IRC5-IRB140 Prod Man 3HAC023297-001 Procedures Rev- En

Product manual (part 1 of 2), procedures Articulated robot IRB 140 M2000, M2000A, M2004



Product manual (part 1 of 2), procedures IRB 140 M2000 M2000A M2004 Document ID: 3HAC 023297-001 Revision: -

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, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted. Additional copies of this manual may be obtained from ABB at its then current charge.

© Copyright 2004 ABB All right reserved. ABB Automation Technologies AB Robotics SE-721 68 Västerås Sweden

Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1 Safety

13

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1.2.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.2.2.1 Safety, service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1.2.2.2 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 1.2.2.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1.2.3 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.2.3.1 Safety risks during service work on robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 1.2.3.2 Safety risks related to gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1.2.3.3 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 1.2.3.4 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 1.2.3.5 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 1.2.3.6 Safety risks during installation and service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 1.2.3.7 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 1.2.4 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.2.4.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 1.2.4.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 1.2.4.3 Emergency release of the robot’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 1.2.4.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 31 1.2.4.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 1.2.4.7 Work inside the manipulator's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 1.3.2 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 1.3.3 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 1.3.4 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 2 Installation and commissioning

41

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 2.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2.2.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 2.2.2 Working range, IRB 140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 2.2.3 Risk of tipping/Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 2.3 On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2.3.1 Lifting manipulator with lifting slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 2.3.2 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 2.3.3 Orienting and securing the manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 2.3.4 Restricting the working space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 2.3.5 Fitting equipment on manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 2.3.6 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 2.3.7 Suspended mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 2.3.8 Bolt pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 2.4 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

2.4.1 Customer connections on manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

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Table of Contents

3 Maintenance

63

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 3.2 Maintenance schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

3.2.1 Maintenance schedule, IRB 140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

3.3.1 Inspection, damper axes 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 3.3.2 Inspection, robot cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 3.3.3 Inspection, timing belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 3.4 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

3.4.1 Cleaning, complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 3.5 Changing/ replacing activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

3.5.1 Oil change, gearbox, axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 4 Repair

77

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 4.2 Complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

4.2.1 Replacement of cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2 Replacement of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.3 Replacement of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.4 Replacement of base, spare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78 85 91 95

4.3 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

4.3.1 Replacement of wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 4.3.2 Replacement of damper, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 4.3.3 Replacement of damper, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 4.3.4 Replacement of cover, arm housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 4.4 Lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

4.4.1 Replacement of lower arm cover and gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 4.4.2 Replacement of damper, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 4.4.3 Replacement of indicator lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 4.5 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

4.5.1 Replacement of cover, console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 4.5.2 Replacement of console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 4.5.3 Replacement of serial measurement unit and battery pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 4.5.4 Replacement of control cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 4.6 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

4.6.1 Replacement of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 4.6.2 Replacement of motor, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 4.6.3 Replacement of motor and timing belt, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 4.6.4 Replacement of motor, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 4.6.5 Replacement of motor and timing belt, axes 5 or 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 4.6.6 Adjustments and measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

4.6.6.1 Measuring the gear play, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 4.6.6.2 Measuring the gear play, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 4.7 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

4.7.1 Replacement of gearbox, axes 1-2 and damper, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 4.7.2 Service work on gearbox, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 5 Calibration information

163

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 Calibration movement directions for all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

163 164 166 167

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Table of Contents

5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 5.6 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

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Table of Contents

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Overview

Overview About this manual This manual contains instructions for •

mechanical and electrical installation of the robot

•

maintenance of the robot

•

mechanical and electrical repair of the robot.

Usage This manual should be used during •

installation, from lifting the robot to its work site and securing it to the foundation to making it ready for operation

•

maintenance work

•

repair work and calibration.

Who should read this manual? This manual is intended for: •

installation personnel

•

maintenance personnel

•

repair personnel.

Prerequisites The reader should... •

be a trained maintenance/repair craftsman

•

have the required knowledge of mechanical and electrical installation/repair/ maintenance work.

Organization of chapters The manual is organized in the following chapters: Chapter

Contents

Safety, service

Safety information that must be read through before performing any installation or service work on robot. Contains general safety aspects as well as more specific information about how to avoid personal injuries and damage to the product.

Installation and commissioning

Required information about lifting and installation of the robot.

Maintenance

Step-by-step procedures that describe how to perform maintenance of the robot. Based on a maintenance schedule that may be used in the work of planning periodical maintenance.

Repair

Step-by-step procedures that describe how to perform repair activities of the robot. Based on available spare parts.

Calibration information

Procedures that does not require specific calibration equipment. General information about calibration.

Decommissioning

Environmental information about the robot and its components.

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Overview

Revisions

8

Revision

Description

-

First edition. Replaces previous manuals: • Installation and commissioning manual • Maintenance manual • Repair manual, part 1 • Repair manual, part 2 Changes made in the material from the previous manuals: • Model M2004 implemented. • Chapter Calibration replaced with chapter Calibration information. • Chapter Safety, service replaced with new safety chapter. • Information about the controller removed from the manual. • Additional spare part numbers for the motors.

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Product documentation, M2000/M2000A

Product documentation, M2000/M2000A General The complete product documentation kit for the M2000 robot system, including controller, robot and any hardware option, consists of the manuals listed below: Hardware manuals All hardware, robots and controller cabinets, will be delivered with a Product manual which is divided into two parts: Product manual, procedures •

Safety information

•

Installation and commissioning (descriptions of mechanical installation, electrical connections and loading system software)

•

Maintenance (descriptions of all required preventive maintenance procedures including intervals)

•

Repair (descriptions of all recommended repair procedures including spare parts)

•

Additional procedures, if any (calibration, decommissioning)

Product manual, reference information •

Reference information (article numbers for documentation referred to in Product manual, procedures, lists of tools, safety standards)

•

Part list

•

Foldouts or exploded views

•

Circuit diagrams

Software manuals The software documentation consists of a wide range of manuals, ranging from manuals for basic understanding of the operating system to manuals for entering parameters during operation. A complete listing of all available software manuals is available from ABB. Controller hardware option manual Each hardware option for the controller is supplied with its own documentation. Each document set contains the types of information specified below: •

Installation information

•

Repair information

•

Maintenance information

In addition, spare part information is supplied for the entire option.

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Product documentation, M2004

Product documentation, M2004 General The robot documentation may be divided into a number of categories. This listing is based on the type of information contained within the documents, regardless of whether the products are standard or optional. This means that any given delivery of robot products will not contain all documents listed, only the ones pertaining to the equipment delivered. However, all documents listed may be ordered from ABB. The documents listed are valid for M2004 robot systems. Hardware manuals All hardware, robots and controller cabinets, will be delivered with a Product manual which is divided into two parts: Product manual, procedures •

Safety information

•

Installation and commissioning (descriptions of mechanical installation, electrical connections and loading system software)

•

Maintenance (descriptions of all required preventive maintenance procedures including intervals)

•

Repair (descriptions of all recommended repair procedures including spare parts)

•

Additional procedures, if any (calibration, decommissioning)

Product manual, reference information •

Reference information (article numbers for documentation referred to in Product manual, procedures, lists of tools, safety standards)

•

Part list

•

Foldouts or exploded views

•

Circuit diagrams

RobotWare manuals The following manuals describe the robot software in general and contain relevant reference information: •

RAPID Overview: An overview of the RAPID programming language.

•

RAPID reference manual part 1: Description of all RAPID instructions.

•

RAPID reference manual part 2: Description of all RAPID functions and data types.

•

Technical reference manual - System parameters: Description of system parameters and configuration workflows.

Application manuals Specific applications (e.g. software or hardware options) are described in Application manuals. An application manual can describe one or several applications. An application manual generally contains information about:

10

•

The purpose of the application (what it does and when it is useful)

•

What is included (e.g. cables, I/O boards, RAPID instructions, system parameters) 3HAC 023297-001 Revision: -

Product documentation, M2004

•

How to use the application

•

Examples of how to use the application

Operator’s manuals This group of manuals is aimed at those having first hand operational contact with the robot, i.e. production cell operators, programmers and trouble shooters. The group of manuals include: •

Operator’s manual - IRC5 with FlexPendant

•

Operator’s manual - RobotStudioOnline

•

Trouble shooting Manual for the controller and robot

Miscellaneous A number of manuals provide generic descriptions of the robot and robot system. These include: •

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Robot fundamentals (describing the fundamental aspects, functions, concept and similar, of a robot system to provide a basic understanding of the robot system)

11

How to read the product manual

How to read the product manual Reading the procedures The procedures contain references to figures, tools, material etc. The references are read as described below. References to figures The procedures often include references to components or attachment points located on the robot/controller. The components or attachment points are marked with italic text in the procedures and completed with a reference to the figure where the current component or attachment point is shown. The denomination in the procedure for the component or attachment point corresponds to the denomination in the referenced figure. The table below shows an example of a reference to a figure from a step in an procedure.

Step Action

Note/Illustration

8.

Shown in the figure Location of gearbox on page xx.

Remove the rear attachment screws, gearbox.

References to required equipment The procedures often include references to equipment (spare parts, tools etc.) required for the different actions in the procedure. The equipment is marked with italic text in the procedures and completed with a reference to the section where the equipment is listed with further information, i.e. article number, dimension. The denomination in the procedure for the component or attachment point corresponds to the denomination in the referenced list. The table below shows an example of a reference to a list of required equipment, from a step in an procedure.

Step Action

Note/Illustration

3.

Art. no. is specified in Required equipment on page xx.

Fit a new sealing, axis 2 to the gearbox.

Safety information The manual includes a separate safety chapter that must be read through before proceeding with any service or installation procedures. All procedures also include specific safety information when dangerous steps are to be performed. Read more in chapter Safety on page 13.

12

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1 Safety 1.1. Introduction

1 Safety 1.1. Introduction Overview The safety information in this manual is divided in two categories: •

general safety aspects, important to attend to before performing any service work on the robot. These are applicable for all service work and are found in section General safety information on page 14.

•

specific safety information, pointed out in the procedure at the moment of the danger. How to avoid and eliminate the danger is either detailed directly in the procedure, or further detailed in separate instructions, found in section Safety related instructions on page 34.

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13

1 Safety 1.2.1. Introduction

1.2 General safety information 1.2.1. Introduction Definitions This section details general safety information for service personnel i.e. personnel performing installation, repair and maintenance work. Sections The general safety information is divided into the following sections: 1. General information contains lists of: •

Safety, service

•

Limitation of liability

•

Referenced documents

2. Safety risks lists dangers relevant when servicing the robot system. The dangers are split into different categories: •

Safety risks during service work on robot

•

Safety risks related to gripper/end effector

•

Safety risks related to tools/workpieces

•

Safety risks related to pneumatic/hydraulic systems

•

Safety risks during operational disturbances

•

Safety risks during installation and service

•

Risks associated with live electric parts

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

14

•

Safety fence dimensions

•

Fire extinguishing

•

Emergency release of the manipulator´s arm

•

Brake testing

•

Risk of disabling function "Reduced speed 250 mm/s"

•

Safe use of the Teach Pendant Unit enabling device

•

Work inside the manipulator´s working range

•

Signal lamp (optional)

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1 Safety 1.2.2.1. Safety, service

1.2.2. General information 1.2.2.1. Safety, service Validity and responsibility The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment, which can influence the safety of the total system. To protect personnel, the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed. The users of ABB industrial robots are responsible for ensuring that the applicable safety laws and regulations in the country concerned are observed and that the safety devices necessary to protect people working with the robot system have been designed and installed correctly. Personnel working with robots must be familiar with the operation and handling of the industrial robot, described in the applicable documents, e.g. User’s Guide and Product Manual. Connection of external safety devices Apart from the built-in safety functions, the robot is also supplied with an interface for the connection of external safety devices. Via this interface, an external safety function can interact with other machines and peripheral equipment. This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot. In the Product Manual - Installation and Commissioning, instructions are provided for connecting safety devices between the robot and the peripheral equipment.

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15

1 Safety 1.2.2.2. Limitation of Liability

1.2.2.2. Limitation of Liability General Any information given in this manual regarding safety, must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions have been complied with.

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1 Safety 1.2.2.3. Related information

1.2.2.3. Related information General The list below specifies documents which contain useful information: Documents Type of information

Detailed in document

Section

Installation of safety devices

Product manual for the manipulator

Installation and commissioning

Changing robot modes

User’s Guide

Start-up

Restricting the working space Product manual for the manipulator

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Installation and commissioning

17

1 Safety 1.2.3.1. Safety risks during service work on robot

1.2.3. Safety risks 1.2.3.1. Safety risks during service work on robot Overview This section includes information of general safety risks to be considered when performing service work on the robot.

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1 Safety 1.2.3.1. Safety risks during service work on robot

Complete robot Safety risk

Description

Hot components!

Caution!

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! Removed parts may result in collapse of robot!

Warning!

Take any necessary measures to ensure that the robot does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Cabling Safety risk

Description

Cable packs are sensitive to mechanical damage!

Caution!

The cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them!

Gearboxes and motors Safety risk

Description

Gears may be damaged if excessive force is used!

Caution!

Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used!

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1 Safety 1.2.3.1. Safety risks during service work on robot

Balancing device Safety risk

Description

Dangerous balancing device!

Warning!

Do not under any circumstances, deal with the balancing device in any other way than that detailed in the product documentation! For example, attempting to open the balancing device is potentially lethal!

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1 Safety 1.2.3.2. Safety risks related to gripper

1.2.3.2. Safety risks related to gripper CAUTION! Ensure that a gripper is prevented from dropping a workpiece, if such is used.

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1 Safety 1.2.3.3. Safety risks related to tools/workpieces

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

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1 Safety 1.2.3.4. Safety risks related to pneumatic/hydraulic systems

1.2.3.4. Safety risks related to pneumatic/hydraulic systems General Special safety regulations apply to pneumatic and hydraulic systems. Residual energy •

Residual energy may be present in these systems so, after shutdown, particular care must be taken.

•

The pressure in pneumatic and hydraulic systems must be released before starting to repair them.

•

Gravity may cause any parts or objects held by these systems to drop.

•

Dump valves should be used in case of emergency.

•

Shot bolts should be used to prevent tools, etc., from falling due to gravity.

Safe design

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1 Safety 1.2.3.5. Safety risks during operational disturbances

1.2.3.5. Safety risks during operational disturbances General •

The industrial robot is a flexible tool which can be used in many different industrial applications.

•

All work must be carried out professionally and in accordance with the applicable safety regulations.

•

Care must be taken at all times.

•

Remedial action must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts.

Qualified personnel

Extraordinary risks If the working process is interrupted, extra care must be taken due to risks other than those associated with regular operation. Such an interruption may have to be rectified manually.

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1 Safety 1.2.3.6. Safety risks during installation and service

1.2.3.6. Safety risks during installation and service General risks during installation and service •

The instructions in the Product Manual - Installation and Commissioning must always be followed.

•

Emergency stop buttons must be positioned in easily accessible places so that the robot can be stopped quickly.

•

Those in charge of operations must make sure that safety instructions are available for the installation in question.

•

Those who install the robot must have the appropriate training for the robot system in question and in any safety matters associated with it.

Nation/region specific regulations To prevent injuries and damage during the installation of the robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with. Non-voltage related risks •

Safety zones, which have to be crossed before admittance, must be set up in front of the robot's working space. Light beams or sensitive mats are suitable devices.

•

Turntables or the like should be used to keep the operator out of the robot's working space.

•

The axes are affected by the force of gravity when the brakes are released. In addition to the risk of being hit by moving robot parts, you run the risk of being crushed by the parallel arm.

•

Energy, stored in the robot for the purpose of counterbalancing certain axes, may be released if the robot, or parts thereof, is dismantled.

•

When dismantling/assembling mechanical units, watch out for falling objects.

•

Be aware of stored heat energy in the controller.

•

Never use the robot as a ladder, i.e. do not climb on the robot motors or other part during service work. There is a serious risk of slipping because of the high temperature of the motors or oil spills that can occur on the robot.

To be observed by the supplier of the complete system •

The supplier of the complete system must ensure that all circuits used in the safety function are interlocked in accordance with the applicable standards for that function.

•

The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner, in accordance with the applicable standards for the emergency stop function.

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25

1 Safety 1.2.3.7. Risks associated with live electric parts

1.2.3.7. Risks associated with live electric parts Voltage related risks, general •

Although troubleshooting may, on occasion, have to be carried out while the power supply is turned on, the robot must be turned off (by setting the mains switch to OFF) when repairing faults, disconnecting electric leads and disconnecting or connecting units.

•

The mains supply to the robot must be connected in such a way that it can be turned off outside the robot’s working space.

Voltage related risks, controller A danger of high voltage is associated with the following parts: •

Be aware of stored electrical energy (DC link) in the controller.

•

Units inside the controller, e.g. I/O modules, can be supplied with power from an external source.

•

The mains supply/mains switch

•

The power unit

•

The power supply unit for the computer system (230 VAC)

•

The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)

•

The drive unit (700 VDC)

•

The service outlets (115/230 VAC)

•

The power supply unit for tools, or special power supply units for the machining process

•

The external voltage connected to the control cabinet remains live even when the robot is disconnected from the mains.

