Professional Documents
Culture Documents
IRC5-IRB140 Prod Man 3HAC023297-001 - Procedures - Rev - en PDF
IRC5-IRB140 Prod Man 3HAC023297-001 - Procedures - Rev - en PDF
Articulated robot
IRB 140
M2000, M2000A, M2004
Product manual (part 1 of 2), procedures
IRB 140
M2000
M2000A
M2004
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Safety 13
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2.1 Safety, service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2.2 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.2.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.3 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.3.1 Safety risks during service work on robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.3.2 Safety risks related to gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.3.3 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.3.4 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.3.5 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.3.6 Safety risks during installation and service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.2.3.7 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.4 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.4.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.4.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.2.4.3 Emergency release of the robot’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.2.4.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.2.4.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.2.4.7 Work inside the manipulator's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.3.2 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.3.3 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.3.4 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3 Maintenance 63
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.2 Maintenance schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.2.1 Maintenance schedule, IRB 140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.3.1 Inspection, damper axes 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.3.2 Inspection, robot cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.3.3 Inspection, timing belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.4 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.4.1 Cleaning, complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.5 Changing/ replacing activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.5.1 Oil change, gearbox, axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4 Repair 77
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.2 Complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.2.1 Replacement of cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.2.2 Replacement of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.2.3 Replacement of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.2.4 Replacement of base, spare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.3 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.3.1 Replacement of wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.3.2 Replacement of damper, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.3.3 Replacement of damper, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.3.4 Replacement of cover, arm housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.4 Lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.4.1 Replacement of lower arm cover and gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.4.2 Replacement of damper, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.4.3 Replacement of indicator lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.5 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.5.1 Replacement of cover, console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.5.2 Replacement of console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.5.3 Replacement of serial measurement unit and battery pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.5.4 Replacement of control cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.6 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.6.1 Replacement of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.6.2 Replacement of motor, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.6.3 Replacement of motor and timing belt, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.6.4 Replacement of motor, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.6.5 Replacement of motor and timing belt, axes 5 or 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.6.6 Adjustments and measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
4.6.6.1 Measuring the gear play, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
4.6.6.2 Measuring the gear play, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4.7 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4.7.1 Replacement of gearbox, axes 1-2 and damper, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4.7.2 Service work on gearbox, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Overview
Usage
This manual should be used during
• installation, from lifting the robot to its work site and securing it to the foundation to
making it ready for operation
• maintenance work
• repair work and calibration.
Prerequisites
The reader should...
• be a trained maintenance/repair craftsman
• have the required knowledge of mechanical and electrical installation/repair/
maintenance work.
Organization of chapters
The manual is organized in the following chapters:
Chapter Contents
Safety, service Safety information that must be read through before performing
any installation or service work on robot. Contains general safety
aspects as well as more specific information about how to avoid
personal injuries and damage to the product.
Installation and Required information about lifting and installation of the robot.
commissioning
Maintenance Step-by-step procedures that describe how to perform
maintenance of the robot. Based on a maintenance schedule
that may be used in the work of planning periodical maintenance.
Repair Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.
Calibration information Procedures that does not require specific calibration equipment.
General information about calibration.
Decommissioning Environmental information about the robot and its components.
Revisions
Revision Description
- First edition.
Replaces previous manuals:
• Installation and commissioning manual
• Maintenance manual
• Repair manual, part 1
• Repair manual, part 2
Changes made in the material from the previous manuals:
• Model M2004 implemented.
• Chapter Calibration replaced with chapter Calibration information.
• Chapter Safety, service replaced with new safety chapter.
• Information about the controller removed from the manual.
• Additional spare part numbers for the motors.
General
The complete product documentation kit for the M2000 robot system, including controller,
robot and any hardware option, consists of the manuals listed below:
Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
is divided into two parts:
Product manual, procedures
• Safety information
• Installation and commissioning (descriptions of mechanical installation, electrical
connections and loading system software)
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
• Repair (descriptions of all recommended repair procedures including spare parts)
• Additional procedures, if any (calibration, decommissioning)
Product manual, reference information
• Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
• Part list
• Foldouts or exploded views
• Circuit diagrams
Software manuals
The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during
operation.
A complete listing of all available software manuals is available from ABB.
General
The robot documentation may be divided into a number of categories. This listing is based on
the type of information contained within the documents, regardless of whether the products
are standard or optional. This means that any given delivery of robot products will not contain
all documents listed, only the ones pertaining to the equipment delivered.
However, all documents listed may be ordered from ABB. The documents listed are valid for
M2004 robot systems.
Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
is divided into two parts:
Product manual, procedures
• Safety information
• Installation and commissioning (descriptions of mechanical installation, electrical
connections and loading system software)
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
• Repair (descriptions of all recommended repair procedures including spare parts)
• Additional procedures, if any (calibration, decommissioning)
Product manual, reference information
• Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
• Part list
• Foldouts or exploded views
• Circuit diagrams
RobotWare manuals
The following manuals describe the robot software in general and contain relevant reference
information:
• RAPID Overview: An overview of the RAPID programming language.
• RAPID reference manual part 1: Description of all RAPID instructions.
• RAPID reference manual part 2: Description of all RAPID functions and data types.
• Technical reference manual - System parameters: Description of system
parameters and configuration workflows.
