IRC5-IRB340 Prod Man 3HAC022546-001 Procedures Rev- En Proc

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Product manual, proceduresIRB 340

Document ID: 3HAC 022546-001Revision -

The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no re-sponsibility for any errors that may appear in this manual.

In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein.

This manual and parts thereof must not be reproduced or copied without 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 2003 ABB All rights reserved.

ABB Automation Technology Products ABRobotics

SE-721 68 VästeråsSweden

Product Manual IRB 340 3

CONTENTS

1 Introduction ....................................................................................................... 7

1.1 How to use this Manual ............................................................................. 7

1.2 What you must know before you use the Robot........................................ 7

1.3 Identification .............................................................................................. 8

1.4 Structure Manipulator ................................................................................ 10

1.5 Structure Controller ................................................................................... 15

1.6 Electronics unit .......................................................................................... 15

1.6.1 The computer system consists of the following parts ...................... 16

1.6.2 Drive system:................................................................................... 16

1.6.3 Miscellaneous.................................................................................. 17

2 Safety ................................................................................................................. 19

2.1 General...................................................................................................... 19

2.1.1 Introduction...................................................................................... 19

2.2 Applicable Safety Standards ..................................................................... 19

2.3 Fire-Extinguishing...................................................................................... 19

2.4 Definitions of Safety Functions.................................................................. 20

2.5 Safe Working Procedures ......................................................................... 20

2.5.1 Normal operations ........................................................................... 20

2.6 Programming, Testing and Servicing......................................................... 21

2.7 Safety Functions........................................................................................ 21

2.7.1 The safety control chain of operation .............................................. 21

2.7.2 Emergency stops............................................................................. 22

2.7.3 Mode selection using the operating mode selector ......................... 22

2.7.4 Programming and testing at reduced speed.................................... 23

2.7.5 Testing at full speed......................................................................... 23

2.7.6 Automatic operation......................................................................... 23

2.7.7 Enabling device ............................................................................... 24

2.7.8 Hold-to-run control........................................................................... 24

2.7.9 General Mode Safeguarded Stop (GS) connection ......................... 24

2.7.10 Automatic Mode Safeguarded Stop (AS) connection .................... 25

2.7.11 Limiting the working space ............................................................ 25

2.7.12 Supplementary functions ............................................................... 25

2.8 Safety Risks Related to End Effectors ...................................................... 26

2.8.1 Gripper............................................................................................. 26

2.8.2 Tools/workpieces ............................................................................. 26

2.8.3 Pneumatic/hydraulic systems .......................................................... 26

2.9 Risks during Operational Disturbances ..................................................... 26

4 Product Manual IRB 340

2.10 Risks during Installation and Service ...................................................... 26

2.11 Dimensioning the safety fence ................................................................ 28

2.12 Standards of interest when the robot is part of a cell .............................. 28

2.13 Risks Associated with Live Electric Parts................................................ 28

2.13.1 Controller ....................................................................................... 28

2.13.2 Manipulator.................................................................................... 29

2.13.3 Tools, material handling devices, etc............................................. 29

2.14 Emergency Release of Mechanical Arm ................................................. 29

2.15 Limitation of Liability ................................................................................ 29

2.16 Related Information ................................................................................. 29

3 Decommissioning ............................................................................................. 31

3.1 General...................................................................................................... 31

3.1.1 Hazardous material ......................................................................... 31

3.1.2 Oil and Greases............................................................................... 31

4 Installation and Commissioning...................................................................... 33

4.1 Transporting and Unpacking ..................................................................... 33

4.1.1 System CD ROM and Diskette ........................................................ 33

4.2 On-Site Installation .................................................................................... 35

4.2.1 Lifting the Manipulator and Controller.............................................. 35

4.2.2 Assembling the Robot ..................................................................... 36

4.2.3 Stress Forces................................................................................... 38

4.2.4 Amount of Space required ............................................................... 39

4.2.5 Manually engaging the Brakes ........................................................ 39

4.2.6 Mounting Equipment on the Manipulator......................................... 40

4.2.7 Loads............................................................................................... 41

4.2.8 Moving the Robot by hand............................................................... 41

4.2.9 Connecting the controller to the manipulator................................... 44

4.2.10 Dimensioning the safety fence ...................................................... 44

4.2.11 Mains power connection ................................................................ 44

4.2.12 Inspection before start-up.............................................................. 46

4.2.13 Start-up .......................................................................................... 47

4.3 Customer Connections on Manipulator ..................................................... 55

