm by unscrewing the nuts from the stud bolts securing the clamp to the lower arm xx0100000142 wmf 12 Remove the upper bracket securing the cables to the arm house by unsc...

Page 443: ...ess axes 5 6 is shown in the figure below xx0200000213 A Cable bracket wrist unit B Cable bracket upper arm tube C Connectors at motor axis 5 R4 FB5 and R4 MP5 D Connectors in upper arm tube R3 FB5 and R3 MP5 F Cable attachment rear G Connectors at cable harness division point R2 M5 6 H Connectors at motor axis 6 R3 FB6 and R3 MP6 A B C F H G D ...

Page 444: ...amaging them Axis 5 must be oriented in the correct position 90 to allow opening the motor 6 cover Step Action Note Illustration 1 Remove the cover wrist unit and the cover upper arm tube xx0200000214 A cover wrist unit B cover upper arm tube 2 Remove the cover of motor axis 6 and dis connect all connectors beneath Specified in the figure Location of cable harness ax 5 6 on page 27 3 Loosen the ca...

Page 445: ...ors R2 M5 6 at the cable harness division point Shown in the figure Location of cable harness ax 5 6 on page 27 10 Gently pull the cable harness out Step Action Note Illustration Step Action Note Illustration 1 Remove the complete wrist unit Detailed in Removal of complete wrist unit on page 47 2 Remove the cover of motor axis 5 3 Disconnect all connectors at motor axis 5 4 Remove the cable gland ...

Page 446: ...R1 SMB4 6 R1 SMB1 7 R2 FB7 and R2 SMB Battery connector X3 R1 G and R2 G Brake release unit con nectors X8 X9 and X10 E Connectors at motor 3 R2 FB3 and R2 MP3 and for signal lamp R2 H1 and R2 H2 F Connectors at motor 4 R2 FB4 and R2 MP4 G Connectors at cable harness separation R2 M5 6 H Connectors at cable harness division inside of upper arm tube R3 FB5 and R3 MP5 Connectors at motor 5 R4 FB5 an...

Page 447: ...le harness axes 5 6 3HAC 14140 1 Cable harness axis 5 3HAC 14139 1 Circuit Diagram 3HAC 13347 1 Included in the Repair Manual part 2 Standard toolkit 3HAC 15571 1 The contents are defined in section Standard toolkit on page 18 Other tools and procedures may be required See refer ences to these procedures in the step by step instruc tions below These procedures include references to the tools requi...

Page 448: ...screws 10 Secure the correct adapter plate to the har ness with its two attachment screws Note Different manipulator ver sions are fitted with different plate versions Make sure the correct one is used to avoid cable failure 11 Pull the cable harness through the lower arm 12 Refit the bracket securing the cables inside the lower arm xx0100000142 13 Refit the bracket securing the cables to the arm ...

Page 449: ...n section Refitting cable harness axis 5 on page 35 15 Reconnect connector R2 M5 6 gently at the rear cable division point Be careful not to bend the attachment plate when fastening the screws Shown in the figure Location of cable harness on page 30 M6 2 pcs 16 Secure the cable harness to the arm house with a velcro strap Shown in the figure Location of cable harness on page 30 Step Action Note Il...

Page 450: ...s Axis 5 90 degrees Axis 6 no significance 2 Gently insert the cable harness from the rear into the upper arm 3 Connect the two connectors inside the upper arm tube R3 FB5 and R3 MP5 and secure the cable bracket with the two attachment screws to the tube Shown in the figure Location of cable harness axes 5 6 on page 33 4 Place the cabling to motor axis 6 correctly on the upper arm and gently pull ...

Page 451: ...he cover wrist unit Make sure the cabling is placed correctly when refitting the covers and does not get jammed xx0200000214 A cover wrist unit B cover upper arm tube 8 Refit eventually removed cable straps to the harness 9 Refit the cable attachment rear Shown in the figure Location of cable harness axes 5 6 on page 33 10 Reconnect connector R2 M5 6 gently at the rear cable division point with tw...

Page 452: ... for the base and gearbox axis 1 i e the upper and lower arms balancing device and frame This is shown in the figure below xx0200000224 Required equip ment A Upper arm B Lower arm C Frame D Gearbox axis 1 E Base attachment screws F Balancing device G Block for calibration H Motor axis 1 A B C D E F G H Equipment etc Spare part no Art no Note Lifting device manipulator 3HAC 15607 1 Instruction 3HAC...

Page 453: ...ng equipment used must be dimensioned accordingly Standard toolkit 3HAC 15571 1 The contents are defined in section Standard toolkit on page 18 Other tools and procedures may be required See refer ences to these procedures in the step by step instruc tions below These procedures include references to the tools required Equipment etc Spare part no Art no Note Step Action Note Illustration 1 Make su...

Page 454: ...ow the instructions before continu ing the lift 6 Remove the block for calibration from the bottom of the frame Shown in the figure Location of arm system on page 36 7 Remove the arm system from the base by unscrewing its 24 attachment screws Shown in the figure Location of arm system on page 36 8 Lift the arm system and secure it in a safe area Make sure all hooks and attachments maintain in corr...

Page 455: ...e base and gearbox axis 1 i e the upper and lower arms balancing device and frame This is shown in the figure below xx0200000224 Required equip ment A Upper arm B Lower arm C Frame D Gearbox axis 1 E Base attachment screws and washers 24 pcs F Balancing device G Block for calibration H Motor axis 1 A B C D E F G H Equipment etc Spare part no Art no Note Lifting device manipulator 3HAC 15607 1 Inst...

Page 456: ...andard toolkit on page 18 Other tools and procedures may be required See refer ences to these procedures in the step by step instruc tions below These procedures include references to the tools required Equipment etc Spare part no Art no Note Step Action Note Illustration 1 Fit the lifting device as detailed in enclosed instruction Art no specified in Required equip ment on page 36 2 Lift the comp...

Page 457: ...uidance from the guide pins previously fitted to the frame This is a complex task to be performed with utmost care in order to avoid injury or damage 5 Refit 22 of the 24 attachment screws before the arm system is completely low ered 6 Remove the guide pins and secure the arm system to the base with its 24 attachment screws and washers Shown in the figure Location of arm system on page 39 M12 x 70...

Page 458: ... Wrist complete on page 211 xx0200000217 Required equip ment A Turning disk B Wrist unit C Oil plug draining D Oil plug filling E 1 Attachment screws turning disk for robot version 175 2 55 6 pcs E 2 Attachment screws turning disk for robot version 225 2 55 175 2 8 125 3 2 or 200 2 75 12 pcs A B C D E E 1 2 A B Equipment etc Spare part no Art no Note Standard toolkit 3HAC 15571 1 The contents are ...

Page 459: ...he robot Take any necessary measures to ensure that the manipulator does not collapse as parts are removed e g to secure the lower arm with fixtures if removing motor axis 2 Step Action Note Illustration 1 Remove any equipment fitted to the turning disk 2 Run the robot to a position where the oil plug draining of axis 6 gearbox faces down wards Shown in the figure Location of turn ing disk on page...

Page 460: ... robot versions result in different designs of the turning disks A more detailed view of the component and its position may be found in the Foldout section Wrist complete on page 211 xx0200000217 A Turning disk B Wrist housing C Oil plug draining D Oil plug filling E 1 Attachment screws turning disk for robot version 175 2 55 6 pcs E 2 Attachment screws turning disk for robot version 225 2 55 175 ...

Page 461: ...ipment etc Spare part no Art no Note Turning disk dia 200 3HAC 9744 5 For robot version 175 2 55 O rings are not included Turning disk dia 200 3HAC 13752 1 For robot version 225 2 55 175 2 8 125 3 2 or 200 2 75 O rings are not included O ring 3HAB 3772 65 1 pc 2152 0431 20 6 pcs For robot v 175 2 55 Must be replaced when replac ing the turning disk O ring 3HAB 3772 64 1 pc 3HAB 3772 61 12 pcs For ...

Page 462: ...ubricate the turning disk o ring with grease Fit the o ring to the rear of the turn ing disk Fit also the 6 or 12 pcs of o rings depending on robot version when refitting the attachment screws Art no specified in Required equipment on page 45 xx0200000218 A Sealing surface o ring 2 Secure the turning disk with its attachment screws Robot v 175 2 55 6 pcs M14 x 25 tightening torque 175 Nm Robot v 2...

Page 463: ... figure below A more detailed view of the component and its location may be found in the Foldout section Wrist complete on page 211 xx0200000184 A Wrist unit B Turning disk C Cover wrist unit D Cover upper arm tube E Connectors upper arm tube with cable bracket R3 FB5 R3 MP5 F Cable bracket cables motor axis 6 G Suffusion to lifting tool wrist unit H Wrist unit attachment screws and washers I Uppe...

Page 464: ...Equipment etc Spare part no Art no Note Lifting tool wrist unit 3HAC 13605 1 Circuit diagram 3HAC 13347 1 Included in Repair Manual part 2 Standard toolkit 3HAC 15571 1 The contents are defined in section Standard toolkit on page 18 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 ...

Page 465: ... axis 6 and place it safely on the tube 8 Loosen the cable bracket in the upper arm tube by unscrewing the two screws on top of the tube Shown in the figure Location of wrist unit on page 47 9 Disconnect the motor axis 5 by disconnecting the two connectors in the upper arm tube R3 FB5 R3 MP5 Shown in the figure Location of wrist unit on page 47 10 Fit the lifting device to the wrist unit Art no sp...

Page 466: ...he figure below A more detailed view of the component and its location may be found in the Foldout section Wrist complete on page 211 xx0200000184 A Wrist unit B Turning disk C Cover wrist unit D Cover upper arm tube E Connectors upper arm tube with cable bracket R3 FB5 R3 MP5 F Cable bracket cables motor axis 6 G Suffusion to lifting tool wrist unit H Attachment screws and washers wrist unit I Up...

Page 467: ...uipment etc Spare part no Art no Note Wrist 175 2 55 3HAC 16627 1 Includes complete axis 6 3HAC 9744 1 3HAC 16032 1 Foundry Includes rotational motor incl gearbox 3HAC 7941 29 Wrist 225 2 55 175 2 8 125 3 2 or 200 2 75 3HAC 16626 1 Includes complete axis 6 3HAC 13890 1 2 Foundry Includes rotational motor incl gearbox 3HAC 7941 30 Guide pin M12 x 200 3HAC 13056 3 Always use guide pins in pairs Lift...

Page 468: ...n the figure Location of wrist unit on page 50 8 In order to have access to motor 6 cover the axis 5 must be positioned 90 degrees Place the cabling to motor axis 6 correctly on the upper arm and gently pull the connec tors through the hole on top of wrist unit to motor axis 6 xx0200000185 Put a loop of cable in this area with cable straps A if necessary The cables are longer to fit to different u...

Page 469: ...ved from the manipulator all normal safety equipment is installed properly e g TPU enabling device all personnel is standing at a safe distance from the manipulator i e out of its reach behind any safety fences etc special attention is paid to the function of the part previously serviced 13 Recalibrate the robot Detailed in Calibration in the Installa tion Manual 14 Refit any equipment previously ...

Page 470: ...ludes the wrist unit but this instruction also describes how to remove the upper arm when there is no wrist unit mounted Note The lifting device is attached differently depending on whether the wrist unit is mounted on the upper arm or not The attachment points are shown in the figure below A more detailed view of the component and its location may be found in the Foldout section Upper arm on page...

Page 471: ...upper arm 2 pcs if there is no wrist unit mounted C Oil plug draining gearbox axis 3 D Connectors at cable harness division R2 M5 6 E Motor axis 3 F Motor axis 4 G Attachment screws and washers upper arm H Sealing axis 2 3 between lower arm and gearbox axis 3 Equipment Spare part no Art no Note Illustration Lifting eye VLBG M12 3HAC 16131 1 Lifting device upper arm 3HAC 15994 1 Lifting tool chain ...

Page 472: ...specified in Required equipment on page 55 7 Drain the oil from gearbox axis 3 Detailed in Oil change gear box axis 3 in the Maintenance Manual 8 Disconnect connector R2 M5 6 at the cable har ness division as well as all remaining connections to the upper arm Shown in the figure Location of upper arm on page 54 9 Remove the cover on top of the motors axis 3 and 4 and disconnect all connectors insi...

Page 473: ...ncludes the wrist unit but this instruction also describes how to refit the upper arm when there is no wrist unit mounted Note The lifting device is attached differently depending on whether the wrist unit is mounted on the upper arm or not The attachment points are shown in the figure below A more detailed view of the component and its location may be found in the Foldout section Upper arm on pag...

Page 474: ...ent screws and washers upper arm H Sealing axis 2 3 between lower arm and gearbox axis 3 Equipment Spare part no Art no Note Sealing axis 2 3 3HAC 12443 2 Always use a new sealing when reassembling Washer axis 3 3 pcs 3HAC 12703 1 To be replaced if damaged Lifting eye VLBG M12 3HAC 16131 1 Lifting device upper arm 3HAC 15994 1 Lifting tool chain 3HAC 15556 1 To be used together with lifting eye M1...

Page 475: ...t screws not affected in this instruction 2 Fit the lifting eye VLBG M12 to the attach ment hole on the upper arm if there is a wrist unit mounted Art no specified in Required equip ment on page 58 Shown in the figure Location of upper arm on page 57 3 Upper arm including wrist unit Fit one of the pieces included in the lifting device upper arm to the attachment for the lifting device on the upper...

Page 476: ...wer arm Do not remove the guide pins until the attachment screws are tightened as detailed below Shown in the figure Location of upper arm on page 57 Removing the plastic mechanical stops may be required before fitting the upper arm If guide pins are removed before the screws are tightened the sealing can be involuntarily moved into wrong posi tion 11 Secure the lower arm to gearbox axis 3 with th...

Page 477: ...alled properly e g TPU enabling device all personnel is standing at a safe distance from the manipulator i e out of its reach behind any safety fences etc special attention is paid to the function of the part previously serviced 18 Perform a leakdown test Detailed in Performing a leak down test on page 21 19 Refill the gearbox with oil Detailed in Oil change gearbox axis 3 in the Maintenance Manua...

Page 478: ...ion of lower arm The lower arm is located as shown in the figure below A more detailed view of the component and its position may be found in the Foldout section Frame Lower arm 2 on page 207 xx0200000255 A Lower arm B Pivot point axis 2 C Front shaft balancing device including securing screw D Attachment for lifting eye M12 balancing device A B C D ...

Page 479: ...n relation to the gearbox is identical for axis 2 The figure 2 shows a cut view through the lower arm pivot point in axis 2 item B in the figure above xx0200000031 A Gear box B Lower arm C Balancing device piston rod ear D Frame E Shaft hole 201 Sealing axis 2 3 202 Attachment screw 204 Washer 401 Bearing 402 Thrust washer 403 Bushing 404 Retaining ring 405 Shaft 406 Protection plug 409 Protection...

Page 480: ...ly lethal Equipment etc Spare part no Art no Note Lifting tool lower arm 3HAC 14691 1 Tool that may be rent from ATRP S Press tool axis 2 shaft 3HAC 13452 1 Lifting eye M12 3HAC 14457 3 Used to lift the balancing device Puller tool balancing device shaft 3HAC 12475 1 Used to pull out the shaft from the balancing device front ear Hydraulic pump 80Mpa 3HAC 13086 1 To be used together with the press ...

Page 481: ... in the figure to the right Pull the shaft out using the puller tool and the hydraulic pump xx0300000056 Note The dimension of the shaft puller tool is M20 Do not mix up with the shaft press tool used when mounting the shaft Art no specified in Required equipment on page 64 7 Lower the balancing device until it rests safely against the bottom of the frame 8 Move the lower arm backwards to the lowe...

Page 482: ...s and washers that attaches the lower arm to the gearbox 2 Shown in the figure Attachment points lower arm on page 63 17 Lift the lower arm down and place it on a secure surface 18 Remove the bearing and thrust washer from the shaft hole in the lower arm Shown in the figure Attachment points lower arm on page 63 On reassembly a new bearing must be used 19 Remove the sealing from the lower arm Show...

Page 483: ...wer arm The lower arm is located as shown in the figure below A more detailed view of the component and its location may be found in the Foldout section Frame Lower arm 2 on page 207 xx0200000255 A Lower arm B Pivot point axis 2 C Front shaft balancing device including securing screw D Attachment for lifting eye M12 balancing device A B C D ...

Page 484: ...in relation to the gearbox is identical for axis 2 The figure 2 shows a cut view through the lower arm pivot point in axis 2 item B in the figure above xx0200000031 A Gear box B Lower arm C Balancing device piston rod ear D Frame E Shaft hole 201 Sealing axis 2 3 202 Attachment screw 204 Washer 401 Bearing 402 Thrust washer 403 Bushing 404 Retaining ring 405 Shaft 406 Protection plug 409 Protectio...