Application manuals
Specific applications (e.g. software or hardware options) are described in Application
manuals. An application manual can describe one or several applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful)
• What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)
Operator’s manuals
This group of manuals is aimed at those having first hand operational contact with the robot,
i.e. production cell operators, programmers and trouble shooters. The group of manuals
include:
• Operator’s manual - IRC5 with FlexPendant
• Operator’s manual - RobotStudioOnline
• Trouble shooting Manual for the controller and robot
Miscellaneous
A number of manuals provide generic descriptions of the robot and robot system. These
include:
• Robot fundamentals (describing the fundamental aspects, functions, concept and
similar, of a robot system to provide a basic understanding of the robot system)
References to figures
The procedures often include references to components or attachment points located on the
robot/controller. The components or attachment points are marked with italic text in the
procedures and completed with a reference to the figure where the current component or
attachment point is shown.
The denomination in the procedure for the component or attachment point corresponds to the
denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in an procedure.
Safety information
The manual includes a separate safety chapter that must be read through before proceeding
with any service or installation procedures. All procedures also include specific safety
information when dangerous steps are to be performed.
Read more in chapter Safety on page 13.
1 Safety
1.1. Introduction
Overview
The safety information in this manual is divided in two categories:
• general safety aspects, important to attend to before performing any service work on
the robot. These are applicable for all service work and are found in section General
safety information on page 14.
• specific safety information, pointed out in the procedure at the moment of the danger.
How to avoid and eliminate the danger is either detailed directly in the procedure, or
further detailed in separate instructions, found in section Safety related instructions on
page 34.
1.2.1. Introduction
Definitions
This section details general safety information for service personnel i.e. personnel performing
installation, repair and maintenance work.
Sections
The general safety information is divided into the following sections:
1. General information contains lists of:
• Safety, service
• Limitation of liability
• Referenced documents
2. Safety risks lists dangers relevant when servicing the robot system. The dangers are split
into different categories:
• Safety risks during service work on robot
• Safety risks related to gripper/end effector
• Safety risks related to tools/workpieces
• Safety risks related to pneumatic/hydraulic systems
• Safety risks during operational disturbances
• Safety risks during installation and service
• Risks associated with live electric parts
3. Safety actions details actions which may be taken to remedy or avoid dangers.
• 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 enabling device
• Work inside the manipulator´s working range
• Signal lamp (optional)
General
Any information given in this manual regarding safety, must not be construed as a warranty
by ABB that the industrial robot will not cause injury or damage even if all safety instructions
have been complied with.
General
The list below specifies documents which contain useful information:
Documents
Overview
This section includes information of general safety risks to be considered when performing
service work on the robot.
Complete robot
Caution!
Warning!
Cabling
Caution!
Caution!
Balancing device
Warning!
CAUTION!
Ensure that a gripper is prevented 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
Special safety regulations apply to pneumatic and hydraulic systems.
Residual energy
• Residual energy may be present in these systems so, after shutdown, particular care
must be taken.
• The pressure in pneumatic and hydraulic systems must be released before starting to
repair them.
Safe design
• Gravity may cause any parts or objects held by these systems to drop.
• Dump valves should be used in case of emergency.
• Shot bolts should be used to prevent tools, etc., from falling due to gravity.
General
• The industrial robot is a flexible tool which can be used in many different industrial
applications.
• All work must be carried out professionally and in accordance with the applicable
safety regulations.
• Care must be taken at all times.
Qualified personnel
• Remedial action must only be carried out by qualified personnel who are familiar with
the entire installation as well as the special risks associated with its different parts.
Extraordinary risks
If the working process is interrupted, extra care must be taken due to risks other than those
associated with regular operation. Such an interruption may have to be rectified manually.
General
Install a safety cell around the robot to ensure safe robot installation and operation.
Dimensioning
Dimension the fence or enclosure to enable it to withstand the force created if the load being
handled by the robot is dropped or released at maximum speed. Determine the maximum
speed from the maximum velocities of the robot axes and from the position at which the robot
is working in the work cell (see Product Specification - Description, Robot Motion).
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating
tool or other device fitted to the manipulator.
NOTE!
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot (manipulator
or controller)!
Description
In an emergency situation, any of the robot’s axes may be released manually by pushing the
brake release buttons on the robot or on an optional external brake release unit.
How to release the brakes is detailed in section:
• Manually releasing the brakes on page 49.
The robot arm may be moved manually on smaller robot models, but larger models may
require using an overhead crane or similar.
Increased injury
Before releasing the brakes, make sure that the weight of the arms does not increase the
pressure on the trapped person, further increasing any injury!
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.
NOTE!
Do not change "Transm gear ratio" or other kinematic parameters from the Teach Pendant
Unit or a PC. This will affect the safety function Reduced speed 250 mm/s.
NOTE!
The enabling device is a push button located on the side of the Teach Pendant Unit (TPU)
which, when pressed halfway in, takes the system to MOTORS ON. When the enabling
device is released or pushed all the way in, the robot is taken to the MOTORS OFF state.
To ensure safe use of the Teach Pendant Unit, the following must be implemented:
• The enabling device must never be rendered inoperative in any way.
• During programming and testing, the enabling device must be released as soon as
there is no need for the robot to move.
• The programmer must always bring the Teach Pendant Unit with him/her, when
entering the robot's working space. This is to prevent anyone else taking control over
the robot without the programmer knowing.
WARNING!
If work must be carried out within the robot’s work envelope, the following points must be
observed:
• The operating mode selector on the controller must be in the manual mode position to
render the enabling device operative and to block operation from a computer link or
remote control panel.
• The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in
position < 250 mm/s. This should be the normal position when entering the working
space. The position 100% ”full speed” may only be used by trained personnel who are
aware of the risks that this entails.
• Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in
order not to get entangled with hair or clothing. Also be aware of any danger that may
be caused by rotating tools or other devices mounted on the manipulator or inside the
cell.
• Test the motor brake on each axis, according to section Brake testing on page 30.
