IRC5-IRB140 Prod Man 3HAC023297-001 References Rev- En
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Product manual (part 2 of 2), reference information Articulated robot IRB 140 M2000, M2000A, M2004
Product manual (part 2 of 2), reference information 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1 Reference information
11
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1.2 Applicable Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1.6 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 1.7 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 1.8 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1.9 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 1.10 Mounting instructions for bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 1.11 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 2 Spare part / part list
27
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 2.2 Spare part / part list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 3 Foldouts
33
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 4 Circuit diagram
35
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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Table of Contents
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Overview
Overview About this manual This manual contains reference information for all procedures in part 1: Product manual, procedures. Usage This manual should be used during: •
installation
•
maintenance work
•
repair work.
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
Reference information
Useful information when performing installation, maintenance or repair works. Includes lists of necessary tools, additional documents, safety standards, etc.
Spare part / Part list
Complete spare part lists and complete lists of robot components, shown in the foldouts.
Foldouts
Detailed illustrations of the robot with reference numbers to the part list.
Circuit diagram
Circuit diagram for the robot.
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Overview
Revisions
6
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. • Section Document references added to the chapter Reference information. • 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:
8
•
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)
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Product documentation, M2004
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1 Reference information 1.1. Introduction
1 Reference information 1.1. Introduction General This chapter includes general information, complementing the more specific information in the Product manual (part 1 of 2), procedures.
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1 Reference information 1.2. Applicable Safety Standards
1.2. Applicable Safety Standards Standards, general The robot is designed in accordance with the requirements of: •
ISO10218, Jan. 1992, Industrial Robot Safety
•
ANSI/RIA 15.06-1999
•
ISO/DIS 11161, Industrial automation systems - safety of integrated manufacturing systems - Basic requirements
•
DIN 19258 - Interbus-S, International Standard
Standards, safety fence The following standards are applicable to the safety fence surrounding the robot cell: •
ISO/DIS 11161, Industrial automation systems -safety of integrated manufacturing systems - Basic requirements
•
prEN 999:1995
Standards, robot cell The following standards are applicable when the robot is part of a robot cell:
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•
IEN 294, Safety of machinery - Safety distance to prevent danger zones being reached by the upper limbs.
•
EN 349, Safety of machinery - Minimum gaps to avoid crushing of parts of the human body.
•
EN 811 Safety of machinery - Safety distance to prevent danger zones being reached by the lower limbs.
•
Pr EN 999 Safety of machinery - The positioning of protective equipment in respect of approach speeds of the human body.
•
EN 1088 Safety of machinery - Interlocking device associated with guards principles for design and selection.
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1 Reference information 1.3. Unit conversion
1.3. Unit conversion Converter table Use the table below to convert units used in this manual.
Quantity
Units
Length
1m
3.28 ft
Weight
1 kg
2.21 lb
Pressure
1 bar
100 kPa
Force
1N
0.738 lbf
Moment
1 Nm
0.738 lbf-tn
Volume
1L
0.264 US gal
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39.37 in 14.5 psi
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1 Reference information 1.4. Screw joints
1.4. Screw joints General This section details how to tighten the various types of screw joints on the robot and the controller. The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials. UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below), and is extremely resistant to fatigue. Whenever used, this is specified in the instructions, and in such cases, no other type of replacement screw is allowed! Using other types of screws will void any warranty and may potentially cause serious damage or injury! Gleitmo treated screws Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint. Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this the screw must be discarded and replaced with a new one. When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should be used. Screws lubricated in other ways Screws lubricated with Molycote 1000 should only be used when specified in the repair, maintenance or installation procedure descriptions. In such cases, proceed as follows: 1. Apply lubricant to the screw thread. 2. Apply lubricant between the plain washer and screw head. 3. Tighten to the torque specified in section Tightening torque below. Screw dimensions of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or smaller may be tightened without a torque wrench if this is done by trained and qualified personnel.
Lubricant
Art. no.
Molycote 1000 (molybdenum disulphide grease)
1171 2016-618
Tightening torque Before tightening any screw, note the following:
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•
Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure description. Any special torque specified overrides the standard value.
•
Use the correct tightening torque for each type of screw joint. 3HAC 023297-001 Revision: -
1 Reference information 1.4. Screw joints
•
Only use correctly calibrated torque keys.
•
Always tighten the joint by hand, and never use pneumatical tools.
•
Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a slow, flowing motion.
•
Maximum allowed total deviation from the specified value is 10%!
