S4CPlus-IRB 940 M2000 Electrical Maintenance Training Manual

Installation and Commissioning Manual
Industrial Robot IRB 940 Tricept

3HAC 16638-1 / M2000 / Rev. IRB 940 Tricept

ABB Automation Technology Products AB

Robotics
S-721 68 VSTERS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax:
+46 (0) 21 132592

IRB 940 Tricept
3HAC 16638-1
-
The information in this manual is subject to change without notice and

should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual.
In no event shall ABB be liable for incidental or consequential damages
arising from use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without
ABBs 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 reserved.

Robotics
SE-721 68 Vsters
Sweden
Table of Contents
Overview
Product Documentation, IRB 940 Tricept
Chapter 1: Safety, service
Introduction
Safety, service - General
Section A: References
Limitation of Liability
Applicable Safety Standards
Related information
Section B: Safety risks
Safety risks related to 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
Section C: Safety actions
Safety fence dimensions

Fire extinguishing
Emergency release of the manipulator's arm
Brake testing
Risk of disabling function "Reduced speed 250 mm/s"
Safe use of the Teach Pendant Unit
Work inside the manipulators working range
Chapter 2: Reference Information
Introduction
Screw joints
Weight specifications
Chapter 3: Manipulator
Introduction
Section A: Unpacking
Pre-installation procedure
Working range, IRB 940 Tricept
Risk of tipping/Stability
Section B: On-site installation
Lifting manipulator in a horizontal orientation
3HAC 16638-1
1
3
5
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6
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Table of Contents
Lifting manipulator in a vertical orientation, using a trolley

Lifting manipulator in a vertical orientation, using a lifting jack
Manually releasing the brakes
Orienting and securing the manipulator
Fitting equipment on manipulator
Loads
Section C: Electrical connections
Installation of cabling on board the manipulator

Connecting the manipulator to the control cabinet, manipulator cabling
Connectors on the distribution box
Chapter 4: Controller
Introduction
Transporting and unpacking, S4Cplus

Section B: On-site Installation
Lifting the controller cabinet

Required installation space, control cabinet
Bolt pattern, control cabinet
Installation of external power transformer
Installation of Distributed Drive Unit (DDU)
C - 1: Signal/Power cables
Connecting the manipulator to the control cabinet, S4Cplus cabling
Connectors on control cabinet, S4Cplus
Connectors on distributed drive unit, DDU
Connection of mains power to control cabinet, S4Cplus
C - 2: Signal connections
Signal Classes
Selecting Cables
Interference elimination
Connection types
Connections to screw terminals
Connections to connectors
C - 3: Customer connections on controller
The MOTORS ON/MOTORS OFF circuit
External customer connections on panel X1 - X4
Connection of external safety relay
ii
31
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49
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3HAC 16638-1
Table of Contents
C - 4: Supplies
External 24V supply
24V I/O supply
115/230 VAC supply
C - 5: Buses
Connection of the CAN bus
Interbus-S, slave DSQC 351
Profibus-DP, slave DSQC 352
C - 6: I/O units
Distributed I/O units
Distributed I/O, digital sensors
Distributed I/O, digital I/O DSQC 328 (option)
AD Combi I/O, DSQC 327 (optional)
Analog I/O, DSQC 355 (optional)
Encoder interface unit, DSQC 354 (optional)
Relay I/O, DSQC 332 (optional)
Digital I/O (120 VAC), DSQC 320 (optional)
C - 7: Communication
Communication concept, Allen-Bradley
RIO, remote I/O for Allen-Bradley PLC DSQC 350
Communication, serial links
Communication, Ethernet
External operators panel
Section D: Start-up
Inspection before start-up

Start-up
Section E: Installation of controller software
Loading system software

RobotWare CD-ROM
Installing new Robot Controller Software with RobInstall
Create a new Robot Controller System
Update the Robot Controller image
Transfer Robot Controller System using Ethernet connection
Transfer Robot Controller System using floppy disks
RobInstall preferences
Section F: Robot controller
BootImage
Start window
Reboot Window
Boot Disk Window
3HAC 16638-1
96
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iii
Table of Contents
Network Settings Window

LAN Settings Window
Service Settings Window
System selection window
How to perform a Restart
How to Start in Query Mode
189
190
192
193
194
198
Section G: System directory structure
200
Media pool in the PC

System pool in the PC
File structure in the robot controller mass storage memory
Preparation of S4Cplus software to be installed
Handling mass memory storage capacity
Chapter 5: Calibration
When to calibrate
Section A: General
How to calibrate the robot system

Calibration tool kit, contents
Section B: Preliminaries
Correct orientation of axes

Checking the calibration position
Updating the revolution counter
Fine calibration procedure on TPU
Section C: Calibration
Directions for all axes

Fine calibration, all axes
Section D: After calibration
Post calibration procedure
iv
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3HAC 16638-1
Overview
About This
Manual
This information product is a manual containing instructions for installing the

complete robot system, mechanically as well as electrically.
Usage
This manual should be used during installation, from lifting the manipulator to its
work site through installing application software in the robot controller, making
the robot ready for operation.
Who Should Read

This Manual?
This manual is intended for:
Prerequisites
The reader should...
Organization of
Chapters
installation personnel on the installation site.
have the required knowledge of mechanical as well as electrical installation work.
The manual is organized in the following chapters:
Chapter
3HAC 16638-1
Contents
1.
Safety, service
2.
Reference Information
3.
Manipulator
4.
Controller
5.
Calibration
References
Reference
Document Id
Circuit diagram, Manipulator
Included in 3HAC 16640-1, Repair Manual,

part 2
Circuit diagram, Controller
Included in 3HAC 16640-1, Repair Manual,

part 2
Revisions
Revision
Description
First edition
3HAC 16638-1
General
The complete documentation of IRB 940 Tricept including controller consists

of several manuals listed below:
Overview,
Installation and
Commissioning
Manual
The Installation and Commissioning Manual contains the following main chapters:
Overview, Repair
Manual
Overview,
Maintenance
Manual
3HAC 16638-1
Safety, Service
Unpacking
On-site Installation
Electrical connections
Start-up
Robot controller
Installation of controller software
System directory structure
Calibration
The Repair Manual contains the following main chapters:
Safety, Service
Remove/Refitting instructions for all manipulator details considered spare

parts
Remove/Refitting instructions for all controller cabinet details considered

spare parts
Circuit Diagram for manipulator
Circuit Diagram for controller cabinet
The Maintenance Manual contains the following main chapters:
Safety, Service
Maintenance schedules
Maintenance activities
Disposal
The chapters for the maintenance activities include instructions for all the maintenance activities specified in the maintenance schedule.
3HAC 16638-1
Safety, service
Chapter 1:Safety, service

Introduction
Definitions
This chapter details safety information for service personnel i.e. personnel performing installation, repair and maintenance work.
Sections
The chapter Safety, service is divided into the following sections:

A. References contains lists of:
Limitation of liability
applicable safety standards
referenced documents
B. Safety risks lists dangers relevant when servicing the robot system.
The dangers are split into different categories:
C. Safety actions details actions which may be taken to remedy or avoid

dangers.
Fire extinguishing
Emergency release of the manipulators arm
Brake testing
Safe use of the Teach Pendant Unit enabling device
3HAC 16638-1
Safety, service
Validity and
responsibility
The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment, which can influence the safety
of the total system. To protect personnel, the complete system must be designed
and installed in accordance with the safety requirements set forth in the standards
and regulations of the country where the robot is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable
safety laws and regulations in the country concerned are observed and that the
safety devices necessary to protect people working with the robot system have
been designed and installed correctly. Personnel working with robots must be
familiar with the operation and handling of the industrial robot, described in the
applicable documents, e.g. Users Guide and Product Manual.
Connection of
external safety
devices
Apart from the built-in safety functions, the robot is also supplied with an interface for the connection of external safety devices. Via this interface, an external
safety function can interact with other machines and peripheral equipment. This
means that control signals can act on safety signals received from the peripheral
equipment as well as from the robot.
In the Product Manual - Installation and Commissioning, instructions are provided for connecting safety devices between the robot and the peripheral equipment.
3HAC 16638-1
Safety, service
References
General
Any information given in this information product regarding safety, must not be
construed as a warranty by ABB Robotics that the industrial robot will not cause
injury or damage even if all safety instructions have been complied with.
Standards
3HAC 16638-1
The robot is designed in accordance with the requirements of:
EN 292-1, Safety of macheniry, basic terminology
EN 292-2, Safety of machinery, technical principles/specifications, emergency stop
EN 418, Safety of machinery, emergency stop equipment
EN 563, Safety of machinery, temperatures of surfaces
EN 614-1, Safety of machinery, ergonomic design principles
EN 775, Robot safety
EN 60204-1, Electrical equipment for industrial machines
EN 50081-2EMC, Generic emission standard. Part 2: Industrial environment

(EN 55011 Class ARadiated emission enclosure)
(EN 55011 Class AConducted emission AC Mains)
EN 61000-6-2EMC, Generic standards - Immunity for Industrial environments

(EN 61000-4-2Electrostatic discharge immunity test)
(EN 61000-4-3Radiated, radio-frequency, electromagnetic field immunity
test)
(EN 61000-4-4Electrical fast transient/burst immunity test)
(EN 61000-4-5Surge immunity test)
(EN 61000-4-6Immunity to conducted disturbances, induced by radio-frequency fields)
(EN 61000-4-11Voltage dips, short interruptions and voltage variations
immunity test)
Safety, service
References
Related information
General
The list below specifies documents which contain useful information:
Documents
Type of information
Detailed in document
Installation of safety devices
Changing robot modes
Users Guide
Section
Start-up
3HAC 16638-1
Safety, service
Safety risks

Make sure to prevent an end effector from dropping a workpiece, if such is used.
Safe handling
It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure
that guards remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
Grippers/end effectors must be designed so that they retain workpieces in the

event of a power failure or a disturbance of the controller.
General
Residual energy
Safe design
3HAC 16638-1
Special safety regulations apply to pneumatic and hydraulic systems.
Residual energy may be present in these systems so, after shutdown, particular care must be taken.
The pressure in pneumatic and hydraulic systems must be released before

starting to repair them.
Note that the interior of the robot may be pressurized.
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.
Safety, service
Safety risks
General
Qualified
personnel
Extraordinary
risks
The industrial robot is a flexible tool which can be used in many different
industrial applications.
All work must be carried out professionally and in accordance with the
applicable safety regulations.
Care must be taken at all times.
Remedial action must only be carried out by qualified personnel who are
familiar with the entire installation as well as the special risks associated
with its different parts.
If the working process is interrupted, extra care must be taken due to risks other
than those associated with regular operation. Such an interruption may have to be
rectified manually.
General risks during installation

and service
Nation/region
specific regulations
10
The instructions in the Product Manual - Installation and Commissioning

must always be followed.
Emergency stop buttons must be positioned in easily accessible places so

that the robot can be stopped quickly.
Those in charge of operations must make sure that safety instructions are
available for the installation in question.
Those who install the robot must have the appropriate training for the robot
system in question and in any safety matters associated with it.
To prevent injuries and damage during the installation, lifting and transport of the
robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with.
3HAC 16638-1
Safety, service
Safety risks
Non-voltage
related risks
To be observed
by the supplier of
the complete system
Safety zones, which have to be crossed before admittance, must be set up

in front of the robot's working space. Light beams or sensitive mats are
suitable devices.
Turntables or the like should be used to keep the operator out of the
robot's working space.
The axes are affected by the force of gravity when the brakes are released
or when the motors or other components are removed.
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 because
of the high temperature of the motors or oil spills that can occur on the
robot.
The supplier of the complete system must ensure that all circuits used in
the safety function are interlocked in accordance with the applicable standards for that function.
the emergency stop function are interlocked in a safe manner, in accordance with the applicable standards for the emergency stop function.
Voltage related
risks, general
3HAC 16638-1
Although troubleshooting may, on occasion, have to be carried out while

the power supply is turned on, the robot must be turned off (by setting the
mains switch to OFF) when repairing faults, disconnecting electric leads
and disconnecting or connecting units.
The mains supply to the robot must be connected in such a way that it can
be turned off outside the robots working space.
11
Safety, service
Safety risks
Voltage related
risks, controller,
S4Cplus
A danger of high voltage is associated with the following parts:
Be aware of stored electrical energy (DC link) in the controller.
Units inside the controller, e.g. I/O modules, can be supplied with power
from an external source.
The mains supply/mains switch
The power unit
The power supply unit for the computer system (230 VAC)
The rectifier unit (400-480 VAC and 700 VDC. N.B.: Capacitors!)
The drive unit (700 VDC)
The service outlets (115/230 VAC)
The power supply unit for tools, or special power supply units for the
machining process
The external voltage connected to the control cabinet remains live even
when the robot is disconnected from the mains.
Additional connections
Voltage related
risks, manipulator, IRB 940 Tricept
A danger of high voltage is associated with the manipulator in:
Voltage related
risks, tools, material handling
devices, etc.
Tools, material handling devices, etc., may be live even if the robot system is in
the OFF position. Power supply cables which are in motion during the working
process may be damaged.
12
The distribution box for the manipulator (up to 430 VDC)
The power supply for the motors (up to 430 VDC)
The user connections for tools or other parts of the installation (max. 230V
AC, see Product Manual - Installation and Commissioning)
3HAC 16638-1
Safety, service
Safety actions

General
Install a safety cell around the robot to ensure safe robot installation and operation.
Dimensioning the
fence or enclosure
Design the safety cell such that it will:
- withstand any impact from a tool failure. Due to the high kinetic energy
associated with HSM (High Speed Machining), a tool failure poses a serious risk as any debris can cause serious personal injury. Both walls and
ceilings must be designed and dimensioned so that they can withstand any
projectiles that they may be subjected to. Windows must be made of suitable safety glass. Study the planned process to determine the forces
involved and appropriate materials.
- insulate against sound pollution from the machining process. Typically

the safety cell should be able to reduce sound from the machining process
down to 75dBA, though individual installations may stipulate other values.
Study the planned process to determine the allowable noise pollution levels and appropriate sound insulation.
- isolate gases and mist generated by the machining process and spray
mist lubrication. Study the planned process to determine the fumes
involved and appropriate ventilation/filtering system.
Fire extinguishing
Use a CARBON DIOXIDE (CO 2 ) extinguisher in the event of a fire in the robot
(manipulator or controller)!
3HAC 16638-1
13
Safety, service
Safety actions
Description
In an emergency situation, any of the manipulators axes may be released manually by pushing the brake release buttons on the distribution box for the manipulator. How to release the brakes is detailed in section "Manually releasing the
brakes" in the Installation Manual.
The manipulator arms may be moved manually when the brakes has been
released.
Increased injury
Before releasing the brakes, make sure that the weight of the arms does not
increase the pressure on the trapped person, further increasing any injury!
Brake testing
When to test
During operation the holding brakes of each axis motor wear normally. A test may
be performed to determine whether the brake can still perform its function.
How to test
The function of each axis motor holding brakes may be checked as detailed
below:
1. Run each manipulator axis to a position where the combined weight of
the manipulator arm and any load is maximized (max. static load).
2. Switch the motor to the MOTORS OFF position with the Operating
mode selector on the controller.
3. Check that the axis maintains its position.
If the manipulator does not change position as the motors are switched off, then
the brake function is adequate.
14
3HAC 16638-1
Safety, service
Safety actions

Do not change "Transm gear ratio" or other kinematic parameters from the Teach
Pendant Unit or a PC. This will affect the safety function Reduced speed 250 mm/s.

The enabling device is a push button located on the side of the Teach Pendant Unit
(TPU) which, when pressed halfway in, takes the system to MOTORS ON. When
the enabling device is released or pushed all the way in, the robot is taken to the
MOTORS OFF state.
To ensure safe use of the Teach Pendant Unit, the following must be implemented:
The enabling device must never be rendered inoperative in any way.
During programming and testing, the enabling device must be released as soon as
there is no need for the robot to move.
The programmer must always bring the Teach Pendant Unit with him/her, when
entering the robots working space. This is to prevent anyone else taking control
over the robot without the programmer knowing.

If work must be carried out within the robots work envelope, the following points
must be observed:
The operating mode selector on the controller must be in the manual mode position
to render the enabling device operative and to block operation from a computer link
or remote control panel.
The robots speed is limited to max. 250 mm/s when the operating mode selector
is in position < 250 mm/s. This should be the normal position when entering the
working space. The position 100% full speed may only be used by trained personnel who are aware of the risks that this entails.
Also be aware of any danger that may be caused by rotating tools or other devices
mounted on the manipulator or inside the cell.
3HAC 16638-1
15
Safety, service
Safety actions
16
3HAC 16638-1
Chapter 2:Reference Information

Introduction
General
3HAC 16638-1
This chapter presents generic pieces of information, complementing the more specific information in the following chapters.
17
Screw joints
General
This section details how to tighten the various types of screw joints in the manipulator as well as the controller.
The instructions and torque values are valid for screw joints comprising metallic
materials and do not apply to soft or brittle materials.
Any instructions given in the repair, maintenance or installation procedure
description override any value or procedure given here, i.e. these instruction are
only valid for standard type screw joints.
Tightening torque
Screws with
slotted or cross
recess head
Screws with
hexagon socket
head
18
The tightening torque values for different types of screw joint are specified in the
tables below:
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
Tightening
torque (Nm)
Class 12.9
M5
M6
10
17
M8
24
28
40
M10
47
55
70
M12
82
95
120
3HAC 16638-1
3HAC 16638-1
Dimension
Tightening
torque (Nm)
Class 8.8 "dry"
Tightening
torque (Nm)
Class 10.9
Tightening
torque (Nm)
Class 12.9
M16
200
235
300
19
Definition
In all repair and maintenance instructions, weights of the components handled are
sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in
this way.
ABB recommends handling all components with a weight exceeding 22 kg using
lifting equipment to avoid inflicting injury.
Example
Below is an example of how a weight specification is presented:

The actuator with motor weighs 40 kg! All lifting equipment used must be dimensioned accordingly!
20
3HAC 16638-1
Manipulator
Chapter 3:Manipulator
Introduction
Definitions
3HAC 16638-1
This chapter contains necessary information for installing the manipulator to the
working site.
21
Manipulator
Unpacking
Pre-installation procedure
General
This instruction is primarily intended for use when unpacking and installing the
manipulator (mechanical robot) for the first time. It also contains information useful during later re-installation of the manipulator.
Checking the prerequisites for

installation
The checklist below details what must be observed before proceeding with the
actual installation of the manipulator:
1. Make sure only qualified installation personnel, conforming to all
national and local codes, are allowed to perform the installation.
2. Make sure the manipulator has not been damaged, by visually inspecting the manipulator and control cabinet exterior.
3. Make sure the lifting device to be used is dimensioned to handle the
weight of the manipulator as stated in Weight, manipulator.
4. If the manipulator is not to be installed directly, it must be stored as in
Storage conditions, manipulator.
5. Make sure the appointed operating environment of the manipulator
conforms to the specifications as in Operating conditions, manipulator.
6. Before taking the manipulator to its installation site, make sure the site
conforms to Loads on flange, manipulator and Protection classes.
7. Before moving the manipulator, please observe Risk of tipping/Stability
regarding risk of tipping!
8. When these prerequisites have been met, the manipulator may be
taken to its installation site as in Lifting manipulator in a horizontal/vertical orientation.
22
3HAC 16638-1
Manipulator
Unpacking
Weight,
manipulator
3HAC 16638-1
The table below shows the weight of the manipulator:
Manipulator model
Weight
IRB 940 Tricept
570 kg
Distribution box
31 kg
23
Manipulator
Unpacking
Loads on flange,
manipulator
The table below shows the maximum forces and torques working on the manipulator during operation.
NOTE! These forces and torques are extreme values that are rarely encountered
during operation. The values also never reach their maximum simultaneously!
Tz
xx0200000362
24
Force
Maximum stress transmitted to the mounting base
Force xy
51 kN
Force z
68 kN
Torque xy
14 kNm
Torque z
45 kNm
3HAC 16638-1
Manipulator
Unpacking
Storage
conditions,
manipulator
Operating
conditions,
manipulator
The table below shows the allowed storage conditions for the manipulator and the
distribution box:
Parameter
Value
Min. ambient temperature, storage
-25C
Max. ambient temperature, storage
+55C
Max. ambient temperature, storage (less than 24 hrs)
+55C
Max. ambient humidity, storage
Max. 95% at constant

temperature
The table below shows the allowed operating conditions for the manipulator and
the distribution box:
Parameter
Value
Min. ambient temperature, operation
+5C
Max. ambient temperature, operation, manipulator
+45C
Max. ambient humidity, operation
Max. 95% at constant

temperature
Note! The robot must not be operated until the internal temperature of the robot is
stabilized within the prescribed operational temperature range!
Protection
classes
3HAC 16638-1
The table below shows the protection class of the main parts of the robot system:
Equipment
Protection class
Manipulator
IP 66
Distribution box
IP 67
Overpressure unit
IP 67
25
Manipulator
Unpacking
Working range, IRB 940 Tricept
Illustration
The illustration below shows the unrestricted working range of IRB 940 Tricept:
400
0
400
800
800
1200
800
400
400
800
1200
1200
800
400
400
800
1200
(mm)
(mm)
xx0200000356
26
Absolute Tolerance Area at the tool-coordinate system, TCP0
Working range, centre of axis 5
3HAC 16638-1
Manipulator
Unpacking
Risk of tipping/Stability
General
The section below details how to make sure the manipulator does not tip over
before it has not been safely secured to the foundation.
Stability
The figure below shows the robot in its shipping position which also is the most
stable.
The robot must be placed on a spacer, at least 100mm in height, in order to avoid
the risk of collision with the axis 2 servomotor.
B
xx0200000357
26 mm (most stable position of axes 1, 2 and 3)
Spacer, min. 100 mm in height
The table below specifies the most stable position of each axis of the manipulator.
Axis
Position
Note
1, 2, 3
26 mm
Shown in figure above!
4, 6
-90
1. DO NOT change the manipulator position before securing it to its foundation. The shipping position is the most stable.
3HAC 16638-1
27
Manipulator
On-site installation
Section B: On-site installation

Lifting manipulator in a horizontal orientation
General
The section below details how to lift the manipulator in a horizontal orientation
from a transportation pallet to a stand.
Required equipment
Lifting in horizontal orientation
Equipment
Note
Crane or hoist
Lifting capacity: 1000 kg.
1 strap, length 2 m
2 straps, length 1 m
2 upper platform eyebolts
M16
2 shackles
The shackles must fit the eyebolts on the

upper platform.
The section below details how to lift and move the manipulator from the transportation pallet, horizontally, using the lifting equipment specified above.
The IRB 940 manipulator weighs 570 kg! All lifting equipment used must be dimensioned accordingly!
No personnel must under any circumstances be present under the suspended

load!
Failure to attach the straps correctly can cause the suspended load to tilt suddenly
and cause both personal injury and severe damage to the load.
28
3HAC 16638-1
Manipulator
Step Action
Note
1.
Run the overhead crane

to a position above the
manipulator.
2.
Fit the 2 metre strap

around the wrist unit, as
shown in the adjacent figure.
xx0200000317
3.
Hook the strap to the lift,

or crane, as shown in the
adjacent figure.
4.
Unless already in posiDimension specified above!

tion, fit the eyebolts to the
upper platform.
xx0200000318
3HAC 16638-1
29
Manipulator
Step Action
5.
Note
Attach the 1 metre straps

to the eyebolts using the
shackles.
C
xx0200000319
30
6.
Attach the straps to the

lift, or crane, as shown in
figure above!
7.
Lift the manipulator to the

required location and disconnect the lifting equipment.
A: Strap, 1 m (2 pcs)
B: Shackle (2 pcs)
C: Eyebolt (2 pcs)
3HAC 16638-1
Manipulator
Lifting manipulator in a vertical orientation, using a trolley
General
The section below details how to lift the manipulator from a transportation pallet
to a stand, after turning it into a vertical orientation.
Notice that there are two different ways of turning the manipulator into a vertical
orientation. The section below details a method using a trolley or a machine skate,
that is used to wheel the front of the manipulator towards the centre of the lift as
the manipulator is hoisted.
Required equipment
Lifting in vertical
orientation, using
a trolley
Equipment
Note
Crane or hoist
M16
2 shackles

upper platform.
Trolley (or machine skate)
Capacity: 500 kg.

Height: 400 mm.
The section below details how to lift and move the manipulator from the transportation pallet, vertically, using the lifting equipment specified above.

load!
3HAC 16638-1
31
Manipulator
- Ensure that the area around the manipulator is clear as the machine can swing
round as it leaves the pallet!
- Ensure that the trolley has free movement while lifting. If the trolley gets stuck, the
manipulator is likely to fall off and can cause personal injury and damage to the
manipulator!
Step Action
Note
1.
Unless already in position, fit the eyebolts to

the upper platform.
2.
Attach the 2 metre

straps to the eyebolts
using the shackles.
Dimension specified above!
C
xx0200000320
3.
32
B: Shackle (2 pcs)
C: Eyebolt (2 pcs)

lift, or crane, as shown
in figure above!
3HAC 16638-1
Manipulator
Step Action
4.
Note
Place the trolley under

the wrist unit and guide
it into the correct position as the manipulator
is lifted, as shown in the
adjacent figure.
A
B
C
E
xx0200000321
5.
3HAC 16638-1
When the wrist is resting squarely on the trolley it is safe to continue

lifting it off the pallet, as
shown in the adjacent
figure.
Note! Exercise extreme
care when lowering the
wrist unit on to the trolley. Dropping the
manipulator onto the
trolley can cause damage to the manipulator
and/or affect the calibration of the tripod.
B: Wrist unit
C: Trolley
D: 125 mm
E: 400 mm
xx0200000322
33
Manipulator
Step Action
Note
6.
As the manipulator is
lifted off the pallet, carefully remove the pallet
to allow free movement
of the trolley towards
the centre of the lift, as
figure.
7.
Continue lifting the

manipulator until it
leaves the trolley and is
hanging vertically, as
figure.
8.
Lift the manipulator and

move it to the required
location.
xx0200000323
xx0200000324
34
3HAC 16638-1
Manipulator
Lifting manipulator in a vertical orientation, using a lifting jack
General
The section below details how to lift the manipulator from a transportation pallet
to a stand, after turning it into a vertical orientation.
Notice that there are two different ways of turning the manipulator into a vertical
orientation. The section below details a method using a lifting jack.
Required equipment
Lifting in vertical
orientation, using
a lifting jack
Equipment
Note
Crane or hoist
1 strap, length 1 m
M16
2 shackles

upper platform.
Lifting jack
The section below details how to lift and move the manipulator from the transportation pallet, vertically, using the lifting equipment specified above.

load!
3HAC 16638-1
35
Manipulator
Step Action
Note
1.
Unless already in posi- Dimension specified above!

tion, fit the eyebolts to
the upper platform.
2.
Attach the 2 metre

straps to the eyebolts
using the shackles.
C
xx0200000320
3.
36
B: Shackle (2 pcs)
C: Eyebolt (2 pcs)

lift, or crane, as shown
in figure above.
3HAC 16638-1
Manipulator
Step Action
4.
Note
Attach the 1 metre strap

to the wrist as shown in
the adjacent figure.
xx0200000317
5.
Connect one end of the Dimension specified above!

lifting jack to the strap
around the wrist and
B
the other to the lift, or
crane. Adjust the length
so that the lifting jack is
tightened, as shown in
A
xx0200000325
6.
3HAC 16638-1
A: Strap around wrist unit
B: Crane
Lift the whole manipulator using the lift, or

crane, away from the
pallet and remove the
pallet.
37
Manipulator
Step Action
7.
Note
Lower the wrist end of

the manipulator using
the lifting jack.
When the wrist gets
near the floor, raise the
whole manipulator further, as shown in the
adjacent figure.
Repeat until the manipulator hangs vertically.
xx0200000326
8.
38
Remove the lifting jack

and lift the manipulator
to the required location.
3HAC 16638-1
Manipulator
Manually releasing the brakes
General
The section below details how to release the holding brakes of each axis motor.
This may be done by:
using push-buttons on the distribution box (internal brake release unit).

This requires either that the controller is connected to the power supply or
that the R1.MP connector (at the distribution box) is supplied with +24 V on
R1.MP.B16 and 0 V on B14 or B15.
Supplying power on the wrong pin may cause all brakes on the manipulator to be
released!
Internal brake
release unit
This section details how to release the holding brakes using the internal brake
release unit.
When releasing the holding brakes, the manipulator axes may move very quickly
and sometimes in unexpected ways! Make sure no personnel is near the manipulator arm!
Step Action
3HAC 16638-1
Info/Illustration
1.
The push-button unit is equipped with six but- The push-button unit is
tons for controlling the axis brakes. The but- located on the outside of
tons are numbered with the axes numbers.
the distribution box.
2.
Release the holding brake on a particular

manipulator axis by pressing the appropriate
button on the internal brake release panel.
The brake will function again as soon as the
button is released.
39
Manipulator
Orienting and securing the manipulator
General
This section details how to orient and secure the manipulator at the stand in order
to run the robot safely.
The cable harness should be installed in the stand before the manipulator is
mounted to it. Installation of the cabling is described in chapter "Electrical connections".
Attachment
screws
The table below specifies the type of securing screws and washers to be used for
securing the manipulator to the foundation. Securing screws are included in the
delivery of the manipulator.
Suitable screws, lightly lubricated
MC6S, M16 x 55
Quality
Quality 8.8
Suitable washer
Thickness: 4 mm
Tightening torque
200 Nm
A locating pin may be used in the mounting flange, when necessary. The dimension for the attachment hole is detailed in part "Hole configuration, mounting
flange".
40
3HAC 16638-1
Manipulator
Illustration,
securing manipulator at stand
The figure below shows how to mount the manipulator to a stand. The figure
shows prepared cabling in the stand.
xx0200000348
3HAC 16638-1
Manipulator attachment bolts
Centering ring
Mounting flange
41
Manipulator
Securing the
manipulator
This section details how to secure the manipulator to the stand in a vertical position, after fitting the stand to the foundation.
Step
42
Action
Info/Illustration
1.
Lift and turn the manipulator to vertical orien- Detailed in "Lifting the
tation.
manipulator in a vertical
orientation, using a trolley/lifting jack".
2.
Move the manipulator to the vicinity of its

installation location.
3.
Pull the cabling through the stand and

through the centering ring. Fit the ring to the
stand.
4.
Guide the manipulator gently while lowering it

into its mounting position.
Make sure the manipulator mounting flange is
correctly fitted onto the centering ring!
If necessary, use a locating pin in the flange.

