Product Manual: IRB 5320 Workpiece Positioners

—
ROBOTICS
Product manual
IRB 5320 workpiece positioners
Product manual
Title page

3HNA018189-001 Rev.12
First edition: 26 January 2012
Last revised: 17 September 2019
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.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to persons
or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from use
of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB’s
written permission.
Additional copies of this manual may be obtained from ABB.
The original language for this manual is English. Any other languages that are supplied
have been translated from English.
© Copyright 2012-2019 ABB. All rights reserved.

Specifications subject to change without notice.
Table of contents
Table of contents
Title page
Preface
1 Introduction 9
2 Safety 11
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 System Description 15
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 Basic Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2.1 Design, 1 Axis Workpiece Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.2 Design, 3 Axes Workpiece Positioner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.3 Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2.4 Purge Air Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2.5 Identification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.3 Servo Unit E11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.4 The Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.5 Servo Unit E21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.6 Axes Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.6.1 1 Axis Workpiece Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.6.2 3 Axes Workpiece Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.7 The Axes Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.8 Boards Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4 Technical Specifications 31
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2 Manipulator Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.3 Positioner Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.4 Servo Unit E11 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.5 Servo Unit E21 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.6 Dimensions Positioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.7 Working Area Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5 Installation and Commissioning 39
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.1.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.1.2 Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2 Positioning the Workpiece Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.3 Mounting Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.4 Mechanical Installation of Workpiece Positioner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.5 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.6 Concluding Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.6.1 IRB 5320 1 Axis Workpiece Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.6.2 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6 Preventive Maintenance 49
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.2 Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.3 General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7 Repair 53
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.2 Releasing Axis Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.2.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.2.2 Brake Release Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.2.3 Manually Releasing Axis Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.3 Servo Unit E11 Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Product manual, IRB 5320 workpiece positioners 5

3HNA018189-001 Rev.12
Table of contents
7.3.1 Removal of Motor for Servo Unit E11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

7.3.2 Installation of Motor for Servo Unit E11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.3.3 Removal of Servo Unit E11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.3.4 Installation of Servo Unit E11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.3.5 Replace Oil for Servo Unit E11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.4 Servo Unit E21 Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
7.4.1 Removal of Motor for Servo Unit E21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7.4.2 Installation of Motor for Servo Unit E21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
7.4.3 Removal of Radial Seals from Servo Unit E21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
7.4.4 Installation of Radial Seals for Servo Unit E21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
7.4.5 Removal of Servo Unit E21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.4.6 Installation of Servo Unit E21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.4.7 Oil Removal Servo Unit E21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.4.8 Oil Filling Servo Unit E21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7.4.9 Removal of Internal Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.4.10 Installation of Internal Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.5 Calibration Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
7.5.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
7.5.2 Calibration Position, 1 Axis Workpiece Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
7.5.3 Calibration Position, 3 Axes Workpiece Positioner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
8 Operation 125
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
8.2 Installation Site Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
8.3 Operator Work Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
8.4 Creating a Paint Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
8.4.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
8.4.2 Create the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
8.4.3 Test/Step Through the Program in Manual Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
8.4.4 Run the Program in Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
9 Decommissioning 137
9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
9.2 Environmental information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
10 Reference information 141
10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
10.2 Configurations for weak foundations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
10.3 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
10.4 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
10.5 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
10.6 Loctite® specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
10.7 Performing a gearbox leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
10.8 Safety instructions for replacing oil in gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
10.9 Oil type specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
10.9.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
10.9.2 Robot types overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
10.10 Grease type specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
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6 Product manual, IRB 5320 workpiece positioners

3HNA018189-001 Rev.12
Preface
About this manual This manual provides information and instructions for installation, replacing parts
and performing preventive maintenance on the IRB 5320 Workpiece Positioners.
WARNING! Before performing any work described in this manual, the Safety
Manual must be read and understood. Work must only be performed by skilled
personnel with the proper training.
The Safety Manual is included in the Software and Documentation DVD following
each robot, and is also shipped with the robot as paper copy, included in the control
cabinet.

3HNA018189-001 Rev.12
3HNA018189-001 Rev.12
1 Introduction
1 Introduction
About This Manual This manual contains information on the following:
• Mechanical and electrical installation of the positioner.

• Description of the design of the positioner.
• Technical specifications for the positioner.
• Maintenance of the positioner.
• Mechanical and electrical repair of the positioner.
Usage This manual should be used during:
• Installation.
• Maintenance work.
• Repair work.
Who Should Read This This manual is intended for:

Manual?
• Installation personnel.
• Maintenance personnel.
• Repair personnel.
Prerequisites The reader should:
• Be a trained maintenance and repair craftsman.

• Have the required knowledge of mechanical-, electrical- and Ex installation,
maintenance and repair work.
Organization of The manual is organized in the following chapters:

Chapters
Chapter Description
1. Introduction This chapter.
2. Safety Information on safety.
3. System Description Information on function and design of the positioner.
4. Technical Specifications Specifications for the positioner, working area drawings,
load on arm etc.
5. Installation and Commissioning Information about installation of the positioner.
6. Preventive Maintenance Information about maintenance work, including
maintenance schedules.
7. Repair Information about repair work, including mounting of
calibration fixture.
8. Operation Information based on an installation example with an
added supervision system that secures the safety of the
operator.
9. Decommissioning General information for decommissioning the positioner.

3HNA018189-001 Rev.12
1 Introduction
Chapter Description
10. Reference Information Information such as mounting instructions for bearings and
seals, screw tightening torques and oil types.
References Following manuals are referred to in this manual:

Manual Description
Safety Manual This manual must be read before any work on the robot
3HNA008924-001 is performed.
Product Manual, Control Cabinet IRC5P Includes information on installation of purge unit.
3HNA009834-001
Unit Description, Paint Includes technical description of the units used in the
3HNA012856-001 paint system.
Unit Description, IRC5P Includes technical description of the control system

3HNA009628-001 electronics etc.
Installation manual, IRC5P Includes description of the calibration function and

3HNA025116-001 procedure for entering calibration data etc.

3HNA018189-001 Rev.12
2 Safety
2.1 Introduction
2 Safety
2.1 Introduction
Safety information Before performing any work described in this manual, 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 describes danger and safety risks when performing the
procedures. Read the Safety Manual before performing any service work.
WARNING! Before performing any work described in this manual, the Safety
Manual must be read and understood. Work must only be performed by skilled
personnel with the proper training.
Important: The description in this chapter is intended as a short reference and is no

substitute for reading the complete Safety Manual.
General hazards The following lists some of the most relevant hazards.
• Before you enter the spray booth, make sure that all robots and other equipment
have stopped, and also make sure that you wear appropriate safety clothes,
antistatic shoes, gloves, safety glasses, etc. In case of danger for toxic gases,
make sure that you wear appropriate safety equipment.
• Always attend to your personal safety.
• The motion of the manipulator is powerful. Always make sure that nobody is
within the reach of the robot when running the robot for test etc.
• The manipulator is normally installed in a hazardous area where there are risks
of explosion. Always consider these risks when working with the robot system
and bringing tools and equipment into the area.
• Always be aware of hazards associated with electric power when working with
the robot system.
• The use of thin layers of non-conductive plastics for covering parts of the
manipulator against exposure of coating materials must be avoided, as they
could present a hazard of propagating brush discharges.
• Releasing the robot axis brakes can be potentially dangerous. Never release the
brakes unless you know the risks involved.
• Electronic units are sensitive to static electricity. It is extremely important that
these units are handled with care in order not to damage the boards or introduce
errors.
• Do not disconnect any connectors, except service ports, while power is applied
to the controller.

3HNA018189-001 Rev.12
2 Safety
2.1 Introduction
Specific hazards The following lists some hazards specific for the manipulator described in this
manual.
• Always be aware that the control system is controlling both the positioner robot
and the paint robot.
Observe before service Following points must be observed before any service work is started:
• Power may remain in the control cabinet even when the mains power switch is
turned ‘off’. To avoid hazards, see ‘Preparing the robot for service’ in Safety
manual.
• Turn ‘off’ all electric power, fluid supply and pneumatic pressure to the
manipulator.
• Residual energy may be present in pneumatic systems, so after shutdown,
particular care must be taken. The pressure in pneumatic systems must be
released before repair can be started. Dump valves should be used in case of
emergency.
• Motors and gears are HOT after running the manipulator. Touching the motors
and gears may result in burns. Allow motors and gears to cool down before
touching them.
• Take any necessary measures to ensure that the manipulator does not collapse as
parts are removed. All work described in this manual must be performed exactly
as described in the procedures.
• Removing an axis motor will disengage the brake function. For this reason, the
axis motor must never be removed while other repair work is being performed.
No other repair work must be performed if one or all of these motors are
removed.
• Use only items listed in the Spare Parts Catalogue to avoid possible damage to
the robot or degradation of its performance or affect the Ex certification of the
robot.
• To avoid contamination by dust etc., always clean outside of manipulator before
opening any cover.
• Avoid any contamination of the robot interior.
Observe before Following points must be observed before performing the first test run after a
concluding service service activity (installation, maintenance, repair):
• When reassembling components in the system, make sure that the components
are properly secured to avoid hazardous situations from parts thrown from the
robot by high accelerations, high fluid pressure etc.
• Before reinstalling covers on purged robot parts, inspect that there is no dust or
other contamination inside. In case of contamination, remove it to avoid any

3HNA018189-001 Rev.12
2 Safety
2.1 Introduction
particles or dust inside the robot before a purge sequence is performed. Do not
clean electronic components directly with a vacuum cleaner as this may cause
ESD discharge, which may lead to damage.
• All service tools and other foreign objects are removed from the manipulator.
• All normal safety equipment is installed properly, such as pendant enabling
device.
• When service work is finished, the calibration position should always be
checked.
• All personnel are standing at a safe distance from the manipulator, out of reach
outside the spray booth or behind any safety fences, etc.
• Special attention is paid to the function of the part which has been serviced.

3HNA018189-001 Rev.12
2 Safety
2.1 Introduction

3HNA018189-001 Rev.12
3 System Description
3.1 Introduction
3.1 Introduction
About this Chapter This chapter provides information on the mechanical function and design of the
IRB 5320 Workpiece Positioners.
The chapter includes description of the different components of the positioners, and
must only be used for reference purposes.
WARNING! Repair work on the positioner must only be performed in accordance

with procedures given in the chapter ‘Repair’ in this manual.

3HNA018189-001 Rev.12
3.2 Basic Design
3.2 Basic Design
General The IRB 5320 workpiece positioner is a manipulator that positions the workpiece
such that a paint robot is able to paint it. The positioner is integrated with the paint
robot, using the same controller. The paint robot is normally a 6 axes robot. The
positioner contains one or three axes. The positioner is approved for installation in a
hazardous area.
Figure 1 IRB 5320 workpiece positioners
Paint robot
Axes 1 - 6
Control cabinet Purge unit
3 Axes Workpiece Positioner

Axes 1 - 3
Purge unit
Identification plate
1 Axis Workpiece Positioner

Axis 1
For more information on the installation site, see ’Installation Site Example’ on
page 126.
Important: When the positioner is used in combination with electrostatic painting,

the workpiece on the turntable needs to be grounded.

3HNA018189-001 Rev.12
3.2 Basic Design
3.2.1 Design, 1 Axis Workpiece Positioner
Design The IRB 5320 1 axis workpiece positioner (1E11) consists of servo unit E11 with a
rotating axis. The customer can equip the rotating axis with a suitable turntable. The
turntable can be used to index the workpieces (objects that shall be painted) before
or during painting, or the turntable can spin the workpieces at a given rotation speed
and rotation direction during painting. The positioner is controlled by one servo
axis, servo unit E11, that rotates the turntable. The turntable may be equipped with a
spindle for arranging workpieces.
Axis Overview The positioner is controlled by one servo axis.
Figure 2 Axis overview
Turntable axis 1
Axis 1 motor
Purge air exhaust
Servo unit E11
Turntable Axis 1 Servo unit E11 rotates the turntable axis 1 with possible spindle and arrayed
workpieces. The axis 1 motor controls the rotation of the turntable via a gearbox.
This servo unit contains the purge sensor. See ’Purge Air Routing’ on page 20 for
location of sensor etc.

3HNA018189-001 Rev.12
3.2 Basic Design
3.2.2 Design, 3 Axes Workpiece Positioner
Design The IRB 5320 3 axes workpiece positioner (1E11-2E21) consists of two turntables
mounted on an arm that can be rotated. The positioner is a manipulator (robot), that
serves the paint robot with workpieces (objects that shall be painted) and moves the
painted workpieces out of the painting zone.
The positioner is controlled by three servo axes, servo unit E11 and two servo units
E21. The positioner arm can be rotated with servo unit E11. Both arm ends contain a
servo unit E21 with a rotating turntable. The turntables can be equipped with a
spindle or fixture for arranging workpieces. Servo unit E11 positions one arm end
into the paint operation station and the other end into the loading/unloading station.
At the loading station, the workpieces are manually or automatically loaded on the
turntable. At the paint operation station, the paint robot paints the workpieces. In the
painting position, the turntable can be used to index the workpieces before or during
painting, or the turntable can spin the workpieces at a given rotation speed and
rotation direction during painting. When the painting operation is finished, the servo
unit E11 rotates the positioner arm and the painted workpieces are placed into the
unloading station.
Axes Overview The positioner is controlled by three servo axes.
Figure 3 Axes overview

Turntable axis 2 Arm rotation axis 1 Turntable axis 3
Arm
Axis 2 motor Axis 3 motor

Servo unit E21 Servo unit E21
Axis 1 motor Purge air exhaust
Servo unit E11
Arm Rotation Axis 1 Servo unit E11 rotates the complete arm with both servo units E21. The axis 1
motor controls the rotation of the arm via a gearbox.
This servo unit contains the purge sensor. See ’Purge Air Routing’ on page 20 for
location of sensor etc.

3HNA018189-001 Rev.12
3.2 Basic Design
3.2.3 Component Identification
General The following gives a short overview of the different components of the positioner.
Figure 4 Positioner components
Arm
Servo unit E21 (2x)
Servo unit E11
Arm The arm joins the three servo units. The length of the arm determines the distance
between the paint operation station and the loading/unloading station. Motor cables
are routed through the arm.
Servo Unit E11 The servo unit E11 contains the motor for the servo unit. It includes mounting holes
and connection for the positioner main cable.
Servo Unit E21 The servo unit E21 contains the motor for the servo unit.

3HNA018189-001 Rev.12
3.2 Basic Design
3.2.4 Purge Air Routing
General The positioner is supplied with compressed air to parts of the positioner which
include electrical components. The positioner is approved for installation in a
hazardous area.
Reference For more information on the purge system, see ‘Unit Description, IRC5P’.

3HNA018189-001 Rev.12
3.2 Basic Design
1 Axis Positioner The air from the purge unit is entered into the servo unit E11 motor compartment.
The servo unit is equipped with a purge valve and purge sensor.
Figure 5 Purged area of IRB 5320 1 Axis Workpiece Positioner
Exi Hazardous area
Purge valve assembly
Purge
controller
Purge sensor
Purge air
exhaust
Flexible hose
Purge connection
Purged area Exp
Figure 6 Purge sensor and purge valve location, servo unit E11 rear view
Purge sensor
Purge valve

3HNA018189-001 Rev.12
3.2 Basic Design
3 Axes Positioner The air from the purge unit is entered into the servo unit E11 motor compartment.
An air hose supplies the air to the first servo unit E21 and from there to the second
servo unit E21. This last servo unit is equipped with a purge valve and purge sensor.
Figure 7 Purged area of IRB 5320 3 Axes Workpiece Positioner
Exi Hazardous area
Purge valve assembly
Purge
controller
Purge air
exhaust
Flexible hose
Purge sensor
Purge connection
Purged area Exp
Figure 8 Purge sensor and purge valve location, servo unit E21 front view
Purge valve
Purge sensor

3HNA018189-001 Rev.12
3.2 Basic Design
3.2.5 Identification Plate
Description Identification plates, indicating the type of robot and serial number etc., are found
on the control cabinet, purge unit and positioner.
The identification plate for the positioner is located on the servo unit E11, as shown
in Figure 1.
Note: The identification plate shown in the illustration below only serves as
example. For exact identification, see plates on your positioner.
Figure 9 Positioner identification plate
II 2G Ex ib pxb IIB T4 Gb
II 2D Ex ib pxb IIIB T: 65°C Db
ABB AS, Robotics II 2GD c T6
PO Box 265, N-4349 Bryne,
Serial No. Batch
Type: IRB 5320
Model: Volume [liter]:
Presafe 18ATEX13503X IECEx PRE 18.0073X
Ref.Dwg.No.:................... 3HNA018376-001
Inert gas:......................... Instrument air
Purge time:...................... 180 sec.
Min. supply Inert gas:...... 470Nl/min.
Max. pressure enclosure: 58mbar
Min. maintenance press.: 0.8mbar Supply press. 3 - 5 bar
Max. leakage comp.:....... 20Nl/min. (at Max enclosure pres.)