4.3.1 Connection of Extra Equipment to the Manipulator ......................... 58

5 Maintenance ...................................................................................................... 61

5.1 Maintenance Schedule.............................................................................. 62

5.2 Instructions for Maintenance ..................................................................... 62

5.2.1 General Instructions for the Manipulator ......................................... 62

Product Manual IRB 340 5

5.2.2 Telescopic Shaft, Axis 4, Plain Bearings. ........................................ 62

5.2.3 Telescopic Shaft, WashDown and Stainless, Axis 4, Plain Bearing 63

5.2.4 Vacuum System .............................................................................. 63

5.2.5 Bar System...................................................................................... 64

5.2.6 Substitute greases........................................................................... 64

5.2.7 Joint Balls ........................................................................................ 64

5.2.8 Upper Arms ..................................................................................... 65

5.2.9 Hoses .............................................................................................. 65

5.2.10 Spring Units ................................................................................... 65

5.2.11 Movable Plate with Swivel ............................................................. 65

5.2.12 Gearboxes, Axes 1-3..................................................................... 65

5.2.13 Manipulator Fan ............................................................................ 66

5.2.14 Location of Maintenance Points .................................................... 67

5.2.15 Changing the Battery in the Measuring System............................ 68

5.3 Cleaning of Robot ..................................................................................... 70

5.3.1 Standard Cleaning........................................................................... 70

5.3.2 Wash Down Cleaning...................................................................... 70

6 Repairs............................................................................................................... 73

6.1 General Description .................................................................................. 73

6.1.1 Document Guidance........................................................................ 74

6.1.2 Caution ............................................................................................ 75

6.1.3 Mounting Instructions for Bearings and Seals................................. 75

6.1.4 Instructions for Tightening Screw Joints.......................................... 77

6.1.5 Tightening Torques.......................................................................... 78

6.1.6 Checking for Play in Gearboxes and Wrist...................................... 79

6.2 Axis 1, 2 and 3 .......................................................................................... 81

6.2.1 Replacing Motor/Gearbox Unit ........................................................ 81

6.2.2 Exchange of Motor or Gearbox ....................................................... 82

6.2.3 Replacing the Upper Arm................................................................ 83

6.2.4 Replacement of Joint Balls.............................................................. 84

6.3 Axis 4 ........................................................................................................ 87

6.3.1 Replacing Motor/Gearbox Unit ........................................................ 87

6.3.2 Exchange of Motor or Gearbox ....................................................... 87

6.3.3 Replacing the Telescopic Shaft ....................................................... 89

6.3.4 Replacing the Plain Bearings, Washdown and Stainless Ver..........sions ................................................................................................... 90

6.4 Movable Plate with Swivel......................................................................... 93

6.4.1 Dismounting Movable Plate............................................................. 93

6.4.2 Replacement of Joint Balls.............................................................. 93

6 Product Manual IRB 340

6.5 Parallel Arm System .................................................................................. 95

6.5.1 Replacing Parallel Arms................................................................... 95

6.5.2 Replacing the Spring Unit ................................................................ 95

6.5.3 Exchange of Wear Rings ................................................................. 96

6.6 Cabling....................................................................................................... 99

6.6.1 Dismounting the Complete Cabling ................................................. 99

6.6.2 Replacing the Serial Measurement Board ....................................... 99

6.6.3 Replacing Pushbutton Unit and Warning Lamp ...............................100

6.6.4 Replacing the Fan............................................................................100

6.7 Vacuum System.........................................................................................101

6.7.1 Dismounting Ejector Unit .................................................................101

6.7.2 Exchange of Hoses..........................................................................101

6.8 Calibration..................................................................................................103

6.8.1 General ............................................................................................103

6.8.2 Checking the Calibration Position....................................................103

6.8.3 Fine Calibration Procedure on the Teach Pendant ..........................104

6.8.4 Fine Calibration................................................................................105

6.8.5 Updating Revolution Counter...........................................................107

6.8.6 Calibration Equipment......................................................................109

6.9 Corrective action in case of a collision.......................................................111

6.9.1 Overview..........................................................................................111

6.9.2 Telescopic Shaft...............................................................................111

6.9.3 Spring Units......................................................................................112

6.9.4 Rollers..............................................................................................112

6.9.5 Bars .................................................................................................112

6.9.6 Joint Balls.........................................................................................113

6.9.7 Universal Joints................................................................................113

6.10 Special Tools List .....................................................................................115

Introduction

Product Manual 7

1 Introduction

1.1 How to use this Manual

This manual provides information on installation, preventive maintenance, troubleshooting, and how to carry out repairs on the manipulator and controller. Its intended audience is trained maintenance personnel with expertise in both mechanical and electrical systems. The manual does not in any way assume to take the place of the maintenance training course offered by ABB.