Page 485: ...w lower arm or replace if damaged Lifting tool lower arm 3HAC 14691 1 Tool to be rent from ATRP Two guidings 3HAC 14446 1 must be used for guiding the sealing axis 2 3 Guidings 3HAC 14446 1 For guiding the sealing axis 2 3 Rotation tool motor 3HAC 17105 1 Used to rotate the motor pinion and gear if necessary when brakes are released Power supply 24 VDC 1 5 A For releasing the brakes Press tool axi...

Page 486: ... to the lower arm Art no specified in Required equipment on page 69 5 Lift the lower arm and run it to its mount ing position 6 In case the holes of the lower arm and the ones of the gearbox axis 2 doesn t match use power supply to release the motor axis 2 brakes and rotate the pin ion and gear with the rotational tool Connect power supply to connector R2 MP2 pin 2 pin 5 xx0200000165 The rotation ...

Page 487: ...5 Increase the pressure of the glycerin pump to 50 kN 16 Check the measurement dial readout Correct value 2 45 mm 0 15 mm 17 Remove the press tool axis 2 shaft Release the pressure from the glycerin pump first then from the hydraulic cylin der approximately 1 2 minute after in order to avoid movement of the shaft 18 Refit the thrust washer to the shaft Shown in the figure Attachment points lower a...

Page 488: ...ention is paid to the function of the part previously serviced 23 Refit and restore the balancing device Detailed in section Refitting of balancing device on page 85 24 Refit the upper arm Detailed in section Refitting of upper arm on page 57 25 Perform a leak down test Detailed in section Performing a leak down test on page 21 26 Refill the gearbox with oil Detailed in section Oil change gearbox ...

Page 489: ...ow details how to remove the SMB battery Please observe the following before commencing any repair work on the manipulator Motors and gears are HOT after running the robot Burns may result from touching the motors or gears Turn off all electric power hydraulic and pneumatic pressure supplies to the robot A Attachment screw SMB battery cover B SMB battery cover C SMB battery D Cable battery SMB boa...

Page 490: ...unit to be damaged from ESD The unit is sensitive to electrostatic discharge It will be destroyed if subjected to electrostatic voltages Before handling make sure you are connected to earth through a special ESD wrist bracelet or similar Step Action Note Illustration 1 Remove the SMB battery cover by unscrew ing its attachment screws Shown in the figure Location of SMB related equipment on page 73...

Page 491: ...0000203 Required equip ment A Attachment screw SMB battery cover B SMB battery cover C SMB battery D Cable battery SMB board E SMB cover F Attachment screw SMB cover G SMB unit H Pins B A E G H D F C Equipment etc Spare part no Art no Note SMB Unit 3HAC 13149 1 SMB Battery 3HAC 16831 1 Battery includes protection circuits Replace it only with given spare part no or an ABB approved eqviv alent Cabl...

Page 492: ...or gears Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Take any necessary measures to ensure that the manipulator does not collapse as parts are removed e g to secure the lower arm with fixtures if removing motor axis 2 Follow these instruction to prevent the unit to be damaged from ESD The unit is sensitive to electrostatic discharge It will be destroyed if su...

Page 493: ...roperly e g TPU enabling device all personnel is standing at a safe distance from the manipulator i e out of its reach behind any safety fences etc special attention is paid to the function of the part previously serviced 4 If disconnected reconnect the con nectors X8 X9 and X10 to the brake release board 5 Secure the SMB cover with its attach ment screws Shown in the figure Location of SMB relate...

Page 494: ...rate box on the frame with the brake release unit inside not shown in the figure xx0200000226 Required equip ment A Brake release unit B Attachment screws brake release unit 4 pcs C Buttons D SMB battery pack E SMB cover F Attachment screws SMB cover A B C D E F Equipment etc Spare part no Art no Note Standard toolkit 3HAC 15571 1 The contents are defined in section Standard toolkit on page 18 Oth...

Page 495: ...damaged from ESD The unit is sensitive to electrostatic discharge It will be destroyed if subjected to electrostatic voltages Before handling make sure you are connected to earth through a special ESD wrist bracelet or similar Step Action Note Illustration 1 Open the SMB cover by unscrewing the attachment screws Let the battery stay connected to avoid the need of synchronization of the robot Shown...

Page 496: ...brake release unit inside not shown in the figure xx0200000226 Required equip ment A Brake release unit B Attachment screws brake release unit 4 pcs C Buttons D SMB battery pack E SMB cover F Attachment screws SMB cover A B C D E F Equipment etc Spare part no Art no Note Brake release unit with buttons 3HAC 16035 1 Located together with the SMB unit at the left hand side of the frame Brake release...

Page 497: ...it is vital that all the service tools and other foreign objects are removed from the manipulator all normal safety equipment is installed properly e g TPU enabling device all personnel is standing at a safe distance from the manipulator i e out of its reach behind any safety fences etc special attention is paid to the function of the part previously serviced Other tools and proce dures may be req...

Page 498: ...rt shaft inside included in balancing device 3HAC 14678 1 F Attachment screws rear cover G Balancing device front eye including shaft and securing screw H Hole in the frame through which shaft puller tool is to be inserted I Bearing attachment J Parallel pin inside bearing attachment K Plug L Attachment screws bearing attachments F D E A C H G L I J K B Equipment etc Spare part no Art no Note Lock...

Page 499: ...ing device is potentially lethal The balancing device weighs 210 kg All lifting equipment used must be dimensioned accord ingly Hydraulic cylinder 3HAC 11731 1 To be used with press tool 3HAC 15767 1 Hydraulic pump 3HAC 13086 1 To be used with hydraulic cylin der 3HAC 11731 1 Securing screw 9ADA 183 66 M12 x 35 2 pcs required For securing the bearing attachments to the balancing device when liftin...

Page 500: ...o specified in Required equip ment on page 82 The hole in the frame is shown in the figure Location of balancing device on page 82 7 Restore the balancing device Detailed in Restoring the balancing device on page 91 8 Secure the two bearing attachments to the balancing device by replacing the plug on the outside of each attachment with a screw Shown in the figure Location of balanc ing device on p...

Page 501: ...aft inside included in balancing device 3HAC 14678 1 F Attachment screws rear cover G Balancing device front eye shaft including securing screw H Hole through which shaft puller tool is to be inserted I Bearing attachment J Parallel pin inside bearing attachment K Plug L Attachment screws bearing attachments F D E A C H G L I J K B Equipment Spare part no Art no Note Balancing device 3HAC 16198 1 ...

Page 502: ...he balancing device when lifting Bearing grease 3HAB 3537 1 For lubricating the o rings and the shaft Grease 3HAA 1001 294 80 ml Optimol PDO For lubrication of spherical roller bearing in ear in case of new bal ancing device Locking liquid Loctite 243 To apply to the securing screw in the shaft Grease pump To lubricate spherical roller bear ing Guide pin M16 x 300 3HAC 13120 5 Always use guide pin...

Page 503: ...f bal ancing device on page 85 4 Fit two guide pins to the upper holes in the frame where the bearing attachments are to be attached 5 Fit the lifting eye to the balancing device Art no specified in Required equip ment on page 85 6 Lift the balancing device and bring it forward gliding the bearing attachments on to the guide pins upper holes Note Make sure not to burden the guide pins with the wei...

Page 504: ... equip ment on page 85 13 Apply the shaft press tool to the lubricated shaft through the hole in the frame Fit the shaft using the shaft press tool and the hydraulic pump The shaft and the hole in the frame are shown in the figure Location of balancing device on page 85 Art no specified in Required equip ment on page 85 Note Make sure the shaft is pressed all the way to the bottom 14 Refit the sec...

Page 505: ...ce The figure below shows the hydraulic cylinder mounted on the press tool xx0200000174 Required equip ment A Bolt 4 pcs B Hydraulic cylinder C Fix plate D Moving pin with marking D B C A 0 1 Equipment etc Spare part no Art no Note Press tool balancing device 3HAC15767 1 Hydraulic cylinder 3HAC 11731 1 To be used with press tool 3HAC 15767 1 Hydraulic pump 3HAC13086 1 To be used with hydraulic cyl...

Page 506: ...the rear of the balancing device with enclosed bolts Tighten them properly Art no specified in Required equipment on page 89 See the figure Press tool and hydraulic cylinder on page 89 5 Fit the hydraulic cylinder to the press tool Art no specified in Required equipment on page 89 See the figure Press tool and hydraulic cylinder on page 89 6 Connect the hydraulic pump to the cyl inder Art no speci...

Page 507: ...e below shows the hydraulic cylinder mounted on the press tool xx0200000174 Required equip ment A Bolt 4 pcs B Hydraulic cylinder C Fix plate D Moving pin with marking D B C A 0 1 Equipment etc Spare part no Art no Note Hydraulic cylinder 3HAC 11731 1 To be used with press tool 3HAC 15767 1 Hydraulic pump 3HAC 13086 1 To be used with hydraulic cylinder 3HAC 11731 1 Standard toolkit 3HAC 15571 1 Th...

Page 508: ... fix plate to position 0 Shown in the figure Press tool and hydraulic cylinder on page 91 Do not apply more pressure than neces sary it could damage bearings and seal ings at the shaft 3 Unload the cylinder and make sure the moving pin indicates that the tool has returned to its starting position Shown in the figure Press tool and hydraulic cylinder on page 91 4 Remove the hydraulic cylinder 5 Rem...

Page 509: ...0200000200 Required equip ment A Motor axis 1 B Motor attachment screws and washers Equipment etc Spare part no Art no Note Lifting tool motor axis 1 4 5 3HAC 14459 1 Removal tool motor M12 3HAC 14631 1 Always use the removal tools in pairs Power supply 24 VDC 1 5 A For releasing the brakes Circuit Diagram 3HAC 13347 1 Included in Repair Man ual part 2 Standard toolkit 3HAC 15571 1 The contents ar...

Page 510: ...f the motor by unscrewing its four attach ment screws 2 Remove the cable gland cover at the cable exit by unscrewing its two attachment screws xx0200000199 A Cable gland cover Make sure the gasket is not damaged 3 Disconnect all connectors beneath the motor cover 4 Apply lifting tool motor axis 1 4 5 to the motor Art no specified in Required equip ment on page 93 5 In order to release the brakes c...

Page 511: ...uipment etc Spare part no Art no Note Motor axis 1 3HAC 15879 1 Includes motor 3HAC 14673 6 Includes pinion 3HAC 11350 1 Includes o ring 2152 2012 430 O ring 2152 2012 430 Must be replaced when reas sembling motor Grease 3HAB 3537 1 Used to lubricate the o ring Lifting tool motor axis 1 4 5 3HAC 14459 1 Power supply 24 VDC max 1 5 A For releasing the brakes Circuit Diagram 3HAC 13347 1 Included in...

Page 512: ...previously serviced Other tools and proce dures may be required See references to these procedures in the step by step instructions below These procedures include refer ences to the tools required Equipment etc Spare part no Art no Note Step Action Note Illustration 1 Make sure the o ring on the circumference of the motor is seated properly Lightly lubricate the o ring with grease Art no specified...

Page 513: ...B Hole for lock screw C Cable gland cover located on the lower side of the motor D Motor attachment holes 4 pcs A B C D Equipment etc Spare part no Art no Note Locking screw 3HAA1001 266 M16 x 60 For securing the lower arm Lifting tool motor axis 2 3 4 3HAC 15534 1 Power supply 24 VDC 1 5 A For releasing the brakes Removal tool motor M12 3HAC 14631 1 Always use the removal tools in pairs Guide pin...

Page 514: ...and pro cedures may be required See refer ences to these pro cedures in the step by step instructions below These procedures include refer ences to the tools required Equipment etc Spare part no Art no Note Step Action Note Illustration 1 Run the manipulator to a position close enough to its calibration position to allow the lock screw to be inserted into the hole for lock screw Shown in the figur...

Page 515: ...r attachment holes Art no specified in Required equipment on page 97 Shown in the figure Location of motor on page 97 Always use the removal tools in pairs 11 Remove the removal tools and fit the lifting tool motor axis 2 3 4 to the motor Art no specified in Required equipment on page 97 12 Lift the motor to get the pinion away from the gear Make sure the motor pinion does not get damaged 13 Remov...

Page 516: ...ent holes 4 pcs A B C D Equipment etc Spare part no Art no Note Motor axis 2 175 2 55 3HAC 15882 1 Includes motor 3HAC 14673 6 Includes pinion 3HAC 10122 15 Includes o ring 2152 2012 430 Motor axis 2 225 2 55 175 2 8 125 3 2 and 200 2 75 3HAC 15885 1 Includes motor 3HAC 14673 9 Includes pinion 3HAC 10122 15 Includes o ring 2152 2012 430 O ring 2152 2012 430 Must be replaced when reassem bling moto...

Page 517: ...1 Included in the Repair Manual part 2 Standard toolkit 3HAC 15571 1 The contents are defined in sec tion Standard toolkit on page 18 Other tools and pro cedures may be required See refer ences to these pro cedures in the step by step instructions below These procedures include refer ences to the tools required Equipment etc Spare part no Art no Note Step Action Note Illustration 1 Make sure the o...

Page 518: ... used beneath the motor cover directly on the motor shaft as shown in figure above A Rotation tool 8 Remove the guide pins 9 Secure the motor with four attachment screws and plain washers M10 x 40 tightening torque 50 Nm Reused screws may be used pro viding they are lubricated as detailed in Screw joints on page 15 before fitting 10 Remove the lifting tool 11 Disconnect the brake release voltage 1...

Page 519: ...d washers 4 pcs A B C Equipment etc Spare part no Art no Note Power supply 24 VDC 1 5 A For releasing the brakes Removal tool motor M12 3HAC 14631 1 Always use the removal tools in pairs Guide pin M10 x 150 3HAC 15521 2 For guiding the motor Always use guide pins in pairs Mech stop axis 3 3HAC 12708 1 Used to fix axis 3 one method of three see step one in the removal procedure Use attachment screw...

Page 520: ...e pro cedures in the step by step instructions below These procedures include refer ences to the tools required Equipment etc Spare part no Art no Note Step Action Note Illustration 1 Unload the manipulator upper arm by either Use a fork lift to rest the upper arm onto Use lifting slings and an overhead crane to rest the upper arm Use a mechanical stop to rest the upper arm Fit the mechanical stop...

Page 521: ...Fit the two guide pins in the two lower motor attachment screw holes Art no specified in Required equip ment on page 103 10 Press the motor out of position by fitting removal tool motor to the motor attachment screw holes Art no specified in Required equip ment on page 103 Always use the removal tools in pairs 11 Apply the lifting tool motor axis 2 3 4 to the motor Art no specified in Required equ...

Page 522: ...C 15882 1 Includes motor 3HAC 14673 6 Includes pinion 3HAC 10122 15 Includes o ring 2152 2012 430 Motor axis 3 225 2 55 175 2 8 125 3 2 and 200 2 75 3HAC 15885 1 Includes motor 3HAC 14673 9 Includes pinion 3HAC 10122 15 Includes o ring 2152 2012 430 O ring 21522012 430 Must be replaced when reassem bling motor Grease 3HAB 3537 1 For lubricating the o ring Guide pin M10 x 100 3HAC 15521 1 For guidi...

Page 523: ...dard toolkit 3HAC 15571 1 The contents are defined in sec tion Standard toolkit on page 18 Other tools and pro cedures may be required See refer ences to these proce dures in the step by step instructions below These procedures include refer ences to the tools required Equipment etc Spare part no Art no Note Step Action Note Illustration 1 Make sure the o ring on the circumfer ence of the motor is...

Page 524: ...ables facing for wards xx0200000165 The rotation tool is used beneath the motor cover directly on the motor shaft as shown in figure above A Rotation tool 8 Remove the guide pins 9 Secure the motor with four attachment screws and plain washers 4 pcs M10 x 40 tightening torque 50 Nm 10 Disconnect the brake release voltage 11 Reconnect all connectors beneath the motor cover Connect in accordance wit...

Page 525: ...art no Art no Note Power supply 24 VDC 1 5 A For releasing the brakes Removal tool motor M10 3HAC 14972 1 Always use the removal tools in pairs Guide pin M8 x 150 3HAC 15520 2 For guiding the motor Always use the guide pins in pairs Circuit Diagram 3HAC 13347 1 Included in the Repair Manual part 2 Standard toolkit 3HAC 15571 1 The contents are defined in sec tion Standard toolkit on page 18 Other ...

Page 526: ...the gear oil which in turn saves time 2 Remove the cable gland cover at the cable exit of the motor by unscrewing its two attachment screws Shown in the figure Location of motor on page 109 Make sure the gasket is not dam aged 3 Remove the cover on top of the motor by unscrewing its four attachment screws 4 Disconnect all connectors beneath the motor cover 5 In order to release the brake connect t...

Page 527: ...60 1 Includes o ring 2152 2012 430 Motor axis 4 225 2 55 175 2 8 125 3 2 and 200 2 75 3HAC 15889 1 Includes motor 3HAC 14673 10 Includes pinion 3HAC 12260 1 Includes o ring 2152 2012 430 O ring 2152 2012 430 Must be replaced when reassem bling motor Grease 3HAC 3537 1 Used to lubricate the o ring Guide pin M8 x 100 3HAC 15520 1 For guiding the motor Guide pin M8 x 150 3HAC 15520 2 For guiding the ...