The table below specifies the recommended standard tightening torque for oil-lubricated screws with slotted or cross-recess head screws.
Dimension
Tightening torque (Nm) Class 4.8, oil-lubricated
M2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
The table below specifies the recommended standard tightening torque for oil-lubricated screws with Allen head screws.
Dimension
Tightening torque (Nm) Class 8.8, oillubricated
Tightening torque (Nm) Class 10.9, oillubricated
Tightening torque (Nm) Class 12.9, oillubricated
M5
6
-
-
M6
10
-
-
M8
24
34
40
M10
47
67
80
M12
82
115
140
M16
200
290
340
The table below specifies the recommended standard tightening torque for Molycotelubricated screws with Allen head screws.
Dimension
Tightening torque (Nm) Tightening torque (Nm) Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M8
28
34
M10
55
66
M12
96
115
M16
235
280
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1 Reference information 1.4. Screw joints
The table below specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass.
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Dimension
Tightening torque Nm - Nominal
Tightening torque Nm - Min.
Tightening torque Nm - Max.
1/8
12
8
15
1/4
15
10
20
3/8
20
15
25
1/2
40
30
50
3/4
70
55
90
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1 Reference information 1.5. Weight specifications
1.5. Weight specifications Definition In all repair and maintenance procedures, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way. To avoid injury, ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each manipulator model. Example Below is an example of how a weight specification is presented: CAUTION! Caution! The motor weighs 32 kg! All lifting equipment used must be sized accordingly!
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1 Reference information 1.6. Document references
1.6. Document references General The contents of this manual may include references to additional documentation necessary to perform certain procedures. This section specifies the article numbers for the referenced documentation. Product specification, robot The product specification includes generic technical data. The specification listed below is the English version.
Document name
Document ID
Product specification
3HAC 9041-1
Product manuals, controller The product manuals include information about installation and service activities. The table below specifies the article numbers of the product manuals for all controller models. The part number -001 is the English version.
Document name
Document ID
Product manual, S4Cplus M2000
3HAC 021333-001
Product manual, S4Cplus M2000A
3HAC 021128-001
Product manual, IRC5 M2004
3HAC 021313-001
Operators manual The operators manual contains instructions for daily operation of robot systems. The table below specifies the article numbers of the operators manuals for different robot systems.
Document name
Document ID
Note
User’s guide (S4Cplus)
3HAC 7793-1
Contains instructions for daily operation of S4Cplus based robot systems.
Operator’s manual (IRC5)
3HAC 16590-1
Document name
Document ID
Note
Calibration Pendulum Instruction
3HAC 16578-1
Enclosed with the Calibration Pendulum Toolkit.
Instructions for Levelmeter calibration (alternative method)
3HAC 022907-001
Enclosed with the Levelmeter 2000.
CalibWare 2.0 Users Guide
3HAC 16090-1
Calibration tool for Absolute Accuracy calibration.
Calibration manuals
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1 Reference information 1.6. Document references
Additional documentation Document name
Document ID
External axes
3HAC 9299-1
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Note
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1 Reference information 1.7. Standard toolkit
1.7. Standard toolkit General All service (repair, maintenance and installation) instructions contain lists of tools required to perform the specified activity. All special tools, i.e. all tools that are not considered standard as defined below, are listed in their instructions respectively. This way, the tools required are the sum of the Standard Toolkit and any tools listed in the instruction. Contents Standard tool, IRB 140: 3HAC020812-001 contains:
20
Qty
Art. no.
Tool
1
-
Ring-open-end spanner 8-19mm
1
-
Socket head cap 2,5-17mm
1
-
Torx socket no:20-60
1
-
Torque wrench 10-100Nm
1
-
Small screwdriver
1
-
Ratchet head for torque wrench 1/2
1
-
Socket head cap no:5, socket 1/2"" bit L 20mm
1
-
Socket head cap no:6, socket 1/2"" bit L 20mm
1
-
Socket head cap no:8, socket 1/2"" bit L 20mm
1
-
Small cutting plier
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1 Reference information 1.8. Performing a leak-down test
1.8. Performing a leak-down test General After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test. Required equipment Equipment, etc.
Art. no.
Leakdown tester
3HAC 0207-1
Leak detection spray
-
Note
Procedure Step
Action
Note/Illustration
1.
Finish the refitting procedure of the motor or gear in question.
2.
Remove the topmost oil plug on the gear in question, Art. no. is specified above! and replace it with the leakdown tester . Adapters may be required, which are included in the leakdown tester kit.
3.