3HNA018189-001 Rev.12
3.3 Servo Unit E11
3.3 Servo Unit E11
General The servo unit E11 serves as a rigid foundation for the positioner. The servo unit
includes a drive motor and gearbox for axis 1. The turntable (axis 1 workpiece
positioner) or positioner arm (3 axes workpiece positioner) is attached to the
gearbox.
Figure 10 Servo unit E11
Grounding clamp
Mounting holes
Cable entrance Cover
Design The servo unit is made from a solid cast iron unit. The servo unit includes a
connector board to interconnect the main cable from the control cabinet with the
axis motors and control electronics in the positioner.
Electrical cables for axes 2 and 3 are routed via the center of the gearbox axis to
prevent cable damage.
For dimensions of the servo unit and footprint drawing, etc., see ’Servo Unit E11
Specifications’ on page 35.
Electrical Connectors Two electrical cables with connectors extend from the drive motor. These cables are
the motor cable, including motor power, brake power and temperature sensor
connection, and the resolver cable.
Control Electronics The servo unit E11 includes the control electronics systems for the positioner. These
systems are located in the chamber of the servo unit. The chamber is accessible via a
cover on a side of the unit.
Purge System The purge system supplies compressed air to the chamber in the servo unit. The last
servo unit in the purge system contains purge sensors. The sensors are monitored by
the purge control system in the control cabinet to control the purge system
functioning. The purged chamber is an air tight compartment. It is for this reason
important that all screws are installed to prevent air leaks.

3HNA018189-001 Rev.12
3.4 The Arm
3.4 The Arm
General The arm joins the two servo units E21 with the servo unit E11. The arm is available
in different lengths.
Figure 11 The arm

Cover
Design The arm is made from steel. The arm is directly mounted to the gearbox of the servo
unit E11. A servo unit E21 is mounted on each end of the arm. The arm is equipped
with fixed stop studs to limit the rotation of the arm.
Electrical cables and purge hoses are routed through the arm.
For dimensions of the arm, see ’Dimensions Positioners’ on page 37.

3HNA018189-001 Rev.12
3.5 Servo Unit E21
3.5 Servo Unit E21
General The servo unit E21 is located at both ends of the arm. The servo unit includes a
drive motor and gearbox to perform rotation of the turntable.
Turntable
Cable entrance
Design The servo unit is made from aluminium. The turntable is directly mounted on the
servo unit E21 gearbox.
For dimensions of the servo unit, see ’Servo Unit E21 Specifications’ on page 36.
Gearbox The gearbox is equipped with an accumulator and membrane, such that the oil is
able to expand when the temperature is rising.
Electrical Connectors Two electrical cables with connectors extend from the drive motor. These cables are
the motor cable, including motor power, brake power and temperature sensor
connection, and the resolver cable.
If the servo unit is equipped with a purge sensor, a purge sensor cable connects the
purge sensor to the main cable in the servo unit E11.
Purge System The purge system supplies compressed air to the chamber in the servo unit. The last
servo unit in the purge system contains a purge sensor. The sensor is monitored by
the purge control system in the control cabinet to control the purge system
functioning.
The purged chamber is an air tight compartment. It is for this reason important that
all screws are installed to prevent air leaks.

3HNA018189-001 Rev.12
3.6 Axes Motion
3.6 Axes Motion
3.6.1 1 Axis Workpiece Positioner
General The illustration shows the simplified layout of the drive system for the axis.
Figure 13 3 Axis configuration, front view
Turntable axis 1
Pinion Gearwheel
Axis 1 motor Servo unit E11
Turntable Axis The servo unit E11 controls the turntable axis. The gearbox is integrated in the servo
unit. The turntable is directly mounted on the gearbox.
3.6.2 3 Axes Workpiece Positioner
General The illustration shows the simplified layout of the drive system for the 3 axes.
Figure 14 3 Axes configuration, front view
Turntable axis 2 Arm rotation axis 1 Turntable axis 3

Gearwheel Gearwheel
Pinion Pinion
Servo unit E21 Arm Servo unit E21
Axis 2 motor Pinion Gearwheel Axis 3 motor

Axis 1 motor Servo unit E11
Arm Axis The servo unit E11 controls the arm. The gearbox is integrated in the servo unit. The
arm is directly mounted on the gearbox.
Turntable Axis The servo unit E21 controls the turntable axis. The gearbox is integrated in the servo
unit. The turntable is directly mounted on the gearbox.

3HNA018189-001 Rev.12
3.7 The Axes Motors
3.7 The Axes Motors
General Each axis of the positioner has its own electric motor unit, including a synchronous
motor, a brake and a feedback device (resolver). The used motors are identical. The
drive shaft of the motor forms part of the gearbox.
The feedback device and brakes are installed by the supplier of the motor and
should never be removed from the motor. The complete motor assembly should be
replaced as a complete unit.
Motor Power Power is applied to the motors when the motor power button on the main panel is
pressed and either manual jogging or program execution is initiated.
Feedback Unit Each motor is equipped with a feedback unit (resolver) for the measuring system,
located on the end inside the motor. The feedback unit is connected to the motor
shaft. The purpose of the unit is to send feedback to the control electronics of the
position of the motor and thereby the positioner axis via the measuring board.
Axis Brakes Each motor is equipped with electrical holding brakes. The purpose of the brakes is
to hold the positioner in unchanged position when power is removed from the
motors. The brakes are active when no power is applied, and released (lifted) when
power is applied. The brakes are automatically released when power is applied to
the motor, but may also be released from the pendant or directly on the motor
connector etc. for service purposes. How to release the axis brakes for service
purposes is described in chapter ‘Repair’ in this manual.
Temperature Monitoring Each motor also includes a temperature sensor. If the temperature should increase
over a specified maximum, motor power will be removed and the brakes activated.
Commutation The motor does not need to be commutated (commutation value is 1.570800).

3HNA018189-001 Rev.12
3.8 Boards Overview
3.8 Boards Overview
General This section provides an overview of the different boards used in the IRB 5320
workpiece positioners.
For detailed description of the components, refer to ‘Unit Description, IRC5P’.
Overview The following boards are used for the IRB 5320 workpiece positioner:
– Serial Measuring Unit, SMU

– Connection board, CBP
For location of the boards, see Figure 15.
SMU The serial measuring unit SMU measures all the motor positions and reports these to
the axis computer in the control cabinet.
CBP The connection board CBP provides interconnection of the main cable with the
internal cabling in the positioner.
The function of the connection board is to distribute power and various signals to
the positioner motors and to interface the positioner motor temperature sensors with
the manipulator enable signal
Location The following illustration shows the location of the boards in the positioner.
Figure 15 Location of boards in the servo unit E11, front view
SMU
CBP

3HNA018189-001 Rev.12
3.8 Boards Overview

3HNA018189-001 Rev.12
4 Technical Specifications
4.1 Introduction
4.1 Introduction
About this Chapter This chapter provides technical specifications on the IRB 5320 workpiece
positioners.
WARNING! Repair work on the positioner must only be performed in accordance

with procedures given in chapter ‘Repair’ in this manual.

3HNA018189-001 Rev.12
4.2 Manipulator Versions
4.2 Manipulator Versions
General The positioner comes in two versions:
– IRB 5320 1 axis workpiece positioner (1E11)

– IRB 5320 3 axes workpiece positioner (1E11-2E21)
Figure 16 Manipulator versions
IRB 5320 1 Axis Workpiece Positioner
IRB 5320 3 Axes Workpiece Positioner
1 Axis Positioner The IRB 5320 1 axis workpiece positioner (1E11) consists of one rotating axis
(E11). The rotating axis can be equipped with a customer designed turntable.
3 Axes Positioner The IRB 5320 3 axes workpiece positioner (1E11-2E21) consists of two rotating
turntables (E21) mounted on an arm that can be rotated with a servo unit (E11).

3HNA018189-001 Rev.12
4.3 Positioner Specifications
General Specifications
1 Axis Positioner 3 Axes Positioner

Number of axes 1 3
Weight 135kg *1 215kg *1
Dimensions See ’Dimensions Positioners’ on page 37
Ex approved Explosion protected Exi/Exp for installation in hazardous area
Zone 1 & Zone 21 (Europe) and Division I, Class I & II.
Purge time The purge time is set in accordance with the Ex certification as
stated on the identification plate on the manipulator.
Airborne noise level < 72 dB (A) Leq (acc. to Machinery directive MD 2006/42/EC)
(The sound pressure level outside the working space)
Color specification Graphite white RAL7035
Ingress protection degree IP66
Ambient temperature 0°C - +40°C (Recommended max. ambient temp, <30°C) *2
Relative humidity Max. 95% Non-condensing.
(Complete robot during transportation, storing and operation)
*1 Weight including main cable.

*2 The temperatures given above do not apply under the following circumstances:
Positioner is covered with material which restricts heat emission. Positioner is
programmed with heavy payload and high speed and high acceleration.
Power Consumption

During a typical continuous 650W 650W
paint process with IRC5P
and an IRB 52 paint robot
Positioner Axes

Axis 1 Rotation of turntable Rotation of complete arm
assembly
Axis 2 NA Rotation of turntable 1
Axis 3 NA Rotation of turntable 2
Working Area

Range of motion Axis 1 360° infinite -15° - +195°
Range of motion Axis 2 NA 360° infinite
Range of motion Axis 3 NA 360° infinite
Working area NA See ’Working Area Drawing’ on
page 38

3HNA018189-001 Rev.12
Performance
Servo Unit E11 Servo Unit E21

Static repeatability at < 1 mm < 1 mm
radius=500mm
Velocity 180°/s 1746°/s (291 rpm)
Permitted Load
Servo Unit E11 Servo Unit E21

Max. load on servo unit 150kg 25kg
Max torque on servo unit 520Nm 270Nm

3HNA018189-001 Rev.12
4.4 Servo Unit E11 Specifications
Description The illustration below shows the dimensions of the servo unit E11.
Figure 17 Dimensions, servo unit E11

Rotating axis 1
Mounting holes
Cable entrance
Cover
395 346
Ø109.6
205
12 x M10
551 504.5
12 x 30°
13
Top view Foot print
Ø109.6
Ø92
Ø70
345
Side view
Axis 1 Top view

3HNA018189-001 Rev.12
Description The illustration below shows the dimensions of the servo unit E21.
Figure 18 Dimensions, servo unit E21
Turntable
Ø214
83.75
313
129
Cable entrance
Ø85
8 x 45°
8 x M8-16
141 118
G1/4"
246.5
383
The center of the turntable is equipped with a through-going cylindrical hole that
may be used for air supply. The top and bottom ends of the hole are equipped with a
G1/4” screw thread. The top of the turntable is equipped with 8 ea. M8 screw
threads that may be used for mounting of a spindle, fixture, etc.

3HNA018189-001 Rev.12
4.6 Dimensions Positioners
4.6 Dimensions Positioners
Description This section includes dimension drawings for the IRB 5320 positioners.
Figure 19 Dimensions, IRB 5320 1 axis workpiece positioner
345
205
395
551
Front view Side view
Figure 20 Dimensions, IRB 5320 3 axes workpiece positioner

1500 / 2000
Ø 214
118
100
642.5 459
205 395
551
Front view Side view

3HNA018189-001 Rev.12
4.7 Working Area Drawing
4.7 Working Area Drawing
Description This section shows the working area for the IRB 5320 3 axes workpiece positioner.
Figure 21 Working area, 3 axes workpiece positioner
-15° +195°
Axis2 Axis 3
Axis1

3HNA018189-001 Rev.12
5 Installation and Commissioning
5.1 Introduction
5.1 Introduction
5.1.1 General
About this Chapter This chapter provides information for secure installation of the IRB 5320 workpiece
positioner at the working site.
The chapter includes information on how to install the positioner at the installation
site, hints and information on how to prepare a mounting base for the positioner.
Important: This chapter only describes installation of the positioner. For complete
installation instructions, see also:
– ‘Product Manual, Control Cabinet IRC5P’ for installation of the control cabinet,
– ‘Product Manual, Manipulator’ for installation of the paint robot,
– ‘Unit Description, Paint’ for connection of the paint system and
– ‘Installation manual, IRC5P’ for starting up the robot system.
Safety Information Before any work described in this chapter is commenced, it is extremely important
that all information concerning safety is carefully studied.
safety information that describes danger and safety risks related to performing the
procedures. Read the ‘Safety Manual’ before performing any installation work.
WARNING! No installation work must be performed on the positioner before the

safety guidelines in the ‘Safety Manual’ have been read and understood. Work must
only be performed by skilled personnel with the proper training.
Welding All welding work at the robot location must be performed before any cables are
connected. Welding on the control cabinet, manipulator or any other components of
the robot system is not allowed. The ‘Welding Safety Precautions’ found under
‘Safety Risks Related to Installation’ in the ‘Safety Manual’ must be read before
any welding activities are started.
Purge Unit Installation of the purge unit is the same for all positioner and manipulator types and
is for this reason described in the ‘Product Manual, Control Cabinet IRC5P’.
Utility Needs Following utility will be required for the installation and operation of the positioner.
– Mains power

3HNA018189-001 Rev.12
5.1 Introduction
Required Tools and Most of the installation work can be performed with normal hand tools. Following
Items special tools will be needed:
– Lifting equipment.
– 24 VDC / Min. 5A, for releasing axis brakes.
Environmental For information on environmental conditions, see ‘Safety Manual’ and ’Positioner
Conditions Specifications’ on page 33.
Other Information For information on foundation loading, servo unit E11 template, performance,
working area, load diagram, etc., see ’Technical Specifications’ on page 31.
Information such as Circuit Diagram and Spare Parts Catalogue is available on the
supplied DVD-ROM. For complete information, see README file on DVD-ROM.
For Autocad drawings of working area, please contact your local ABB organization.
Preparing the Installation Before you start the installation, it is recommended that you make necessary
Site drawings to establish location of positioner, paint robot, control cabinet and other
components to be installed, design a solid mounting base for the positioner and plan
the location of process equipment, conduits for cables and hoses etc.
Lifting Equipment Make sure that the lifting equipment to be used for lifting the positioner is
dimensioned to handle the weight of the positioner. For information on positioner
weight, see ’Positioner Specifications’ on page 33.
Check for Damage When unpacking the positioner, control cabinet and associated components, check
that they have not been damaged during transportation. If any damage is found,
immediately report this to the producing unit, using the appropriate online tool. Also
check that all components are correctly delivered in accordance with the packing list
attached to the shipping crate.

3HNA018189-001 Rev.12
5.1 Introduction
5.1.2 Installation Guidelines
General The following sections detail the main steps on how to unload, transport and install
the positioner.
Installation Procedure
# Action Reference
1 Prepare for installation What you should be aware of before starting to
install the positioner is described in section
’Introduction’ on page 39
2 Position the positioner How to place the positioner in correct position is
described in section ’Positioning the Workpiece
Positioner’ on page 42
3 Designing a mounting base How to design a mounting base for the positioner is
described in ’Mounting Base’ on page 43
4 Install positioner How to lift and install the positioner is described in
’Mechanical Installation of Workpiece Positioner’
on page 44
5 Check electrical connections Check the electrical connections for the positioner
as described in ’Electrical Connections’ on page 46
6 Conclude installation Before the positioner can be used in production
some additional installation activities have to be
performed, as described in ’Concluding Activities’
on page 47

3HNA018189-001 Rev.12
5.2 Positioning the Workpiece Positioner
5.2 Positioning the Workpiece Positioner
General The necessity of finding an exact position for the positioner depends largely on the
used paint robot and the safe loading/unloading station. The positioner is designed
to be mounted on a horizontal plane.
For information on working area for the positioner, see ’Working Area Drawing’ on
page 38.
Important Notes Following points should be observed when planning the position of the positioner
and trimming the positioner to the accurate position:
• The positioner must be positioned so that all surfaces to be painted can be

reached.
• The positioner must be positioned so that the working area encounters no
obstructions.
• The foundation must be strong enough to support the weight of the positioner. In
addition, the foundation should deflect as little as possible due to the dynamic
forces from the positioner. Recommended is a concrete base or a rigid steel
structure. For more information, see ’Mounting Base’ on page 43.
Installation Example An installation example for the positioner is shown in ’Installation Site Example’ on
page 126.