•

Additional connections

Voltage related risks, robot A danger of high voltage is associated with the robot in: •

The power supply for the motors (up to 800 VDC)

•

The user connections for tools or other parts of the installation (max. 230 VAC, see Installation and Commissioning Manual)

Voltage related risks, tools, material handling devices, etc Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged.

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1 Safety 1.2.4.1. Safety fence dimensions

1.2.4. Safety actions 1.2.4.1. Safety fence dimensions General Install a safety cell around the robot to ensure safe robot installation and operation. Dimensioning Dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed. Determine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot is working in the work cell (see Product Specification - Description, Robot Motion). Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the manipulator.

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27

1 Safety 1.2.4.2. Fire extinguishing

1.2.4.2. Fire extinguishing NOTE! Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot (manipulator or controller)!

28

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1 Safety 1.2.4.3. Emergency release of the robot’s arm

1.2.4.3. Emergency release of the robot’s arm Description In an emergency situation, any of the robot’s axes may be released manually by pushing the brake release buttons on the robot or on an optional external brake release unit. How to release the brakes is detailed in section: •

Manually releasing the brakes on page 49.

The robot arm may be moved manually on smaller robot models, but larger models may require using an overhead crane or similar. Increased injury Before releasing the brakes, make sure that the weight of the arms does not increase the pressure on the trapped person, further increasing any injury!

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1 Safety 1.2.4.4. Brake testing

1.2.4.4. Brake testing When to test During operation the holding brakes of each axis motor wear normally. A test may be performed to determine whether the brake can still perform its function. How to test The function of each axis’ motor holding brakes may be checked as detailed below: 1. Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized (max. static load). 2. Switch the motor to the MOTORS OFF position with the Operating mode selector on the controller. 3. Check that the axis maintains its position. If the manipulator does not change position as the motors are switched off, then the brake function is adequate.

30

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1 Safety 1.2.4.5. Risk of disabling function "Reduced speed 250 mm/s"

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

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31

1 Safety 1.2.4.6. Safe use of the Teach Pendant Unit

1.2.4.6. Safe use of the Teach Pendant Unit NOTE! The enabling device is a push button located on the side of the Teach Pendant Unit (TPU) which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device is released or pushed all the way in, the robot is taken to the MOTORS OFF state. To ensure safe use of the Teach Pendant Unit, the following must be implemented:

32

•

The enabling device must never be rendered inoperative in any way.

•

During programming and testing, the enabling device must be released as soon as there is no need for the robot to move.

•

The programmer must always bring the Teach Pendant Unit with him/her, when entering the robot's working space. This is to prevent anyone else taking control over the robot without the programmer knowing.

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1 Safety 1.2.4.7. Work inside the manipulator’s working range

1.2.4.7. Work inside the manipulator’s working range WARNING! If work must be carried out within the robot’s work envelope, the following points must be observed: •

The operating mode selector on the controller must be in the manual mode position to render the enabling device operative and to block operation from a computer link or remote control panel.

•

The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in position < 250 mm/s. This should be the normal position when entering the working space. The position 100% ”full speed” may only be used by trained personnel who are aware of the risks that this entails.

•

Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in order not to get entangled with hair or clothing. Also be aware of any danger that may be caused by rotating tools or other devices mounted on the manipulator or inside the cell.

•

Test the motor brake on each axis, according to section Brake testing on page 30.

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33

1 Safety 1.3.1. Safety signals, general

1.3 Safety related instructions 1.3.1. Safety signals, general General This section specifies all dangers that may arise from performing the work detailed in the manual. Each danger is detailed in its own section consisting of: •

A caption specifying the danger level (DANGER, WARNING or CAUTION) and the type of danger.

•

A brief description of what will happen if the operator/service personnel does not eliminate the danger.

•

An instruction of how to eliminate the danger to facilitate performing the activity at hand.

Danger levels The table below defines the captions specifying the danger levels used throughout this manual.

Symbol

Designation

Signification

DANGER

Warns that an accident will occur if the instructions are not followed, resulting in a serious or fatal injury and/or severe damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height etc.

WARNING

Warns that an accident may occur if the instructions are not followed, that can lead to serious injury, possibly fatal, and/or great damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height etc.

ELECTRICAL SHOCK

The electrocution or electrical shock symbol indicates electrical hazards which could result in severe personal injury or death.

CAUTION

Warns that an accident may occur if the instructions are not followed, that can result in injury and/or damage to the product. It also applies to warnings of risks that include burns, eye injury, skin injury, hearing damage, crushing or slipping, tripping, impact, fall from height etc. Furthermore, it applies to warnings that include function requirements when fitting and removing equipment, where there is a risk of damaging the product or causing a breakdown.

danger

warning

Electrical shock

caution

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1 Safety 1.3.1. Safety signals, general

Symbol

Designation

Signification

ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates DISCHARGE (ESD) electrostatic hazards which could result in severe damage to the product.

Electrostatic discharge (ESD)

NOTE

Note symbols alert you to important facts and conditions.

TIP

Tip symbols direct you to specific instructions, where to find additional information or how to perform a certain operation in an easier way.

Note

Tip

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35

1 Safety 1.3.2. DANGER - Moving manipulators are potentially lethal!

1.3.2. DANGER - Moving manipulators are potentially lethal! Description Any moving manipulator is a potentially lethal machine. When running the manipulator, it may perform unexpected and sometimes irrational movements. However, all movements are performed with great force and may seriously injure any personnel and/or damage any piece of equipment located within the manipulator working range. Elimination Step

36

Action

Info/Illustration

1.

Before attempting to run the manipulator, Emergency stop equipment such as make sure all emergency stop equipment gates, tread mats, light curtains, etc. has been correctly installed and connected.

2.

If possible, use the hold-to-run button whenever possible. The hold-to-run button is used in manual mode, not in automatic mode.

3.

Make sure no personnel is present within the manipulator working range before pressing the start button.

How to use the hold-to-run control in RobotWare 5.0 is detailed in section How to use the hold-to-run switch in the Operator’s Manual, IRC5. How to use the hold-to-run control in RobotWare 4.0 is detailed in section The Teach Pendant unit in the User’s Guide.

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1 Safety 1.3.3. WARNING - The unit is sensitive to ESD!

1.3.3. WARNING - The unit is sensitive to ESD! Description ESD (electro static discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not connected to ground potential may transfer high static charges. This discharge may destroy sensitive electronics. Elimination Step

Action

Note/Illustration

1.

Use a wrist strap

Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly.

2.

Use an ESD protective floor mat.

The mat must be grounded through a currentlimiting resistor.

3.

Use a dissipative table mat.

The mat should provide a controlled discharge of static voltages and must be grounded.

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1 Safety 1.3.4. WARNING - Safety risks during work with gearbox oil

1.3.4. WARNING - Safety risks during work with gearbox oil 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! Warnings and elimination Warning

Description

Elimination / Action

Changing and draining Make sure that protective gear gearbox oil may require like goggles and gloves are handling hot oil of up to 90 °C! always worn during this activity.

-

Hot oil! When opening the oil plug, Open oil plug carefully and keep there may be pressure present away from the opening. Do not in the gearbox, causing oil to overfill the gearbox when filling. spray from the opening! -

Possible pressure build up in gearbox!

-

Do not overfill!

Overfilling of gearbox oil can lead to internal over-pressure inside the gearbox which in turn may: • damage seals and gaskets • completely press out seals and gaskets • prevent the manipulator from moving freely.

Make sure not to overfill the gearbox when filling with oil! After filling, check the correct oil levels.

Mixing types of oil may cause severe damage to the gearbox!

When filling gearbox oil, do not mix different types of oil unless specified in the instruction. Always use the type of oil specified by the manufacturer!

-

Do not mix types of oil!

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1 Safety 1.3.4. WARNING - Safety risks during work with gearbox oil

Warning

Description

Elimination / Action

Warm oil drains quicker than cold oil.

When changing gearbox oil, first run the robot for a time to heat up the oil.

-

Heat up the oil!

-

Specified amount depends on drained volume!

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The specified amount of oil is After refilling, check the oil level. 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.

39

1 Safety 1.3.4. WARNING - Safety risks during work with gearbox oil

40

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2 Installation and commissioning 2.1. Introduction

2 Installation and commissioning 2.1. Introduction General This chapter contains information for installing the robot to the working site. More detailed technical data, such as load diagram, permitted extra loads (equipment) and location of extra loads (equipment), may be found in the Product Specification for the robot.

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41

2 Installation and commissioning 2.2.1. Pre-installation procedure

2.2 Unpacking 2.2.1. Pre-installation procedure General This instruction is primarily intended for use when unpacking and installing the robot for the first time. It also contains information useful during later re-installation of the robot. Checking the pre-requisites for installation The check-list below details what must be observed before proceeding with the actual installation of the manipulator: Step

Action

Info/Illustration

1.

Make sure only qualified installation personnel conforming to all national and local codes are allowed to perform the installation.

2.

Make sure the manipulator has not been damaged, by visually inspecting the manipulator and control cabinet exterior.

3.

Make sure the lifting device to be used is dimensioned to handle the weight of the manipulator.

Specified in section Weight, manipulator on page 42.

4.

If the manipulator is not to be installed directly, it must be stored.

Specified in section Storage conditions, manipulator on page 43.

5.

Make sure the appointed operating Specified in section Operating environment of the manipulator conforms to conditions, manipulator on page 43. the specifications.

6.

Before taking the manipulator to its Specified in section : installation site, make sure the site conforms • Loads on foundation, to applicable requirements. manipulator on page 43 • Requirements on foundation, manipulator on page 43 • Protection classes on page 44

7.

Before moving the manipulator, make sure it Described in section Risk of tipping/ does not tip over! Stability on page 47.

8.

When these prerequisites have been met, the manipulator may be taken to its installation site.

Detailed in section Lifting manipulator with lifting slings on page 48.

Weight, manipulator The net weight of the manipulator is approximately: 100 kg.

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2 Installation and commissioning 2.2.1. Pre-installation procedure

Loads on foundation, manipulator The table below shows the different forces and torques working on the manipulator during different kinds of operation. NOTE! These forces and torques are extreme values that are rarely encountered during operation. The values also never reach their maximum simultaneously!

Force

Endurance load (operation)

Max. load (emergency stop)

Force xy (upright/suspended)

± 1300 N

± 3200 N

Force z (upright)

-1000 ± 1000 N

-1000 ± 2000 N

Forze z (suspended)

-2800 ± 1000 N

+1000 ± 2000 N

Mxy

± 1300 Nm

± 220 Nm

Mz

± 300 Nm

± 750 Nm

Torque

Requirements on foundation, manipulator Requirement

Value

Min. levelity

0.5 mm

Max. tilt

5°

Min. resonance frequency

22 Hz

Storage conditions, manipulator The table below shows the allowed storage conditions for the manipulator:

Parameter

Value

Max. ambient temperature

+55° C

Max. ambient temperature (less than 24 hrs)

+70° C

Min. ambient temperature

-25° C

Max. ambient humidity

Max. 95% at constant temperature

Operating conditions, manipulator The table below shows the allowed operating conditions for manipulator:

Parameter

Value

Max. ambient temperature

+45° C

Min. ambient temperature

+5° C

Max. ambient humidity

Max. 95% at constant temperature

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2 Installation and commissioning 2.2.1. Pre-installation procedure

Protection classes The table below shows the protection class of the main parts of the robot system:

44

Equipment

Protection class

Manipulator

IP 67

Control cabinet

IP 54

Programming unit

IP 54

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2 Installation and commissioning 2.2.2. Working range, IRB 140

2.2.2. Working range, IRB 140 Working range axis 2 -3 The illustration below shows the unrestricted working range axis 2-3.

xx0200000058

Pos

Position at wrist centre

Angle (degrees)

X

Z

Axis 2

Axis 3

0

450

712

0°

0°

1

70

1092

0°

-90°

2

314

421

0°

+50°

3

765

99

+110°

-90°

4

255

-119

+110°

+4°

5

-480

23

-90°

-150°

6

1

596

-90°

+50°

7

218

558

+110°

-230°

8

-670

352

-90°

-90°

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2 Installation and commissioning 2.2.2. Working range, IRB 140

Working range axis 1 The illustrations below shows the unrestricted working range of axis 1.

xx0200000061

46

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2 Installation and commissioning 2.2.3. Risk of tipping/Stability

2.2.3. Risk of tipping/Stability General The section below details instructions for making sure the manipulator does not tip over when it has not been safely secured to the foundation. Procedure The procedure below details how to make sure the manipulator does not tip during installation while not secured to the foundation. CAUTION! When the manipulator is not fastened to the floor, it will not be stable in any part of its working area. 1. DO NOT change the manipulator position before securing it to its foundation. The shipping position is the most stable. 2. If the manipulator, for some reason, must be move from its original position, ensure that the centre of gravity not is displaced.

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2 Installation and commissioning 2.3.1. Lifting manipulator with lifting slings

2.3 On-site installation 2.3.1. Lifting manipulator with lifting slings General This section details how to lift the manipulator using lifting slings.

Equipment

Note

Sling line

Length: 2 m. Load: 500 kg.

Illustration The following figures shows how to lift the manipulator with lifting slings.

xx0200000084

1

Sling line for manipulator

2

Sling line for manipulator

3

Sling line for control cable

How to lift the manipulator 1. Adjust the manipulator to lifting position according to the picture. 2. Put one sling line around each leg on the lower arm (Pos. 1 and 2). 3. Use further one sling line to secure the lifting of the control cable (Pos. 3).

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2 Installation and commissioning 2.3.2. Manually releasing the brakes

2.3.2. Manually releasing the brakes General The section below details how to release the holding brakes of each axis’ motor. This may be done in one of three ways: •

using the pushbutton when the manipulator is connected to the controller.

•

using the pushbutton on the manipulator with an external power supply.

•

using an external voltage supply.

DANGER! When releasing the holding brakes, the manipulator axes may move very quickly and sometimes in unexpected ways! Make sure no personnel is near the manipulator arm! Using the pushbutton when the manipulator is connected to the controller This section details how to release the holding brakes using the internal brake release unit. Step 1.

Action

Info/Illustration

Push the "brake release button" to release the holding brakes.

xx0200000069

•

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A: Pushbutton

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2 Installation and commissioning 2.3.2. Manually releasing the brakes

Using the pushbutton on the manipulator with an external power supply This section details how to release the holding brakes with the pushbutton using an external voltage supply. Step 1.

Action

Info/Illustration

Connect an external power supply to connector XP1.

xx0200000071

• • 2.

A: B16 24V DC B: B14 0V

Push the "brake release button" to release the holding brakes.

NOTE! Be careful not to interchange the 24V DC and the 0V pins. If they are mixed up, damage can be caused to a resistor diode and to the system board. Using External power supply This section details how to release the holding brakes using a external voltage supply. If the positions of the manipulator axes are to be changed without connecting the controller, an external voltage supply (24 V DC) must be connected to enable the brake release buttons on the manipulator. Step 1.

Action

Info/Illustration

Remove the screws and dismount the cover on the back of the manipulator base.

xx0200000072

• •

50

A: 13 0 V B: 15 24 V DC

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2 Installation and commissioning 2.3.2. Manually releasing the brakes

Step

Action

2.

Locate the R1.MP4-6 connector and disconnect.

3.

Connect an external power supply to release the holding brake on all axis.

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Info/Illustration

51

2 Installation and commissioning 2.3.3. Orienting and securing the manipulator

2.3.3. Orienting and securing the manipulator General This section details how to orient and secure the manipulator to the foundation in order to safely run the robot. Bolting requirements When bolting a mounting plate or frame to a concrete floor, follow the general instructions for expansion-shell bolts. The screw joint must be able to withstand the stress loads defined in section Loads on foundation, manipulator on page 43. NOTE! When the robot is to be mounted in a tilted or a suspended position, the guide sleeves must be used to secure the bolted joint. Attachment screws The table below specifies the type of securing screws and washers to be used for securing the manipulator to the base plate/foundation.

Suitable screws, lightly lubricated:

M12

Quality

Quality 8.8

Suitable washer:

Thickness: 2.5 mm Outer diameter: 24 mm Inner diameter: 13.4 mm

Tightening torque:

85 Nm

Hole configuration and cross section The bolt pattern requirements are shown in section Bolt pattern on page 59. Guide sleeves Two guide sleeves can be fitted to the two rear bolt holes to allow the same robot to be remounted without re-adjusting the program.

52

Equipment

Art. no.

Guide sleeves

3HAC 9519-1

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2 Installation and commissioning 2.3.4. Restricting the working space

2.3.4. Restricting the working space General When installing the manipulator, make sure that it can move freely within its entire working space. If there is a risk that it may collide with other objects, its working space should be limited. WARNING! The working space can only be limited using soft ware, for this reason the limited area can not be classified as a safe zone. All work within this zone is prohibited. Limiting devices Limiting devices is listed below. 1. Light curtains. 2. Tread mats. 3. Other similar devices. 4. SoftWare. Limiting the working space using software is described in the User’s Guide chapter: System Parameters.