Apply compressed air, and raise the pressure with the Recommended value: 0.2 knob until the correct value is shown on the 0.25 bar (20 - 25 kPa) manometer.
4.
Disconnect the compressed air supply.
5.
Wait for approx. 8-10 minutes. No pressure loss must If the compressed air is be detected. significantly colder or warmer than the gearbox to be tested, a slight pressure increase or decrease respectively may occur. This is quite normal.
6.
Was any pressure drop evident? Localize the leak as detailed below. Remove the leakdown tester, and refit the oil plug. The test is complete.
7.
Spray suspected leak areas with leak detection spray . Bubbles indicate a leak.
8.
When the leak has been localized: take the necessary measures to correct the leak.
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Art. no. is specified above!
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1 Reference information 1.9. Lifting equipment and lifting instructions
1.9. Lifting equipment and lifting instructions General Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each procedure. The use of each piece of lifting equipment is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting equipment. This implies that the instructions delivered with the lifting equipment should be stored for later reference.
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1 Reference information 1.10. Mounting instructions for bearings
1.10. Mounting instructions for bearings General This section details how to mount and grease different types of bearings on the manipulator. Equipment Equipment, etc.
Art. no.
Note
Grease
3HAB 3537-1
Used to grease the bearings, if not specified otherwise.
Assembly of all bearings Follow the instructions below when mounting a bearing on the manipulator. 1. To avoid contamination, let a new bearing remain in its wrapping until it is time for fitting. 2. Ensure that all parts included in the bearing fitting are free from burrs, grinding waste and other contamination. Cast components must be free from foundry sand. 3. Bearing rings, inner rings and roller elements must under no circumstances be subjected to direct impact. Furthermore, the roller elements must not be exposed to any stresses during the assembly work. Assembly of tapered bearings Follow the previous instructions for assembly of all bearings, when mounting a tapered bearing on the manipulator. In addition to those instructions, the procedure below must be carried out to enable the roller elements to adjust to the correct position against the race flange. 1. Tension the bearing gradually until the recommended pre-tension is achieved. Note! The roller elements must be rotated a specified number of turns before pretensioning is carried out and also rotated during the pre-tensioning sequence. 2. Make sure the bearing is properly aligned, as this will directly affect the lifespan of the bearing. Greasing of bearings The bearings must be greased after assembly, according to instructions below: •
The bearings must not be completely filled with grease. However, if space is available beside the bearing fitting, the bearing may be totally filled with grease when mounted, as excessive grease will be pressed out from the bearing when the robot is started.
•
During operation, the bearing should be filled to 70-80% of the available volume.
•
Ensure that grease is handled and stored properly, to avoid contamination.
Grease the different types of bearings as detailed below: •
Grooved ball bearings must be filled with grease from both sides.
•
Tapered roller bearings and axial needle bearings must be greased in the split condition.
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1 Reference information 1.11. Mounting instructions for seals
1.11. Mounting instructions for seals General This sections details how to mount different types of seals to the manipulator. Equipment Equipment, etc.
Art. no.
Note
Grease
3HAB 3537-1
Used to lubricate the seals.
Rotating seals The procedure below details how to fit rotating seals. CAUTION! Please observe the following before commencing any assembly of seals: •
Protect the sealing surfaces during transport and mounting.
•
Keep the seal in its original wrappings or protect it well before actual mounting.
•
The fitting of seals and gears must be carried out on clean workbenches.
•
Use a protective sleeve for the sealing lip during mounting, when sliding over threads, keyways, etc.
Step
24
Action
Note
1.
Check the seal to ensure that: • the seal is of the correct type (provided with cutting edge). • there is no damage to the sealing edge (feel with a fingernail).
2.
Inspect the sealing surface before mounting. If scratches or damage are found, the seal must be replaced, as it may result in future leakage.
3.
Lubricate the seal with grease just before fitting. (Not too Art. no. is specified in early as there is a risk of dirt and foreign particles adhering Equipment on page to the seal.) 24. Fill the space between the dust tongue and sealing lip to 2/ 3 with grease. The rubber coated external diameter must also be greased, unless otherwise specified.
4.
Mount the seal correctly with a mounting tool. Never hammer directly on the seal as this may result in leakage.
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1 Reference information 1.11. Mounting instructions for seals
Flange seals and static seals The procedure below details how to fit flange seals and static seals. Step
Action
Note
1.
Check the flange surfaces. They must be even and free from pores. It is easy to check flatness using a gauge on the fastened joint (without sealing compund). If the flange surfaces are defective, the parts may not be used beacuse leakage could occur.