Anyone reading this manual should also have access to the User’s Guide.

The chapter entitled System Description provides general information on the robot structure, such as its computer system, input and output signals, etc.

How to assemble the robot and install all signals, etc., is described in the chapter on Installation and Commissioning.

If an error should occur in the robot system, you can find out why it has happened in the chapter on Troubleshooting. If you receive an error message, you can also consult the chapter on System and Error Messages in the User’s Guide. It is very helpful to have a copy of the circuit diagram at hand when trying to locate cabling faults.

Servicing and maintenance routines are described in the chapter on Maintenance.

1.2 What you must know before you use the Robot

Normal maintenance and repair work

Usually requires only standard tools. Some repairs, however, require specific tools. These repairs and the type of tool required, are described in more detail in the chapter Repairs.

The power supply

Must always be switched off whenever work is carried out in the controller cabinet. Note that even though the power is switched off, the orange-coloured cables may be live. The reason for this is that these cables are connected to external equipment and are consequently not affected by the mains switch on the controller.

Circuit boards - printed boards and components

Must never be handled without Electro-Static Discharge (ESD) protection in order not to damage them. Use the wrist strap located on the inside of the controller door.

All personnel working with the robot system must be very familiar with the safety regulations outlined in the chapter on Safety. Incorrect operation can damage the robot or injure someone.

Introduction

8 Product Manual

1.3 Identification

Identification plates indicating the type of robot and serial number, etc., are located on the manipulator (see Figure 1) and on the front of the controller (see Figure 2).

Note! The identification plates and label shown in the figures below, only serve as examples. For exact identification see the plates on the robot in question.

Figure 1 Examples of identification plate and its location on different manipulator types.

IRB 6400R

Identification plate showinthe IRB 6400R / M2000

IRB 140(0)

IRB 640IRB 840/AIRB 340

IRB 4400IRB 2400

Made in SwedenS-721 68 Västerås SwedenABB Robotics Products AB

IRB 6400R M2000

IRB 6400R/2.5-150

XXXXXX

See instructions

6400R-XXXX

2000-XX-XX

2,8-150 : 2240 kg2,8-200 : 2390 kg3.0-100 : 2250 kg

IRB 140

Type:

Robot version:

Man. order:

Nom. load

Serial. No:

Date of manufacturing:

Net weight2,5.120 : 2060 kg2.5-150 : 2060 kg2,5-200 : 2230 kg

Introduction

Product Manual 9

.

Figure 2 Identification plate on the controller.

Made in SwedenS-721 68 Västerås SwedenABB Robotics Products AB

Type:

Robot version:

Voltage: 3 x 400 V

Power:

Man. order:

Re.No:

Serial. No:

Date of manufacturing:

Net weight:

IRB 6400R M2000

IRB 6400R/2.5-150

Frequency: 50-60 Hz

7.2 kVA

XXXXXX

RXXXXXXXXXX

64-XXXXX

2000-XX-XX

240 kg

Introduction

10 Product Manual

1.4 Structure Manipulator

The robot is made up of two main parts, the manipulator and controller. The controller is described in section 1.5.

The Manipulator is equipped with maintenance-free AC motors, which have electromechanical brakes. The brakes lock the motors when the robot is inoperative for more than 1000 hours. The time can be configured by the user.

The following figures show the various ways in which the different manipulators move and their component parts.

Figure 3 The motion patterns of the IRB 1400 and IRB 140.

Motor axis 5Motor axis 6

Motor axis 4

Axis 2

Axis 1

Motor axis 1

Axis 3

Motor axis 2

Motor axis 3

Axis 4 Axis 5

Axis 6

Upper arm

Lower arm

Base

Introduction

Product Manual 11

Figure 4 The motion patterns of the IRB 2400.

Figure 5 The motion patterns of the IRB 4400

Motor unit axis 4Motor unit axis 5

Upper arm

Motor unit andgearbox axis 2

Base


Lower arm

Axis 1

Axis 2

Axis 3Axis 4

Axis 5

Axis 6

Motor unit axis 6


Motor axis 4Motor axis 5Motor axis 6

Axis 2

Axis 1

Motor axis 1

Axis 3

Motor axis 2

Axis 4Axis 5

Axis 6

Upper arm

Lower arm

Base

Motor axis 3

Introduction

12 Product Manual

Figure 6 The motion patterns of the IRB 6400R M99.