3HNA018189-001 Rev.12
5.3 Mounting Base
5.3 Mounting Base
General When designing a mounting base, following points must be kept in mind. For
information on weight, permitted loads etc., see ’Positioner Specifications’ on
page 33.
• The base must be strong enough to carry the weight of the positioner.
• The base must have a stiffness which will minimize swinging related to dynamic
forces in X, Y and Z direction. (A common mistake is to make the mounting
base too weak). Note that if the positioner is mounted to the same structure as the
paint robot, the workpiece may be influenced by the paint robot.
• If the base is built on H-bars etc., measures should be taken to prevent bending
which may cause oscillations when the positioner is moving.
• It is recommended that deflection of the structure does not exceed more than
±1.5mm at worst case scenario (emergency stop). Note that repeated identical
painting movement at a low frequency may match the natural frequency of a
weak under structure.
• The mounting surface should be horizontal.
Positioner The positioner is recommended to be installed on a steel plate mounted to concrete

or a rigid steel structure. The steel plate requires a thickness of minimum 12mm.
For drawing and dimensions of the servo unit, see ’Servo Unit E11 Specifications’
on page 35.
The M12 mounting screws, minimum quality 8.8, must be tightened with correct
torque, see ’Tightening torques’ on page 146. Add Kernite K-NATE NLGI-2 grease
to the screws to prevent corrosion.

3HNA018189-001 Rev.12
5.4 Mechanical Installation of Workpiece Positioner
Procedure This section describes the mechanical installation of the workpiece positioner. The
positioner is lifted by using an overhead crane or similar lifting equipment.
1. Lift transport pallet with mounted positioner off lorry using a forklift.
2. Unpack the supplied packages and check that the contents is correct and
undamaged.
Note: Keep the positioner mounted to the pallet. Do not remove the positioner
attachment screws yet.
3. Lift pallet with mounted positioner and transport it to the installation area,
using a forklift.
4. For 1 axis workpiece positioner, install a lifting eye on turntable axis 1 on top
of the servo unit and attach lifting straps of the lifting equipment to the lifting
eye.
For 3 axes workpiece positioner, attach lifting straps of the lifting equipment to
the arm.
Figure 22 Lifting 3 axes positioner
Lifting strap attachment to hook
WARNING! The positioner is heavy! Make sure that the positioner is properly
supported.
5. Tension the lifting straps. Check that straps are properly secured.
6. Remove positioner from pallet, by removing 4 attachment screws.

3HNA018189-001 Rev.12
WARNING! Do not walk under the hanging load.
7. Lift positioner carefully and place the servo unit E11 upon the mounting base.
8. Tighten 4 attachment screws with correct torque, see ’Tightening torques’ on

page 146.
9. Remove lifting equipment.

3HNA018189-001 Rev.12
5.5 Electrical Connections
5.5 Electrical Connections
General Connections on the positioner have been made before shipment. The positioner
cable needs to be installed in the control cabinet.
Check Connection The attachment clamps for the positioner cable may have been disrupted during
handling and transportation of the positioner. It is for this reason important that the
connector connections and the securing of the cables are checked to prevent faulty
operation of the positioner due to noise related to a poorly grounded cable screen,
etc.
Remove cover on positioner servo unit E11. Inspect connectors and check that the
cable bracket is firmly secured. Re-install cover and tighten attachment screws.
Also check that ground cable is connected to grounding clamp beside cable inlet.
Figure 23 Main cable connections in workpiece positioner
X1 X10 X8 X7 X54
Grounding clamp
Routing Cable Route positioner cable via cable conduit etc. and through spray booth wall to
location where purge unit is installed. (For a non-Ex positioner, the cable is routed
directly to the control cabinet).
CAUTION! Cables must be laid in such a manner that they will not be damaged.
Also be aware that going through booth wall may require flame proof passage.

3HNA018189-001 Rev.12
5.6 Concluding Activities
5.6.1 IRB 5320 1 Axis Workpiece Positioner
Turntable The 1 axis positioner is equipped with a covering plate upon the rotating axis. A
customer designed turntable, that may be specially designed for specific
workpieces, can be installed upon the covering plate. For specifications on the
covering plate and attachment screws, see ’Servo Unit E11 Specifications’ on
page 35.
Calibration Marks To enable calibration of the 1 axis positioner, calibration marks must be applied on
the positioner:
1. Place the axis 1 in +180°.
2. Mark the turntable and the servo unit E11 such that these markings are aligned
when the axis 1 is in +180° position.
3. Calibrate the axis in this position.
5.6.2 General
Protections The positioner can be installed to operate under many different environmental
conditions and performing different type of operations. Some of these environments
and operations may include use of fluids which can be damaging to the positioner or
parts of it.
It is for this reason strongly recommended that the positioner is protected as

required by applying grease film or other means to avoid damages such as
corrosion, solvent entering into the servo units, etc. Use of plastic protection should
be avoided.
For more information on this subject, see chapter ’Preventive Maintenance’ on

page 49.

3HNA018189-001 Rev.12

3HNA018189-001 Rev.12
6 Preventive Maintenance
6.1 Introduction
6.1 Introduction
About this Chapter This chapter provides instructions for performing scheduled preventive
maintenance on the workpiece positioner.
The preventive maintenance is based on a maintenance chart with information about

required maintenance activities including intervals, and references to procedures for
the activities.
Note that the intervals described are recommended intervals. The intervals needed
for your installation may vary, depending on environmental conditions, number of
working hours etc. The maintenance routines in this description must be seen in
relation to the plant’s own maintenance routines for the paint equipment.
WARNING! No maintenance work must be performed on the positioner before the

safety guidelines in the ‘Safety Manual’ and ’Safety’ on page 11 have been read and
understood. Work must only be performed by skilled personnel with the proper
training.
General Considerations The prime objective of any preventive maintenance program is to ensure maximum
system availability. Each scheduled and properly performed preventive maintenance
activity should assist in realizing this objective. Preventive maintenance that does
not reduce system downtime is unnecessary and costly.
The positioner and paint system are designed to be able to work under very
demanding conditions with a minimum of maintenance. Nevertheless, certain
routine checks and preventative maintenance must be carried out at given periodical
intervals.
When performing routine maintenance or repair work, a number of precautions

must be kept in mind to avoid introducing additional errors into the system.
• Do not perform more than recommended preventive maintenance on equipment

which is working satisfactorily.
• Wipe all surfaces clean before starting maintenance procedures.
• To avoid unnecessary contamination by dust etc., always clean outside of control
cabinet and positioner before opening doors and covers.

3HNA018189-001 Rev.12
6.2 Maintenance Chart
6.2 Maintenance Chart
General Perform operations described in this list.
No. Activity and reference Interval Sign.

1 ’General Maintenance’ on page 51 Daily *1
*1 Interval strongly dependent on environmental conditions.

3HNA018189-001 Rev.12
6.3 General Maintenance
General Following points should be checked / attended to as often as required.
Cleaning the Positioner Dust on the manipulator surface causes a risk for static electricity. It is therefore
important to clean the manipulator surface regularly. Wipe all surfaces clean using a
wet lint-free cloth. Solvents may be used but with care. Strong solvents such as
acetone etc. should be avoided. High pressure cleaning devices may be used in the
spray booth, but spraying directly on the positioner should be avoided. If the
positioner is protected by a grease film or other means, replace as required. (Use of
plastic protection should be avoided.)
When the positioner is used in combination with powder coating applications,

special attention is required for cleaning the space beneath the turntables.
WARNING! To avoid static electricity, always use a wet or moist cloth on non
conductive surfaces such as paint equipment, hoses etc. Do not use a dry cloth.
Check Regularly Following points should be checked as often as required:
• Check for oil leaks. If a major oil leak is discovered, call for service personnel.
• Check for excessive play in gears. If this develops, call for service assistance.
• Check that cables between control cabinet, purge unit and positioner are not
damaged.
• In case of electrostatic spraying, daily check the grounding of the workpieces
(< 1MΩ).
Check Foundation Fastening screws and clamps which fasten the positioner in position to the
Attachment Screws foundation must be kept clean for corrosive fluids such as water, basic solutions and
acid solutions. This to avoid corrosion of security parts. If the corrosion protection
such as zinc coat or paint have been damaged, parts must be cleaned and covered by
anti-corrosive paint.

3HNA018189-001 Rev.12

3HNA018189-001 Rev.12
7 Repair
7.1 Introduction
7 Repair
7.1 Introduction
About this Chapter This chapter details all repair activities recommended for the workpiece positioner.
It is made up of separate procedures, each detailing a specific repair activity. Each

procedure contains all information required to perform the activity, such as required
tools and items.
WARNING! No repair work must be performed on the positioner before the safety
guidelines in the Safety Manual and ’Safety’ on page 11 have been read and
understood. Work must only be performed by skilled personnel with the proper
training.
Organization of The procedures are divided into a procedure for removal and a procedure for
Procedures installation. At the start of each procedure, a reference list shows information
located other places in the manual than in the procedure. If you want to print out a
procedure, you should also print the information referred to under reference to get
all information you need to perform the repair operation.
The manual describes the type of service work that can be carried out by the
customer´s own service staff on site. Certain types of work, requiring special
experience or special aids, are not dealt with in the manual. In such cases, the
defective module or component should be replaced on site. The faulty item should
be sent to your local ABB organization for service.
Replacement Items Make sure that any replacement items are available before performing any repair
procedures. Use only replacement items listed in the spare parts catalogue.
Purge System During operation, the positioner is supplied by compressed air. For this reason, the
positioner can not operate unless all covers are in place and properly sealed.
Missing screws will cause air leaks and result in increased air consumption or
failure in the purge system.

3HNA018189-001 Rev.12
7 Repair
7.1 Introduction
Tools Most of the repair work on the positioner can be performed with normal hand tools.
A few special tools are however required. These tools will be stated in the
procedures where they are needed.
Reference Information Following reference information is included in the manual:
– ’Configurations for weak foundations’ on page 142

– ’Mounting instructions for bearings’ on page 143
– ’Mounting instructions for seals’ on page 144
– ’Tightening torques’ on page 146
– ’Loctite® specifications’ on page 148
– ’Performing a gearbox leak-down test’ on page 149
– ’Safety instructions for replacing oil in gearboxes’ on page 150
– ’Oil type specifications’ on page 151
– ’Grease type specifications’ on page 153
Illustration References Some references to illustrations are placed in brackets ( ) indicating figure number
and position in the figure. Example: (fig.15/3) means figure 15 position 3.
Calibration Calibration of the positioner must be performed after replacing mechanical parts,
when a resolver error has occurred or when the power supply between a
measurement board and resolver has been interrupted etc.
Calibrating the positioner means to place the positioner arm (if applicable) and
turntables in a specific position and enter resolver data for this position into the
control system.
To place the arm and turntables of the 3 axis workpiece position in this calibration
position, a calibration fixture must be available.
For description of the calibration function and procedure for entering calibration
data, see Installation manual IRC5P, Configuration/General configuration.
For information on the calibration position, see ’Calibration Position’ on page 120.

3HNA018189-001 Rev.12
7 Repair
7.2 Releasing Axis Brakes
7.2.1 Introduction
General The axis brakes need to be released in some cases during repair work to install the
motors and possibly to reposition the positioner arm or turntables. These are
situations where the positioner is not powered which means that the normal brake
release function on the pendant can not be used.
The following describes how the axis brakes can be released by applying power to
connectors on the positioner.

3HNA018189-001 Rev.12
7 Repair
7.2.2 Brake Release Safety
General A number of precautions must be taken when releasing the axis brakes. These
precautions are described in the following.
Motors May Generate Make absolutely certain that no personnel is working on the positioner or control
Power system when moving the positioner arm or turntables by hand. Moving the electric
motors will generate 400VAC which will be present in the positioner and control
system.
Explosion Safety Make absolutely certain that the spray booth is tested to be non-hazardous before
bringing power supply for releasing the brakes into the spray booth.

3HNA018189-001 Rev.12
7 Repair
7.2.3 Manually Releasing Axis Brakes
General There are different methods available for manually releasing the axis brakes when
the positioner is not powered. These methods, together with information on required
power supply etc. will be described in the following.
Power Supply To release the brakes when the positioner is not operative, an external power source
must be available.
Figure 24 Brake release power supply
24 Volt power supply
Female pins
2
Wires (min. 1.5 mm )
The power supply must be capable of supplying 24 VDC with minimum 5 Ampere.
To connect the power supply to any of the described connectors, 2 wires fitted with
correct contra connector/pins must be available.

3HNA018189-001 Rev.12
7 Repair
Releasing All Brakes All axis brakes can be released simultaneously via a connector on the CBP-01
board, located in the servo unit E11, as described in the following.
Figure 25 Brake release on CBP-01, connector X2 mating face
9 16
X2
8 1 X2 X1 X4
X5
X3
0 Volt +24VDC
X16 X15 X14 X13 X12 X11
ABB AS, Robotics

X10
CBP
BAR CODE AREA
CONNECTION BOARD
1. Open servo unit E11 cover.
2. Locate connector X2 on the CBP-01 board as shown in illustration above.
WARNING! Read ’Brake Release Safety’ on page 56 before continuing.
3. Connect +24VDC to pin 4 and 0Volt to pin 5.
4. The brakes are now released and the positioner arm and turntables can be freely
moved.
The axes can also be released simultaneously via connector X411 on the positioner
main cable:
Connect +24VDC to connector X411 pin 4

Connect 0 Volt to connector X411 pin 5
Figure 26 Brake release on main cable, connector X411 mating face
+24VDC
16 1
4
5
18 3
0 volt

3HNA018189-001 Rev.12
7 Repair
Releasing Individual Axis brakes can be released individually using a connector on the CBP-01 board as
Brake via CBP-01 described in the following.
For overview of the positioner axes, see ’Basic Design’ on page 16.
Figure 27 Individual brake release on CBP-01

Motor 9
Motor 10
Motor 11
Motor 12
9 16
X2
8 1
Motor 8 X5
X2 X1 X4 X3
Motor 7
0 Volt X16 X15 X14 X13 X12 X11
ABB AS, Robotics

CBP X10
BAR CODE AREA
CONNECTION BOARD
CBP, connector X2
Positioner Axis Pin no. Connector signal
Motor for axis 1 7 Brakes for motor 7
1. Open servo unit E11 cover.
2. Locate connector X2 on the CBP-01 board as shown in illustration above.
3. Connect 0 Volt to pin 5 in connector X2.
4. To release brake for a certain axis, connect +24VDC to pin for required motor.
E.g. to release brakes for the motor for axis 1, connect +24VDC to pin 7.
5. The brake for the selected axis is now released and the axis can be freely
moved.

3HNA018189-001 Rev.12
7 Repair
Releasing Individual Axis brakes can be released individually by applying power directly in the motor
Brake Directly on Motor connector as described in the following.
For overview of the positioner axes, see ’Basic Design’ on page 16.
Figure 28 Brake release on axis motor

Connector on motors
3 1
8 7 +24VDC
9
0 volt
Motor connector
1. Locate axis motor and remove cover to get access to the motor.
2. Disconnect motor connector.
3. Connect +24VDC to pin 7 and 0 Volt to pin 8 in connector for required motor.
4. The brake for the selected axis is now released and the axis can be freely
moved.

3HNA018189-001 Rev.12
7 Repair
7.3 Servo Unit E11 Guidelines
General Following procedures provide information for replacing components on the servo
unit E11 of the IRB 5320 workpiece positioner.
Note: The procedures describe the IRB 5320 3 axes workpiece positioner. The
procedures for the IRB 5320 1 axis workpiece positioner are identical unless
specifically noted.