2.
Clean the surfaces properly and in accordance with ABB ROBOTICS PRODUCTS recommendations.
3.
Distribute the sealing compound evenly over the surface, preferably with a brush.
4.
Tighten the screws evenly when fastening the flange joint.
O-rings The procedure below details how to fit o-rings. Step
Action
Note
1.
Ensure that the correct o-ring size is used.
2.
Check the o-ring for surface defects, burrs, shape accuracy, etc. Defective o-rings may not be used.
3.
Check the o-ring grooves. Defective o-rings The grooves must be geometrically correct and free from pores may not be used. and contamination.
4.
Lubricate the o-ring with grease.
5.
Tighten the screws evenly when assembling.
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1 Reference information 1.11. Mounting instructions for seals
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2 Spare part / part list 2.1. Introduction
2 Spare part / part list 2.1. Introduction Definitions This chapter specifies all spare parts and replacement articles of the robot.
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2 Spare part / part list 2.2. Spare part / part list
2.2. Spare part / part list Spare part / part list The table below details all replacement articles on the robot. The items refer to chapter Foldouts.
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Item
Qty
Art. no.
Name
Rem.
1
1
3HAC 10470-1
Base spare
2
1
3HAC 8999-1
Bottom plate
3
26
9ADA 629-44
Torx pan head roll. screw
4
1
3HAC 6599-1
Gasket bottom plate
5
1
3HAC 9522-1
Serial meas. board ass.
6
1
4944 026-4
Battery pack
7.2V 4Ah NiCd
7
2
2166 2055-6
Cable straps, outdoors
7.6x368
8
28
9ADA 618-46
Torx pan head screw
M5x20
9
1
3HAC 9030-1
Cable bracket
10
1
3HAC 9415-1
Clamp
11
1
3HAC 6755-1
Cable holder
12
4
9ADA 618-50
Torx pan head screw
M5x40
13
1
3HAC 10476-1
Control cable spare Std/F
L=3m
14
1
3HAC 10477-1
Control cable spare Std/F
L=7m
15
1
3HAC 7527-1
Damper axis 1
16
20
3HAB 3402-52
Hex. socket head cap screw
17
2
3HAC 7950-1
Washer
18
2
3HAC 9860-1
Protecting plate
19
1
3HAC 8466-1
Protective earth cable
20
2
3HAC 9063-1
Hose clip
21
1
SK 615 503-2
Membrane
22
1
SK 616 013-F
Bracket
23
1
1SFA 616100R1006
Actuator black
24
1
3HAC 7870-1
Gasket base-cover
25
10
9ADA 290-1
Hexagon nut with flange
M5
26
1
2529 1920-2
Plug
R 1/8"
27
2
2522 2101-8
Protective hood
D=11.4-13
28
1
3HAC 8806-1
Clamp
29
1
3HAC 7370-1
Cable harness IRB 140
30
1
3HAC 2589-1
Instruction plate
Battery replacement
31
10
2166 2055-3
Cable straps, outdoors
4.8x208
32
20 ml
1234 0011-116
Flange sealing
Lotctite 574
33
1
3HAC 10470-3
Base, spare CR
34
1
3HAC 10476-4
Control cable spare CR
M5x12
M10x35 8.8 Gleitmo 610
D = 10 CBK
L=3m
3HAC 023297-001 Revision: -
2 Spare part / part list 2.2. Spare part / part list
Item
Qty
Art. no.
Name
Rem.
35
1
3HAC 10477-2
Control cable spare CR
L=7m
36
1
3HAC 11331-1
Control cable spare Std/F
L = 15 m
37
1
3HAC 11331-2
Control cable spare CR
L = 15 m
38
1
3HAC 13089-1
Control cable spare Std/F
L = 30 m
39
1
3HAC 13090-1
Control cable spare Std/F
L = 22 m
50
1
3HAC 10467-1
Gearbox axes 1-2, spare Std/F
Item 67 incl.