Base

Axis 1Lower arm

Axis 2

Motor axis 2

Motor axis 6 Axis 5

Axis 3 Upper arm

Motor axis 5 Motor axis 4

Motor axis 1

Motor axis 3

Axis4

Axis 6

Axis 1

Axis 2

Axis 3

Axis 6

Upper arm

Lower arm

Motor axis 2

Motor axis 6

Motor axis 1

Motor axis 3

Introduction

Product Manual 13

Figure 8 The motion patterns of the IRB 840/A

4(C)-axis

1(X)-axis

2(Y)-axis

3(Z)-axis

Motor 1(X)-axis

Motor 4(C)-axis

Motor 3(Z)-axis

Motor 2(Y)-axis

Introduction

14 Product Manual

.



Axis 2

Axis 1

Axis 3

Axis 4,

Bars (x3)

Upper arm (x3)

telescopic shaftSwivel

Axis 2

Axis 3

X

Y

Z

Base box

Motorsencapsulated

Motor axis 4Motor axis 5Motor axis 6

Axis 2

Axis 1

Motor axis 1

Axis 3

Motor axis 3

Axis 4

Axis 5

Axis 6

Upper arm

Base

Lower arm

Motor axis 2

Structure

Product Manual 15

1.5 Structure Controller

The controller, which contains the electronics used to control the manipulator and peripheral equipment, is specifically designed for robot control and consequently provides optimal performance and functionality.

Figure 11 shows the location of the various components on the cabinet.

Figure 11 The exterior of the cabinet showing the location of the various units.

1.6 Electronics unit

All control and supervisory electronics, apart from the serial measurement board that is located inside the manipulator, are gathered together inside the controller.

Figure 12 The locations of the electronics boards and units behind the front door.

Manipulator connection

Mains switch

Teach pendant

Operator’s panel

Service outlet

ComputerSystem

max.

max.+70°C

Flashdisk

Battery unit

Com

pute

rP

ower

Sup

plyDC

Lin

k

Driv

e un

it 3

Driv

e un

it 2

Driv

e un

it 1

Transformer Opt

iona

l boa

rd 1

-5

Axi

s co

mpu

ter

Mai

n co

mpu

ter

I/O c

ompu

ter

+55°C

Structure

16 Product Manual

1.6.1 The computer system consists of the following parts

Backplane:

One Main computer slot and 7 PCI slots.

Main computer:

Controls the entire robot system. Intel PentiumTM

- CPU. 32 MB DRAM. 10/100 Mb, 7/s Ethernet controller.

Mass Storage:

64 Mb Flash disk, (Optional 128 Mb).

Axis computer:

Control of the manipulator motors.

I/O computer:

Handles I/O communication (CAN, Ethernet, serial links).

Optional boards:

Handles external axis and I/O computers, field bus communication, etc.

Computer power supply:

Four regulated and short-circuit-protected output voltages (±12V, 5V, 3.3V).24V DC Input.

Battery unit:

Rechargeable NiCd battery and battery management card.

1.6.2 Drive system:

DC-link:

converts a three-phase AC voltage to a DC voltage.

Drive unit:

controls the torque of 2-3 motors.

When the maximum capacity for external axes is utilized, a second control cabinet is required. The external axes cabinet comprises AC connection, main switch, contactors, transformer, DC-link, drive module(s), and supply unit, but no computer unit.

Structure

Product Manual 17

Figure 13 The location of units under the top cover.

1.6.3 Miscellaneous

Process power supply

230V AC supply, distributes DC power to computer system.

Panel unit:

Gathers and coordinates all signals that affect operational and personal safety.

I/O units:

Enables communication with external equipment by means of digital inputs and outputs, analog signals, or field buses.

I/O units can alternatively be located outside the cabinet. Communication with robot data is implemented via a stranded wire CAN bus, which allows the units to be positioned close to the process.

Serial measurement board (in the manipulator):

Gathers resolver data and transfers it serially to the robot computer board. The serial measurement board has battery backup so that the revolution information will not be lost during a power failure.

Connector units:

Distributes signals between computer system and process.

Base connector unit

I/O units (x4)

AC connection

Motors On and brake contactors Floppy disk (Opt.)

Connector

Panel unit

Computer System

Structure

18 Product Manual

- Axis computer Drive and Measurement System.