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2 Installation and commissioning 2.3.5. Fitting equipment on manipulator

2.3.5. Fitting equipment on manipulator General The manipulator features mounting holes for additional equipment. In addition to the stock mounting holes, extra mounting holes may be added on the manipulator under certain conditions. These special conditions are specified in the Product Specification. Illustration, holes on upper arm The illustration below shows the stock holes available for fitting extra equipment on the upper arm.

xx0200000062

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2 Installation and commissioning 2.3.5. Fitting equipment on manipulator

Illustration, holes on mounting flange The illustration below shows the stock holes available for fitting equipment on the mounting flange.

xx0200000063

Fastener quality When fitting tools on the mounting flange (see the figures in sections Illustration, holes on upper arm on page 54 and Illustration, holes on mounting flange on page 55), use only screws with quality 12.9. When fitting other equipment, standard screws with quality 8.8 can be used.

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2 Installation and commissioning 2.3.6. Loads

2.3.6. Loads General Any loads mounted on the manipulator must be defined correctly and carefully (with regard to the position of centre of gravity and inertia factor) in order to avoid jolting movements and overloading the motors. If this is not done correctly operation stops may result. References Load diagrams, permitted extra loads (equipment) and their positions as specified in the Product Specification. The loads must also be defined in the software as detailed in User’s Guide. Brake performance Manipulator motor brake performance depends on any loads attached. For further information about brake performance, please contact ABB.

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2 Installation and commissioning 2.3.7. Suspended mounting

2.3.7. Suspended mounting General Initially the system is configured for mounting on the floor, without leaning. The method for mounting the manipulator in a suspended position is basically the same as for floor mounting. NOTE! With inverted installation, make sure that the gantry or corresponding structure is rigid enough to prevent unacceptable vibrations and deflections, so that optimum performance can be achieved. System Parameters If the robot is mounted at any other angle, the system parameter “gravity beta” must be updated. Gravity beta specifies the robot’s mounting angle expressed in radians. NOTE! It is very important to configure gravity beta correctly so that the robot system can control the movements in the best possible way. Incorrect definition of mounting angle (gravity beta) will result in: •

Overloading the mechanical structure.

•

Lower path performance and path accuracy.

•

Some S4 functions will not work properly: e.g Load Identification & Collision detection.

Mounting Angles and Values The parameter “gravity beta” specifies the robot’s mounting angle in radians. It is calculated in the following way for a mounting angle of 45°. Gravity beta = 45° x 3.141593/180 = 0.785398 radians.

Examples of Position

Mounting Angle

Gravity Beta

Floor (pos 1)

0°

0.000000 (Default)

Tilted (pos 2)

45°

0.785398

Wall (pos 3)

90°

1.570796

Ceiling (pos 4)

180°

3.141593

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2 Installation and commissioning 2.3.7. Suspended mounting

xx0200000066

Defining the parameters Following steps describes how to enter the correct gravity beta values. Step

Action

1.

Choose Topics: Manipulator.

2.

Choose Types: Robot.

3.

Select Master and press Enter.

Info/Illustration

xx0200000073

58

4.

Select the desired parameter “gravity beta” and change its value.

5.

Press OK to confirm.

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2 Installation and commissioning 2.3.8. Bolt pattern

2.3.8. Bolt pattern Hole configuration The illustration below shows the hole configuration used when securing the manipulator:

xx0200000085

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2 Installation and commissioning 2.3.8. Bolt pattern

Cross section, guide sleeve hole The illustration below shows the cross section of the guide sleeve holes:

xx0200000086

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2 Installation and commissioning 2.4.1. Customer connections on manipulator

2.4 Electrical connections 2.4.1. Customer connections on manipulator General For connection of extra equipment on the manipulator there are cables integrated into the manipulator’s cabling. There are both air and electrical connectors on the manipulator.

xx0200000074

Connections Connections

Description

1. For air on base / upper arm

R1/4" Max. 8 bar/hose inner diameter: 6.5 mm

2. Signal connector on upper arm

FCI UT 071412SH44N connector Number of signals: 12 signals, 49V, 500mA

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2 Installation and commissioning 2.4.1. Customer connections on manipulator

Recommended parts To connect power and signal conductors to the upper arm connector, the following parts are recommended

xx0200000132

ABB’s recommended contact set, for connector R2.CS (3HAC 12497-1) contains: •

Multipole connector 12 pin

•

Adapter Tin plated 12 pin

•

Pins for cable area 0.25-0.5 mm 2

•

Pins for cable area 0.5-1.5 mm 2

•

Shrinking hose, bootled shaped

•

Shrinking hose angled

The connection set is delivered in a plastic bag also containing a Technical and assembly instruction.

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3 Maintenance 3.1. Introduction

3 Maintenance 3.1. Introduction Structure of this chapter This chapter details all maintenance activities recommended for the robot and any external units of the robot. It is based on the maintenance schedule, located in the beginning of the chapter. The schedule contains information about required maintenance activities including periodicity and refers to procedures for the activities. Each procedure contains all information required to perform the activity, e.g. required tools and materials. The procedures are gathered in different sections, divided according to the maintenance activity. Safety information Before any service work is commenced, it is extremely important that all safety information is observed! There are general safety aspects that must be read through, as well as more specific safety information that describe danger and safety risks when performing the procedures. Make sure to read through the chapter Safety on page 13.

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3 Maintenance 3.2.1. Maintenance schedule, IRB 140

3.2 Maintenance schedules 3.2.1. Maintenance schedule, IRB 140 General The robot, consisting of manipulator and controller cabinet, must be maintained regularly to ensure its function. The maintenance activities and their respective intervals are specified in the table below. Non-predictable situations also give rise to inspections of the robot. Any damages must be attended to immediately! The inspection intervals do not specify the life of each component. Activities and intervals, standard equipment The sections referred to in the table can be found in the different chapters for every maintenance activity. The table below specifies the required maintenance activities and intervals:

Maintenance activity

Equipment

Inspection

Damper, axes 2-3 Regularly *)

Inspection, damper axes 2-3 on page 66

Inspection

Cable harnesses

Regularly *)

Inspection, robot cabling on page 68

Inspection

Timing belts

36 mths

Inspection, timing belts on page 69

Change

Gearbox 5, oil

36 mths

Oil change, gearbox, axes 5 and 6 on page 73

Change

Gearbox 6, oil

36 mths

Oil change, gearbox, axes 5 and 6 on page 73

Change

Measurement system, battery

Depending on battery type Replacement of serial and operation pattern as measurement unit and specified in section Battery battery pack on page 122. type selection on page 65.

Clean

Complete manipulator

Regularly *)

Interval

Detailed in section:

Cleaning, complete robot on page 72

*) "Regularly" implies that the activity is to be performed regularly, but the actual interval may not be specified by the robot manufacturer. The interval depends on the operation cycle of the robot, its working environment and movement pattern. Generally, the more contaminated environment, the shorter intervals. The more demanding movement pattern (sharper bending cable harness), the shorter intervals.

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3 Maintenance 3.2.1. Maintenance schedule, IRB 140

Battery type selection The table below shows the selection criteria for the three available battery types.

Operation pattern

Change interval, 3-cell lithium

Change interval, 6-cell lithium

Max. 4 weeks power off per year

60 mths

60 mths

Weekend power off + operation pattern 1

24 mths

48 mths

Nightly power off + operation patterns 1 and 2 12 mths

24 mths

No longer change interval than 60 months are allowed regardless of the operation pattern due to material ageing, etc.

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3 Maintenance 3.3.1. Inspection, damper axes 2-3

3.3 Inspection activities 3.3.1. Inspection, damper axes 2-3 Location of dampers, axes 2-3 The figure below shows the location of all the dampers to be inspected.

xx0200000426

A

Damper, axis 2

xx0200000427

A

66

Damper, axis 3

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3 Maintenance 3.3.1. Inspection, damper axes 2-3

Required equipment Equipment

Art. no.

Note

Standard toolkit

3HAC020812-001

The contents are defined in section Standard toolkit in the Product manual, reference information!

Inspection, damper axis 2-3 The procedure below details how to inspect the dampers, axis 2-3 WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Step

Action

Note

1.

Check all dampers for damage, such as cracks or existing impressions larger than 1 mm.

Shown in the figure in section Location of dampers, axes 2-3 on page 66!

2.

Check attachment screws for deformation.

3.

If any damage is detected, the damper must be replaced with a new one!

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Art. no. specified in section Required equipment on page 67! Replacement is detailed in section Replacement of damper, axis 2 on page 111 and Replacement of damper, axis 3 on page 102.

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3 Maintenance 3.3.2. Inspection, robot cabling

3.3.2. Inspection, robot cabling Location, robot cabling The robot cabling comprises the cabling between the manipulator and controller cabinet as well as the externally visible cabling around motors 1 and 2. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information. Required equipment Equipment

Art. no.

Note

Standard toolkit

3HAC020812-001

The contents are defined in section Standard toolkit in the Product manual, reference information!

Other tools and procedures may be required. See references to these procedures in the stepby-step instructions below. Circuit diagram

These procedures include references to the tools required.

3HAC 6816-3

WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

CAUTION! The cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them! Inspection The procedure below details how to inspect the robot cabling. Step

68

Action

1.

Visually inspect the control cabling between the manipulator and control cabinet. Look for abrasions, cuts or crush damages.

2.

Replace the cabling if wear or damage is detected.

Note

This is detailed in Replacement of cable harness on page 78.

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3 Maintenance 3.3.3. Inspection, timing belts

3.3.3. Inspection, timing belts Location of timing belts Axes 3, 5 and 6 are fitted with timing belts. These are located as shown in the figures below. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.

xx0200000448

G

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Timing belt, axis 3

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3 Maintenance 3.3.3. Inspection, timing belts

xx0200000453

R

Timing belt, axis 6

V

Timing belt, axis 5

Required equipment Equipment, etc.

Art. no.

Note

Standard toolkit

3HAC020812-001

The contents are defined in section Standard toolkit in the Product manual, reference information!

Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.

70

These procedures include references to the tools required.

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3 Maintenance 3.3.3. Inspection, timing belts

Inspection The procedure below details how to inspect the timing belts. WARNING! Please observe the following before commencing any repair work on the manipulator: •

Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them!

•

Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot!

•

When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures.

Step

Action

Note

1.

Gain access to each belt by removing covers, etc.

These procedures are detailed in sections Replacement of motor and timing belt, axis 3 on page 139 and Replacement of motor and timing belt, axes 5 or 6 on page 147.

2.

Check each belt for damage.

Replace the timing belts if found defective as detailed in sections Replacement of motor and timing belt, axis 3 on page 139 and Replacement of motor and timing belt, axes 5 or 6 on page 147.

3.

Check each belt for tension. If the belt tension is not correct, it should be adjusted.

The belt tension should be: • Axis 3: F = 35-60 N • Axis 5: F = 35-60 N • Axis 6: F = 35-60 N

xx0200000474

Belt tension adjustment is detailed in sections Replacement of motor and timing belt, axis 3 on page 139 and Replacement of motor and timing belt, axes 5 or 6 on page 147.

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3 Maintenance 3.4.1. Cleaning, complete robot

3.4 Cleaning activities 3.4.1. Cleaning, complete robot General The protection class is IP 67, i.e. the manipulator is watertight. Required equipment Equipment, etc.

Art. no. Note

May be used on Foundry versions only! Steam cleaner

-

May be used on Foundry versions only! High pressure water cleaner

-

• • • • • • •

Vacuum cleaner Cloth with mild detergent

-

Water pressure at nozzle: max. 2,500 kN/ m 2 (25 bar) Type of nozzle: fan jet, min. 45° spread Flow: max. 100 litres/min. Water temperature: max. 80° C Max. water pressure on enclosures: 50 kN/ m 2 (0.5 bar) Fan jet nozzle should be used, min. 45° spread Flow: max. 100 litres/min.

May be used on Standard version

Do’s and don’ts! The section below specifies some special considerations when cleaning the manipulator. Always! •

Always use cleaning equipment as specified above! Any other cleaning equipment may shorten the life of paintwork, rust inhibitors, signs, or labels!

•

Always check that all protective covers are fitted to the robot before cleaning!

•

Never point the water jet at bearing seals, contacts, and other seals!

•

Never spray from a distance closer than 0.4 m!

•

Never remove any covers or other protective devices before cleaning the robot!

•

Never use any cleaning agents, e.g. compressed air or solvents, other than those specified above!

•

Although the manipulator is watertight, avoid spraying connectors and similar items with a high pressure cleaner!

Never!

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3 Maintenance 3.5.1. Oil change, gearbox, axes 5 and 6

3.5 Changing/ replacing activities 3.5.1. Oil change, gearbox, axes 5 and 6 Location of oil plugs The gearboxes for axes 5 and 6 are located in the wrist unit as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.

xx0200000475

A

Oil plug, gearbox axis 5

B

Oil plug, gearbox, axis 6

Required equipment Equipment, etc.

Art. no.

Note

Lubricating oil

1171 2016-604 3HAC 0860-1

Corresponds to: • Optimol, BM 100 Amount, gearbox 5 and 6: 350 ml

Oil collecting vessel Standard Toolkit, IRB 140

Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.

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Capacity: 400 ml. 3HAC020812-001

The contents are defined in section Standard toolkit in the Product manual, reference information! These procedures include references to the tools required.

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3 Maintenance 3.5.1. Oil change, gearbox, axes 5 and 6

WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

TIP! When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains quicker than cold oil. WARNING! When filling gearbox oil, do not mix different types of oil unless specified in the instruction. Always use the type of oil specified by the manufacturer! WARNING! When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside the gearbox which in turn may: •

damage seals and gaskets

•

completely press out seals and gaskets

•

prevent the manipulator from moving freely

WARNING! Changing and draining gearbox oil may require handling hot oil of up to 90 °C! Make sure that protective gear like goggles and gloves are always worn during this activity. Also, be aware of possible pressure build up in gearbox! When opening the oil plug, there may be pressure present in the gearbox, causing oil to spray from the opening! Draining, axes 5 and 6 The procedure below details how to drain the oil from gearboxes, axes 5 and 6. Step

74

Action

Note

1.

Move the robot to a position where the upper arm is close to horizontal and axis 4 in the calibration position.

2.

Remove the oil plugs. The cavity behind the plugs, containing the oil, is common to gearboxes 5 and 6, but during draining, both must be removed.

3.

Move axis 4 90° to a position where the axis 6 oil plug faces downwards.

4.

Drain the oil from the gearbox.

Vessel capacity specified in section Required equipment on page 73!

5.

Move axis 4 another 90°.

This allows the remaining oil to be drained.

6.

Refit the oil plug.

Shown in the figure Location of oil plugs on page 73!

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3 Maintenance 3.5.1. Oil change, gearbox, axes 5 and 6

Refill, axes 5 and 6 The procedure below details how to refill the oil in gearboxes, axes 5 and 6. Step

Action

Note

1.

Run the robot to a position where the upper arm is close to horizontal and axis 4 in the calibration position.

2.

Remove the oil plug, axis 5.. Shown in the figure Location of The cavity behind the plugs, containing the oil, is oil plugs on page 73! common to gearboxes 5 and 6, but during draining, both must be removed.

3.

Fill oil in gearbox 5 until the oil level reaches the The figure shows the oil plug hole on the side of the wrist. manipulator positions for filling and draining respectively for a standing manipulator:

xx0300000161

Positions: • A: Draining position • B: Filling position The figure shows the manipulator positions for filling and draining respectively for an inverted manipulator:

xx0300000162

Positions: • A: Draining position • B: Filling position The oil quality is specified in section Required equipment on page 73! 4.

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Refit the oil plug.

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3 Maintenance 3.5.1. Oil change, gearbox, axes 5 and 6

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4 Repair 4.1. Introduction

4 Repair 4.1. Introduction Structure of this chapter This chapter details all repair activities recommended for the robot and any external units of the robot. It is made up of separate units, each detailing a specific repair activity. Each unit contains all information required to perform the activity, e.g. spare parts numbers, required special tools and materials. The units are gathered in different sections, divided according to the component location on the robot. Required equipment All equipment required to perform a specific repair activity is listed together with the current procedure. The equipment is also gathered in different lists in the Product manual, reference information. Safety information Before any service work is commenced, it is extremely important that all safety information is observed! There are general safety aspects that must be read through, as well as more specific safety information that describe danger and safety risks when performing specific steps in a procedure. Make sure to read through the chapter Safety on page 13 before commencing any service work.

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4 Repair 4.2.1. Replacement of cable harness

4.2 Complete robot 4.2.1. Replacement of cable harness Location of cable harness The cable harness runs from the base to the motors of axes 3-6. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information. Required equipment Equipment, etc.

Spare part no. Art. no.

Note

Cable harness

3HAC 7370-1

Standard and Foundry versions Clean room version Includes cabling: • Cable harness, power axis 1-3 • Cable harness, power axis 4-6 • Cable harness, signals axis 1-3 • Cable harness, signals axis 4-6 • Cable harness, customer connections

Standard toolkit

3HAC020812-001

Other tools and procedures may be required. See references to these procedures in the stepby-step instructions below. Circuit Diagram

78

The contents are defined in section Standard toolkit in the Product manual, reference information! These procedures include references to the tools required.

3HAC 6816-3

See chapter Circuit diagram in the Product manual, reference information.

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4 Repair 4.2.1. Replacement of cable harness

Removal, cable harness The procedure below details how to remove the cable harness. WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

CAUTION! The cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them! Step

Action

Note/Illustration

1.

Remove the serial measurement board.

Detailed in section Replacement of serial measurement unit and battery pack on page 122.