3HNA018189-001 Rev.12
7 Repair
7.3.1 Removal of Motor for Servo Unit E11
Location The motor for the servo unit E11 is located as shown in the figure below.
2 4
1
3
Rear view
5
6
7
10 11
8
16 17 18 19 20
12 13 14 15
21

3HNA018189-001 Rev.12
7 Repair
1 Servo unit E11 motor

2 Servo unit E11 front cover
3 Servo unit E11 bottom cover
4 Servo unit E11 attachment screws
5 Motor bracket attachment screws
6 Motor bracket
7 Motor power connector
8 Measuring system connector
9 Motor attachment screws
10 SMU board
11 O-ring on motor unit
12 CBP board
13 Main cable connector X1
14 CBP bracket attachment screws
18 Connector bracket attachment screws
19 Connector bracket
21 Cable bracket
References – Figure 56
Tools and Items – Hand tools

– Lifting equipment
Procedure The procedure describes how to remove the motor (fig.29/1) for servo unit E11.
WARNING! No repair work must be performed on the robot before the safety
regulations in ’Safety’ on page 11 have been read and understood.
1. Prepare operation.
a. Jog robot to a convenient position.
b. Turn the electrical disconnect switch Off and lock switch in Off position.
WARNING! Make sure that the mains switch is Off and locked in Off position
before continuing. Also make sure that possible other connected systems are Off.
c. Remove front cover (fig.29/2) from servo unit E11.

3HNA018189-001 Rev.12
7 Repair
2. Remove main cable.
Note: Before disconnecting any connectors, ground wires, cable brackets or

cable straps, carefully note position to simplify correct reinstallation.
a. Disconnect main cable connectors X1 (fig.29/13) and X10 (fig.29/15) from

CBP (fig.29/12).
b. Disconnect main cable connectors X7 (fig.29/16) and X8 (fig.29/17) from

SMU (fig.29/10).
c. Disconnect main cable connector X54 (fig.29/20) from connector bracket

(fig.29/19).
d. Remove ground connection from clamp beside main cable inlet.
e. Remove the main cable out of the servo unit E11.
3. Remove brackets from servo unit E11 bottom cover.
Note: It may not be necessary to disconnect all cables and remove the brackets
out of the servo unit. Just lay them aside and protect them during the lifting
operation.
a. Remove cable bracket (fig.29/21) from bottom cover (fig.29/3) (not

applicable for IRB 5320 1 axis workpiece positioner).
b. Remove CBP bracket attachment screws (fig.29/14) and remove bracket

with mounted CBP board (fig.29/12) from bottom cover.
c. Remove connector bracket attachment screws (fig.29/18) and remove

connector bracket (fig.29/19) from bottom cover.
4. Lift positioner.
a. For 1 axis workpiece positioner, install a lifting eye on the servo unit and
attach lifting straps of the lifting equipment to the lifting eye.
For 3 axes workpiece positioner, attach lifting straps of the lifting

equipment to the arm.

3HNA018189-001 Rev.12
7 Repair
Figure 30 Lifting 3 axes workpiece positioner
WARNING! The positioner is heavy! Make sure that the positioner is properly
supported.
b. Tension the lifting straps. Check that straps are properly secured.
c. Remove positioner from base, by removing 4 attachment screws (fig.29/4).
d. Lift positioner carefully.
e. Place the servo unit on a side on the floor.
f. Remove lifting straps.
g. Attach lifting straps to the servo unit E11 attachment holes (fig.29/4).
h. Carefully lift the positioner such that it is hanging upside down. Ensure
that the servo unit E11 is level such that the oil does not need to be
removed from the gearbox.
5. Remove electrical connections.

cable straps, carefully note position to simplify correct installation of new
motor. Connector numbers can be found in the illustration in Figure 56.
a. Remove servo unit E11 bottom cover attachment screws and remove
bottom cover (fig.29/3).
b. Disconnect motor power connector (fig.29/7).

3HNA018189-001 Rev.12
7 Repair
c. Disconnect measuring system connector (fig.29/8).
d. Remove motor bracket attachment screws (fig.29/5) and remove motor

bracket (fig.29/6) from motor.
6. Remove motor.
a. Mark position of motor before removing it to ensure correct reinstallation.
b. Remove 4 e.a. motor attachment screws (fig.29/9). Retain screws for use
with new motor.
c. Carefully take the motor out of the servo unit.
Note: The motor unit is heavy!

3HNA018189-001 Rev.12
7 Repair
7.3.2 Installation of Motor for Servo Unit E11
Location The motor for the servo unit E11 shall be located as shown in the figure below.
2 4
1
3
Rear view
5
6
7
10 11
8
16 17 18 19 20
12 13 14 15
21

3HNA018189-001 Rev.12
7 Repair

6 Motor bracket
10 SMU board
12 CBP board
21 Cable bracket
References – ’Releasing Axis Brakes’ on page 55

– Figure 30 (not applicable for IRB 5320 1 axis workpiece positioner)

– Rotor rotating tool
– Kernite K-NATE NLGI-2 grease
Procedure The procedure describes how to install the motor for servo unit E11.
a. Keep positioner in same upside down position.
b. Clean mounting surface on motor flange and servo unit using a lint-free
cloth.

3HNA018189-001 Rev.12
7 Repair
c. Check that motor flange and mounting surface on servo unit are not
scratched or damaged.
d. Make sure that the o-ring (fig.31/11) on new motor is properly positioned
in the groove. Add 4 spots of Kernite K-NATE NLGI-2 grease pitched 90°
in the groove to keep o-ring in position.
2. Install new motor unit.
a. Release axis brakes for the new motor. - Ref.: ’Releasing Axis Brakes’ on
page 55.
b. Align rotor on motor with gear and place motor unit carefully into correct
position in the servo unit. Pay attention to the direction of the cables.
c. Install motor attachment screws (fig.31/9) and tighten with torque 2Nm.
3. Align motor.
a. Insert screw of rotor rotating tool (fig.32/2) on rear of motor shaft. Rotate
tool until it stops. Tighten lightly.
b. Place a crowbar (fig.32/1) or other suitable tool between the motor flange
and the servo unit wall.
c. Bend carefully using the tool until play is at a minimum.
Figure 32 Alignment of motor unit
d. Use a combination of turning the rotor using the tool and rotating the
positioner arm / turntable by hand to find the position where the play
between the gear of the motor and gearbox is the smallest.
e. Bend carefully using the crowbar while rotating rotor until play is next to
nothing.

3HNA018189-001 Rev.12
7 Repair
f. Cross-tighten motor attachment screws (fig.31/9) with correct torque.

- Ref.: ’Tightening torques’ on page 146.
g. Rotate rotor and move arm to feel that rotation is not too tight or loose over
the full area of the robot axis motion.
h. Activate axis brakes.
i. Remove rotor rotating tool and crowbar.
4. Install motor connections.
a. Place motor bracket (fig.31/6) in position and install motor bracket

attachment screws (fig.31/5).
b. Install motor power (fig.31/7) and measuring system connector (fig.31/8).
c. Install servo unit E11 bottom cover (fig.31/3). Tighten screws with correct
torque, see ’Tightening torques’ on page 146.
5. Install positioner.
a. Lower the positioner carefully and lay it on one side on the floor.
b. Remove lifting straps.
c. For 1 axis workpiece positioner, attach lifting straps of the lifting

equipment to the lifting eye on the servo unit.
For 3 axes workpiece positioner, attach lifting straps of the lifting

equipment to the arm, refer to Figure 30.
d. Lift positioner carefully and check that there is no oil leakage.
e. Place the servo unit upon the mounting base.
f. Tighten 4 attachment screws (fig.31/4) with correct torque, see ’Tightening

torques’ on page 146.
g. Remove tension from lifting straps and remove lifting equipment.
6. Install brackets on servo unit E11 bottom cover.
a. Place bracket with mounted CBP board in position on bottom cover and
install attachment screws (fig.31/14).
b. Place connector bracket (fig.31/19) in position on bottom cover and install

attachment screws (fig.31/18).
c. Install cable bracket (fig.31/21) on bottom cover (not applicable for

IRB 5320 1 axis workpiece positioner).

3HNA018189-001 Rev.12
7 Repair
7. Install main cable.
a. Insert main cable in servo unit.
b. Install ground connection to clamp beside cable inlet.
c. Connect cable connectors X1 (fig.31/13) and X10 (fig.31/15) on CBP

(fig.31/12).
d. Connect cable connectors X7 (fig.31/16) and X8 (fig.31/17) on SMU

(fig.31/10).
e. Connect cable connector X54 (fig.31/20) on connector bracket (fig.31/19).
8. Conclude operation.
a. Install servo unit E11 front cover (fig.31/2).
b. Calibrate the robot. For information, see ’Calibration Position’ on

page 120.

3HNA018189-001 Rev.12
7 Repair
7.3.3 Removal of Servo Unit E11
Location The servo unit E11 is located as shown in the figure below.

1 2 3
4 5
6
Front view
7 8 9 3 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25
26

3HNA018189-001 Rev.12
7 Repair
1 Servo unit E11

2 Arm
3 Arm cover
7 Arm attachment screws
8 Cable feed clamp attachment screws
9 Internal cabling
12 SMU board
13 SMU attachment screws
14 Motor unit
17 CBP board
21 Cable bracket
References – ’Replace Oil for Servo Unit E11’ on page 86

– Figure 56

Procedure The procedure describes how to remove the servo unit E11.

3HNA018189-001 Rev.12
7 Repair
c. Remove oil from gearbox, as described in ’Replace Oil for Servo Unit
E11’ on page 86.
d. Remove arm cover attachment screws and remove cover (fig.33/3) (not
applicable for IRB 5320 1 axis positioner).
e. Remove front cover (fig.33/4) from servo unit E11.
2. Remove main cable.

a. Disconnect main cable connectors X1 (fig.33/18) and X10 (fig.33/20) from

CBP (fig.33/17).
b. Disconnect main cable connectors X7 (fig.33/24) and X8 (fig.33/22) from

SMU (fig.33/12).
c. Disconnect main cable connector X54 (fig.33/25) from connector bracket

(fig.33/16).
d. Protect the disconnected connectors.
e. Remove ground connection from clamp beside cable inlet.
f. Remove the main cable out of the servo unit E11.
3. Remove cabling out of servo unit E11.

Connector numbers can be found in the illustration in Figure 56.
a. Disconnect connectors from CBP (fig.33/17). Remove p-clips.
b. Disconnect measurement system (fig.33/11) and power (fig.33/10)

connectors from motor unit (fig.33/14).
c. Disconnect connectors from SMU (fig.33/12).
d. Remove purge connector X54 (fig.33/25) from connector bracket

(fig.33/16).
e. Remove cable bracket (fig.33/21) from bottom cover (fig.33/6) (not

applicable for IRB 5320 1 axis workpiece positioner).
f. Protect the disconnected connectors (not applicable for IRB 5320 1 axis
workpiece positioner).

3HNA018189-001 Rev.12
7 Repair
g. At the center of the arm, remove cable feed clamp attachment screws
(fig.33/8) (not applicable for IRB 5320 1 axis workpiece positioner).
h. Pull the cable feed clamp, gasket and cables out of the servo unit E11, as
shown in the illustration below (fig.34/1) (not applicable for
IRB 5320 1 axis workpiece positioner).
Figure 34 Cable feed clamp and cables removal

1
4. Remove electronic boards out of Servo unit E11.
a. Remove CBP bracket attachment screws (fig.33/19) and take CBP

(fig.33/17) out of the servo unit.
b. Remove SMU attachment screws (fig.33/13) and remove SMU (fig.33/12)

out of the servo unit.
c. Remove connector bracket attachment screws (fig.33/23) and remove

connector bracket (fig.29/16) from bottom cover.
5. Remove purge sensor (not applicable for IRB 5320 3 axis workpiece
positioner).
a. If servo unit E11 is equipped with purge sensor, remove purge sensor
connector and purge hose from purge sensor (fig.35/1).

3HNA018189-001 Rev.12
7 Repair
Figure 35 Purge unit
b. Remove purge sensor attachment screws and remove purge sensor out of
servo unit E11.
c. Remove purge valve attachment screws and remove purge valve (fig.35/2).
6. Dismount the positioner arm (not applicable for IRB 5320 1 axis workpiece
positioner).
a. Attach lifting straps of the lifting equipment to the arm of the positioner
(fig.33/2).

3HNA018189-001 Rev.12
7 Repair
Figure 36 Lifting positioner
WARNING! The positioner arm is heavy! Make sure that the positioner arm is
properly supported. Suitable lifting equipment may be required to lift the positioner
arm in a secure way.
WARNING! Make sure that the arm is properly supported and sufficiently balanced.
c. Remove arm attachment screws (fig.33/7).
d. Lift positioner arm carefully from servo unit E11.
e. Carefully lower the arm and place it on a solid support.
7. Remove motor unit out of servo unit E11.
a. Remove servo unit E11 from base, by removing 4 attachment screws

(fig.33/5).
b. Place the servo unit on a side on the floor.
c. Remove servo unit E11 bottom cover attachment screws and remove
bottom cover (fig.33/6).
d. Mark position of motor before removing it to ensure correct reinstallation.
e. Support the motor.

3HNA018189-001 Rev.12
7 Repair
WARNING! The motor is heavy! Make sure that the motor is properly supported to
prevent it from falling when removing the attachment screws. Suitable lifting
equipment may be required to remove the motor in a secure way.
f. Remove 4 e.a. motor attachment screws (fig.33/15). Retain screws for

reinstallation of the motor.
g. Carefully take the motor out of the servo unit.

3HNA018189-001 Rev.12
7 Repair
7.3.4 Installation of Servo Unit E11
Location The servo unit E11 shall be located as shown in the figure below.

1 2 3
4 5
6
Front view
7 8 9 3 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25
26

3HNA018189-001 Rev.12
7 Repair
1 Servo unit E11

2 Arm
3 Arm cover
7 Arm attachment screws
8 Cable feed clamp attachment screws
9 Internal cabling
12 SMU board
13 SMU attachment screws
14 Motor unit
17 CBP board
21 Cable bracket

– ’Replace Oil for Servo Unit E11’ on page 86
– Figure 62

Procedure The procedure describes how to install the servo unit E11.

3HNA018189-001 Rev.12
7 Repair
a. Clean mounting surfaces on servo unit flanges, motor flange and positioner
arm (not applicable for IRB 5320 1 axis workpiece positioner) using a
lint-free cloth.
b. Check that mounting surfaces on servo unit, motor flange and positioner
arm (not applicable for IRB 5320 1 axis workpiece positioner) are not
c. Place the servo unit on a side on the floor.
2. Install motor unit.
a. Make sure that the o-ring (fig.37/26) on motor is properly positioned in the
groove. Add 4 spots of Kernite K-NATE NLGI-2 grease pitched 90° in the
groove to keep o-ring in position.
b. Release axis brakes for the new motor. - Ref.: ’Releasing Axis Brakes’ on
page 55.
c. Align rotor on motor with gear and place motor unit carefully into correct
position in the servo unit. Pay attention to the direction of the cables.
d. Install attachment screws (fig.37/15) and tighten with torque 2Nm.
3. Align motor.
b. Place a crowbar (fig.38/1) or other suitable tool between the motor flange
and the servo unit wall.
c. Bend carefully using the tool until play is at a minimum.

3HNA018189-001 Rev.12
7 Repair
d. Turn the rotor using the tool to find the position where the play between
the gear of the motor and gearbox is the smallest.
e. Bend carefully using the crowbar while rotating rotor until play is next to
nothing.
f. Cross-tighten motor attachment screws (fig.37/15) with correct torque.

g. Rotate rotor to feel that rotation is not too tight or loose over the full area
of the robot axis motion.
h. Activate axis brakes.
i. Remove rotor rotating tool and crowbar.
j. Install servo unit E11 bottom cover (fig.37/6). Tighten screws with correct
torque, see ’Tightening torques’ on page 146.
4. Install electronic boards.
a. Install SMU (fig.37/12) to gear housing wall and tighten SMU attachment
screws (fig.37/13).
b. Place CBP (fig.37/17) on bottom cover and install CBP bracket attachment
screws (fig.37/19).
c. Place connector bracket (fig.37/16) on bottom cover and install attachment

screws (fig.37/23).
5. If required, install purge unit (not applicable for IRB 5320 3 axis workpiece
positioner).
a. Place purge valve (fig.39/2) in position in servo unit E11 and install
attachment screws.

3HNA018189-001 Rev.12
7 Repair
Figure 39 Purge unit
b. Place purge sensor (fig.39/1) in position in servo unit E11 and install
attachment screws.
c. Install purge sensor connector and purge hose on purge sensor.
d. Install purge connector on connector bracket (fig.37/16).
6. Install motor connections.
a. Install motor power (fig.37/10) and measuring system connector

(fig.37/11) on motor.
b. Install measuring system cable to SMU (fig.37/12).
c. Install motor power cable and p-clips to CBP (fig.37/17).
7. Install servo unit.
Note: The servo unit is heavy!
a. Carefully lift servo unit and place it on the foundation.
b. To ensure that the gearbox is properly sealed, it is recommended to

perform a leak-down test. Perform a leak-down test as described in
’Performing a gearbox leak-down test’ on page 149.
c. Install servo unit attachment screws (fig.37/5). Cross-tighten screws with

correct torque. - Ref.: ’Tightening torques’ on page 146.