General
This section specifies all dangers that may arise from performing the work detailed in the
manual. Each danger is detailed in its own section consisting of:
• A caption specifying the danger level (DANGER, WARNING or CAUTION) and the
type of danger.
• A brief description of what will happen if the operator/service personnel does not
eliminate the danger.
• An instruction of how to eliminate the danger to facilitate performing the activity at
hand.
Danger levels
The table below defines the captions specifying the danger levels used throughout this
manual.
Electrical shock
Electrostatic discharge
(ESD)
Note
Tip
Description
Any moving manipulator is a potentially lethal machine.
When running the manipulator, it may perform unexpected and sometimes irrational
movements. However, all movements are performed with great force and may seriously
injure any personnel and/or damage any piece of equipment located within the manipulator
working range.
Elimination
Description
ESD (electro static discharge) is the transfer of electrical static charge between two bodies at
different potentials, either through direct contact or through an induced electrical field. When
handling parts or their containers, personnel not connected to ground potential may transfer
high static charges. This discharge may destroy sensitive electronics.
Elimination
Description
When handling the gearbox oil, there are several dangers to both personal injuries and product
damages! Following safety information must be regarded before performing any work with
the oil in the gearboxes!
Hot oil!
When opening the oil plug, Open oil plug carefully and keep
there may be pressure present away from the opening. Do not
in the gearbox, causing oil to overfill the gearbox when filling.
spray from the opening!
General
This chapter contains information for installing the robot to the working site.
More detailed technical data, such as load diagram, permitted extra loads (equipment) and
location of extra loads (equipment), may be found in the Product Specification for the robot.
2.2 Unpacking
General
This instruction is primarily intended for use when unpacking and installing the robot for the
first time. It also contains information useful during later re-installation of the robot.
Weight, manipulator
The net weight of the manipulator is approximately: 100 kg.
Requirement Value
Min. levelity 0.5 mm
Max. tilt 5°
Min. resonance frequency 22 Hz
Parameter Value
Max. ambient temperature +55° C
Max. ambient temperature (less than 24 hrs) +70° C
Min. ambient temperature -25° C
Max. ambient humidity Max. 95% at constant temperature
Parameter Value
Max. ambient temperature +45° C
Min. ambient temperature +5° C
Max. ambient humidity Max. 95% at constant temperature
Protection classes
The table below shows the protection class of the main parts of the robot system:
xx0200000058
xx0200000061
General
The section below details instructions for making sure the manipulator does not tip over when
it has not been safely secured to the foundation.
Procedure
The procedure below details how to make sure the manipulator does not tip during installation
while not secured to the foundation.
CAUTION!
When the manipulator is not fastened to the floor, it will not be stable in any part of its
working area.
1. DO NOT change the manipulator position before securing it to its foundation. The
shipping position is the most stable.
2. If the manipulator, for some reason, must be move from its original position, ensure that
the centre of gravity not is displaced.
General
This section details how to lift the manipulator using lifting slings.
Equipment Note
Sling line Length: 2 m. Load: 500 kg.
Illustration
The following figures shows how to lift the manipulator with lifting slings.
xx0200000084
General
The section below details how to release the holding brakes of each axis’ motor.
This may be done in one of three ways:
• using the pushbutton when the manipulator is connected to the controller.
• using the pushbutton on the manipulator with an external power supply.
• using an external voltage supply.
DANGER!
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!
xx0200000069
• A: Pushbutton
xx0200000071
• A: B16 24V DC
• B: B14 0V
2. Push the "brake release button" to release the
holding brakes.
NOTE!
Be careful not to interchange the 24V DC and the 0V pins. If they are mixed up, damage can
be caused to a resistor diode and to the system board.
xx0200000072
• A: 13 0 V
• B: 15 24 V DC
General
This section details how to orient and secure the manipulator to the foundation in order to
safely run the robot.
Bolting requirements
When bolting a mounting plate or frame to a concrete floor, follow the general instructions
for expansion-shell bolts. The screw joint must be able to withstand the stress loads defined
in section Loads on foundation, manipulator on page 43.
NOTE!
When the robot is to be mounted in a tilted or a suspended position, the guide sleeves must
be used to secure the bolted joint.
Attachment screws
The table below specifies the type of securing screws and washers to be used for securing the
manipulator to the base plate/foundation.
Guide sleeves
Two guide sleeves can be fitted to the two rear bolt holes to allow the same robot to be
remounted without re-adjusting the program.
General
When installing the manipulator, make sure that it can move freely within its entire working
space. If there is a risk that it may collide with other objects, its working space should be
limited.
WARNING!
The working space can only be limited using soft ware, for this reason the limited area can
not be classified as a safe zone. All work within this zone is prohibited.
Limiting devices
Limiting devices is listed below.
1. Light curtains.
2. Tread mats.
3. Other similar devices.
4. SoftWare.
Limiting the working space using software is described in the User’s Guide chapter: System
Parameters.
General
The manipulator features mounting holes for additional equipment.
In addition to the stock mounting holes, extra mounting holes may be added on the
manipulator under certain conditions. These special conditions are specified in the Product
Specification.
xx0200000062
xx0200000063
Fastener quality
When fitting tools on the mounting flange (see the figures in sections Illustration, holes on
upper arm on page 54 and Illustration, holes on mounting flange on page 55), use only screws
with quality 12.9. When fitting other equipment, standard screws with quality 8.8 can be
used.
2.3.6. 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 operation stops may result.
References
Load diagrams, permitted extra loads (equipment) and their positions as specified in the
Product Specification. The loads must also be defined in the software as detailed in User’s
Guide.
Brake performance
Manipulator motor brake performance depends on any loads attached. For further
information about brake performance, please contact ABB.