Page 528: ...contents are defined in sec tion Standard toolkit on page 18 Other tools and pro cedures may be required See refer ences to these pro cedures in the step by step instructions below These procedures include refer ences to the tools required Equipment etc Spare part no Art no Note Step Action Note Illustration 1 Make sure the o ring on the circumference of the motor is seated properly Lightly lubri ...

Page 529: ...ged Make sure the motor is turned the right direction i e the cables facing for wards xx0200000165 The rotation tool is used beneath the motor cover directly on the motor shaft as shown in figure above A Rotation tool 6 Remove the guide pins 7 Secure the motor with four attachment screws and plain washers 4 pcs M8 x 25 tightening torque 24 Nm 8 Disconnect the brake release voltage 9 Reconnect all ...

Page 530: ...rist unit A B C Equipment etc Spare part no Art no Note Power supply 24 VDC 1 5 A For releasing the brakes Removal tool motor M10 3HAC 14972 1 Always use the removal tools in pairs Measuring tool 6896 134 GN Guide pin M8 x 100 motor 3HAC 15520 1 For guiding the motor Guide pin M8 x 150 motor 3HAC 15520 2 For guiding the motor Nipple 6896 134 AA For pressing out the pinion motor 5 TREDO washer Use ...

Page 531: ...tep instructions below These procedures include references to the tools required Equipment etc Spare part no Art no Note Step Action Note Illustration 1 Drain the oil from gearbox axis 5 Detailed in Oil change gearbox axis 5 in the Maintenance Manual 2 Remove the wrist unit Detailed in section Removal of complete wrist unit on page 47 3 Place the wrist unit safely on a work bench in a fixture or s...

Page 532: ...lange and the wrist housing 13 Measure the distance between the motor flange included eventual shims and the outer surface of the pinion with measur ing tool Art no specified in Required equipment on page 114 Make a note of the distance 14 Press out the pinion from the dismounted motor with equipment specified in table above The pinion is matched with the beveral gear for axis 5 When the motor is ...

Page 533: ...HAC 14673 7 Does not include pinion Use the pinion from the motor to be replaced Includes o ring 2152 2012 430 Motor axis 5 225 2 55 175 2 8 125 3 2 and 200 2 75 3HAC 14673 10 Does not include pinion Use the pinion from the motor to be replaced Includes o ring 2152 2012 430 Set of shim motor 3HAC7941 28 Used to obtain the correct dis tance between motor flange and outer surface of motor pinion O r...

Page 534: ... 18 Other tools and pro cedures may be required See refer ences to these proce dures in the step by step instructions below These procedures include refer ences to the tools required Equipment etc Spare part no Art no Note Step Action Note Illustration 1 Make sure the o ring on the circumference of the motor is seated properly Lightly lubri cate the o ring with grease Art no specified in Required ...

Page 535: ... separate cable if not removed pin C pin D 8 Fit the two guide pins in two of the motor attachment holes Art no specified in Required equip ment on page 117 9 Fit the motor with guidance from the pins making sure the motor pinion is properly mated to the gear of axis 5 Make sure the motor pinion does not get damaged 10 Secure the motor with four attachment screws and plain washers 4 pcs M8 x 25 ti...

Page 536: ...its location may be found in the Foldout section Wrist complete on page 211 xx0200000222 Required equip ment A Wrist unit B Motor axis 6 A B Equipment etc Spare part no Art no Note Power supply 24 VDC 1 5 A For releasing the brakes Removal tool motor M10 3HAC14972 1 Always use the removal tools in pairs Circuit Diagram 3HAC13347 1 Included in the Repair Man ual part 2 Standard toolkit 3HAC15571 1 ...

Page 537: ...se procedures include ref erences to the tools required Equipment etc Spare part no Art no Note Step Action Note Illustration 1 Run the robot to a position where the motor in axis 6 is pointed straight up This position enables the motor to be replaced without draining the gear oil which in turn saves time 2 Remove the rear motor cover by unscrewing six attachment screws 3 Disconnect all connectors...

Page 538: ...200000222 Required equip ment A Wrist unit B Motor axis 6 A B Equipment etc Spare part no Art no Note Motor axis 6 175 2 55 3HAC 15990 1 Includes motor 3HAC 14673 8 Includes pinion 3HAC 10122 24 Includes o ring 2152 2012 430 Motor axis 6 225 2 55 175 2 8 125 3 2 and 200 2 75 3HAC 15991 1 Includes motor 3HAC 14673 8 Includes pinion 3HAC 11173 3 Includes o ring 2152 2012 430 O ring 2152 2012 430 Mus...

Page 539: ...ired See refer ences to these proce dures in the step by step instructions below These procedures include refer ences to the tools required Equipment etc Spare part no Art no Note Step Action Note Illustration 1 Make sure the o ring on the circumference of the motor is seated properly Lightly lubricate the o ring with grease Art no specified in Required equip ment on page 122 2 In order to release...

Page 540: ...intenance it is vital that all the service tools and other foreign objects are removed from the manipulator all normal safety equipment is installed properly e g TPU enabling device all personnel is standing at a safe distance from the manipulator i e out of its reach behind any safety fences etc special attention is paid to the function of the part previously serviced ...

Page 541: ...f the component and its location may be found in the Foldout section Base incl Frame on page 203 xx0300000015 Required equip ment A Gearbox axis 1 B Frame C Base Attachment screws base to gearbox not shown in figure A B C Equipment etc Spare part no Art no Note Standard toolkit 3HAC 15571 1 The contents are defined in section Standard toolkit on page 18 Support base and gear 1 3HAC 15535 1 Lifting...

Page 542: ...eighs 155 kg All lifting equipment used must be dimensioned accordingly The base without gearbox 1 weighs 263 kg All lifting equipment used must be dimensioned accordingly Other tools and procedures may be required See refer ences to these procedures in the step by step instruc tions below These procedures include references to the tools required Equipment etc Spare part no Art no Note Step Action...

Page 543: ...n Required equipment on page 125 9 Fit the support base Make sure the base remains in a stable position before performing any work underneath the base 10 Unscrew the 18 attachment screws B and remove the 3 washers C shown in the figure to the right xx0200000227 A view from below A Oil drain hose B Gearbox 1 attachment screws 18 pcs C Washers 3 pcs 11 Remove the cable guide in the cen ter of gearbo...

Page 544: ...Frame on page 203 xx0300000015 Required equip ment A Gearbox axis 1 B Frame C Base Attachment screws base to gearbox not shown in figure A B C Equipment etc Spare part no Art no Note Gearbox axis 1 3HAC 10828 8 Includes gearbox 3HAC 10828 3 Includes all o rings and sealing rings O ring 3HAB 3772 54 Replace only when damaged O ring 3HAB 3772 55 Replace only when damaged Sealing ring 3HAC 11581 4 Re...

Page 545: ...r and gearbox the gears may be damaged if excessive force is used The gear box weighs 155 kg All lifting equipment used must be dimensioned accordingly The base without gearbox 1 weighs 263 kg All lifting equipment used must be dimensioned accordingly Lifting device base and gear 1 3HAC 15560 1 Lifting tool chain 3HAC 15556 1 Standard toolkit 3HAC 15571 1 The contents are defined in section Standa...

Page 546: ...g 3HAB 3772 54 D O ring 3HAB 3772 55 E Sealing ring 3HAC 11581 4 3 Refit the cable guide in the center of gear box 1 with its attachment screws xx0200000256 A Location for attachment screws cable guide cable guide removed in figure 4 Fit the lifting device base and the lifting tool chain to the gearbox Art no specified in Required equip ment on page 128 5 Lift the gearbox to its mounting position ...

Page 547: ...tailed in Screw joints before fitting xx0200000227 A view from below A Oil drain hose B Attachment screws base to gearbox 18 pcs C Washers 3 pcs 8 Lift the manipulator base and gearbox 1 to allow removing the support base and gear 9 Secure the base to the mounting site Detailed in Orienting and securing the manipulator in the Installation Manual 10 Refit the complete arm system Detailed in section...

Page 548: ...the oil plugs The service work differ some between the designs Be aware of the differences made in the instruction Location of gear box The gearbox axis 2 is located in the lower arm rotational center underneath the motor attach ment The figure below shows the later design of the motor attachment A more detailed view of the component and its location may be found in the Foldout section Frame Lower...

Page 549: ...ingly H Attachment screws motor attachment I Additional cover J Motor attachment Equipment etc Spare part no Art no Note Fixture lower arm 3HAC 13659 1 Includes locking screw for securing the lower arm Locking screw lower arm 3HAA1001 266 M16 x 60 Accompanying the fixture Lifting tool gearbox axis 2 3HAC 13698 1 Guide pins M12 x 150 3HAC 13056 2 For guiding the gearbox Guide pins M12 x 250 3HAC 13...

Page 550: ...w into a specific attach ment hole Art no specified in Required equip ment on page 133 Shown in the figure Location of gear box on page 132 5 Fit the fixture lower arm to prevent the lower arm from falling Make sure that both adjusters B on the fixture are screwed back Align the fixture with the frame and lower arm Tighten the four M16 bolts C on the inside of the frame in attachment holes with ti...

Page 551: ...Remove the motor attachment In the early design this is done by unscrew ing the 24 front gearbox attachment screws In the later design this is done by unscrew ing the 15 attachment screws motor attach ment Read more about the variations in design in Different designs on page 132 Shown in the figure Location of gear box on page 132 11 If the robot is equipped with the later design of the motor atta...

Page 552: ...xx0200000172 A M12 holes for pressing the gearbox out 14 Fit the lifting tool gearbox axis 2 to the gear box Art no specified in Required equip ment on page 133 15 Remove the gearbox axis 2 using an over head crane or similar with guidance from the mounted guide pins 16 Remove the friction washer and clean it 17 Remove the sealing from the lower arm Step Action Note Illustration A A ...

Page 553: ... and holds the oil plugs The service work differ some between the designs Be aware of the differences made in the instruction Location of gear box The gearbox axis 2 is located in the lower arm rotational center underneath the motor attach ment The figure below shows the later design of the motor attachment A more detailed view of the gearbox may be found in the Foldout section Frame Lower arm 1 o...

Page 554: ...ent Equipment Spare part no Art no Note Gear axis 2 3HAC 10828 12 Includes gearbox 3HAC 10828 11 and all o rings Does not include Sealing axis 2 3 O ring 3HAB 3772 68 2 pcs O ring 3HAB 3772 69 3HAB 3772 70 O rings in the additional cover Should be replaced if damaged Sealing axis 2 3 3HAC 12443 2 A new sealing must be used on each assembly Grease 3HAB 3537 1 For lubricating o rings Lifting tool ge...

Page 555: ...e them with grease Art no specified in Required equip ment on page 138 xx0200000173 A O rings 2 pcs gearbox axis 2 2 Fit the lifting tool gearbox axis 2 to the gearbox Art no specified in Required equip ment on page 138 3 Fit the guide pins sealing axis 2 3 on the gearbox axis 2 Use the attachment holes A shown in the figure to the right xx0200000166 A Holes for guide pins seal ing axis 2 3 on the...

Page 556: ... from the guide pins and slide it into position If necessary use the front gearbox attach ment screws to press the gearbox into place 10 Remove the lifting tool from the gearbox and continue refitting the motor attachment as described below Choose correct instruction depending on which motor attachment the robot is equipped with Read more about the variations in Different designs on page 137 11 Ea...

Page 557: ...ue 115 Nm Reused screws may be used provid ing they are lubricated as detailed in Screw joints on page 15 before fitting 18 Remove the guide pins sealing axis 2 3 and tighten the two remaining screws as detailed above 19 Refit the motor Detailed in section Refitting of motor axis 2 on page 100 20 Perform a leak down test Detailed in section Performing a leak down test on page 21 21 Refill the gear...

Page 558: ...ew of the component and its location may be found in the Foldout section Upper arm on page 209 xx0200000194 Required equip ment A Gearbox axis 3 sealing axis 2 3 between lower arm and gearbox 3 B Motor axis 3 C Upper arm D Gearbox attachment screws 24 pcs A B C D Equipment etc Spare part no Art no Note Mech stop axis 3 3HAC 12708 1 Used to secure the upper arm Use attachment screws 3HAB 3409 86 M1...

Page 559: ...uide pin M12 x 250 3HAC 13056 4 For guiding the gearbox Guides are to be used in pairs Lifting eye M12 3HAC 14457 3 Standard toolkit 3HAC 15571 1 The contents are defined in sec tion Standard toolkit on page 18 Other tools and pro cedures may be required See refer ences to these proce dures in the step by step instructions below These procedures include refer ences to the tools required Equipment ...

Page 560: ...tachment screw holes Art no specified in Required equip ment on page 142 8 If required apply M12 screws to the holes A shown in the figure to the right to press the gearbox free xx0200000201 A M12 holes for pressing the gearbox out B Gearbox attachment screw holes C Upper attachment screw holes gearbox lower arm 9 Fit the lifting eye M12 to the gearbox in one of the upper attachment screw holes th...

Page 561: ...ailed view of the component and its location may be found in the Foldout section Upper arm on page 209 xx0200000194 Required equip ment A Gearbox axis 3 sealing axis 2 3 between lower arm and gearbox 3 B Motor axis 3 C Upper arm D Gearbox attachment screws A B C D Equipment etc Spare part no Art no Note Gearbox axis 3 3HAC 10828 12 Includes gearbox 3HAC 10828 11 Includes all o rings Does not inclu...

Page 562: ...ifting eye M12 3HAC 14457 3 Guide pin M12 x 200 3HAC 13056 3 For guiding the gearbox Guides are to be used in pairs Guide pin M12 x 250 3HAC 13056 4 For guiding the gearbox Guides are to be used in pairs Guide pin sealing axis 2 3 80 mm 3HAC 14628 1 For guiding Sealing axis 2 3 Guides are to be used in pairs Guide pin sealing axis 2 3 100 mm 3HAC 14628 2 For guiding Sealing axis 2 3 Guides are to ...

Page 563: ...ated properly and correctly ori ented 8 Remove the lifting tool 9 Secure the gearbox with 22 of the 24 gear box attachment screws Remove the guide pins and tighten the remaining two screws 24 pcs M12 x 60 Tightening torque 115 Nm Reused screws may be used provid ing they are lubricated as detailed in Screw joints on page 15 before fitting 10 Refit the upper arm with a new sealing axis 2 3 Art no i...

Page 564: ...intenance it is vital that all the service tools and other foreign objects are removed from the manipulator all normal safety equipment is installed properly e g TPU enabling device all personnel is standing at a safe distance from the manipulator i e out of its reach behind any safety fences etc special attention is paid to the function of the part previously serviced ...

Page 565: ...xx0200000219 Required equip ment A Gearbox axis 6 B 1 Attachment screws and washers gearbox for robot version 175 2 55 8 pcs B 2 Attachment screws and washers gearbox for robot version 225 2 55 175 2 8 125 3 2 and 200 2 75 18 pcs C Oil plug draining D Oil plug filling O ring not shown in figure A C B B 1 2 A D Equipment etc Spare part no Art no Note Standard toolkit 3HAC15571 1 The contents are de...

Page 566: ...ng motor axis 2 Whenever parting mating motor and gearbox the gears may be damaged if excessive force is used Step Action Note Illustration 1 Drain the oil from gearbox axis 6 Detailed in Oil change gearbox axis 6 in the Maintenance Manual 2 Remove the turning disc Detailed in section Removal of turning disk on page 42 3 Remove the gearbox by unscrewing its 8 or 18 attachment screws and washers am...

Page 567: ... for robot version 175 2 55 8 pcs B 2 Attachment screws and washers gearbox for robot version 225 2 55 175 2 8 125 3 2 and 200 2 75 18 pcs C Oil plug draining D Oil plug filling O ring not shown in figure A C B B 1 2 A D Equipment etc Spare part no Art no Note Gear axis 6 175 2 25 3HAC 10828 10 Includes o ring 3HAB 3772 58 Gear axis 6 225 2 55 175 2 8 125 3 2 and 200 2 75 3HAC 10828 13 Includes o ...

Page 568: ...removing motor axis 2 Standard toolkit 3HAC 15571 1 The contents are defined in section Standard toolkit on page 18 Other tools and proce dures may be required See references to these procedures in the step by step instruc tions below These procedures include references to the tools required Equipment etc Spare part no Art no Note Step Action Note Illustration 1 Make sure the o ring is fitted to t...

Page 569: ...he function of the part previously serviced 3 Secure the gearbox with the attach ment screws and washers Shown in figure above 8 pcs or 18 pcs depending on robot version M8 x 40 12 9 quality UNBRAKO tightening torque 30 Nm Reused screws may be used providing they are lubricated as detailed in Screw joints on page 15 before fitting 4 Refit the turning disc Detailed in section Refitting of turning d...