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8. Install positioner arm (not applicable for IRB 5320 1 axis workpiece
positioner).
a. Attach lifting straps of the lifting equipment to the arm of the positioner
(fig.37/2).
Figure 40 Lifting positioner
WARNING! The positioner arm is heavy! Make sure that the arm is properly
supported and sufficiently balanced. Do not walk under the hanging load.
c. Lift positioner arm.
d. Carefully lower the arm and place it on the servo unit.
e. Install arm attachment screws (fig.37/7). Cross-tighten screws with correct

torque. - Ref.: ’Tightening torques’ on page 146.
f. Remove lifting equipment.
9. Install cabling in servo unit E11 (not applicable for IRB 5320 1 axis workpiece
positioner).
a. Route cables (fig.37/9) from positioner arm, through the cable feed clamp
and gasket, into the servo unit E11.
b. Place cable feed clamp in position and cross-tighten attachment screws

(fig.37/8).
c. Install cable connectors to SMU (fig.37/12).

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d. Install cable connectors and p-clips to CBP (fig.37/17).
e. Install purge connector on connector bracket (fig.37/16) (not applicable if

purge sensor is installed in servo unit E11).
f. Install cable bracket (fig.37/21) on bottom cover. Cable arc length is

260mm, see Figure 62.
10. Install main cable.
a. Insert main cable in servo unit.
b. Install ground connection to clamp beside cable inlet.
c. Connect cable connectors X1 (fig.37/18) and X10 (fig.37/20) on CBP

(fig.37/17). Install ground connections
d. Connect cable connectors X7 (fig.37/24) and X8 (fig.37/22) on SMU

(fig.37/12).
e. Connect cable connector X54 (fig.37/25) on connector bracket (fig.37/16).
a. Install servo unit front cover (fig.37/4).
b. Install arm cover (fig.37/3) (not applicable for IRB 5320 1 axis workpiece
positioner).
c. Tighten screws with correct torque, see ’Tightening torques’ on page 146.
d. Refill oil in gearbox, as described in ’Replace Oil for Servo Unit E11’ on
page 86.
e. Calibrate the robot. For information, see ’Calibration Position’ on

page 120.

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7.3.5 Replace Oil for Servo Unit E11
Location The filling plug on the gearbox for servo unit E11 is located as shown in the figure
below.
Figure 41 Location of filling plug servo unit E11

1
Servo unit E11
1 Filling plug servo unit E11 gearbox
References – ’Safety instructions for replacing oil in gearboxes’ on page 150

– Pump, hose and container
Oil Specification
Oil type: Mobil MobilgearTM 600 XP 320

Quantity: Approx. 3.4liter
Level: 0-20 mm below filling hole
Note: Oil quantity refers to an empty, clean gearbox. Later refilling will require a
lower quantity.
Procedure The procedure describes how to replace oil for the servo unit E11 gearbox.

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WARNING! Before starting to replace oil, observe ’Safety instructions for replacing
oil in gearboxes’ on page 150.
1. Prepare oil removal operation.
a. Turn the electrical disconnect switch Off and lock switch in Off position.
2. Remove oil.
a. Place a suitable container with sufficient volume beside the servo unit.
b. Remove the filling plug (fig.41/1).
c. Connect hose to filling hole.
d. Drain as much oil as possible, using a pump, hose and container.
Note: Oil drained from the positioner must be disposed of in accordance

with local regulations.
e. Clean filling plug. Re-install plug and tighten.
3. Prepare oil filling operation.
4. Fill new oil.
a. Remove filling plug (fig.41/1).
b. Carefully fill gearbox with Mobil MobilgearTM 600 XP 320 until oil level
is as specified, see ’Oil Specification’ on page 86.
c. Clean filling plug. Re-install plug and tighten.

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General Following procedures provide information for replacing components on the servo
units E21 of the IRB 5320 3 axis workpiece positioner.

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7.4.1 Removal of Motor for Servo Unit E21
Location The motor for the servo unit E21 is located as shown in the figure below.
Figure 42 Servo unit E21, rear view

1 1
2 2
Rear view
5
6
1 1 4 7 5

2 Servo unit E21 cover
4 Motor bracket

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References – ’Oil Removal Servo Unit E21’ on page 103
Procedure The procedure describes how to remove the motor for servo unit E21 (fig.42/1).
c. Remove oil from gearbox, as described in ’Oil Removal Servo Unit E21’
on page 103.
2. Remove motor.
a. Remove motor bracket attachment screws (fig.42/7) and remove bracket

(fig.42/4) from motor.
b. Support motor (fig.42/1).
WARNING! The motor is heavy! Make sure that the motor is properly supported to
prevent it from falling when removing the attachment screws. Suitable lifting
equipment may be required to remove and lower the motor in a secure way.
c. Mark position of motor before removing it to ensure correct reinstallation.
d. Remove 4 e.a. motor attachment screws (fig.42/3). Retain screws for use
with new motor.
e. Carefully lower the motor out of the servo unit.

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7.4.2 Installation of Motor for Servo Unit E21
Location The motor for the servo unit E21 shall be located as shown in the figure below.

1 1
2 2
Rear view
5
6
1 1 4 7 5

4 Motor bracket
6 Measuring connector

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– ’Oil Filling Servo Unit E21’ on page 107

Procedure The procedure describes how to install the motor for servo unit E21.
a. Clean mounting surface on motor flange and servo unit using a lint-free
cloth.
b. Check that motor flange and mounting surface on servo unit are not
c. Make sure that the o-ring on new motor (fig.43/8) is properly positioned in
the groove. Add 4 spots of Kernite K-NATE NLGI-2 grease pitched 90° in
the groove to keep o-ring in position.
2. Install motor.
a. Release axis brakes for the new motor. - Ref.: ’Releasing Axis Brakes’ on
page 55.
b. Align rotor on motor with gear and lift new motor into correct position in
servo unit.
c. Install attachment screws (fig.43/3) and tighten with torque 2Nm.
d. Place motor bracket (fig.43/4) in position and install attachment screws

(fig.43/7).
3. Align motor.

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b. Place a rod (fig.44/2) or other suitable tool against the motor flange. Push
or hit the rod with a rubber hammer until play is at a minimum.
1 2
c. Use a combination of turning the rotor using the tool and rotating the
turntable axis by hand to find the position where the play between the gear
of the motor and gearbox is the smallest.
d. Adjust play carefully using the rod while rotating rotor until play is next to
nothing.
e. Cross-tighten motor attachment screws (fig.43/3) with correct torque.

f. Rotate rotor and rotate turntable to feel that rotation is not too tight or loose
over the full area of the robot axis motion.
g. Activate axis brakes.
h. Remove rotor rotating tool and rod.
a. To ensure that the gearbox is properly sealed, it is recommended to

b. Refill oil in gearbox, as described in ’Oil Filling Servo Unit E21’ on

page 107.
c. Calibrate the robot. For information, see ’Calibration Position’ on

page 120.

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7 Repair
7.4.3 Removal of Radial Seals from Servo Unit E21
Location The radial seals are located as shown in the figure below.
Figure 45 Radial seals, servo unit E21

1
2
3 4 1
Front view
1 Radial seal servo unit E21, upper

2 Radial seal servo unit E21, lower
3 Turntable
4 Turntable attachment screws
References – ’Oil Removal Servo Unit E21’ on page 103
Procedure The procedure describes how to remove the radial seals from the servo unit E21.

3HNA018189-001 Rev.12
7 Repair
c. Remove oil from gearbox, as described in ’Oil Removal Servo Unit E21’
on page 103.
d. Prepare a suitable container to collect the oil that will slowly drip out of the
gearbox when the seals have been removed.
2. Remove turntable.
a. Remove 2 ea. turntable attachment screws (fig.45/4).
b. Remove turntable (fig.45/3) from the servo unit E21.
3. Remove the upper (fig.45/1) and lower radial seals (fig.45/2).
a. Use a center punch and a hammer to make 2 small holes in the radial seals.
b. Insert 2 wood screws in the holes.
c. Pull out the radial seals using a vise grip pliers. Discard old radial seal.
d. Collect the oil dripping out of the gearbox.

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7.4.4 Installation of Radial Seals for Servo Unit E21
Location The radial seals for the servo unit E21 shall be located as shown in the figure below.
Figure 46 Radial seals, servo unit E21

1
2
3 4 1
Front view
1 Radial seal servo unit E21, upper

2 Radial seal servo unit E21, lower
3 Turntable
4 Turntable attachment screws
References – ’Performing a gearbox leak-down test’ on page 149

– ’Oil Filling Servo Unit E21’ on page 107

– Special tool for installing seals
– Loctite® 270 glue (green)
Procedure The procedure describes how to install the radial seals for servo unit E21.

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a. Clean mounting surface on servo unit using a lint-free cloth.
2. Install new radial seals.
a. Check the mounting surfaces on servo unit for scratches and wearing. If
needed, use a rubbing brick to remove damages that may have caused the
leakage.
b. Add Kernite K-NATE NLGI-2 grease on inside (fig.47/1) of new radial

seals (fig.46/1,2).
Figure 47 Upper and lower radial seals

1 2
Upper radial seal
Lower radial seal

1 2

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7 Repair
c. Add Loctite® 270 glue (green) on outside (fig.47/2) of new radial seals.
d. Install the new radial seals. Use a special tool for installing the new seal.
Note: The seals need to be pushed equally on all sides. Never hammer
directly on the seal, as this may result in leakage.
a. To ensure that the gearbox is properly sealed, it is recommended to

b. Refill oil in gearbox, as described in ’Oil Filling Servo Unit E21’ on

page 107.
c. Calibrate the robot. For information, see ’Calibration Position’ on

page 120.

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7.4.5 Removal of Servo Unit E21

1 2
5 6 7
1 Servo unit E21

2 Servo unit E21
5 Purge valve
6 Purge sensor
7 Purge valve attachment screws
References – ’Removal of Motor for Servo Unit E21’ on page 89

Procedure The procedure describes how to remove the servo unit E21 (fig.48/1 and/or 2).

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b. Remove motor unit as described in ’Removal of Motor for Servo Unit E21’
on page 89.
2. Remove purge sensor (if applicable).
a. Remove purge sensor attachment screws and remove purge

sensor (fig.48/6) out of servo unit E21.
b. Remove purge valve attachment screws (fig.48/7) and remove purge valve
(fig.48/5).

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7.4.6 Installation of Servo Unit E21

1 2
5 6 7
1 Servo unit E21

2 Servo unit E21
5 Purge valve
6 Purge sensor
7 Purge valve attachment screws
References – ’Installation of Motor for Servo Unit E21’ on page 91

Procedure The procedure describes how to install the servo unit E21.

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a. Clean mounting surfaces on servo unit flange and positioner arm using a
lint-free cloth.
b. Check that mounting surfaces on servo unit and positioner arm are not
2. Install purge unit (if applicable).
a. Place purge valve (fig.49/5) in position in servo unit and install attachment
screws (fig.49/7).
b. Place purge sensor (fig.49/6) in position in servo unit and install

attachment screws.
a. Install motor, as described in ’Installation of Motor for Servo Unit E21’ on

page 91.

page 120.

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7 Repair
7.4.7 Oil Removal Servo Unit E21

1 2 6 8
5 7
10
11
12 13 14 15
16
1 Servo unit E21

5 Cable clamp
6 Arm cover
7 Cable clamp
8 Servo unit E21
9 Purge hose connection
10 Internal cabling
11 E21 cable feed clamp attachment screws
13 Purge sensor connector

3HNA018189-001 Rev.12
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16 Purge sensor
References – Figure 56
Procedure The procedure describes how to remove the oil out of the gearbox of servo unit E21
(fig.50/1 and/or 8).
b. Remove cover from servo unit E21(fig.50/3).
c. Remove servo unit E11 front cover (fig.50/4).
d. Remove arm cover (fig.50/6).
2. Disconnect cable and hose connections in servo unit E21.

Connector numbers can be found in the illustration in Figure 56.
a. Disconnect motor power connector (fig.50/15).
b. Disconnect measuring system connector (fig.50/14).
c. If servo unit E21 is equipped with purge sensor, remove purge sensor
connector (fig.50/13) and purge hose from purge sensor (fig.50/16).
3. Disconnect hose connection and cable clamp in arm.
a. Disconnect purge hose (fig.50/9) in center of positioner arm.
b. Remove relevant cable clamp (fig.50/5 or 7) out of positioner arm.
4. Loosen cabling in servo unit E11.
a. Remove cable bracket (fig.51/2) from bottom cover.

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7 Repair
b. At the center of the arm, remove E11 cable feed clamp attachment screws
(fig.50/12).
c. Pull the cable feed clamp and gasket out of the servo unit E11, as shown in
the illustration below (fig.51/1).
Figure 51 Cable feed clamp removal

1
d. Pull cables (fig.50/10) as much as possible out of the servo unit E11, to
enable disconnection of servo unit E21 from the arm.
5. Remove servo unit.
WARNING! The servo unit is heavy! Make sure that the servo unit is properly
supported. Suitable lifting equipment may be required to lower the servo unit in a
secure way.
a. If required, install a lifting eye on the servo unit.
b. Tension the lifting strap. Check that strap is properly secured.
c. Remove servo unit E21 attachment screws (fig.50/2).
d. Lift servo unit carefully from positioner arm.
e. Place the servo unit on a support.
6. Remove cable feed clamp from servo unit E21.
a. Remove E21 cable feed clamp attachment screws (fig.50/11).
b. Take cables out of the cable feed clamp and gasket and take cables out of
the servo unit E21.
7. Remove oil out of gearbox.
a. Carefully place the servo unit E21 such that the oil plug (fig.52/2) is at the
lowest position.

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7 Repair
Figure 52 Oil plugs and accumulator hose
1
3
8. Remove oil.
WARNING! Before starting to remove oil, observe ’Safety instructions for replacing
oil in gearboxes’ on page 150.
a. Place a suitable container with sufficient volume beneath the oil plug
(fig.52/2).
b. Remove oil plug (fig.52/2).
c. Remove hose (fig.52/3) from accumulator.
d. After most oil has been run out of the gearbox, remove oil plug (fig.52/1)
such that all oil will run out.
Note: Oil drained from the positioner must be disposed of in accordance

with local regulations.
e. Clean oil plugs and hose connection. Re-install plugs and hose connection
and tighten.

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7.4.8 Oil Filling Servo Unit E21

1 2 6 8
5 7
10
11
12 13 14 15
16
1 Servo unit E21

5 Cable clamp
6 Arm cover
7 Cable clamp
8 Servo unit E21
9 Purge hose connection
10 Internal cabling
13 Purge sensor connector

3HNA018189-001 Rev.12
7 Repair

16 Purge sensor
References – ’Safety instructions for replacing oil in gearboxes’ on page 150

– Figure 62

Oil Specification
Oil type: Kyodo Yushi TMO 150

Quantity: Full gearbox with membrane at minimum gearbox volume (approx. 1.4liter)
Level: Level with filling hole
Procedure The procedure describes how to fill the gearbox of servo unit E21 with oil.
1. Prepare oil filling operation.
b. Clean mounting surfaces on servo unit flange and positioner arm using a
lint-free cloth.
c. Check that mounting surfaces on servo unit and positioner arm are not
d. Place the servo unit E21 such that the filling plug (fig.54/1) is at the
highest position.
Figure 54 Filling plug at highest position

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7 Repair
e. Ensure that filling plug (fig.54/2) and hose connection (fig.54/3) are
tightened.
2. Fill new oil.
WARNING! Before starting to fill oil, observe ’Safety instructions for replacing oil
in gearboxes’ on page 150.
a. Remove filling plug (fig.54/1).
b. Push the membrane completely inwards, as shown by the arrow (fig.54/4).
Important: Keep the membrane completely pushed inwards during the whole filling
procedure, such that the gearbox volume will be at minimum. When the temperature
is rising during operation, the oil will so be able to expand.
c. Carefully fill gearbox with Kyodo Yushi TMO 150 until oil level is as
specified, see ’Oil Specification’ on page 108.
d. Clean filling plug. Re-install plug and tighten.
3. Install cable feed clamp on servo unit E21.
a. Route cables and purge hose from positioner arm, through the E21 cable
feed clamp and gasket, into the servo unit E21.
b. Place E21 cable feed clamp in position and cross-tighten attachment

screws (fig.53/11).
4. Install servo unit.
Note: The servo unit is heavy! Suitable lifting equipment may be required to
install the servo unit in a secure way.
a. If required install lifting eye on the servo unit.
b. Attach lifting straps of the lifting equipment to the servo unit E21.
c. Tension the lifting straps. Check that straps are properly secured.
d. Carefully lift servo unit and place it in position against the arm.
Simultaneously pull cables and hoses through positioner arm.
e. Install servo unit attachment screws (fig.53/2). Cross-tighten screws with

5. Install cable and hose connections.
a. Install cable clamp (fig.53/5 or 7) in positioner arm.
b. Connect purge hose (fig.53/9) in center of positioner arm.