Location of the attachment hole for the pin is
shown in part "Hole configuration, mounting
flange".
5.
Fit the 8 bolts and washers in the mounting

flange attachment holes.
Specified in "Attachment
screws".
Note! Lightly lubricate the
bolts before assembly!
6.
Tighten the bolts in a criss-cross pattern to

ensure that the flange is not distorted.
3HAC 16638-1
Manipulator
Hole configuration, mounting

flange
The illustration below shows the hole configuration used when securing the
manipulator. Note that the holes are not equally spaced on the flange.
A-A
(400)
350
53
86.5
C-C
18 Through
8x)
3
10 H8 Through
87.5
xx0200000358
3HAC 16638-1
43
Manipulator
Fitting equipment on manipulator
General
The manipulator features mounting holes for additional equipment.
Illustration, fitting
of extra equipment on upper
platform
The illustration below shows the mounting holes available for fitting extra equipment on the upper platform.
309.5
x M8x12 Deep
xx0200000360
44
3HAC 16638-1
Manipulator
Illustration, fitting
on mounting
flange
The illustration below shows the mounting holes available for fitting equipment
on the mounting flange.
xx0200000359
Fastener quality
When fitting tools on the mounting flange (see the figure above), use only screws
with quality 12.9. When fitting other equipment, standard screws with quality 8.8
can be used.
A guiding pin may be used when fitting equipment on to the tool flange. Attach
the pin to the extra equipment using a press fit, in order to make sure that the pin
remains in the equipment when removing it from the flange.
3HAC 16638-1
45
Manipulator
Loads
General
Any loads mounted on the manipulator must be defined correctly and carefully
(with regard to the position of centre of gravity and inertia factor) in order to avoid
jolting movements 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 the Users Guide.
Brake performance
Manipulator motor brake performance depends on any loads attached. For further
information about brake performance, please contact ABB Robotics.
46
3HAC 16638-1
Manipulator

Installation of cabling on board the manipulator
General
The manipulator is connected to the control cabinet via a distribution box, after
mounting it on the stand.
The section below describes how to install the cabling on board the manipulator.
All the necessary cabling is included in the delivery of the robot but must be connected both to the manipulator and to the distribution box.
All cabling is specified in the part "Connecting the manipulator to the control
cabinet, manipulator (/controller) cabling"
The figure below shows how the cabling is installed to the manipulator.
xx0200000349
3HAC 16638-1
Cabling in one of the two grooves in the upper platform
47
Manipulator
Installation of
cabling on board
the manipulator
Step
Action
Note/Illustration
1.
Attach the cables, axes 1-2-3,

with straps in the cable grooves
on the upper platform, as shown
in the figure above.
The cabling is marked with a red
ring at the correct attachment
point. The ring is then located
behind the straps.
When installing the cabling in the
robot it is very important to adjust
its looseness correctly.
2.
Connect the cables, axes 1-2-3, Connection points detailed in "Conto the motors of axes 1-2-3. Fit the necting the manipulator to the concables to the brackets mounted
trol cabinet, manipulator cabling".
nearby the motors and secure
with straps.
3.
Fit the cables, axis 4-5-6, inside

the cable chain.
4.
Connect the cables on top of the

housing, at the upper end of the
center unit.
5.
Fasten the cable chain with

attachment screws in the cable
bracket at axis 2 and at top of the
housing.
Connection points detailed in "Connecting the manipulator to the control cabinet, manipulator cabling".
4x
4x
xx0200000428
48
3HAC 16638-1
Manipulator
Connecting the manipulator to the control cabinet, manipulator cabling
General
The manipulator is to be connected to the control cabinet via a distribution box,

after mounted to the stand. This section specifies the cabling to be used and their
connection points.
How to install the manipulator cables on board the manipulator is detailed in the
part "Installation of cabling on board the manipulator".
Main cable categories

Cable category
Description
Manipulator cables
The cables between the distribution box and the manipulator motors are specially manufactured with extra
strong screening. The cabling for each motor consists
of two separate cables, one power cable and one signal
cable. The cabling contains conductors for:
The power cable contains conductors for:
Motor phases
Earth connection
Motor brake
Motor temperature sensors
The signal cable contains conductors for:

Resolvers
Distribution box cables
3HAC 16638-1
Handles power supply to and control of the manipulator's motors as well as feedback from the serial measurement board.
49
Manipulator
Manipulator
cables
The manipulator cables are included in the standard delivery. They are completely
pre-manufactured and ready to plug in.
The cabling transfers drive power and resolver data for drive and control of the six
axes.
Distribution box
cables
Cable sub-category
Connection point, Connection point,

distribution box
manipulator
Manipulator cable, power, axis 1
XM1
XM1.1
Manipulator cable, signal, axis 1
XR1
XR1.1
XM2
XM2.1
XR2
XR2.1
XM3
XM3.1
XR3
XR3.1
XM4
XM4.1
XR4
XR4.1
XM5
XM5.1
XR5
XR5.1
XM6
XM6.1
XR6
XR6.1
These cables are included in the standard delivery. They are completely pre-manufactured and ready to plug in.
Cable subcategory
Distribution box
cable, power
50
Description
Transfers drive
power from the
drive units in the
control cabinet to
the manipulators
distribution box.
Connection
Connection point,
point, cabinet distribution box
XS1
R1.MP
3HAC 16638-1
Manipulator
Cable subcategory
Distribution box
cable, signals
Description
Connection
Connection point,
point, cabinet distribution box
Transfers resolver XS2

data from the serial
measurement
board and power
supply to the SMB
in the distribution
box.
R1.SMB
Distribution box
cable, power
Cable
Article number
Distribution box cable, power, 7 m
3HAC 11818-1
3HAC 11818-2
3HAC 11818-4
Cable
Article number
Distribution box cable, signal, shielded, 7 m
3HAC 7998-1
3HAC 7998-2
3HAC 7998-4
Distribution box
cable, signals
3HAC 16638-1
51
Manipulator
Connectors on the distribution box
General
Section "Connecting the distribution box to the control cabinet" specifies which
cables to use in order to connect the manipulators distribution box to the controller.
Connectors on
the distribution
box
All distribution box connectors are shown in the figure below.
R1.SMB
R1.MP
XM4
XM1
XM5
XM2
XM6
XM3
XR1
XR2
XR3
XR4
XR5
XR6
xx0200000430
The connectors on the controller cabinet are located as detailed in part "Connectors on the controller cabinet, S4CPlus".
52
3HAC 16638-1
Controller
Chapter 4:Controller
Introduction
Definitions
3HAC 16638-1
This chapter contains necessary information for installing the controller to the
working site.
53
Controller
Unpacking
Transporting and unpacking, S4Cplus
General
Before starting to unpack and install the robot system, read the safety regulations
and other instructions very carefully. These are found in separate sections in the
Users Guide and Product manual.
The installation must be done by qualified installation personnel and should conform to all national and local codes.
When you have unpacked the cabinet, check that it has not been damaged during
transport or while unpacking.
Weight,
controller cabinet
Storage
conditions,
controller cabinet
The table below shows the weights for the controller cabinet:
Controller
Weight
S4Cplus controller cabinet
240 kg
Distributed Drive Unit (option)
30 kg
The table below shows the allowed storage conditions for the controller:
Parameter
Value
Min. ambient temperature
-25C
Max. ambient temperature
+55C
Max. ambient temperature (less than 24 h) +70C

Max. ambient humidity
54
Max. 95% at constant temperature
3HAC 16638-1
Controller
Unpacking
The table below shows the allowed operating conditions for the controller:
Operating conditions, controller
cabinet
Protection class,
controller
3HAC 16638-1
Parameter
Value
Min. ambient temperature
+5C
Max. ambient temperature
+45C
Max. ambient humidity
Max. 95% at constant temperature
The table below shows the protection class of the controller:
Equipment
Protection class
Control cabinet
IP 54
Programming unit
IP 54
Distributed Drive Unit (option)
IP 54
55
Controller
Section B: On-site Installation

Lifting the controller cabinet
Lifting device
Use the four lifting devices on the cabinet or a fork lift when lifting the controller
cabinet S4Cplus as shown below.
The figure below shows the minimum angle between the lifting straps and the
cabinet when lifting the controller.
B
xx0100000153
Cabinet delivered
without top cover
56
Min. 60when lifting with straps
Fork lift
If the controller is delivered without its top cover, a fork lift must be used. Do not
use lifting devices!
3HAC 16638-1
Controller
Required installation space, control cabinet
Dimensions
The figure below shows the required installation space for the S4CPlus control
cabinet:
A
200
200
800
800
820
950
980*
500
70
620
xx0100000156
3HAC 16638-1
Air distance to wall
Cabinet extension (Option 124)
Castor wheels (Option 126)
57
Controller
Bolt pattern, control cabinet
Dimensions
The figure below shows the bolt pattern for the S4CPlus control cabinet:
720
400
xx0100000157
58
3HAC 16638-1
Controller
Installation of external power transformer
Location of external power transformer
The external power transformer (option) is located outside the controller as shown
in the figure below:
B
A
xx0100000154
Cable glands for input and output cables (large gland; input cable, small
gland; output cable)
Locking screws/lifting lugs
Required equipment
Equipment, etc.
Spare part no. Art. no.
External power transformer unit
3HAC 16638-1
Note
3HAC 11668-1
Input cables
Rec. 16 mm 2
Output cables
Rec. 6 mm 2
59
Controller
Equipment, etc.
Note
Fuse and holder
Mains voltage 200

VAC: 63 A
Mains voltage 600
VAC: 25 A
Circuit breaker
Dimensioned for
the expected currents
Standard toolkit
3HAC 15571-1
Other tools and procedures may be required.

See references to
these procedures in the
step-by-step instructions below.
Connections
The contents are

defined in section
"Standard toolkit"!
These procedures
include references
to the tools
required.
Circuit Diagram, controller
3HAC 5582-2
Circuit Diagram, external power transformer
3HAC 11668-11
The procedure below details how to connect the external power transformer unit.
Please observe the following 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. Many module and unit fronts are fitted with a special ESD
protection button for connection of the bracelet. Use it!
Step
60
Action
Note/Illustration
1.
Connect the shop mains power supply
Detailed in "Shop mains

power supply" below!
2.
Connect the external power transformer

input.
Detailed in "Transformer
input" below!
3HAC 16638-1
Controller
Step
Shop mains
power supply
Action
Note/Illustration
3.
Connect the external power transformer out- Detailed in "Transformer

put.
output" below!
4.
Connect the controller input.
Detailed in "Controller
input" below!
The procedure below details how to connect the Shop mains power supply.
Step
1.
Transformer input
Action
Note/Illustration
Make sure the shop supply is fitted with suit- Fuse size specified in the
able circuit breakers and fuses.
table above!
The procedure below details how to connect the Transformer input.

Step
1.
3HAC 16638-1
Action
Note/Illustration
Run a cable from the shop supply outlet

through the input cable inlet on the transformer unit.
Shown in the figure

above!
61
Controller
Step
Transformer
output
Action
Note/Illustration
2.
Open the transformer unit by removing the

lock screws on top of the unit.
Shown in the figure

above!
3.
Connect the input cable earth conductor to

the earth terminal.
4.
Connect the three input phases to the long

Terminal: X1
terminal.
Make sure the cables are connected to the
terminals marked with the voltage value corresponding to the voltage supplied.
5.
Make sure all terminals are tightened to

ensure good electric contact.
Tightening torque:
approx. 2 Nm
The procedure below details how to connect the Transformer output.
Step
62
Action
Note/Illustration
1.
Run a cable from the transformer unit through Shown in the figure
the output cable outlet to the robot controller. above!
2.
Connect the output cable earth conductor to

the transformer unit earth terminal.
3.
Connect the three output phases to the output terminals.

The terminals are marked with "475" for the
output voltage.
Terminals: X1.1, X1:2

and X1:3
4.
Make sure all terminals are tightened to

ensure good electric contact.
Tightening torque:
approx. 2 Nm
3HAC 16638-1
Controller
Controller input
The procedure below details how to connect the Controller input.

Step
Note/Illustration
1.
Remove the left cover plate

under the robot controller top
lid.
2.
Route the transformer output

cable through the gland
located on the left cabinet wall.
3.
Connect the cable inside the

robot controller (not dependent on phase sequence):
Phase 1 to L1
4.
3HAC 16638-1
Action
Phase 2 to L2
Phase 3 to L3
0 to XT26.N
Earth to the cabinet

earth connection (C in
the figure). The earth
connection is marked
with a "PE" sticker.
A
B
C
D
xx0100000155
A: Terminal X26
B: Connectors
C: Earth connection (PE)
D: Cable glands
Make sure all terminals are

Tightening torque: approx. 2 Nm
tightened to ensure good electric contact.
63
Controller
Installation of Distributed Drive Unit (DDU)
Required installation space, DDU
The external DDU (option) is located outside the control cabinet. The figure
below shows the required installation space for the DDU.
300
xx0200000340
64
50 mm, required free area for the exhaust air
3HAC 16638-1
Controller
Bolt pattern, DDU
The DDU is to be suspended nearby the control cabinet, using the bolt pattern
shown in the figure below.
260
xx0200000374
Connection to
earth
If the difference of potential between the control system and the DDU is too large
or there are suspicions of shorter drops in voltage, the DDU must be connected to
earth. This is done at the connection point GND (see the part "Connectors on the
DDU").
Fan cooling
The main power from the control cabinet also feeds two fans in the DDU via an
internal transformer with three input taps.
The transformer wires are connected as
3HAC 16638-1
0 - 400V for nominal mains input 400V
65
Controller
Overheating
Changing the
connection of the
transformer
Overheating of the DDU may be caused by the following:
A line voltage lower than 480V is used, while the fans are connected as
480V. This causes a reduced fan cooling. See Changing the connection of
the transformer below.
The fuse, located at the screw terminal, has caused the fans to stop.
Insufficient airflow. See Increasing the airflow below.
Too heavy drive at too high ambient temperature. See the manual External axes.
The default connection of the transformer is the nominal mains input 480V. The
cooling is, however, reduced, when a lower line voltage is used and there may be
a risk that the drive unit is triggered at a high surrounding temperature. Therefore,
if the line voltage differs from 480V, it is recommended to switch over the default
connection to 440V or 400V instead.
To change the voltage, remove the lid of the DDU and switch the connections on
the screw terminals (see the part "Connections to screw terminals").
66
3HAC 16638-1
Controller
Increasing the
airflow
If there appears to be an overheating of the DDU, without suspicion of reduced

fan cooling, the airflow may be increased by replacing the two covering plates
with vents, see figure below. This gives four openings instead of the normal two.
xx0200000373
Cabling
3HAC 16638-1
Vent
Covering plate
Section "Connecting the manipulator to the control cabinet" specifies which

cables to use and to which connectors these are to be connected, in order to connect the DDU to either the controller, the manipulator or to the external axis.
67
Controller

C - 1: Signal/Power cables
Connecting the manipulator to the control cabinet, S4Cplus cabling
General
Connect the manipulator and control cabinet to each other after securing them to
the foundation. The lists below specify which customer cables to be used.
Manipulator cabling is specified in chapter Manipulator, section Electrical
connections.
Customer cables
68
These cables are not included in the standard delivery, but are included in the
delivery of each specific option. The cables are not ready to plug in, but require
connection to terminals inside the control cabinet as well as keying. These activities are detailed in Customer Connection Kit.
Connection Connection
point,
point,
cabinet
manipulator
Cable
Art. no.
Fieldbus cable, CAN, 7 m
3HAC 13173-1
XT/XP5.1
XT/XP6
XS6
R1.CP/CS
3HAC 13173-2
XT/XP5.1
XT/XP6
XS6
R1.CP/CS
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
3HAC 16638-1
Controller
Cable
3HAC 16638-1
Art. no.
Connection Connection
point,
point,
cabinet
manipulator
Fieldbus cable, Profibus, 30 m 3HAC 13174-4
XT/XP5.1
XT/XP6
DP/M
R1.CP/CS
Harness CP/CS, CAN, 7 m
3HAC 14890-4
XT/XP5.1 XT/XP5.2 XT/XP6.1

XS13
R1.CP/CS
3HAC 14890-1

XS13
R1.CP/CS
3HAC 14890-6

XS13
R1.CP/CS
Harness CP/CS, Interbus, 7 m 3HAC 15644-4

XS13
R1.CP/CS
Harness CP/CS, Interbus, 15

m
3HAC 15644-1

XS13
R1.CP/CS
Harness CP/CS, Interbus, 30

m
3HAC 15644-5

XS13
R1.CP/CS
69
Controller
Connectors on control cabinet, S4Cplus
General
Section "Connecting the manipulator to the control cabinet" specifies which

cables to use and to which connectors these are to be connected, in order to connect the controller to the manipulator.
Connections to
the cabinet
All control cabinet connectors are shown in the figure below.
xx0100000247
70
For 6400S/640 and Can Bus
**
Option for 66X0 and 7600
3HAC 16638-1
Controller
Connectors on distributed drive unit, DDU
General
The section "Connecting the manipulator to the control cabinet" specifies which
cables to use and to which connectors these are to be connected, in order to connect the DDU (distributed drive unit) to either the controller, the manipulator or
to the external axis.
Connections to
the DDU
All DDU connectors are shown in the figure below.
S77
XS78
XP40
GND
XP49
xx0200000372
The connections on the manipulator are located on the rear of the robot base.
3HAC 16638-1
71
Controller
Connection of mains power to control cabinet, S4Cplus
General
Connect the power supply either inside the cabinet, or to a optional socket on the
left-hand side of the cabinet or the lower section of the front. The cable connector
is supplied but not the cable.
Dimension the mains supply cables and fuses 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 the required connections to the
mains switch:
C
D
xx0100000248
XT 26
Protective Earth connection
Cable gland
Connector
Step
1.
72
Action
Info/Illustration
Remove the left cover plate under the top lid.
3HAC 16638-1
Controller
Step
Connection
through a power
socket
Action
Info/Illustration
2.
Pull the mains cable (outer diam. 10.2 mm)

through the gland located on the left cabinet
wall.
Shown in the figure

above!
3.
Release the connector from the knob by

pushing the release buttons located on the
side of the connector.
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 the protective

earth connection.
5.
Snap the breaker on to the knob again and

check that it is fixed properly in the correct
position.
6.
Tighten the cable gland.
7.
Fasten the cover plate.
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.
It is possible to connect the mains supply via an industrial Harting connector (DIN
41 640). See the figure below:
Cable connectors are supplied (option 132 - 134).
A
xx0100000162
3HAC 16638-1
DIN connector
73
Controller
C - 2: Signal connections
Signal Classes
Overview
Signals
74
Different rules apply to the different classes when selecting and laying cable. Signals from different classes must not be mixed.
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.
3HAC 16638-1
Controller
Selecting Cables
Controller cables:
All cables laid in the controller must be capable of withstanding +70C.
Power Signal:
Shielded cable with an area of at least 0.75mm 2 or AWG 18.

Note that any local standards and regulations concerning insulation and area must
always be complied with.
Control signals:
Shielded cables.
Measuring
signals:
Shielded cable with twisted pair conductors.
Data communication signals:
Shielded cable with twisted pair conductors.
A specific cable should be used for Gateway (Field bus) connections.
CAN bus with

DeviceNet for distributing I/O units:
A 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 suppling I/O loads is required.
3HAC 16638-1
75
Controller
Allen-Bradley
Remote I/O:
Cables according to Allen-Bradley specification, e.g. "Blue hose", should be used

for connections between DSQC 350 and the Allen-Bradley PLC bus.
Interbus-S:
Cables according to Phoenix specification, e.g. "Green type", should be used for
connections between the DSQC 351 and external Interbus-S bus.
Profibus DP:
Cables according to Profibus DP specification should be used for connections

between the I/O unit DSQC 352 and the external Profibus DP bus.
Ethernet:
Shielded twisted pair conductors (10 Base T STP).
76
3HAC 16638-1
Controller
Interference elimination
External units
External relay coils, solenoids, and other units that will be connected to the controller must be neutralized. The figure below illustrates how this can be done.
The turn-off time for DC relays increases after neutralization, especially if a diode
is connected across the coil. Varistors give shorter turn-off times. Neutralizing the
coils lengthens the life of the switches that control them.
Clamping with a
diode
The diode should be dimensioned for the same current as the relay coil, and a
voltage of twice the supply voltage.
+24V
0V
xx0100000163
Clamping with a
varistor
The varistor should be dimensioned for the same current as the relay coil, and a
voltage of twice the supply voltage.
+24V
0V
xx0100000164
3HAC 16638-1
77
Controller
Clamping with an
RC circuit
R 100 ohm, 1W C 0.1 - 1 mF.

>500V max. voltage, 125V nominal voltage.
+24V DC,
or AC voltage
0V
xx0100000165
78
3HAC 16638-1
Controller
Connection types
General
I/O, external emergency stops, safety stops, etc. can be supplied on screw connections or as industrial connectors.
Connections
3HAC 16638-1
Designation
Connection type
X(T)
Screw terminal
XP
Pin (male)
XS
Sockets (female)
79
Controller
Connections to screw terminals
Overview
This section describes how to connect conductors to screw terminals. Detailed

information about connection location and functions will be found in the circuit
diagram (Service Manual).
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, disconnected conductors should be
grounded (0V) at both ends.
80
3HAC 16638-1
Controller
Connections to connectors
Location of connectors
If ordered, industrial connectors can be found on the left-hand side or front of the
control cabinet (depending on the customer order). Also see the figure in section
"Connectors on control cabinet"!
The manipulator arm (not IRB 940 Tricept) is equipped with round Burndy/Framatome connectors (customer connector not included).
Connectors,
description
Each industrial connector has accommodation for four rows of 16 conductors with
a maximum conductor area of 1.5 mm 2. The pull-relief clamp must be used when
connecting the shield to the case.
Making the connection
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 conductor.
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 housing.

3. Push the pin into the connector until it locks.
4. A special extractor tool must be used when removing pins or sockets
from industrial connectors.
C - 3: Customer connections on controller

The MOTORS ON/MOTORS OFF circuit
Outline diagram
The MOTORS ON/MOTORS OFF circuit is made up of two identical chains of

switches.
The diagram shows the available customer connections, AS, GS and ES.
3HAC 16638-1
81
Controller
A
E
C
D
H
J
R
N
P
xx0100000174
82
ES (emergency stop)
LS (Limit switch)
Solid state switches
Contactor
Mains
Drive unit
Second chain interlock
GS (general mode safeguarded space stop)
AS (Automatic mode safeguarded space stop)
ED (TPU enabling device)
Manual mode
Motor
Automatic mode
Operating mode selector
RUN
EN1
3HAC 16638-1
Controller
EN2
Function of the
MOTORS ON/
MOTORS OFF circuit
The 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.
Connection of
safety chains
The diagram below shows the two-channel safety chain.
3HAC 16638-1
As long as the two chains are not identical, the robot will remain in MOTORS
OFF mode.
The supply from internal 24V (X3/X4:12) and 0 V (X3/X4:7) is displayed. For an
external supply of GS and AS, X3/X4:10,11 is connected to 24V and X3/X4:8,9
is connected to external 0V. Connection tables for X1-X4 are given in "External
customer connections on panel X1 - X4".
83
Controller
24V
X3:12
X4:12
Ext LIM1
24V
K1
0V
X1:11 12
ES1
X3:10
Opto GS1
isol.
TPU En1
8
11
&
Opto AS1
isol.
Auto1
K1
EN
Run
Intern
locking
K2
Man1
External contactors
0V
24 V
0V
X3:3
X4:3
4
4
CONT1
CONT2
Ext LIM2
X2:11 12
K2
Opto GS2
isol.
TPU En2
11
9
Drive Unit
ES2
X4:10
24 V
&
Opto AS2
isol.
Auto2
Man2
xx0100000166
Technical data per chain
84
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"
<5V
External supply of GS/AS
Max. + 35 VDC
Min. - 35 VDC
3HAC 16638-1
Controller
Technical data per chain
3HAC 16638-1
Max. potential in relation to the cabinet

earthing and other signal groups
300 V
Signal class
Control signals
85
Controller
Connection of
ES1/ES2 on panel
unit
The diagram below shows the terminals for the emergency circuits.
The supply from internal 24V (X1/X2:10) and 0V (X1/X2:10) is displayed. For
an ext. supply, X1/X2:3 is connected to ext. 24V and X1/X2:8 is connected to ext.
0V (dotted lines).
A
24V 0V
B
X1:3
1:4
X1:7
X1:10
X1:9
X1:8
X1:1
X1:2
24V
X1:6
E
24V
G
24V 0V
F
B
2:4
X2:7
X2:8
X2:1
X2:2
24V
X2:6
H
24V
X2:4
X2:5
J
xx0100000191
86
3HAC 16638-1
Controller
Internal
Ext shop
TPU
Cabinet
ES1 internal
Run chain 1 top
Internal
ES2 internal
Run chain 2 top
Technical data
3HAC 16638-1
ES1 and ES2 max output voltage
120 VAC 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

300 V
Signal class
Control signals
87
Controller
Connection to
MOTORS ON/
MOTORS OFF
contactor
The diagram below shows the connection of terminals for customer use.
A
B
X3:2
1
X4:2
1
xx0100000193
K1 (Motor on/off 1)
K1 (Motor on/off 2)
Technical data
88
Max. voltage
48 VDC
Max. current
4A

300 V
Signal class
Control signals
3HAC 16638-1
Controller
Connection to
operating mode
selector
S1.1.x1 8
A
7
6
5
S1.1.x1 4
D
3
2
1
xx0100000197
Auto 1
MAN1
100% (Option)
Auto 2
MAN2
100% (Option)
Technical data
3HAC 16638-1
Max. voltage
48 VDC
Max. current
4A

300 V
Signal class
Control signals
89
Controller
Connection to
brake contactor
A
X4:5
6
xx0100000199
K3 (Brake)
Technical data
90
Max. voltage
48 VDC
Max. current
4A

300 V
Signal class
Control signals
3HAC 16638-1
Controller
External customer connections on panel X1 - X4
Outline diagram
The diagram shows the customer connections X1 - X4 located on the panel unit.
WARNING
REMOVE JUMPERS BEFORE CONNECTING
ANY EXTERNAL EQUIPMENT
xx0100000205
grey field
Connection of X1:
12-pole type
Phoenix COMBICON connector
3HAC 16638-1
Jumper
The table below shows the signal descriptions for X1.