Page 570: ...3 Repair activities manipulator 3 6 8 Refitting of gearbox axis 6 154 A 3HAC 16247 1 ...

Page 571: ...he controller It is made up of separate units each detailing a specific repair activity e g Removal or Refit ting of a certain component in the controller Each unit contains all information required to perform the activity e g spare parts numbers required special tools and materials The chapter is divided into Removal instructions for all components Refitting instructions for all components Remain...

Page 572: ... electric power supply to the cabinet Many components inside the cabinet are sensitive to ESD ElectroStatic Discharge and will be destroyed if subjected to it Before handling make sure you are connected to earth through a special ESD wrist bracelet or similar A Battery unit Rectifier A0 X3 X2 X1 X2 X2 X2 X1 X1 X1 X2 X1 A Equipment etc Spare part no Art no Note Battery unit 3HAC 5393 2 To be replac...

Page 573: ...jected to it Before handling make sure you are connected to earth through a special ESD wrist bracelet or similar Step Action Note Illustration 1 Remove the battery unit by unscrewing its attachment screws 1 xx0200000004 2 Pull the battery unit out 3 Disconnect the three cables from the battery unit xx0200000005 Rectifier A0 X3 X2 X1 X2 X2 X2 X1 X1 X1 X2 X1 Step Action Note Illustration 1 Place th...

Page 574: ...the cabinet B Four available slots for I O and gateway units I O 1 I O 2 I O 3 I O 4 Equipment etc Spare part no Art no Note Digital 24 VDC I O 3HAB 7229 1 DSQC 328 Analog I O 3HNE 00554 1 DSQC 355 AD Combi I O 3HAB 7230 1 DSQC 327 Digital 120 VAC I O 3HAB 7231 1 DSQC 320 Digital I O with relays 3HAB 9669 1 DSQC 332 Gateway for Allen Bradley RIO 3HNE00025 1 DSQC 350 Gateway for Interbus S 3HNE0000...

Page 575: ...any components inside the cabinet are sensitive to ESD ElectroStatic Discharge and will be destroyed if subjected to it Before handling make sure you are connected to earth through a special ESD wrist bracelet or similar Step Action Note Illustration 1 Disconnect any connectors from the unit Note which connector goes where to facil itate reassembly The actual number of connectors vary depending on...

Page 576: ...ollowing before commencing any repair work on the controller Turn off all electric power supply to the cabinet Many components inside the cabinet are sensitive to ESD ElectroStatic Discharge and will be destroyed if subjected to it Before handling make sure you are connected to earth through a special ESD wrist bracelet or similar A Bleeder resistor unit B Air outlet device B A Equipment etc Spare...

Page 577: ...g make sure you are connected to earth through a special ESD wrist bracelet or similar 2 Disconnect the cable secured on top of the bleeder resistor unit see position 1 in the figure xx0200000015 3 Push down and pull out the bleeder resis tor unit to release the bleeder resistor unit from the enclosure see position 2 and 3 in the figure Step Action Note Illustration 1 1 2 Step Action Note Illustra...

Page 578: ...he manipulator Motors and gears are HOT after running the robot Burns may result from touching the motors or gears Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Take any necessary measures to ensure that the manipulator does not collapse as parts are removed e g securing the lower arm with fixtures before removing motor axis 2 A Computer unit Rectifier A0 X3 X2...

Page 579: ...ull the computer unit out of the cabinet until locked in its end position Then swing it to the left as shown in the figure xx0200000018 5 If work is to be performed on the computer unit while in the service position it must be locked in this position This is done by placing the puck located on the lower left side on the metal bar Alternatively the computer unit may be lifted straight up and placed...

Page 580: ... running the robot Burns may result from touching the motors or gears Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Take any necessary measures to ensure that the manipulator does not collapse as parts are removed e g securing the lower arm with fixtures before removing motor axis 2 Step Action Note Illustration 1 Swing the computer unit back into position and ...

Page 581: ... to ESD ElectroStatic Discharge and will be destroyed if subjected to it Before handling make sure you are connected to earth through a special ESD wrist bracelet or similar A Computer system Rectifier A0 X3 X2 X1 X2 X2 X2 X1 X1 X1 X2 X1 A Equipment etc Spare part no Art no Note Mass storage memory 64 MB 3HAC 7519 2 Mass storage memory 128 MB 3HAC 7519 3 Standard toolkit 3HAC15571 1 The contents a...

Page 582: ...elet or similar 2 Open the cover on the right side of the com puter system by unsnapping the two snaps item 1 in the figure xx0200000019 3 Disconnect the connectors X1 and X2 from the front of the mass storage memory items 2 and 3 in the figure 4 Remove the mass storage memory by unscrewing its M4 attachment screws as shown in the figure item 1 in the figure See figure above Step Action Note Illus...

Page 583: ...AC 16247 1 A 167 3 Close the cover on the right side of the com puter unit and secure it with the snaps item 1 in the figure 4 Put the computer system back in regular operation position Detailed in section Putting the com puter in the service position Step Action Note Illustration 1 ...

Page 584: ...y to the cabinet Many components inside the cabinet are sensitive to ESD ElectroStatic Discharge and will be destroyed if subjected to it Before handling make sure you are connected to earth through a special ESD wrist bracelet or similar A Computer system A0 X3 X2 X1 X2 X2 X2 X1 X1 X1 X2 X1 A Equipment etc Spare part no Art no Note Internal cooling fan 3HAC 6655 1 Two fans required Other tools an...

Page 585: ...inside the cabinet are sensitive to ESD ElectroStatic Discharge and will be destroyed if subjected to it Before handling make sure you are connected to earth through a special ESD wrist bracelet or similar 2 Disconnect the connector E5 or E6 respec tively depending on which fan is to be replaced xx0200000020 A Upper fan B Lower fan C Locking tabs D Connector E5 E Connector E6 3 Remove the internal...

Page 586: ...e hole see the figure Art no specified above xx0200000021 A Push direction 2 With the wall between the upper lock spring hooks push the fan unit up and in until the locking tab snaps to the wall See the figure above 3 Reconnect the connector E5 or E6 respectively depend ing on which fan was replaced 4 Put the computer unit back in regular operation position Detailed in Putting the computer in the ...

Page 587: ...s how to remove the drive units Please observe the following before commencing any repair work on the controller Turn off all electric power supply to the cabinet A Rectifier drive unit B Drive units C Power supply unit A B C Equipment etc Spare part no Art no Note Drive unit rectifier 3HAB 8101 17 DSQC 545A Drive unit axes 1 6 3HAB 8101 18 DSQC 546A Other tools and proce dures may be required See...

Page 588: ...nside the cabinet are sensitive to ESD ElectroStatic Discharge and will be destroyed if subjected to it Before handling make sure you are connected to earth through a special ESD wrist bracelet or similar Step Action Note Illustration 1 Swing the panel shutter out of the way pos A in figure 2 Disconnect connectors X1 and X2 four connectors each see position 1 in the figure xx0200000013 3 Remove th...

Page 589: ... A 173 Step Action Note Illustration 1 Fit the unit into position and secure it with the spring Also see figure above 2 Refit the power bar in front of the unit 3 Reconnect all connectors X1 and X2 4 Swing the power supply unit back into position Detailed in section Replacement of power supply unit ...

Page 590: ...e cabinet Many components inside the cabinet are sensitive to ESD ElectroStatic Discharge and will be destroyed if subjected to it Before handling make sure you are connected to earth through a special ESD wrist bracelet or similar A Air outlet device B Bleeder resistor unit C System fan unit Equipment etc Spare part no Art no Note System fan unit 3HAC 15449 1 Other tools and procedures may be req...

Page 591: ... through a special ESD wrist bracelet or similar 3 Disconnect the cable see position 1 in the figure xx0200000008 4 Pull the back of the system fan unit upwards to free it and then tip it out of the enclosure see position 2 in the fig ure Step Action Note Illustration 2 2 Rectifier A0 1 1 Step Action Note Illustration 1 Fit the system fan unit into position and secure it see position 2 in the figu...

Page 592: ...tatic Discharge and will be destroyed if subjected to it Before handling make sure you are connected to earth through a special ESD wrist bracelet or similar A Power supply unit B Power supply unit locking spring Equipment etc Spare part no Art no Note Power supply unit 3HAB 4297 1 DSQC 506 Other tools and procedures may be required See refer ences to these procedures in the step by step instructi...

Page 593: ...oyed if subjected to it Before handling make sure you are connected to earth through a special ESD wrist bracelet or similar 4 Lift the unit straight up to release it from the hooks in the back and remove it outwards Step Action Note Illustration Step Action Note Illustration 1 Fit the power supply unit into position onto its hooks and secure it with the attachment screw see position 2 in the sect...

Page 594: ...Many components inside the cabinet are sensitive to ESD ElectroStatic Discharge and will be destroyed if subjected to it Before handling make sure you are connected to earth through a special ESD wrist bracelet or similar 1 Cover 2 M5 screw 3 Extended Power supply 1 3 2 Equipment etc Spare part no Art no Note Extended Power supply 3HAB 13398 1 Other tools and procedures may be required See refer e...

Page 595: ...de the cabinet are sensitive to ESD ElectroStatic Discharge and will be destroyed if subjected to it Before handling make sure you are connected to earth through a special ESD wrist bracelet or similar 4 Remove the Power supply from the mounting rail See pos 3 in previous illustration Step Action Note Illustration Step Action Note Illustration 1 Fit the power supply unit onto the mounting rail 2 R...

Page 596: ...4 Repair activities controller cabinet 4 1 10 Replacement of Peltier Cooler power supply 180 A 3HAC 16247 1 ...

Page 597: ...5 0 1 Introduction This chapter is an appendix to the manual and contains part lists with item numbers refering to the Appendix 2 Foldouts The part list for the manipulator sometimes differ for robot versions 225 2 25 175 2 8 and 175 2 25 In case of difference the version is stated in the title ...

Page 598: ... 185 103 1 3HAC 8114 1 Wrist 175 2 55 See Wrist robot v 175 2 55 3HAC 8114 1 on page 189 103 1 3HAC 8114 3 Wrist 225 2 55 175 2 8 125 3 2 200 2 75 See Wrist robot v 225 2 55 175 2 8 125 3 2 200 2 75 3HAC 8114 3 on page 189 103 1 3HAC 8114 6 Wrist Foundry 175 2 55 See Wrist Foundry robot v 175 2 55 3HAC 8114 6 on page 189 103 1 3HAC 8114 5 Wrist Foundry 225 2 55 175 2 8 125 3 2 200 2 75 See Wrist F...

Page 599: ... screw M6x16 113 4 9ADA 618 56 Torx pan head screw M6x16 114 1 3HAC 13416 1 Protection cover Shell size 16 Item Qty Art number Description Dimension Note Item Qty Art number Description Dimension 5 1 1 3HAC 12812 1 Mech stop 5 2 1 9ABA 142 92 Spring pin slotted 10x30 Item Qty Art number Description Dimension Note 101 1 1 3HAC 13054 2 Base machining See Base machining 3HAC 13054 2 on page 183 101 2...

Page 600: ...01 134 Washer 13x19x1 5 Item Qty Art number Description Note 102 1 1 3HAC 13350 1 Material set ax 4 See Material set ax 4 3HAC 13350 1 on page 185 102 2 1 3HAC 10139 1 Tube shaft 2 55 See Tube shaft 2 55 3HAC 10139 1 on page 187 102 3 1 3HAC 13351 2 Axis 3 See Axis 3 3HAC 13351 2 1 on page 187 102 4 1 3HAC 14753 1 Rot ac motor incl gearbox See Rot ac motor incl gear box 3HAC 14753 1 on page 188 It...

Page 601: ...350 1 on page 185 102 2 1 3HAC 15859 1 Tube shaft 2 55 foundry 102 3 1 3HAC 13351 1 Axis 3 See Axis 3 3HAC 13351 2 1 on page 187 102 4 1 3HAC 14752 1 Rot ac motor incl gearbox See Rot ac motor incl gear box 3HAC 14752 1 on page 189 Item Qty Art number Description Dimension Note 102 1 1 1 3HAC 12261 1 Gear Z4 4 102 1 3 8 9ADA 183 37 Hex socket head cap screw M8x25 102 1 4 8 9ADA 312 7 Plain washer ...

Page 602: ...aling Nilos 180x215x4 102 1 26 1 3HAB 4317 1 SEALING 102 1 27 1 3HAC 3774 7 Spacer ring 102 1 28 1 3HAB 3772 27 O ring 170x5 102 1 29 1 9ABA 107 56 Parallel pin 10x20 102 1 30 8100 ml 1171 2016 604 Lubricating oil 102 1 31 30 g 3HAB 3537 1 Bearing grease 102 1 32 1 ml 3HAB 7116 1 Locking liquid 102 1 33 1 ml 3HAB 7116 2 Locking liquid 102 1 34 1 3HAC 16721 1 Magnetic plug R 1 2 Item Qty Art number...

Page 603: ...over compl See Protection Cover compl 3HAC 1383 2 on page 187 Item Qty Art number Description Dimension 102 2 2 1 1 9ADA 624 69 Torx counters head screw M8x20 102 2 2 2 1 3HAB 3772 66 O ring 8x2 102 2 2 3 1 3HAC 1383 1 Protection Cover 102 2 2 4 1 3HAC 1383 3 Gasket Item Qty Art number Description Dimension Note 102 3 1 1 3HAC 10133 1 Axis 4 housing 102 3 2 1 3HAC 10828 12 RV 410F 270 176 assembly...

Page 604: ...1 1 3HAC 10828 11 RV 410F i 270 176 102 3 2 2 1 3HAB 3772 68 O ring 276 x 3 53 Item Qty Art number Description Dimension 102 3 5 1 1 3HAC 14673 6 Rotational ac motor M6 102 3 5 2 1 3HAC 10122 15 Input gear RV 410F 270 17 102 3 5 3 0 2152 2012 430 O ring 89 5x3 102 3 5 4 1 9ADA 183 444 Hex socket head cap screw M8x130 102 3 5 5 3 ml 3HAB 7116 1 Locking liquid Item Qty Art number Description Dimensi...

Page 605: ...C 7941 29 Rot ac motor incl gearbox See Rot ac motor incl gearbox 3HAC 7941 29 on page 192 103 3 8 3HAB 3409 89 Hex socket head cap screw M16x80 103 4 1 3HAC 9744 1 Axis 6 complete See Axis 6 complete 3HAC 9744 1 16032 1 on page 192 103 5 1 3HAC 12732 1 Label Item Qty Art number Description Dimension Note 103 1 1 3HAC 8114 4 Material set See Material set 3HAC 8114 4 on page 190 103 2 1 3HAC 7941 3...

Page 606: ...6 complete 3HAC 13890 2 1 on page 193 103 5 1 3HAC 12732 1 Label Item Qty Art number Description Dimension Note 103 1 1 1 3HAC 7956 1 Wrist housing 225kg 103 1 2 1 3HAC 7941 28 Set of shim motor 103 1 3 1 3HAC 7941 19 Set of shim bevel gear 103 1 4 8 9ADA 183 37 Hex socket head cap screw M8x25 103 1 5 8 9ADA 312 7 Plain washer 8 4x16x1 6 103 1 6 1 3HAA 2166 11 VK Cover D 80 B 10 103 1 7 1 3HAC 433...

Page 607: ...HAC 7941 21 on page 192 103 1 29 1 3HAC 8081 8 Cover with gasket 225kg 103 1 30 1 3HAC 8081 3 Cable cover 103 1 31 1 3HAC 14140 1 Manip Harn ax 5 6 103 1 32 2 2166 2055 3 Cable straps outdoors 4 8x208 Item Qty Art number Description Dimension Note Item Qty Art number Description Dimension 103 1 15 1 1 3HAC 14731 1 Shaft 103 1 15 2 1 3HAB 3643 11 Groove ball bearing 130x165x18 103 1 15 3 3 9ADA 618...

Page 608: ...liquid Item Qty Art number Description Dimension Note 103 2 1 1 3HAC 14673 7 Rotational ac motor M7 103 2 2 1 3HAC 7941 1 Bevel gear set unit z1 3 5 103 2 3 0 2152 2012 430 O ring 89 5x3 Item Qty Art number Description Dimension Note 103 2 1 1 3HAC 14673 10 Rotational ac motor M10 103 2 2 1 3HAC 7941 1 Bevel gear set unit z1 3 5 103 2 3 0 2152 2012 430 O ring 89 5x3 Item Qty Art number Description...

Page 609: ...head screw M4x8 103 4 20 1 3HAC 14263 1 Protection Cover 103 4 21 1 9ADA 624 69 Torx counters head screw M8x20 Item Qty Art number Description Dimension Note Item Qty Art number Description Dimension 103 4 2 1 1 3HAC 10828 5 RV 40E i 81 103 4 2 2 1 3HAB 3772 58 O ring 151 99x3 53 Item Qty Art number Description Dimension 103 4 4 1 1 3HAC 14673 8 Rotational ac motor M8 103 4 4 2 1 3HAC 10122 24 Pin...