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7 Repair
6. Install cabling in servo unit E11.
a. Install cable bracket (fig.55/2) on bottom cover. Cable arc length is

260mm, see Figure 62.
Figure 55 E11 Cable feed clamp installation

1
b. Place cable feed clamp in position (fig.55/1) and cross-tighten attachment

screws (fig.53/12).
7. Install cable and hose connections in servo unit E21.
a. Install motor power (fig.53/15) and measuring system connector

(fig.53/14).
b. If applicable, install purge sensor connector (fig.53/13) and purge hose on

purge sensor (fig.53/16).
a. Install servo unit E21 cover (fig.53/3), servo unit E11 front cover (fig.53/4)
and arm cover (fig.53/6). Tighten screws with correct torque, see
’Tightening torques’ on page 146.

page 120.

3HNA018189-001 Rev.12
7 Repair
7.4.9 Removal of Internal Cabling
Location The internal cabling connects the electric components in the IRB 5320 3 axes
workpiece positioner as shown in the figure below.
Figure 56 Internal cabling

2 3 4 5 4 3 2
6 3 6
Servo unit E21 (1) Servo unit E21 (2)
7
1
Servo unit E11

Purge
Motor axis 2 Motor axis 3 sensor
3 3
X81 X82 X91 X92 X54
Positioner arm
3
Servo unit E11
Motor axis 1
X71 X72
1
X11 X12 X13 X3 X7 X1 X2 X3
CBP SMU
X54
1 Internal cabling
3 Cable feed clamp

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7 Repair
4 Cable clamp
5 Arm cover
8 Cable bracket on servo unit E11 bottom cover
References – No references
Procedure The procedure describes how to remove the internal cabling (fig.56/1).
a. Jog positioner arm to an end position (e.g. axis 1 = -15°).
c. Remove servo unit E21 cover attachment screws and remove both covers
(fig.56/6).
d. Remove positioner arm cover attachment screws and remove cover

(fig.56/5).
e. Remove servo unit E11 front cover attachment screws and remove cover
(fig.56/7).
2. Remove connections in servo unit E11.
Note: Before disconnecting any connectors, ground wires, cable conduits,

cable brackets or cable straps, carefully note position to simplify correct
installation of new cable. Connector numbers can be found in the illustration in
Figure 56.
a. Disconnect relevant connectors from CBP. Remove p-clips.
b. Disconnect measuring system connector and power connector from motor

unit.
c. Disconnect relevant connectors from SMU.
d. Disconnect main cable purge connector and remove purge connector X54
from connector bracket.

3HNA018189-001 Rev.12
7 Repair
e. Remove cable bracket (fig.56/8) from bottom cover.
f. Protect disconnected connectors against mechanical damage.
3. Remove cables out of servo unit E11.
a. At the center of the arm, remove cable feed clamp attachment screws
(fig.57/3).
b. Pull the cable feed clamp, gasket and cables (fig.57/2) out of the servo unit
E11, as shown in the illustration below (fig.57/1).
c. Remove cables out of the gasket and cable feed clamp.
Figure 57 Center of positioner arm

1
2
3
4. Remove connections in servo unit E21 (1)
a. Disconnect measuring system connector and power connector from motor

unit.
b. Protect disconnected connectors against mechanical damage.
5. Remove connections in servo unit E21 (2)
a. Disconnect measuring system connector and power connector from motor

unit.
b. Disconnect purge connector from purge sensor.
c. Protect disconnected connectors against mechanical damage.
6. Remove connections in arm.
a. Remove cable clamps (fig.56/4) out of the positioner arm.
b. Disconnect purge hose (fig.57/4) in center of arm.

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7. Remove both servo units E21.
WARNING! The servo unit is heavy! Make sure that the servo unit is properly
supported. Suitable lifting equipment may be required to lower the servo unit in a
secure way.
a. If required install a lifting eye on the servo unit.
b. Tension the lifting strap. Check that strap is properly secured.
c. Remove servo unit E21 attachment screws (fig.56/2).
d. Lift servo unit carefully from positioner arm.
e. Carefully lower the servo unit.
8. Remove cable feed clamps (fig.56/3) from servo units E21.
a. Remove cable feed clamp attachment screws (fig.58/2).
b. Take cables (fig.58/1) out of the cable feed clamp and gasket and take
cables out of the servo unit E21.
Figure 58 Cable feed clamp on servo unit E21
c. Return complete cabling to your local ABB organization.

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7.4.10 Installation of Internal Cabling
Location The internal cabling shall connect the electric components in the IRB 5320 3 axes
workpiece positioner as shown in the figure below.
Figure 59 Internal cabling
2 3 4 5 4 3 2
6 3 6
7
1
Servo unit E11

Purge
Motor axis 2 Motor axis 3 sensor
3 3
X81 X82 X91 X92 X54
Positioner arm
3
Servo unit E11
Motor axis 1
X71 X72
1
X11 X12 X13 X3 X7 X1 X2 X3
CBP SMU
X54
1 Internal cabling
3 Cable feed clamp

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4 Cable clamp
5 Arm cover
8 Cable bracket on servo unit E11 bottom cover
References – ’Tightening torques’ on page 146

– Castrol Optitemp® RB1 cable grease
Procedure The procedure describes how to install the internal cabling (fig.59/1).
a. Clean mounting surfaces for cable feed clamps and cable brackets using a
lint-free cloth.
b. Check that mounting surfaces are not scratched or damaged.
c. Ensure that positioner arm is in an end position (e.g. axis 1 = -15°).
d. Protect all connectors of the new cables against mechanical damage.
2. Install internal cabling.
a. Route the cables to the servo units E21 from the center of the arm, through
the arm and out of each end of the arm.
b. Align cables, avoid all crossing and twisting.
3. Install cable feed clamp (fig.59/3) on both servo units E21.
a. Route cables (fig.60/1) from positioner arm through the cable feed clamp

(fig.60/2).

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Figure 60 Cable feed clamp on servo unit E21
4. Install both servo units E21.
Note: The servo unit is heavy! Suitable lifting equipment may be required to
install the servo unit in a secure way.
a. If required install lifting eye on the servo unit.
b. Attach lifting straps of the lifting equipment to the servo unit E21.
c. Tension the lifting straps. Check that straps are properly secured.
d. Carefully lift servo unit and place it in position against the arm.
Simultaneously pull cables and hoses through positioner arm and out
through the center of the arm.
e. Install servo unit attachment screws (fig.59/2). Cross-tighten screws with

5. Install connections in servo unit E21 (2).
Note: All connections must be made according to markings on connectors and

Figure 59.
a. Install motor power connector to motor unit.
b. Install measuring system connector to motor unit.
c. Install purge connector to purge sensor.
6. Install connections in servo unit E21 (1).
a. Install motor power connector to motor unit.
b. Install measuring system connector to motor unit.
7. Install cable and hose connections in arm.
a. Install cable clamps (fig.59/4) in positioner arm.
b. Connect purge hose (fig.61/1) in center of positioner arm.

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Figure 61 Center of positioner arm
2
3
8. Install cabling in servo unit E11.
a. Route cables (fig.61/2) from positioner arm, through the cable feed clamp

(fig.61/3).
c. Install cable connectors to SMU.
d. Instal motor power and measuring system connector to axis 1 motor.
e. Install cable connectors and p-clips to CBP.
f. Install purge connector X54 on connector bracket.
g. Connect main cable purge connector to purge connector X54 on connector

bracket.
h. Install cable bracket (fig.59/8) on bottom cover. Cable arc length is

260mm.
Figure 62 Servo unit E11, cable arc length
Cable arc length 260 mm

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7 Repair
a. Check that moving cables do not cross.
b. Check that all moving cables have the same length between clamps.
c. Check that moving cables do not touch any sharp objects.
d. Add Castrol Optitemp® RB1 cable grease to moving cables.
e. Install all covers. Tighten screws with correct torque, see ’Tightening
torques’ on page 146.
f. Calibrate the robot. For information, see ’Calibration Position’ on

page 120.

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7.5 Calibration Position
7.5.1 Introduction
General The following provides information on the calibration position.
Note: The following only includes information on the calibration position. For
description of the calibration function and procedure for entering calibration data,
see Installation manual IRC5P, Configuration/General configuration.
Safety Information Before any calibration work is commenced, it is extremely important that all safety
information is observed.
guidelines in the Safety Manual have been read and understood. Work must only be
performed by skilled personnel with the proper training.
Safety Information for Changing calibration data are operations which may result in unexpected motion of
Calibration the positioner or cause the positioner to race if performed incorrectly. Following
points MUST therefore be observed when running or starting the positioner after
having changed the calibration data.
• ALWAYS check that the calibration fixture has been removed and that no person
or object is within the reach of the positioner before applying power to the
positioner and/or starting the positioner.
• ALWAYS stand ready by an EMERGENCY STOP before applying power to the
positioner and/or starting the positioner.
• ALWAYS check movement of all positioner axes in both directions after
calibration has been performed.

3HNA018189-001 Rev.12
7 Repair
7.5.2 Calibration Position, 1 Axis Workpiece Positioner
General Following procedure describes how to place the axis in calibration position.
Calibration Position Value
Axis 1
1 Axis Workpiece Positioner +180°
Procedure The following procedure describes how to place the axis on the positioner in
calibration position.
regulations in ’Safety Information’ on page 120 and ’Safety Information for
Calibration’ on page 120 have been read and understood.
Servo Unit E11

1. Jog servo unit E11 axis to 180° position.
2. Ensure that the calibration marks on servo unit E11 and turntable are aligned.
3. Perform calibration as described in Installation manual IRC5P,

Configuration/General configuration/Fine-calibrating the robot.

3HNA018189-001 Rev.12
7 Repair
7.5.3 Calibration Position, 3 Axes Workpiece Positioner
General Following procedure describes how to place the three axes in calibration position.
Following illustration shows the calibration position and the locations of the
calibration fixture.
Figure 63 Calibration position and locations of calibration fixture

Calibration fixture Calibration fixture
Calibration fixture
E11 front side
Calibration fixture Calibration fixture
Axis2 Axis 3
Axis1
Calibration fixture
Calibration Position Values

Axis 1 Axis 2 Axis 3
3 Axis Workpiece Positioner +180° 0° 0°
Procedure The following procedure describes how to place the three axes on the positioner in
calibration position.
regulations in ’Safety Information’ on page 120 and ’Safety Information for
Calibration’ on page 120 have been read and understood.
Servo Unit E11

2. Place calibration fixture in position on the aligned studs on servo unit E11 and
arm.

3HNA018189-001 Rev.12
7 Repair
Figure 64 Calibration fixture on servo unit E11
Calibration fixture

Configuration/General configuration/Fine-calibrating the robot..
CAUTION! After the calibration is completed, remove calibration fixture.
Servo Unit E21 (2 units)

2. Place calibration fixture in the aligned holes on the turntable and servo unit.
Figure 65 Calibration fixture on servo unit E21
Calibration fixture

Configuration/General configuration/Fine-calibrating the robot..
CAUTION! After the calibration is completed, remove calibration fixture.

3HNA018189-001 Rev.12
7 Repair

3HNA018189-001 Rev.12
8 Operation
8.1 Introduction
8 Operation
8.1 Introduction
About this Chapter This chapter describes an operation procedure for the IRB 5320 3 Axes positioner.
The operation procedure is based on an installation example with an added
supervision system that secures the safety of the operator.

3HNA018189-001 Rev.12
8 Operation
8.2 Installation Site Example
General The installation site of the IRB 5320 3 axes positioner requires a supervision system
that secures the operator against any danger during loading and unloading the
workpieces (work objects). The operator loads and unloads the workpieces at the
loading/unloading station. The paint robot paints the workpieces at the paint
operation station.
Installation Example An installation example for the positioner is shown in the illustration below.
Figure 66 Positioner installation example, top view

Hazardous area Non-
hazardous
area
Paint operation station Loading station
Turntable Emy stop Entrance
detection
Emy
stop
IRB 5320 3 axes positioner
Arm in home position
Operator
Motion panel
detection
Indicator
lamps
Paint robot
Operator If the loading/unloading station is part of the hazardous area, it needs to be

adequately separated from the paint operation station, to ensure a safe environment
for the operator to load and unload workpieces. The operator must use protective
clothing as required.
Hazardous Area To enable the operator to enter the loading/unloading station requires an opening
between the hazardous and non-hazardous areas. A risk analysis must therefore be
carried out with respect to the hazardous areas.
Entrance Detection The loading/unloading station must be equipped with an entrance detection, like
door switch or light curtain, to enable the supervision system to detect if the
operator has entered the loading/unloading station. The entrance detection must be
part of the Auto mode stop chain, as shown in Figure 67.
Motion Detection The loading/unloading station must be equipped with a motion detection, to enable
the supervision system to detect if the positioner arm is not in home position, that

3HNA018189-001 Rev.12
8 Operation
means that the positioner arm is moving or that no positioner turntable is located at
the loading/unloading station. The motion detection must be part of the Auto mode
stop chain, as shown in Figure 67.
Emergency Stop The loading/unloading station and operating panel must be equipped with an
emergency stop button, to enable the operator to stop all processes in case of an
emergency.
Auto Mode Stop Chain The entrance and motion detection, load ready and Load / Run key switch signals
are part of the Auto mode stop chain.
Figure 67 Auto mode stop chain, principle diagram
Auto Mode Stop Chain out
Robot Load ready signal

Entrance detection
Load mode
Run mode Motion detection
Auto Mode Stop Chain in

3HNA018189-001 Rev.12
8 Operation
Indicator Lamps The loading/unloading station should be equipped with indicator lamps, to give the
operator a clear indication of the loading/unloading station status. An example is
shown in the following table.
Table 1 Indicator lamps example

Indicator lamp Light Mode Description
Red Steadily lit Auto mode and Run mode.
The positioner can operate the arm rotation axis.
Fast flashing Error - motion detector is not activated.
Positioner is not able to get the positioner arm in home
position.
Yellow Steadily lit Ready for loading / unloading workpieces.
Robot load ready signal.
Motion detector is activated.
Positioner arm is in home position.
Slowly flashing Loading / unloading in progress.
Load selector is in load mode.
Positioner arm is in home position.
Operator has entered the loading/unloading station.
Green Steadily lit Loading mode.
Flashing Manual mode.