2.

Disconnect connectors in the manipulator base.

xx0300000090

Connectors: • A: R1.MP1-3 • B: R1.CS • C: Air hose • D: R1.MP4-6 3.

Remove the cable holder by unscrewing its attachment screws.

xx0300000091

• • •

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A: Cable holder B: Attachment screws C: Cable securing screws

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4 Repair 4.2.1. Replacement of cable harness

Step

Action

Note/Illustration

4.

Remove the cables from the See figure above! cable holder by unscrewing the cable securing screws.

5.

Remove the cover, arm housing.

Detailed in section Replacement of cover, arm housing, IRB 140.

6.

Remove the lower arm cover.

Detailed in section Replacement of lower arm cover and gasket on page 108.

7.

Gently knock out the VK cover. Detailed in section Removing the VK cover on page 88.

8.

Disconnect connectors in the rear of the upper arm.

xx0300000092

Connectors: • A: R2.CS • B: Pressurized air connection • C: R3.FB4 • D: R3.FB5 • E: R3.FB6 • F: R3.MP5 • G: R3.MP4 • H: R3.MP6 Parts: • J: Shield 9.

Remove the shield by unscrewing its attachment screws.

See figure above!

10. Cut any cable ties securing the cabling inside the lower arm.

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4 Repair 4.2.1. Replacement of cable harness

Step

Action

Note/Illustration

11. Disconnect the connectors inside the lower arm.

xx0200000449

•

G: Connectors R3.MP3 and R3.FB3

12. Pull the cables out of the upper arm. 13. Remove the cover, console.

Detailed in section Replacement of cover, console on page 115.

14. Disconnect the connectors inside the console and undo the cable holders.

Connectors: • R3.MP1 • R3.MP2 • R3.FB1 • R3.FB2

15. Gently pull the cabling from the base up through the console. 16. Gently pull the cabling out of the lower arm.

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4 Repair 4.2.1. Replacement of cable harness

Refitting, cable harness The procedure below details how to refit the cable harness. WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.

CAUTION! The cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them! Step

Action

1.

Refit in reverse order to what is detailed above. Detailed below are some recommendations on how to route the cables.

2.

Cable distribution in the cable holder in the manipulator base.

Note/Illustration

xx0300000093

Cables: • A: Signal • B: Signal • C: Customer signal • D: Power cable, axes 4-6 • E: Pressurized air supply • F: Power cable, axes 1-3

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4 Repair 4.2.1. Replacement of cable harness

Step 3.

Action

Note/Illustration

Cable layout in the lower arm.

xx0200000449

• • • • • • •

3HAC 023297-001 Revision: -

A: Cable ties B: Pressurized air hose C: Power cables, axes 4, 5 and 6 D: Customer cables, signal E: Signal cables, axes 4, 5 and 6 F: Signal cable, axis 3 G: Connectors R3.MP3 and R3.FB3

83

4 Repair 4.2.1. Replacement of cable harness

Step 4.

Action

Note/Illustration

Cable holder in the upper arm.

xx0300000094

Cables: • A: Customer signal • B: Signal • C: Pressurized air supply • D: Power cables

84

3HAC 023297-001 Revision: -

4 Repair 4.2.2. Replacement of complete upper arm

4.2.2. Replacement of complete upper arm Location of upper arm The upper arm is located on top of the manipulator as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.

xx0200000446

A

Cover, armhousing

B

Attachment screws, cover armhousing, (4 pcs)

C

CS-connector

D

Pressurized air connector

E

VK cover

F

Cable guide

G

Attachment screws, cable guide

H

Attachment screws, upper arm (6 pcs)

J

Sealing ring

3HAC 023297-001 Revision: -

85

4 Repair 4.2.2. Replacement of complete upper arm

Required equipment Equipment

Spare part no. Art. no.

Note

Upper arm, spare Std/F

3HAC 10466-1

Standard and Foundry versions Includes all required sealings and gaskets.

Upper arm, spare CR

3HAC 10466-3

Clean room versions Includes all required sealings and gaskets.

Sealing ring

3HAB 3732-13

VK cover

3HAC 2166-13

Gasket upper arm cover

3HAC 7867-1

To be replaced if damaged only Included in the upper arm assembly

Standard toolkit

3HAC020812-001

The contents are defined in section Standard toolkit in the Product manual, reference information!

Special socket

-

For fitting the CSconnector

Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.

To be replaced if damaged only Included in the upper arm assembly

These procedures include references to the tools required.

WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Removal, upper arm The procedure below details how to remove the complete upper arm. Step

86

Action

1.

Run the manipulator arm to a horizontal position.

2.

Remove all brackets securing any exterior cabling to the upper arm by unscrewing their attachment screws respectively.

Note/Illustration

3HAC 023297-001 Revision: -

4 Repair 4.2.2. Replacement of complete upper arm

Step

Action

Note/Illustration

3.

Remove the rear cover armhousing by unscrewing Shown in the figure Location of its four attachment screws. upper arm on page 85!

4.

DO NOT under any circumstance unscrew the six screws on top of the lower arm! Doing so will cause the manipulator to require a complete rebuild!

xx0300000101

•

A: DO NOT touch these screws! (NOTE! Only two screws shown!)

5.

Disconnect all cables to/from motors 4-6.

6.

Disconnect any connector from the CS-connector. Shown in the figure Location of upper arm on page 85!

7.

Use a special socket to remove the CS-connector from the housing and pull it into the upper arm assembly.

Shown in the figure Location of upper arm on page 85! Art. no. specified in section Required equipment on page 86!

8.

Remove the pressurized air connector from the housing and pull it into the upper arm assembly.

Shown in the figure Location of upper arm on page 85! Art. no. specified in section Required equipment on page 86!

9.

Remove the VK-cover from the upper arm/lower arm joint.

Shown in the figure Location of upper arm on page 85! Detailed in section Removing the VK cover on page 88.

10. Remove the cable guide by unscrewing its two attachment screws.

Connectors • R3.MP4 • R3.MP5 • R3.MP6 • R3.FB4 • R3.FB5 • R3.FB6

Shown in the figure Location of upper arm on page 85!

11. Gently pull all cables and hoses out. 12. Remove the upper arm by unscrewing its six attachment screws.

Shown in the figure Location of upper arm on page 85!

13. Lift the upper arm and place it on a secure surface.

3HAC 023297-001 Revision: -

87

4 Repair 4.2.2. Replacement of complete upper arm

Removing the VK cover The procedure below details how to remove the VK cover from the upper arm.

xx0200000433

A

Lower arm

B

Lower arm cover gasket

C

Cover l. arm, spare (without lamp unit)

D

Cover l. arm, spare (with lamp unit)

Step

88

Action

Note

1.

Remove the lower arm cover by unscrewing its attachment screws.

2.

Tap the VK coverwith a long blunt edged bar Make sure to press the through the hole in the lower arm to press it out. circumference of the VK cover evenly to avoid damaging it. Shown in the figure in section Location of upper arm on page 85!

3.

If the VK cover is damaged, it must be replaced Specified in section Refitting of on refitting. complete upper arm.

3HAC 023297-001 Revision: -

4 Repair 4.2.2. Replacement of complete upper arm

Refitting The procedure below details how to refit the complete upper arm. Step

Action

Note

1.

Check the sealing ring to see whether it is damaged. Replace if it is damaged!

Shown in the figure Location of upper arm on page 85! Art. no. specified in section Required equipment on page 86!

2.

Lift the upper arm into position.

3.

Secure the upper arm with its six attachment screws.

4.

Gently pull all cables and hoses through the hole in the upper arm.

5.

Reconnect all connectors to motors 4-6.

Connectors • R3.MP4 • R3.MP5 • R3.MP6 • R3.FB4 • R3.FB5 • R3.FB6

6.

Refit the cable guide with its two attachment screws.

Shown in the figure Location of upper arm on page 85!

7.

Pull the pressurized air connector through the Shown in the figure Location of housing and secure it into fitting in the upper upper arm on page 85! arm assembly.

8.

Pull the CS-connector through the housing and secure it into the fitting in the upper arm assembly. Use a special socketto secure it.

9.

Reconnect any connector previously connected externally to the CS connector.

Shown in the figure Location of upper arm on page 85! Tightening torque: 35 Nm ± 3 Nm

Shown in the figure Location of upper arm on page 85! Art. no. specified in section Required equipment on page 86!

10. Fit a newVK-cover to the upper arm/lower arm Shown in the figure Location of joint. upper arm on page 85! Gently knock it into position. Art. no. specified in section Required equipment on page 86! Use a plastic mallet or similar. 11. Refit the rear cover armhousing with its four attachment screws.

Shown in the figure Location of upper arm on page 85!

12. Refit any brackets securing any exterior cabling to the upper arm with their attachment screws respectively. 13. Recalibrate the robot.

3HAC 023297-001 Revision: -

Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.

89

4 Repair 4.2.2. Replacement of complete upper arm

DANGER! When performing the first test run after a service activity (repair, installation or maintenance, it is vital that:

90

•

all the service tools and other foreign objects are removed from the manipulator!

•

all normal safety equipment is installed properly, e.g. TPU enabling device.

•

all personnel are standing at a safe distance from the manipulator, i.e. out of its reach behind any safety fences, etc.

•

special attention is paid to the function of the part previously serviced.

3HAC 023297-001 Revision: -

4 Repair 4.2.3. Replacement of complete lower arm

4.2.3. Replacement of complete lower arm Location of lower arm The lower arm is located between upper arm and frame as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.

xx0200000469

A

3HAC 023297-001 Revision: -

Lower arm

91

4 Repair 4.2.3. Replacement of complete lower arm

Required equipment Equipment

Spare part no. Art. no.

Note

Lower arm, spare

3HAC 10468-1

Standard and Foundry versions Includes all required bearings, oil and VK cover.

Lower arm, spare

3HAC 10468-4

Clean room versions Includes all required bearings, oil and VK cover.

Standard toolkit

3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information!

Lifting device for lower arm Special socket Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.

Lifting capacity xx kg -

For fitting the CSconnector These procedures include references to the tools required.

Removal, lower arm The procedure below details how to remove the complete lower arm. WARNING! Please observe the following before commencing any repair work on the manipulator:

92

•

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

3HAC 023297-001 Revision: -

4 Repair 4.2.3. Replacement of complete lower arm

Step

Action

Info/Illustration

1.

Remove the console.

Detailed in section Replacement of console on page 118.

2.

DO NOT under any circumstance unscrew the six screws on top of the lower arm! Doing so will cause the manipulator to require a complete rebuild!

xx0300000101

Parts: • A: DO NOT touch these screws! (Note! Only 2 screws are shown.) 3.

Remove the VK cover by pressing a screwdriver, or similar, through it and pulling.

xx0300000097

Parts: • A: Washer • B: Lower arm attachment screws (10 pcs) • C: VK cover 4.

Unscrew thelower arm attachment screws. Also remove the washer.

5.

Raise the lifting device to remove the lower arm.

3HAC 023297-001 Revision: -

Shown in the figure above!

93

4 Repair 4.2.3. Replacement of complete lower arm

Refitting, lower arm The procedure below details how to refit the complete lower arm. Step

Action

1.

Fit the lifting device and lift the lower arm into position.

2.

Fit the lower arm to gearbox, axis 2, and secure it with its attachment screws and washers.

Info/Illustration

xx0300000097

Parts: • A: Washer • B: Lower arm attachment screws (10 pcs) • C: VK cover Tightening torque: 35 Nm ± 3 Nm

94

3.

Fit a new VK cover by gently tapping it into position.

Shown in the figure above!

4.

Refit the console.

Detailed in section Replacement of console on page 118.

5.

Recalibrate the robot.

Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.

3HAC 023297-001 Revision: -

4 Repair 4.2.4. Replacement of base, spare

4.2.4. Replacement of base, spare Location of base The base is located at the bottom of the manipulator as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.

xx0200000423

A

Base

B

Bottom plate

C

Bottom plate attachment screws (26 pcs)

D

Gearbox/base attachment screws and washers (20 pcs each)

E

Joint, gearbox/base

F

Damper, axis 1

G

Washer

Required equipment Equipment

Spare part no. Art. no.

Note

Base, spare

3HAC 10470-1

Standard and Foundry versions Includes Parallel pin 3HAC 3785-2

Base, spare

3HAC 10470-3

Clean room versions Includes Parallel pin 3HAC 3785-2

Lifting slings

3HAC 023297-001 Revision: -

-

Min. capacity 20 kg

95

4 Repair 4.2.4. Replacement of base, spare

Equipment

Spare part no. Art. no.

Note

LocTite 574 Standard toolkit

For sealing the base to the gearbox 1-2 3HAC020812-001

Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.

The contents are defined in section Standard toolkit in the Product manual, reference information! These procedures include references to the tools required.

Removal, base The procedure below details how to remove the base. WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Step

96

Action

Info

1.

Remove motors 1 and 2.

Detailed in sections Replacement of motor, axis 1 on page 130 and Replacement of motor, axis 2 on page 135 respectively.

2.

Remove the cable harness.

Detailed in section Replacement of cable harness on page 78.

3.

Remove the serial measurement board.

Detailed in section Replacement of serial measurement unit and battery pack on page 122.

4.

Remove the complete upper arm.

Detailed in section Replacement of complete upper arm on page 85.

5.

Remove the complete lower arm.

Detailed in section Replacement of complete lower arm on page 91.

6.

Place the remaining base/gearbox axes 1- Shown in the figure Location of base. 2 assembly upside down on a work bench. Remove the bottom plate.

7.

Remove the gearbox/base attachment screws.

8.

Separate the base from the gearbox 1-2.

Shown in the figure Location of base.

3HAC 023297-001 Revision: -

4 Repair 4.2.4. Replacement of base, spare

Refitting The procedure below details how to refit the complete lower arm. WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Step

Action

Note

1.

Place the gearbox 1-2 and the base on a workbench.

2.

After making sure the mating surface Art. no. is specified in section between the base and gearbox is completely Required equipment on page 95. clean, apply Loctite to it.

3.

Secure the gearbox to the base with the gearbox/base attachment screws and washers.

Shown in the figure Location of base. Tightening torque: 35 Nm ± 3Nm

4.

Refit the bottom plate and secure it with its attachment screws.

Shown in the figure Location of base.

5.

Turn the base into standing upright.

6.

Refit the complete lower arm.

Detailed in section Replacement of complete lower arm on page 91.

7.

Refit the complete upper arm.

Detailed in section Replacement of complete upper arm on page 85.

8.

Refit motors 1 and 2.

Detailed in sections Replacement of motor, axis 1 on page 130 and Replacement of motor, axis 2 on page 135 respectively.

9.

Refit the serial measurement board.

Detailed in section Replacement of serial measurement unit and battery pack on page 122.

10. Refit the cable harness.

Detailed in section Replacement of cable harness on page 78.

11. Recalibrate the robot.

Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.

DANGER! When performing the first test run after a service activity (repair, installation or maintenance, it is vital that: •

all the service tools and other foreign objects are removed from the manipulator!

•

all normal safety equipment is installed properly, e.g. TPU enabling device.

3HAC 023297-001 Revision: -

97

4 Repair 4.2.4. Replacement of base, spare

98

•

all personnel are standing at a safe distance from the manipulator, i.e. out of its reach behind any safety fences, etc.

•

special attention is paid to the function of the part previously serviced.

3HAC 023297-001 Revision: -

4 Repair 4.3.1. Replacement of wrist unit

4.3 Upper arm 4.3.1. Replacement of wrist unit Location of wrist unit The wrist unit is located in the frontmost part of the upper arm. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.

xx0200000438

A

Wrist unit attachment screws (3 pcs)

B

Oil plug (one shown)

C

Wrist unit

Required equipment Equipment, etc.

Spare part no. Art. no.

Note

Wrist unit (Std/F)

3HAC 10475-1

Standard and Foundry versions O-ring sealing plate not included!

Wrist unit (CR)

3HAC 10475-4

Clean room versions O-ring sealing plate not included!

O-ring sealing plate

3HAC 7191-1

Must be replaced

Grease

3HAC 3537-1

For lubricating the o-ring sealing plate

3HAC 023297-001 Revision: -

99

4 Repair 4.3.1. Replacement of wrist unit

Equipment, etc.

Spare part no. Art. no.

Note

Standard toolkit

3HAC020812-001

The contents are defined in section Standard toolkit in the Product manual, reference information!

Arm

3HAC 9037-1

For adjusting the gear play, motor/pinion

Other tools and procedures may be required. See references to these procedures in the stepby-step instructions below.

These procedures include references to the tools required.

Removal, wrist unit The procedure below details how to remove the complete wrist unit. Step

Action

Note

1.

-

Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.

Drain the oil from the wrist unit.

Detailed in section Oil change, gearbox, axes 5 and 6 on page 73.

3.

Remove the wrist unit by unscrewing its three attachment screws.

Shown in the figure in section Location of wrist unit on page 99.

Refitting, wrist unit The procedure below details how to refit the complete wrist unit. Step

Action

Note

1.

-

Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

100

2.

Run the robot to a position where the upper arm is vertical. The axis 5 motion plane should be horizontal.

3.

Lightly lubricate the o-ring sealing plate with Art. no. is specified in section Required grease. equipment on page 99.

3HAC 023297-001 Revision: -

4 Repair 4.3.1. Replacement of wrist unit

Step

Action

Note

4.