The signal names refer to the Circuit Diagram.
Signal
Terminal no. Comment
ES1 out: A
Emergency stop out chain 1
ES1 out: B
ES1 top
Top of emergency stop chain 1
24 V panel
+ 24 V emergency stop chain 1 and run chain 1
Run ch1 top
Top of run chain 1
ES1 internal
Internal signal from emergency stop relay chain 1
Sep. ES1: A
Separated emergency stop chain 1
Sep. ES1: B
91
Controller
Connection of X2:
12-pole type
Connection of X3:
12-pole type
Signal
ES1 bottom
Bottom of emergency stop chain 1
0V
10
0 V emergency stop chain 1
Ext. LIM1: A
11
External limit switch chain 1
Ext. LIM1: B
12

Signal
ES2 out: A
ES2 out: B
ES2 top
Top of emergency stop chain 2
0V
0 V emergency stop chain 2
Run ch2 top
Top of run chain 2
ES2 internal
Internal signal from emergency stop relay chain 2
Sep. ES2: A
Sep. ES2: B
ES2 bottom
Bottom of emergency stop chain 2
24 V panel
10
+ 24 V emergency stop chain 1 and run chain 2
Ext. LIM2: A
11
Ext. LIM2: B
12

Signal
92
Ext. MON 1: A 1
Motor contactor 1
Ext. MON 1: B 2
Motor contactor 1
3HAC 16638-1
Controller
Connection of X4:
12-pole type
Signal
0V
External contactor 1 0 V
CONT1
External contactor 1
No connection
No connection
0V
0 V to auto stop (AS) and general stop (GS)
GS1-
General stop minus chain 1
AS1-
Auto stop minus chain 1
GS1+
10
General stop plus chain 1
AS1+
11
Auto stop plus chain 1
24 V panel
12
24 V to auto stop and general stop

Signal
3HAC 16638-1
Ext. MON 2: A 1
Motor contactor 2
Ext. MON 2: B 2
Motor contactor 2
24 V panel
External contactor 2 24 V
CONT2
External contactor 2
Ext. BRAKE A 5
Contactor for external brake
Ext. BRAKE B 6
Contactor for external brake
0V
0 V to auto stop (AS) and general stop (GS)
GS2-
General stop minus chain 2
AS2-
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
93
Controller
Connection of external safety relay
Description
The motor contactors K1 and K2 in the controller can operate with external equipment if external relays are used.
The figure below shows two examples of how to connect the external safety
relays:
94
3HAC 16638-1
Controller
Connection
examples
X4:4
CONT 2
24 V X4:3
E xt MON 2
X4:2
0V
K2
X4:1
X3:2
K1
E xt MON 1
X3:1
24 V
0 V X3:3
CONT 1 X3:4
E
AS
AS
GS
GS
F
G
E
K
H
J
xx0100000246
3HAC 16638-1
Panel unit
95
Controller
Relays with positive action
Robot 1
Robot 2
External supply
ES (emergency stop) out
Safety relay
To other equipment
Safety gate
Cell ES (emergency stop)
C - 4: Supplies
External 24V supply
When is an external supply recommended?
How to connect
the external supply
An external supply is recommended to make use of the advantages offered by the

galvanic insulation on the I/O units or on the panel unit.
An external supply must be used in the following cases:
When the internal supply is insufficient
When the emergency stop circuits must be independent of whether 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.
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 the controller, or
some other common earthing point.
Technical data
Potential difference to chassis earth Max. 60 V continuously
Max. 500 V during 1 minute
96
3HAC 16638-1
Controller
Permitted supply voltage
3HAC 16638-1
I/O units 19 VDC - 35 VDC incl. ripple

Panel unit 20.6 VDC - 30 VDC incl. ripple
97
Controller
24V I/O supply
General
24 VDC supply for

internal and
external use
24 VDC supply
available at XT 31
98
The 24V I/O is not galvanically separated from the rest of the controller voltages.
Voltage
24.0 - 26.4V
Ripple
Max. 0.2V
Permitted customer load
Max. 7A
Current limit
13,5 ~0A.
24V I/O available for customer connections at XT 31 is shown in the figure in

"Connections to screw terminals".
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)
3HAC 16638-1
Controller
115/230 VAC supply
General
115/230 VAC supply for internal

and external use
115/230 VAC supply available at XT

21
This voltage is used in the robot for supplying optional service outlets. The AC
supply is not galvanically separated from the rest of the controller voltages.
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
115 VAC/230 VAC available for customer connections at XT 21 is shown in the

figure in "Connection to screw terminals".
XT.21.1-5
230 VAC
XT.21.6-8
115 VAC
XT.21.9-13
N (connected to cabinet structure)
C - 5: Buses
Connection of the CAN bus
Illustration
3HAC 16638-1
The illustration below shows an example of how to connect the CAN bus:
99
Controller
C
A
X15 CAN1.1 (Internal I/O)
X6 CAN1.2
X7 CAN1.3
G
D
D
E
X15, X6, X7
1.
2.
3.
4.
5.
0V_CAN
CAN_L
drain
CAN_H
24V_I/O
1.
2.
3.
4.
5.
xx0100000241
100
Base connector unit
CAN bus
3HAC 16638-1
Controller
Control cabinet
I/O
Termination of last unit
120 ohm, 1%, 0.25 W metal film resistor
See figure in section "CAN 2" below!
CAN 1.1
Used for internal I/O unit mounted inside the cabinet. No terminating resistor is
fitted on CAN 1.1 regardless of whether any I/O units are used or not. CAN 1.1 is
connected 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!).
If CAN 1.2 is used, the terminating resistor should be moved to the last I/O unit
on the CAN 1.2 chain.
If CAN 1.2, for example, is not connected at 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.
CAN 1.3
If CAN 1.3 is unused, a terminating resistor must be connected to the X7 socket.

If CAN 1.3 is used, the terminating resistor should be moved to the last I/O unit
on the CAN 1.3 chain.
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.
3HAC 16638-1
101
Controller
Termination
resistors in CAN
bus
The CAN chain must be terminated with terminating resistors at each end!
CAN 2
The illustration below shows an example of how to connect the CAN 2 bus:
mounted in CAN 1.3.
B
D
X8 CAN 2
1. 0V_CAN
2. CAN_L
3. drain
4. CAN_H
5. 24V_I/O
X8
1. 0V_CAN
2. CAN_L
3. drain
4. CAN_H
5. 24V_I/O
1.
2.
3.
4.
5.
xx0100000242
102
Controller
Base connector unit
See figure in section "Illustration" above!
I/O
Termination of last unit
120 ohm, 1%, 0.25 W metal film resistor
3HAC 16638-1
Controller
The illustration below shows CAN connections on base connector unit:
A
B
C
D
xx0100000243
3HAC 16638-1
X6 CAN 1.2 (external I/O)
X7 CAN 1.3 (external I/O)
X8 CAN 2 (external I/O)
X15 CAN 1.1 (internal I/O)
103
Controller
Interbus-S, slave DSQC 351
General
The unit can be operated as a slave for an Interbus-S system.
Supply
The Interbus-S slave must be fed externally to avoid shutting down the InterbusS net if a robot cell is switched off. The 24V power supply must be fed from
outside the control cabinet and be connected to pin 2 on the Phoenix connector
located on the Interbus-S cards front panel marked 24V.
Technical data
Also see the Interbus-S specification.
Further information
For setup parameters, see Users Guide - System Parameters, Topic: Controller.
Unit ID
The 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.
Layout, DSQC
351
The figure below shows the layout of the DSQC 351 board:
104
3HAC 16638-1
Controller
X20
X21
X5
X3
xx0100000225
Communication
concept
X3
Power connector
X5
DeviceNet connector
X20
Interbus-S, input
X21
Interbus-S, output
The Interbus-S system is able to communicate with a number of external devices,

depending on the number of process words occupied by each unit. The robot may
be equipped with one or two DSQC 351. The Interbus-S inputs and outputs are
accessible in the robot as general inputs and outputs.
For application data, refer to Interbus-S, International Standard, DIN 19258.
An outline diagram of the communication concept is shown below:
3HAC 16638-1
105
Controller
E
A
B
In
C
Out
In
*1
D
Out
In
Out
*1
xx0100000224
Master PLC
Robot 1, word 1:3
Robot 1, word 4:7
Robot 2, word 8:11
128 inputs/128 outputs
*1
xx
Termination link
A link is connected between pins 5 and 9 in the 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 connectors
See DeviceNet Connectors.
106
3HAC 16638-1
Controller
Connections,
connector X20,
Interbus-S IN
The figure below shows the pin configuration of the connector:
6
9
xx0100000220
The table below shows the connections to connector X20, Interbus-S IN:
Connections,
connector X21,
Interbus-S OUT
Signal name
X20 pin
Function
TPDO1
Communication line TPDO1
TPDI1
Communication line TPDI1
GND
Ground connection
NC
Not connected
NC
Not connected
TPDO1-N
Communication line TPDO1-N
TPDI1-N
Communication line TPDI1-N
NC
Not connected
NC
Not connected
6
9
xx0100000220
The table below shows the connections to connector X21, Interbus-S OUT:
3HAC 16638-1
107
Controller
Connections,
connector X3
Signal name
X21 pin
Function
TPDO2
Communication line TPDO2
TPDI2
Communication line TPDI2
GND
Ground connection
NC
Not connected
+5V
+ 5 VDC
TPDO2-N
Communication line TPDO2-N
TPDI2-N
Communication line TPDI2-N
NC
Not connected
RBST
Synchronization
xx0100000221
The table below shows the connections to connector X3:
Bus status LEDs
108
Signal name
X3 pin
Function
0 VDC
External supply of Interbus-S
NC
Not connected
GND
Ground connection
NC
Not connected
+ 24 VDC
+ 24 VDC
The designations refer to LEDs shown in the figure in section "Layout, DSQC
352" above.
3HAC 16638-1
Controller
The figure and table below show the location and significance of the LEDs on the
board.
3HAC 16638-1
Designation
Color
Description
POWER-24 VDC
Green
Indicates that a supply voltage is present, and

has a level above 12 VDC.
NS/MS
Green/red
See section "CAN bus status LED description".
CAN Tx/CAN Rx
Green/red
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 network.
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 when Interbus-S communication runs

without errors.
109
Controller
Profibus-DP, slave DSQC 352
General
The unit can be operated as a slave for a Profibus-DP system.
Supply
The Profibus does not need any external power supply. All the robot cells are
connected to the trunk cable through a special D-sub connector which works as a
very short drop cable. Because of this the profibus will work correctly even if a
robot cell is turned off.
Technical data
Also see the Profibus-DP specification, International Standard DIN E 19245, part
3.
Further information
For setup parameters, see Users Guide - System Parameters, Topic: I/O Signals.
Also see the Circuit diagram.
Layout, DSQC
352
110
3HAC 16638-1
Controller
X20
X5
X3
xx0100000223
Communication
concept
X3
Power connector
X5
DeviceNet connector
X20
Profibus connection
The Profibus-DP system is able to communicate with a number of external

devices, depending on the number of process words occupied by each unit. The
robot may be equipped with one or two DSQC 352. The Profibus-DP inputs and
outputs are accessible in the robot as general inputs and outputs.
An outline diagram of the communication concept is shown below:
E
A
F
C
xx0100000222
3HAC 16638-1
111
Controller
Master PLC
Robot 1, word 1:8
Robot 1, word 9:16
Robot 2, word 17:24
Termination
The Profibus cable must be terminated in both ends.
Connections, X5
DeviceNet connectors
See "Device Net Connectors".
Connections,
connector X20,
Profibus-DP
6
9
xx0100000220
The table below shows the connections to connector X20, Interbus-S IN:
112
Signal name
X20 pin
Function
Shield
Cable screen
NC
Not connected
RxD/TxD-P
Receive/Transmit data P
Control-P
GND
+5 VDC
Ground
3HAC 16638-1
Controller
Connections,
connector X3
Signal name
X20 pin
Function
NC
Not connected
RxD/TxD-N
Receive/Transmit data N
NC
Not connected
xx0100000221
Bus status LEDs
Signal name
X3 pin
Function
0 VDC
External supply of Profibus-DP
NC
Not connected
GND
Ground connection
NC
Not connected
+ 24 VDC
External supply of Profibus-DP
board.
352" above.
3HAC 16638-1
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.
113
Controller
Designation
Color
Description
NS/MS
Green/red
CAN Tx/CAN Rx
Green/red
POWER, 24 VDC Green

If there is no light, check that voltage is
present in the power unit and in the power
connector. If not, check cables and connectors.
If power is applied to the unit but it does not
work, replace the unit.
C - 6: I/O units
Distributed I/O units
General
Up to 20 units can be connected to the same controller but only four of these can
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
114
For setup parameters, see Users Guide, section System Parameters, Topic: I/O
Signals.
3HAC 16638-1
Controller
Distributed I/O, digital sensors
General
Digital sensors are connected to one optional digital unit.
Technical data
See Product Specification for Controller S4Cplus.
Allowed types of
digital sensors
The table below shows the allowed types of digital sensors to be used, and their
signal levels respectively:
3HAC 16638-1
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)
115
Controller
Distributed I/O, digital I/O DSQC 328 (option)
General
The digital I/O unit handles digital communication between the robot system and
any external systems.
Technical data
No. of inputs
16 (divided into two groups of 8, galvanically isolated from

each other)
No. of outputs

each other)
Supply voltage
24 VDC
Supply source
24 V I/O or separate external supply
Also see Product Specification for controller S4Cplus.
Further information
Layout, DSQC
328
The figure below show the layout of the DSQC328 board:

A
OUT
MS
IN
NS
X1
X3
OUT
9
10
11
12
13
14
15
16
IN
X2
1
10
10
X4
1
10
10
12
X5
xx0100000240
116
Status LEDs
3HAC 16638-1
Controller
Connections,
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 Users Guide.
Connections,
connector X2
Unit function
Signal name
X1 pin
Optically isolated output
Out ch 1
Out ch 2
Out ch 3
Out ch 4
Out ch 5
Out ch 6
Out ch 7
Out ch 8
0 V for outputs 1-8
24 V for outputs 1-8
10

3HAC 16638-1
Unit function
Signal name
X2 pin
Out ch 9
Out ch 10
Out ch 11
Out ch 12
Out ch 13
Out ch 14
Out ch 15
117
Controller
Connections,
connector X3
Unit function
Signal name
X2 pin
Out ch 16
10
Unit function
Signal name
X3 pin
Optically isolated input
In ch 1
In ch 2
In ch 3
In ch 4
In ch 5
In ch 6
In ch 7
In ch 8
0 V for inputs 1-8
Not used
10
The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected
to ground, to prevent disturbances, causes a short rush of current when setting the
input.
When connecting outputs, sensitive to pre-oscillation current, a series resistor
(100 W) may be used.
Connections,
connector X4
118
Unit function
Signal name
X4 pin
In ch 9
In ch 10
3HAC 16638-1
Controller
Unit function
Signal name
X4 pin
In ch 11
In ch 12
In ch 13
In ch 14
In ch 15
In ch 16
0 V for inputs 9-16
Not used
10
input.
3HAC 16638-1
119
Controller
AD Combi I/O, DSQC 327 (optional)
General
The digital I/O unit handles digital and analog communication between the robot
system and any external systems.
Technical data
No. of digital inputs
16 (divided into two groups of 8, galvanically isolated

from each other)
No. of digital outputs
16 (divided into two groups of 8, galvanically isolated

from each other)
No. of analog outputs
2 (galvanically isolated from the controller electronics)
Supply voltage
24 VDC
Supply source, digital I/O
Supply source, analog I/O 24 V_CAN (with galvanically isolated DC/AC converter)
Further information
Layout, DSQC
327
The figure below shows the layout of the DSQC327 board:
120
3HAC 16638-1
Controller
OUT
MS
IN
NS
X1
X3
10
11
12
13
14
15
IN
X2
1
10
X4
10
X6
1
10
OUT
16
10
12
X5
xx0100000239
Status LEDs
Connector X5 is a CAN connector further described in section "Connection and

address keying of the CAN bus".
Connections,
connector X1

3HAC 16638-1
Unit function
Signal name
X1 pin
Out ch 1
Out ch 2
Out ch 3
Out ch 4
Out ch 5
Out ch 6
Out ch 7
Out ch 8
0 V for outputs 1-8
10
121
Controller
Connections,
connector X2

Connections,
connector X3
122
Unit function
Signal name
X2 pin
Out ch 9
Out ch 10
Out ch 11
Out ch 12
Out ch 13
Out ch 14
Out ch 15
Out ch 16
10
Unit function
Signal name
X3 pin
In ch 1
In ch 2
In ch 3
In ch 4
In ch 5
In ch 6
In ch 7
In ch 8
0 V for inputs 1-8
Not used
10
3HAC 16638-1
Controller
Connections,
connector X4
Connections,
connectors X6
Unit function
Signal name
X4 pin
In ch 9
In ch 10
In ch 11
In ch 12
In ch 13
In ch 14
In ch 15
In ch 16
0 V for inputs 9-16
Not used
10
The table below shows the connections to connectors X6:
Signal name:
X6 pin:
Explanation:
AN_ICH1
For test purposes only
AN_ICH2
For test purposes only
0V
0 V for In channels 1-2
0 VA
0 V for Out channels 1-2
AN_OCH1
Out channels 1
AN_OCH2
Out channels 2
input.
3HAC 16638-1
123
Controller
Analog I/O, DSQC 355 (optional)
General
The analog I/O unit handles communication between the robot system and any
external systems through analog sensors.
Technical data
No. of analog inputs
4 (-10 V/+10 V)
3 (-10 V/+10 V)
1 (4-20 mA))
2 (galvanically isolated from the controller electronics)
Supply voltage
24 VDC
Further information
Layout, DSQC
355
124
3HAC 16638-1
Controller
X7
X8
X8
Bus s tatus
X7
S2S3
X2
X5 X3
Analog I/O
DS QC 355
X5
AB B F lexible Automation
X3
xx0100000238
Connections,
connectors X7
analog output
X3
Not used
X5
DeviceNet input and ID connector
X7
Analog outputs
X8
Analog inputs
13
12
24
xx0100000236
3HAC 16638-1
125
Controller
Signal name: X7 pin:
Explanation:
ANOUT_
Analog output 1, -10 V/+10 V
ANOUT_
ANOUT_
ANOUT_
Analog output 4, 4-20 mA
Not used
Not used
Not used
Not used
Not used
Not used
10
Not used
11
Not used
12
Not used
13
Not used
14
Not used
15
Not used
16
Not used
17
Not used
18
GND
19
Analog output 1, 0 V
GND
20
GND
21
GND
22
GND
23
GND
24
input.
Connect a resistor (100 W) in series when connecting outputs, sensitive to preoscillation current.
126
3HAC 16638-1
Controller
Connections,
connectors X8
analog input
17
16
32
xx0100000237
3HAC 16638-1
Explanation:
ANIN_1
Analog input 1, -10 V/+10 V
ANIN_2
ANIN_3
ANIN_4
Not used
Not used
Not used
Not used
Not used
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
127
Controller
Explanation:
+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
+24 VDC supply
GND
25
Analog input 1, 0 V
GND
26
Analog input 2, 0 V
GND
27
Analog input 3, 0 V
GND
28
Analog input 4, 0 V
GND
29
GND
30
GND
31
GND
32
input.
Connect a resistor (100 W) in series when connecting outputs, sensitive to preoscillation current.
Bus status LEDs
128
board.
Designation
Color
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.
3HAC 16638-1
Controller
Designation
Color
Description
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 rack.
Green
Indicates that supply voltage is present and at

correct level.
If there is no light, check that voltage is present
on power unit and that power is present in power
connector. If not, check cables and connectors.
If power is applied to the unit but it does not work,
replace the unit.
+5VDC / +12VDC /
-12VDC
3HAC 16638-1
129
Controller
Encoder interface unit, DSQC 354 (optional)
General
The encoder interface unit handles communication with an external conveyor:
One encoder input (synchronization of conveyor position with robot movements). The encoder is supplied with 24 V and 0 V, and sends position
information on two channels. This information is computed by the on-board
computer using quadrature decoding (QDEC) to determine position and
direction.
One digital input (external start signal/conveyor synchronization point)
Technical data
No. of encoder inputs
1 (24 VDC)
Supply voltage
24 VDC
Supply source
24 V I/O or external supply
Further information
130
User reference Description Conveyor Tracking. For setup parameters, see Users
Guide - System Parameters, Topic: Controller. Also see the Circuit Diagram.
3HAC 16638-1
Controller
Layout, DSQC
354
X20
X5
X3
xx0100000233
3HAC 16638-1
X3
Not used
X5
DeviceNet input and ID connector
X20
Conveyor connection
131
Controller
Encoder connections
The figure below shows the encoder connections:

AF
AA
AB
24 VDC
0V
AC
A
B
24 VDC
AD
0V
AE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Opto
Opto
Opto
Opto
Opto
Opto
AG
xx0100000234
132
AA
AB
AC
Encoder
AD
Sync switch
AE
10-16 not used
AF
Encoder unit
AG
Galvanic isolation
3HAC 16638-1
Controller
Connections,
connectors X20
encoder and digital input connections
Explanation:
24 VDC
24 VDC supply
0V
0V
ENC
Encoder 24 VDC
ENC
Encoder 0 VDC
ENC_A
Encoder phase A
ENC_B
Encoder phase B
DIGIN
Synchronization switch 24 VDC
DIGIN
0V
DIGIN
Synchronization switch digital input
Not used
10
Not used
11
Not used
12
Not used
13
Not used
14
Not used
15
Not used
16
The figure below shows the layout of the pins in connector X20:
16
xx0100000235
3HAC 16638-1
133
Controller
Bus status LEDs
board.
Designation
Color
Description
POWER, 24 VDC Green

If there is no light, check that voltage is present
on power unit and in connector X20. If not, check
cables and connectors.
If power is applied to the unit but it does not
work, replace the unit.
NS/MS
Green/red
CAN Tx/CAN Rx Green/red
ENC 1A/1B
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 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).
Green
Defective input circuit on board.
Short circuit or broken wire in external

wiring or connectors.
Internal error in unit.
Constant light indicates constant high level on

input and vice versa.
No light on one LED indicates fault in one
encoder phase.
134
3HAC 16638-1
Controller
3HAC 16638-1
Designation
Color
Description
DIGIN1
Green
Digital input. Lit when digital input is active. The

input is used for external start signal/conveyor
synchronization 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 connectors.
Defective input circuit on board.
135
Controller
Relay I/O, DSQC 332 (optional)
General
The unit handles communication between the robot system and any external systems through relay outputs and digital inputs.
Technical data

each other)
No. of relay outputs
16 (a single normally open contact, isolated from each

other)
Supply voltage
24 VDC
Supply source
Further information
Layout, DSQC
332
A
OUT
MS
IN
NS
OUT
9
10
11
12
13
14
15
16
IN
X1
X2
16
16
X3
X4
16
16
12
X5
xx0100000232
136
Status LEDs
3HAC 16638-1
Controller
Connections,
connector X1
Connections,
connector X2
3HAC 16638-1
X1
See below for connection tables!
X2
X3
X4
X5
CAN connection detailed in section "Connection of CAN bus"!
Signal name
X1 pin
Function
Out ch 1a
Contact, relay 1
Out ch 1b
Contact, relay 1
Out ch 2a
Contact, relay 2
Out ch 2b
Contact, relay 2
Out ch 3a
Contact, relay 3
Out ch 3b
Contact, relay 3
Out ch 4a
Contact, relay 4
Out ch 4b
Contact, relay 4
Out ch 5a
Contact, relay 5
Out ch 5b
10
Contact, relay 5
Out ch 6a
11
Contact, relay 6
Out ch 6b
12
Contact, relay 6
Out ch 7a
13
Contact, relay 7
Out ch 7b
14
Contact, relay 7
Out ch 8a
15
Contact, relay 8
Out ch 8b
16
Contact, relay 8
Signal name
X2 pin
Function
Out ch 9a
Contact, relay 9
137
Controller
Connections,
connector X3
138
Signal name
X2 pin
Function
Out ch 9b
Contact, relay 9
Out ch 10a
Contact, relay 10
Out ch 10b
Contact, relay 10
Out ch 11a
Contact, relay 11
Out ch 11b
Contact, relay 11
Out ch 12a
Contact, relay 12
Out ch 12b
Contact, relay 12
Out ch 13a
Contact, relay 13
Out ch 13b
10
Contact, relay 13
Out ch 14a
11
Contact, relay 14
Out ch 14b
12
Contact, relay 14
Out ch 15a
13
Contact, relay 15
Out ch 15b
14
Contact, relay 15
Out ch 16a
15
Contact, relay 16
Out ch 16b
16
Contact, relay 16
Signal name
X3 pin
In ch 1
In ch 2
In ch 3
In ch 4
In ch 5
In ch 6
In ch 7
In ch 8
0 v for In ch 1-8
Not used
10
Not used
11
3HAC 16638-1
Controller
Connections,
connector X4
3HAC 16638-1
Signal name
X3 pin
Not used
12
Not used
13
Not used
14
Not used
15
Not used
16
Signal name
X4 pin
In ch 9
In ch 10
In ch 11
In ch 12
In ch 13
In ch 14
In ch 15
In ch 16
0 v for In ch 9-16
Not used
10
Not used
11
Not used
12
Not used
13
Not used
14
Not used
15
Not used
16
139
Controller
Digital I/O (120 VAC), DSQC 320 (optional)
General
The unit handles communication between the robot system and any external systems through galvanically isolated outputs and inputs.
Technical data
No. of inputs
16 (galvanically isolated from each other)
No. of outputs
16 (galvanically isolated from each other)
Supply voltage
120 VAC
Further information
Layout, DSQC
320
A
OUT
MS
IN
NS
OUT
9
10
11
12
13
14
15
16
IN
X1
X2
16
16
X3
X4
16
16
12
X5
xx0100000231
140
Status LEDs
X1
X2
3HAC 16638-1
Controller
Connections,
connector X1
Connections,
connector X2
3HAC 16638-1
X3
X4
X5
CAN connection detailed in section "Connection of CAN bus"!
Signal name X1 pin
Function
Out ch 1a
AC voltage to switch 1/AC output signal from switch 1
Out ch 1b
Out ch 2a
Out ch 2b
Out ch 3a
Out ch 3b
Out ch 4a
Out ch 4b
Out ch 5a
Out ch 5b
10
Out ch 6a
11
Out ch 6b
12
Out ch 7a
13
Out ch 7b
14
Out ch 8a
15
Out ch 8b
16
Signal
name
X2 pin
Function
Out ch 9a
Out ch 9b
141
Controller
Connections,
connector X3
142
Signal
name
X2 pin
Function
Out ch 10a
Out ch 10b
Out ch 11a
Out ch 11b
Out ch 12a
Out ch 12b
Out ch 13a
Out ch 13b
10
Out ch 14a
11
Out ch 14b
12
Out ch 15a
13
Out ch 15b
14
Out ch 16a
15
Out ch 16b
16
Signal
name
X3 pin
Function
In ch 1a
AC input signal from switch 1/Neutral voltage to switch 1
In ch 1b
In ch 2a
In ch 2b
In ch 3a
In ch 3b
In ch 4a
In ch 4b
In ch 5a
In ch 5b
10
3HAC 16638-1
Controller
Connections,
connector X4
3HAC 16638-1
Signal
name
X3 pin
Function
In ch 6a
11
In ch 6b
12
In ch 7a
13
In ch 7b
14
In ch 8a
15
In ch 8b
16
Signal
name
X4 pin
Function
In ch 9a
In ch 9b
In ch 10a
In ch 10b
In ch 11a
In ch 11b
In ch 12a
In ch 12b
In ch 13a
In ch 13b
10
In ch 14a
11
In ch 14b
12
In ch 15a
13
In ch 15b
14
In ch 16a
15
In ch 16b
16
143
Controller
C - 7: Communication
Communication concept, Allen-Bradley
General
The robot may communicate with the Allen Bradley system only, or be used in
combination with the I/O system in the robot. For example, the inputs to the robot
may come from the Allen Bradley system while the outputs from the robot control
external equipment go via general I/O addresses and the Allen Bradley system
only reads the outputs as status signals.
Definitions
The Allen Bradley system can communicate with up to 64 external systems. Each
of these systems is called a Rack and is given a Rack Address 0-63. Basically, each
robot connected to the Allen Bradley system will occupy one rack.
Each rack is divided into four sections called Quarters. Each quarter 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.
144
3HAC 16638-1
Controller
Illustration
The illustration below shows a block diagram of the Allen-Bradley system, where
Robot 1 uses a full rack while robot 2 and robot 3 share one rack. The rack address,
starting quarter, and other required parameters such as baud rate, LED status etc.
are entered in the configuration parameters.
Allen Bradley
control system
Robot 1 - 128 in / 128 out

Quarter 1
Quarter 2
Robot 2 - 64 in / 64 out
Quarter 1
128 in / 128 out
64 in / 64 out
Quarter 4
Rack ID 12 (example)
Rack size 4
Starting quarter 1
Quarter 1
Quarter 2
Quarter 2
Rack size 2
Starting quarter 1
Quarter 3
Other systems
Quarter 3
Quarter 4
Robot 3 - 64 in / 64 out
Quarter 3
64 in / 64 out
Quarter 4
Rack size 2
Starting quarter 3
en0100000255
3HAC 16638-1
145
Controller
RIO, remote I/O for Allen-Bradley PLC DSQC 350
General
The unit handles communication between the robot system and the Allen Bradley
system.
Technical data
Unit is programmable for 32, 64, 96 or 128 digital inputs
No. of digital outputs
Unit is programmable for 32, 64, 96 or 128 digital outputs
Also see the Allen-Bradley RIO specification.
Further information
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
X5
X9
X3
X8
DS QC 350
AB B F lexible Automation
xx0100000226
146
3HAC 16638-1
Controller
Connections,
connector X8
X3
Not used
X5
DeviceNet and ID connector
X8
RIO in
X9
RION out
xx0100000221
Connections,
connector X9
Signal name
X8 pin
Function
LINE1 (blue)
Remote I/O in
LINE2 (clear)
Remote I/O in
Shield
Remote I/O in
Cabinet ground
Remote I/O in
xx0100000221
3HAC 16638-1
Signal name
X9 pin
Function
Blue
Remote I/O out
Clear
Remote I/O out
Shield
Remote I/O out
Cabinet ground
Remote I/O out
147
Controller
Termination
When the robot is last in a RIO loop, the loop must be terminated with a termination resistor according to Allen-Bradleys specification.
Warranty
This product incorporates a communications link which is licensed under patents

and proprietary technology of the Allen-Bradley Company, Inc. The Allen-Bradley Company, Inc. does not warrant or support this product. All warranty and support services for this product are the responsibility of and provided by ABB
Flexible Automation.
Bus status LEDs
board.
350" above.
Designation
Color
POWER-24 VDC Green
148
Description
If there is no light, check that voltage is present on
power unit and in power connector. If not, check
cables 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
Yellow
NAC STATUS
Green
Steady green indicates RIO link in operation.