Page 610: ... 103 4 15 18 3HAB 7700 55 Hex socket head cap screw M8x40 103 4 18 2 9ADA 618 32 Torx pan head screw M4x8 103 4 20 1 3HAC 14263 1 Protection Cover 103 4 21 1 9ADA 624 69 Torx counters head screw M8x20 Item Qty Art number Description Dimension Note Item Qty Art number Description Dimension 103 4 2 1 1 3HAC 10828 14 RV 70F i 125 8 103 4 2 2 1 3HAB 3772 57 O ring 164 69x3 53 Item Qty Art number Descr...

Page 611: ...1 Cover 108 229 1 3HAC 15431 1 Cable protection 108 230 1 3HAC 14880 1 Cable fixing bracket t 3 108 232 4 3HAC 16721 1 Magnetic plug R 1 2 108 234 3 9ADA 618 56 Torx pan head screw M6x16 Item Qty Art number Description Dimension Note Item Qty Art number Description Dimension Note 109 301 1 3HAC 17271 1 RV 410F 270 176 assembly See RV 410F 270 176 assembly 3HAC 17271 1 on page 197 109 302 1 3HAC 16...

Page 612: ...MB and BRU See Cover SMB and BRU 3HAC 14692 3 on page 198 109 328 1 3HAC 16831 1 Battery pack 34x102x63 109 329 1 3HAC 13151 1 Cable battery SMB L 350 20 109 330 2 3HAC 11526 1 Stud screw M6x150 109 332 1 3HAC 14791 3 Cover battery box See Cover battery box 3HAC 14791 3 on page 198 109 334 4 9ADA 618 53 Torx pan head screw M6x8 109 335 1 3HAA 2166 23 VK Cover D 120 B 12 109 336 1 3HAC 13915 1 Atta...

Page 613: ... O ring 89 5x3 Item Qty Art number Description Dimension 109 307 1 1 3HAC 14673 6 Rotational ac motor M6 109 307 2 1 3HAC 10122 15 Input gear RV 410F 270 17 109 307 3 0 2152 2012 430 O ring 89 5x3 109 307 4 1 9ADA 183 444 Hex socket head cap screw M8x130 109 307 5 3 ml 3HAB 7116 1 Locking liquid Item Qty Art number Description Dimension 109 307 1 1 3HAC 14673 9 Rotational ac motor M9 109 307 2 1 3...

Page 614: ...2 2 1 3HAC 14791 2 Gasket T 3 109 332 3 1 3HAC 16977 1 Warning label battery Item Qty Art number Description Dimension 110 401 1 3HAC 12441 2 Spherical roller bearing 65x120x38 110 402 1 3HAC 12481 1 Thrust washer 110 403 1 3HAC 12627 1 Bushing 110 404 1 9ABA 135 31 Retaining ring shaft 65 110 405 1 3HAC 12480 1 Shaft 110 406 1 3HAC 4836 7 Protection plug 16x12 3x9x7 110 407 4 3HAB 7700 5 Hex sock...

Page 615: ...d cap screw M12x50 111 504 12 3HAA 1001 134 Washer 13x19x1 5 111 505 1 9ABA 107 56 Parallel pin 10x20 111 506 1 3HAC 9760 9 Cable cover 250mm 111 507 4 9ADA 618 56 Torx pan head screw M6x16 Item Qty Art number Description Dimension 111 501 1 3HAC 9760 7 Arm extender 450mm 111 501 1 3HAC 15859 3 Arm extender 450mm Foundry 111 503 12 3HAB 7700 69 Hex socket head cap screw M12x50 111 504 12 3HAA 1001...

Page 616: ...5 Appendix 1 Part Lists 5 1 15 Arm extension set 450 mm 3HAC 12311 5 200 A 3HAC 16247 1 ...

Page 617: ...n Definitions This chapter is an appendix to the manual and contains detailed views of the components on the manipulator The numbered details are specified with item numbers in the Appendix 1 Part List The foldouts are divided into Base incl frame Frame Lower arm 1 Frame Lower arm 2 Upper arm Wrist complete ...

Page 618: ...6 Appendix 2 Foldouts 6 0 1 Introduction 202 A 3HAC 16247 1 ...

Page 619: ...6 Appendix 2 Foldouts 6 0 2 Base incl Frame 3HAC 16247 1 A 203 6 0 2 Base incl Frame xx0200000329 101 2 1 101 6 101 5 101 9 101 7 101 8 101 2 2 101 2 4 101 2 3 101 1 101 3 101 4 ...

Page 620: ...6 Appendix 2 Foldouts 6 0 2 Base incl Frame 204 A 3HAC 16247 1 ...

Page 621: ...e Lower arm 1 3HAC 16247 1 A 205 6 0 3 Frame Lower arm 1 xx0200000334 109 314 109 303 109 302 109 315 109 316 109 318 109 301 1 109 306 2 109 306 1 109 306 3 109 304 109 305 109 319 109 317 108 232 109 307 1 109 307 3 109 308 109 309 ...

Page 622: ...6 Appendix 2 Foldouts 6 0 3 Frame Lower arm 1 206 A 3HAC 16247 1 ...

Page 623: ...pendix 2 Foldouts 6 0 4 Frame Lower arm 2 3HAC 16247 1 A 207 6 0 4 Frame Lower arm 2 xx0200000335 1 1 0 4 0 2 1 1 0 4 0 1 1 1 0 4 0 4 110 410 110 414 110 415 1 1 0 4 0 5 1 1 0 4 0 3 108 201 108 204 108 202 ...

Page 624: ...6 Appendix 2 Foldouts 6 0 4 Frame Lower arm 2 208 A 3HAC 16247 1 ...

Page 625: ...6 Appendix 2 Foldouts 6 0 5 Upper arm 3HAC 16247 1 A 209 6 0 5 Upper arm xx0200000337 102 1 5 5 ...

Page 626: ...6 Appendix 2 Foldouts 6 0 5 Upper arm 210 A 3HAC 16247 1 ...

Page 627: ...6 Appendix 2 Foldouts 6 0 6 Wrist complete 3HAC 16247 1 A 211 6 0 6 Wrist complete xx0200000336 ...

Page 628: ...6 Appendix 2 Foldouts 6 0 6 Wrist complete 212 A 3HAC 16247 1 ...

Page 629: ... Maintenance Manual Industrial Robot IRB 6600 225 2 55 IRB 6600 175 2 8 IRB 6600 175 2 55 IRB 6650 200 2 75 IRB 6650 125 3 2 M2000A ...

Page 630: ......

Page 631: ...Maintenance Manual IRB 6600 6650 M2000A 3HAC 16246 1 Revision A ...

Page 632: ...rom 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 2003 ABB All rights res...

Page 633: ...g function Reduced speed 250 mm s 11 1 3 6 Safe use of the Teach Pendant Unit 11 1 3 7 Work inside the manipulator s working range 11 Chapter 2 Reference information 13 2 0 1 Introduction 13 Section 2 1 Reference information 14 2 1 1 Applicable Safety Standards 14 2 1 2 Screw joints 15 2 1 3 Weight specifications 17 2 1 4 Standard toolkit 18 2 1 5 Special tools IRB 6600 6650 7600 19 2 1 6 Performi...

Page 634: ...5 1 14 Inspection UL signal lamp 73 Section 5 2 Changing activities 75 5 2 1 Oil change gearbox axis 1 75 5 2 2 Oil change gearbox axis 2 78 5 2 3 Oil change gearbox axis 3 81 5 2 4 Oil change gearbox axis 4 83 5 2 5 Oil change gearbox axis 5 85 5 2 6 Oil change gearbox axis 6 87 Section 5 3 Lubrication activities 89 5 3 1 Lubrication balancing device bearing 89 Section 5 4 Cleaning activities 91 ...

Page 635: ...ce work OR have the required knowledge of electrical maintenance work Organization of Chapters The information product is organized in the following chapters References Revisions Chapter Contents 1 Safety service 2 Reference information 3 Service Information System SIS 4 Maintenance Schedules 5 Maintenance activities 6 Maintenance activities for options Reference Document Id Circuit diagram Manipu...

Page 636: ...0 0 1 Overview 2 A 3HAC 16246 1 ...

Page 637: ...ons for all manipulator details considered spare parts Remove Refitting instructions for all controller cabinet details considered spare parts If there is any model specific information Maintenance Manual The Maintenance Manual contains the following information Safety Service Reference Information Maintenance schedules Instructions for all maintenance activities specified in the maintenance sched...

Page 638: ...l Each hardware option is supplied with its own documentation Each document set contains the types of information specified above Installation information Repair information Maintenance information In addition spare part information is supplied for the complete option ...

Page 639: ...rvicing the robot system The dan gers 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 r...

Page 640: ...ction 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 inter act with other machines and peripheral equipment This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot In the...

Page 641: ...fter 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 from falling due to gravity 1 2 4 Safety risks during operational disturbances Gener...

Page 642: ...y stored in the robot for the purpose of counterbalancing certain axes may be released if the robot or parts thereof is dismantled When dismantling assembling mechanical units watch out for falling objects Be aware of stored heat energy in the controller Never use the robot as a ladder i e do not climb on the robot motors or other parts during service work There is a serious risk of slipping becau...

Page 643: ... machining pro cess The external voltage connected to the control cabinet remains live even when the robot is disconnected from the mains Additional connections Voltage related risks manipula tor A danger of high voltage is associated with the manipulator in The power supply for the motors up to 800 VDC The user connections for tools or other parts of the installation max 230 VAC see Installation ...

Page 644: ...eased manually by push ing the brake release buttons on the manipulator or on an optional external brake release unit How to release the brakes is detailed in section Manually releasing the brakes 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 o...

Page 645: ...t Unit with him her when entering the robot s working space This is to prevent anyone else taking control over the robot without the programmer knowing 1 3 7 Work inside the manipulator s working range 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 ena...

Page 646: ...1 Safety service 1 3 7 Work inside the manipulator s working range 12 A 3HAC 16246 1 ...

Page 647: ...ion 2 0 1 Introduction 3HAC 16246 1 A 13 Chapter 2 Reference information 2 0 1 Introduction General This chapter presents generic pieces of information complementing the more specific infor mation in the following chapters ...

Page 648: ...sessment ANSI RIA 15 06 1999 Industrial robots safety requirements DIN 19258 Interbus S International Standard Standards robot cell The following standards are applicable when the robot is part of a robot cell EN 953 Fixed and moveable guards EN 811 Safety distances to prevent danger zones being reached by the lower limbs EN 349 Minimum gaps to avoid crushing of parts of the human body EN 294 Safe...

Page 649: ...rious damage or injury Gleitmo treated screws Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint Screws treated with Gleitmo may be reused 3 4 times before the coating disappears After this the screw must be discarded and replaced with a new one When handling screws treated with Gleitmo protective gloves of nitrile rubber type should be used Screwslubrica...

Page 650: ...Dimension Tightening torque Nm Class 4 8 dry M2 5 0 25 M3 0 5 M4 1 2 M5 2 5 M6 5 0 Dimension Tightening torque Nm Class 8 8 dry Tightening torque Nm Class 10 9 dry Tightening torque Nm Class 12 9 dry M5 6 M6 10 M8 24 34 40 M10 47 67 80 M12 82 115 140 M16 200 290 340 Dimension Tightening torque Nm Class 10 9 Tightening torque Nm Class 12 9 M8 28 34 M10 55 66 M12 96 115 M16 235 280 ...

Page 651: ...onents exceeding 22 kg 50 lbs are high lighted in this way ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg to avoid inflicting injury A wide range of lifting tools and devices is avail able for each manipulator model Example Below is an example of how a weight specification is presented The motor weighs 65 kg All lifting equipment used must be dim...

Page 652: ...t and defined in the table below In this way the tools required are the sum of the Standard Toolkit and any tools listed in the instruction Contents standard toolkit 3HAC 15571 1 Qty Art no Tool Rem 1 Ring open end spanner 8 19mm 1 Socket head cap 5 17mm 1 Torx socket no 20 60 1 Box spanner set 1 Torque wrench 10 100Nm 1 Torque wrench 75 400Nm 1 Ratchet head for torque wrench 1 2 2 Hexagon headed ...

Page 653: ...60 for Mech stop ax 3 2 3HAB 3409 86 Bolts M16 x 80 for Mech stop ax 3 2 3HAB 3409 89 Cal tool a a 68080011 GM Calibration bracket a 3HAC 13908 9 Calibration tool ax1 a a 3HAC 13908 4 CalPen Calibration Pendulum 1 1 3HAC 15716 1 Extension 300mm for bits 1 2 1 1 3HAC 12342 1 Fixture lower arm 1 3HAC 13659 1 Fixture lower arm 1 3HAC 13660 1 Gearbox crank 1 3HAC 16488 1 Guide pins M12 x 150 2 3HAC 13...

Page 654: ... 1 3HAC 14459 1 Lifting tool motor ax 2 3 4 1 1 3HAC 15534 1 Lifting tool wrist unit 1 3HAC 13605 1 Lifting tool wrist unit 1 3HAC 12734 1 Measuring pin a 3HAC 13908 5 Mech stop ax 3 2 3HAC 12708 1 Mech stop ax 3 2 3HAC 12708 2 Press tool ax 2 bearing 1 3HAC 13527 1 Press tool ax 2 bearing 1 3HAC 13453 1 Press tool ax 2 shaft 1 1 3HAC 13452 1 Press tool balancing device shaft 1 1 3HAC 17129 1 Pres...

Page 655: ...ncluded in the leakdown tester kit Art no specified above 3 Apply compressed air and raise the pressure with the knob until the correct value is shown on the manometer 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 signif icantly colder or warmer than the gearbox to be tested ...

Page 656: ...ctivities require different pieces of lifting equipment which are specified in each activity instruction However how to use each piece of lifting equipment is not detailed in the activity instruction 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 657: ...S input parameters on page 30 Maintenance intervals recommended by ABB are specified in section Mainte nance Schedule in the Maintenance Manual 3 Enter these parameters in the system How to do this is detailed in Setting the SIS parameters on page 33 4 Run the robot in normal operation 5 Reset the counter if a repair has to be made or if a counter for any other reason has to be restarted The TPU d...

Page 658: ...based on calendar time Operation time counter a general alarm based on operational time Gearbox 1 operation time counter based on percentage of the axis 1 gearbox service interval Gearbox 2 operation time counter based on percentage of the axis 2 gearbox service interval Gearbox 3 operation time counter based on percentage of the axis 3 gearbox service interval Gearbox 6 operation time counter bas...

Page 659: ... is detailed in section Reading the SIS output logs on page 35 Prev service Date when the counter was reset last time i e after the last service This date was entered manually as detailed in section Setting the SIS param eters on page 33 Elapsed time Elapsed time since the counter was reset the last time Next service Date when next scheduled service is planned This date is entered man ually as det...

Page 660: ...ws the window for axis 1 but is also valid for the other axes Axis x OK Service status for axis x i e the automatically calculated time parameter has not been exceeded Axis x NOK The service interval for the axis in question has been reached Axis x N A No service time parameter calculation available Applies to axes 4 and 5 IRB 6600 and IRB 7600 Consumed time The consumed time as a percentage of th...

Page 661: ...alendarT are reset The variables are described in section Exporting the SIS data on page 36 en0200000041 When resetting variable sisRunT is reset The variables are described in section Exporting the SIS data on page 36 Yes Resets the counter to zero No Does not reset the counter but returns to the previous menu Yes Resets the counter to zero No Does not reset the counter but returns to the previou...

Page 662: ...ceeded When the service time has been exceeded for the selection made a message Service interval exceeded is displayed below the data of the counter in question en0200000044 This window may be shown for any time mode calendar time operation time or gearbox time In addition to this view an error message is also displayed on the TPU when the service interval is exceeded Yes Resets the counter to zer...

Page 663: ...ata is available for the selection made a message No data available is displayed below the function in question en0200000043 This window may be shown for any time mode calendar time operation time or gearbox time Exit en0200000042 Yes Exits the Service Information System No Returns to the Service Information System ...

Page 664: ...ot s working conditions are accumulated Since the counters are to be used for purposes defined by the user ABB cannot give any recommendations regarding their definitions The figure below shows the options of parameters to be set en0200000049 Operation time limit service level The number of operation hours selected as service interval E g by setting the value 20 000 the SIS will save this as the n...

Page 665: ...me en0200000053 Calendar time limit service level The number of calendar years selected as service interval E g by setting the value 2 the SIS will save this as the nominal time for activating the alarm not counting the percentage described below en0200000050 Calendar time warning A percentage of the Calendar time limit specified above E g by setting the value 90 the SIS will alert the operator af...

Page 666: ...90 the SIS will alert the operator after 90 of the expected service interval of each gearbox The robot system automatically detects and stores all required variables to calculate the expected service interval of each gearbox This is done by extrapolating data from earlier operation into a function of time using a formula including input and output torque gearbox spindle speed other variables en020...