General
Initially the system is configured for mounting on the floor, without leaning. The method for
mounting the manipulator in a suspended position is basically the same as for floor mounting.
NOTE!
With inverted installation, make sure that the gantry or corresponding structure is rigid
enough to prevent unacceptable vibrations and deflections, so that optimum performance can
be achieved.
System Parameters
If the robot is mounted at any other angle, the system parameter “gravity beta” must be
updated. Gravity beta specifies the robot’s mounting angle expressed in radians.
NOTE!
It is very important to configure gravity beta correctly so that the robot system can control the
movements in the best possible way. Incorrect definition of mounting angle (gravity beta) will
result in:
• Overloading the mechanical structure.
• Lower path performance and path accuracy.
• Some S4 functions will not work properly: e.g Load Identification & Collision
detection.
xx0200000066
xx0200000073
Hole configuration
The illustration below shows the hole configuration used when securing the manipulator:
xx0200000085
xx0200000086
General
For connection of extra equipment on the manipulator there are cables integrated into the
manipulator’s cabling. There are both air and electrical connectors on the manipulator.
xx0200000074
Connections
Connections Description
1. For air on base / upper arm R1/4" Max. 8 bar/hose inner diameter: 6.5 mm
2. Signal connector on upper arm FCI UT 071412SH44N connector
Number of signals: 12 signals, 49V, 500mA
Recommended parts
To connect power and signal conductors to the upper arm connector, the following parts are
recommended
xx0200000132
ABB’s recommended contact set, for connector R2.CS (3HAC 12497-1) contains:
• Multipole connector 12 pin
• Adapter Tin plated 12 pin
• Pins for cable area 0.25-0.5 mm 2
• Pins for cable area 0.5-1.5 mm 2
• Shrinking hose, bootled shaped
• Shrinking hose angled
The connection set is delivered in a plastic bag also containing a Technical and assembly
instruction.
3 Maintenance
3.1. Introduction
Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed!
There are general safety aspects that must be read through, as well as more specific safety
information that describe danger and safety risks when performing the procedures. Make sure
to read through the chapter Safety on page 13.
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. Any damages must be
attended to immediately!
The inspection intervals do not specify the life of each component.
Maintenance
Equipment Interval Detailed in section:
activity
Inspection Damper, axes 2-3 Regularly *) Inspection, damper axes
2-3 on page 66
Inspection Cable harnesses Regularly *) Inspection, robot cabling
on page 68
Inspection Timing belts 36 mths Inspection, timing belts on
page 69
Change Gearbox 5, oil 36 mths Oil change, gearbox,
axes 5 and 6 on page 73
Change Gearbox 6, oil 36 mths Oil change, gearbox,
axes 5 and 6 on page 73
Change Measurement Depending on battery type Replacement of serial
system, battery and operation pattern as measurement unit and
specified in section Battery battery pack on page 122.
type selection on page 65.
Clean Complete Regularly *) Cleaning, complete robot
manipulator on page 72
*) "Regularly" implies that the activity is to be performed regularly, but the actual interval
may not be specified by the robot manufacturer. The interval depends on the operation cycle
of the robot, its working environment and movement pattern.
Generally, the more contaminated environment, the shorter intervals. The more demanding
movement pattern (sharper bending cable harness), the shorter intervals.
No longer change interval than 60 months are allowed regardless of the operation pattern due
to material ageing, etc.
xx0200000426
A Damper, axis 2
xx0200000427
A Damper, axis 3
Required equipment
Required equipment
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• 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. secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!
The cable packs are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!
Inspection
The procedure below details how to inspect the robot cabling.
xx0200000448
xx0200000453
Required equipment
Inspection
The procedure below details how to inspect the timing belts.
WARNING!
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!
• 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.
xx0200000474
General
The protection class is IP 67, i.e. the manipulator is watertight.
Required equipment
Always!
• Always use cleaning equipment as specified above! Any other cleaning equipment
may shorten the life of paintwork, rust inhibitors, signs, or labels!
• Always check that all protective covers are fitted to the robot before cleaning!
Never!
• Never point the water jet at bearing seals, contacts, and other seals!
• Never spray from a distance closer than 0.4 m!
• Never remove any covers or other protective devices before cleaning the robot!
• Never use any cleaning agents, e.g. compressed air or solvents, other than those
specified above!
• Although the manipulator is watertight, avoid spraying connectors and similar items
with a high pressure cleaner!
xx0200000475
Required equipment
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• 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. secure the lower arm with fixtures if removing motor, axis 2.
TIP!
When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains
quicker than cold oil.
WARNING!
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
WARNING!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
• damage seals and gaskets
• completely press out seals and gaskets
• prevent the manipulator from moving freely
WARNING!
Changing and draining gearbox oil may require handling hot oil of up to 90 °C! Make sure
that protective gear like goggles and gloves are always worn during this activity.
Also, be aware of possible pressure build up in gearbox! When opening the oil plug, there
may be pressure present in the gearbox, causing oil to spray from the opening!
xx0300000161
Positions:
• A: Draining position
• B: Filling position
The figure shows the
manipulator positions for filling
and draining respectively for an
inverted manipulator:
xx0300000162
Positions:
• A: Draining position
• B: Filling position
The oil quality is specified in
section Required equipment on
page 73!
4. Refit the oil plug.
4 Repair
4.1. Introduction
Required equipment
All equipment required to perform a specific repair activity is listed together with the current
procedure.
The equipment is also gathered in different lists in the Product manual, reference information.
Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed!
There are general safety aspects that must be read through, as well as more specific safety
information that describe danger and safety risks when performing specific steps in a
procedure. Make sure to read through the chapter Safety on page 13 before commencing any
service work.