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 configuration, rack size etc.
does not match configuration set in PLC.
If LED keeps flashing continuously, check setup
3HAC 16638-1
Controller
Communication, serial links
General
Further information
Technical data
3HAC 16638-1
The robot has three serial channels, which can be used by the customer to communicate with printers, terminals, computers, and other equipment (see the figure
in "Connections" below).
COM1 (computer system) - RS 232 115 kbps. This was formerly referred
to as Com2.
COM2 - RS 232 with RTS-CTS-control and support for XON/XOFF, transmission speed 300 - 38 400 bps. This was formerly referred to as SIO1.
COM3 - RS 422 full duplex TXD4, TXD4-N, RXD4, RXD4-N, transmission

speed 300 - 38 400 bps. This was formerly referred to as SIO2.
For temporary use: MC/CONSOLE - RS 232 115 kbps. This was formerly
referred to as Com1.
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").
See Product Specification for controller S4Cplus. Separate documentation is

included when the option RAP Serial link is ordered.
149
Controller
Connections
The figure below shows the connection of serial channels:
xx0100000219
External computer
Customer terminals, on base connector board: X10 (COM2) and X9 (COM3), see
section "Connection to screw terminals".
Connections on
DSQC 504, COM1
Standard RS232 port.

5
6
9
xx0100000220
The table below shows the signals from the COM1 (RS232):
150
Signal
Pin
Description
DCD
Data carrier Detect
RX
Receive Data
TX
Transmit Data
3HAC 16638-1
Controller
Connections on
DSQC 504, D-sub
connector X10,
COM2
Signal
Pin
Description
DTR
Data Terminal Ready
GND
Signal Ground
DSR
Data Set Ready
RTS
Request To Send
CTS
Clear To Send
RI
Ring Indicator
NC
10
Not Connected

5
6
9
xx0100000220
COM2 Signal name
X10 pin
1
RxD (Receive Data)
TxD (Transmit Data)
DTR (Data Terminal Ready)
0V
DSR (Data Ready Set)
RTS N (Request To Send N)
CTS (Clear To Send)
8
9
3HAC 16638-1
151
Controller
Connections on
DSQC 504, D-sub
connector X9,
COM3

5
6
9
xx0100000220
Connections to
MC/CONSOLE
COM3 Signal name
X9 socket
TxD (Transmit Data)
TxD N (Transmit Data N)
RxD (Receive Data)
RxD N (Receive data N)
0V
DATA (Data Signals in Half Duplex Mode)
DATA N (Data Signals in Half Duplex Mode N)
DCLK (Data Transmission Clock)
DCLK N (Data Transmission Clock N)
The figure below shows the MC/CONSOLE connection behind the service hatch:
xx0100000218
152
3HAC 16638-1
Controller
External computer
Standard RS232 port intended for temporary use, e.g. connection of laptop/PC.
The table below shows the signals on the MC/CONSOLE (RS232):
3HAC 16638-1
Signal
Pin
Description
RX
Receive Data
TX
Transmit Data
GND
Signal Ground
153
Controller
Communication, Ethernet
General
Connection of
LAN (Main computer)
The robot has two Ethernet channels available:
LAN (connected to the Main computer)
Service (connected to the I/O computer)
The figure below shows an outline diagram of the Ethernet TCP/IP:
E thernet hub
xx0100000217
External computer
Controller Robot 1
Controller Robot 2
Used for connection of shielded twisted-pair Ethernet (TPE), or as defined 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.
154
Signal
X1 Pin
Description
TX+
Transmit data line +
3HAC 16638-1
Controller
Signal
X1 Pin
Description
TX-
Transmit data line -
RX+
Receive data line +
NC
Not Connected
NC
Not Connected
RX-
Receive data line -
NC
Not Connected
NC
Not Connected
The figure below shows the main computer board front:

1
X1
LAN
PWR
HDD
STATUS
X2
xx0100000216
3HAC 16638-1
155
Controller
Connection of
Service (I/O Computer)
Used for connection of a laptop to the service outlet on the front of the controller
cabinet (behind service hatch).
The figure below shows how to connect a laptop to the service outlet:
E thernet
xx0100000215
Also see the Circuit Diagram. Separate documentation is included when the
option Ethernet services is ordered.
156
3HAC 16638-1
Controller
External operators panel
General
All necessary components are supplied, except for the external enclosure.
Dimensions for
installation
Install the assembled panel in a housing which satisfies protection class, IP 54, in
accordance with IEC 144 and IEC 529!
The figure below shows the main dimensions of the external operators panel:
A
B
M8 (x4)
M4 (x4)
62
C
45
70
140
184
200
E
90
5 (x2)
155
F
G
xx0100000214
3HAC 16638-1
Holes for operators panel
Holes for flange
157
Controller
158
Required depth: 200 mm
External panel enclosure (option)
Holes for teach pendant unit (TPU) holder
Teach pendant unit (TPU) connector
Connection to the controller
3HAC 16638-1
Controller
Start-up
Section D: Start-up
Inspection before start-up
General
Perform the following checks before starting up the robot system:
Check that:
1. the controller mains section is protected with fuses.

2. the electrical connections are correct and correspond to the identification plate on the controller.
3. the teach pendant and peripheral equipment are properly connected.
4. any limiting devices that establish the restricted space (when utilized)
are installed.
5. the physical environment is as specified.
6. the operating mode selector on the operators panel is in the Manual
mode position.
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:
3HAC 16638-1
Device
XS3
Panel unit
External limit switches
A5-A6, B5-B6
X1.3-4, X2.3-4
External emergency stop
A3-A4, B3-B4
X1.9-10, X2.9-10
External emergency stop

internal 24 V
A1-A2, B1-B2
X1.7-8, X2.7-8
General stop +
A11-A12, B11-B12
X3.10-12, X4.10-12
General stop -
A13-A14, B13-B14
X3.7-8, X4.7-8
Auto stop +
A7-A8, B7-B8
X3.11-12, X4.11-12
Auto stop -
A9-A10, B9-10
X3.7-9, X4.7-9
Motor off clamping
A15-A16, B15-16
X1.5-6, X2.5-6
159
Controller
Start-up
Start-up
General
1. Switch on the mains switch on the cabinet.

1. The robot performs its self-test on both the hardware and software,
which takes approximately 1 minute.
2. If the robot is not supplied with the software already installed, install the
software as described in chapter "Robot Controller".
A welcome message is shown on the Teach Pendant Unit display.
3. To switch from MOTORS OFF to MOTORS ON, press the enabling

device on the teach pendant.
4. Update the revolution counters as described in the Calibration chapter,
section "Updating the revolution counters".
5. IRB 940: Check the position of the spiral cable in the centre tube
sleeve. Correct position is described in the Calibration chapter, section
"Correct orientation of axes".
6. Check the calibration position as described in the Calibration chapter,
section "Checking the calibration position".
7. When the controller, with the manipulator electrically connected, is
powered up for the first time, ensure that the power supply is connected
for at least 36 hours continuously, 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 (if possible) as intended.
emergency stop and safety stop (where included) circuits and devices are
functional.
it is possible to disconnect and isolate the external power sources.
the teach and playback facilities work correctly.
the safeguarding is in place.
160
3HAC 16638-1
Controller
Start-up
at reduced speed, the robot operates properly and has the capability to
handle the product or workpiece.
in automatic (normal) operation, the robot operates properly and has the
capability to perform the intended task at the rated speed and load.
9. The robot is now ready for operation.
Operating the
robot
3HAC 16638-1
Starting and operating the robot is described in the Users Guide. Before start-up,
make sure that the robot cannot collide with any other objects in the working
space.
161
Controller
Section E: Installation of controller software

Loading system software
General
The robot system may be delivered with or without system software. When the
system is not delivered with software, this must be downloaded in one of a number
of ways.
Software installed
on delivery
If the robot controller is ordered with the software installed on delivery, the controller software and settings are already stored in the storage memory and the
system is ready to use.
Software not
installed on delivery
If the robot controller is ordered and delivered without software or if you want to
reconfigure your system, the RobInstall tool must be used to install the controller
software. The RobInstall 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
A
B
C
D
E
xx0100000192
162
3HAC 16638-1
Controller
RobotWare CD-ROM to install RobInstall and System Pack on PC
Floppy Disks
IOC Ethernet (service) with delivered boot cable UTP-X
Connected to IOC
MC Ethernet (LAN) network in workshop
When downloading, the controller software can be transferred to the controller

storage memory in three ways as shown in the figure above.
Boot Image
using floppy disks,
using Ethernet connected direct to the IO computer (IOC) service outlet on

the front of the controller cubicle,
using Ethernet connected via a local area network (LAN) to the main computer (MC).
The transfer and installation of the controller software to the controller storage
memory via Ethernet or floppy disks is executed by a basic program named Boot
Image.
This basic program must always be in the storage memory. When starting the
controller, with no 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 a cold start and then the Boot Image
will be reactivated.
3HAC 16638-1
163
Controller
RobotWare CD-ROM
The CD contains all the System software and should therefore be treated and
stored carefully.
RobotWare CDROM contents
164
The RobotWare CD-ROM contains the following:
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
Controller Operating System Package for

S4Cplus. This package includes all the software needed to create the controller operating
system with any ordered options. Please note
that it is possible to install different releases
with different versions of the same system
package (see section "Media Pool in the PC").
4.
Test Signal Viewer
A tool (created in LabView) for viewing MotionTest Signals (oscilloscope function) and also
for logging these signals.
5.
FTP Client
On the CD is also included a so called FTP client named Voyager. Please note that this is not
an ABB product but a shareware program,
which means that it can be installed and used
for a limited time, but that it has to be registered for permanent use. Registering means
that a certain fee must be paid to the vendor.
The FTP client is used to transport files manually between the PC and the robot controller
storage memory. These actions are carried out
in the same way as in a file manager or in Windows Explorer.
3HAC 16638-1
Controller
Installation of the
RobotWare on the
PC (except FTP
Client)
This section describes how to install the software delivered on the RobotWare
CD-ROM onto a PC hard drive, to be transferred to the robot system.
1. Insert the CD in your reader.
1. The Install Shield will automatically start and guide you through the
install process (if it does not start, double-click the CD icon on your PC).
When the setup type window is displayed, it is recommended to select
the Custom button. Then Next button will open the Select Components
window, where normally all the four options, RobInstall, Documentation, Controller OS Package and Test Signal Viewer should be marked
as selected.
Installation of the
FTP Client on the
PC
This section describes how to install the FTP Client onto a PC hard drive.
1. In the Explorer, select and open the directory "ftp" on the CD.
2. Double-click the file ftpvsetup.exe.
The Install Shield for the FTP client will start and guide you through the installation. Please read the "Readme" file for information about license regulations.
3HAC 16638-1
165
Controller
Installing new Robot Controller Software with RobInstall
General
Nomenclature
How to use RobInstall
166
Since most systems have the operating system installed already on delivery, the
RobotWare CD-ROM is normally not needed. However it should be used when:
creating a new controller operating system,
changing the current operating system configuration, e.g. concerning

included options.
In the text dealing with RobInstall, the following nomenclature is used:
Concept:
Means:
System pack
This is the RobotWare Controller Operating System Package

for S4Cplus, including all options, even if they are not ordered
and activated.
Key
This is a text string, or a special file with the text string, which
is used to define and open both the BaseWare and all ordered
RobotWare options.
System
This is a complete controller software, i.e. controller operating

system, based on the system pack and the key. It can also
include any user files to be added to the home directory on the
controller storage memory.
Robinstall is used to create and install the controller software in the S4Cplus robot
controller. With RobInstall, you can:
create a new system,
update an existing system,
download a system to the controller using the Ethernet connection,
create Boot Disks to transfer the system to the Controller.
3HAC 16638-1
Controller
Step
Action
Illustration/Info
1.
Make sure RobInstall is

installed. If not, install it
according to the instructions in section "Installation of the RobotWare on
the PC".
2.
Click the start button on

your PC and select programs/ABB Robotics/RobInstall/RobInstall.
3.
The RobInstall start window will open.
xx0100000185
3HAC 16638-1
167
Controller
Create a new Robot Controller System
Setting up the
system
Step
Action
Illustration/Info
1.
Start RobInstall as
described in section "How
to use Robinstall".
2.
Choose New to create a

new Robot Controller system as shown in the figure.
xx0100000179
3.
Enter a name for the new

controller system. Select
a saving location or use
the default directory, normally "Program
Files\ABB Robotics\system" (see the figure
below, position 1).
xx0100000180
4.
168
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, position 2).
3HAC 16638-1
Controller
Step
Action
Illustration/Info
5.
Press OK. The configured

system will be displayed
in the next window (see
the figure below).
6.
If no external options or
parameters are to be
added or changed, press
Finish to create the new
controller system. Otherwise press Next to continue to "Additional Keys"
(see section "Add or
remove external
options").
xx0100000181
Add or remove
external options
Step
1.
Action
Illustration/Info
To add or remove external

options, press Next in the
screen shown in the last figure in section "Setting up the
system" or click on "Additional
Keys" in the menu to the left.
xx0100000182
3HAC 16638-1
169
Controller
Step
Add or remove
additional system
parameters
Action
Illustration/Info
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

controller system or press
Next to continue to "Parameter Data" (see section "Add or
remove additional system
parameters).
Step
Action
Illustration/Info
1.
To add or remove additional parameters, press

Next in the screen shown
in the last figure in section
"Add or remove external
options" or click on
"Parameter Data" in the
menu to the left.
2.
Press Add to load manipulator calibration data (see

the figure above, position
1). This is the calib.cfg file
delivered on the Manipulator Parameter disk (see
section "The manipulator
parameter disk").
xx0100000183
170
3HAC 16638-1
Controller
Step
Change options
or system pack
revision
Action
Illustration/Info
3.
To remove manipulator
calibration data, press
Remove.
4.
Press Add to load additional system parameters,

see pos. 2. All system
parameter files added
here will be automatically
loaded together with the
system, when the controller is restarted with the
new system.
5.
To remove additional
parameters, select the
parameter in the "Loaded
Additional Parameters" list
and press Remove.
6.

Next to continue to
"Options" (see section
"Change options or system pack revision").
Step
1.
Action
Illustration/Info
To change the option configuration, press Next in

the screen shown in the
figure below or click on
"Options" in the menu to
the left.
xx0100000184
3HAC 16638-1
171
Controller
Step
172
Action
Illustration/Info
2.
To change the Teach Pendant Unit language, robot

type, or software options,
press Options (see the figure above, position 1).
3.
Normally the latest

release or revision of all
system packages and
option packages stored in
the media pool (see section "Media Pool in the
PC") will be used. If an
earlier revision should be
used, uncheck the check
mark and press Rev.
Select (see the figure
above, position 2). In the
new window select the
system package to use
and press OK.
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.

Next to view the current
configuration.
3HAC 16638-1
Controller
Update the Robot Controller image
Actions
Step
1.
Action
Illustration/Info
To update an existing controller system, press

Update, see the figure
below.
xx0100000189
2.
Select a 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
3HAC 16638-1
173
Controller
Step
3.
174
Action
Illustration/Info
The window displaying the

current configuration of the
system will be shown. Follow the instructions in sections "Add or remove
external options", "Add or
remove additional system
parameters" or "Change
options or system pack revision" to modify the system.
3HAC 16638-1
Controller
Transfer Robot Controller System using Ethernet connection
Selecting type of
set-up
Before a system can be downloaded to a robot controller using the RobInstall tool
some preparations and set up must be done. This may be done in one of two ways:
...then see instructions

in section:
If you are using:
...and continue
in section:
a direct connection between "If using a direct connection "Download Robot

PC and IOC service outlet
between PC and IOC service Controller System"
on controller
outlet on controller" below!
below!
If using a direct
connection
between PC and
IOC service outlet
on controller
3HAC 16638-1
Network Intranet connection "If using Network Intranet

with fixed IP addresses
connection with fixed IP
addresses " below!
"Download Robot
Controller System"
below!
Network Intranet connection "If using Network Intranet

with DHCP (Dynamic Host connection with DHCP "
Configuration Protocol)
below!
"Download Robot
Controller System"
below!
Step
Action
Illustration/Info
1.
Connect a patch-cable
between the Ethernet connection on the front of the
controller and the corresponding connection on
the PC/Laptop.
2.
Make sure that the Network protocol is set for

TCP/IP properties.
175
Controller
Step
3.
Action
Illustration/Info
Change the TCP/IP Properties in accordance with

the following table and figure:
xx0100000178
If using Network
Intranet connection with fixed IP
addresses
176
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 Gateway.
3.
Perform a X-START (see section "x-START") or CSTART (see section "C-start") on the S4Cplus controller.
4.
Configure the IP address to be used for the robot

controller from the TPU.
3HAC 16638-1
Controller
If using Network
Intranet connection with DHCP
Step
1.
Action
Illustration/Info
Read Ethernet MAC-id on the Teach Pendant Unit

(see section "LAN settings").
Download Robot
Controller System
Before downloading, check the following:
Make sure there is at least 25 Mb free disk space on the controller mass storage
memory. For information on how to perform a manual storage capacity check, see
section "Check Storage Capacity".
Make sure that the robot controller displays the Start Window on the Teach Pendant Unit (see section "Start window").
Step
1.
Action
Illustration/Info
To download a controller
system, press Download as
in the figure below:
xx0100000176
3HAC 16638-1
177
Controller
Step
Action
Illustration/Info
2.
Select a target system as in If a direct connection is used with the patch

the figure, position 1.
cable between the PC and the controller
front, then just select the default IP address
(192.168.125.1) and "Direct" option.
In other cases, write the correct IP address
for the robot controller and select "Hostname or IP-address". RobInstall will store
already used IP addresses, which can later
be selected with the down arrow.
3.
Type your username and

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 possible to
select another system pool
than the shown one (in
such case be sure to select
the system pool directory,
not the system itself on the
lower level).
xx0100000175
178
3HAC 16638-1
Controller
Step
6.
3HAC 16638-1
Action
Illustration/Info
RobInstall will now create a After downloading it is possible to restart

system file and download it the controller with the new downloaded
to the controller.
controller system. Otherwise, the controller
may be restarted from the Teach Pendant
Unit as detailed in section "Reboot".
179
Controller
Transfer Robot Controller System using floppy disks

Before downloading, make sure:
there is at least 25 Mb free disk space on the controller mass storage memory. For
information on how to perform a manual storage capacity check, see section
"Check Storage Capacity".
that the robot controller 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
1.
Action
Illustration/Info
Press Create Boot Disk as

in the figure below.
xx0100000173
180
3HAC 16638-1
Controller
Step
2.
Action
Illustration/Info
Select a system in the list

on the left and press OK as
RobInstall will now create
an image file and estimate
the number of disks
needed.
xx0100000175
xx0100000188
3HAC 16638-1
3.
Insert a formatted 1.44 Mb

diskette into the disk drive.
4.
Press Continue to start

copy the Robot Controller
System image to the disks.
5.
Use the finished floppy

disks to boot your system
as described in section
"Boot Disks".
181
Controller
RobInstall preferences
Customizing RobInstall
RobInstall may be customized to suit particular requirements.
Step
Action
Illustration/Info
1.
To customize RobInstall for

new programs and
optional products, press
Preferences as shown in
the figure. See also chapter "System Directory
Structure".
2.
To select another media

pool (see section "Media
Pool in the PC"), press
Select Media Pool as
shown in the figure, position 1.
xx0100000186
xx0100000187
182
3HAC 16638-1
Controller
Step
3.
3HAC 16638-1
Action
Illustration/Info
To add a new system package or option package to

the media pool, press
Import Program as shown
in the figure, position 2.
Also see chapter "System
Directory Structure".
183
Controller
Robot controller
Section F: Robot controller

BootImage
General
The BootImage 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:
184
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.
3HAC 16638-1
Controller
Robot controller
Start window
When is it
shown?
xx0100000168
The start window displays the start menu and will appear in the following cases:
When no controller operating system is installed at power on.
After X-START (see the part "How to perform a Restart").
After C-START (see the part "How to perform a Restart").
Possible actions
From this window 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 the part "Reboot Window").
Load a system
from diskettes,
Boot Disks
(See the part "Boot Disk Window".)
Set the network

settings, Network
Settings
Set network settings for the Main Computer or check how to configure your PC
(see the part "Network Settings Window").
3HAC 16638-1
185
Controller
Robot controller
Choose a system
from the mass
storage memory,
Select System
186
If there is one or more systems in the mass storage memory, you can choose to
activate one of them (see the part "System selection window").
3HAC 16638-1
Controller
Robot controller
Reboot 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
3HAC 16638-1
Button
Function
YES
Restarts the system
NO
Returns to the start window
187
Controller
Robot controller
Boot Disk Window
When is it
shown?
The Boot Disk window will be displayed when Boot Disks is pressed in the Start
window as shown in the figure in section "Start window".
How 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
1.
Action
Illustration/Info
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 figure in
section "Start window".
xx0100000170
188
3HAC 16638-1
Controller
Robot controller
Network Settings Window
When is it
shown?
The Network Settings window will be displayed when Network Settings is

pressed in the Start window as shown below.
xx0200000209
3HAC 16638-1
LAN Settings
Press to configure the Main Computer for communication with

a PC on a Local Area Network (LAN). Also see "LAN settings"!
Service Settings
Press to view the required settings for the PC to communicate

with the I/O Computer. Also see "Service settings"!
CANCEL
Press to return to the Start window as shown in figure "Start

window".
189
Controller
Robot controller
LAN Settings Window
When is it
shown?
The LAN Settings window will be displayed when LAN Settings is pressed in the
Network Settings window as shown in the figure in section "Network Settings".
en0100000256.gif
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 Window", without changing any settings.
Node identification
190
Parameter
Type
Description
MAC ID
Node identification
The Main Computers ethernet address.
Current IP
Node identification
The Main Computers current IP address.

This row is blank if the LAN Settings have
not been defined.
IP
Network setting
Space for typing in a new IP address, for

the Main Computer or the DHCP server.
See Configure for fixed IP network and
Configure for DHCP distributed IP network
below.
3HAC 16638-1
Controller
Robot controller
Parameter
Configure for
fixed IP network
Type
Description
(Subnet mask) Network setting
Shows the subnet mask of the network.

Only visible when configured for fixed IP.
(Gateway)
Shows the gateway IP for the network.

Only visible when configured for fixed IP.
Network setting
1. Press FIX IP.

2. Fill in the assigned IP address for the Main Computer, and the Subnet
Mask and Gateway for the Network and press OK.
You will be asked to reboot the system.
3. Press YES to make the new setting take effect.
Configure for
DHCP distributed
IP network
1. Press DHCP.
1. The value for IP will change to DHCP.
2. Press OK.
You will be asked to reboot the system.
3. Press YES to make the new setting take effect.
3HAC 16638-1
191
Controller
Robot controller
Service Settings Window
When is it
shown?
The Service Settings window will be displayed when Service Settings is pressed
in the Network Settings window as shown in the figure in section "Network Settings".
en0100000257
OK
returns to the Start window as shown in the figure in section "Start Window".
Service Setting
Parameter
Description
IP (service setting) The IP Address for the I/O Computer
192
IP
Required to configure your PCs network settings for communication between RobInstall and the I/O Computer.
Subnet mask
Gateway
3HAC 16638-1
Controller
Robot controller
System selection window
When is it
shown?
The Select System window will be displayed when Select System is pressed in the
Start window, as shown in the figure in section "Start Window".
xx0100000171
CANCEL
How to select
system
returns to the Start window as shown in the figure in section

"Start Window".
The window shows all systems installed on the controller mass storage memory.
Step
1.
Action
Illustration/Info
Select by moving the X to a

desired system and press OK.
The system will reboot with the
new system and then display the
Welcome window as shown in
the figure.
xx0100000172
3HAC 16638-1
193
Controller
Robot controller
How to perform a Restart
General
Performing a restart may be done in a number of ways. These are detailed below:
Reboot (Warm
start), apply
changed settings
When executing a Warm start, the system reboots with the current system, e.g. to
make new or changed settings take effect.
Step
1.
Action
Illustration/Info
Press the button Miscellaneous and select

Service window or System Parameter window
Miscellaneous button:
xx0100000194
2.
P-START, reinstallation of RAPID
Select Restart from the File menu and press

OK.
The system reboots and returns to the Welcome window as shown in the second figure
in section "Select System".
A P-Start will warm start the current system, with a reinstallation of the RAPID
language and all auto-loaded modules. This means that all RAPID program and
system modules currently loaded in the working memory will be closed, and thus
have to be reloaded again after the P-Start, with the exception of such modules that
are automatically loaded, due to settings in the System Parameters/Controller/
Task Modules.
Step
Action
Illustration/info
1.

Service window.
2.
Select Restart from the File menu.
xx0100000194
194
3HAC 16638-1
Controller
Robot controller
Step
X-START, change
active controller
system
Action
Illustration/info
3.
Enter the numbers: 2_5_8 (the fifth function

key changes to P-START)
4.
Press P-START.
The system will reboot, reinstall RAPID and
its auto-loaded modules, and return to the
Welcome window as shown in the second figure in section "Select System".
An X-start will exit the running system, store system data on the mass storage
memory, and then execute the BootImage to display the Start window. Any system
stored in the mass storage 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.

Service window.
2.
3.

key changes to X-START)
4.
Press X-START.
The system will reboot and return to the Start
window as shown in the figure in section
"Start Window".
xx0100000194
I-START, start in
Query mode
3HAC 16638-1
An I-start can be done if "Use Query Mode at System Boot" was selected when
creating the running system in RobInstall (see section "Change options or system
pack revision"). An I-Start will restart the current system and give the opportunity
195
Controller
Robot controller
to set some values at start-up, e.g. language, IRB type (within the same model) or
options (see section "Start in Query Mode").
Step
Action
Illustration/Info
1.
Press the button Miscellaneous and selectService window.
2.
3.

key changes to I-START).
4.
Press I-START.
The system will start to reboot, then pause to
ask for Silent, Easy, or Query mode. For more
information on the different modes, continue
to section "Start in Query Mode".
xx0100000194
C-START (Cold
start), delete the
active system
When executing a C-Start, the system exits the running system and deletes it from
the mass storage memory. The BootImage is then executed and the Start window
as shown in the figure in section "Start Window" is displayed.
Use C-start with caution. Since it deletes the current system, it should not be used
to just switch between installed systems. For this purpose, use X-Start (see section
"X-start").
It will take quite some time to implement a Cold start. Just wait until the robot shows
the Start window. When the Start window is shown, a new system can be selected
if available in the mass storage memory (see section "Select System) or a new
system can be downloaded and started (see section "Transfer Robot Controller
System using Ethernet connection" or "Transfer 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 section "Start Window".
196
3HAC 16638-1
Controller
Robot controller
Step
1.
Action
Illustration/Info
Press the button Miscellaneous and selectService window.
xx0100000194
3HAC 16638-1
2.
3.
Enter the numbers: 1_3_4_6_7_9 (the fifth

function key changes to C-START)
4.
Press C-START.
197
Controller
Robot controller
How to Start in Query Mode
Pre-conditions
for selecting
Query Mode start
If "Use Query Mode at System Boot" was selected when creating the system in
RobInstall (see section "Change options or system pack revision"), it is possible
to set some values, e.g. language, IRB type (within the same model) or options, at
the first start-up of the system, using a C-Start (see section "C-start"), or later on
when performing an I-Start (see section "I-start").
Types of Query
Mode
The first question from the system is which Query Mode to start. Depending on
your needs, you should select one of the following three:
Easy Query Mode
Silent Mode, pushbutton Silent. If Silent Mode is selected, the operating

system will be installed with the system configured as defined in RobInstall.
Easy Query Mode, pushbutton Easy Query. In Easy Query Mode you can
change language, remove selected options and select service or standard
mode (see section "Easy Query Mode").
Query Mode, pushbutton Query. In Query Mode you can, as well as 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").
If Easy Query was chosen as start-up query mode, the following steps will be
required to start the system:
Step
198
Action
Illustration/Info
1.
Select Service/Standard motion param.

Choose between standard or service motion
parameters (pushbutton Stand / pushbutton
Service).
2.
Choose TP Language. If there was another

language than English selected in RobInstall
(see section "Change options or system pack
revision"), it will be possible to choose the
language (pushbutton English /pushbutton
"Other").
3HAC 16638-1
Controller
Robot controller
Step
3.
Query Mode
Action
Illustration/Info
Install xxx? For every option that was

selected in RobInstall (see section "Change
options or system pack revision") it is now
possible to select Yes to keep the option, or
No to remove it from the system.
If Query Mode was chosen as start-up query mode, the following steps will be
required to start the system:
Step
Action
Illustration/info
1.
Select Service/Standard motion param. See

section "Easy Query Mode", step 1.
2.
Choose TP Language. See section "Easy

Query Mode", step 2.
3.
Select external axes config.