Page 667: ...umber of parameters must be set How to do this is detailed below Procedure This is an instruction of how to enter SIS parameters to the robot system Step Action Rem 1 Open System parameters using the TPU Detailed in the User s Guide 2 Go to System parameters Manipulator types 2 xx0200000045 en0200000046 3 Select 0 SIS parameters and press Enter en0200000047 xx0100000200 ...

Page 668: ...6246 1 4 Select the required system The parameter list is displayed en0200000048 en0200000049 5 Select the required parameters by step ping up and down through the parame ter list Available parameters are described in Defining the SIS input parameters on page 30 Step Action Rem ...

Page 669: ...own is detailed in section Setting the SIS parameters on page 33 Operation time Service Message Service is due X production hours since last service The manually set operation time limit has expired How to set the limit is detailed in section Setting the SIS parameters on page 33 Proceed with the required service as detailed in the Repair Manual or Maintenance Manual depending on which type of ser...

Page 670: ...g 1 1 1970 in accor dance with ANSI c standard sisCalendarT sec Calendar time The number of seconds since start last reset sisTotRunT sec Operation time Total number of operation seconds since the sys tem was started Corresponds to the operating time counter on the control cabinet sisRunT sec Operation time The number of operation seconds since start last reset of the operation time counter Corres...

Page 671: ...ied out and the working conditions of the robot Calendar time specified in months regardless of whether the robot system is run or not Operating time specified in operating hours More frequent running of the robot means more frequent maintenance activities SIS specified by the robot s Service Information System SIS How to access this information is detailed in section Access to SIS information A t...

Page 672: ...2 mths Ambient tempera ture below 50 C 1 Inspection oil level gearbox axis 2 Inspection Axis 3 gear oil level 12 mths Ambient tempera ture below 50 C 1 Inspection oil level gearbox axis 3 Inspection Axis 4 gear oil level 12 mths Inspection oil level gearbox axis 4 Inspection Axis 5 gear oil level 12 mths Inspection oil level gearbox axis 5 Inspection Axis 6 gear oil level 12 mths Ambient tempera t...

Page 673: ... gear oil 48 mths Ambient tempera ture below 50 C 1 Oil change gearbox axis 6 Replacement Axis 1 gear oil As speci fied by the SIS or typ ically 96 mths Remove Refit gear box axis 1 in Repair Manual Replacement Axis 2 gear oil As speci fied by the SIS or typ ically 96 mths Remove Refit gear box axis 2 in Repair Manual Replacement Axis 3 gear oil As speci fied by the SIS or typ ically 96 mths Remov...

Page 674: ...nce activity Equipment Interval Note Detailed in section Inspection UL lamp Inspection UL lamp Inspection Mechanical stop axes 1 3 12 mths Mechanical stops in addition to the fixed stops Inspection mechanical stop axes 1 3 Inspection Position switches axes 1 3 12 mths Inspection position switches axes 1 3 ...

Page 675: ... on a test cycle that starts from the initial position and goes to maximum extension and back Deviations from this cycle will result in differences in expected life 3 The robot is dimensioned for a life of 8 years 350 000 cycles per year in a normal spot welding application Depending on the actual application the life of individual gearboxes may vary greatly from this specification The SIS Service...

Page 676: ...vities and their respective intervals are specified in the table below Intervals 1 Hours denote operational time while months denote the actual calender time Maintenance activity Equipment Interval Detailed in section Inspection Controller cabinet 6 mths Inspection controller cabinet Cleaning Controller cabinet Cleaning of controller cabinet Replacement Battery unit 12 000 h 36 mths 1 Replacement ...

Page 677: ... 43 Chapter 5 Maintenance activities manipulator 5 0 1 Introduction General This chapter contains information on how to maintain the equipment in question i e how to perform the preventive maintenance activities specified in the maintenance schedule for the same equipment ...

Page 678: ...low xx0200000228 Required equip ment A Gearbox axis 1 B Oil plug inspection C Motor axis 1 D Oil plug filling A B C D Equipment Spare part no Art no Note Lubricating oil 3HAC 16843 1 Optimol Optigear RMO 150 Standard toolkit 3HAC 15571 1 The contents are defined in section Standard toolkit on page 18 Other tools and proce dures may be required See references to these procedures in the step by step...

Page 679: ...e of oil specified by the manufacturer When filling gearbox oil do not overfill since this could 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 Changing and draining gearbox oil may require handling hot oil of up to 90 C Make sure that protective gear like goggles and glo...

Page 680: ...rectly to the frame This design also includes an additional cover that overlaps the motor attachment and holds the oil plugs The correct oil level varies depending on the design of the motor attachment Location of gear box The gearbox axis 2 is located in the lower arm rotational center underneath the motor attach ment The figure below shows the later design of the motor attachment xx0200000229 Re...

Page 681: ...y require handling hot oil of up to 90 C Make sure that protective gear like goggles and gloves are always worn during this work Also be aware of possible over pressure in gearbox When opening the oil plug there may be pressure resident in the gearbox causing oil spray from the opening Standard toolkit 3HAC15571 1 The contents are defined in section Standard toolkit on page 18 Other tools and proc...

Page 682: ...x0200000230 Required equip ment A Gearbox axis 3 B Oil plug filling C Oil plug draining A B C Equipment etc Spare part no Art no Note Lubricating oil 3HAC 16843 1 Optimol Optigear RMO 150 Standard toolkit 3HAC 15571 1 The contents are defined in section Standard toolkit on page 18 Other tools and proce dures may be required See references to these procedures in the step by step instructions below ...

Page 683: ...illing gearbox oil do not overfill since this could 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 Changing and draining gearbox oil may require handling hot oil of up to 90 C Make sure that protective gear like goggles and gloves are always worn during this work Also be ...

Page 684: ... Motors and gears are HOT after running the robot Burns may result from touching the motors or gears Turn off all electric power hydraulic and pneumatic pressure supplies to the robot A Oil plug filling B Oil plug draining A B Equipment etc Spare part no Art no Note Lubricating oil 1171 2016 604 BP Energol GR XP 320 This is a common oil that can be replaced with an equivalent oil from another manu...

Page 685: ...s prevent the manipulator from moving freely Changing and draining gearbox oil may require handling hot oil of up to 90 C Make sure that protective gear like goggles and gloves are always worn during this work Also be aware of possible over pressure in gearbox When opening the oil plug there may be pressure resident in the gearbox causing oil spray from the opening Step Action Note Illustration 1 ...

Page 686: ... gears Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Take any necessary measures to ensure that the manipulator does not collapse as parts are removed e g to secure the lower arm with fixtures if removing motor axis 2 A Oil plug filling B Oil plug draining A B Equipment etc Spare part no Art no Note Lubricating oil 1171 2016 604 BP Energol GR XP 320 This is a c...

Page 687: ...rbox oil may require handling hot oil of up to 90 C Make sure that protective gear like goggles and gloves are always worn during this work Also be aware of possible over pressure in gearbox When opening the oil plug there may be pressure resident in the gearbox causing oil spray from the opening Step Action Note Illustration 1 Turn the wrist unit so that both oil plugs face upwards 2 Open the oil...

Page 688: ...t Take any necessary measures to ensure that the manipulator does not collapse as parts are removed e g to secure the lower arm with fixtures if removing motor axis 2 When changing gearbox oil first run the robot for a time to heat up the oil Warm oil drains quicker than cold oil When filling gearbox oil do not mix different types of oil unless specified in the instruction Always use the type of o...

Page 689: ...tive gear like goggles and gloves are always worn during this work Also be aware of possible over pressure in gearbox When opening the oil plug there may be pressure resident in the gearbox causing oil spray from the opening Step Action Note Illustration 1 Make sure the oil plug filling is facing upwards and open it Shown in the figure Location of gearbox on page 54 2 Measure the oil level Require...

Page 690: ...pgrade must be performed depending on version of balancing device Balancing device 3HAC 14678 1 and 3HAC 16189 1 requires maintenance while 3HAC 12604 1 requires an upgrade xx0200000110 Required equip ment general A Balancing device B Piston rod inside the cylinder C Shaft including securing screw D Ear with spherical roller bearing inside E Bearing attachment F Rear cover A B D C E F Equipment et...

Page 691: ...s may be required See references to these procedures in the step by step instructions below These procedures include refer ences to the tools required Equipment etc Spare part no Art no Note Equipment etc Spare part no Art no Note Maintenance kit 3HAC 16195 1 Includes complete kit 3HAC 16192 1 and instructions for main tenance 3HAC 15864 5 Maintenance kit 3HAC 16194 1 Includes kit with bearings an...

Page 692: ...ce Carry out an over haul as detailed in Maintenance kit or Upgrade kit depending on the version of bal ancing device Shown in the figure Location of bal ancing device on page 56 2 Check for dissonance from the cylinder The springs inside the cylinder can cause a tapping sound Replace the balancing device or consult ABB Robotics Replacing balancing device is detailed in Remove Refit balancing devi...

Page 693: ...ached with velcro straps and mounting plate C Connectors at cable harness division point R2 M5 6 D Connectors at base A B C D Equipment etc Spare part no Art no Note Harness manipulator 1 4 3HAC 14940 1 IRB 6600 Harness manipulator 1 4 3HAC 16331 1 IRB 6650 Cable harness ax 5 6 3HAC 14140 1 Cable harness axis 5 3HAC 14139 1 Circuit diagram 3HAC13347 1 Included in the Repair Man ual part 2 Standard...

Page 694: ...r 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 Equipment etc Spare part no Art no Note Step Action Note Illustration 1 Make an overall visual inspection of the cable harness in order to detect wear and damage 2 Check the connectors at the division point and at the base Shown...

Page 695: ...from touching the motors or gears Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Take any necessary measures to ensure that the manipulator does not collapse as parts are removed e g to secure the lower arm with fixtures if removing motor axis 2 The cable harnesses are sensitive to mechanical damage They must be handled with care especially the connectors in ord...

Page 696: ...k the connectors at the cable harness division Make sure the attachment plate is not bent or in other way damaged Shown in the figure Loca tion of cabling axes 5 6 on page 61 3 Replace the cable harness if wear or damage is detected Art no specified in Required equipment on page 59 Removal and refitting of cable harness is detailed in the Repair Manual Step Action Note ...

Page 697: ...igures below show the location of the information labels to be inspected xx0200000236 A Warning label High temperature 3HAC 4431 1 B Warning sign a symbol of a lightning flash located on motor cover 3HAC 1589 1 C Instruction label Safety instructions 3HAC 4591 1 D Warning label Brake release 3HAC 15334 1 A Wa rning A B Warning A B X X B X X A B D B C ...

Page 698: ... can tip forward 3HAC 9191 1 G Foundry logotype 3HAC 8256 1 H Warning label Stored energy 3HAC 9526 1 F G Warning H E Lifting of robot Warning Equipment etc Spare part no Art no Note Labels and plate set 3HAC 8711 1 Step Action Note Illustration 1 Check the labels located as shown in the figures Location of labels on page 63 2 Replace any missing or damaged labels Art no specified in Required equi...

Page 699: ...electric power hydraulic and pneumatic pressure supplies to the robot Take any necessary measures to ensure that the manipulator does not collapse as parts are removed e g to secure the lower arm with fixtures if removing motor axis 2 A Mechanical stop stop pin A Equipment etc Spare part no Art no Note Mechanical stop ax 1 3HAC12812 2 To be replaced when damaged Includes spring pin Standard toolki...

Page 700: ...stops on axes 1 2 and 3 IRB 7600 shown xx0200000150 Required equip ment A Additional stop B Fixed stop A B A B A B Equipment etc Spare part no Art no Note Mechanical stop ax 1 3HAC 11076 1 Limits the robot working range by 7 5 Mechanical stop ax 1 3HAC 11076 2 Limits the robot working range by 15 Mechanical stop ax 2 3HAC 13787 1 Mechanical stop ax 3 3HAC 13128 2 Standard toolkit 3HAC 15571 1 The ...

Page 701: ...pneumatic pressure supplies to the robot Take any necessary measures to ensure that the manipulator does not collapse as parts are removed e g to secure the lower arm with fixtures if removing motor axis 2 Step Action Note Illustration 1 Check the additional stops on axes 1 2 and 3 for damage Shown in the figure Location of mechanical stops on page 66 2 Make sure the stops are properly attached Co...

Page 702: ...p ment A Damper axis 2 2 pcs B Damper axis 3 2 pcs C Damper axis 4 1 pc D Damper axis 5 2 pcs A B C D Equipment Spare part no Art no Note Damper axis 2 3HAC 12991 1 To be replaced if damaged Damper axis 3 3HAC 12320 1 To be replaced if damaged Damper axis 4 3HAC 13564 1 To be replaced if damaged Damper axis 5 3HAB 4337 2 To be replaced if damaged Standard toolkit 3HAC 15571 1 The contents are defi...

Page 703: ...tic pressure supplies to the robot Take any necessary measures to ensure that the manipulator does not collapse as parts are removed e g to secure the lower arm with fixtures if removing motor axis 2 Step Action Note Illustration 1 Check all dampers for damage and for cracks or existing impressions larger than 1 mm To inspect the damper axis 4 remove the two covers on top of the upper arm Shown in...

Page 704: ...n position switch axes 1 2 and 3 Location of posi tion switches The illustration below shows the position switch for axis 1 xx0100000158 The illustration below shows the position switch for axis 2 xx0100000159 A Position switch axis 1 B Cam C Set screw cam D Protection sheet E Rail F Rail attachment A B C D E F B E A C F ...

Page 705: ...tch axis 2 B Cam C Set screw cam E Rail F Rail attachment A Position switch axis 3 B Cam C Set screw cam E Rail F Rail attachment C A B E F Equipment etc Spare part no Art no Note Position switch axis 1 3HAC 15715 1 To be replaced in case of detected damage Position switch axis 2 3HAC 16418 1 To be replaced in case of detected damage Position switch axis 3 3HAC 16417 1 To be replaced in case of de...

Page 706: ...r tools and proce dures may be required See references to these procedures in the step by step instruc tions below These procedures include ref erences to the tools required Equipment etc Spare part no Art no Note Step Action Note Illustration 1 Check the position switch Check that the rollers are easy to push in and that they roll freely 2 Check the rail Check that the rail is firmly attached wit...

Page 707: ...le numbers for the UL lamp The difference is due to the accom panying motor cover which is either flat or vaulted xx0200000240 Required equip ment A UL signal lamp B Clamp C Position for cable gland D Warning label on motor cover E Warning sign on motor cover B A C D E Equipment etc Spare part no Art no Note Signal lamp 3HAC 10830 1 To be replaced in case of detected damage Includes vaulted motor ...

Page 708: ...llapse as parts are removed e g to secure the lower arm with fixtures if removing motor axis 2 Other tools and proce dures may be required See references to these procedures in the step by step instruc tions below These procedures include ref erences to the tools required Equipment etc Spare part no Art no Note Step Action Note Illustration 1 Check that the UL lamp is lit when the motors are put i...

Page 709: ...hanging the oil the amount of refilled oil may therefor differ from the specified amount depending on how much oil has previously been drained from the gearbox The correct oil level is specified in the section about inspection of oil level A Gearbox axis 1 B Oil plug inspection C Motor axis 1 D Oil plug filling A B C D Equipment etc Spare part no Art no Note Lubricating oil 3HAC 16843 1 Optimol Op...

Page 710: ...ernal 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 Changing and draining gearbox oil may require handling hot oil of up to 90 C Make sure that protective gear like goggles and gloves are always worn during this work Also be aware of possible over pressure in gearbox When opening the oil...

Page 711: ...ocation of gearbox on page 75 9 Refill the gearbox with lubricating oil The amount of oil to be refilled depends on the amount previously being drained The correct oil level is detailed in section Inspection oil level gearbox axis 1 on page 44 Art no and the total amount are speci fied in Required equipment on page 75 10 Refit the oil plug filling Tightening torque 24 Nm Step Action Note Illustrat...

Page 712: ...me versions of IRB 6600 The later design of the motor attachment is attached directly to the frame This design also includes an additional cover that overlaps the motor attachment and holds the oil plugs The correct amount oil varies depending on the design of the motor attachment Location of gear box The gearbox axis 2 is located in the lower arm rotational center underneath the motor attach ment...

Page 713: ... quicker than cold oil 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 When filling gearbox oil do not overfill since this could 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...

Page 714: ...n the tempera ture of the oil 3 Refit the oil plug Tightening torque 24 Nm 4 Remove the oil plug filling Shown in the figure Location of gearbox on page 78 5 Refill the gearbox with lubricating oil The amount of oil to be refilled depends on the amount previously being drained The correct oil level is detailed in section Inspection oil level gearbox axis 2 on page 46 Art no and total amount specif...

Page 715: ... the oil the amount of refilled oil may therefor differ from the specified amount depending on how much oil has previously been drained from the gearbox The correct oil level is specified in the section about inspection of oil level A Gearbox axis 3 B Oil plug filling C Oil plug draining A B C Equipment etc Spare part no Art no Note Lubricating oil 3HAC 16843 1 Optimol Optigear RMO 150 Total amoun...