51
2
3HAC 10469-1 Motor with pinion spare Std/F 3HAC 021965-001
52
24
3HAB 3409-25
Hex socket head cap screw
M6x20 12.9 Gleitmo 610
53
18
9ADA 312-6
Plain washer
6.4x12x1.6
54
2
2152 2012-426
O-ring
74.5x3
55
1
3HAC 6788-1
Bearing hub
56
1
3HAC 10478-1
Console spare Std/F
57
1
3HAC 10472-1
Cover console spare Std/F
58
1
3HAC 7868-1
Gasket console-cover
59
1
3HAC 5894-1
Cable bracket
T=1.5
60
1
3HAC 6965-1
Sealing ring
150x189x8.5
61
3
3HAC 3785-6
Parallel pin
D = 6 m6 L = 16
62
2
3HAB 3732-19
Sealing ring (V-ring)
85x11
63
11
9ADA 618-55
Torx pan head screw
M6x12
64
2
2166 2018-2
Clamp
D = 11
65
1
3HAC 10481-1
Connector bracket
66
25
2166 2055-1
Cable straps, outdoors
67
3000 ml 1171 2016-604
Lubricating oil
68
1
3HAC 10467-3
Gearbox axes 1-2, spare CR
69
2
3HAC 10469-3 / Motor with pinion, spare CR 3HAC 021966-001
70
1
3HAC 10478-3
Console, spare CR
71
1
3HAC 10472-3
Cover console, spare CR
72
1
3HAC 10645-1
Clamp
D = 4.7
100
1
3HAC 10468-1
Lower arm (axis 3), spare
Item 67, 107 and 108 incl.
101
1
3HAC 10471-1
Cover, without lamp unit
Item 103 incl.
102
1
3HAC 10474-1
Cover, with lamp unit
Item 103 incl.
103
1
3HAC 7869-1
Gasket lower-arm cover
104
1
3HAC 7866-1 / Rot. ac motor incl. pinion 3HAC 021756-001
105
1
3HAC 6793-1
Timing belt
106
1
3HAC 6762-1
Belt shield
107
1
3HAB 3643-17
Groove ball bearing
80x100x10
108
2
3HAA 2166-13
VK-Cover
D = 100 B = 10
109
1
3HAC 7880-1
Damper axis 2
110
1
3HAA 2356-14
Washer SRKB
3HAC 023297-001 Revision: -
Item 58 incl.
2.5x101
6.4x18x1.6 29
2 Spare part / part list 2.2. Spare part / part list
30
Item
Qty
Art. no.
Name
Rem.
111
4
3HAB 3402-15
Hex. socket head cap screw
M5x20 8.8 Gleitmo 610
112
12
9ADA 312-5
Plain washer
5.3x10x1
113
1
3HAC 9258-1
Indicator lamp
114
1
3HAC 10468-4
Lower arm, spare CR
115
1
3HAC 10471-3
Cover, without lamp unit
116
1
3HAC 10474-3
Cover, with lamp unit
150
1
3HAC 10466-1
Upper arm compl. with wrist
Motors incl.
151
1
3HAC 10475-1
Wrist, spare Std/F
Item 155, 181 and 182 incl.
152
1
3HAC 7191-1
O-ring sealing plate
153
3
3HAB 3409-37
Hex. socket head cap screw
M8x25 12.9 Gleitmo 610
154
3
9ADA 312-7
Plain washer
8.4x16x1.6
155
3
2529 1920-2
Plug
R 1/8"
156
1
3HAC 10479-1
Axis 4 complete, spare Std/F
Item 111, 112, 180, 159, 161, 160 and 182 incl.
157
6
3HAB 3409-39
Hex. socket head cap screw
M8x35 12.9 Gleitmo 610
158
6
9ADA 334-7
Spring washer, conical
8.4x18x2
159
1
3HAB 3732-13
Sealing ring (V-ring)
99x10.5
160
1
3HAC 7842-1 / Rot. ac motor with pinion 3HAC 021757-001
161
1
3HAB 3772-24
162
2
3HAC 7841-1 / Rot. ac motor with pinion 3HAC 021758-001
163
4
3HAB 3402-18
Hex. socket head cap screw
164
1
3HAC 6773-1
Motor Console axes 5-6
165
5
9ADA 183-13
Hex. socket head cap screw
M5x12
166
3
3HAA 2356-15
Washer SRKB
5.3x15x1.2
167
1
3HAC 7367-1
Cable holder
168
1
3HAC 8572-1
Clamp
169
2
3HAC 6779-1
Timing belt
170
1
3HAC 6777-1
Timing Belt Pulley Z2/5
171
1
3HAC 6778-1
Timing Belt Pulley Z2/6
172
1
3HAC 7939-1
Clamping unit
173
1
3HAC 7391-1
Belt shield
174
1
3HAC 10473-1
Cover armhousing spare
175
1
3HAC 7867-1
Gasket upper arm cover
176
1
3HAC 7881-1
Damper axis 3
177
1
3HAC 6761-1
Cable guide
178
1
3HAC 7561-3
Dustcap for receptacles 12p
O-ring
29x3
M5x35 8.8 Gleitmo 610
Item 175 incl.