3HNA018189-001 Rev.12
8 Operation
Operator Panel The loading/unloading station should be equipped with an operator panel, to enable
the operator to control the process according to an easy and safe procedure. An
example is shown in the following table.
Table 2 Operator panel buttons example

Button Light Mode Description
(switch)
Load / Run Key switch selector to choose between Load mode and Run
mode.
Selects between light curtain and motion detector as safety
device, as shown in Figure 67.
Program Selects the required paint program.
Start Steadily lit Paint robot and positioner are in Run mode.
Slowly flashing System is waiting for the operator to start a new paint cycle by
pushing the button.
Home Steadily lit Paint robot and positioner are in home position.
Slowly flashing System is waiting for the operator to run the paint robot and
positioner to home position by pushing the button.
Not lit Not possible to run paint robot and positioner to home position.
Program needs control of the paint robot and positioner.
Light Steadily lit Light curtain chain is closed.
Curtain
Slowly flashing Light curtain chain is open.
System is waiting for the operator to reset the light curtain by
pushing the button.
Production Steadily lit Paint cell is ready for production.
Ready
Slowly flashing Paint cell is not initiated for production.
System is waiting for the operator to prepare the paint cell for
production (enable applicator, job queue, etc.) by pressing the
button.
Emergency Stops all operation of paint robot and positioner.
Stop

3HNA018189-001 Rev.12
8 Operation
8.3 Operator Work Flow
General This section describes an example for the operator work flow with the positioner
and the supervision system, as described in ’Installation Site Example’ on page 126.
Prepare Paint Cell Before a painting cycle can be started, the paint cell needs some preparation. The
assumed starting point is a positioner without any loaded workpieces and a paint
robot that is ready to run.
1. Push Light Curtain button, resets light curtain. Light Curtain button is steadily
lit, entrance detection switch (see Figure 67) is closed.
2. On control cabinet panel, set controller in Auto mode and switch motors ON.
3. Push Production Ready button, enables the paint cell for production (applicator,
job queue, etc.). Production Ready button is steadily lit.
4. Push Home button, paint robot and positioner go to home position. Home
button is steadily lit. Motion detector is activated, switch is closed. Yellow
indicator lamp is steadily lit, robot load ready switch (see Figure 67) is closed.
5. Turn Load / Run mode selector to Load position, paint cell selector is in Load
mode. Green indicator lamp is steadily lit. Take key out of Load/Run mode
selector and keep it with you to prevent other persons from taking over control
of the operation.
6. Enter the loading/unloading station and load positioner turntable with

workpieces. Load in progress, yellow indicator lamp and light curtain button
are slowly flashing.
Important: For electrostatic painting, the workpieces on the positioner turntable

need to be grounded.
7. Exit the loading/unloading station and push Light Curtain button, resets light
curtain. Light Curtain button is steadily lit, switch is closed.
8. Turn Load / Run mode selector to Run position, paint cell selector is in Run
mode. Start button is slowly flashing.

3HNA018189-001 Rev.12
8 Operation
Run Production The paint cell is prepared for production. The assumed starting point is a positioner
that is loaded with workpieces in the loading/unloading station, no workpieces have
been installed in the paint operation station and the paint robot is up and running in
Auto mode.
1. Select program number on Program button according to loaded workpieces.
2. Push Start button, button is steadily lit. Red indicator lamp is steadily lit,
positioner axis 1 turns the workpieces into the paint operation station and paint
robot starts paint operation.
3. During the paint operation, workpieces can be loaded:
a. Turn Load / Run mode selector to Load position, paint cell selector is in
Load mode. Green indicator lamp is steadily lit. Take key out of Load/Run
mode selector and keep it with you to prevent other persons from taking
over control of the operation.
b. Enter the loading/unloading station and load positioner turntable with

workpieces. Load in progress, yellow indicator lamp and Light Curtain
button are slowly flashing.
c. Exit the loading/unloading station and push Light Curtain button, resets
light curtain. Light Curtain button is steadily lit, switch is closed.
d. Turn Load / Run mode selector to Run position, paint cell selector is in
Run mode.
4. When paint robot has finished the paint program, the positioner axis 1 turns the
painted workpieces into the loading/unloading station and the yellow indicator
lamp becomes steadily lit. The loading/unloading station is ready for unloading
the workpieces.
5. Push Start button, button is steadily lit. Red indicator lamp is steadily lit,
positioner axis 1 turns the workpieces into the paint operation station and paint
robot starts paint operation.
6. Turn Load / Run mode selector to Load position, paint cell selector is in Load
mode, yellow and green indicator lamps are steadily lit. Take key out of
Load/Run mode selector and keep it with you to prevent other persons from
taking over control of the operation.
7. Enter the loading/unloading station, yellow indicator lamp starts slowly

flashing, and unload the finished workpieces. Load new workpieces.
8. Exit the loading/unloading station and push Light Curtain button, resets light
curtain. Light Curtain button is steadily lit, switch is closed.

3HNA018189-001 Rev.12
8 Operation
9. Turn Load / Run mode selector to Run position, paint cell selector is in Run
mode. Yellow indicator lamp is steadily lit. Start button is slowly flashing.
10. Continue with Step 1.

3HNA018189-001 Rev.12
8 Operation
8.4 Creating a Paint Program
8.4.1 Introduction
Brief Description This section describes how to create a paint program for the positioner, using
absolute and continuous movement instructions.
The installation consists of a 6 axes paint robot with an IRB5320 3 axes positioner.
The programming is performed without any framework that would otherwise help
in reducing the codebase for a complete positioner system. (E.g. move the axis 1
automatically before each paint program.)
Since it is not possible to program Rapid Functions from the PTPU, some Paint
specific support procedures must be used instead. If not, this part of the
programming must be done offline.
Some functions normally used to program independent axes have been ‘wrapped’ in
procedures shown below in order to avoid the Function type, which can not be used
on the PTPU.
Wait until positioner axis n has reached a given position:

proc WaitOBPInPos(num nAxis)
WaitUntil IndInpos(OBP, nAxis);
endproc
Wait until positioner axis n has reached a given speed:

proc WaitOBPInSpeed(num nAxis)
WaitUntil IndSpeed(OBP, nAxis \InSpeed);
endproc
Wait until positioner axis n has reached a zero speed:

proc WaitOBPZeroSpeed(num nAxis)
WaitUntil IndSpeed(OBP, nAxis \ZeroSpeed);
endproc
Reference The functions IndInpos and IndSpeed are described in ‘Technical reference manual,
RAPID Instructions, Functions and Data types’.
Special Requirements The control cabinet must be installed with the option Independent Movement.
RobotWare 5.14.03 and later is required to utilize the positioner support procedures.

3HNA018189-001 Rev.12
8 Operation
8.4.2 Create the Program
Precondition The turntable axis 2 or axis 3 located in the loading station is loaded with a
workpiece.
The controller is in Manual mode, and ready for teaching.
Procedure The procedure describes how to create a program.
1. In order to separate the positioner from any subsequent paint robot movement
instructions (MoveAbsJ/PaintL, etc.), the axes need to be put into independent
mode, by using any independent move instruction.
A common way is to set the speed of the axes to zero like this:
IndCMove OBP,1,0;
IndCMove OBP,2,0;
IndCMove OBP,3,0;
WaitOBPZeroSpeed 1;
WaitOBPZeroSpeed 2;
WaitOBPZeroSpeed 3;
2. Move the paint robot to an appropriate waiting position near the positioner, and
insert a movement instruction (e.g. MoveAbsJ).
Remember to use a fine point for this instruction to prevent the positioner
movement from happening too early in the next step.
3. Insert an IndAMove instruction to turn the axis 1 of the positioner such that the
workpiece on the turntable axis 2 or axis 3 is placed into the paint operation
station, like this example:
IndAMove OBP,1\ToAbsNum:= 0,50;
WaitOBPInPos 1;
If the paint robot is located on the other side of the positioner, a 180 degree
variant must be used:
IndAMove OBP,1\ToAbsNum:=180,50;
4. Continuous rotation of the turntable axis 2 or axis 3 of the positioner can then
be started like this:
IndCMove OBP,2,20;
WaitOBPInSpeed 2;
5. Now, PaintL and SetBrush instructions can be inserted to paint the workpiece.
Remember to use a fine point for the last instruction to prevent the positioner
from stopping too early in the next step.

3HNA018189-001 Rev.12
8 Operation
6. After painting is done, the rotating turntable can be stopped like this:
IndCMove OBP,2,0;
WaitOBPZeroSpeed 2;
7. In order to prevent the turntable axis of the positioner from spinning into the
revolution limit, a ‘reset’ instruction can be inserted at the end of the program:
IndReset OBP,2\RefNum:=0\Short;

3HNA018189-001 Rev.12
8 Operation
8.4.3 Test/Step Through the Program in Manual Mode
workpiece.
The controller is in Manual mode.
Procedure The procedure describes how to step through the program in manual mode in order
to test the program.
1. On the Paint TPU, load the created program into the memory using the program
editor.
2. Stepping through the program should result in continuously moving, stopping

and starting in the same pace as the PaintL/paint robot movements.
3. Run the program continuously from start to end.
8.4.4 Run the Program in Automatic Mode
workpiece.
The controller is running in Automatic mode.
Procedure On the Paint TPU, load the created program into the job queue using the Production
screen.

3HNA018189-001 Rev.12
9 Decommissioning
9.1 Introduction
9 Decommissioning
9.1 Introduction
Introduction This section contains information to consider when taking a product, robot or
controller, out of operation.
It deals with how to handle potentially dangerous components and potentially

hazardous materials.
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 are
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 (which is 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 are installed.
Disposal of storage Before disposal of any storage equipment (anything from an SD card to a complete
media controller), make sure that all sensitive information has been deleted.
Note: To remove all data from the SD card, use the Clean Disk function (part of
Recovery Disk function) in RobotStudio. See ‘Operating manual - RobotStudio’.

3HNA018189-001 Rev.12
9 Decommissioning
9.2 Environmental information
Symbol The following symbol indicates that the product must not be disposed of as common
garbage. Handle each product according to local regulations for the respective
content (see tables below).
General The components of the robot are manufactured from many different materials. Some
of them are listed below to facilitate scrapping, i.e. so that the components can be
disposed of in a way that does not have a detrimental effect on anyone’s health or
the environment.
CAUTION! Decommissioning must always be performed in accordance with

standards and regulations of the country where the robot is installed.
Manipulators
Material Examples of components Part of

Copper Cables, motors All robot types
Cast iron/nodular iron Foot unit, elevated rail IRB 5500 / IRB 5510
Foot unit, base unit, IRB 5400
vertical arm (axis 2 arm) lower part,
trolley rail
Foot unit, base, arm assembly IRB 52
Servo unit E11 IRB 5320
Foot unit, inner arm IRB 5350
Steel Gears, screws, base-frame, etc. All robot types
Arm IRB 5320
Front sheet IRB 5310 CBS II
Samarium-Cobalt Brakes, motors All robot types
Plastic/rubber (PVC) Cables, connectors, drive belts etc. All robot types
Oil, grease Gearboxes All robot types

3HNA018189-001 Rev.12
9 Decommissioning
Material Examples of components Part of

Aluminium Covers, sync. brackets All robot types
Vertical/horizontal arm All robot types except IRB 52
(axis 2 arm/axis 3 arm)
Base unit IRB 5500 / IRB 5510
Servo unit E21 IRB 5320
Outer arm and tower IRB 5350
Castings in wrist, arms All robot types
Frame IRB 5310 CBS II
Neodymium Brakes, motors All robot types
Lead Electronics All robot types
Brominated flame Electronics All robot types
retardants
Control cabinet
Material Examples of components

Copper Transformers, cables
Steel Cabinet structure, plates, screws, etc.
Tin Cables
Aluminium Heat sinks on power supplies and drive units
Alu-Zinc sheets Control cabinets, various sheet material parts
Iron Transformers
Polyester Circuit boards
Plastic/rubber (PVC) Cables, connectors, pendant, covers (drive units, I/O units) etc.
Lithium Batteries
Lead Electronics
Brominated flame Electronics
retardants
Scrapping Following warning must be observed before disassembling.
WARNING! Before removing any parts from the manipulator, study the removal
instructions for the component in question.
Oil and grease Where possible, arrange for the oil and grease to be recycled. Dispose of via an
authorized person/contractor in accordance with local regulations. Do not dispose of
oil and grease near lakes, ponds, ditches, down drains, or onto soil. Incineration
must be carried out under controlled conditions in accordance with local
regulations.
Also note that:
– Spills may form a film on water surfaces causing damage to organisms. Oxygen
transfer could also be impaired.
– Spillage may penetrate the soil causing ground water contamination.

3HNA018189-001 Rev.12
9 Decommissioning
Balancing system If the robot includes balancing springs, special care is needed when removing the
balancing system.
The balancing system contains 2 preloaded spiral springs. Before scrapping

(melting down, or other form of destruction) the springs must be unloaded in a safe
way.

3HNA018189-001 Rev.12
10 Reference information
10.1 Introduction
10.1 Introduction
About this chapter This chapter includes various information complementing the more specific
information in the previous chapters.
Following sections are included:
– ’Configurations for weak foundations’ on page 142

– ’Mounting instructions for bearings’ on page 143
– ’Mounting instructions for seals’ on page 144
– ’Loctite® specifications’ on page 148
– ’Oil type specifications’ on page 151
– ’Grease type specifications’ on page 153

3HNA018189-001 Rev.12
10.2 Configurations for weak foundations
10.2 Configurations for weak foundations
General Manipulator mounted on weak foundation requires special attention. If the

manipulator movement during a paint program causes the foundation to vibrate,
resonance of the manipulator arms will occur. This resonance causes overshoots of
the programmed path.
Vibration compensation Compensation of foundation vibration is accomplished by using the TUNE_DH

RAPID instruction.
The TUNE_DH RAPID instruction is the best remedy to compensate foundation

vibrations and to reduce path errors. A tune value less than 100% decreases the
bandwidth of the system and increases the smoothness, thereby reducing overshoots
and vibrations. TUNE_DH is normally more cycle time efficient than using AccSet.
For information on the TUNE_DH instruction, see ‘Technical reference manual -

RAPID Instructions, Functions and Data types’, Instructions / TuneServo - Tuning
Servos / Reduce overshoots and vibrations - TUNE_DH.
Important: Do not use SoftServo to compensate for foundation vibrations, as this

introduces unfavorable servo lag. Especially in combination with SafeMove, servo
lag is unacceptable.
Simplified tuning If an accelerometer is not available or on-site tuning is not possible, perform
procedure following simplified DH tuning procedure:
1. Run the customer paint program. Perform visual inspection of vibration.
2. Stop the robot, the RAPID instruction must only be executed when the
manipulator is standing still. (This is also applicable for the TuneReset
command.)
3. If the vibrations are too large, add following instruction to the RAPID program:
TuneServo ROB_1,1, 20\Type:=TUNE_DH
(TUNE_DH applied for axis 1, 20 means DH adjusted to 20%)
Note: Although TUNE_DH is applied for axis 1 only, changes of the

bandwidth are affected to all axes (whole robot/controller is subject to DH
changes). DH is a controllable factor of bandwidth of the system controller
(system response speed). A typical DH value range is: 10 – 100. In this case, it
is recommended to start tuning with a 20% value. The DH_value can only be
lowered.
4. Run the customer paint program again. Perform visual inspection of vibration.
5. If the vibrations are still too large, reduce the DH value.

3HNA018189-001 Rev.12
10.3 Mounting instructions for bearings
10.3 Mounting instructions for bearings
General This section details how to mount and grease different types of bearings on the
manipulator.
Mounting Following points must be observed when mounting a bearing on the manipulator.
• To avoid contamination, let a new bearing remain in its wrapping until it is time
for fitting.
• Ensure that all parts included in the bearing fitting are free from burrs, grinding
waste and other contamination. Cast components must be free from foundry
sand.
• Bearing rings, inner rings and roller elements must under no circumstances be
subjected to direct impact. Furthermore, the roller elements must not be exposed
to any stresses during the assembly work.
Following additional points must be observed for tapered bearings to enable the
roller elements to adjust to the correct position against the race flange.
• The bearing must be tensioned gradually until the recommended pre-tension is

achieved.
• The roller elements must be rotated a specified number of turns before pre-
tensioning is carried out, and also rotated during the pre-tensioning sequence.
• Make sure that the bearing is properly aligned, as this will directly affect the
lifespan of the bearing.
Greasing Following points must be observed when greasing a bearing.
• The bearings must not be completely filled with grease. However, if space is
available beside the bearing fitting, the bearing may be totally filled with grease
when mounted, as excessive grease will be pressed out from the bearing when
the robot is started.
• During operation, the bearing should be filled to 70-80% of the available
volume.
• Ensure that grease is handled and stored properly, to avoid contamination.

3HNA018189-001 Rev.12
10.4 Mounting instructions for seals
General A common cause of leakage in seals is incorrect fitting. This section details how to
mount different types of seals on the manipulator.
General precautions Following points must be observed before commencing any assembling of seals.
• Protect the sealing surfaces during transport and mounting.