Fit the o-ring sealing plate and the wrist unit Do not tighten its attachment screws! to the upper arm with the attachment screws, but do not tighten them.

5.

In order to release the brake, connect the 24 VDC power supply to motors:

Connect to connector R3.MP5 or 6: • +: pin 7 • -: pin 8

6.

Fit the Arm to the rear of the motor.

Art. no. is specified in section Required equipment on page 99.

7.

Manually push the motor to adjust the motor in relation to the gear in the gearbox. Minimize the gear play as shown in the figure.

xx0200000445

• • • •

A: Wrist unit, axes 5 and 6 gears B: Drive shafts from motors, axes 5 and 6 gears C: Adjustment direction D: Gear play

8.

Tighten the wrist unit attachment screws.

9.

Check the gear play by moving axes 5 and The gear play should be xx to pass the 6 by hand. test.

Tightening torque: 28 Nm ± 3 Nm

10. Perform a leak-down test.

Detailed in section Leak-down test.

11. Refill the wrist unit with oil.

Detailed in section Oil change, gearbox, axes 5 and 6 on page 73.

12. Recalibrate the robot!

Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.

DANGER! When performing the first test run after a service activity (repair, installation or maintenance, it is vital that: •

all the service tools and other foreign objects are removed from the manipulator!

•

all normal safety equipment is installed properly, e.g. TPU enabling device.

•

all personnel are standing at a safe distance from the manipulator, i.e. out of its reach behind any safety fences, etc.

•

special attention is paid to the function of the part previously serviced.

3HAC 023297-001 Revision: -

101

4 Repair 4.3.2. Replacement of damper, axis 3

4.3.2. Replacement of damper, axis 3 Location of damper, axis 3 The damper, axis 3, is shown in the figure below! A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.

xx0200000427

A

Damper, axis 3

Required equipment Equipment, etc.

Spare part no. Art. no.

Damper axis 3

3HAC 7881-1

Standard toolkit

Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.

102

Note

3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information! These procedures include references to the tools required.

3HAC 023297-001 Revision: -

4 Repair 4.3.2. Replacement of damper, axis 3

Removal, damper axis 3 The procedure below details how to remove the damper, axis 3. Step

Action

Note

1.

-

Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.

Run the robot to a position that enables access to Shown in the figure Location of damper, axis 3. damper, axis 3 on page 102.

3.

Remove the damper by gently prying it from the cast tab.

Refitting, damper axis 3 The procedure below details how to refit the damper, axis 3. Step

Action

Note

1.

-

Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.

Run the robot to a position that enables access to the Shown in the figure Location location where the damper, axis 3, is fitted. of damper, axis 3 on page 102.

3.

Refit the damper by gently pressing it onto the cast tab on the upper arm.

DANGER! When performing the first test run after a service activity (repair, installation or maintenance, it is vital that: •

all the service tools and other foreign objects are removed from the manipulator!

•

all normal safety equipment is installed properly, e.g. TPU enabling device.

•

all personnel are standing at a safe distance from the manipulator, i.e. out of its reach behind any safety fences, etc.

•

special attention is paid to the function of the part previously serviced.

3HAC 023297-001 Revision: -

103

4 Repair 4.3.3. Replacement of damper, axis 5

4.3.3. Replacement of damper, axis 5 Location of damper, axis 5 The damper, axis 5, is located as shown in the figure below!

xx0200000429

A

Damper, axis 5

B

Recess

Required equipment Equipment, etc.

Spare part no. Art. no.

Damper axis 5

3HAC 8964-1

Standard toolkit

Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.

104

Note

3HAC020812-001

The contents are defined in section Standard toolkit in the Product manual, reference information! These procedures include references to the tools required.

3HAC 023297-001 Revision: -

4 Repair 4.3.3. Replacement of damper, axis 5

Removal, damper axis 5 The procedure below details how to remove the damper, axis 5. Step

Action

Note

1.

-

Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.

Run the robot to a position that enables the end of the Shown in the figure in damper to be pushed into the recess in the wrist unit section Location of damper, axis 5 on page 104.

3.

Unhook the end of the damper, and push it into the recess.

4.

Manually move the wrist (robot axis 5) away from the damper to pull it out.

Refitting, damper axis 5 The procedure below details how to refit the damper, axis 5. Step

Action

Note

1.

-

Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.

Push the end of the damper into the gap between the Make sure the damper is wrist unit and upper arm. turned the correct way!

3.

Manually move the wrist (robot axis 5) in order to pull the damper into position.

4.

Fold out the damper hooks to secure it in position.

DANGER! When performing the first test run after a service activity (repair, installation or maintenance), it is vital that: •

- all the service tools and other foreign objects are removed from the manipulator!

•

- all normal safety equipment is installed properly, e.g. TPU enabling device.

•

- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind any safety fences, etc.

•

- special attention is paid to the function of the part previously serviced.

3HAC 023297-001 Revision: -

105

4 Repair 4.3.4. Replacement of cover, arm housing

4.3.4. Replacement of cover, arm housing Location of cover, armhousing The cover, armhousing is located on the rear of the upper arm as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.

xx0200000464

A

Cover, arm housing

B

Attachment screws, cover, armhousing

C

Gasket, upper arm cover

Required equipment Equipment, etc.

Spare part. no.

Cover, arm housing

3HAC 10473-1

Standard and Foundry version Includes gasket 3HAC 7867-1

Cover, arm housing

3HAC 10473-3

Clean Room versions Includes gasket 3HAC 7867-1

Note

Gasket, upper arm cover

3HAC 7867-1

Standard toolkit

3HAC020812-001

Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.

106

Art. no.

The contents are defined in section Standard toolkit in the Product manual, reference information! These procedures include references to the tools required.

3HAC 023297-001 Revision: -

4 Repair 4.3.4. Replacement of cover, arm housing

Removal The procedure below details how to remove the cover, armhousing. WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Step

Action

1.

Manually, run the robot to a position that enables access to the rear of the upper arm.

2.

Remove the cover, armhousing by unscrewing its attachment screws.

Note

Shown in the figure Location of cover, armhousing on page 106. NOTE! Do not damage the gasket inside the cover!

Refitting The procedure below details how to refit cover, armhousing. WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Step

Action

Note

1.

Manually, run the robot to a position that enables access to the rear of the upper arm.

Shown in the figure Location of cover, armhousing on page 106.

2.

Make sure the gasket inside the cover, arm housing has not been damaged.

Replace if damaged. Shown in the figure Location of cover, armhousing on page 106.

3.

Secure the cover, arm housing to the upper arm with its attachment screws.

3HAC 023297-001 Revision: -

107

4 Repair 4.4.1. Replacement of lower arm cover and gasket

4.4 Lower arm 4.4.1. Replacement of lower arm cover and gasket Location of lower arm cover and gasket The lower arm cover and gasket are located as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.

xx0200000433

108

A

Lower arm

B

Gasket lower-arm cover

C

Cover l. arm, spare (without lamp unit)

D

Cover l. arm, spare (with lamp unit) 3HAC 023297-001 Revision: -

4 Repair 4.4.1. Replacement of lower arm cover and gasket

Required equipment Equipment, etc.

Spare part no. Art. no.

Note

Cover l. arm, spare, Std/F

3HAC 10471-1

Standard and Foundry versions No lamp unit included Includes gasket 3HAC 7869-1

Cover l. arm, spare, CR

3HAC 10471-3

Clean room versions No lamp unit included Includes gasket 3HAC 7869-1

Gasket lower-arm cover

3HAC 7869-1

Isopropanol

1177 1012-208

For cleaning sealing surfaces

Standard toolkit

3HAC020812-001

The contents are defined in section Standard toolkit in the Product manual, reference information!

Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.

These procedures include references to the tools required.

Removal, lower arm cover and gasket The procedure below details how to remove the lower arm cover and gasket. WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Step

Action

Note

1.

Remove the lower arm cover by unscrewing its attachment screws.

Shown in the figure Location of lower arm cover and gasket on page 108.

2.

If the gasket is to be replaced, proceed below! Use a knife to gently remove the old gasket from the cover.

3.

Clean the sealing surface with isopropanol, making sure it is completely clean and free from scratches and burrs.

3HAC 023297-001 Revision: -

Art. no. specified in section Required equipment on page 109.

109

4 Repair 4.4.1. Replacement of lower arm cover and gasket

Refitting, lower arm cover and gasket The procedure below details how to refit the lower arm cover and gasket. WARNING! Please observe the following before commencing any repair work on the manipulator: •

- Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears!

•

- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

- Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.

Step

110

Action

Note

1.

If the Gasket lower-arm cover is to be replaced, proceed below. If not, see further down!

Shown in the figure Location of lower arm cover and gasket on page 108.

2.

Remove the protective backing from the selfadhesive gasket and fit it onto the cover sealing surface.

Make absolutely sure it is correctly located!

3.

Refit the lower arm coverwith its attachment screws. Shown in the figure Location of lower arm cover and gasket on page 108.

3HAC 023297-001 Revision: -

4 Repair 4.4.2. Replacement of damper, axis 2

4.4.2. Replacement of damper, axis 2 Location of damper, axis 2 The damper, axis 2, is located as shown in the figure below! A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.

xx0200000426

A

Damper, axis 2

Required equipment Equipment, etc.

Spare part no.

Damper ax. 2

3HAC 7880-1

Standard toolkit

Other tools and procedures may be required. See references to these procedures in the stepby-step instructions below.

3HAC 023297-001 Revision: -

Art. no.

Note

3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information! These procedures include references to the tools required.

111

4 Repair 4.4.2. Replacement of damper, axis 2

Removal, damper axis 2 The procedure below details how to remove the damper, axis 2. Step

Action

Note

1.

-

Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.

Run the robot to a position that enables you to access the attachment screw of damper, axis 2.

3.

Remove the damper by unscrewing the single attachment screw and washer.

Refitting, damper axis 2 The procedure below details how to refit the damper, axis 2. Step

Action

Note

1.

-

Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.

Run the robot to a position that enables access to the attachment screw of the damper, axis 2.

3.

Secure the damper with its single attachment screw and washer.

1 pc: M6 x 16.

DANGER! When performing the first test run after a service activity (repair, installation or maintenance, it is vital that:

112

•

all the service tools and other foreign objects are removed from the manipulator!

•

all normal safety equipment is installed properly, e.g. TPU enabling device.

•

all personnel are standing at a safe distance from the manipulator, i.e. out of its reach behind any safety fences, etc.

•

special attention is paid to the function of the part previously serviced.

3HAC 023297-001 Revision: -

4 Repair 4.4.3. Replacement of indicator lamp

4.4.3. Replacement of indicator lamp Location of indicator lamp The indicator lamp is located on the side of the lower arm as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.

xx0200000472

A

Indication lamp

B

Lower arm cover

Required equipment Equipment, etc. Spare part no. Art. no. Indicator lamp Standard toolkit

Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.

3HAC 023297-001 Revision: -

Note

3HAC 9258-1 3HAC020812-001

The contents are defined in section Standard toolkit in the Product manual, reference information! These procedures include references to the tools required.

113

4 Repair 4.4.3. Replacement of indicator lamp

Removal The procedure below details how to remove the indicator lamp. WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Step

Action

Note

1.

Remove the lower arm cover.

Detailed in section Replacement of lower arm cover and gasket on page 108.

2.

Remove the damper by gently prying the plastic semitransparent damper from the cast tab.

Refitting The procedure below details how to refit the indicator lamp. WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Step

Action

1.

Run the robot to a position that enables access to damper, axis 3.

2.

Refit the damper by gently pressing it onto the cast tab on the upper arm.

Note

DANGER! When performing the first test run after a service activity (repair, installation or maintenance, it is vital that:

114

•

all the service tools and other foreign objects are removed from the manipulator!

•

all normal safety equipment is installed properly, e.g. TPU enabling device.

•

all personnel are standing at a safe distance from the manipulator, i.e. out of its reach behind any safety fences, etc.

•

special attention is paid to the function of the part previously serviced.

3HAC 023297-001 Revision: -

4 Repair 4.5.1. Replacement of cover, console

4.5 Frame and base 4.5.1. Replacement of cover, console Location of cover, console The cover, console is located on top of the console as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.

xx0200000462

A

Cover, console

B

Attachment screws, cover, console (4 pcs)

C

Gasket

D

Console

Required equipment Equipment, etc.

Spare part. no.

Cover, console, spare

3HAC 10472-1

Standard and Foundry version Includes gasket 3HAC 7868-1

Cover, console, spare

3HAC 10472-3

Clean Room versions Includes gasket 3HAC 7868-1

Gasket, cover console

3HAC 023297-001 Revision: -

Art. no.

Note

3HAC 7868-1

115

4 Repair 4.5.1. Replacement of cover, console

Equipment, etc. Standard toolkit

Spare part. no.

Art. no.

Note

3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information!

Other tools and procedures may be required. See references to these procedures in the stepby-step instructions below.

These procedures include references to the tools required.

Removal The procedure below details how to remove the cover, console. WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Step

Action

Note

1.

Manually, run the robot to a position that enables Shown in the figure Location of access to the top of the console. cover, console on page 115.

2.

Remove the cover, console by unscrewing its attachment screws.

NOTE! Do not damage the gasket inside the cover!

Refitting The procedure below details how to refit cover, console. WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Step 1.

116

Action

Note

Manually, move the robot to a position that enables Shown in the figure Location of access to the top of the console. cover, console on page 115.

3HAC 023297-001 Revision: -

4 Repair 4.5.1. Replacement of cover, console

Step

Action

Note

2.

Make sure the gasket inside the cover, console has not been damaged.

Replace if damaged. Shown in the figure Location of cover, console on page 115.

3.

Secure the cover, console to the console with its attachment screws.

3HAC 023297-001 Revision: -

117

4 Repair 4.5.2. Replacement of console

4.5.2. Replacement of console Location of console The console is located on top of gearbox, axes 1-2 as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.

xx0200000462

A

Cover, console

B

Attachment screws, cover, console (4 pcs)

C

Gasket

D

Console

Required equipment Equipment, etc.

Spare part. no.

Console, spare

3HAC 10478-1

Standard and Foundry version

Console, spare

3HAC 10478-3

Clean Room versions

Standard toolkit

Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below. 118

Art. no.

Note

3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information! These procedures include references to the tools required.

3HAC 023297-001 Revision: -

4 Repair 4.5.2. Replacement of console

Removal The procedure below details how to remove the cover, console. WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Step

Action

Note/Illustration

1.

Remove the cable harness.

Detailed in section Replacement of cable harness on page 78.

2.

Remove the serial measurement board.

Detailed in section Replacement of serial measurement unit and battery pack on page 122.

3.

Remove the complete upper arm.

Detailed in section Replacement of complete upper arm on page 85.

4.

DO NOT under any circumstance unscrew the six screws on top of the lower arm! Doing so will cause the manipulator to require a complete rebuild!

xx0300000101

Parts: • A: DO NOT touch these screws! (Note! Only two screws shown!) 5.

Remove the motor of axis 3.

6.

Attach the lifting device to the lower arm.

3HAC 023297-001 Revision: -

Detailed in section Replacement of motor and timing belt, axis 3 on page 139.

119

4 Repair 4.5.2. Replacement of console

Step 7.

Action

Note/Illustration

Remove the bearing hub by unscrewing its attachment screws.

xx0300000096

Parts: • • • • • 8.

Remove the console by unscrewing its attachment screws.

A: Console B: Bearing hub C: Bearing hub attachment screws (6 pcs) D: Console attachment screws (10 pcs) E: Washers (10 pcs)

Shown in the figure above!

Refitting The procedure below details how to refit cover, console. WARNING! Please observe the following before commencing any repair work on the manipulator:

120

•

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

3HAC 023297-001 Revision: -

4 Repair 4.5.2. Replacement of console

Step 1.

Action

Note/Illustration

Refit the console and secure it with its attachment screws and washers.

xx0300000096

Parts: • A: Console • B: Bearing hub • C: Bearing hub attachment screws (6 pcs) • D: Console attachment screws (10 pcs) • E: Washers (10 pcs) Tightening torque: 11 Nm ± 1 Nm 2.

Refit the bearing hub and secure it with its attachment screws.

Shown in the figure above! Tightening torque: 15 Nm ± 1 Nm

3.

Refit the complete upper arm.

Detailed in section Replacement of complete upper arm on page 85.

4.

Refit motor 3 and timing belt.

Detailed in section Replacement of motor and timing belt, axis 3 on page 139.

5.

Refit the serial measurement board. Detailed in section Replacement of serial measurement unit and battery pack on page 122.

6.

Refit the cable harness.

Detailed in section Replacement of cable harness on page 78.

7.

Recalibrate the robot!

Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.

3HAC 023297-001 Revision: -

121

4 Repair 4.5.3. Replacement of serial measurement unit and battery pack

4.5.3. Replacement of serial measurement unit and battery pack Location of serial measurement unit and battery pack The serial measurement unit and battery pack are located inside the manipulator base as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.

xx0200000432

A

Rear cable cover

B

Battery pack

C

Serial measurement board (SMB)

D

SMB attachment screws (4 pcs)

E

Manipulator base bottom plate

Required equipment Equipment, etc.

Spare part. no. Art. no.