You can find the article number of the DC-link
used on the unit inside the controller, then
use the table below to find out the configuration ID for that DC-link.
3HAC 16638-1
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.
199
Controller
Section G: System directory structure

Media pool in the PC
Directory
All RobotWare System Packages and Option Packages are stored in a media pool
directory (folder) as shown in the table below.
Two revisions of the same system package may exist in the pool. By default, after
having installed RobInstall, a directory "MediaPool" will be found in the directory
Program Files\ABB Robotics\, and will also be the current one. However any
directory in the structure can be set up as the current media pool in the Preference
window (see section "Robinstall Preferences").
xx0100000259
Naming conventions
200
Art. no./folder name
Description
3HAXaaaa-1.00
RobotWare System Pack 3HAXaaaa-1, rev 00
3HAXbbbb-1.02
RobotWare System Pack 3HAXbbbb-1, rev 02
3HAXcccc-1.01
ABB Robotics external option program 3HAXcccc-1,

rev 01
3HYZdddd-1.00
OEM customer external option program 3XYZdddd-1,

rev 00
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
loaded into the program pool, to be added to the old one, without changing the
article number.
3HAC 16638-1
Controller
System pool in the PC
Directory
All systems created with the RobInstall will be stored in a system pool. The
default name of such a system pool is "system" as shown below. Each system
stored in the system pool is a directory with the name of the system as shown in
the table below.
By default, after installing RobInstall, a directory "system" will be found in Program Files\ABB Robotics\ and will also be the current one. However any directory in the structure can be set up as the current system directory in the Create New
System window or Select System window.
Directory view
Folder "System 1"
xx0100000260
xx0100000261
File system
requirements
3HAC 16638-1
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 procedure. All system parameter files, included when creating a system with RobInstall, are stored in this syspar directory as shown in the
table in section "System Pool Directory".
A directory called Home. In this home directory the user can include any
file or files, which should be downloaded to the controller together with the
operating system. Such files will then be placed in the home directory of
the system in the controller.
201
Controller
File structure in the robot controller mass storage memory
Files in root directory, hd0a
The root directory of the mass storage memory is called hd0a. This includes several components:
File name
Description
E.g. 3HAC6811-1.00 Control system package, named as an article number

bin
BootImage code
BootRom.sys
System configuration and description file for the mass

storage memory
MC.cfg
Network configuration for the main computer
ctrl.bin
Holds e.g. revolution counter values
system.dir
Holds information on the current system
system directories
Different systems stored in the mass storage memory
Directories and
subdirectories
Each system directory holds a number of subdirectories, defining for instance language, options, robots, etc.
"Home" directory
The system directory is the "home" directory for the system. When using the
address "home:" in the RAPID program, this directory will be addressed.
"Bin" subdirectory
The subdirectory bin, containing the storage area 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 memory.
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 it will be impossible to use
the mass storage memory.
202
3HAC 16638-1
Controller
Preparation of S4Cplus software to be installed
Illustration
Media pool
S ystem Pack in
/3haxbbbb-1.nn
*.* si gnature no
S ystem pool
E xt Option in
/3haxcccc1.nn
*.* relkey.txt
Created files
key.id
program.id
E xternal option from

disk or CD-R OM
S ystem Pack from

R obotWare CD-R OM
My syst em
/syst em_n
key.id
program.id
keystr.txt
/syspar
*.cfg
Inserted key strings

are saved in keystr.txt
R obotWare keystrings define the options
to be included from the S ystem Pack
they belong to and E xt opt keystrings define
added external option packages.
All keys must have the same serial number.
xx0100000262
Files to be prepared
3HAC 16638-1
The list details what happens during preparation:
RobInstall creates a file named Key.id from the key strings specifying the
options to be installed from the System Pack and the external option programs to be installed.
Unless deselected in RobInstall, the latest revision of the System Pack and
External Option Programs is selected as default (see section "Change
options or system pack revisions").
These are 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 controller via Ethernet or a set of diskettes. The target
file is temporarily stored in the system directory before downloading or creating diskettes.
203
Controller
Handling mass memory storage capacity
General
In some cases it is very important that there is enough free space in the mass
storage memory, before attempting to download new system software. How to
check its capacity, and if required increase it, is detailed below.
A manual check on the free space can be done in one of the following ways:
Checking storage
capacity from the
Teach Pendant
Unit
Checking storage
capacity through
connection to the
MC/CONSOLE
port
1. Press the button Miscellaneous to select Service window.

2. Select Storage Capacity from the System Info menu. The Mass
Storage Memory is called hd0a.
1. Connect a console to the MC/CONSOLE outlet on the controller and

execute the command 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 systems from the mass storage memory. This can be done in one of the following ways:
1. Boot up on the system you would like to remove and then make a CSTART (see section "C-start").
2. Use the FileManager in the Teach Pendant Unit, see Users Guide - File
Manager, for more information on how to use the FileManager.
3. Use a third-party "ftp" client (like FTPVoyager supplied on the RobotWare CD).
204
3HAC 16638-1
Controller
Removing systems using the FileManager or FTP-client may be hazardous since

the \bin and BootRom.sys directories must be kept intact.
Proceed with the utmost care to avoid accidentally removing such files or directories!
3HAC 16638-1
205
Controller
206
3HAC 16638-1
Calibration
Chapter 5:Calibration
When to calibrate
Types of calibration procedures
Calibrate the measurement system carefully if any of the resolver values has been
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" if the contents of the revolution counter memory are lost. This may occur
when:
3HAC 16638-1
the battery is discharged
a resolver error occurs
the signal between a resolver and measurement board is interrupted
a robot axis has been moved with the control system disconnected
207
Calibration
General
Section A: General
How to calibrate the robot system
General
This section provides an overview of the procedure required when calibrating the
robot system. Many of the steps in the procedure are detailed in other sections to
which references are given.
Procedure
Step
208
Action
Note/Illustration
1.
Check that all required hardware is

available for calibrating the robot.
Required hardware is specified

in the calibrating procedures for
each axis.
2.
Check the correct orientation of axis 4. Detailed in "Correct orientation

Incorrect orientation of the axis may
of axes".
cause damage on cabling!
3.
Manually, run the robot axes to a posi- Use the calibration scales or distion close to the correct calibration
tances to locate this position,
position.
detailed in "Correct orientation
of axes".
4.
Start the calibration procedure on the

TPU.
Detailed in "Fine calibration procedure on TPU".
5.
Calibrate each axis.
Detailed in "Fine calibration, all

axes".
6.
Verify that the calibration was successfully carried out.
Detailed in "Post calibration procedure".
3HAC 16638-1
Calibration
General
Additional
information
In addition to the basic calibration procedure detailed above, a number of calibration related actions may be performed:
Action
Detailed in section:
How to update the robot revolution counter

without performing a complete calibration.
How to manually check the current calibration Checking the calibration position
position.
3HAC 16638-1
209
Calibration
General
Calibration tool kit, contents
Calibration tool
kit, 3HAC xxxxx-x
The calibration tool kit, 3HAC xxxxx-x, can be ordered from ABB Automation
Technologies AB, Robotics.
The kit contains:
210
Digital indicator
Magnetic stand
Calibration tool for actuator
Calibration tool for wrist
Tool case
3HAC 16638-1
Calibration
Preliminaries
Section B: Preliminaries
Correct orientation of axes
General
This section details the correct orientation of all axes.

The orientation of axis 4 must be especially checked and corrected if necessary
before performing any calibration!
3HAC 16638-1
211
Calibration
Preliminaries
Index marks
The figure below shows the index marks of axes 4-5-6 and the correct position of
the spiral cable. It also shows the calibration distance on axes 1-2-3.
C
B
G
D
xx0200000341
212
Axis 4 (center tube)
Index marks for axis 5
Spiral cable inspection cover
Correct orientation of the spiral

cable (and axis 4)
Calibration distance for axes 12-3: 26 mm on each axis
3HAC 16638-1
Calibration
Preliminaries
Correct position
of axes 1-2-3
The axes 1-2-3 should be positioned with an approximate distance of 26 mm

between the actuator and the calibration spacer above the lower joint, shown in
figure above. This distance is set exactly during the fine calibration procedure.
Correct orientation of axis 4
The procedure below details how to check and eventually correct the orientation
of axis 4.
Axis 4 has no mechanical limitation! Cabling inside the manipulator may be damaged if axis 4 is oriented incorrectly when performing calibration of the robot!
must be observed:
working space. The position 100%full speed may only be used by trained personnel who are aware of the risks that this entails.
Step Action
Note
1. Remove the spiral cable inspection cover on Shown in figure above!

the center tube sleeve by removing its 4
attachment screws.
2. Make a visual check of the numbers, marked Directions detailed in part
on the spiral cable.
Directions for all axes.
The numbers 4-3-2-1 must be positioned in a
straight line, as shown in figure above!
In case the index marks are not present:
make sure that the normal vector of the face
of the gearbox, axis 5, is pointing in approximate (+ / - a couple of degrees) +Y direction!
3. In case correction is necessary, turn axis 4
with the TPU into the approximate calibration
position by positioning the numbers into a
straight line!
3HAC 16638-1
213
Calibration
Preliminaries
Step Action
Note
4. Refit the spiral cable inspection cover with the

4 attachment screws!
Correct orientation of axes 5-6
The procedure below details the correct orientation of axes 5-6.
Step
214
Action
Note/Illustration
1.
Make sure that the index marks of axis 5 are

roughly aligned.
make sure that the normal vector of the face
of the tool flange is pointing approximately (+
/ - a couple of degrees) in the +Z direction
(positive)!
Location shown in figure

above!
Directions detailed in part
2.
Make sure that the index marks of axis 6 are

roughly aligned.
make sure that the hole for the guide pin in
the tool flange is pointing approximately (+ / a couple of degrees) in the -X direction (negative)!
Location shown in figure

above!
Directions detailed in part
3HAC 16638-1
Calibration
Preliminaries
Checking the calibration position
General
Using the Jogging window on

the teach pendant
Check the calibration position before beginning any programming of the robot
system. This may be done as detailed below.
Step
1.
Action
Note/Illustration
Open the Jogging window.
xx0100000195
2.
Choose running axis-by-axis.
3.
Check that the positions of axes 1-2-3 are

reached and that the calibration marks on
axes 4-5-6 are aligned correctly.
If they are not, update the revolution counters
as detailed in "Update the revolution
counter".
xx0100000196
3HAC 16638-1
Calibration positions and

marks for each axis are
shown in section "Correct
orientation of axes".
215
Calibration
Preliminaries
Manually running
the manipulator
to the sync position
This section details the first step when updating the revolution counter; manually
running the manipulator to the synchronization position.
Axis 4 has no mechanical limitation! Cabling inside manipulator may be damaged

if axis 4 is oriented incorrectly when performing calibration of the robot!
the
Step
Storing the revolution counter

setting
Action
Illustration
1.
Select axis-by-axis motion mode
2.
Press the enabling device on the teach pen- Calibration marks shown
dant and, using the joystick, move the robot in section "Correct orienmanually so that the calibration marks or dis- tation of axes".
tances lie within the tolerance zone.
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
calibrated.
4.
When all axes have been positioned as

above, store the revolution counter settings
using the Teach Pendant Unit as detailed
below:
This section details the second step when updating the revolution counter; storing
the revolution counter settings.
If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, which in turn may cause damage or injury!
216
3HAC 16638-1
Calibration
Preliminaries
Step
1.
Action
Illustration
Press the button "Miscellaneous".
xx0100000194
2.
Select the Service window

by pressing ENTER.
xx0100000200
3.
Select Calibration from

the 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.
3HAC 16638-1
Select the desired axis and

press Incl to include it (it
will be marked with an x) or
press All to select all axes.
217
Calibration
Preliminaries
Step
218
Action
Illustration
6.
Press OK when all axes that

are to be updated are
marked with an x.
CANCEL returns to the Calibration window.
7.
Press OK again to confirm

and start the update.
CANCEL returns to the Revolution Counter Update window.
8.
At this point, it is recommended that the revolution

counter values are saved to
a diskette.
9.
Recheck the calibration position as described in "Checking the calibration position".
Not required.
3HAC 16638-1
Calibration
Preliminaries
Fine calibration procedure on TPU
General
The section below details how to use the Teach Pendant Unit (TPU) when performing a fine-calibration of the robot.
Procedure
Step
Action
Note/Illustration
1.
Press the button "Miscellaneous".
2.
Select the Service window

by pressing ENTER.
xx0100000194
xx0100000200
3HAC 16638-1
219
Calibration
Preliminaries
Step
3.
Action
Note/Illustration
Choose Calibration
from the View menu. The
Calibration window appears.
xx0100000201
Explanation of status:
Synchronized: all axes are calibrated and their positions are
known. The unit is ready for use.
4.
Revolution Counter not updated:

all axes are fine-calibrated but one
(or more) of the axes has a
counter that is NOT updated. This
axis, or these axes, must therefore
be updated as described in
"Updating the revolution counter".
Not calibrated: one (or more) of

the axis is NOT fine-calibrated.
This axis, or these axes, must
therefore be fine-calibrated as
described in "Fine calibration".
Select the desired unit and

choose Fine Calibrate
from the Calib menu. A
Warning window appears.
xx0100000203
220
3HAC 16638-1
Calibration
Preliminaries
Step
5.
Action
Note/Illustration
Move the manipulator to its

calibration position and
press OK. The Fine Calibrate window appears.
Calibration positions for the manipulator

detailed in "Checking the calibration position".
xx0100000204
3HAC 16638-1
6.
Select the desired axis and

press Incl to include it (it
will be marked with an x) or
press All to select all axes.
7.
Press OK when all axes that

are to be updated are
marked with an x.
CANCEL returns to the Calibration window.
8.
Press OK again to confirm

and start the update.
CANCEL returns to the Fine
Calibration window.
An alert box is displayed during calibration. The Status
window appears when the
fine calibration is complete.
The revolution counters are
always updated at the same
time as the calibration is performed.
221
Calibration
Calibration
Section C: Calibration
Directions for all axes
Calibration movement directions
The figure below shows the positive and negative directions for each axis.
+
4
+
+
xx0200000355
222
3HAC 16638-1
Calibration
Calibration
Jogging
directions
The figure below shows the linear directions when jogging the robot.
+Y
+Z
+X
+Z
xx0200000378
3HAC 16638-1
223
Calibration
Calibration
Fine calibration, all axes
Introduction
This section details how to calibrate the complete robot, using calibration tools.
The section is divided into the following parts:
Before calibration
Before calibration
Required equipment
Calibration order
Calibration, axes 1, 2 and 3
Calibration, axis 5
Calibration, axis 6
Calibration, axis 4
Before calibrating the robot, make sure that the requirements in the previous sections "General" and "Preliminaries" are met!
Required equipment
Calibration order
224
Equipment, etc.
Art. no.
Note
Calibration tool kit
Contains tools for calibration of complete

robot. May be ordered from ABB Automation Technologies AB, Robotics.
The order of calibration of the axes 1, 2 and 3 is of no importance, but the remaining axes must be calibrated in the following sequence: 5 - 6 - 4.
3HAC 16638-1
Calibration
Calibration
Calibration axis 1,
2 and 3
The procedure below details how to calibrate axis 1, but it is the same for axes 2
and 3. Calibrate one axis at a time and then repeat the procedure for the remaining
axes.
Step
Action
Note/Illustration
1.
Turn the operating mode selector to MANUAL MODE AT REDUCED SPEED.
2.
Operate current axis (axis 1, 2 or 3) in manual mode with the joystick until only 40-50
mm of the movable part of the actuator is
visible.
3.
Insert the gauge block between the platform and the actuator cover (see adjacent
figure) and then gently contract the actuator until the gauge block fits exactly but is
not jammed.
Note! All three actuators should have
approximately the same length when one
of them is calibrated.
xx0200000351
3HAC 16638-1
4.
Update only the current axis (axis 1, 2 or 3)

as detailed in "Fine calibration procedure
on TPU".
5.
Remove the calibration tools.
A: 26 mm
225
Calibration
Calibration
Calibration, axis 5
The procedure below details how to calibrate axis 5.
Step
1.
Action
Note/Illustration
Put a dial gauge (mounted on a support positioned on a flat surface

external to the robot) against the
edge of the tool flange as shown in
The purpose of this procedure is to
adjust axis 5 so that it is possible to
rotate axis 4 without reading any offset on the indicator.
xx0200000352
226
3HAC 16638-1
Calibration
Calibration
Step
2.
3HAC 16638-1
Action
Note/Illustration
Lock all other axes when jogging

axis 4.
Rotate axis 4 in joint +180
degrees.
Rotate axis 5 to compensate

for half the value read on the
indicator (i.e. the indicator
shows 0.58 mm, move axis 5
gently until the indicator
shows 0.29).
Rotate axis 4 -180 degrees

(=back to the starting position, 0 degrees).
Repeat until it is possible to

rotate axis 4 180 degrees
without reading any error on
the gauge. Normally, it
requires 2-4 attempts.
3.
Update only axis 5, as detailed in

"Fine calibration procedure on TPU".
4.
227
Calibration
Calibration
Calibration axis 6
Step
Action
Note/Illustration
1.
Run the following axis to the specified

position:
Axis 5: -90 degrees.
2.
Fit the wrist calibration tool at the tool

flange and put a dial gauge (mounted
on as support positioned on a flat surface external to the robot) against the
edge of the tool, see the adjacent figure.
xx0200000353
3.
228
Lock all other linear directions except Directions shown in Directions

for Z.
for all axes.
3HAC 16638-1
Calibration
Calibration
Step
Calibration, axis 4
Action
Note/Illustration
4.
Move the robot in +/-Z (in base) and Directions shown in Directions
adjust axis 6 until the indicator shows for all axes.
minimum change (usually a few hundredths of a millimeter) while travelling from the middle of the tool to one
end (i.e. if the indicator shows 0.46
mm while travelling from the center of
the tool to one end of the tool, rotate
axis 6 by 0.46 mm).
5.
Update only axis 6, as detailed in

"Fine calibration procedure on TPU".
6.
Step
1.
2.
Action
Note/Illustration
Run the following axes to

the specified positions:
Axis 5: -90 degrees.
Axis 6: +90 degrees.
Axis 4: 0 degrees.
Put a dial gauge (mounted

on a support positioned on a
flat surface external to the
robot) against the ground
face of the tool, see the adjacent figure.
xx0200000354
3HAC 16638-1
229
Calibration
Calibration
Step
230
Action
Note/Illustration
3.
Lock all other linear directions except for Y.
Directions shown in Directions for all

axes.
4.
Move the robot in +/-Y (in

Directions shown in Directions for all
base) and adjust axis 4 until axes.
the indicator shows minimum change (usually a few
hundredths of a millimeter)
while travelling from the middle of the tool to one end (i.e.
if the indicator shows 0.52
mm while travelling from the
center of the tool to one end
of the tool, rotate axis 4 by
0.52 mm).
5.
Update only axis 4, as

detailed in "Fine calibration
procedure on TPU".
6.
Remove the calibration

tools.
3HAC 16638-1
Calibration
After calibration
Section D: After calibration

Post calibration procedure
General
Perform the following procedure after calibrating any manipulator axes. The procedure is intended to verify that all calibration positions are correct.
Procedure
Step
3HAC 16638-1
Action
Illustration
1.
Run the calibration home position program

Detailed in "Checking the
twice.
calibration position".
Do not change the position of the manipulator
axes after running the program!
2.
Check all calibration positions.
3.
Repeat the check as above.
4.
Adjust the calibration marks when the calibra- Shown in section "Cortion is done.
rect orientation of axes".
5.
The system parameters will be saved to the

storage memory at power off.
6.
Remove any calibration equipment from the

manipulator.
Detailed in "Checking the

calibration position".
231
Calibration
After calibration
232
3HAC 16638-1
Index
3HAC 16638-1
233
Index
234
3HAC 16638-1
Repair Manual


Robotics
S-721 68 VSTERS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax:
+46 (0) 21 132592
Repair Manual, IRB 940 Tricept

3HAC 16640-1
-

will be prosecuted.
current charge.

Robotics
SE-721 68 Vsters
Sweden
Table of Contents
Overview
Introduction
Related information


Fire extinguishing
Brake testing
Introduction
Screw joints
Chapter 3: Manipulator
Introduction
Section A: Manipulator repairs
Removal of actuator, including motor

Refitting of actuator, including motor
Removal of servomotor, axes 1-3
Refitting of servomotor, axes 1-3
Removal of servomotor, axis 4
3HAC 16640-1
1
3
5
5
6
7
7
7
8
9
9
9
9
10
10
11
13
13
13
14
14
15
15
15
17
17
18
20
21
21
22
22
27
34
38
43
Table of Contents
Refitting of servomotor, axis 4

Removal of lower joint
Refitting of lower joint
Removal of wrist
Refitting of wrist
Removal of center unit
Refitting of center unit
Removal of spiral cable
Refitting of spiral cable
49
55
58
62
67
72
77
82
85
Section B: Distribution box repairs
89
Replacement of battery, distribution box

Replacement of serial measurement card, distribution box
Replacement of brake release card, distribution box
Chapter 4: Controller
Introduction
Putting the computer unit in the service position
Replacement of air filter, controller
Replacement of battery unit, controller
Replacement of I/O and gateway units
Replacement of bleeder resistor
Replacement of mass storage memory
Replacement of internal cooling fan
Replacement of drive units and rectifier
Replacement of system fan unit
Replacement of power supply unit
Chapter 5: Circuit Diagram, IRB 940 Tricept
Introduction
=M1/2, Potentials from control
=M1/3, Axis 1
=M1/4, Axis 2
=M1/5, Axis 3
=M1/6, Axis 4
=M1/7, Axis 5
=M1/8, Axis 6
=M1/9, Serial Measure board, Earth connections
=M/10, Brake release unit
ii
89
92
95
99
99
100
103
106
109
113
116
120
125
129
132
135
135
136
137
138
139
140
141
142
143
144
144
3HAC 16640-1
Table of Contents
Chapter 6: Circuit Diagram, S4Cplus

Introduction
System 1: General information
Sheet 1-1. Block Diagram

Sheet 1-2. View of Control Cabinet
Sheet 1-4. Designation
System 2: Mains Connection and Power Supply
Sheet 2-1. Mains Connection

Sheet 2-2. Transformer Unit
Sheet 2-3. Power Supply
Sheet 2-5. External transformer unit 200-500V IRB6600/7600
Sheet 2-6. Transformer unit 400-475V IRB 6600/7600
System 3: Computer Unit and Connector Unit
Sheet 3-1. Block Diagram/Computer Unit

Sheet 3-2. Cabling in Computer Unit
Sheet 3-3. Main Computer and Hard Disk / Flash Disk Drive
Sheet 3-4. Compute Cooling
Sheet 3-5. Base Connector Board and I/O Computer
Sheet 3-6. Connector Board and I/O Computer
Sheet 3-7. Connector Board and Axis Computer
Sheet 3-8. Base Connector Unit
Sheet 3-9. Connector Plate on Controller Panel
System 4: Emergency Stops and Run Chain
Sheet 4-1. Emergency Stop

Sheet 4-2. Run Chain
Sheet 4-4. Power Unit Servo Disconnector
System 5: Drive System and Robot Cable

Sheet 5-2. Rectifier, Fans and Bleeder
Sheet 5-3. Drive System Signal Connection 2 Drive Units
Sheet 5-5. Servo Drive Units / IRB 140
Sheet 5-7. Servo Drive Units / IRB 640, 840
3HAC 16640-1
145
145
146
146
147
148
149
150
151
151
152
153
154
155
156
157
157
158
159
160
161
162
163
164
165
166
166
167
168
169
170
170
171
172
173
174
175
176
177
iii
Table of Contents
Sheet 5-9. Servo Drive Units / IRB 4400, 6400S/PE

Sheet 5-10. Servo Drive Units / IRB 6400R
Sheet 5-11. Control Cable IRB 140
Sheet 5-12. Control Cable IRB 340, 1400 and 2400
Sheet 5-13. Control Cable IRB 640, 840, 4400 and 6400S/PE
Sheet 5-14. Control Cable IRB 6400R
Sheet 5-15. Rectifier, fans and bleeder
Sheet 5-16. Servo Drive System
Sheet 5-17. Control cable
System 6: External axes
Sheet 6-1. External axes

Sheet 6-2. Axes Computer 2 and Connector Board
Sheet 6-3. Expansion Board Axis Connector Board
Sheet 6-4. Drive System Signal Connection External Axes
Sheet 6-5. External axes no. 7th - 9th Control Signal Connection
Sheet 6-6. Axis Computer 2 and Axis Connector Unit if External Axis Cabinet
Sheet 6-7. Connection to External Axis Cabinet
Sheet 6-8. Servogun-SMB power/signals cable
System 7: I/O Units and Field Bus Modules
Sheet 7-1. I/O Unit Position

Sheet 7-2. Digital Part of Combi I/O and Digital I/O Unit Input Part
Sheet 7-3. Digital I/O Unit Output Part
Sheet 7-4. Combi I/O Unit Digital and Analogue Output Part
Sheet 7-5. Digital Input Part of 120V AC I/O Unit
Sheet 7-6. Digital Output Part of 120V AC I/O Unit
Sheet 7-7. Relay I/O Unit Input 1-16
Sheet 7-8. Digital with Relays I/O Output 1-8
Sheet 7-10. Analogue I/O Unit
Sheet 7-11. Remote I/O Unit For Allen Bradley PLC
Sheet 7-12. Interbus-S Master/Slave - Interbus-S Master
Sheet 7-13. Profibus DP SLave
Sheet 7-14. Encoder Unit
Sheet 7-15. Profibus DP Master/Slave
Sheet 7-16. Interbus master/slave optical fibre and copper wire
System 8: Other options
Sheet 8-1. Floppy Disk

Sheet 8-2. Service Equipment Supply
Sheet 8-3. External Connections System Signals
Sheet 8-4. Position Switches on Manipulator
iv
178
179
180
181
182
183
184
185
186
187
187
188
189
190
191
192
193
194
195
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
211
212
213
214
3HAC 16640-1
Table of Contents
Sheet 8-5. Customer Signals

Sheet 8-6. Sustomer Power/SIgnal IRB 2400, 4400, 6400S/PE
Sheet 8-7. Customer Cable Power/Signal/CAN IRB 6400R
Sheet 8-8. External Control Panel
Sheet 8-9. Extension Cable Teach Pendant
Sheet 8-10. Time Relay
Sheet 8-11. Customer Precess / Power / Signal / Profibus DP M/S
Sheet 8-12. Optional customer power/signal Profibus IRB 6400R
Sheet 8-13. LAN Ethernet connection
Sheet 8-14. Customer power/CAN-BUS IRB 640/6400S
Sheet 8-15. Customer cable power/signal CAN-BUS IRB 6600/7600
Sheet 8-16. Customer cable power/signal Profibus IRB 6600/7600
System 9: External Axis Cabinet

Sheet 9-2. View of External Axis Cabinet
Sheet 9-6. Power Supply, I/O Supply
Sheet 9-7. Power Unit
Sheet 9-9. Drive Unit Signal Connection 1 External Drive Unit
Sheet 9-10. Drive Unit Signal Connection 2 External Drive Units
Sheet 9-12. Drive Unit and Control Cable Drive Unit GT
Sheet 9-13. Drive Unit and Control Cable Drive Unit GT+CCB
Sheet 9-14. Drive Unit and Control Cable
3HAC 16640-1
215
216
217
218
219
220
221
222
223
224
225
226
227
228
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
Table of Contents
vi
3HAC 16640-1
Overview
About This
Manual
This information product is a manual containing instructions for repairing the

complete robot system, mechanically as well as electrically.
Usage
This manual should be used during repair work.
Who Should Read

This Manual?
Prerequisites
Organization of
Chapters
repair personnel in the users organization.
repair personnel in other organizations.
be a trained repair craftsman
have the required knowledge of mechanical repair work OR
have the required knowledge of electrical repair work.
The manual is organized in the following chapters:
Chapter
Contents
1.
Safety
2.
Reference information
3.
Manipulator
4.
Controller
References
3HAC 16640-1
Reference
Document Id
Circuit diagrams, Manipulator
Included in Repair Manual,

3HAC 16640-1
Reference
Document Id
Circuit diagrams, Controller
Included in Repair Manual,

3HAC 16640-1
Revisions
Revision
Description
First edition
3HAC 16640-1
General

Overview,
Installation and
Commissioning
Manual
Overview, Repair
Manual
Overview,
Maintenance
Manual
3HAC 16640-1
Safety, Service
Unpacking
Start-up
Robot controller
Calibration
Safety, Service

parts

spare parts
Safety, Service
Disposal
3HAC 16640-1
Safety, service

Introduction
Definitions
Sections
The chapter "Safety, service" is divided into the following sections:


dangers.
Fire extinguishing
Brake testing
3HAC 16640-1
Safety, service
Validity and
responsibility
Connection of
external safety
devices
3HAC 16640-1
Safety, service
References
General
Standards
3HAC 16640-1


test)
immunity test)
Safety, service
References
Related information
General
Documents
Type of information
Users Guide
Section
Start-up
3HAC 16640-1
Safety, service
Safety risks

Safe handling
Safe design

General
Residual energy
Safe design
3HAC 16640-1

Safety, service
Safety risks
General
Qualified
personnel
Extraordinary
risks
rectified manually.

and service
Nation/region
10


3HAC 16640-1
Safety, service
Safety risks
Non-voltage
related risks
To be observed
by the supplier of
the complete system

suitable devices.

objects.
robot.
Voltage related
risks, general
3HAC 16640-1

11
Safety, service
Safety risks
Voltage related
risks, controller,
S4Cplus
The power unit
machining process
Voltage related
Voltage related
devices, etc.
12
3HAC 16640-1
Safety, service
Safety actions

General
Dimensioning the
fence or enclosure
projectiles that they may be subjected to. Windows must be made from
suitable safety glass. Study the planned process to determine the forces

Fire extinguishing
3HAC 16640-1
13
Safety, service
Safety actions
Description
released.
Increased injury
Brake testing
When to test
How to test
below:
14
3HAC 16640-1
Safety, service
Safety actions


MOTORS OFF state.

must be observed:
3HAC 16640-1
15
Safety, service
Safety actions
16
3HAC 16640-1

Introduction
General
3HAC 16640-1
17
Screw joints
General
materials and does not apply to soft or brittle materials.
Tightening torque
Screws with
slotted or cross
recess head
Screws with
hexagon socket
head
18
tables below:
Dimension
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
Tightening
torque (Nm)
Class 12.9
M5
M6
10
17
M8
24
28
40
M10
47
55
70
M12
82
95
120
3HAC 16640-1
3HAC 16640-1
Dimension
Tightening
torque (Nm)
Class 8.8 "dry"
Tightening
torque (Nm)
Class 10.9
Tightening
torque (Nm)
Class 12.9
M16
200
235
300
19
Definition
Within all repair and maintenance instructions, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are highlighted in this way.
Example

20
3HAC 16640-1
Manipulator
Chapter 3:Manipulator
Introduction
Definitions
This chapter details all repair activities recommended for the manipulator, including the manipulators distribution box.
It is made up of separate units, each detailing a specific repair activity, e.g.
Removal or Refitting 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:
3HAC 16640-1
Removal/refitting instructions for all the spare parts on the manipulator
Replacement instructions for all the spare parts in the manipulators distribution box
21
Manipulator
Manipulator repairs
Section A: Manipulator repairs

Removal of actuator, including motor
Location
The three actuators are located on the manipulator as shown in the figure below.
D
A
C
xx0200000296
22
3HAC 16640-1
Manipulator
Manipulator repairs
Actuator
Actuator servomotor
Lower joint
Actuator fork
Center tube
Wrist
Required equipment
Equipment, etc.
Hook wrench
Note
3 mm pin, shown in
figure the below!
xx0200000350
Safety
Hook wrench with 3 mm pin
Please read the following notations before the removal.