3HAC 023297-001 Revision: -
2 Spare part / part list 2.2. Spare part / part list
Item
Qty
Art. no.
Name
Rem.
179
2
2125 2052-178
Distance bolt
M5X55
180
1
3HAC 6598-1
Hose nipple
G 1/4"
181
1
3HAB 8964-1
Damper axis 5
182
550 ml
3HAC 0860-1
Lubricating oil
183
1
3HAC 10466-3
Upper arm, spare CR
184
1
3HAC 10475-4
Wrist, spare CR
185
1
3HAC 10479-3
Axis 4 complete, spare CR
186
1
3HAC 10439-3
Cover armhousing, spare CR
187
1
3HAC 11922-1
Slip strip
3HAC 023297-001 Revision: -
Optimol Optigear BM 100
31
2 Spare part / part list 2.2. Spare part / part list
32
3HAC 023297-001 Revision: -
3 Foldouts 3.1. Introduction
3 Foldouts 3.1. Introduction Overview The foldouts in this chapter refer to the part list.
3HAC 023297-001 Revision: -
33
1
15
33
27
18
32
8
13
34
35
36
37
38
39
3
20
31
19
R1/4
21
22
23
28
3
Inside of cover
4
7
5
16
35 Nm
17
24
6
8
12
11
9
26
29
31
3
10
2
3
30
25
Inside of base
Base complete
Foldout 1
51
62
56
70
8
57
58
71
53
52
65
32
25
25
72
31
A
62
52
A (1 : 2)
15,5 Nm
55
31 52 53 54
52
53
51
52
69
53 54
63 64
68
50 67
61
ax.1 1,2 litre ax.2 1,0 litre
61
60
63
31
59
31
63
63
Foldout 2
0,4 litre
67 100
104
114
105
64
3
103
101
115
8
113
102
116 Do not loosen these screws
Do not loosen these screws
3
110
109
18
66
17
16
35 Nm
108
107
112
111 4,1 Nm
Lower arm (shown without cables)
106
Lower arm complete with cables (shown without cover)
Foldout 3
0,35 litre oil (at oil change). 0,30 litre oil (New wrist) 182 151
184
0,2 litre oil 152
180
182 156
185
159
176
162
162
164
163
4,1 Nm
112
169
153
28 Nm
154
170
171
172
3 Nm
173
181
108
157
35 Nm
158
161
Upper arm (shown without cables)
112
111
6 Nm
160
112
4,1 Nm 163
112
4,1 Nm 111
166
165
6 Nm
169
112
163
4,1 Nm
175
8
174
186
12
Foldout 4
177
179
168
167
150 183
20
165
3 187
Upper arm with cables (shown without cover)
178
155
Upper arm complete
Foldout 5
4 Circuit diagram 4.1. Introduction
4 Circuit diagram 4.1. Introduction Overview This chapter includes the circuit diagram for the robot.
3HAC 023297-001 Revision: -
35
Circuit Diagram CONTENTS
Page
Manipulator, diagram 3HAC 6816-3, Rev. 0 ..............................................................101-108
IRB 140
Manipulator Circuit Diagram
3HAC 6816-3
LIST OF CONTENTS IRB 140
No. of Sheets 8
Sheet no.
101
Manipulator Circuit Diagram
3HAC 6816-3
CONNECTION POINT LOCATIONS IRB 140
No. of Sheets 8
Sheet no.
102
Manipulator Circuit Diagram
3HAC 6816-3
SERIAL MEASUREMENT BOARD IRB 140
No. of Sheets 8
Sheet no.
103
Manipulator Circuit Diagram
3HAC 6816-3
MOTOR AXIS 1 - 3 IRB 140
No. of Sheets 8
Sheet no.
104
Manipulator Circuit Diagram
3HAC 6816-3
FEEDBACK AXIS 1 - 3 IRB 140
No. of Sheets 8
Sheet no.
105
Manipulator Circuit Diagram
3HAC 6816-3
MOTOR AXIS 4 - 6 IRB 140
No. of Sheets 8
Sheet no.
106
Manipulator Circuit Diagram
3HAC 6816-3
FEED-BACK AXIS 4 - 6 IRB 140
No. of Sheets 8
Sheet no.
107
Manipulator Circuit Diagram
3HAC 6816-3
CUSTOMER CONNECTIONS IRB 140
No. of Sheets 8
Sheet no.
108
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