Page 716: ...seals and gaskets prevent the manipulator from moving freely Changing and draining gearbox oil may require handling hot oil of up to 90 C Make sure that protective gear like goggles and gloves are always worn during this work Also be aware of possible over pressure in gearbox When opening the oil plug there may be pressure resident in the gearbox causing oil spray from the opening Step Action Note...

Page 717: ...ed oil may therefor differ from the specified amount depending on how much oil has previously been drained from the gearbox The correct oil level is specified in the section about inspection of oil level A Oil plug filling B Oil plug draining A B Equipment etc Spare part no Art no Note Lubricating oil 1171 2016 604 BP Energol GR XP 320 This is a common oil that can be replaced with an equivalent o...

Page 718: ... manipulator from moving freely Changing and draining gearbox oil may require handling hot oil of up to 90 C Make sure that protective gear like goggles and gloves are always worn during this work Also be aware of possible over pressure in gearbox When opening the oil plug there may be pressure resident in the gearbox causing oil spray from the opening Step Action Note Illustration 1 Run the upper...

Page 719: ...l in gearbox axis 5 Please observe the following before commencing any repair work on the manipulator Motors and gears are HOT after running the robot Burns may result from touching the motors or gears Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Take any necessary measures to ensure that the manipulator does not collapse as parts are removed e g to secure the...

Page 720: ... pressure in gearbox When opening the oil plug there may be pressure resident in the gearbox causing oil spray from the opening Step Action Note Illustration 1 Run axis 4 to a position where the oil plug draining is facing downwards 2 Open the oil plug draining Remove the oil plug filling in order to drain the oil quicker Shown in the figure Location of gear box on page 85 3 Drain the oil from the...

Page 721: ...the gearbox When changing the oil the amount of refilled oil may therefor differ from the specified amount depending on how much oil has previously been drained from the gearbox The correct oil level is specified in the section about inspection of oil level A Gearbox axis 6 B Oil plug filling C Oil plug draining A C B Equipment etc Spare part no Art no Note Lubricating oil 3HAC 16843 1 Optimal Opt...

Page 722: ...ets completely press out seals and gaskets prevent the manipulator from moving freely Changing and draining gearbox oil may require handling hot oil of up to 90 C Make sure that protective gear like goggles and gloves are always worn during this work Also be aware of possible over pressure in gearbox When opening the oil plug there may be pressure resident in the gearbox causing oil spray from the...

Page 723: ...n of the lubrication nipple etc Note The balancing device must be mounted on the manipulator when lubricating the bear ing xx0200000109 Required equip ment A Ear spherical roller bearing located inside B Lubrication nipple C Sealing spacer D Hole through which the shaft is pressed A B C D Equipment etc Spare part no Art no Note Grease 3HAA 1001 294 Optimol PDO max 80 ml For lubrication of the sphe...

Page 724: ...es to ensure that the manipulator does not collapse as parts are removed e g to secure the lower arm with fixtures if removing motor axis 2 Do not under any circumstances deal with the balancing device in any other way than that detailed in the product documentation For example attempting to open the balancing device is potentially lethal Step Action Note Illustration 1 Lubricate the spherical rol...

Page 725: ...specifies how to clean the manipulator Periodicity The periodicity of cleaning the manipulator varies a great deal depending on the actual envi ronment and function of the robot Clean a contamined manipulator as required Special points Special points to be observed are shown in the figure below xx0200000239 A Spiral cables to motor 6 B Inside of upper arm tube C Rear of upper arm tube D Inside of ...

Page 726: ...ssure cleaner onto the sealing cup at the bottom of the motor 6 spiral cable item A in the figure Special points on page 91 Although the manipulator is watertight avoid spraying connectors and similar items with a high pressure cleaner Foundry versions In working environments e g foundries where the manipulator may be exposed to fluids that dry to make a crusty surface e g release agents clean the...

Page 727: ... 93 Chapter 6 Maintenance activities controller cabinet 6 0 1 Introduction General This chapter contains information on how to maintain the equipment in question i e how to perform the preventive maintenance activities specified in the maintenance schedule for the same equipment ...

Page 728: ...d to it Before handling make sure you are connected to earth through a special ESD wrist bracelet or similar Step Action Note Illustration 1 Inspect the cabinet interior to make sure there is no contamination If any contamination is found the cabinet interior must be cleaned and all gaskets and seals to the cabinet inspected Replace any faulty seals as required 2 Inspect all sealing joints and cab...

Page 729: ...pair work on the controller Turn off all electric power supplies to the cabinet Many components inside the cabinet are sensitive to ESD ElectroStatic Discharge and will be destroyed if subjected to it Before handling make sure you are connected to earth through a special ESD wrist bracelet or similar A Battery unit Rectifier A0 X3 X2 X1 X2 X2 X2 X1 X1 X1 X2 X1 A Equipment etc Spare part no Art no ...

Page 730: ...ubjected to it Before handling make sure you are connected to earth through a special ESD wrist bracelet or similar Step Action Note Illustration 1 Remove the battery unit by unscrew ing its attachment screws 1 xx0200000004 2 Pull the battery unit out 3 Disconnect the three cables from the battery unit xx0200000005 Rectifier A0 X3 X2 X1 X2 X2 X2 X1 X1 X1 X2 X1 Step Action Note Illustration 1 Place...

Page 731: ...rist bracelet or similar Do s and don ts The section below specifies special considerations when cleaning the controller cabinet Always Always use cleaning equipment as specified above Any other cleaning equipment may shorten the life of paintwork rust inhibitors signs or labels Always check that all protective covers are fitted to the controller before cleaning Never Never remove any covers or ot...

Page 732: ...mputer fans Please observe the following before commencing any repair work Turn off all electric power supplies to the robot Take any necessary measures to ensure that the manipulator does not collapse as parts are removed e g securing the lower arm with fixtures before removing the gearbox axis 2 1 Cover 2 Fan 3 Screw 1 3 2 Equipment etc Spare part no Art no Note Vacuum cleaner ESD Safe Step Acti...

Page 733: ...intenance activities controller cabinet 6 3 2 Cleaning computer fans 3HAC 16246 1 A 99 2 Remove the covers 3 Clean the fans with an ESD safe vacuum cleaner 4 Remount the covers Step Action Note Illustration ...

Page 734: ...r outlet device Please observe the following before commencing any repair work on the controller Turn off all electric power supplies to the cabinet Many components inside the cabinet are sensitive to ESD ElectroStatic Discharge and will be destroyed if subjected to it Before handling make sure you are connected to earth through a special ESD wrist bracelet or similar 1 Drive units 2 Air outlet de...

Page 735: ...u are connected to earth through a special ESD wrist bracelet or similar 3 Remove the bleeder resistor Detailed in Repairs Manual section Replacement of bleeder resistor 4 Clean the Inside of the air outlet Use an ESD safe vacuum cleaner 5 Clean the back side of the drive units See Note above 6 Clean the bleeder resistor See Note above 7 Clean the drive unit fans See Note above Step Action Illustr...

Page 736: ...s inside the cabinet are sensitive to ESD ElectroStatic Discharge and will be destroyed if subjected to it Before handling make sure you are connected to earth through a special ESD wrist bracelet or similar 1 Air outlet 1 Equipment etc Spare part no Art no Note Vacuum cleaner ESD Safe 1 Remove the drive units Detailed in Repairs Manual section Replacement of drive units and rectifier 2 Remove the...

Page 737: ...et Many components inside the cabinet are sensitive to ESD ElectroStatic Discharge and will be destroyed if subjected to it Before handling make sure you are connected to earth through a special ESD wrist bracelet or similar Step Action Note Illustration 1 Refit the drive units Detailed in Repairs Manual section Replacement of drive units and recti fier 2 Refit the Bleeder resistor and system fan ...

Page 738: ...ies to the cabinet Many components inside the cabinet are sensitive to ESD ElectroStatic Discharge and will be destroyed if subjected to it Before handling make sure you are connected to earth through a special ESD wrist bracelet or similar 1 Filter holder 2 M5 screw 3 Drain filter 3 2 1 Equipment etc Spare part no Art no Note Filter 3HAC 5393 2 Standard toolkit 3HAC 15571 1 The contents are defin...

Page 739: ...cted to earth through a special ESD wrist bracelet or similar Step Action Note Illustration 1 Place the computer unit in the service posi tion Detailed in Repairs Manual section Putting the computer unit in service position 2 Loosen the M5 screw pos 2 in illustration 3 Remove the filter holder pos 1 in previous illustration 4 Clean or replace the filter 3 2 1 Step Action Note Illustration 1 Fit th...

Page 740: ...6 Maintenance activities controller cabinet 6 3 5 Cleaning Drain filter 106 A 3HAC 16246 1 ...

Page 741: ... Repair Manual part 2 Circuit Diagrams Industrial Robot IRB 6600 225 2 55 IRB 6600 175 2 8 IRB 6600 175 2 55 IRB 6650 200 2 75 IRB 6650 125 3 2 M2000A ...

Page 742: ......

Page 743: ...Repair Manual part 2 Circuit Diagrams IRB 6600 6650 M2000A 3HAC 16247 1 Revision A ...

Page 744: ...rom 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 2003 ABB All rights res...

Page 745: ...intenance work Who Should Read This Manual This manual is intended for personnel in the user s organization personnel in other organizations Organization of Chapters The information product is organized in the following chapters Revisions Chapter Contents 1 Circuit Diagram manipulator 3HAC 13347 1 IRB 66X0 7600 2 Circuit Diagram controller 3HAC 14189 2 S4Cplus M2000A Revision Description 0 First e...

Page 746: ...0 0 1 Overview 2 A 3HAC 16247 1 ...

Page 747: ...ase unit IRB 7600 104 1 Serial Measurement Board 105 Axis 1 106 Axis 2 107 Axis 3 108 Axis 4 109 Axis 5 IRB 7600 110 Axis 5 IRB 6600 110 1 Axis 6 111 Customer Power Signal Bus Connections 112 Customer Power Signal Bus and External axis 112 1 Customer Power Signal Bus Connections ax 3 6 112 5 Switches axis 1 113 Switches Fan axis 2 114 Switches Fan axis 3 115 Weld connections 116 ...

Page 748: ......

Page 749: ...Revision No of sheets sheet 20 Circuit Diagram 3HAC 13347 1 Contents 101 01 ...

Page 750: ......

Page 751: ...Revision No of sheets sheet 20 Circuit Diagram 3HAC 13347 1 Connection Point Location 102 01 ...

Page 752: ......

Page 753: ...Revision No of sheets sheet 20 Circuit Diagram 3HAC 13347 1 Legend 103 01 ...

Page 754: ......

Page 755: ...Revision No of sheets sheet 20 Circuit Diagram 3HAC 13347 1 Brake Release Unit 104 01 ...

Page 756: ......

Page 757: ...Revision No of sheets sheet 20 Circuit Diagram 3HAC 13347 1 Service brake release unit IRB 7600 104 1 00 ...

Page 758: ......

Page 759: ...Revision No of sheets sheet 20 Circuit Diagram 3HAC 13347 1 Serial Measurement Board 105 01 ...

Page 760: ......

Page 761: ...Revision No of sheets sheet 20 Circuit Diagram 3HAC 13347 1 Axis 1 106 01 ...

Page 762: ......

Page 763: ...Revision No of sheets sheet 20 Circuit Diagram 3HAC 13347 1 Axis 2 107 01 ...

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Page 765: ...Revision No of sheets sheet 20 Circuit Diagram 3HAC 13347 1 Axis 3 108 01 ...

Page 766: ......

Page 767: ...Revision No of sheets sheet 20 Circuit Diagram 3HAC 13347 1 Axis 4 109 01 ...

Page 768: ......

Page 769: ...Revision No of sheets sheet 20 Circuit Diagram 3HAC 13347 1 Axis 5 IRB 7600 110 01 ...

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Page 771: ...Revision No of sheets sheet 20 Circuit Diagram 3HAC 13347 1 Axis 5 IRB 6600 110 1 01 ...

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Page 773: ...Revision No of sheets sheet 20 Circuit Diagram 3HAC 13347 1 Axis 6 111 01 ...

Page 774: ......

Page 775: ...Revision No of sheets sheet 20 Circuit Diagram 3HAC 13347 1 Customer Power Signal Bus Connections 112 01 ...

Page 776: ......

Page 777: ...Revision No of sheets sheet 20 Circuit Diagram 3HAC 13347 1 Customer Power Signal Bus and External axis 112 1 01 ...

Page 778: ......

Page 779: ...Revision No of sheets sheet 20 Circuit Diagram 3HAC 13347 1 Customer Power Signal Bus Connections ax 3 6 112 5 01 ...

Page 780: ......

Page 781: ...Revision No of sheets sheet 20 Circuit Diagram 3HAC 13347 1 Switches axis 1 113 01 ...

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Page 783: ...Revision No of sheets sheet 20 Circuit Diagram 3HAC 13347 1 Switches Fan axis 2 114 01 ...

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Page 785: ...Revision No of sheets sheet 20 Circuit Diagram 3HAC 13347 1 Switches Fan axis 3 115 01 ...

Page 786: ......

Page 787: ...Revision No of sheets sheet 20 Circuit Diagram 3HAC 13347 1 Weld connections 116 01 ...

Page 788: ...ABB Automation Technology Products AB Robotics S 721 68 VÄSTERÅS SWEDEN Telephone 46 0 21 344000 Telefax 46 0 21 132592 ...

Page 789: ...Board and I O Computer 3 6 Connector Board and Axis Computer 3 7 Base Connector Unit 3 8 Connector Plate on Controller Panel 3 9 4 Emergency Stops and Run Chain 1 Emergency Stop 4 1 Run Chain Operating Mode Selector 3 modes 4 2 Run Chain Operating Mode Selector 2 modes 4 3 Power Unit Servo Disconnector 4 4 5 Drive System and Robot Cable 1 Block Diagram 5 1 Rectifier Fans and Bleeder 5 2 Drive Syst...

Page 790: ...rnal axis no 8 SG IRB 6600 7600 6 14 7 I O Units and Field Bus Modules 1 I O Unit Position 7 1 Digital Part of Combi I O and Digital I O Unit Input Part 7 2 Digital I O Unit Output Part 7 3 Combi I O Unit Digital and Analogue Output Part 7 4 Digital Input Part of 120V AC I O Unit 7 5 Digital Output Part of 120V AC I O Unit 7 6 Relay I O Unit Input 1 16 7 7 Digital with Relays I O Output 1 8 7 8 Di...

Page 791: ...ition Switches 1 2 3 on Manipulator IRB 66X0 7600 8 18 Customer Cable Power Signals IBS IRB 6600 7600 8 19 9 External Axis Cabinet 1 Block Diagram 9 1 View of External Axis Cabinet 9 2 Designation 9 3 Mains Connection 9 4 Transformer Unit 9 5 Power Supply I O Supply 9 6 Power Unit 9 7 Rectifier Fans and Bleeder 9 8 Drive Unit Signal Connection 1 External Drive Unit 9 9 Drive Unit Signal Connection...

Page 792: ...Circuit Diagram 3HAC 5582 2 Rev 03 Contents Page 4 Circuit Diagram S4Cplus ...

Page 793: ...Revision 04 No of sheets sheet 1 0 107 Circuit Diagram 3HAC 5582 2 1 General Information ...

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Page 795: ...Revision 04 No of sheets sheet 1 1 91 Circuit Diagram 3HAC 5582 2 Block Diagram ...

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Page 797: ...Revision 04 No of sheets sheet 1 2 91 Circuit Diagram 3HAC 5582 2 View of Control Cabinet ...

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Page 799: ...Revision 04 No of sheets sheet 1 3 91 Circuit Diagram 3HAC 5582 2 View of Control Cabinet ...

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Page 801: ...Revision 04 No of sheets sheet 1 4 91 Circuit Diagram 3HAC 5582 2 Designation ...

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Page 803: ...Revision 04 No of sheets sheet 1 5 91 Circuit Diagram 3HAC 5582 2 Designation ...

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Page 805: ...Revision 04 No of sheets sheet 2 0 107 Circuit Diagram 3HAC 5582 2 2 Mains Connection and Power Supply ...

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Page 807: ...Revision 04 No of sheets sheet 2 1 107 Circuit Diagram 3HAC 5582 2 Mains Connection ...

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Page 809: ...Revision 04 No of sheets sheet 2 2 107 Circuit Diagram 3HAC 5582 2 Transformer Unit 400 600V ...

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Page 811: ...Revision 04 No of sheets sheet 2 3 107 Circuit Diagram 3HAC 5582 2 Transformer unit 200 440V ...

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Page 813: ...Revision 04 No of sheets sheet 2 4 107 Circuit Diagram 3HAC 5582 2 Power Supply ...

Page 814: ......

Page 815: ...Revision 04 No of sheets sheet 2 5 107 Circuit Diagram 3HAC 5582 2 External transformer unit 200 600V IRB 66X0 7600 ...

Page 816: ......