Please observe the following before commencing any repair work on the manipulator:
- Some parts are HOT after running the robot, e.g. motors and lights! Burns may
result from touching them!
- Turn off all electrical power, hydraulic and pneumatic pressure supplies to the
robot!
3HAC 16640-1
23
Manipulator
Manipulator repairs
- When replacing motors/reducers, make sure that those parts of the robot which
could move unexpectedly are mechanically blocked as specified in the individual
procedures.
- Before removing, clean the work area and the components to be removed.
- Place the removed components in a clean container.
Preparatory work
Follow the instructions below for preparatory work, before commencing to

remove an actuator.
Step
24
Action
Note/Illustration
1.
Run the actuators to half way in length, and

ensure all the actuators are of equal length.
This is done in order to allow the actuator to
retract when the lower joint is unscrewed.
2.
Switch off the power supply.
3.
The weight of an actuator is around 40kg (88lb). Shown in the figure

Before removal, the actuator must therefore be above!
secured using straps, as the center unit will tend
to move away from the corner with the removed
actuator.
If the manipulator is vertically orientated, it is
important to anchor the center tube to the surrounding equipment in order to prevent this. For
other orientations, try to anticipate the movement
and secure accordingly.
3HAC 16640-1
Manipulator
Manipulator repairs
Removal of actuator
The procedure below details how to remove an actuator, including the motor. The
procedure is the same for all actuators. Make sure the preparatory work above is
done before removing an actuator!
Step
3HAC 16640-1
Action
Note/Illustration
1.
Remove the eletric cabling from the servomotor located on the actuator to be
removed.
Move and secure the cabling so it can not
get damaged during removal of the actuator.
2.
Secure the actuator from above using

straps from a hoist or from the forks of a
fork lift.
3.
Use a heating gun to loosen the threadlocking substance, before unscrewing the
lower joint from the lower platform.
4.
To release the bottom end of the actuator Shown in the figure above!
from the lower platform, unscrew the lower Specified above!
joint using thehook wrench.
Make sure the center tube and wrist are
anchored as detailed in the preparatory
work above!
5.
Unscrew the four attachment screws hold- Shown in the figure above!
ing the actuator to the actuator fork.
6.
Gently remove the actuator and lift it safely

to a flat surface.
7.
Inspect the actuator fork and the thread in

the lower platform for damage.
8.
If only the actuator is to be replaced,

remove the servomotor as detailed below.
25
Manipulator
Manipulator repairs
Removal of motor
The procedure below details how to remove the motor from a dismounted actuator.
Step
1.
Action
Note/Illustration
Unscrew the four fixing screws

that hold the servomotor to the
actuator housing.
A
B
D
C
xx0200000302
26
2.
Remove the servomotor from

the actuator.
3.
If the toothed wheel ring stays

with the backlash-free coupling
attached to the actuator (shown
in the figure above), detach it
and fit it to the coupling on the
servomotor.
4.
Remove the coupling from the

actuator shaft.
A: Servomotor
B: Fixing screws (4 pcs)
C: Toothed wheel ring
D: Backlash-free coupling
3HAC 16640-1
Manipulator
Manipulator repairs
Refitting of actuator, including motor
Location
The actuators are located as shown in the figure below.
D
A
C
xx0200000296
3HAC 16640-1
Actuator
Actuator servomotor
27
Manipulator
Manipulator repairs
Lower joint
Actuator fork
Center tube
Wrist
Required equipment
Equipment, etc.
Actuator with motor
3HAC 17151-1
Note
Thread-locking substance
e.g. Loctite 242.

Used when securing
the lower joint to the
lower platform.
Hook wrench
3 mm pin
xx0200000350
Safety
Please read the following notations before refitting.

28
3HAC 16640-1
Manipulator
Manipulator repairs
robot!
procedures.
Please observe the following when refitting components:
- Carefully clean the mating surfaces.
- Ensure that there are no damaged surfaces or other parts that need rectifying or
replacing.
- Replace all gaskets.
Refitting of motor
In case the servomotor has been removed from the actuator, refit it as detailed in
procedure below.
Step
1.
Action
Note/Illustration
Fit the backlash-free coupling

onto the new actuator.
Make sure the shaft lies flush
with the coupling surface, as
shown in figure to the right.
xx0200000303
3HAC 16640-1
A: Actuator shaft
B: 0mm
29
Manipulator
Manipulator repairs
Step
2.
Action
Note/Illustration
Assemble the servomotor, back- 4 pcs; tightening torque: 24 Nm.

lash-free coupling and the actuator. Tighten the fixing screws of
the motor.
A
B
D
C
xx0200000302
Refitting of actuator
A: Servomotor
D: Backlash-free coupling
The procedure below details how to refit the actuator, including the motor. The
procedure is the same for all actuators.
Step
30
Action
Note/Illustration
1.
Refit the motor, in case it has been

removed, as detailed above.
2.
Place the actuator in the actuator

fork by lifting it with a hoist.
Shown in the figure above!
3HAC 16640-1
Manipulator
Manipulator repairs
Step
3.
Action
Note/Illustration
Push the actuator to the left so that

it is flush with the left hand side of
the fork, as shown with the arrow
in figure to the right.
The direction is the same for all
three actuators.
A
B
xx0200000304
A: Clamp
B: Circlip
4.
Adjust the circlip so that the actuator remains tight against the left
hand side.
5.
Fit the clamps and tighten the four 4 pcs; tightening torque: 10 Nm.
hexagonal screws that hold the
clamps.
6.
Fit the sealing caps onto either

side of the actuator fork as shown
in figure to the right.
xx0200000305
3HAC 16640-1
A: Sealing cap
31
Manipulator
Manipulator repairs
Step
Commissioning
Action
Note/Illustration
7.
Refit the actuator by screwing the Shown in the figure above!

lower joint to the lower platform.
Use normal thread-locking fluid.
Note that, as each turn of the lower
joint will alter the length of the
actuator by 10 mm, the actuator
will be extended around 150 mm
as the universal joint is screwed in.
8.
Attach the supplied labels to the

actuator and motor; the warning
label close to the actuator fork and
the appropriate axis label on the
housing of the actuator.
9.
Reconnect the cables to the servomotor.
Follow the instructions below before commissioning after refitting an actuator.
Step
Action
Note/Illustration
1.
Check the manipulator and its surrounding

equipment to ensure that all screws, nuts and
bolts are tightened and that no foreign objects
remain within the workspace.
2.
Recalibrate the robot.

Failure to calibrate the robot will seriously
affect the performance and can, in the worst
case, cause damage to equipment.
3.
When the spare part replacements have been

completed, ensure that the machine data
folder is updated, specifying all details such
as what has been replaced and when, part
serial numbers and other related component
data.
Detailed in Installation
Manual.
When performing the first test run after a service activity (repair, installation or
maintenance), it is vital that:
- all normal safety equipment is installed properly, e.g. TPU enabling device.
32
3HAC 16640-1
Manipulator
Manipulator repairs
- 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.
3HAC 16640-1
33
Manipulator
Manipulator repairs
Removal of servomotor, axes 1-3
Location
The servomotors of axes 1, 2 and 3 are located on top of the actuators, as shown
xx0200000297
34
Servomotors, axes 1-3
3HAC 16640-1
Manipulator
Manipulator repairs
Required equipment
Safety
Equipment, etc. Spare part no. Art. no.
Note
Circuit Diagram
Repair Manual, part 2
3HAC 16640-1

robot!
procedures.
Preparatory work
Follow the instructions below for preparatory work, before commencing the
removal of a motor.
Step
3HAC 16640-1
Action
Note/Illustration
1.
Support the wrist before disconnecting the servomotor from the actuator, in order to keep the lower
platform stable and reduce the risk of injury and/or
damage.
2.
3.
The weight of an actuator servomotor is around

14kg (31lb). The actuator may therefore need to
be secured using straps before being removed.
35
Manipulator
Manipulator repairs
Step
4.
Removal
Note/Illustration
The actuator is free to turn when the servomotor is

removed. If not correctly supported, the center unit
will tend to move away from the corner with the
removed actuator servomotor. In a vertically orientated manipulator, it is important to anchor the center tube to the surrounding equipment in order to
prevent this.
For manipulators in other orientations, try to anticipate the movement and secure accordingly.
The procedure below details how to remove the servomotor, axes 1, 2 and 3.
Step
36
Action
Action
Note/Illustration
1.
Remove the eletric cabling from

the servomotor.
Move and secure the cabling so
that it can not get damaged during the removal of the actuator.
2.
Unscrew the four fixing screws

that hold the servomotor to the
actuator housing, as shown in
the figure below.
3.
Lift the servomotor straight up

from the actuator.
3HAC 16640-1
Manipulator
Manipulator repairs
Step
4.
Action
Note/Illustration
If the toothed wheel ring stays

with the backlash-free coupling
attached to the servomotor,
detach it and fit it to the coupling
on the actuator.
A
B
D
C
xx0200000302
5.
3HAC 16640-1
A: Servomotor
D: Backlash-free coupling on
servomotor shaft
Remove the coupling from the

servomotor shaft.
37
Manipulator
Manipulator repairs
Refitting of servomotor, axes 1-3
Location
The servomotors of axes 1, 2 and 3 are located on top of the actuators, as shown
xx0200000297
38
Servomotors, axes 1-3
3HAC 16640-1
Manipulator
Manipulator repairs
Required equipment
Servomotor, axes
1-3
3HAC 17152-1
Circuit Diagram
Safety
Note
3HAC 16640-1
Please read the following notations before the refitting.

robot!
procedures.
replacing.
Refitting
3HAC 16640-1
The procedure below details how to refit the servomotor, axes 1-3.
39
Manipulator
Manipulator repairs
Step
1.
Action
Note/Illustration
Fit the backlash-free coupling Spare part no. specified above!

onto the new servomotor,
ensuring that the shaft enters
the coupling to a depth of 10
mm, as shown in figure to the
right.
A
xx0200000308
40
A: 10 0.5 mm
3HAC 16640-1
Manipulator
Manipulator repairs
Step
2.
Action
Note/Illustration
Assemble the servomotor,

4 pcs; tightening torque: 24Nm.
backlash-free coupling and
the actuator. Tighten the fixing
screws.
Note! The brake performance
is reduced if the servomotor
shaft is pushed in too far into
the actuator. Make sure there
B
is a lash. Measure the distance between the coupling
D
C
and the contact surface,
according to the figure to the xx0200000302
right.
A: Servomotor
D: Backlash-free coupling on the

servomotor shaft
A
79
51
xx0200000447
3.
3HAC 16640-1
A: Coupling on actuator shaft
B: Coupling on servomotor shaft
79 mm, required distance

between coupling and contact
surface on actuator.
51 mm, required distance

between coupling and contact
surface on servomotor.
Reconnect the cables to the

servomotor.
41
Manipulator
Manipulator repairs
Commissioning
Follow the instructions below before commissioning after refitting motor on axes
1, 2 and 3.
Step
Action
Note/Illustration
1.

2.

3.

data.
Manual.
42
3HAC 16640-1
Manipulator
Manipulator repairs
Removal of servomotor, axis 4
Location
The motor unit of axis 4 is located inside the center tube sleeve, at the lower part
of the center unit, as shown in the figure below.
B
C
A
xx0200000299
3HAC 16640-1
Axis 4 motor unit (located beneath center tube sleeve)
Center tube sleeve
Gimbal
Lower platform
43
Manipulator
Manipulator repairs
Required equipment
Note
Lifting bracket
String
Attach to the cabling to

be able to feed it
through the center tube
while lifting.
Circuit Diagram
Safety
3HAC 16640-1 Repair Manual, part 2

robot!
procedures.
The center unit is very heavy and in a vertically orientated robot, there is a risk of
pinching between the center tube and the axis 4 motor.
44
3HAC 16640-1
Manipulator
Manipulator repairs
Preparatory work
removal of the motor unit on axis 4.
Step
Removal
Note/Illustration
1.
Run the actuators so that they are extended to

around 500 mm in length. All actuators should
have equal length.
This is done in order to allow enough space
between the center tube sleeve and the center
tube.
2.
Position axes 4, 5 and 6 at 0respectively.
3.
The procedure below details how to remove the motor unit on axis 4. Make sure
the preparatory work above is done before removing the actuator!
Step
3HAC 16640-1
Action
Action
Note/Illustration
1.
Cut the straps and disconnect the

cabling to axes 4, 5 and 6, at the top of
the center tube. Also remove the cable
guide for the cabling.
2.
Remove the top plate of the center

tube.
The cabling underneath the lid is still
attached! Remove the lid carefully!
3.
Note the position of each connector

and remove the cable connector holders from the lid. Attach a string to the
cabling in order not to drop it into the
center tube when lifting.
See the figure below!
45
Manipulator
Manipulator repairs
Step
4.
Action
Note/Illustration
Remove the housing and the lower

plate, exercising care with the cables
inside the housing. See figure to the
right for layout.
A
B
C
D
xx0200000306
46
5.
Fit the lifting tool to the center tube,

ensuring that the cables can pass
through the loop freely and not get
caught.
6.
Remove the spiral cable cover on the

back of center tube sleeve. Remove
also the spiral cable inspection cover.
A: Top plate of center

tube
B: Cable connector
holder
C: Housing
D: Lower plate
E: Center tube
3HAC 16640-1
Manipulator
Manipulator repairs
Step
7.
Action
Note/Illustration
Unscrew the 18 screws that hold the

center tube to the axis 4 motor and
remove the locating pin, center tube.
A
B
D
xx0200000363
A: 6 pcs: M8.
B: 12 pcs: M6.
C: Locating pin, center

tube
D: Locating pin, center

tube sleeve
On reassembly the same locating pin is refitted!
3HAC 16640-1
8.
Lift the center tube, using a hoist or lift, Shown in the figure above!
until the bottom of the center tube
almost reaches the gimbal.
When lifting the center tube, be very
careful not to stretch or squash the
cables inside. Eliminate the risk of
stretching the cabling by feeding it
through at the top at the same rate as
the center tube is lifted, with the help
of a string.
9.
Remove the cable clamp that holds

the spiral cable in place.
47
Manipulator
Manipulator repairs
Step
Action
Note/Illustration
10.
Remove the 12 screws that hold the Shown in the figure above!
center tube sleeve to the lower platOn reassembly the same locatform interface.
ing pin is refitted!
Remove the locating pin that positions
the center tube sleeve.
11.
Lift the center tube sleeve, tilting the

wrist slightly for increased accessibility.
A
B
C
xx0200000307
48
12.
Make a note of the position of the

motor unit.
13.
Remove the spacer from the axis 4

motor unit.
14.
Unscrew the 8 screws that attach the

motor unit to the center shaft and
remove the motor unit.
15.
Check all surfaces to make sure they

are free from damage and contamination before proceeding with the
assembly routine.
A: center tube sleeve
B: Spacer
C: Axis 4 motor unit
3HAC 16640-1
Manipulator
Manipulator repairs
Refitting of servomotor, axis 4
Location
The motor unit of axis 4 is located inside the center tube sleeve, at the lower part
of the center unit, as shown in the figure below.
B
C
A
xx0200000299
3HAC 16640-1
Axis 4 motor unit (located inside the center tube sleeve)
Center tube sleeve
Gimbal
Lower platform
49
Manipulator
Manipulator repairs
Required equipment
Servomotor, axis 4
Note
3HAC 17153-1
Lifting bracket
Circuit Diagram
Safety
3HAC 16640-1

robot!
procedures.
replacing.
Refitting
The procedure below details how to refit the motor unit, axis 4.
Step
1.
50
Action
Note/Illustration
Fit the axis 4 motor unit to the center 8 pcs: tightening torque: 33
shaft and tighten the screws. Ensure it Nm.
has the same orientation as the old
one
3HAC 16640-1
Manipulator
Manipulator repairs
Step
2.
Action
Note/Illustration
Fit and align the spacer to the axis 4

motor unit.
A
B
C
xx0200000307
3HAC 16640-1
3.
Refit the center tube sleeve, ensuring

that the locating pin, center tube
sleeve, has the correct orientation.
Tighten the 12 screws that hold the
sleeve.
4.
Refit the cable clamp for the spiral

cable.
Ensure that the spiral cable runs freely
360in either direction by manually
turning the wrist and watching the
cable through the inspection hole in
the side of the center tube.
5.
Align the fixing holes in the axis 4

motor unit to the holes in the center
tube sleeve by turning the wrist.
6.
Feed the cabling through the center

tube (with the help of the string) and
lower the center tube carefully in order
not to squash the cables.
A: Center tube sleeve
B: Spacer
C: Axis 4 motor unit

12 pcs; tightening torque:
17Nm.
Make sure to refit the correct
locating pin!
51
Manipulator
Manipulator repairs
Step
7.
Action
Note/Illustration
Locate the center tube using the location pin, center tube, as reference and
fit the 18 screws.
A
B
D
xx0200000363
A: 6 pcs: M8; tightening

torque: 40 Nm.
B: 12 pcs: M6; tightening torque: 17 Nm.
C: Locating pin, center

tube
D: Locating pin, center

tube sleeve
Make sure to refit the correct

locating pin!
52
8.
Refit the spiral cable inspection cover

and the spiral cable cover, including
their sealings.
9.
Remove the lifting tool from the center

tube.
3HAC 16640-1
Manipulator
Manipulator repairs
Step
10.
Action
Note/Illustration
Refit the lower plate and the housing to

the top of the center tube, taking extra
care not to squash any cables, or subject them to any undue stress.
A
B
C
D
xx0200000306
3HAC 16640-1
11.
Fit the cable connectors to the top

plate, ensuring that the cables are orientated the same way as when they
were removed.
12.
Fit the top plate to the housing.
13.
Refit the cable guide for the axes 4, 5

and 6 cabling and reconnect the
cabling previously disconnected.
A: Top plate
B: Cable connector
holder
C: Housing
D: Lower plate
E: Center tube
53
Manipulator
Manipulator repairs
Commissioning
Follow the instructions below before commissioning after refitting the motor, axis
4.
Step
Action
Note/Illustration
1.

2.

3.

data.
Manual.
54
3HAC 16640-1
Manipulator
Manipulator repairs
Removal of lower joint
Location
The lower joint is located between the actuator and the lower platform, as shown
C
D
A
xx0200000298
3HAC 16640-1
Lower joint (beneath the cover)
Lower platform
Actuator
Calibration spacer
55
Manipulator
Manipulator repairs
Required equipment
Note
Hook wrench
3 mm pin
xx0200000350
Safety

robot!
procedures.
56
3HAC 16640-1
Manipulator
Manipulator repairs
Preparatory work
removal of the lower joint.
Step
Removal
Note/Illustration
1.
Run actuators to half way in length. All the actuators should also have an equal length.
This is done in order to allow the actuator to retract
when the lower joint is unscrewed.
2.
3.
In a vertically orientated manipulator the center

unit will tend to move away from the corner with the
removed lower joint. It is therefor important to
anchor the center tube to the surrounding equipment in order to avoid this. For manipulators in
other orientations, try to anticipate the movement
and secure accordingly.
The procedure below details how to remove a lower joint. The procedure is the
same for all actuators. Make sure the preparatory work above is done before separating the parts!
Step
3HAC 16640-1
Action
Action
Note/Illustration
1.
Use a heating gun to loosen the thread-locking substance, before removing the lower
joint.
2.
Loosen the actuator piston from the lower

joint with the hook wrenches.
The actuator is top heavy and will tend to
swing, once disconnected at the bottom.
Ensure that the actuator is well anchored.
3.
Loosen the lower joint from the lower platform Shown in figure above!
using a hook wrench, 3 mm pin.
Specified above!
4.
Remove the lower joint and the cover.
5.
Remove the calibration spacer from the lower

joint, in order to refit it onto the new joint!
Shown in the figure

above!
Specified above!
57
Manipulator
Manipulator repairs
Refitting of lower joint
Location
The lower joint is located between the actuator and the lower platform, as shown
C
D
A
xx0200000298
58
Lower joint (beneath the cover)
Lower platform
Actuator
Calibration spacer
3HAC 16640-1
Manipulator
Manipulator repairs
Required equipment
Equipment, etc.
Lower joint
3HAC 17154-1
Note
e.g. Loctite 242.

Used when securing the lower joint to
the lower platform.
Hook wrench
3 mm pin
xx0200000350
Safety

robot!
procedures.
3HAC 16640-1
59
Manipulator
Manipulator repairs

replacing.
Refitting
The procedure below details how to refit the lower joint. The procedure is the
same for all actuators.
Step
Commissioning
Note/Illustration
1.
Fit the calibration spacer and the cover Spare part no. specified above!
to the new lower joint.
2.
Fit the lower joint to the actuator, using

normal thread-locking fluid.
3.
Refit the actuator by screwing the

lower joint into the lower platform.
Note that, as each turn of the lower
joint will alter the length of the actuator
by 10 mm, the actuator will be
extended around 150 mm as the universal joint is screwed in.
Follow the instructions below before commissioning after refitting the lower joint.
Step
60
Action
Action
Note/Illustration
1.

2.

Failure to calibrate a robot will seriously affect
the performance and can, in the worst-case,
cause damage to equipment.
Manual.
3HAC 16640-1
Manipulator
Manipulator repairs
Step
3.
Action
Note/Illustration

completed, ensure that the machine data folder
is updated, specifying all details such as what
has been replaced and when, part serial numbers and other related component data.
3HAC 16640-1
61
Manipulator
Manipulator repairs
Removal of wrist
Location
The wrist is located on the lower platform, as shown in the figure below.
E
C
F
A
xx0200000300
62
Wrist
Center tube
Gimbal
Center tube sleeve
Lower platform
3HAC 16640-1
Manipulator
Manipulator repairs
Required equipment
Note
Lifting bracket
Safety
Punch tool
Used for the crossed roller

bearing.
Lifting jack
Stroke of at least 100 mm.

robot!
procedures.
The wrist weighs 36 kg! All lifting equipment used must be dimensioned accordingly!
3HAC 16640-1
63
Manipulator
Manipulator repairs
Preparatory work
removal of the wrist unit.
Step
64
Action
Note/Illustration
1.

around 500 mm in length. All the actuators should
have equal length.
This is done in order to allow enough space
between the centre tube sleeve and the centre
tube.
2.
3.
3HAC 16640-1
Manipulator
Manipulator repairs
Removal
The procedure below details how to remove the wrist. Make sure the preparatory
work above is done before removing the wrist!
Step
1.
Action
Note/Illustration
Remove the 6 attachment screws that

hold the axis 4 motor unit to the centre
tube.
A
B
D
xx0200000363
3HAC 16640-1
A: Attachment screws,
axis 4 motor to centre
tube: 6 pcs, M8 x 60.
B: Attachment screws
C: Locating pin, centre

tube
D: Locating pin, centre

tube sleeve
2.
Remove the spiral cable cover on the Shown in the figure above!
back of centre tube sleeve and the spiral cable inspection cover on the
same sleeve.
3.
Remove the cable clamp that holds

the spiral cable in place.
65
Manipulator
Manipulator repairs
Step
Note/Illustration
4.
Unscrew 10 of the 12 screws in the

wrist flange that hold the wrist to the
lower platform. Turn the wrist to
access all the screws.
Leave one screw at the front and one
at the rear of the wrist, but ensure that
they are both accessible for removal
without having to turn the wrist.
5.
Position the lifting jack underneath the

wrist housing, in its extended position,
so that it can lower the wrist at least
100 mm without being repositioned.
6.
Remove the final two screws.
7.
Lower the wrist gently until the screws

that attach the centre shaft to the wrist
are accessible.
If the wrist appears to be stuck, it
needs to be pressed out. Use two of
the fixing holes for the wrist/lower platform joint, that are threaded M8 and lie
180in relation to each other.
Note! Turn the wrist so that these
holes are not aligned with the M6
holes in the lower platform, as this will
damage the threads and hamper
assembly at a later stage. If possible,
insert a metal shim to protect the surface of the lower platform flange.
Insert two M8 bolts, with at least 40
mm of thread, into the holes, and pull
the wrist off the lower platform.
8.
66
Action
xx0200000364
Remove the screws and lower the

wrist while disconnecting the cabling.
Note! When removing the wrist: make
sure it is lowered carefully, following
the same orientation when mounted. If
tilted, the interface of the wrist and the
lower platform may be damaged!
3HAC 16640-1
Manipulator
Manipulator repairs
Refitting of wrist
Location
The wrist is located on the lower platform, as shown in the figure below.
E
C
F
A
xx0200000300
3HAC 16640-1
Wrist
Center tube
Gimbal
Center tube sleeve
Lower platform
67
Manipulator
Manipulator repairs
Required equipment
Safety
Equipment, etc.
Wrist
3HAC 17155-1
Note
Punch tool
Used for the

crossed roller
bearing.
Lifting jack
Stroke of at least
100 mm.

robot!
procedures.
replacing.
The wrist weighs 36 kg! All lifting equipment used must be dimensioned accordingly!
68
3HAC 16640-1
Manipulator
Manipulator repairs
Refitting
The procedure below details how to refit the wrist.
Step
Action
Note/Illustration
1.
Replace the o-ring on the centre shaft

with the new one that is included in the
spare parts kit. Ensure that the o-ring is
lubricated prior to fitment.
2.
Ensure that the jack is correctly positioned underneath the lower platform, and
that it is in its lowest position. Place the
wrist on the jack.
3.
Reconnect the cabling.
4.
Elevate the wrist with the jack and guide it

so that it fits onto the centre shaft. Ensure
that the cabling is guided into the correct
position and does not get jammed.
Note! Make sure the wrist is elevated in
the same direction that the centre tube is
pointing, so that the interfaces are not
damaged!
5.
Attach the centre shaft to the wrist using

the 12 screws.
xx0200000367
3HAC 16640-1
12 pcs; tightening torque: 17

Nm.
69
Manipulator
Manipulator repairs
Step
Commissioning
Note/Illustration
6.
Lift the wrist with the jack until it is possi- 12 pcs; tightening torque: 10
ble to fasten the attachment screws
Nm.
through the wrist flange into the lower
platform. Press the wrist to its topmost
position by tightening two of the attachment screws, 180in relation to each
other.
Check that the bearing runs smoothly by
turning the wrist manually.
7.
Refit the spiral cable clamp and ensure

that the spiral cable twists freely throughout the 360of the axis 4 rotation.
It must not catch or have any tendency to
rub or over-tighten, as this will drastically
shorten the life of the cable.
8.
Align the holes in the centre tube sleeve

with the holes in the axis 4 motor unit by
turning the wrist.
9.
Fit the six M8 screws. Tighten them as

detailed to the right.
6 pcs: M8; tightening torque:

40 Nm.
10.
Refit the spiral cable cover and the spiral Shown in the figure above!
cable inspection cover with their sealings.
Follow the instructions below before commissioning after refitting.
Step
70
Action
Action
Note/Illustration
1.

2.