Required equipment
xx0300000090
Connectors:
• A: R1.MP1-3
• B: R1.CS
• C: Air hose
• D: R1.MP4-6
3. Remove the cable holder by
unscrewing its attachment
screws.
xx0300000091
• A: Cable holder
• B: Attachment screws
• C: Cable securing screws
xx0300000092
Connectors:
• A: R2.CS
• B: Pressurized air connection
• C: R3.FB4
• D: R3.FB5
• E: R3.FB6
• F: R3.MP5
• G: R3.MP4
• H: R3.MP6
Parts:
• J: Shield
9. Remove the shield by See figure above!
unscrewing its attachment
screws.
10. Cut any cable ties securing the
cabling inside the lower arm.
xx0200000449
xx0300000093
Cables:
• A: Signal
• B: Signal
• C: Customer signal
• D: Power cable, axes 4-6
• E: Pressurized air supply
• F: Power cable, axes 1-3
xx0200000449
• A: Cable ties
• B: Pressurized air hose
• C: Power cables, axes 4, 5 and 6
• D: Customer cables, signal
• E: Signal cables, axes 4, 5 and 6
• F: Signal cable, axis 3
• G: Connectors R3.MP3 and R3.FB3
xx0300000094
Cables:
• A: Customer signal
• B: Signal
• C: Pressurized air supply
• D: Power cables
xx0200000446
A Cover, armhousing
B Attachment screws, cover armhousing, (4 pcs)
C CS-connector
D Pressurized air connector
E VK cover
F Cable guide
G Attachment screws, cable guide
H Attachment screws, upper arm (6 pcs)
J Sealing ring
Required equipment
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• 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. secure the lower arm with fixtures if removing motor, axis 2.
xx0300000101
xx0200000433
A Lower arm
B Lower arm cover gasket
C Cover l. arm, spare (without lamp unit)
D Cover l. arm, spare (with lamp unit)
Refitting
The procedure below details how to refit the complete upper arm.
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
• all the service tools and other foreign objects are removed from the manipulator!
• all normal safety equipment is installed properly, e.g. TPU enabling device.
• all personnel are 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.
xx0200000469
A Lower arm
Required equipment
xx0300000101
Parts:
• A: DO NOT touch these screws! (Note!
Only 2 screws are shown.)
3. Remove the VK cover by
pressing a screwdriver, or
similar, through it and pulling.
xx0300000097
Parts:
• A: Washer
• B: Lower arm attachment screws (10 pcs)
• C: VK cover
4. Unscrew thelower arm Shown in the figure above!
attachment screws.
Also remove the washer.
5. Raise the lifting device to
remove the lower arm.
xx0300000097
Parts:
• A: Washer
• B: Lower arm attachment screws (10 pcs)
• C: VK cover
Tightening torque: 35 Nm ± 3 Nm
3. Fit a new VK cover by gently Shown in the figure above!
tapping it into position.
4. Refit the console. Detailed in section Replacement of console on
page 118.
5. Recalibrate the robot. Calibration is detailed in separate calibration
manuals.
Art. no. for the manuals are specified in section
Document references in the Product manual,
reference information.
Location of base
The base is located at the bottom of the manipulator as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.
xx0200000423
A Base
B Bottom plate
C Bottom plate attachment screws (26 pcs)
D Gearbox/base attachment screws and washers (20 pcs each)
E Joint, gearbox/base
F Damper, axis 1
G Washer
Required equipment
Removal, base
The procedure below details how to remove the base.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• 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. secure the lower arm with fixtures if removing motor, axis 2.
Refitting
The procedure below details how to refit the complete lower arm.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• 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. secure the lower arm with fixtures if removing motor, axis 2.
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
• all the service tools and other foreign objects are removed from the manipulator!
• all normal safety equipment is installed properly, e.g. TPU enabling device.
• all personnel are 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.
xx0200000438
Required equipment
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Drain the oil from the wrist unit. Detailed in section Oil
change, gearbox, axes 5
and 6 on page 73.
3. Remove the wrist unit by unscrewing its three Shown in the figure in
attachment screws. section Location of wrist unit
on page 99.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Run the robot to a position where the upper
arm is vertical. The axis 5 motion plane
should be horizontal.
3. Lightly lubricate the o-ring sealing plate with Art. no. is specified in section Required
grease. equipment on page 99.
xx0200000445
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
• all the service tools and other foreign objects are removed from the manipulator!
• all normal safety equipment is installed properly, e.g. TPU enabling device.
• all personnel are 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.
xx0200000427
A Damper, axis 3
Required equipment
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Run the robot to a position that enables access to Shown in the figure Location of
damper, axis 3. damper, axis 3 on page 102.
3. Remove the damper by gently prying it from the
cast tab.
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Run the robot to a position that enables access to the Shown in the figure Location
location where the damper, axis 3, is fitted. of damper, axis 3 on page
102.
3. Refit the damper by gently pressing it onto the cast
tab on the upper arm.
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
• all the service tools and other foreign objects are removed from the manipulator!
• all normal safety equipment is installed properly, e.g. TPU enabling device.
• all personnel are 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.
xx0200000429
A Damper, axis 5
B Recess
Required equipment
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Run the robot to a position that enables the end of the Shown in the figure in
damper to be pushed into the recess in the wrist unit section Location of damper,
axis 5 on page 104.
3. Unhook the end of the damper, and push it into the
recess.
4. Manually move the wrist (robot axis 5) away from the
damper to pull it out.
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Push the end of the damper into the gap between the Make sure the damper is
wrist unit and upper arm. turned the correct way!
3. Manually move the wrist (robot axis 5) in order to pull
the damper into position.
4. Fold out the damper hooks to secure it in position.
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
• - all the service tools and other foreign objects are removed from the manipulator!