Page 817: ...Revision 04 No of sheets sheet 2 6 107 Circuit Diagram 3HAC 5582 2 Transformer unit 400 475V IRB 66X0 7600 ...

Page 818: ......

Page 819: ...Revision 04 No of sheets sheet 3 0 107 Circuit Diagram 3HAC 5582 2 3 Computer Unit and Connector Unit ...

Page 820: ......

Page 821: ...Revision 04 No of sheets sheet 3 1 91 Circuit Diagram 3HAC 5582 2 Block Diagram Computer Unit ...

Page 822: ......

Page 823: ...Revision 04 No of sheets sheet 3 2 91 Circuit Diagram 3HAC 5582 2 Cabling in Computer Unit ...

Page 824: ......

Page 825: ...Revision 04 No of sheets sheet 3 3 91 Circuit Diagram 3HAC 5582 2 Main Computer and Hard Disk Flash Disk Drive ...

Page 826: ......

Page 827: ...Revision 04 No of sheets sheet 3 4 91 Circuit Diagram 3HAC 5582 2 Computer Cooling ...

Page 828: ......

Page 829: ...Revision 04 No of sheets sheet 3 5 91 Circuit Diagram 3HAC 5582 2 Base Connector Board and I O Computer ...

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Page 831: ...Revision 04 No of sheets sheet 3 6 91 Circuit Diagram 3HAC 5582 2 Connector Board and I O Computer ...

Page 832: ......

Page 833: ...Revision 04 No of sheets sheet 3 7 91 Circuit Diagram 3HAC 5582 2 Connector Board and Axis Computer ...

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Page 835: ...Revision 04 No of sheets sheet 3 8 91 Circuit Diagram 3HAC 5582 2 Base Connector Unit ...

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Page 837: ...Revision 04 No of sheets sheet 3 9 91 Circuit Diagram 3HAC 5582 2 Connector Plate on Controller Panel ...

Page 838: ......

Page 839: ...Revision 04 No of sheets sheet 4 0 107 Circuit Diagram 3HAC 5582 2 4 Emergency Stops and Run Chain ...

Page 840: ......

Page 841: ...Revision 04 No of sheets sheet 4 1 107 Circuit Diagram 3HAC 5582 2 Emergency Stop ...

Page 842: ......

Page 843: ...Revision 04 No of sheets sheet 4 2 107 Circuit Diagram 3HAC 5582 2 Run Chain Operating Mode Selector 3 modes ...

Page 844: ......

Page 845: ...Revision 04 No of sheets sheet 4 3 107 Circuit Diagram 3HAC 5582 2 Run Chain Operating Mode Selector 2 modes ...

Page 846: ......

Page 847: ...Revision 04 No of sheets sheet 4 4 107 Circuit Diagram 3HAC 5582 2 Power Unit Servo Disconnector ...

Page 848: ......

Page 849: ...Revision 04 No of sheets sheet 5 0 107 Circuit Diagram 3HAC 5582 2 5 Drive System and Robot Cable ...

Page 850: ......

Page 851: ...Revision 04 No of sheets sheet 5 1 107 Circuit Diagram 3HAC 5582 2 Block Diagram ...

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Page 853: ...Revision 04 No of sheets sheet 5 2 107 Circuit Diagram 3HAC 5582 2 Rectifier Fans and Bleeder ...

Page 854: ......

Page 855: ...Revision 04 No of sheets sheet 5 3 107 Circuit Diagram 3HAC 5582 2 Drive System Signal Connection 2 Drive Units ...

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Page 857: ...Revision 04 No of sheets sheet 5 4 107 Circuit Diagram 3HAC 5582 2 Drive System Signal Connection 3 Drive Units ...

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Page 859: ...Revision 04 No of sheets sheet 5 5 107 Circuit Diagram 3HAC 5582 2 Servo Drive Units IRB 140 ...

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Page 861: ...Revision 04 No of sheets sheet 5 6 107 Circuit Diagram 3HAC 5582 2 Servo Drive Units IRB 340 ...

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Page 863: ...Revision 04 No of sheets sheet 5 7 107 Circuit Diagram 3HAC 5582 2 Servo Drive Units IRB 640 840 ...

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Page 865: ...Revision 04 No of sheets sheet 5 8 107 Circuit Diagram 3HAC 5582 2 Servo Drive Units IRB 1400 2400 IRC ...

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Page 867: ...Revision 04 No of sheets sheet 5 9 107 Circuit Diagram 3HAC 5582 2 Servo Drive Units IRB 4400 6400S PE ...

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Page 869: ...Revision 04 No of sheets sheet 5 10 107 Circuit Diagram 3HAC 5582 2 Servo Drive System IRB 6400R IRC ...

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Page 871: ...Revision 04 No of sheets sheet 5 11 107 Circuit Diagram 3HAC 5582 2 Control Cable IRB 140 ...

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Page 873: ...Revision 04 No of sheets sheet 5 12 107 Circuit Diagram 3HAC 5582 2 Control Cable IRB 340 1400 2400 IRC ECB ...

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Page 875: ...Revision 04 No of sheets sheet 5 13 107 Circuit Diagram 3HAC 5582 2 Control Cable IRB 640 840 4400 and 6400S PE ...

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Page 877: ...Revision 04 No of sheets sheet 5 14 107 Circuit Diagram 3HAC 5582 2 Control Cable IRB 6400R IRC GT GU ...

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Page 879: ...Revision 04 No of sheets sheet 5 15 107 Circuit Diagram 3HAC 5582 2 Rectifier fans and bleeder IRB 66X0 7600 ...

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Page 881: ...Revision 04 No of sheets sheet 5 16 107 Circuit Diagram 3HAC 5582 2 Servo drive system IRB 66X0 7600 ...

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Page 883: ...Revision 04 No of sheets sheet 5 17 107 Circuit Diagram 3HAC 5582 2 Control cable IRB 66X0 7600 ...

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Page 885: ...Revision 04 No of sheets sheet 6 0 107 Circuit Diagram 3HAC 5582 2 6 External Axes ...

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Page 887: ...Revision 04 No of sheets sheet 107 6 1 Circuit Diagram 3HAC 5582 2 External Axes ...

Page 888: ......

Page 889: ...Revision 04 No of sheets sheet 107 6 2 Circuit Diagram 3HAC 5582 2 Axes Computer 2 and Connector Board ...

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Page 891: ...Revision 04 No of sheets sheet 107 6 3 Circuit Diagram 3HAC 5582 2 Expansion Board Axis Connector Board ...

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Page 893: ...Revision 04 No of sheets sheet 107 6 4 Circuit Diagram 3HAC 5582 2 Drive System Signal Connection External Axes ...

Page 894: ......

Page 895: ...Revision 04 No of sheets sheet 107 6 5 Circuit Diagram 3HAC 5582 2 External Axes no 7th 9th Control Signal Connection ...

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Page 897: ...Revision 04 No of sheets sheet 107 6 6 Circuit Diagram 3HAC 5582 2 Axis Computer 2 and Axis Connector Unit if External Axis Cabinet ...

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Page 899: ...Revision 04 No of sheets sheet 107 6 7 Circuit Diagram 3HAC 5582 2 Connection to External Axis Cabinet ...

Page 900: ......

Page 901: ...Revision 04 No of sheets sheet 107 6 8 Circuit Diagram 3HAC 5582 2 Servogun SMB power signals cable ...

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Page 903: ...Revision 04 No of sheets sheet 107 6 9 Circuit Diagram 3HAC 5582 2 DDU Power Signals Cable IRB 6400R ...

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Page 905: ...Revision 04 No of sheets sheet 107 6 10 Circuit Diagram 3HAC 5582 2 DDU Power Signals Cable IRB 6600 7600 ...

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Page 907: ...Revision 04 No of sheets sheet 107 6 11 Circuit Diagram 3HAC 5582 2 DDU Cable IRB 6600 7600 ...

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Page 909: ...Revision 04 No of sheets sheet 107 6 12 Circuit Diagram 3HAC 5582 2 Ext Axis no 7 SG IRB 6600 7600 ...

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Page 911: ...Revision 04 No of sheets sheet 107 6 13 Circuit Diagram 3HAC 5582 2 External axis no 7 RG IRB 6600 7600 ...

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Page 913: ...Revision 04 No of sheets sheet 107 6 14 Circuit Diagram 3HAC 5582 2 External axis no 8 SG IRB 6600 7600 ...

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Page 915: ...Revision 04 No of sheets sheet 7 0 107 Circuit Diagram 3HAC 5582 2 7 I O Units and Field Bus Modules ...

Page 916: ......

Page 917: ...Revision 04 No of sheets sheet 107 7 1 Circuit Diagram 3HAC 5582 2 I O Unit Position ...

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Page 919: ...Revision 04 No of sheets sheet 107 7 2 Circuit Diagram 3HAC 5582 2 Digital Part of Combi I O and Digital I O Unit Input Part ...

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Page 921: ...Revision 04 No of sheets sheet 107 7 3 Circuit Diagram 3HAC 5582 2 Digital I O Unit Output Part ...

Page 922: ......

Page 923: ...Revision 04 No of sheets sheet 107 7 4 Circuit Diagram 3HAC 5582 2 Combi I O Unit Digital and Analogue Output Part ...

Page 924: ......

Page 925: ...Revision 04 No of sheets sheet 107 7 5 Circuit Diagram 3HAC 5582 2 Digital Input Part of 120V AC I O Unit ...

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Page 927: ...Revision 04 No of sheets sheet 107 7 6 Circuit Diagram 3HAC 5582 2 Digital Output Part of 120V AC I O Unit ...

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Page 929: ...Revision 04 No of sheets sheet 107 7 7 Circuit Diagram 3HAC 5582 2 Relay I O Unit Input 1 16 ...

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Page 931: ...Revision 04 No of sheets sheet 107 7 8 Circuit Diagram 3HAC 5582 2 Digital with Relays I O Output 1 8 ...

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Page 933: ...Revision 04 No of sheets sheet 107 7 9 Circuit Diagram 3HAC 5582 2 Digital with Relays I O Output 9 16 ...

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Page 935: ...Revision 04 No of sheets sheet 107 7 10 Circuit Diagram 3HAC 5582 2 Analogue I O Unit ...

Page 936: ......

Page 937: ...Revision 04 No of sheets sheet 107 7 11 Circuit Diagram 3HAC 5582 2 Remote I O Unit For Allen Bradley PLC ...

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Page 939: ...Revision 04 No of sheets sheet 107 7 12 Circuit Diagram 3HAC 5582 2 Interbus S Slave ...

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Page 941: ...Revision 04 No of sheets sheet 107 7 13 Circuit Diagram 3HAC 5582 2 Profibus DP Slave ...

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Page 943: ...Revision 04 No of sheets sheet 107 7 14 Circuit Diagram 3HAC 5582 2 Encoder Unit ...

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Page 945: ...Revision 04 No of sheets sheet 107 7 15 Circuit Diagram 3HAC 5582 2 Profibus DP Master Slave ...

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Page 947: ...Revision 04 No of sheets sheet 107 7 16 Circuit Diagram 3HAC 5582 2 Interbus master slave optical fibre and copper wire ...

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Page 949: ...Revision 04 No of sheets sheet 8 0 107 Circuit Diagram 3HAC 5582 2 8 Other Options ...

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Page 951: ...Revision 04 No of sheets sheet 107 8 1 Circuit Diagram 3HAC 5582 2 Floppy Disk ...

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Page 953: ...Revision 04 No of sheets sheet 107 8 2 Circuit Diagram 3HAC 5582 2 Service Equipment Supply ...

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Page 955: ...Revision 04 No of sheets sheet 107 8 3 Circuit Diagram 3HAC 5582 2 External Connection System Signals ...

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Page 957: ...Revision 04 No of sheets sheet 107 8 4 Circuit Diagram 3HAC 5582 2 Position Switches on Manipulator ...

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Page 959: ...Revision 04 No of sheets sheet 107 8 5 Circuit Diagram 3HAC 5582 2 Customer Signal IRB 140 340 1400 ...

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Page 961: ...Revision 04 No of sheets sheet 107 8 6 Circuit Diagram 3HAC 5582 2 Customer Power Signal IRB 2400 4400 6400S PE ...

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Page 963: ...Revision 04 No of sheets sheet 107 8 7 Circuit Diagram 3HAC 5582 2 Customer Cable Power Signal CAN IRB 6400R ...

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Page 965: ...Revision 04 No of sheets sheet 107 8 8 Circuit Diagram 3HAC 5582 2 External Control Panel ...

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Page 967: ...Revision 04 No of sheets sheet 107 8 9 Circuit Diagram 3HAC 5582 2 Extension Cable Teach Pendant ...

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Page 969: ...Revision 04 No of sheets sheet 107 8 10 Circuit Diagram 3HAC 5582 2 Time Relay ...

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Page 971: ...Revision 04 No of sheets sheet 107 8 11 Circuit Diagram 3HAC 5582 2 External I O CAN BUS Connection ...

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Page 973: ...Revision 04 No of sheets sheet 107 8 12 Circuit Diagram 3HAC 5582 2 Customer power signal Profibus IRB 6400R ...

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Page 975: ...Revision 04 No of sheets sheet 107 8 13 Circuit Diagram 3HAC 5582 2 LAN Ethernet connection ...

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Page 977: ...Revision 04 No of sheets sheet 107 8 14 Circuit Diagram 3HAC 5582 2 Customer power CAN BUS IRB 640 6400S ...

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Page 979: ...Revision 04 No of sheets sheet 107 8 15 Circuit Diagram 3HAC 5582 2 Customer cable power signal CAN BUS IRB 6600 7600 ...

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Page 981: ...Revision 04 No of sheets sheet 107 8 16 Circuit Diagram 3HAC 5582 2 Customer cable power signal Profibus IRB 66X0 7600 ...

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Page 983: ...Revision 04 No of sheets sheet 107 8 17 Circuit Diagram 3HAC 5582 2 Extended customer power signal Profibus IRB 6400R ...

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Page 985: ...Revision 04 No of sheets sheet 107 8 18 Circuit Diagram 3HAC 5582 2 Position Switches 1 2 3 on Manipulator IRB 66X0 7600 ...

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Page 987: ...Revision 04 No of sheets sheet 107 8 19 Circuit Diagram 3HAC 5582 2 Customer Cable Power Signals IBS IRB 6600 7600 ...

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Page 989: ...Revision 04 No of sheets sheet 9 0 107 Circuit Diagram 3HAC 5582 2 9 External Axis Cabinet ...

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Page 991: ...Revision 04 No of sheets sheet 107 9 1 Circuit Diagram 3HAC 5582 2 Block Diagram ...

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Page 993: ...Revision 04 No of sheets sheet 107 9 2 Circuit Diagram 3HAC 5582 2 View of External Axis Cabinet ...

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Page 995: ...Revision 04 No of sheets sheet 107 9 3 Circuit Diagram 3HAC 5582 2 Designation ...

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Page 997: ...Revision 04 No of sheets sheet 107 9 4 Circuit Diagram 3HAC 5582 2 Mains Connection ...

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Page 999: ...Revision 04 No of sheets sheet 107 9 5 Circuit Diagram 3HAC 5582 2 Transformer Unit ...

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Page 1001: ...Revision 04 No of sheets sheet 107 9 6 Circuit Diagram 3HAC 5582 2 Power Supply I O Supply ...

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Page 1003: ...Revision 04 No of sheets sheet 107 9 7 Circuit Diagram 3HAC 5582 2 Power Unit ...

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Page 1005: ...Revision 04 No of sheets sheet 107 9 8 Circuit Diagram 3HAC 5582 2 Rectifier Fans and Bleeder ...

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Page 1007: ...Revision 04 No of sheets sheet 107 9 9 Circuit Diagram 3HAC 5582 2 Drive Unit Signal Connection 1 External Drive Unit ...

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Page 1009: ...Revision 04 No of sheets sheet 107 9 10 Circuit Diagram 3HAC 5582 2 Drive Unit Signal Connection 2 External Drive Units ...

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Page 1011: ...Revision 04 No of sheets sheet 107 9 11 Circuit Diagram 3HAC 5582 2 Drive Unit Signal Connection 3 External Drive Units ...

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Page 1013: ...Revision 04 No of sheets sheet 107 9 12 Circuit Diagram 3HAC 5582 2 Drive Unit and Control Cable Drive Unit GT ...

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Page 1015: ...Revision 04 No of sheets sheet 107 9 13 Circuit Diagram 3HAC 5582 2 Drive Unit and Control Cable Drive Unit GT CCB ...

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Page 1017: ...Revision 04 No of sheets sheet 107 9 14 Circuit Diagram 3HAC 5582 2 Drive Unit and Control Cable ...

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Page 1019: ...Revision 04 No of sheets sheet 107 9 15 Circuit Diagram 3HAC 5582 2 Service Equipment Supply ...

Page 1020: ...ABB Automation Technology Products AB Robotics S 721 68 VÄSTERÅS SWEDEN Telephone 46 0 21 344000 Telefax 46 0 21 132592 ...

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