Serial measurement unit

3HAC 9522-1

Battery pack

4944 026-4

NiCd type

Battery pack

3HAB 9999-1

3 cell, lithium type

Battery pack

3HAB 9999-2

6 cell, lithium type

Cable tie Gasket base-cover

122

Note

Indoors 3HAC 7870-1

Replace only if required!

3HAC 023297-001 Revision: -

4 Repair 4.5.3. Replacement of serial measurement unit and battery pack

Equipment, etc.

Spare part. no. Art. no.

Note

Standard Toolkit, IRB 140

3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information!

Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.

These procedures include references to the tools required.

Circuit Diagram

3HAC 6816-3

See chapter Circuit diagram in the Product manual, reference information.

Removal The procedure below details how to remove the serial measurement unit and battery pack. WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

DANGER! Follow these instruction to prevent the unit to be damaged from ESD: •

The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to electrostatic voltages.

•

Before handling, make sure you are grounded through a special ESD wrist bracelet or similar.

CAUTION! This component is classified as Hazardous waste and must be disposed of accordingly! If in doubt of the correct disposal procedure, please contact your local environmental authority!

3HAC 023297-001 Revision: -

123

4 Repair 4.5.3. Replacement of serial measurement unit and battery pack

CAUTION! The cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them! Step

Action

Note

1.

Set the robot system to MOTORS OFF state.

This will simplify calibration of the robot after replacement since no coarse calibration will be required.

2.

Remove the rear cable cover from the base of Shown in the figure Location of the robot by unscrewing its attachment screws. serial measurement unit and battery pack on page 122!

3.

Remove the serial measurement unit by Shown in the figure Location of unscrewing its attachment screws . serial measurement unit and The removal is simplified by pushing the unit to battery pack on page 122! the side and then pulling it backwards.

4.

If only the battery is to be replaced, disconnect Connectors the cables to the battery only! • R2.SMB Disconnect all connectors from the serial • R2.FB1-3 measurement unit. • R2.FB4-6 • R2.G

5.

Lift the board out.

6.

If the battery pack is to be replaced, proceed Shown in the figure Location of below! serial measurement unit and battery pack on page 122! Cut the cable tie and disconnect the battery connector to remove the battery pack. Battery includes protection circuits. Replace it only with the specified spare part in the refitting instruction or with an ABB approved eqvivalent.

Refitting The procedure below details how to refit the serial measurement unit and battery pack. WARNING! Please observe the following before commencing any repair work on the manipulator: •

- Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears!

•

- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

- Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.

DANGER! Follow these instruction to prevent the unit to be damaged from ESD:

124

•

The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to electrostatic voltages.

•

Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar.

3HAC 023297-001 Revision: -

4 Repair 4.5.3. Replacement of serial measurement unit and battery pack

CAUTION! This component is classified as Hazardous waste and must be disposed of accordingly! If in doubt of the correct disposal procedure, please contact your local environmental authority! CAUTION! The cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them! Step

Action

Note

1.

Connect the new battery pack to the serial measurement unit and secure it with a cable tie.

2.

Reconnect all connectors to the unit.

3.

Place the serial measurement unit in position Shown in the figure Location of inside the manipulator base and secure it with its serial measurement unit and four attachment screws. battery pack on page 122!

4.

Make sure the gasket sealing the rear cable cover Shown in the figure Location of has not been damaged. serial measurement unit and battery pack on page 122! Replace the gasket if required. Art. no. specified in section Required equipment on page 122!

5.

Making sure all cables are correctly located behind the rear cable cover, refit it into position. Make sure no cables or other equipment fitted behind the cover get pinched by the cover.

Shown in the figure Location of serial measurement unit and battery pack on page 122!

6.

Secure the rear cable cover to the base of the robot with its attachment screws.

Shown in the figure Location of serial measurement unit and battery pack on page 122!

7.

This is valid if NiCd type batteries are used only! Lithium batteries do not require charging before use. Recharge the battery for at least 36 hrs by leaving the mains supply switched on for this amount of time.

8.

Recalibrate the robot!

3HAC 023297-001 Revision: -

Connectors • R2.SMB • R2.FB1-3 • R2.FB4-6 • R2.G

Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.

125

4 Repair 4.5.4. Replacement of control cable

4.5.4. Replacement of control cable Location of control cable The control cable is located on the rear of the manipulator base as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.

xx0200000467

A

Gasket, base-cover

B

Attachment screws and washers (9 pcs each), control cable

C

Control cable, spare

Required equipment

126

Equipment, etc.

Spare part. no. Art. no.

Note

Control cable, spare

3HAC 10476-1

3m Standard and Foundry versions Cover gasket included

Control cable, spare

3HAC 10477-1

7m Standard and Foundry versions Cover gasket included

Control cable, spare

3HAC 11331-1

15 m Standard and Foundry versions Cover gasket included

Control cable, spare

3HAC 13090-1

22 m Standard and Foundry versions Cover gasket included

3HAC 023297-001 Revision: -

4 Repair 4.5.4. Replacement of control cable

Equipment, etc.

Spare part. no. Art. no.

Note

Control cable, spare

3HAC 13089-1

30 m Standard and Foundry versions Cover gasket included

Control cable, spare

3HAC 10476-4

3m Clean Room versions Cover gasket included

Control cable, spare

3HAC 10477-2

7m Clean Room versions Cover gasket included

Control cable, spare

3HAC 11331-2

15 m Clean Room versions Cover gasket included

Control cable, spare

3HAC 13090-2

22 m Clean Room versions Cover gasket included

Control cable, spare

3HAC 13089-2

30 m Clean Room versions Cover gasket included

Standard toolkit

3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information!

Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.

These procedures include references to the tools required.

Removal The procedure below details how to remove the control cable. WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

3HAC 023297-001 Revision: -

127

4 Repair 4.5.4. Replacement of control cable

Step

Action

1.

Make sure the robot system has been switched off, and that no power is supplied to the manipulator.

2.

Remove the Control cable, spareby unscrewing its attachment screws.

3.

Disconnect connectors inside the manipulator base.

Note/Illustration

Shown in the figure Location of control cable on page 126. Make sure the gasket does not get damaged!

xx0300000090

Connectors: • A: R1.MP1-3 • B: R1.CS • C: Air hose • D: R1.MP4-6

128

4.

Pull the cable out of the manipulator base.

5.

Disconnect the connectors from the control cabinet.

3HAC 023297-001 Revision: -

4 Repair 4.5.4. Replacement of control cable

Refitting The procedure below details how to refit control cable. WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Step

Action

Note/Illustration

1.

Place the control cable on the floor with the manipulator base cover close to the manipulator.

Shown in the figure Location of control cable on page 126.

2.

Connect the connectors inside the manipulators base.

xx0300000090

Connectors: • A: R1.MP1-3 • B: R1.CS • C: Air hose • D: R1.MP4-6 3.

Fit a new gasket when refitting the cover. Included in the spare part

4.

Fit the cover onto the manipulator base Shown in the figure Location of control and secure it with its attachment screws. cable on page 126.

3HAC 023297-001 Revision: -

129

4 Repair 4.6.1. Replacement of motor, axis 1

4.6 Motors 4.6.1. Replacement of motor, axis 1 Location of motor axis 1 The motor axis 1 is located on the rear of the manipulator as shown in the figure below: A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.

xx0200000407

A

Motor, axis 1

B

Cover for connector access

C

Motor attachment screws (4 pcs)

D

Cable gland attachment screws (4 pcs)

E

Console

Required equipment

130

Equipment, etc.

Spare part no.

Art no.

Note

Rot. ac motor with pinion

3HAC 10469-3 3HAC 021966-001

Clean room versions.

Rot. ac motor with pinion

3HAC 10469-1 3HAC 021965-001

Standard and Foundry versions.

Rot. ac motor w pinion TStd/TF

3HAC 10469-4

High performance version.

O-ring

2152 2012-426

Must be replaced when replacing motor! Included in the spare parts motor kits

Cable gland gasket

3HAC xx

Fitted onto the console cable gland

3HAC 023297-001 Revision: -

4 Repair 4.6.1. Replacement of motor, axis 1

Equipment, etc.

Spare part no.

Art no.

Note

Grease

3HAB 3537-1

Used to lubricate the o-ring

Standard toolkit

3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information!

Arm

3HAC 9037-1

For adjusting the gear play, motor/pinion

Power supply

24 VDC, max. 1,5 A For releasing the brakes

Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.

These procedures include references to the tools required.

Circuit Diagram

3HAC 023297-001 Revision: -

3HAC 6816-3

See chapter Circuit diagram in the Product manual, reference information.

131

4 Repair 4.6.1. Replacement of motor, axis 1

Removal The procedure below details how to remove motor, axis 1. CAUTION! If the manipulator normally works in an inverted position, it must be removed from this position and placed on the floor before the work detailed in this instruction may be carried out ! WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

NOTE! Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! Step

132

Action

Note

1.

Remove the Cover for connector access on top of Shown in the figure Location the motor by unscrewing its four attachment screws. of motor axis 1 on page 130. Detailed in section Replacement of cover, console on page 115.

2.

Disconnect the motor 1 connectors inside the console.

3.

Cut any cable ties and remove any brackets securing the cables.

4.

Remove the cable gland by removing its attachment Shown in the figure Location screws, and pull the cables out from the console. of motor axis 1 on page 130.

5.

In order to release the brakes, connect the 24 VDC power supply:

6.

Remove the motor by unscrewing its four attachment Shown in the figure Location screws and plain washers. of motor axis 1 on page 130.

7.

Lift the motor to get the pinion away from the gear and disconnect the brake release voltage.

8.

Remove the motor by gently lifting it straight up.

Connectors: • R3.MP1 • R3.FB1

Connect to connector R3.MP1 • +: pin 7 • -: pin 8

3HAC 023297-001 Revision: -

4 Repair 4.6.1. Replacement of motor, axis 1

Refitting The procedure below details how to refit motor, axis 1. WARNING! Please observe the following before commencing any repair work on the manipulator: •

- Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears!

•

- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

- Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.

NOTE! Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! Step

Action

Note

1.

Make sure the mating surfaces on the motor and the gearbox are clean and free from burrs.

2.

Make sure the o-ring on the circumference of Art. no. is specified in section the motor is seated properly. Lightly lubricate Required equipment on page 130. the o-ring with grease .

3.

In order to release the brake, connect the 24 VDC power supply:

4.

Fit the motor, making sure the motor pinion is Make sure the motor is turned the properly mated to gearbox 1. right way, i.e. connections rearwards. Make sure the motor pinion does not get damaged!

5.

Fit the motor with four attachment screws and Tightening torque: approx 2 Nm plain washers.

6.

Fit the Arm to the end of the motor shaft.

Art. no. is specified in section Required equipment on page 130.

7.

Adjust the motor in relation to the gear in the gearbox. Use the Arm tool to wiggle the motor shaft back and forth to feel the play.

There should be a barely noticable gear play.

8.

Tighten the motor attachment screws.

Tightening torque: approx 11 Nm ± 1 Nm

9.

Disconnect the brake release voltage.

10. Make sure the cable gland gasket has not been damaged. Replace, if it has.

Connect to connector R2.MP1 • +: pin 7 • -: pin 8

Art. no. is specified in section Required equipment on page 130.

11. Push the cables into the console, and refit the cable gland with its attachment screws.

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133

4 Repair 4.6.1. Replacement of motor, axis 1

Step

134

Action

Note

12. Perform a leak-down test.

Detailed in section .

13. Recalibrate the robot!

Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.

3HAC 023297-001 Revision: -

4 Repair 4.6.2. Replacement of motor, axis 2

4.6.2. Replacement of motor, axis 2 Location of motor axis 2 The motor axis 2 is located on the front of the manipulator as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.

xx0200000408

A

Motor, axis 2

B

Cover for connector access

C

Motor attachment screws (4 pcs)

D

Cable gland attachment screws (4 pcs)

E

Console

Required equipment Equipment, etc. Spare part no.

Art. no.

Note

Rot. ac motor with pinion, spare

3HAC 10469-3 3HAC 021966-001

Clean room versions.

Rot. ac motor with pinion, spare

3HAC 10469-1 3HAC 021965-001

Standard and Foundry versions.

Rot. ac motor with pinion, spare, TStd/TF

3HAC 10469-4

High performance version.

O-ring

2152 2012-426

Must be replaced when replacing motor!

Cable gland gasket

3HAC xx

Fitted onto the console cable gland

Grease

3HAB 3537-1

For lubricating the o-ring.

Standard toolkit

3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information!

3HAC 023297-001 Revision: -

135

4 Repair 4.6.2. Replacement of motor, axis 2

Equipment, etc. Spare part no.

Art. no.

Note

Arm

3HAC 9037-1

For adjusting the gear play, motor/pinion

Power supply

24 VDC, 1.5 A. For releasing the brakes.

Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.

These procedures include references to the tools required.

Circuit Diagram

3HAC 6816-3

See chapter Circuit diagram in the Product manual, reference information.

Removal The procedure below details how to remove motor, axis 2. WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

NOTE! Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! Step

136

Action

Note

1.

Remove the Cover for connector access on top of Shown in the figure in the motor by unscrewing its four attachment screws. section Location of motor axis 2 on page 135.

2.

Disconnect the motor 2 connectors inside the console.

3.

Cut any cable ties and remove any brackets securing the cables.

4.

Remove the cable gland by removing its attachment Shown in the figure in screws, and pull the cables out from the console. section Location of motor axis 2 on page 135.

5.

In order to release the brakes, connect the 24 VDC power supply:

6.

Remove the motor by unscrewing its four attachment Shown in the figure Location screws and plain washers. of motor axis 2 on page 135.

7.

Lift the motor to get the pinion away from the gear.

Connectors: • R3.MP2 • R3.FB2

Connect to connector R3.MP2 • +: pin 2 • -: pin 5

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4 Repair 4.6.2. Replacement of motor, axis 2

Step

Action

Note

8.

Disconnect the brake release voltage.

9.

Remove the motor by gently pulling it out. There is a real danger of oil running out of the motor attachment hole when removing the motor. Take any necessary measures to collect the oil.

10. Remove any remaining oil from the gearbox by siphoning it out.

Refitting The procedure below details how to refit motor, axis 2. WARNING! Please observe the following before commencing any repair work on the manipulator: •

- Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears!

•

- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

- Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.

NOTE! Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! Step

Action

Note

1.

Make sure the mating surfaces on the motor and the gearbox are clean and free from burrs.

2.

Make sure the o-ring on the circumference of the Art no. is specified in section motor is seated properly. Lightly lubricate the oRequired equipment on page ring with grease . 135.

3.

In order to release the brake, connect the 24 VDC Connect to connector R2.MP2 power supply: • +: pin 7 • -: pin 8

4.

Fit the motor, making sure the motor pinion is properly mated to gearbox 2.

5.

Fit the motor with four attachment screws and plain Tightening torque: approx 2 washers. Nm

6.

Fit the Arm to the end of the motor shaft.

7.

Adjust the motor in relation to the gear in the There should be a barely gearbox. noticable gear play. Use the Arm tool to wiggle the motor shaft back and forth to feel the play.

8.

Tighten the motor attachment screws.

3HAC 023297-001 Revision: -

Make sure the motor is turned the right way, i.e. connections rearwards. Make sure the motor pinion does not get damaged!

Art no. is specified in section Required equipment on page 135.

Tightening torque: approx 11 Nm ± 1 Nm

137

4 Repair 4.6.2. Replacement of motor, axis 2

Step 9.

Action

Note

Disconnect the brake release voltage.

10. Make sure the cable gland cover gasket has not been damaged. Replace if it has.

Art no. is specified in section Required equipment on page 135.

11. Push the cables into the console, and refit the cable gland with its attachment screws. 12. Perform a leak-down test.

Detailed in section Leak-down test.

13. Refill the gearbox with oil. 14. Recalibrate the robot!

138

Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.

3HAC 023297-001 Revision: -

4 Repair 4.6.3. Replacement of motor and timing belt, axis 3

4.6.3. Replacement of motor and timing belt, axis 3 Location of motor axis 3 The motor axis 3 is located behind the lower arm cover on the right hand side of the manipulator as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.

xx0200000448

A

Lower arm cover

B

Attachment screws, lower arm cover (13 pcs)

C

Belt shield

D

Motor 3

E

Attachment screws, belt shield (3 pcs)

F

Attachment screws, motor 3 (4 pcs)

G

Belt

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139

4 Repair 4.6.3. Replacement of motor and timing belt, axis 3

Required equipment Equipment, etc.

Spare part no.

Rot. ac motor with pinion

3HAC 7866-1 3HAC 021756-001

Art. no.

Note Includes timing belt pulley.

Timing belt

3HAC 6793-1

Grease

3HAB 3537-1

For lubricating the oring.

Standard toolkit

3HAC020812-001

The contents are defined in section Standard toolkit in the Product manual, reference information!

Other tools and procedures may be required. See references to these procedures in the stepby-step instructions below. Circuit Diagram

These procedures include references to the tools required.

3HAC 6816-3

See chapter Circuit diagram in the Product manual, reference information.

Removal The procedure below details how to remove motor, axis 3. WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

NOTE! Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! Step

140

Action

Note/Illustration

1.

Remove any equipment hindering access to the lower arm cover.

Shown in the figure in section Location of motor axis 3 on page 139.

2.

Remove the lower arm cover by unscrewing its attachment screws.