• - all normal safety equipment is installed properly, e.g. TPU enabling device.
• - all personnel is standing at a safe distance from the manipulator, i.e. out of its reach
behind any safety fences, etc.
• - special attention is paid to the function of the part previously serviced.
xx0200000464
Required equipment
Removal
The procedure below details how to remove the cover, armhousing.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• 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. secure the lower arm with fixtures if removing motor, axis 2.
Refitting
The procedure below details how to refit cover, armhousing.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• 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. secure the lower arm with fixtures if removing motor, axis 2.
xx0200000433
A Lower arm
B Gasket lower-arm cover
C Cover l. arm, spare (without lamp unit)
D Cover l. arm, spare (with lamp unit)
Required equipment
xx0200000426
A Damper, axis 2
Required equipment
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Run the robot to a position that enables you to access the
attachment screw of damper, axis 2.
3. Remove the damper by unscrewing the single attachment
screw and washer.
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Run the robot to a position that enables access to the
attachment screw of the damper, axis 2.
3. Secure the damper with its single attachment screw 1 pc: M6 x 16.
and washer.
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
• all the service tools and other foreign objects are removed from the manipulator!
• all normal safety equipment is installed properly, e.g. TPU enabling device.
• all personnel are 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.
xx0200000472
A Indication lamp
B Lower arm cover
Required equipment
Removal
The procedure below details how to remove the indicator lamp.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• 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. secure the lower arm with fixtures if removing motor, axis 2.
Refitting
The procedure below details how to refit the indicator lamp.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• 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. secure the lower arm with fixtures if removing motor, axis 2.
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
• all the service tools and other foreign objects are removed from the manipulator!
• all normal safety equipment is installed properly, e.g. TPU enabling device.
• all personnel are 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.
xx0200000462
A Cover, console
B Attachment screws, cover, console (4 pcs)
C Gasket
D Console
Required equipment
Removal
The procedure below details how to remove the cover, console.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• 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. secure the lower arm with fixtures if removing motor, axis 2.
Refitting
The procedure below details how to refit cover, console.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• 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. secure the lower arm with fixtures if removing motor, axis 2.
Location of console
The console is located on top of gearbox, axes 1-2 as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.
xx0200000462
A Cover, console
B Attachment screws, cover, console (4 pcs)
C Gasket
D Console
Required equipment
Removal
The procedure below details how to remove the cover, console.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• 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. secure the lower arm with fixtures if removing motor, axis 2.
xx0300000101
Parts:
• A: DO NOT touch these screws! (Note! Only
two screws shown!)
5. Remove the motor of axis 3. Detailed in section Replacement of motor and
timing belt, axis 3 on page 139.
6. Attach the lifting device to the
lower arm.
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Parts:
• A: Console
• B: Bearing hub
• C: Bearing hub attachment screws (6 pcs)
• D: Console attachment screws (10 pcs)
• E: Washers (10 pcs)
8. Remove the console by Shown in the figure above!
unscrewing its attachment
screws.
Refitting
The procedure below details how to refit cover, console.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• 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. secure the lower arm with fixtures if removing motor, axis 2.
xx0300000096
Parts:
• A: Console
• B: Bearing hub
• C: Bearing hub attachment screws (6
pcs)
• D: Console attachment screws (10 pcs)
• E: Washers (10 pcs)
Tightening torque: 11 Nm ± 1 Nm
2. Refit the bearing hub and secure it Shown in the figure above!
with its attachment screws. Tightening torque: 15 Nm ± 1 Nm
3. Refit the complete upper arm. Detailed in section Replacement of complete
upper arm on page 85.
4. Refit motor 3 and timing belt. Detailed in section Replacement of motor and
timing belt, axis 3 on page 139.
5. Refit the serial measurement board. Detailed in section Replacement of serial
measurement unit and battery pack on page
122.
6. Refit the cable harness. Detailed in section Replacement of cable
harness on page 78.
7. Recalibrate the robot! Calibration is detailed in separate calibration
manuals.
Art. no. for the manuals are specified in section
Document references in the Product manual,
reference information.
xx0200000432
Required equipment
Removal
The procedure below details how to remove the serial measurement unit and battery pack.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• 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. secure the lower arm with fixtures if removing motor, axis 2.
DANGER!
Follow these instruction to prevent the unit to be damaged from ESD:
• The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to
electrostatic voltages.
• Before handling, make sure you are grounded through a special ESD wrist bracelet or
similar.
CAUTION!
This component is classified as Hazardous waste and must be disposed of accordingly!
If in doubt of the correct disposal procedure, please contact your local environmental
authority!
CAUTION!
The cable packs are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!
Refitting
The procedure below details how to refit the serial measurement unit and battery pack.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• - Motors and gears are HOT after running the robot! Burns may result from touching
the motors or gears!
• - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• - Take any necessary measures to ensure that the manipulator does not collapse as
parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
DANGER!
Follow these instruction to prevent the unit to be damaged from ESD:
• The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to
electrostatic voltages.
• Before handling, make sure you are connected to earth through a special ESD wrist
bracelet or similar.
CAUTION!
This component is classified as Hazardous waste and must be disposed of accordingly!
If in doubt of the correct disposal procedure, please contact your local environmental
authority!
CAUTION!
The cable packs are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!
xx0200000467
A Gasket, base-cover
B Attachment screws and washers (9 pcs each), control cable
C Control cable, spare
Required equipment
Removal
The procedure below details how to remove the control cable.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• 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. secure the lower arm with fixtures if removing motor, axis 2.
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Connectors:
• A: R1.MP1-3
• B: R1.CS
• C: Air hose
• D: R1.MP4-6
4. Pull the cable out of the manipulator
base.