• Keep the seal in the original wrappings or protect it well before actual mounting.
• If the fitting of seals and gears is not performed directly on the robot, the fitting
must be carried out on a clean workbench.
• Use a protective sleeve for the seal during mounting, when sliding over threads,
keyways, etc.
Rotating seals The instruction below details how to fit rotating seals.
1. Check the seal to ensure that the seal is of the correct type (provided with
cutting edge), and that there is no damage to the sealing edge (feel with a
fingernail).
2. Inspect the sealing surfaces before mounting. If scratches or damage are found,
the seal must be replaced, as it may result in future leakage.
3. Lubricate the seal with grease just before fitting. (Not too early as there is a risk
of dirt and foreign particles adhering to the seal.) Fill the space between the
dust tongue and sealing lip to 2/3 with grease. The rubber coated external
diameter must also be greased, unless otherwise specified.
4. Mount the seal correctly using a mounting tool. Never hammer directly on the
seal, as this may result in leakage.
Flange seals and static The instruction below details how to fit flange seals and static seals.
seals
1. Check the flange surfaces. They must be even and free from pores. It is easy to
check flatness using a gauge on the fastened joint (without sealing compound).
If the flange surfaces are defective, the parts may not be used, because leakage
could occur.
2. Clean the surfaces properly.
3. Distribute the sealing compound evenly over the surface, preferably with a
brush.
4. Tighten the screws evenly when fastening the flange joint.

3HNA018189-001 Rev.12
O-rings The instruction below details how to fit o-rings.
1. Ensure that the correct o-ring size is used.
2. Check the o-ring for surface defects, burrs, shape accuracy, etc. Defective
o-rings must not be used.
3. Check the o-ring grooves. The grooves must be geometrically correct and free
from pores and contamination. Defective o-rings must not be used.
4. Lubricate the o-ring with Grease, free of products that may react with paint, ie.
grease free of silicone, perfluorinated polyether, etc.
5. Tighten the screws evenly when assembling.

3HNA018189-001 Rev.12
10.5 Tightening torques
Description It is of the utmost importance that all screws are tightened with the correct torque.
All screws in metallic materials on the robot, except for adjusting screws, must be
tightened with torque according to the tables below unless otherwise specified.
These instructions do not apply to screw joints comprising soft or brittle materials.
Galvanized screws are of 8.8 quality and untreated screws (black oxide) are of 12.9
quality. Torques apply to lightly lubricated screws.
Hexagon socket head The table below shows tightening torques to be used for screws with hexagon socket
head.
Nominal Tightening torque
diameter Screw quality Screw quality
8.8 12.9
M4 2.9 Nm 4.9 Nm
M5 5.9 Nm 10.0 Nm
M6 9.9 Nm 16.5 Nm
M8 24.0 Nm 40.0 Nm
M10 47.0 Nm 79.0 Nm
M12 82.0 Nm 140.0 Nm
M14 130.0 Nm 220.0 Nm
M16 200.0 Nm 340.0 Nm
Slotted or cross The table below shows tightening torques to be used for screws with slotted or cross
recessed head recessed heads, as used for electrical connections, terminal board screws etc.
diameter Screw quality
4.8 ‘Dry’
M2.5 0.25 Nm
M3 0.5 Nm
M4 1.2 Nm
M5 2.5 Nm
M6 5.0 Nm

3HNA018189-001 Rev.12
Stainless steel screws The table below shows tightening torques to be used for stainless steel screws. The
screws need to be greased. If Loctite® is not described, use Grease, free of products
that may react with paint, ie. grease free of silicone, perfluorinated polyether, etc.
diameter Screw quality A2 / A4
50 70 80
M5 1.9 Nm 4.1 Nm 5.4 Nm
M6 3.3 Nm 7.0 Nm 9.3 Nm
M8 7.8 Nm 17.0 Nm 22.0 Nm
M10 15.0 Nm 33.0 Nm 44.0 Nm
M12 27.0 Nm 57.0 Nm 76.0 Nm
M16 65.0 Nm 140.0 Nm 187.0 Nm
M20 127.0 Nm 273.0 Nm 364.0 Nm
M24 230.0 Nm 472.0 Nm 629.0 Nm

3HNA018189-001 Rev.12
10.6 Loctite® specifications
10.6 Loctite® specifications
Description The following Loctite types are used.
Which type to use is specified in the procedures where Loctite is required.
Note: Do not use Loctite Glue on Hexagon socket head cap screws (guide screws)
with grounded cylindrical stem BS 4168 - ISO 7379, and all swivels.
– Loctite® 243 glue (blue)

Add a drop of Loctite 243 to screws which you can see have Loctite when
dismounted.
– Loctite® 270 glue (green)
Must be used on screws where it is especially important that the screws are
firmly fixed. Screws with green Loctite are much harder to open than screws
with blue Loctite. It may be required to heat screws to be able to loosen!
– Loctite® 574 liquid gasket
Must be used whenever liquid gasket is specified in the procedures. Use first
Loctite 7063, or equivalent, to clean the relevant surfaces.
– Loctite® 577 liquid gasket
Must be used whenever liquid gasket for hoses and screws is specified in the
procedures.
– Loctite® 603
Must be used on bearings whenever specified in the procedures.
– Loctite® 7063 solvent cleaner (or equivalent)
Must be used before liquid gasket (Loctite 574) is applied.
– Teroson® Terostat MS 939 sealing glue
Must be used whenever sealing glue is specified in the procedures.

3HNA018189-001 Rev.12
10.7 Performing a gearbox leak-down test
10.7 Performing a gearbox leak-down test
Introduction Perform a leak-down test after reinstallation of a motor or a gearbox, such that the
integrity of all seals enclosing the gearbox oil is ensured.
Tools and items – Leak-down tester

– Leak detection spray
Procedure The procedure describes how to perform a leak-down test.
1. Finish the reinstallation procedure of the current motor or gearbox.
2. Remove a filling plug from the gearbox and replace it with the leak-down
tester.
3. Carefully apply compressed air with the leak-down tester and raise the pressure
until the pressure has reached 0.2 - 0.25 bar.
4. Stop the compressed air supply.
5. Wait for approximate 8 - 10 minutes and make sure that no pressure loss
occurs.
If the compressed air is significantly colder or warmer than the gearbox, a slight
pressure increase or decrease may occur.
6. If you note any pressure drop, then localize the leak.
Spray any suspected leak areas with the leak detection spray. Air bubbles
indicate a leak.
When the leak has been localized, take the necessary measures to correct the
leak. Repeat the leak-down test.
7. If you note no pressure drop, then remove the leak-down tester and reinstall the
filling plug. The leak-down test is finished successfully.

3HNA018189-001 Rev.12
10.8 Safety instructions for replacing oil in gearboxes
10.8 Safety instructions for replacing oil in gearboxes
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.
• 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 worn during this
activity.
• When opening the oil plug, there may be pressure present in the gearbox,
causing oil to spray from the opening. Open oil plug carefully and keep away
from the opening.
• Overfilling of gearbox oil can lead to internal high pressure inside the gearbox
which in turn may damage seals and gaskets, completely press out seals and
gaskets and/or prevent the manipulator from moving freely. Make sure not to
overfill the gearbox. After filling, check that the oil level is correct.
• Mixing types of oil may cause severe damage to the gearbox. When filling
gearbox oil, do not mix different types of oil. Always use the specified oil type.
• Warm oil drains quicker than cold oil. When changing gearbox oil, first run the
robot for a time to heat up the oil.
• The specified amount of oil is based on the total volume of the gearbox. When
changing the oil, the amount of refilled oil may differ from the specified amount,
depending on how much oil has previously been drained from the gearbox. After
refilling, check the oil level.

3HNA018189-001 Rev.12
10.9 Oil type specifications
10.9.1 Description
Oil types Following oil types are used in the gearboxes in the robots.
– Mobil MobilgearTM 600 XP 320

– Kyodo Yushi TMO 150
– Optimol Optigear® BM100
Which oil type that is used in the different gearboxes is specified in the oil change
procedures for the specific robot. An overview is found below.
Important: Only specified oil type shall be used.
See also ’Safety instructions for replacing oil in gearboxes’ on page 150.
Temperature Ambient temperature: Minimum 0°C, maximum 70°C.
10.9.2 Robot types overview
IRB 5500
Axis Oil type

1-2 Kyodo Yushi TMO 150
3-6 Mobil MobilgearTM 600 XP 320
7 (F52 foot) Kyodo Yushi TMO 150
IRB 5510
Axis Oil type

IRB 52
Axis Oil type

5-6 Optimol Optigear® BM100
IRB 5400
Axis Oil type


3HNA018189-001 Rev.12
IRB 5350 door opener
Axis Oil type

3 Mobil MobilgearTM 600 XP 320
Trolley axis Mobil MobilgearTM 600 XP 320
T32 trolley
Axis Oil type

7 Mobil MobilgearTM 600 XP 320
T33 trolley
Axis Oil type

7 Kyodo Yushi TMO 150
T34 trolley
Axis Oil type

7 Kyodo Yushi TMO 150
Compact CBS II
Axis Oil type

Compact CBS (v1) for

IRC5P w/RW6
Axis Oil type
Gripper arm Kyodo Yushi TMO 150
rotational
axis
IRB 5320
workpiece positioner
Servo unit Oil type
E11 Mobil MobilgearTM 600 XP 320
E21 Kyodo Yushi TMO 150

3HNA018189-001 Rev.12
10.10 Grease type specifications
Description The following grease types are used.
Which type to use is specified in the procedures where lubrication is required.

General lubrication grease. Alternatively, Magna Omega 77 may also be used.
– Shell Alvania EP2 LF grease
General purpose extreme-pressure industrial grease.
– Castrol Optitemp® RB1 cable grease
Special cable grease for movable cables.
– AOS 340 WC 52055 thermal grease
Non-silicone based thermal grease
– Grease, free of products that may react with paint, ie. grease free of silicone,
perfluorinated polyether, etc.

3HNA018189-001 Rev.12

3HNA018189-001 Rev.12
Manual status
Manual status
Product manual
3HNA018189-001 Rev.12
Documents included in manual:
Chp.: Subject: File Identification: Page:
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A018189.fm 7
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T02934 Rev.04 9
2 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T02935 Rev.04 11
3 System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T02936 Rev.05 15
4 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T02937 Rev.07 31
5 Installation and Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T02938 Rev.05 39
6 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T02939 Rev.03 49
7 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T02940 Rev.08 53
8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T02948 Rev.01 125
9 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T02611 Rev.13 137
10 Reference information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T02619 Rev.22 141

3HNA018189-001 Rev.12
Manual status

3HNA018189-001 Rev.12
List of imported graphics
Product manual
3HNA018189-001 Rev.12
Graphic files imported in manual:
Pg.: Illustration: Pg.: Illustration: Pg.: Illustration:
1 FrontImage.jpg @ 300 dpi 72 T0294016.JPG @ 300 dpi 103 T0294026.jpg @ 300 dpi
16 T0293612.wmf 72 T0294011.jpg @ 300 dpi 105 T0294046.wmf
18 T0293601.wmf 72 T0293811.jpg @ 300 dpi 106 T0294043.jpg @ 300 dpi
21 T0293625.wmf 75 T0294028.wmf 107 T0294030.wmf
21 T0293610.wmf 76 T0294033.wmf 107 T0294031.jpg @ 300 dpi
22 T0293609.wmf 79 T0294013.JPG @ 300 dpi 108 T0294044.wmf
23 ID_5320.wmf 79 T0294020.wmf 108 T0294043.jpg @ 300 dpi
26 T0293606.wmf 79 T0294016.JPG @ 300 dpi 111 T0294029.jpg @ 300 dpi
46 T0293810.jpg @ 300 dpi 89 T0294022.JPG @ 300 dpi 122 T0294073.wmf
46 T0293811.jpg @ 300 dpi 89 T0294025.jpg @ 300 dpi 123 T0294070.jpg @ 300 dpi
46 T0293815.jpg @ 300 dpi 91 T0294014.wmf 123 T0294072.jpg @ 300 dpi
58 T0294005.wmf 93 T0294023.JPG @ 300 dpi
59 T0294003.wmf 93 T0294024.jpg @ 300 dpi
60 T0294004.wmf 94 T0294060.wmf
62 T0294010.wmf 94 T0294061.jpg @ 300 dpi
62 T0294011.jpg @ 300 dpi 94 T0294062.jpg @ 300 dpi
62 T0294015.JPG @ 300 dpi 94 T0294063.jpg @ 300 dpi
62 T0294018.jpg @ 300 dpi 96 T0294060.wmf
62 T0294019.jpg @ 300 dpi 96 T0294061.jpg @ 300 dpi
62 T0294013.JPG @ 300 dpi 96 T0294062.jpg @ 300 dpi
62 T0294025.jpg @ 300 dpi 96 T0294063.jpg @ 300 dpi
65 T0294012.wmf 97 T0294064.jpg @ 300 dpi
67 T0294010.wmf 97 T0294065.jpg @ 300 dpi
67 T0294011.jpg @ 300 dpi 97 T0294066.jpg @ 300 dpi
67 T0294015.JPG @ 300 dpi 97 T0294067.jpg @ 300 dpi
67 T0294018.jpg @ 300 dpi 99 T0294031.jpg @ 300 dpi
67 T0294019.jpg @ 300 dpi 99 T0294034.jpg @ 300 dpi
67 T0294013.JPG @ 300 dpi 99 T0294035.wmf
67 T0294025.jpg @ 300 dpi 101 T0294031.jpg @ 300 dpi
69 T0294017.JPG @ 300 dpi 101 T0294034.jpg @ 300 dpi
72 T0294013.JPG @ 300 dpi 101 T0294035.wmf
72 T0294020.wmf 103 T0294034.jpg @ 300 dpi
72 T0294026.jpg @ 300 dpi 103 T0294030.wmf
72 T0294015.JPG @ 300 dpi 103 T0294031.jpg @ 300 dpi

3HNA018189-001 Rev.12
Pg.: Illustration: Pg.: Illustration: Pg.: Illustration:

3HNA018189-001 Rev.12
Contact us
—
ABB AS, Robotics
Robotics and Discrete Automation
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000
ABB Engineering (Shanghai) Ltd.

Robotics and Discrete Automation
No.4528, Kangxin Highway
Pudong District
SHANGHAI 201319, China
Tel: +86 21 6105 6666
abb.com/robotics
3HNA018189-001 Rev.12

Specifications subject to change without notice.

Product Manual: IRB 5320 Workpiece Positioners

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IRB 5320 workpiece positioners

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Product manual, IRB 5320 workpiece positioners 5

7.3.1 Removal of Motor for Servo Unit E11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

6 Product manual, IRB 5320 workpiece positioners

Product manual, IRB 5320 workpiece positioners 7

About This Manual This manual contains information on the following:

• Mechanical and electrical installation of the positioner.

Usage This manual should be used during:

Who Should Read This This manual is intended for:

Prerequisites The reader should:

• Be a trained maintenance and repair craftsman.

Organization of The manual is organized in the following chapters:

Product manual, IRB 5320 workpiece positioners 9

References Following manuals are referred to in this manual:

Unit Description, IRC5P Includes technical description of the control system

Installation manual, IRC5P Includes description of the calibration function and

10 Product manual, IRB 5320 workpiece positioners

Important: The description in this chapter is intended as a short reference and is no

Product manual, IRB 5320 workpiece positioners 11

12 Product manual, IRB 5320 workpiece positioners

Product manual, IRB 5320 workpiece positioners 13

14 Product manual, IRB 5320 workpiece positioners

WARNING! Repair work on the positioner must only be performed in accordance

Product manual, IRB 5320 workpiece positioners 15

3.2 Basic Design

Figure 1 IRB 5320 workpiece positioners

Control cabinet Purge unit

3 Axes Workpiece Positioner

1 Axis Workpiece Positioner

Important: When the positioner is used in combination with electrostatic painting,

16 Product manual, IRB 5320 workpiece positioners

3.2.1 Design, 1 Axis Workpiece Positioner

Axis Overview The positioner is controlled by one servo axis.

Figure 2 Axis overview

Purge air exhaust

Servo unit E11

Product manual, IRB 5320 workpiece positioners 17

3.2.2 Design, 3 Axes Workpiece Positioner

Axes Overview The positioner is controlled by three servo axes.

Figure 3 Axes overview

Axis 2 motor Axis 3 motor

Axis 1 motor Purge air exhaust

Servo unit E11

18 Product manual, IRB 5320 workpiece positioners

3.2.3 Component Identification

Figure 4 Positioner components

Servo unit E21 (2x)

Servo unit E11

Product manual, IRB 5320 workpiece positioners 19

3.2.4 Purge Air Routing

20 Product manual, IRB 5320 workpiece positioners

Figure 5 Purged area of IRB 5320 1 Axis Workpiece Positioner

Exi Hazardous area

Purge valve assembly

Purged area Exp

Product manual, IRB 5320 workpiece positioners 21

Figure 7 Purged area of IRB 5320 3 Axes Workpiece Positioner

Exi Hazardous area

Purge valve assembly

Purged area Exp

22 Product manual, IRB 5320 workpiece positioners