Manual.
3HAC 16640-1
Manipulator
Manipulator repairs
Step
3.
Action
Note/Illustration

3HAC 16640-1
71
Manipulator
Manipulator repairs
Removal of center unit
Location
The center unit includes the center tube, wrist, spiral cable, linear guide and axis
4 motor unit. It is located in the center of the manipulator, as shown in the figure
below. When removed, the housing and the gimble is left mounted on the center
unit, as shown in the figure below.
C
I
H
G
E
B
A
F
xx0200000301
72
Center unit
Lower joint
Wrist unit
Upper platform
Center tube
Gimbal
Axis 4 motor unit (inside center

tube sleeve)
Linear guide
Lower platform
3HAC 16640-1
Manipulator
Manipulator repairs
Required equipment
Equipment, etc.
Hook wrench
Note
3 mm pin
xx0200000350
Safety

robot!
procedures.
The center unit weighs over 100 kg! All lifting equipment must be dimensioned
accordingly!
3HAC 16640-1
73
Manipulator
Manipulator repairs
Preparatory work
removal of the center unit.
Step
Removal
Note/Illustration
1.

have equal length.
This is done in order to allow enough space for the
center unit to be removed.
2.
3.
The procedure below details how to remove the center unit. Make sure the preparatory work above is done before removal!
Step
1.
74
Action
Action
Note/Illustration
Disconnect the cabling running

into the center unit, at the top of
the center unit.
3HAC 16640-1
Manipulator
Manipulator repairs
Step
2.
Action
Note/Illustration
Secure the center unit with a

strap attached to a hoist or lift.
Fasten the strap around the
body of the center tube just
below the upper housing so
that it hangs well balanced, in
such a way that the center unit
will be easy to handle.
Note! The center unit weighs
over 100 kg and must be
secured properly when the gimbal and actuator joints are disconnected as the unit will tend
to move suddenly as it is top
heavy.
xx0200000365
3HAC 16640-1
3.
Use a heating gun at the lower

joint, to loosen the thread-locking substance before removing
the joint.
4.
Remove the actuators from the Shown in the figure above!

lower platform by disconnect- Specified above!
ing the lower joints from the
lower platform using the hook
wrench.
Note! The actuators are top
heavy and will turn when
released from the lower platform. Ensure that they are fastened before releasing them
after removal.
75
Manipulator
Manipulator repairs
Step
5.
Action
Note/Illustration
Remove the center unit from

the upper platform by removing
the 4 attachment screws,
located as shown in the figure
to the right.
Note! The gimbal weighs
approximately 20 kg, be careful A
when removing the attachment
screws!
xx0200000309
76
A: Attachment screws that hold

the gimbal to the upper platform (4 pcs)
6.
Lower the gimbal to the bottom Shown in the figure above!

of the run of the linear guides
so that it rests securely. Secure
it to the center unit so that it
does not turn or move suddenly
when the center unit is
released.
7.
Lower the center unit with the

hoist.
3HAC 16640-1
Manipulator
Manipulator repairs
Refitting of center unit
Location
The center unit includes the center tube, wrist and axis 4 motor unit. It is located
in the center of the manipulator, as shown in the figure below. When removed, the
housing and the gimble is left mounted on the center unit, as shown in the figure
below.
C
I
H
G
E
B
A
F
xx0200000301
3HAC 16640-1
Center unit
Lower joint
Wrist
Upper platform
Center tube
Gimbal
Axis 4 motor unit (inside center

tube sleeve)
Linear guide
Lower platform
77
Manipulator
Manipulator repairs
Required equipment
Equipment, etc.
Center Unit
3HAC 17156-1
Note
e.g. Loctite 242.

Used when securing
the lower joint to the
lower platform.
Hook wrench
3 mm pin
xx0200000350
Safety

robot!
procedures.
78
3HAC 16640-1
Manipulator
Manipulator repairs

replacing.
The center unit weighs over 100 kg! All lifting equipment must be dimensioned
accordingly!
Refitting
The procedure below details how to refit the center unit.
Step
3HAC 16640-1
Action
Note/Illustration
1.
Lift the center unit in position with the hoist.
2.
Insert the four screws that Shown in the figure above!

hold the gimbal to the upper
platform, but do not tighten
them. Just screw them in to
the point where it is still possible to move the gimbal in
relation to the upper platform.
79
Manipulator
Manipulator repairs
Step
3.
Action
Note/Illustration
Push the gimbal to the left

(as seen when facing the
front of the robot) so that the
surfaces of the master lie
flush, as shown in the figure
to the right.
B
C
xx0200000310
80
A: center unit
B: Gimbal
C: Upper platform
D: Master
E: Direction for pushing the gimbal
4.
Tighten the 4 screws.
5.
Refit the actuators by

screwing the lower joint of
each actuator to the lower
platform, with the hook
wrench and using normal
thread-locking fluid.
Note that, as each turn of
the lower joint will alter the
length of the actuator by 10
mm, the actuator will be
extended around 150 mm
as the universal joint is
screwed in.
4 pcs; tightening torque: 40 Nm.
3HAC 16640-1
Manipulator
Manipulator repairs
Commissioning
Follow the instructions below before commissioning after refitting the center unit.
Step
Action
Note/Illustration
1.

2.

Failure to calibrate the robot will seriously affect Manual.
the performance and can, in the worst case,
3.

3HAC 16640-1
81
Manipulator
Manipulator repairs
Removal of spiral cable
Location
The spiral cable is located inside the center tube, running from the top of the
manipulator to the wrist unit.
C
A
xx0200000312
82
Spiral cable
Wrist unit
3HAC 16640-1
Manipulator
Manipulator repairs
Required equipment
Equipment, etc.

See references to
Safety
Note
These procedures
include references
to the tools
required.

robot!
procedures.
3HAC 16640-1
83
Manipulator
Manipulator repairs
Preparatory work
removal of the spiral cable.
Step
Removal
Note/Illustration
1.

have equal length.
This is done in order to allow enough space for the
center tube to be removed.
2.
Position axes 4, 5 and 6 at 0 respectively.
3.
The procedure below details how to remove the spiral cable. Make sure the preparatory work above is done before removal!
Step
84
Action
Action
Note/Illustration
1.
Remove the axis 4 motor unit.
Detailed in Removal of servomotor, axis 4.
2.
Remove the wrist unit.
Detailed in Removal of wrist

unit.
3.
Remove the cable clamp that holds the

spiral cable to the center shaft and remove
the spiral cable.
3HAC 16640-1
Manipulator
Manipulator repairs
Refitting of spiral cable
Location
The spiral cable is located inside the center tube, running from the top of the
manipulator down to the wrist unit.
C
A
xx0200000312
3HAC 16640-1
Spiral cable
Wrist unit
85
Manipulator
Manipulator repairs
Required equipment
Equipment, etc.
Spiral Cable
3HAC 17157-1

See references to
Safety
Note
These procedures
include references
to the tools required.

robot!
procedures.
replacing.
86
3HAC 16640-1
Manipulator
Manipulator repairs
Refitting
The procedure below details how to refit the spiral cable.
Step
Action
Note/Illustration
1.
Fit the new spiral cable and refit

Spare part no. specified above!
the cable clamp that holds the spiral cable to the centre shaft.
Make sure that the spiral cable is
properly attached so that it can not
run up and down on the shaft.
Press down the spiral cable so that
the first bend is tightly secured
against the upper surface of the
shaft as shown in the figure to the
right!
2.
Refit the wrist unit.
Detailed in Refitting of wrist unit.
3.
Refit the axis 4 motor unit.
Detailed in Refitting of servomotor,

axis 4.
xx0200000366
Commissioning
Follow the instructions below before commissioning after refitting the spiral cable
and wrist unit.
Step
1.
3HAC 16640-1
Action
Note/Illustration

87
Manipulator
Manipulator repairs
Step
Action
Note/Illustration
2.

Failure to calibrate the robot will seriously affect Manual.
the performance and can, in the worst case,
3.

88
3HAC 16640-1
Manipulator
Distribution box repairs
Section B: Distribution box repairs

Replacement of battery, distribution box
Location
The battery is located in the distribution box as shown in the figure below.
xx0200000394
3HAC 16640-1
Serial measurement card
Battery
89
Manipulator
Required equipment
Battery
Safety
Note
4944026-4
Please read the following notations before the replacement.

Please observe the following before commencing any repair work on the controller
or units connected to the controller:
Many components inside the cabinet or inside any external units are sensitive to
ESD (ElectroStatic Discharge) and will be destroyed if subjected to it!
Removal
The procedure below details how to remove the battery from the distribution box.
Step
90
Action
Note/Illustration
1.
Note the position of the battery and cable ties.
Shown in the figure

above!
2.
Remove the battery connector connecting the

battery to the serial measurement circuit board.
3.
Cut the two cable ties and remove the battery.

The battery must be disposed of through the
appropriate recycling channels.
3HAC 16640-1
Manipulator
Refitting
The procedure below details how to refit the battery to the distribution box.
Step
3HAC 16640-1
Action
Note/Illustration
1.
Place the new battery on top of the serial

measurement card cover.
Part no. specified above!

Shown in the figure
above!
2.
Use cable ties to fix the battery.
3.
Connect the electrical connector.
91
Manipulator
Replacement of serial measurement card, distribution box
Location
The serial measurement card is located in the distribution box as shown in the
figure below.
xx0200000394
92
Serial measurement card
Battery
3HAC 16640-1
Manipulator
Required equipment
Equipment, etc.
Serial Measurement card
Safety
Note
3HAC 14505-1

Removal
The procedure below details how to remove the serial measurement card from the
distribution box.
Step
3HAC 16640-1
Action
Note/Illustration
1.
Remove the four electrical connectors attached

to the serial measurement card.
2.
Remove the three screws holding the card and

the battery to the enclosure.
3.
Remove the serial measurement card together

with the battery.
Shown in the figure

above!
4.
Remove the battery from the card.
The battery is refitted

on to the new card.
93
Manipulator
Refitting
The procedure below details how to refit the serial measurement card to the distribution box.
Step
94
Action
Note/Illustration
1.
Fit the battery to the new serial measurement

card.
Part no. specified

above!
Shown in the figure
above!
2.
Carefully fit the card and the battery in place.
3.
Refit the three screws holding the serial measurement card and the battery to the enclosure.
4.
Refit the four electrical connectors.
3HAC 16640-1
Manipulator
Replacement of brake release card, distribution box
Location
The brake release card is located in the distribution box as shown in the figure
below.
xx0200000393
3HAC 16640-1
Brake release card
Brake release buttons
95
Manipulator
Required equipment
Equipment, etc.
Brake Release card
Safety
Note
3HAC 0017-1

Removal
The procedure below details how to remove the brake release card from the distribution box.
Step
96
Action
Note/Illustration
1.
Remove the three electrical connectors attached

to the brake release card.
2.
Remove the four screws holding the card to the

enclosure.
3.
Remove the brake release card.
Shown in the figure

above!
3HAC 16640-1
Manipulator
Refitting
The procedure below details how to refit the brake release card to the distribution
box.
Step
3HAC 16640-1
Action
Note/Illustration
1.
Carefully fit the new brake release card in

place.
Part no. specified above!

Shown in the figure
above!
2.
Refit the four screws holding the brake

release card to the enclosure.
3.
Replace the three electrical connectors.

Note! It is very important that all screening is
reconnected correctly in order to achieve
maximum performance from the equipment.
97
Manipulator
98
3HAC 16640-1
Controller repair
Chapter 4:Controller
Introduction
Definitions
This chapter details all repair activities recommended for the controller.
It is made up of separate units, each detailing a specific repair activity, e.g.
Removal or Refitting 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:
3HAC 16640-1
Removal instructions for all components
Refitting instructions for all components
Remaining instructions
99
Controller repair
Putting the computer unit in the service position
Location of computer unit
The computer unit is located as shown in the figure below.
A
xx0200000105
Opening
Computer unit
The procedure below details how to open the computer unit.

- 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.
100
3HAC 16640-1
Controller repair
Step
Action
Note/Illustration
1.
Make sure the ESD-wrist

band is worn and connected
to ground.
2.
Disconnect all connectors/

cables and make sure they
do not obstruct pulling the
computer unit out.
3.
Unscrew the transport locks

in both corners of the computer unit. This is done by
turning the screw two turns
(see position 1 in the figure)
and pushing the lock washers towards the screw (see
position 2).
4.
Lift the two handles and

push them together to
release the computer unit
(see position 1 in the figure).
xx0200000016
xx0200000017
5.
3HAC 16640-1
Push the locking device on See the figure above!

the front of the computer unit
to the right (see position 2 in
the figure).
101
Controller repair
Step
Action
Note/Illustration
6.
Pull the computer unit out of

the cabinet until it locks in its
end position. Then swing it
to the left as shown in the
figure.
7.
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 on a work bench.
xx0200000018
Closing
The procedure below details how to close the computer unit.

- 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.
Step
1.
102
Action
Note/Illustration
Swing the computer unit back into

position and secure it.
See the figure above!

Also see the procedure above!
3HAC 16640-1
Controller repair
Location of air filter
The air filter is located in the air filter magazine in the front hatch.
A
xx0200000284
Air filter magazine
Required equipment
Equipment, etc.
Air filter
3HAB 8028-1

See references to
3HAC 16640-1
Note
These procedures include references to the
tools required.
103
Controller repair
Removal, air filter
The procedure below details how to remove the air filter.
Step
Action
Note/Illustration
1.
Open the bottom of the air filter

magazine as shown in the figure.
2.
Unlock the lower springs. Lower

the magazine and remove.
3.
Remove the old filter by releasing

the lock shackle and lifting it.
Note! In cases of less contamination, the air filter may be cleaned
and refitted. The procedure for
this is detailed in section "Cleaning the air filter, controller" in the
Maintenance Manual.
xx0200000001
xx0200000003
Refitting, air filter
The procedure below details how to refit the air filter.
Step
1.
104
Action
Note/Illustration
Fit the air filter in the magazine. Art. no. is specified above!
3HAC 16640-1
Controller repair
Step
2.
Action
Note/Illustration
Fit the spring at the top of the air

filter magazine into the cabinet
door and push upwards inwards.
Push until the lower springs
snap into the cabinet door.
xx0200000006
3HAC 16640-1
105
Controller repair
Location of battery unit
The battery unit is located at the bottom of the controller.
A
xx0200000103
Battery unit
Required equipment
106
Equipment, etc.
Spare part no. Art no.
Note
Battery unit
3HAC 5393-2
To be replaced as
a complete unit
3HAC 16640-1
Controller repair
Equipment, etc.
Note

See references to
Removal, battery
unit

tools required.
The procedure below details how to remove the battery unit.
Turn off all electric power supplies to the cabinet!
Step
1.
Action
Note/Illustration
Remove the battery unit by

unscrewing its attachment
screws (1).
X1
X1
X1
X2
X2
X2
X1
X2
X3
xx0200000004
2.
3HAC 16640-1
Pull the battery unit out.
107
Controller repair
Step
3.
Action
Note/Illustration
Disconnect the three cables

from the battery unit.
xx0200000005
Refitting, battery
unit
The procedure below details how to refit the battery unit.
Step
108
Action
Note/Illustration
1.
Place the battery unit close to its position.
Art. no. specified above!

See illustration above!
2.
Reconnect the cables and push the unit into

position.
3.
Secure it with the attachment screws.
3HAC 16640-1
Controller repair
Replacement of I/O and gateway units
Location of I/O
and gateway units
The I/O and gateway units are located as shown in the figure below.
xx0200000009
3HAC 16640-1
I/O and gateway units located beneath the top cover of the cabinet
Four available slots for I/O and gateway units
109
Controller repair
Required equipment
Equipment, etc.
Removal
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
3HNE00006-1 DSQC 351
Gateway for Profibus DP,

slave unit
3HNE00009-1 DSQC 352
The procedure below details how to remove an I/O or gateway board.

Step
1.
110
Action
Note/Illustration
Disconnect any connec- The actual number of connectors vary

tors from the unit. Note depending on type of unit.
which connector goes
where, to facilitate reassembly.
3HAC 16640-1
Controller repair
Step
2.
Action
Note/Illustration
Lift the unit until the

upper claw, that holds
the unit to the rail, is
released. Use:
a screwdriver
when replacing
I/O units (position 2a in the figure).
by hand when
replacing a gateway unit (position 2b in the
figure).
2a
3a
2b
3b
xx0200000010
3.
Refitting
With the upper claw

released, tip the unit
away from the mounting
rail and remove it (positions 3a and 3b in the
figure).
The procedure below details how to refit an I/O or gateway board.

Step
1.
3HAC 16640-1
Action
Note/Illustration
Hook the unit back onto the mounting rail and

snap it gently in position.
111
Controller repair
Step
2.
112
Action
Note/Illustration
Reconnect all connectors disconnected during

removal.
3HAC 16640-1
Controller repair
Replacement of bleeder resistor
Location of
bleeder resistor
The bleeder resistor is located behind the drive units, as shown in the figure below.
xx0200000007
3HAC 16640-1
Drive units
Bleeder resistor unit
System fan unit
Rectifier (drive unit)
Power supply unit
113
Controller repair
Required equipment
Removal
Equipment, etc.
Bleeder resistor
3HAC 4560-5
Note
The procedure below details how to remove the bleeder resistor.

Step
Action
Note/Illustration
1.
Swing the power supply Detailed in section "Replacement of power

unit out of the way.
supply unit".
2.
Remove the drive units. Detailed in section "Replacement of drive units

and rectifier".
3.
Disconnect the cable

secured on top of the
bleeder resistor unit
1
2
xx0200000015
4.
114
Remove the bleeder

resistor unit from the
enclosure (see position
2 in the figure).
3HAC 16640-1
Controller repair
Refitting
The procedure below details how to refit the bleeder resistor.

Step
3HAC 16640-1
Action
Note/Illustration
1.
Fit the bleeder resistor into position and

secure it with the spring.

Also see the figure
above!
2.
Secure the cable disconnected during disassembly.
3.
Refit the drive unit.
Detailed in section
"Replacement of drive
units and rectifier".
4.
Swing the power supply unit back into position.
Detailed in section
"Replacement of power
supply unit".
115
Controller repair
Replacement of mass storage memory
Location of mass
storage memory
The mass storage memory is located in the computer system, which is shown in
the figure below.
A
xx0200000105
Computer system
Required equipment
Equipment, etc.
Note
Mass storage memory, 3HAC 7519-2

64 MB
Mass storage memory, 3HAC 7519-3
128 MB
116
3HAC 16640-1
Controller repair
Equipment, etc.
Note

See references to
Removal

tools required.
The procedure below details how to remove the mass storage memory.
Step
Action
Note/Illustration
1.
Put the computer unit in the

service position.
Detailed in section "Putting the computer in the service position".
2.
Remove the cover from the

right side of the computer system by unscrewing the ten M5
screws (item 1 in the figure).
xx0200000019
3.
3HAC 16640-1
Disconnect the connectors

X1 and X2 from the front of
the mass storage memory
(item 2 in the figure).
See figure above!
117
Controller repair
Step
4.
Refitting
Action
Note/Illustration
Remove the mass storage

See figure above!
memory by unscrewing its M4
attachment screws as shown
in the figure (items 3 and 4 in
the figure).
The procedure below details how to refit the mass storage memory.
Step
1.
Action
Note/Illustration
Fit the mass storage mem- Art. no. is specified above!

ory in position and secure it
1
with its M4 attachment
screws (items 3 and 4 in
the figure)
3
xx0200000019
2.
118
Reconnect connectors X1 See the figure above!

and X2 to the front of the
computer unit (item 2 in the
figure).
3HAC 16640-1
Controller repair
Step
3HAC 16640-1
Action
Note/Illustration
3.
Refit the cover on the right See the figure above!

side of the computer unit
and secure it with its ten M5
attachment screws (item 1
in the figure).
4.
Put the computer system

Detailed in section "Putting the computer in
back in its regular operation the service position".
position.
119
Controller repair
Replacement of internal cooling fan
Location of internal cooling fan
The internal cooling fan is located in the computer system, which is shown in the
figure below.
A
xx0200000105
Computer system
Required equipment
Equipment, etc.
Note
Internal cooling fan
3HAC 6655-1
Two fans required

See references to
120
These procedures
include references
to the tools
required.
3HAC 16640-1
Controller repair
Removal
The procedure below details how to remove the internal cooling fan.
Step
1.
3HAC 16640-1
Action
Note/Illustration
Put the computer unit in the service position.
Detailed in "Putting the computer in

the service position".
121
Controller repair
Step
2.
Action
Note/Illustration
Disconnect the connector E5 or

E6 respectively, depending on
which fan is to be replaced.
E
xx0200000020
3.
Refitting
Remove the internal cooling fan

inwards by gently pressing the
locking tabs upwards.
A: Upper fan
B: Lower fan
C: Locking tabs
D: Connector E5
E: Connector E6
The procedure below details how to refit the internal cooling fan.
122
3HAC 16640-1
Controller repair
Step
1.
Action
Note/Illustration
Tip the internal cooling fan with its top towards Art. no. specified above!
the cabinet wall and fit it into the hole (see the
figure).
xx0200000021
2.
3HAC 16640-1
With the wall between the upper lock spring

hooks, push the fan unit upward and inward
until the locking tab snaps to the wall.
A: Push direction
123
Controller repair
Step
124
Action
Note/Illustration
3.
Reconnect the connector E5 or E6 respectively, depending on which fan was replaced.
4.
Put the computer unit back in the regular

operation position.
Detailed in "Putting the

computer in the service
position".
3HAC 16640-1
Controller repair
Replacement of drive units and rectifier
Location of drive
units and rectifier
The drive units and rectifier are located as shown in the figure below.
xx0200000007
3HAC 16640-1
Drive units
System fan unit
Power supply unit
125
Controller repair
Required equipment
Equipment, etc.
Note
Drive unit (rectifier)
3HAB 8101-17
DSQC 545A
Drive unit, axes 1-6
3HAB 8101-18
DSQC 546A

See references to
Removal

tools required.
The procedure below details how to remove the drive units.

Step
1.
126
Action
Note/Illustration
Swing the power supply

unit out of the way.
Detailed in section "Replacement of power

supply unit"
3HAC 16640-1
Controller repair
Step
2.
Action
Note/Illustration
Disconnect connectors X1
and X2, four connectors
each (see position 1 in the
figure).
1
xx0200000013
3.
Remove the power supply See figure above!

bar in front of the drive
units (see position 2 in the
figure).
4.
Lift the spring to release

the drive unit and pull it
slightly outwards (see
position 3 in the figure).
xx0200000014
5.
3HAC 16640-1
Tip it out and remove it

See figure above!
127
Controller repair
Refitting
The procedure below details how to refit the drive units.

Step
128
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"
3HAC 16640-1
Controller repair
Location of system fan unit
The system fan unit is located as shown in the figure below.
xx0200000007
3HAC 16640-1
Drive units
System fan unit
Power supply unit
129
Controller repair
Required equipment
Equipment, etc.
System fan unit
3HAC 12924-2
Note

See references to
Removal

tools required.
The procedure below details how to remove the system fan unit.
Step
Action
Note/Illustration
1.
Remove the bleeder

resistor unit.
Detailed in "Replacement of bleeder resistor" in

the Repair Manual.
2.

(see position 1 in the
figure).
xx0200000008
130
3HAC 16640-1
Controller repair
Step
3.
Refitting
Action
Note/Illustration
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 figure).
The procedure below details how to refit the system fan unit.
Step
3HAC 16640-1
Action
Note/Illustration
1.
Fit the system fan unit into position and

secure it (see position 2 in the figure above).
2.
Reconnect the cable disconnected during

disassembly (see position 1 in the figure
above).
3.
Refit the bleeder resistor unit.
Detailed in section
"Replacement of bleeder
resistor" in the Repair
Manual.
131
Controller repair
Replacement of power supply unit
Location of power
supply unit
The power supply unit is located as shown in the figure below.
xx0200000011
Power supply unit locking spring (view from front)
Power supply unit folded out from the cabinet (view from above)
Required equipment
Equipment, etc.
Note
Power supply unit
3HAB 4297-1
DSQC 506

See references to
132

tools required.
3HAC 16640-1
Controller repair
Removal
The procedure below details how to remove the power supply unit.
Step
Action
Note/Illustration
1.
Push the power supply

unit locking spring down
to release the power supply unit.
2.
Swing the unit out of the

cabinet.
3.
Remove the cable straps

on top of the power supply unit (see position 1 in
the figure).
Shown in figure above
xx0200000012
3HAC 16640-1
4.
Disconnect the cables at

the back of the unit (see
5.
Remove the screw (see

133
Controller repair
Step
6.
Refitting
Action
Note/Illustration
Lift the unit straight up to

release it from the hooks
and remove it outwards
The procedure below details how to refit the power supply unit.
Step
134
Action
Note/Illustration
1.
Fit the power supply unit into position onto its

hooks and secure it with the attachment
screws (see position 3 and 4 in figure in the
section Removal).
2.
Reconnect all connectors disconnected during

removal (see position 2 in figure).
3.
Secure the cables on top of the unit with new

cable straps (see position 1 in figure).
4.
Swing the unit back into the cabinet and secure

it with the locking spring.
3HAC 16640-1
Circuit Diagram, IRB 940 Tricept
Chapter 5:Circuit Diagram, IRB 940 Tricept

Introduction
Definitions
This chapter contains all the circuit diagrams for the IRB 940 Tricept.
3HAC 16640-1
135
contact
R1 SMB
contact
R1 MP
3HAC 16640-1
en0200000410
=M1/2, Potentials from control
+EC1
+EC1
Circuit Diagram, IRB 940 Tricept - =M1/2, Potentials from control
136
3HAC 16640-1
-XM1.1
WM1
-XM1
AWG16
grey
-R1MP
en0200000411
Motor
axis 1
+M1
4.0
+EC1
M
3
A2
A1
PE
D6
A3
A4
D8
A5
A6
AWG16
yel/gr
-XTPE
AWG16
yel/gr
D10
PE
PE
PE
PE
PE
PE
PE
PE
4.3
PE1
-RT1
C1
-Y1
AWG20
blue
10
=M1/3, Axis 1
AWG20
blue
C3
CE
CE
-SMB
9.5
Serial
measuring
board
-XR1.1
WR1
-XR1
AWG22
blue
-XP1-4
14
R2.SMB1-4
15
18
Resolver 1
-B1
CE
Circuit Diagram, IRB 940 Tricept - =M1/3, Axis 1
137
3HAC 16640-1
-XM2.1
WM2
-XM2
AWG16
grey
-R1MP
en0200000412
Motor
axis 2
+M2
3.0
+EC1
A8
A7
PE
A9
A10
A11 A12
AWG16
yel/gr
-XTPE
PE
PE
5.3
PE1
3.4
PE1
C4
-Y2
AWG20
blue
10
=M1/4, Axis 2
-RT2
AWG20
blue
C5
CE
CE
-SMB
9.5
Serial
measuring
board
-XR2.1
WR2
-XR2
AWG22
blue
-XP1-4
16
R2.SMB1-4
17
19
Resolver 2
-B2
CE
138
3HAC 16640-1
-XM3.1
WM3
-XM3
AWG16
grey
-R1MP
en0200000414
Motor
axis 3
+M3
3.0
+EC1
PE
A13 A14 C13 A15 A16 C14 B1
B2
AWG16
yel/gr
-XTPE
PE
PE
6.3
PE1
4.3
PE1
C15
-RT3
C6
-Y3
AWG20
blue
10
=M1/5, Axis 3
AWG20
blue
C7
CE
CE
-SMB
9.5
Serial
measuring
board
-XR3.1
WR3
-XR3
AWG22
blue
-XP1-4
21
10
R2.SMB1-4
22
20
Resolver 3
-B3
CE
139
3HAC 16640-1
Wmotor4.1
-XMTR4
Wmotor4
-XM4.1
PE
WM4
B4
D11
B3
-XM4
AWG16
grey
-R1MP
en0200000415
Motor
axis 4
+M4
3.0
+EC1
D12
B5
D13
AWG16
yel/gr
-XTPE
PE
7.3
PE1
5.3
PE1
-RT4
C8
-Y4
AWG20
blue
10
=M1/6, Axis 4
AWG20
blue
C9
CE
CE
-SMB
9.5
Serial
measuring
board
Wmotor4.1
-XMTR4
-XR4.1
WR4
-XR4
AWG22
blue
-XP3-6
12
13
14
15
R2.SMB3-6
14
15
11
10
18
Resolver 4
-B4
CE
140
3HAC 16640-1
-XM5.1
Wmotor5
18x
-XMTR5-6
PE
WM5
B6
en0200000416
Motor
axis 5
D15
B7
-XM5
AWG16
grey
-R1MP
Wmotor_5-6
Spiral 28x
+M5
3.0
+EC1
D14
B8
D9
AWG16
yel/gr
-XTPE
PE
12
8.3
PE1
6.3
PE1
-RT5
10
11
-Y5
-X5
AWG20
blue
CE
CE
-SMB
Wbrake5
-XR5.1
WR5
-XR5
AWG22
blue
-XP3-6
Wmotor5
-XMTR5-6
9.5
Serial
measuring
board
Wmotor6_and_brake 5
18
10
=M1/7, Axis 5
AWG20
blue
C11 C10
21
22
16
24
R2.SMB3-6
23
17
20
19
19
Resolver 5
-B5
25
CE
141
3HAC 16640-1
-XMTR5-6
Wmotor_5-6
+M6
en0200000417
Motor
axis 6
PE
WM6
-XM6.1
B10
B9
-XM6
AWG16
grey
-R1MP
motor6_and_brake 5
3.0
+EC1
B11
AWG16
yel/gr
-XTPE
PE
16
9.1
PE1
7.3
PE1
14
15
C12
-Y6
AWG20
blue
27
36
10
=M1/8, Axis 6
-RT6
AWG20
blue
C2
CE
CE
-SMB
9.5
Serial
measuring
board
-XR6.1
WR6
-XR6
AWG22
blue
-XP3-6
30
31
21
33
10
R2.SMB3-6
32
22
29
28
20
Resolver 6
-B6
34
CE
142
3HAC 16640-1
PE1
earth conn.
(screw)
distribution
box chassie
AWG10
yel/gr
-XTPE
R1MP D1
AWG20
blue
=M1
+FO
earth conn. (screw)

manip. foot
earth conn. (screw)

distribution box outside
8.3/
en0200000418
3.0
EC1
D2
AWG10
5m
yel/gr
PE
D3
D4
earth conn.
(screw)
cover
earth conn.
(screw)
mounting plate
PE
-SMB
3.6
Serial
measuring
board
R2SMB
9
=M1/9, Serial Measure board, Earth connections
PE
WSMB
canbus
8x
R1SMB A
CE
CE
R2G 2
blue
7,2VDC/4Ah
Battery
-G
black
Circuit Diagram, IRB 940 Tricept - =M1/9, Serial Measure board, Earth connec-
143
3HAC 16640-1
en0200000419
3.0
+EC1
-BU
Brake
release
unit
-X9
-X8
AWG16
blue
-R1MP
10
11
B14 B15
-X10
5
=M1/10 Brake release unit
AWG16
blue
B16 B12 B13
Circuit Diagram, IRB 940 Tricept - =M1/10 Brake release unit
144
Circuit Diagram, S4Cplus
Chapter 6:Circuit Diagram, S4Cplus