5. Disconnect the connectors from the
control cabinet.
Refitting
The procedure below details how to refit control cable.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• 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. secure the lower arm with fixtures if removing motor, axis 2.
xx0300000090
Connectors:
• A: R1.MP1-3
• B: R1.CS
• C: Air hose
• D: R1.MP4-6
3. Fit a new gasket when refitting the cover. Included in the spare part
4. Fit the cover onto the manipulator base Shown in the figure Location of control
and secure it with its attachment screws. cable on page 126.
4.6 Motors
xx0200000407
A Motor, axis 1
B Cover for connector access
C Motor attachment screws (4 pcs)
D Cable gland attachment screws (4 pcs)
E Console
Required equipment
Removal
The procedure below details how to remove motor, axis 1.
CAUTION!
If the manipulator normally works in an inverted position, it must be removed from this
position and placed on the floor before the work detailed in this instruction may be carried
out !
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• 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. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
Refitting
The procedure below details how to refit motor, axis 1.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• - Motors and gears are HOT after running the robot! Burns may result from touching
the motors or gears!
• - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• - Take any necessary measures to ensure that the manipulator does not collapse as
parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
xx0200000408
A Motor, axis 2
B Cover for connector access
C Motor attachment screws (4 pcs)
D Cable gland attachment screws (4 pcs)
E Console
Required equipment
Removal
The procedure below details how to remove motor, axis 2.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• 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. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
Refitting
The procedure below details how to refit motor, axis 2.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• - Motors and gears are HOT after running the robot! Burns may result from touching
the motors or gears!
• - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• - Take any necessary measures to ensure that the manipulator does not collapse as
parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
xx0200000448
Required equipment
Removal
The procedure below details how to remove motor, axis 3.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• 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. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
xx0200000449
• A: Cable ties
• B: Pressurized air hose
• C: Power cables, axes 4, 5 and 6
• D: Customer cables, signal
• E: Signal cables, axes 4, 5 and 6
• F: Signal cable, axis 3
• G: Connectors R3.MP3 and R3.FB3
4. Disconnect motor connectors. Connectors:
• R3.MP3
• R3.FB3
• R3.H1 (if Safety lamp is fitted)
• R3.H2 (if Safety lamp is fitted)
xx0300000102
Parts:
• DO NOT touch these screws! (3 pcs)
6. Remove the belt shield by unscrewing Shown in the figure in section Location of
its twoattachment screws. motor axis 3 on page 139.
7. Remove the remaining Shown in the figure in section Location of
motorattachment screws. motor axis 3 on page 139.
8. Remove the belt. Shown in the figure in section Location of
motor axis 3 on page 139.
9. Remove the motor. Shown in the figure in section Location of
motor axis 3 on page 139.
Refitting
The procedure below details how to refit motor, axis 3.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• - Motors and gears are HOT after running the robot! Burns may result from touching
the motors or gears!
• - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• - Take any necessary measures to ensure that the manipulator does not collapse as
parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
xx0200000449
• A: Cable ties
• B: Pressurized air hose
• C: Power cables, axes 4, 5 and 6
• D: Customer cables, signal
• E: Signal cables, axes 4, 5 and 6
• F: Signal cable, axis 3
10. Recalibrate the robot! Calibration is detailed in separate
calibration manuals.
Art. no. for the manuals are specified in
section Document references in the
Product manual, reference information.
xx0200000455
Required equipment
Removal
The procedure below details how to remove motor, axis 4.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• 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. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
Refitting
The procedure below details how to refit motor, axis 4.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• - Motors and gears are HOT after running the robot! Burns may result from touching
the motors or gears!
• - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• - Take any necessary measures to ensure that the manipulator does not collapse as
parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
xx0200000453
G CS connector
H Cable guide
J Attachment screws, cable guide
K Belt shield
L Attachment screws, belt shield
M Motor attachment screws, 4 pcs per motor
N Attachment screws, motor console
P Clamping unit screws
Q Clamping unit
R Timing belt, axis 6
S Pulley, axis 6
T Screws securing the pulley to the axis 5 drive shaft
U Timing belt, axis 5
V Pulley, axis 5
W Motor console, ax. 5-6
X Motor, axis 4
Y Motor, axis 5
Z Motor, axis 6
Required equipment
Removal
The procedure below details how to remove motor, axis 5 or 6.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• 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. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
Refitting
The procedure below details how to refit motor, axis 5.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• - Motors and gears are HOT after running the robot! Burns may result from touching
the motors or gears!
• - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• - Take any necessary measures to ensure that the manipulator does not collapse as
parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
General
After reassembly due to repair work or any other reason, the gear play must be checked to
ensure the repetition accuracy of the robot positioning. The procedure for axis 5 is detailed
below.
Certain measurement tools must be fashioned to enable measuring. The dimensions of these
are specified.
Required equipment
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• 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. secure the lower arm with fixtures if removing motor, axis 2.
Measurement
The procedure below details how to measure the gear play for axis 5.
xx0200000457
xx0200000458
General
After reassembly due to repair work or any other reason, the gear play must be checked to
ensure the repetition accuracy of the robot positioning. The procedure for axis 6 is detailed
below.
Certain measurement tools must be fashioned to enable measuring. The dimensions of these
are specified.
Required equipment
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• 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. secure the lower arm with fixtures if removing motor, axis 2.