Shown in the figure in section Location of motor axis 3 on page 139.

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4 Repair 4.6.3. Replacement of motor and timing belt, axis 3

Step 3.

Action

Note/Illustration

Cut the cable ties to facilitate accessing the motor.

xx0200000449

• • • • • • • 4.

3HAC 023297-001 Revision: -

Disconnect motor connectors.

A: Cable ties B: Pressurized air hose C: Power cables, axes 4, 5 and 6 D: Customer cables, signal E: Signal cables, axes 4, 5 and 6 F: Signal cable, axis 3 G: Connectors R3.MP3 and R3.FB3

Connectors: • R3.MP3 • R3.FB3 • R3.H1 (if Safety lamp is fitted) • R3.H2 (if Safety lamp is fitted)

141

4 Repair 4.6.3. Replacement of motor and timing belt, axis 3

Step 5.

Action

Note/Illustration

DO NOT under any circumstance unscrew the three screws securing the belt wheel! Doing so will cause the manipulator to require a complete rebuild!

xx0300000102

Parts: • DO NOT touch these screws! (3 pcs) 6.

Remove the belt shield by unscrewing Shown in the figure in section Location of its twoattachment screws. motor axis 3 on page 139.

7.

Remove the remaining motorattachment screws.

Shown in the figure in section Location of motor axis 3 on page 139.

8.

Remove the belt.

Shown in the figure in section Location of motor axis 3 on page 139.

9.

Remove the motor.

Shown in the figure in section Location of motor axis 3 on page 139.

Refitting The procedure below details how to refit motor, axis 3. WARNING! Please observe the following before commencing any repair work on the manipulator: •

- Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears!

•

- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

- Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.

Step

142

Action

1.

Make sure the mating surfaces on the motor and the lower arm are clean and free from burrs.

2.

Fit the motor in the lower arm.

3.

Fit the belt.

4.

Tighten the two motor attachment screws slightly, but not completely.

Note/Illustration

Shown in the figure in section Location of motor axis 3 on page 139.

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4 Repair 4.6.3. Replacement of motor and timing belt, axis 3

Step

Action

Note/Illustration

5.

Adjust the position of the motor in such a Correct belt tension F=35 - 60 N way that the correct belt tension is achieved.

6.

DO NOT adjust the belt tension using the intermediate wheel securing screws.

7.

Fit the belt shield and secure it with the two remaining screws.

Tightening torque: 4 Nm ± 0.5 Nm

8.

Tighten the last motor attachment screws.

Tightening torque: 4 Nm ± 0.5 Nm

9.

Refit the cabling as shown.

xx0200000449

• • • • • • 10. Recalibrate the robot!

3HAC 023297-001 Revision: -

A: Cable ties B: Pressurized air hose C: Power cables, axes 4, 5 and 6 D: Customer cables, signal E: Signal cables, axes 4, 5 and 6 F: Signal cable, axis 3

Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.

143

4 Repair 4.6.4. Replacement of motor, axis 4

4.6.4. Replacement of motor, axis 4 Location of motor, axis 4 The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.

xx0200000455

A

Attachment screws, motor 4 (4 pcs)

B

Motor, axis 4

C

O-ring

Required equipment Equipment, etc.

Spare part no.

Rot. ac motor with pinion

3HAC 7842-1 3HAC 021757-001

Art. no.

Standard, Clean Room and Foundry versions Does not include the o-ring!

O-ring

3HAC 3772-24

Must be replaced when replacing motor!

Grease

3HAC 3537-1

Used to lubricate the o-ring.

Standard toolkit

3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information!

Power supply Arm

144

Note

24 VDC, max. 1,5 A. For releasing the brakes. 3HAC 9037-1

For adjusting the gear play

3HAC 023297-001 Revision: -

4 Repair 4.6.4. Replacement of motor, axis 4

Equipment, etc.

Spare part no.

Art. no.

Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Circuit Diagram

Note These procedures include references to the tools required.

3HAC 6816-3

See chapter Circuit diagram in the Product manual, reference information.

Removal The procedure below details how to remove motor, axis 4. WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

NOTE! Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! Step

Action

Note

1.

Remove the motors for axes 5 and 6.

Detailed in section Replacement of motor and timing belt, axes 5 or 6 on page 147.

2.

Manually run the manipulator to a position where the upper arm points straight down.

This will enable the motor 4 to be removed without draining the oil in the gearbox.

3.

Remove the motor, axis 4 by unscrewing the motor Shown in the figure Location of attachment screws. motor, axis 4 on page 144.

4.

In order to release the brake, connect the 24 VDC Connect to connector R3.MP4 power supply: • +: pin 7 • -: pin 8

5.

Lift the motor to get the pinion away from the gear and disconnect the brake release voltage.

6.

Remove the motor by gently lifting it straight out.

3HAC 023297-001 Revision: -

Make sure the motor pinion is not damaged!

145

4 Repair 4.6.4. Replacement of motor, axis 4

Refitting The procedure below details how to refit motor, axis 4. WARNING! Please observe the following before commencing any repair work on the manipulator: •

- Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears!

•

- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

- Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.

NOTE! Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! Step

Action

1.

Make sure the mating surfaces on the motor Shown in the figure Location of and the gearbox are clean and free from burrs. motor, axis 4 on page 144.

2.

Make sure the o-ring on the circumference of Art. no. is specified in section the motor is seated properly. Lightly lubricate Required equipment on page 144. the o-ring with grease .

3.

In order to release the brake, connect the 24 VDC power supply:

Connect to connector R3.MP4 • +: pin 7 • -: pin 8

4.

Fit the motor with the attachment screws.

Tightening torque: approx. 2 Nm

5.

Fit the Arm to the end of the motor shaft.

Art. no. is specified in section Required equipment on page 144.

6.

Adjust the motor in relation to the gear in the gearbox. Use the Arm tool to wiggle the motor shaft back and forth to feel the play.

There should be a barely noticable gear play.

7.

Tighten the motor attachment screws.

Shown in the figure Location of motor, axis 4 on page 144. Tightening torque: 6 Nm ± 0.6 Nm

8.

Refit motors 5 and 6.

Detailed in section Replacement of motor and timing belt, axes 5 or 6 on page 147.

9.

Perform a leak-down test.

Detailed in section Leak-down test.

10. Recalibrate the robot!

146

Note

Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.

3HAC 023297-001 Revision: -

4 Repair 4.6.5. Replacement of motor and timing belt, axes 5 or 6

4.6.5. Replacement of motor and timing belt, axes 5 or 6 Location of motor and timing belt, axes 5 or 6 The motor and timing belt axes 5 or 6 are located in the rear of the upper arm as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.

xx0200000453

A

Lower arm cover

B

Attachment screws, lower arm cover

C

Cover, armhousing

D

Attachment screws, cover armhousing (4 pcs)

E

VK cover

F

Pressurized air hose (on front of upper arm)

3HAC 023297-001 Revision: -

147

4 Repair 4.6.5. Replacement of motor and timing belt, axes 5 or 6

G

CS connector

H

Cable guide

J

Attachment screws, cable guide

K

Belt shield

L

Attachment screws, belt shield

M

Motor attachment screws, 4 pcs per motor

N

Attachment screws, motor console

P

Clamping unit screws

Q

Clamping unit

R

Timing belt, axis 6

S

Pulley, axis 6

T

Screws securing the pulley to the axis 5 drive shaft

U

Timing belt, axis 5

V

Pulley, axis 5

W

Motor console, ax. 5-6

X

Motor, axis 4

Y

Motor, axis 5

Z

Motor, axis 6

Required equipment Equipment, etc.

Spare part no.

Rot. ac motor with pinion

3HAC 7842-1 3HAC 021757-001

Axis 4 Standard, Clean room and Foundry versions.

Rot. ac motor with pinion

3HAC 7841-1 3HAC 021758-001

Axes 5 and 6 Standard, Clean room and Foundry versions.

Timing belt

3HAC 6779-1

VK cover Clamping unit

Art. no.

Note

Axes 5 and 6 3HAC 2166-13

3HAC 7939-1

Standard toolkit

3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information!

Special socket xx

3HAC xx

For fitting the CSconnector

Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below. Circuit Diagram

148

These procedures include references to the tools required.

3HAC 6816-3

See chapter Circuit diagram in the Product manual, reference information.

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4 Repair 4.6.5. Replacement of motor and timing belt, axes 5 or 6

Removal The procedure below details how to remove motor, axis 5 or 6. WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

NOTE! Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! Step

Action

Note

1.

Run the robot to a position where the upper arm is close to horizontal

2.

Remove the lower arm cover by unscrewing its attachment screws.

Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147!

3.

Remove the rear cover armhousing by unscrewing its four attachment screws.

Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147!

4.

Disconnect all cables to/from motors 4-6.

Connectors: • R3.MP4 • R3.MP5 • R3.MP6 • R3.FB4 • R3.FB5 • R3.FB6

5.

Disconnect any connector from the CSconnector.

Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147!

6.

Use a special socket to remove the CSShown in the figure in section Location connector from the housing and pull it into of motor and timing belt, axes 5 or 6 on the upper arm assembly. page 147! Art. no. specified in section Required equipment

7.

Remove the pressurized air connector from Shown in the figure in section Location the housing and pull it into the upper arm of motor and timing belt, axes 5 or 6 on assembly. page 147! Art. no. specified in section Required equipment!

8.

Remove the VK-cover from the upper arm/ Shown in the figure in section Location lower arm joint. of motor and timing belt, axes 5 or 6 on page 147! Detailed in section Removing the VK cover on page 88.

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149

4 Repair 4.6.5. Replacement of motor and timing belt, axes 5 or 6

Step 9.

Action

Note

Remove the cable guide by unscrewing its Shown in the figure in section Location two attachment screws. of motor and timing belt, axes 5 or 6 on page 147!

10. Gently pull the cables out of the upper arm. 11. Remove the belt shield by unscrewing its attachment screws.

Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147!

12. Unscrew the motor attachment screws.

Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147!

13. Unscrew the clamping unit screws

Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147!

14. Use the previously removed clamping unit Shown in the figure in section Location screws to press the clamping unit apart by of motor and timing belt, axes 5 or 6 on inserting them into the adjacent holes in the page 147! clamping unit. 15. Remove the clamping unit.

150

16. Remove the pulley and belt from motor, axis 6.

Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147!

17. Remove the screws securing the pulley to the axis 5 drive shaft.

Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147!

18. Remove the pulley and belt from motor, axis 5.

Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147!

19. Remove the motor console, ax. 5-6 by unscrewing its attachment screws.

Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147!

3HAC 023297-001 Revision: -

4 Repair 4.6.5. Replacement of motor and timing belt, axes 5 or 6

Refitting The procedure below details how to refit motor, axis 5. WARNING! Please observe the following before commencing any repair work on the manipulator: •

- Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears!

•

- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

- Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.

NOTE! Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! Step

Action

Note

1.

Make sure the mating surfaces on the motor and the console are clean and free from burrs.

2.

Fit the motors in the motor console without tightening the attachment screws.

3.

Fit the motor console in the upper arm Shown in the figure in section housing. Secure with its attachment screws. Location of motor and timing belt, axes 5 or 6 on page 147! Tightening torque: 4 Nm ± 0.5 Nm

4.

Fit pulley, axis 5 and timing belt, axis 5 with their attachment screws and washers.

Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147! Tightening torque: 6 Nm ± 0.5 Nm

5.

Tighten the motor attachment screws to enable the motor to be shifted slightly.

This will facilitate adjustment of the belt tension.

6.

Adjust the belt tension by xx.

Correct belt tension F=35 - 60 N

7.

Secure the motor with its attachment screws Tightening torque: 4 Nm ± 0.5 Nm including the ones in the motor console.

8.

Fit pulley, axis 6 and timing belt, axis 6 with their attachment screws and washers.

Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147! Tightening torque: 3 Nm ± 0.5 Nm

9.

Fit the clamping unit and secure it with its clamping unit attachment screws.

Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147! Tightening torque: 3 Nm ± 0.5 Nm

Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147!

10. Repeat the belt adjustment procedure detailed above for the remaining motor. 11. Secure the motor with its attachment screws. Tightening torque: 4 Nm ± 0.5 Nm 12. Fit the belt shield with its attachment screws. Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147! Tightening torque: 4 Nm ± 0.5 Nm

3HAC 023297-001 Revision: -

151

4 Repair 4.6.5. Replacement of motor and timing belt, axes 5 or 6

Step

Action

Note

13. Pull the pressurized air connector through the housing and secure it into fitting in the upper arm assembly.

Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147! Art. no. specified in section Required equipment

14. Pull the CS-connector through the housing and secure it into the fitting in the upper arm assembly. Use a special socketto secure it.

Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147! Art. no. specified in section Required equipment

15. Reconnect any connector to the CSconnector.

Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147!

16. Reconnect all cables to/from motors 4-6.

Connectors • R3.MP4 • R3.MP5 • R3.MP6 • R3.FB4 • R3.FB5 • R3.FB6

17. Refit the cable guide with its two attachment Shown in the figure in section screws. Location of motor and timing belt, axes 5 or 6 on page 147! 18. Fit a newVK-cover to the upper arm/lower arm joint. Gently knock it into position.

Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147! Art. no. specified in section Required equipment Use a plastic mallet or similar.

19. Refit the rear cover armhousing with its four Shown in the figure in section attachment screws. Location of motor and timing belt, axes 5 or 6 on page 147! 20. Refit any brackets securing any exterior cabling to the upper arm with their attachment screws respectively. 21. Recalibrate the robot.

152

Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.

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4 Repair 4.6.6.1. Measuring the gear play, axis 5

4.6.6. Adjustments and measurements 4.6.6.1. Measuring the gear play, axis 5 General After reassembly due to repair work or any other reason, the gear play must be checked to ensure the repetition accuracy of the robot positioning. The procedure for axis 5 is detailed below. Certain measurement tools must be fashioned to enable measuring. The dimensions of these are specified. Required equipment Equipment, etc.

Art no.

Note

Standard toolkit

3HAC020812-001

The contents are defined in section Standard toolkit in the Product manual, reference information!

Arm

3HAC 9037-1

For adjusting the gear play, motor/pinion

Measurement dial with magnetic base

Measuring range 0-xx mm, accuracy xx

Power supply

24 VDC, max. 1,5 A For releasing the brakes

Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.

These procedures include references to the tools required.

WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

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4 Repair 4.6.6.1. Measuring the gear play, axis 5

Measurement The procedure below details how to measure the gear play for axis 5. Step

Action

1.

Manually, turn axis 4 90°.

2.

Fit the dial fitting arm and dial to the manipulator turning disk as shown in the figure. Apply the 40 N load as shown.

3.

Remove the load and read Value 1.

4.

Apply 40 N load as shown.

Note/Illustration

xx0200000457

xx0200000458

154

5.

Remove the load and read Value 2.

6.

Calculate the gear play value. Gear play value = value 1 - value 2

7.

Determine whether or not the value is OK.

OK < 0.18 mm (4.1 arc minutes)

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4 Repair 4.6.6.2. Measuring the gear play, axis 6

4.6.6.2. Measuring the gear play, axis 6 General After reassembly due to repair work or any other reason, the gear play must be checked to ensure the repetition accuracy of the robot positioning. The procedure for axis 6 is detailed below. Certain measurement tools must be fashioned to enable measuring. The dimensions of these are specified. Required equipment Equipment, etc.

Art no.

Note

Standard toolkit

3HAC020812-001

The contents are defined in section Standard toolkit in the Product manual, reference information!

Arm

3HAC 9037-1

For adjusting the gear play, motor/pinion

Measurement dial with magnetic base

Measuring range 0-xx mm, accuracy xx

Power supply

24 VDC, max. 1,5 A For releasing the brakes

Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.

These procedures include references to the tools required.

WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

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4 Repair 4.6.6.2. Measuring the gear play, axis 6

Measurement The procedure below details how to measure the gear play for axis 6. Step

Action

1.

Manually, turn axis 4 90°.

2.

Fit the dial fitting arm and dial to the manipulator turning disk as shown in the figure. Apply the 40 N load as shown.

Note/Illustration

xx0200000460

3.

Remove the load and read Value 1.

4.

Apply 40 N load as shown.

5.

Remove the load and read Value 2.

6.

Calculate the gear play value.

Gear play value = value 1 - value 2

7.

Determine whether or not the value is OK.

OK < 0.30 mm (10.3 arc minutes)

xx0200000461

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4 Repair 4.7.1. Replacement of gearbox, axes 1-2 and damper, axis 1

4.7 Gearboxes 4.7.1. Replacement of gearbox, axes 1-2 and damper, axis 1 Location of gearbox axes 1-2 The axes 1-2 gearbox is located as shown in the figure below. Note that both gearboxes, 1 and 2, are a single unit! The damper, axis 1, is shown in the figure in the procedure! A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.

xx0200000422

A

Gearbox, axis 1-2

Required equipment Equipment, etc. Spare part no. Art. no.

Note

Gearbox, ax. 1-2 spare, Std/F

3HAC 10467-1

Standard and Foundry versions Includes gearbox 3HAC 6603-1 Includes all required lubricant! Includes all o-rings and sealing rings!

Gearbox, ax. 1-2 spare, CR

3HAC 10467-3

Clean room version Includes gearbox 3HAC 6603-1 Includes all required lubricant! Includes all o-rings and sealing rings!