Introduction
Definitions
This chapter contains the circuit diagram for the controller S4Cplus. The chapter is divided into the separate systems..
3HAC 16640-1
145
System 1: General information
Circuit Diagram, S4Cplus - Sheet 1-1.
3HAC 16640-1
146
3HAC 16640-1
147
3HAC 16640-1
148
3HAC 16640-1
149
3HAC 16640-1
150
System 2: Mains Connection and Power Supply
3HAC 16640-1
151
3HAC 16640-1
152
3HAC 16640-1
153
3HAC 16640-1
154
Sheet 2-5. External transformer unit 200-500V IRB6600/7600
3HAC 16640-1
155
Sheet 2-6. Transformer unit 400-475V IRB 6600/7600
3HAC 16640-1
156
Sheet 3-1. Block Diagram/Computer Unit
System 3: Computer Unit and Connector Unit
3HAC 16640-1
157
Sheet 3-2. Cabling in Computer Unit
3HAC 16640-1
158
Sheet 3-3. Main Computer and Hard Disk / Flash Disk Drive
3HAC 16640-1
159
Sheet 3-4. Compute Cooling
3HAC 16640-1
160
Sheet 3-5. Base Connector Board and I/O Computer
3HAC 16640-1
161
Sheet 3-6. Connector Board and I/O Computer
3HAC 16640-1
162
Sheet 3-7. Connector Board and Axis Computer
3HAC 16640-1
163
Sheet 3-8. Base Connector Unit
3HAC 16640-1
164
Sheet 3-9. Connector Plate on Controller Panel
3HAC 16640-1
165
Sheet 4-1. Emergency Stop
System 4: Emergency Stops and Run Chain
3HAC 16640-1
166
3HAC 16640-1
167
3HAC 16640-1
168
Sheet 4-4. Power Unit Servo Disconnector
3HAC 16640-1
169
System 5: Drive System and Robot Cable
3HAC 16640-1
170
3HAC 16640-1
171
3HAC 16640-1
172
3HAC 16640-1
173
3HAC 16640-1
174
3HAC 16640-1
175
3HAC 16640-1
176
3HAC 16640-1
177
Sheet 5-9. Servo Drive Units / IRB 4400, 6400S/PE
3HAC 16640-1
178
Sheet 5-10. Servo Drive Units / IRB 6400R
3HAC 16640-1
179
Sheet 5-11. Control Cable IRB 140
3HAC 16640-1
180
Sheet 5-12. Control Cable IRB 340, 1400 and 2400
3HAC 16640-1
181
Sheet 5-13. Control Cable IRB 640, 840, 4400 and 6400S/PE
3HAC 16640-1
182
Sheet 5-14. Control Cable IRB 6400R
3HAC 16640-1
183
Sheet 5-15. Rectifier, fans and bleeder
3HAC 16640-1
184
Sheet 5-16. Servo Drive System
3HAC 16640-1
185
Sheet 5-17. Control cable
3HAC 16640-1
186
Sheet 6-1. External axes
System 6: External axes
3HAC 16640-1
187
Sheet 6-2. Axes Computer 2 and Connector Board
3HAC 16640-1
188
Sheet 6-3. Expansion Board Axis Connector Board
3HAC 16640-1
189
Sheet 6-4. Drive System Signal Connection External Axes
3HAC 16640-1
190
Sheet 6-5. External axes no. 7th - 9th Control Signal Connection
3HAC 16640-1
191
Sheet 6-6. Axis Computer 2 and Axis Connector Unit if External Axis Cabinet
3HAC 16640-1
192
Sheet 6-7. Connection to External Axis Cabinet
3HAC 16640-1
193
Sheet 6-8. Servogun-SMB power/signals cable
3HAC 16640-1
194
Sheet 7-1. I/O Unit Position
System 7: I/O Units and Field Bus Modules
3HAC 16640-1
195
Sheet 7-2. Digital Part of Combi I/O and Digital I/O Unit Input Part
3HAC 16640-1
196
Sheet 7-3. Digital I/O Unit Output Part
3HAC 16640-1
197
Sheet 7-4. Combi I/O Unit Digital and Analogue Output Part
3HAC 16640-1
198
Sheet 7-5. Digital Input Part of 120V AC I/O Unit
3HAC 16640-1
199
Sheet 7-6. Digital Output Part of 120V AC I/O Unit
3HAC 16640-1
200
Sheet 7-7. Relay I/O Unit Input 1-16
3HAC 16640-1
201
3HAC 16640-1
202
3HAC 16640-1
203
Sheet 7-10. Analogue I/O Unit
3HAC 16640-1
204
Sheet 7-11. Remote I/O Unit For Allen Bradley PLC
3HAC 16640-1
205
Sheet 7-12. Interbus-S Master/Slave - Interbus-S Master
3HAC 16640-1
206
Sheet 7-13. Profibus DP SLave
3HAC 16640-1
207
Sheet 7-14. Encoder Unit
3HAC 16640-1
208
Sheet 7-15. Profibus DP Master/Slave
3HAC 16640-1
209
Sheet 7-16. Interbus master/slave optical fibre and copper wire
3HAC 16640-1
210
Sheet 8-1. Floppy Disk
System 8: Other options
3HAC 16640-1
211
3HAC 16640-1
212
Sheet 8-3. External Connections System Signals
3HAC 16640-1
213
Sheet 8-4. Position Switches on Manipulator
3HAC 16640-1
214
Sheet 8-5. Customer Signals
3HAC 16640-1
215
Sheet 8-6. Sustomer Power/SIgnal IRB 2400, 4400, 6400S/PE
3HAC 16640-1
216
Sheet 8-7. Customer Cable Power/Signal/CAN IRB 6400R
3HAC 16640-1
217
Sheet 8-8. External Control Panel
3HAC 16640-1
218
Sheet 8-9. Extension Cable Teach Pendant
3HAC 16640-1
219
Sheet 8-10. Time Relay
3HAC 16640-1
220
Sheet 8-11. Customer Precess / Power / Signal / Profibus DP M/S
3HAC 16640-1
221
3HAC 16640-1
222
Sheet 8-13. LAN Ethernet connection
3HAC 16640-1
223
Sheet 8-14. Customer power/CAN-BUS IRB 640/6400S
3HAC 16640-1
224
Sheet 8-15. Customer cable power/signal CAN-BUS IRB 6600/7600
3HAC 16640-1
225
Sheet 8-16. Customer cable power/signal Profibus IRB 6600/7600
3HAC 16640-1
226
3HAC 16640-1
227
System 9: External Axis Cabinet
3HAC 16640-1
228
Sheet 9-2. View of External Axis Cabinet
3HAC 16640-1
229
3HAC 16640-1
230
3HAC 16640-1
231
3HAC 16640-1
232
Sheet 9-6. Power Supply, I/O Supply
3HAC 16640-1
233
Sheet 9-7. Power Unit
3HAC 16640-1
234
3HAC 16640-1
235
Sheet 9-9. Drive Unit Signal Connection 1 External Drive Unit
3HAC 16640-1
236
3HAC 16640-1
237
3HAC 16640-1
238
Sheet 9-12. Drive Unit and Control Cable Drive Unit GT
3HAC 16640-1
239
Sheet 9-13. Drive Unit and Control Cable Drive Unit GT+CCB
3HAC 16640-1
240
Sheet 9-14. Drive Unit and Control Cable
3HAC 16640-1
241
3HAC 16640-1
242
Index
3HAC 16640-1
243
Index
244
3HAC 16640-1
Maintenance Manual


Robotics
S-721 68 VSTERS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax:
+46 (0) 21 132592
Maintenance Manual, IRB 940 Tricept

3HAC 16639-1
-

will be prosecuted.
current charge.

Robotics
SE-721 68 Vsters
Sweden
Table of Contents
Overview
Introduction
Related information


Fire extinguishing
Brake testing
Introduction
Screw joints
Chapter 3: Maintenance activities, manipulator
Introduction
Section A: Maintenance intervals
Specification of maintenance intervals

Maintenance schedule, IRB 940 Tricept
Section B: Daily maintenance
Daily maintenance, complete robot
3HAC 16639-1
1
3
5
5
6
7
7
7
8
9
9
9
9
10
10
11
13
13
13
14
14
15
15
15
17
17
18
20
21
21
22
22
23
24
24
Table of Contents
Section C: Lubrication activities
25
Lubrication, linear bearings

Lubrication, actuators
25
27
Section D: Replacement activities
Replacement of filter element, OP-unit

Adjusting the overpressure unit
Chapter 4: Maintenance activities, controller
Introduction

Maintenance schedule, controller S4CPlus
Section B: Inspection activities
Inspection of controller cabinet, S4Cplus

Section C: Replacement activities

Section D: Cleaning activities
Cleaning of controller cabinet

Cleaning of air filter
Chapter 5: Disposal
Disposal
ii
29
29
31
33
33
34
34
35
36
36
37
37
40
44
47
47
49
51
51
3HAC 16639-1
Overview
About This
Manual
This information product is a manual containing instructions for maintenance of

the complete robot system, mechanically as well as electrically.
Usage
This manual should be used during maintenance work.
Who Should Read

This Manual?
Prerequisites
Organization of
Chapters
maintenance personnel in the user's organization.
maintenance personnel in other organizations.
be a trained maintenance craftsman
have the required knowledge of mechanical maintenance work OR
have the required knowledge of electrical maintenance work.
The information product is organized in the following chapters:
Chapter
3HAC 16639-1
Contents
1.
Safety, service
2.
Reference information
3.
Maintenance activities, manipulator
4.
Maintenance activities, controller
5.
Disposal
References
Reference
Document Id
Circuit diagram, Manipulator
3HAC 16640-1, Repair Manual part 2
Circuit diagram, Controller
3HAC 16640-1, Repair Manual part 2
Revisions
Revision
Description
First edition
3HAC 16639-1
General

Overview,
Installation and
Commissioning
Manual
Overview, Repair
Manual
Overview,
Maintenance
Manual
3HAC 16639-1
Safety, Service
Unpacking
Start-up
Robot controller
Calibration
Safety, Service

parts

spare parts
Safety, Service
Disposal
3HAC 16639-1
Safety, service

Introduction
Definitions
Sections
The chapter "Safety, service" is divided into the following sections:


dangers.
Fire extinguishing
Brake testing
3HAC 16639-1
Safety, service
Validity and
responsibility
Connection of
external safety
devices
3HAC 16639-1
Safety, service
References
General
Standards
3HAC 16639-1


test)
immunity test)
Safety, service
References
Related information
General
Documents
Type of information
Users Guide
Section
Start-up
3HAC 16639-1
Safety, service
Safety risks

Safe handling
Safe design

General
Residual energy
Safe design
3HAC 16639-1

Safety, service
Safety risks
General
Qualified
personnel
Extraordinary
risks
rectified manually.

and service
Nation/region
10


3HAC 16639-1
Safety, service
Safety risks
Non-voltage
related risks
To be observed
by the supplier of
the complete system

suitable devices.

objects.
robot.
Voltage related
risks, general
3HAC 16639-1

11
Safety, service
Safety risks
Voltage related
risks, controller,
S4Cplus
The power unit
machining process
Voltage related
Voltage related
devices, etc.
12
3HAC 16639-1
Safety, service
Safety actions

General
Dimensioning the
fence or enclosure
projectiles that they may be subjected to. Windows must be made from
suitable safety glass. Study the planned process to determine the forces

Fire extinguishing
3HAC 16639-1
13
Safety, service
Safety actions
Description
released.
Increased injury
Brake testing
When to test
How to test
below:
14
3HAC 16639-1
Safety, service
Safety actions


MOTORS OFF state.

must be observed:
3HAC 16639-1
15
Safety, service
Safety actions
16
3HAC 16639-1

Introduction
General
3HAC 16639-1
17
Screw joints
General
materials and does not apply to soft or brittle materials.
Tightening torque
Screws with
slotted or cross
recess head
Screws with
hexagon socket
head
18
tables below:
Dimension
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
Tightening
torque (Nm)
Class 12.9
M5
M6
10
17
M8
24
28
40
M10
47
55
70
M12
82
95
120
3HAC 16639-1
3HAC 16639-1
Dimension
Tightening
torque (Nm)
Class 8.8 "dry"
Tightening
torque (Nm)
Class 10.9
Tightening
torque (Nm)
Class 12.9
M16
200
235
300
19
Definition
In all repair and maintenance instructions, weights of the components handled are
sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in
this way.
Example

20
3HAC 16639-1
Chapter 3:Maintenance activities, manipulator

Introduction
Definitions
This chapter details all maintenance activities recommended for the manipulator.
This chapter is made up of separate units, each detailing a specific maintenance
activity. Each unit contains all the information required to perform the activity,
e.g. spare parts numbers, required special tools and materials.
3HAC 16639-1
21

Maintenance intervals

Description
22
The intervals may be specified in different ways depending on the type of maintenance activity to be carried 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.
3HAC 16639-1

Maintenance schedule, IRB 940 Tricept
General
The robot, consisting of manipulator and controller cabinet, must be maintained

regularly to ensure its function. The maintenance activities and their respective
intervals are specified in the table below.
Non-predictable situations also give rise to inspections of the robot. If damage is
discovered, attend to it immediately!
Activities and
intervals
The section referred to in the table can be found in the different chapters for every
maintenance activity.
The table below specifies the required maintenance activities and intervals:
Maintenance
activity
Equipment
Interval
Detailed in section
Daily maintenance
Complete robot
Daily
"Daily maintenance"
1
Lubrication
Linear bearings
1000h
"Lubrication, linear bearings"
Lubrication
Actuator
1000h 1
Changing
Filter, overpressure unit
Changing
Battery, distribution box
Removal/Refitting of battery, distribution box in

the Repair Manual.
"Lubrication, actuators"
1)
The interval is based on utilization under normal operating conditions. Operation under severe conditions such as increased ambient temperature or the presence of abrasive or grease absorbent dust will require a more regular maintenance
cycle.
3HAC 16639-1
23

Daily maintenance
Section B: Daily maintenance

Daily maintenance, complete robot
General
Daily
maintenance
24
The IRB 940 Tricept requires regular maintenance. It is therefore important to

adhere to the following maintenance chart as well as applying the preventive
maintenance schedules set out in any auxiliary equipment chapters. When maintaining the robot it is important to:
Clean the robot and its surrounding environment daily.
Not to use compressed air in sections of the machinery which may suffer
from chips or dust being blown into sensitive areas.
Only use soft cloths when cleaning so as not to cause abrasions on the
machine surfaces.
Not to use any solvents that may have an abrasive or corrosive effect on
the machine surfaces.
The daily maintenance of the robot and its surrounding environment includes:
Removing all chips and/or dust that result from the machining process.
Performing checks on all safety related equipment such as safety switches

and barriers.
Checking for signs of damage or wear on all cables, hoses and other components that can lead to a safety risk or interrupted production in case of
failure.
Checking levels of all lubrication and cooling fluids on both the manipulator
and auxiliary equipment.
Checking that all media supplies, such as compressed air and water, maintain the correct pressures and flows.
3HAC 16639-1

Lubrication activities
Section C: Lubrication activities

Lubrication, linear bearings
Location
The figure below shows the location of the grease lubrication nipple on the linear
guide bearing. The other linear bearing is located on the other side of the center
tube.
xx0200000293
Grease lubrication nipple (one on either side of the center tube)
Required equipment
Lubricant
3HAC 16639-1
Note
Klber Isoflex NBU 15 2 x 4 ml per linear bearing.
25

Lubrication
The procedure below details how to lubricate the linear bearings.

robot!
procedures.
- Before lubrication, always clean lubrication interfaces to prevent contamination
entering the lubrication system.
- After lubrication, always clean any spillage around lubrication interfaces.
Step
26
Action
Note/Illustration
1.
Clean the rails from old grease and dust.
2.
Apply 4 ml lubricant through the nipple at the Shown in figure above!

bottom end of the linear guide bearing.
Lubricant specified
Both sides must be lubricated!
above!
Note! The ends of the linear bearing are
made from plastic and can crack if not sufficient care is taken when lubricating the bearings.
3.
Run the robot back and forth in the Z-direction several times.
4.
Apply a further 4 ml lubricant through the

same nipples at both side of the center tube.
3HAC 16639-1

Lubrication, actuators
Location
The three actuators require lubrication with grease. There are four separate grease
nipples for the lubrication on each actuator. The grease nipple that faces up is used
so that as the grease is applied it falls onto the lead screw inside the actuator housing.
The figure below shows the location of the grease lubrication nipples on the actuator.
xx0200000294
Grease lubrication nipples on the actuator
Required equipment
3HAC 16639-1
Note
Lubricant
2 x 4 ml per actuator.
For lubrication of the
actuators.
Klberplex BEM
34-132
27

Lubrication
The procedure below details how to lubricate the actuators.

robot!
procedures.
- Before lubrication, always clean lubrication interfaces to prevent contamination
entering the lubrication system.
- After lubrication, always clean any spillage around lubrication interfaces.
Step
28
Action
Note/Illustration
1.
Extend the actuators to their maximum allowable length.

If a fixture or other work area restrictions
affect the positioning of the robot, run it so
that one of the actuators is extended, lubricate it and move on to the other two in turn.
2.
Apply 4 ml of lubricant to each actuator

through the topmost grease nipple.
Note! Ensure that the grease nipple that
faces upwards is used, as any other orientated grease nipple will not ensure that the
grease is applied to the lead screw correctly.
3.
Run the actuators through their whole stroke

several times.
Note! The actuators must be extended prior
to lubrication in order to get the correct application onto the actuator screw. Lubricating a
contracted actuator will not apply any grease
on the screw threads.
4.
Apply a further 4 ml through the same grease

nipple.
Lubricant specified
above!
Shown in the figure
above!
3HAC 16639-1

Replacement activities
Section D: Replacement activities

Location
The filter element is located in the overpressure (OP) unit as shown in the figure
below.
xx0200000420
Removal of the filter element
Required equipment
3HAC 16639-1
Equipment, etc.
Spare part no.
Filter
3HAC 17158-1
Art. no.
Note
29

Replacement of
filter
The procedure below details how to replace the filter element in the overpressure
unit.
Step
30
Action
Note/Illustration
1.
Exhaust the system and the unit.
2.
Unscrew the filter bowl in an anti-clockwise

direction.
3.
Grasp a new filter element only at the lower

end.
4.
Refit the parts in the reverse order from dismantling.
5.
Recommission the overpressure unit.
Detailed in the section

"Adjusting the overpressure unit".
3HAC 16639-1

Adjusting the overpressure unit
Location
The overpressure unit is installed as shown in figure below.
C
xx0200000421
3HAC 16639-1
Regulator
Pressure guard
Pressure indicator light
Air input
31

Adjusting
The procedure below details how to adjust the overpressure unit after installation
or after replacement of the filter element.
Step
Action
Note/Illustration
1.
Slowly pressurize the complete system.
2.
Pull the pressure setting button upwards (away

from the housing).
3.
Turn the pressure setting until the desired pressure (1 bar) is shown on the manometer. The input
pressure must be at least 1 bar greater than the
output pressure.
4.
Press the pressure setting button downwards

(towards the housing) to secure it against unintentional turning.
The output pressure must under no circumstances exceed 1 bar!
32
3HAC 16639-1
Chapter 4:Maintenance activities, controller

Introduction
Definitions
This chapter details all maintenance activities recommended for the control cabinet.
This chapter is made up of separate units, each detailing a specific maintenance
activity. Each unit contains all the information required to perform the activity,
e.g. spare parts numbers, required special tools and materials.
3HAC 16639-1
33


Description
34
The intervals may be specified in different ways depending on the type of maintenance activity to be carried 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.
3HAC 16639-1

Maintenance schedule, controller S4CPlus
General
The robot controller must be maintained at regular intervals to ensure its function.
The maintenance activities and their respective intervals are specified in the table
below:
Intervals
Maintenance
activity
Equipment
Interval
Detailed in section
Inspection
Controller cabinet
6 mths
"Inspection, controller
cabinet"
Cleaning
Controller cabinet
"Cleaning, controller
cabinet"
Cleaning
Air filter
"Cleaning, air filter"
Replacement
Air filter
4 000 h/
24 mths 1
"Replacement, air filter"
Replacement
Battery unit
12 000 h/
36 mths 1
"Replacement, battery
unit"
Replacement
System fan unit
60 mths
"Replacement, system
fan unit".
1)
3HAC 16639-1
Hours denotes operational time whereas months denotes actual calender time.
35

Inspection activities
Section B: Inspection activities

Inspection of controller cabinet, S4Cplus
Inspection
The procedure below details how to inspect the controller cabinet.

Step
36
Action
Note/Illustration
1.
Inspect the cabinet interior to make sure

Replace any faulty seals
there is no contamination.
as required.
If any contamination is found, the cabinet
interior must be cleaned and all gaskets and
seals to the cabinet inspected.
2.
Inspect all sealing joints and cable glands to

make sure they are airtight in order to prevent
dust and dirt from being sucked into the cabinet.
3.
Inspect connectors and cabling to make sure

they are securely fastened and cabling not
damaged.
4.
Inspect any air filters to make sure they are

clean.
Clean any contaminated

filters as detailed in
"Cleaning, air filter".
5.
Inspect any fans to make sure they function

correctly.
Replace any malfunctioning fans as detailed

in their sections respectively.
3HAC 16639-1

Section C: Replacement activities

The air filter is located in the air filter magazine in the front hatch.
A
xx0200000284
Air filter magazine
Required equipment
Equipment, etc.
Air filter
3HAB 8028-1

See references to
3HAC 16639-1
Note
These procedures
include references to
the tools required.
37

Removal, air filter
The procedure below details how to remove the air filter.
Step
1.
Action
Note/Illustration
Open the bottom of the air filter

magazine as shown in the figure.
xx0200000001
2.
Unlock the lower springs. Lower

the magazine and remove.
3.
Remove the old filter by releasing

the lock shackle and lifting it.
Note! In cases of less contamination, the air filter may be cleaned
and refitted. The procedure for
this is detailed in section "Cleaning the air filter, controller" in the
Maintenance Manual.
xx0200000003
38
3HAC 16639-1

Refitting, air filter
The procedure below details how to refit the air filter.
Step
Action
Note/Illustration
1.
Fit the air filter in the Art. no. is specified above!

magazine.
2.
Fit the spring at the

top of the air filter
magazine into the
cabinet door and
push upwards
inwards.
Push until the lower
springs snap into the
cabinet door.
xx0200000006
3HAC 16639-1
39

Location of battery unit
The battery unit is located at the bottom of the controller.
A
xx0200000103
40
Battery unit
3HAC 16639-1

Required equipment
Equipment, etc.
Note
Battery unit
3HAC 5393-2
To be replaced as a
complete unit

See references to
Removal, battery
unit
These procedures
the tools required.
The procedure below details how to remove the battery unit.
3HAC 16639-1
41

Step
1.
Action
Note/Illustration
Remove the battery unit by

unscrewing its attachment
screws (1).
X1
X1
X1
X2
X2
X2
X1
X2
X3
xx0200000004
2.
Pull the battery unit out (2).
3.
Disconnect the three cables

from the battery unit (3).
xx0200000005
42
3HAC 16639-1

Refitting, battery
unit
The procedure below details how to refit the battery unit.
Step
3HAC 16639-1
Action
Note/Illustration
1.
Place the battery unit close to its position.

2.
Reconnect the cables (3) and push the unit

into position.
3.
Secure it with the attachment screws (1).
43

Location of system fan unit
The system fan unit is located as shown in the figure below.
A
D
A
B
xx0200000007
44
Drive units
System fan unit
Power supply unit
3HAC 16639-1

Required equipment
Equipment, etc.
System fan unit
3HAC 12924-2
Note

See references to
Removal
These procedures
the tools required.
The procedure below details how to remove the system fan unit.
Step
Action
Note/Illustration
1.
Remove the bleeder

resistor unit.
Detailed in "Replacement of bleeder resistor"

in the Repair Manual.
2.

(see position 1 in the
figure).
1
xx0200000008
3HAC 16639-1
45

Step
3.
Refitting
Action
Note/Illustration
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 figure).
The procedure below details how to refit the system fan unit.
Step
46
Action
Note/Illustration
1.
Fit the system fan unit into position and

secure it (see position 2 in the figure above).
2.
Reconnect the cable disconnected during

disassembly (see position 1 in the figure
above).
3.
Refit the bleeder resistor unit.
Detailed in section
"Replacement of
bleeder resistor" in the
Repairs Manual.
3HAC 16639-1

Cleaning activities
Section D: Cleaning activities

Cleaning of controller cabinet
Required equipment
Equipment, etc.
Note
Vacuum cleaner
Cleaning agent, exterior cleaning
Cleaning of
functional
components
Use rag with e.g. alcohol, if necessary
The procedure below details how to clean the functional components of the controller cabinet.
Step
3HAC 16639-1
Action
Note/Illustration
1.
Clean the cabinet interior with a vacuum

cleaner if necessary.
2.
If the cabinet is equipped with heat exchangers, it is of the utmost importance that these
are cleaned.
Heat exchangers are normally found:
on the rear of power supplies
on the rear of computer modules
on drive units
If required, remove any

heat exchangers before
cleaning as detailed in
the "Repair Manual".
47

Cleaning activities
Dos and donts!
Always!
Never!
48
The section below specifies special considerations when cleaning the controller
cabinet.
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 remove any covers or other protective before cleaning the controller!
Never use any cleaning agents, e.g. compressed air or solvents, other
than those specified above!
Never spray with a high pressure cleaner!
3HAC 16639-1

Cleaning activities
Cleaning of air filter
The air filter is located as shown in the figure below:

B
xx0200000002
Air filter
I/O and gateway units
Power supply unit
Drive system
Computer system
Required equipment
Equipment, etc.
Cleaning agent
Note
Water 30-40C with
washing-up liquid or
detergent
Compressed air
3HAC 16639-1
49

Cleaning activities
Cleaning
The procedure below details how to clean the air filter.

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 gearbox, axis 2.
Step
Action
1.
Clean with the rough surface (on the clean-air

side) turned inwards.
2.
Clean the filter three or four times.
3.
Allow the filter to dry in one of these ways:

Lying flat on a flat surface
50
Note/Illustration
Do not wring the filter out!
Blow dry with compressed air from

the clean-air side.
3HAC 16639-1
Disposal
Chapter 5:Disposal
Disposal
General
All used grease/oils and dead batteries must be disposed of in accordance with the
current legislation of the country in which the robot and the control unit have been
installed.
If the robot or the control unit is partially or completely disposed of, the various
parts must be grouped together according to their nature (e.g. all iron together and
all plastic together), and disposed of accordingly. These parts must also be disposed of in accordance with the current legislation of the country in which the
robot and control unit have been installed.
3HAC 16639-1
51
Disposal
52
3HAC 16639-1
Index
3HAC 16639-1
53
Index
54
3HAC 16639-1

S4CPlus-IRB 940 M2000 Electrical Maintenance Training Manual

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Installation and Commissioning Manual

Industrial Robot IRB 940 Tricept

ABB Automation Technology Products AB

Installation and Commissioning Manual

The information in this manual is subject to change without notice and

Copyright 2002 ABB All rights reserved.

Safety risks related to end effector

Safety fence dimensions

Lifting manipulator in a horizontal orientation

Lifting manipulator in a vertical orientation, using a trolley

Installation of cabling on board the manipulator

Transporting and unpacking, S4Cplus

Lifting the controller cabinet

Inspection before start-up

Loading system software

Network Settings Window

Section G: System directory structure

Media pool in the PC

How to calibrate the robot system

Correct orientation of axes

Directions for all axes

Post calibration procedure

This information product is a manual containing instructions for installing the

Who Should Read

This manual is intended for:

The reader should...

installation personnel on the installation site.

have the required knowledge of mechanical as well as electrical installation work.

The manual is organized in the following chapters:

Circuit diagram, Manipulator

Included in 3HAC 16640-1, Repair Manual,

Circuit diagram, Controller

Included in 3HAC 16640-1, Repair Manual,

Product Documentation, IRB 940 Tricept

The complete documentation of IRB 940 Tricept including controller consists

Installation of controller software

System directory structure

The Repair Manual contains the following main chapters:

Remove/Refitting instructions for all manipulator details considered spare

Remove/Refitting instructions for all controller cabinet details considered

Circuit Diagram for manipulator

Circuit Diagram for controller cabinet

The Maintenance Manual contains the following main chapters:

Chapter 1:Safety, service

The chapter Safety, service is divided into the following sections:

C. Safety actions details actions which may be taken to remedy or avoid

Safety, service - General

Applicable Safety Standards

The robot is designed in accordance with the requirements of:

EN 292-1, Safety of macheniry, basic terminology

EN 292-2, Safety of machinery, technical principles/specifications, emergency stop

EN 418, Safety of machinery, emergency stop equipment

EN 563, Safety of machinery, temperatures of surfaces

EN 614-1, Safety of machinery, ergonomic design principles

EN 775, Robot safety

EN 60204-1, Electrical equipment for industrial machines

EN 50081-2EMC, Generic emission standard. Part 2: Industrial environment

EN 61000-6-2EMC, Generic standards - Immunity for Industrial environments

The list below specifies documents which contain useful information:

Installation of safety devices

Installation and Commissioning Manual

Changing robot modes

Section B: Safety risks

Safety risks related to tools/workpieces