Measurement
The procedure below details how to measure the gear play for axis 6.
xx0200000460
xx0200000461
4.7 Gearboxes
xx0200000422
Required equipment
xx0200000423
• A: Gearbox 1-2
• B: Bottom plate
• C: Bottom plate attachment screws (26
pcs)
• D: Gearbox/base attachment screws (20
pcs)
• E: Joint, gearbox/base
• F: Damper, axis 1
10. Remove the gearbox/base Shown in the figure Location of gearbox axes 1-2
attachment screws and lift the on page 157.
gearbox 1-2 away from the base.
xx0200000423
• A: Gearbox 1-2
• B: Bottom plate
• C: Bottom plate attachment screws (26 pcs)
• D: Gearbox/base attachment screws (20
pcs)
• E: Joint, gearbox/base
• F: Damper, axis 1
• G: Washer
3. Fit the base to the gearbox unit Shown in the figure Location of gearbox axes 1-2 on
and secure it with the page 157.
attachment screws and the flat Quality Gleitmo, tightening torque: 35 Nm ± 3 Nm.
washer.
4. Refit the bottom plate and Shown in the figure Location of gearbox axes 1-2 on
secure it with its attachment page 157.
screws.
General
The gearbox, axis 4, is intended to run without requiring any repairs or maintenance work.
This implies that it must under no circumstances be opened or serviced.
If it requires replacement, the complete upper arm is to be replaced. This procedure is detailed
in section Replacement of complete upper arm on page 85.
5 Calibration information
5.1. Introduction
General
This chapter includes general information about different calibration methods and details also
procedures that does not require specific calibration equipment.
When the robot system must be recalibrated, it is done according to documentation enclosed
with the calibration tools.
When to calibrate
The system must be calibrated if any of the below occurs.
References
The article numbers for the Calibration manuals are listed in section Document references in
the Product manual (part 2 of 2), reference information. Article numbers for the calibration
tools are also listed in part 2 of the Product manual.
Overview
This section specifies the different types of calibration and the calibration methods that are
supplied from ABB.
Types of calibration
Type of
Description Calibration method
calibration
Standard The calibrated robot is positioned at home Calibration Pendulum
calibration position, i.e. the axes positions (angles) are (standard method)
set to 0º. or
Standard calibration data is found in the file Levelmeter calibration
calib.cfg, supplied with the robot at delivery. (alternative method)
The file identifies the correct resolver/motor
position corresponding to the robot home
position.
From deliveries together with RobotWare 5.0.5
and higher, the data will instead be found on
the SMB (serial measurement board) in the
robot, and not in a separate file.
Absolute Accuracy Based on standard calibration, but besides CalibWare
calibration positioning the robot at home position, the
(optional) Absolute Accuracy calibration also
compensates for:
• mechanical tolerances in the robot
structure
• deflection due to load.
Absolute Accuracy calibration focuses on
positioning accuracy in the Cartesian
coordinate system for the robot.
Absolute Accuracy data is found in the file
absacc.cfg, supplied with the robot at delivery.
The file replaces the calib.cfg file and identifies
motor positions as well as absacc-
compensation parameters.
From deliveries together with RobotWare 5.0.6
and higher, the data will instead be found on
the SMB (serial measurement board) in the
robot, and not in a separate file.
A robot calibrated with AbsAcc has a sticker
next to the identification plate of the robot.
To regain 100% Absolute Accuracy
performance, the robot must be recalibrated
for Absolute Accuracy!
xx0400001197
Calibration methods
Each calibration method is detailed in separate manuals. Below is a brief description of the
methods available.
Introduction
This section specifies the calibration scale positions and/or correct axis position for all robot
models.
xx0200000157
xx0200000089
General
This section details how to perform a rough calibration of each robot axis, i.e. updating the
revolution counter value for each axis, using either the TPU or the FlexPendant.
xx0100000194
xx0100000201
xx0100000202
4. Select the desired axis and press Incl to include it (it will
be marked with an x) or press All to select all axes.
5. Press OK when all axes that are to be updated are marked
with an x.
CANCEL returns to the Calibration window.
Caution!
If a revolution counter is incorrectly updated, it will cause
incorrect robot positioning, which in turn may cause damage or
injury!
Check the calibration position very carefully after each update.
How to perform the check is detailed in section Checking the
calibration position on page 172.
Step Action
1. On the ABB menu, tap Calibration.
All mechanical units connected to the system are shown along with their calibration
status.
2. Tap the mechanical unit in question.
A screen is displayed: tap Rev. Counters.
en0400000771
Step Action
3. Tap Update revolution counters....
A dialog box is displayed, warning that updating the revolution counters may change
programmed robot positions:
• Tap Yes to update the revolution counters.
• Tap No to cancel updating the revolution counters.
Tapping Yes displays the axis selection window.
4. Select the axis to have its revolution counter updated by:
• Ticking in the box to the left
• Tapping Select all to update all axes.
Then tap Update.
5. A dialog box is displayed, warning that the updating operation cannot be undone:
• Tap Update to proceed with updating the revolution counters.
• Tap Cancel to cancel updating the revolution counters.
Tapping Update updates the ticked revolution counters and removes the tick from
the list of axes.
6.
Caution!
If a revolution counter is incorrectly updated, it will cause incorrect robot positioning,
which in turn may cause damage or injury!
Check the calibration position very carefully after each update.
See section Checking the calibration position on page 172.
General
Check the calibration position before beginning any programming of the robot system. This
may be done in one of two ways:
• Using a MoveAbsJ instruction with argument zero on all axes
• Using the Jogging window on the teach pendant
xx0100000195
xx0100000196
C
Calibration position 168
calibration position, checking 172
calibration position, jog to 173
Connection of external safety devices 15
D
direction of axes 167
L
Limitation of Liability 16
N
negative directions, axes 167
P
positive directions, axes 167
R
Revolution counters 168
S
Safety, service 15
U
Updating revolution counters 168
V
Validity and responsibility 15