Damper, axis 1

3HAC 7527-1

Flange sealing

1234 0011-116

2 ml

LocTite, 574

3HAC xx

For sealing gearbox/base

Sealing ring

3HAC 6965-1

Replace only when damaged!

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4 Repair 4.7.1. Replacement of gearbox, axes 1-2 and damper, axis 1

Equipment, etc. Spare part no. Art. no.

Note

Standard toolkit

3HAC020812-001

The contents are defined in section Standard toolkit in the Product manual, reference information!

Lifting device, gearbox 1-2

3HAC xx

Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.

These procedures include references to the tools required.

Removal, gearbox 1-2 The procedure below details how to remove gearbox, axes 1-2. WARNING! Please observe the following before commencing any repair work on the manipulator: •

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

•

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

NOTE! Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! CAUTION! Caution! The gear box weighs 39 kg! All lifting equipment used must be dimensioned accordingly! Step

158

Action

Note/Illustration

1.

Remove motor 1.

Detailed in section Replacement of motor, axis 1 on page 130.

2.

Remove motor 2.

Detailed in section Replacement of motor, axis 2 on page 135.

3.

Remove the cable harnesses.

Detailed in section Replacement of cable harness on page 78.

4.

Remove the serial measurement Detailed in section Replacement of serial board. measurement unit and battery pack on page 122Replacement of serial measurement unit and battery pack on page 122.

5.

Remove the upper arm.

Detailed in section Replacement of complete upper arm on page 85.

6.

Remove the lower arm.

Detailed in section Removal of complete lower arm.

7.

Drain the oil from gearbox 1.

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4 Repair 4.7.1. Replacement of gearbox, axes 1-2 and damper, axis 1

Step

Action

Note/Illustration

8.

Fit the lifting tool to the base/ Art. no. is specified in section Required frame and turn it upside down on equipment on page 157. top of a suitable workbench.

9.

Remove the bottom plate by unscrewing its 26 attachment screws.

xx0200000423

• • • • • •

A: Gearbox 1-2 B: Bottom plate C: Bottom plate attachment screws (26 pcs) D: Gearbox/base attachment screws (20 pcs) E: Joint, gearbox/base F: Damper, axis 1

10. Remove the gearbox/base Shown in the figure Location of gearbox axes 1-2 attachment screws and lift the on page 157. gearbox 1-2 away from the base.

Removal of damper, axis 1 The procedure below details how to remove the damper, axis 1. Step

Action

Note

1.

Open the base of the robot.

Detailed in section Removal, gearbox 1-2 on page 158.

2.

Remove the damper, axis 1.

Refitting of damper, axis 1 The procedure below details how to refit the damper, axis 1. Step

Action

Note

1.

Fit the damper, axis 1.

Shown in the illustration Refitting, gearbox 1-2 on page 160.

2.

Proceed with assembling the robot.

Detailed in section Refitting, gearbox 1-2 on page 160.

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4 Repair 4.7.1. Replacement of gearbox, axes 1-2 and damper, axis 1

Refitting, gearbox 1-2 The procedure below details how to refit gearbox, axes 1-2. WARNING! Please observe the following before commencing any repair work on the manipulator: •

- Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears!

•

- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

•

- Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.

NOTE! Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! CAUTION! The gearbox weighs 39 kg! All lifting equipment used must be dimensioned accordingly! Step

Action

1.

Place the gearbox 1-2 on a suitable workbench.

2.

Fit a small amount of LocTite 574 onto the Joint, gearbox/ base.

Note/Illustration

xx0200000423

• • • • • • •

160

A: Gearbox 1-2 B: Bottom plate C: Bottom plate attachment screws (26 pcs) D: Gearbox/base attachment screws (20 pcs) E: Joint, gearbox/base F: Damper, axis 1 G: Washer

3.

Fit the base to the gearbox unit Shown in the figure Location of gearbox axes 1-2 on and secure it with the page 157. attachment screws and the flat Quality Gleitmo, tightening torque: 35 Nm ± 3 Nm. washer.

4.

Refit the bottom plate and secure it with its attachment screws.

Shown in the figure Location of gearbox axes 1-2 on page 157.

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4 Repair 4.7.1. Replacement of gearbox, axes 1-2 and damper, axis 1

Step

Action

Note/Illustration

5.

Fit the lifting tool to the base/ frame and turn it right side up on top of a suitable workbench.

Art. no. is specified in section Required equipment on page 157.

6.

Refit the lower arm.

Detailed in section Refitting of complete lower arm.

7.

Refit the upper arm.

Detailed in section Refitting of complete upper arm.

8.

Refit the serial measurement board.

Detailed in section Replacement of serial measurement unit and battery pack on page 122.

9.

Refit the cable harnesses.

Detailed in section Refitting of cable harness.

10. Refit motors 1 and 2.

Detailed in section Refitting of motor 1 and Refitting of motor 2 respectively.

11. Perform a leak-down test.

Detailed in section Leak-down test.

12. Refill the gear box with oil. 13. Recalibrate the robot.

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Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.

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4 Repair 4.7.2. Service work on gearbox, axis 4

4.7.2. Service work on gearbox, axis 4 General The gearbox, axis 4, is intended to run without requiring any repairs or maintenance work. This implies that it must under no circumstances be opened or serviced. If it requires replacement, the complete upper arm is to be replaced. This procedure is detailed in section Replacement of complete upper arm on page 85.

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5 Calibration information 5.1. Introduction

5 Calibration information 5.1. Introduction General This chapter includes general information about different calibration methods and details also procedures that does not require specific calibration equipment. When the robot system must be recalibrated, it is done according to documentation enclosed with the calibration tools. When to calibrate The system must be calibrated if any of the below occurs. The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied from ABB. Calibrate the robot carefully with standard calibration. The different methods are briefly described in section Calibration methods on page 164, and further detailed in separate Calibration manuals. If the robot has Absolute Accuracy calibration, it is also recommended but not always needed to be calibrated for new Absolute Accuracy. The resolver values will change when parts affecting the calibration position are replaced on the robot, e.g. motors, wrist or part of transmission. Contents of the revolution counter memory are lost If the contents of the revolution counter memory are lost, the counters must be updated as detailed in section Updating revolution counters on page 168. This will occur when: •

the battery is discharged

•

a resolver error occurs

•

the signal between a resolver and measurement board is interrupted

•

a robot axis is moved with the control system disconnected

The revolution counters must also be updated after the robot and controller are connected at the first installation. The robot is rebuilt If the robot has been rebuilt, e.g. after a crash or when the robot has been changed for other reachability, it needs to be recalibrated for new resolver values. If the robot has Absolute Accuracy calibration, it needs to be calibrated for new Absolute Accuracy. References The article numbers for the Calibration manuals are listed in section Document references in the Product manual (part 2 of 2), reference information. Article numbers for the calibration tools are also listed in part 2 of the Product manual.

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5 Calibration information 5.2. Calibration methods

5.2. Calibration methods Overview This section specifies the different types of calibration and the calibration methods that are supplied from ABB. Types of calibration Type of calibration

Description

Calibration method

Standard calibration

The calibrated robot is positioned at home position, i.e. the axes positions (angles) are set to 0º. Standard calibration data is found in the file calib.cfg, supplied with the robot at delivery. The file identifies the correct resolver/motor position corresponding to the robot home position. From deliveries together with RobotWare 5.0.5 and higher, the data will instead be found on the SMB (serial measurement board) in the robot, and not in a separate file.

Calibration Pendulum (standard method) or Levelmeter calibration (alternative method)

Absolute Accuracy calibration (optional)

Based on standard calibration, but besides CalibWare positioning the robot at home position, the Absolute Accuracy calibration also compensates for: • mechanical tolerances in the robot structure • deflection due to load. Absolute Accuracy calibration focuses on positioning accuracy in the Cartesian coordinate system for the robot. Absolute Accuracy data is found in the file absacc.cfg, supplied with the robot at delivery. The file replaces the calib.cfg file and identifies motor positions as well as absacccompensation parameters. From deliveries together with RobotWare 5.0.6 and higher, the data will instead be found on the SMB (serial measurement board) in the robot, and not in a separate file. A robot calibrated with AbsAcc has a sticker next to the identification plate of the robot. To regain 100% Absolute Accuracy performance, the robot must be recalibrated for Absolute Accuracy!

xx0400001197

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5 Calibration information 5.2. Calibration methods

Calibration methods Each calibration method is detailed in separate manuals. Below is a brief description of the methods available. Calibration Pendulum - standard method Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB 6400R, IRB 640, IRB 1400H and IRB 4400S) and is also the most accurate method for the standard type of calibration. It is the recommended method in order to achieve proper performance. The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including the manual Calibration Pendulum Instruction. Levelmeter Calibration - alternative method Levelmeter Calibration is referred to as the alternative method for calibration of ABB robots, because of the less accurate values obtained during calibration. The method uses the same principles as Calibration Pendulum but has not as good mechanical tolerances to the toolkit parts as the standard method with Calibration Pendulum. This method may, after calibration, require modifications in the robot program, and is therefore not recommended. The calibration equipment for Levelmeter Calibration is ordered as separate parts for each robot and the manual Instruction for Levelmeter Calibration is enclosed with the Levelmeter 2000. CalibWare - Absolute Accuracy calibration In order to achieve a good positioning in the Cartesian coordinate system, Absolute Accuracy is used as a TCP calibration. The tool CalibWare guides through the calibration process and calculates new compensation parameters. This is detailed further in the manual CalibWare 2.0 Users Guide. If a service operation is done to a robot with Absolute Accuracy, a new absolute accuracy calibration is required in order to establish full performance. For most cases after motor and transmission replacements that do not include taking apart the robot structure, standard calibration is sufficient. Standard calibration also supports wrist exchange.

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5 Calibration information 5.3. Calibration scales and correct axis position

5.3. Calibration scales and correct axis position Introduction This section specifies the calibration scale positions and/or correct axis position for all robot models. Calibration scales, IRB 140 The illustration below shows the calibration scale positions on IRB 140:

xx0200000157

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5 Calibration information 5.4. Calibration movement directions for all axes

5.4. Calibration movement directions for all axes Calibration movement directions When calibrating, the axis must consistently be run towards the calibration position in the same direction, in order to avoid position errors caused by backlash in gears etc. Positive directions are shown in the figure below. This is normally handled by the robot calibration software. Note! The figure shows an IRB 7600, but the positive direction is the same for all robots, except the positive direction of axis 3 for IRB 6400R which is in the opposite direction!

xx0200000089

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167

5 Calibration information 5.5. Updating revolution counters

5.5. Updating revolution counters General This section details how to perform a rough calibration of each robot axis, i.e. updating the revolution counter value for each axis, using either the TPU or the FlexPendant. Manually running the robot to the calibration position This procedure details the first step when updating the revolution counter; manually running the robot to the calibration position. Step

Action

Note

1.

Select axis-by-axis motion mode.

2.

Jog the robot so that the calibration marks lie Shown in section Calibration scales within the tolerance zone. and correct axis position on page 166.

3.

When all axes are positioned, store the revolution counter settings.

Detailed in sections: Storing the revolution counter setting with the TPU on page 169 (RobotWare 4.0). Storing the revolution counter setting with the FlexPendant on page 170 (RobotWare 5.0).

Correct calibration position of axis 4 and 6 When running the robot to calibration position, it is extremely important to make sure that axes 4 and 6 of the below mentioned robots are positioned correctly. The axes do not have any mechanical stops and can therefore be calibrated at the wrong turn. Make sure the axes are positioned according to the correct calibration values, not only according to the calibration marks. The correct values are found on a label, located either on the lower arm or underneath the flange plate on the base. At delivery the robot is in the correct position, do NOT rotate axis 4 or 6 at power up before the revolution counters are updated. If one of the below mentioned axes are rotated one or more turns from its calibration position before updating the revolution counter, the exact calibration position will be lost due to uneven gear ratio. This affects the following robots:

168

Robot variant

Axis 4

Axis 6

IRB 140

Yes

Yes

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5 Calibration information 5.5. Updating revolution counters

Storing the revolution counter setting with the TPU This section details the second step when updating the revolution counter; storing the revolution counter setting with the TPU (RobotWare 4.0). Step 1.

Action

Note

Press the button "Miscellaneous" then ENTER to select the service window.

xx0100000194

2.

Select Calibration from the View menu. The Calibration window appears. If there is more than one unit connected to the robot, they will be listed in the window.

xx0100000201

3.

Select the desired unit and choose Rev Counter Update from the Calib menu. The Revolution Counter Update window appears.

xx0100000202

4.

Select the desired axis and press Incl to include it (it will be marked with an x) or press All to select all axes.

5.

Press OK when all axes that are to be updated are marked with an x. CANCEL returns to the Calibration window.

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5 Calibration information 5.5. Updating revolution counters

Step

Action

Note

6.

Press OK again to confirm and start the update. CANCEL returns to the Revolution Counter Update window.

7.

At this point, it is recommended that the revolution counter values are saved to a diskette.

Not required.

8.

-

Caution! If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, which in turn may cause damage or injury! Check the calibration position very carefully after each update. How to perform the check is detailed in section Checking the calibration position on page 172.

Storing the revolution counter setting with the FlexPendant This procedure details the second step when updating the revolution counter; storing the revolution counter setting with the FlexPendant (RobotWare 5.0). Step

Action

1.

On the ABB menu, tap Calibration. All mechanical units connected to the system are shown along with their calibration status.

2.

Tap the mechanical unit in question. A screen is displayed: tap Rev. Counters.

en0400000771

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5 Calibration information 5.5. Updating revolution counters

Step

Action

3.

Tap Update revolution counters.... A dialog box is displayed, warning that updating the revolution counters may change programmed robot positions: • Tap Yes to update the revolution counters. • Tap No to cancel updating the revolution counters. Tapping Yes displays the axis selection window.

4.

Select the axis to have its revolution counter updated by: • Ticking in the box to the left • Tapping Select all to update all axes. Then tap Update.

5.

A dialog box is displayed, warning that the updating operation cannot be undone: • Tap Update to proceed with updating the revolution counters. • Tap Cancel to cancel updating the revolution counters. Tapping Update updates the ticked revolution counters and removes the tick from the list of axes.

6.

-

Caution! If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, which in turn may cause damage or injury! Check the calibration position very carefully after each update. See section Checking the calibration position on page 172.

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5 Calibration information 5.6. Checking the calibration position

5.6. Checking the calibration position General Check the calibration position before beginning any programming of the robot system. This may be done in one of two ways: •

Using a MoveAbsJ instruction with argument zero on all axes

•

Using the Jogging window on the teach pendant

Using a MoveAbsJ instruction on the TPU, S4Cplus This section describes how to create a program, which runs all the robot axes to their zero position Step

Action

1.

Crate a new program

2.

Use MoveAbsJ

3.

Create the following program: MoveAbsJ [[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E9]]\NoEOffs , v1000, z50, Tool0

4.

Run the program in manual mode

5.

Check that the calibration marks for the axes align correctly. If they do not, update the revolution counters!

Note

The calibration marks are shown in section Calibration scales and correct axis position on page 166. How to update the revolution counters is detailed in section Updating revolution counters on page 168

Using a MoveAbsJ instruction on the FlexPendant, IRC5 This section describes how to create a program, which runs all the robot axes to their zero position. Step

172

Action

1.

On ABB menu tap Program Editor.

2.

Create a new program.

3.

Use MoveAbsJ in the Motion&Proc menu.

4.

Create the following program: MoveAbsJ [[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E9]]\NoEOff s, v1000, z50, Tool0

5.

Run the program in manual mode.

6.

Check that the calibration marks for the axes align correctly. If they do not, update the revolution counters!

Note

The calibration marks are shown in section Calibration scales and correct axis position on page 166. How to update the revolution counters is detailed in section Updating revolution counters on page 168.

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5 Calibration information 5.6. Checking the calibration position

Using the Jogging window on the TPU, S4Cplus This section describes how to jog the robot to all axes zero position. Step

Action

Illustration/information

1.

Open the Jogging window.

2.

Choose running axes-by-axes.

3.

Manually run the robot axes to a position where the axis position value read on the TPU, is equal to zero.

4.

Check that the calibration marks for the axes align The calibration marks are correctly. If they do not, update the revolution shown in section Calibration counters! scales and correct axis position on page 166. Detailed in section Updating revolution counters on page 168.

xx0100000195

xx0100000196

Using the Jogging window on the FlexPendant, IRC5 This section describes how to jog the robot to all axes zero position. Step

Action

1.

Tap Jogging in the ABB menu.

2.

Tap Motion mode to choose group of axes to jog.

3.

Tap axes 1-3 to jog axes 1, 2 or 3.

4.

Manually run the robots axes to a position where the axis position value read on the FlexPendant, is equal to zero.

5.

Check that the calibration marks for the axes align correctly. If they do not, update the revolution counters!

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Note

The calibration marks are shown in section Calibration scales and correct axis position on page 166. How to update the counters is detailed in section Updating revolution counters on page 168.

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5 Calibration information 5.6. Checking the calibration position

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Index

C Calibration position 168 calibration position, checking 172 calibration position, jog to 173 Connection of external safety devices 15 D direction of axes 167 L Limitation of Liability 16 N negative directions, axes 167 P positive directions, axes 167 R Revolution counters 168 S Safety, service 15 U Updating revolution counters 168 V Validity and responsibility 15

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