- I/O computer Serial ports, CAN bus, Safety system, TPU.

Axis 3 connector unit (Optional)

- Extra axis computer D and M Sys.

I/O connector unit (Optional)

- Extra I/O computer Serial ports, CAN bus.

Safety

Product Manual 19

2 Safety

2.1 General

This information on safety covers functions that have to do with the operation of the industrial robot.

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.

People who work with robots must be familiar with the operation and handling of the industrial robot, described in the applicable documents, e.g. Users’s Guide and Product Manual.

The diskettes which contain the robot’s control programs must not be changed in any way because this could lead to the deactivation of safety functions, such as reduced speed.

2.1.1 Introduction

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.

2.2 Applicable Safety Standards

The robot is designed in accordance with the requirements of ISO10218, Jan. 1992, Industrial Robot Safety. The robot also fulfils the ANSI/RIA 15.06-1999 stipulations.

2.3 Fire-Extinguishing

Use a CARBON DIOXIDE extinguisher in the event of a fire in the robot (manip-ulator or controller).

Safety Safety

20 Product Manual

2.4 Definitions of Safety Functions

Emergency stop – IEC 60204-1, 10.7

A condition which overrides all other robot controls, removes drive power from robot axis actuators, stops all moving parts and removes power from other dangerous functions controlled by the robot.

Enabling device – ISO 11161, 3.4

A manually operated device which, when continuously activated in one position only, allows hazardous functions but does not initiate them. In any other position, hazardous functions can be stopped safely.

Safety stop – ISO 10218 (EN 775), 6.4.3

When a safety stop circuit is provided, each robot must be delivered with the necessary connections for the safeguards and interlocks associated with this circuit. It is necessary to reset the power to the machine actuators before any robot motion can be initiated. However, if only the power to the machine actuators is reset, this should not suffice to initiate any operation.

Reduced speed – ISO 10218 (EN 775), 3.2.17

A single, selectable velocity provided by the robot supplier which automatically restricts the robot velocity to that specified in order to allow sufficient time for people either to withdraw from the hazardous area or to stop the robot.

Interlock (for safeguarding) – ISO 10218 (EN 775), 3.2.8

A function that interconnects a guard(s) or a device(s) and the robot controller and/or power system of the robot and its associated equipment.

Hold-to-run control – ISO 10218 (EN 775), 3.2.7

A control which only allows movements during its manual actuation and which causes these movements to stop as soon as it is released.

2.5 Safe Working Procedures

Safe working procedures must be used to prevent injury. No safety device or circuit may be modified, bypassed or changed in any way, at any time.

2.5.1 Normal operations

Note! All normal operations in automatic mode must be executed from outside the safe-guarded space.

Safety Safety

Product Manual 21

2.6 Programming, Testing and Servicing

The robot is extremely heavy and powerful, even at low speed. When entering into the robot’s safeguarded space, the applicable safety regulations of the country concerned must be observed.

Operators must be aware of the fact that the robot can make unexpected movements. A pause (stop) in a pattern of movements may be followed by a movement at high speed. Operators must also be aware of the fact that external signals can affect robot programs in such a way that a certain pattern of movement changes without 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 (10 inches/s) when the operat-ing mode selector is in position < 250 mm/s. This should be the normal posi-tion 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.

Check axis by axis in positions where the load of the manipulator arm and the gripper apply the maximum static torque on each axis. Do the brake function test by switching to motors Off when the axis has maximum load and check that the axis maintains its position.

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.

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

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

- The programmer must always take the Teach Pendant Unit with him/her when entering through the safety gate to the robot’s working space so that nobody else can take over control of the robot without his/her knowledge.

2.7 Safety Functions

2.7.1 The safety control chain of operation

The safety control chain of operation is based on dual electrical safety chains which interact with the robot computer and enable the MOTORS ON mode.

Each electrical safety chain consist of several switches connected in such a way that all of them must be closed before the robot can be set to MOTORS ON mode (LIM 1/2, ES1/2, GS 1/2, TPU En1/2, Man1/2, Auto1/2. See section Figure 14 on page 22). The MOTORS ON mode means that drive power is supplied to the motors.

Safety Safety

22 Product Manual

If any contact in the safety chain of operation opens, the robot always reverts to the MOTORS OFF mode. The MOTORS OFF mode means that drive power is removed from the robot’s motors and the brakes are applied.

Figure 14 Safety control chain of operation

The status of the switches is indicated by LEDs on top of the panel unit in the control cabinet and is also displayed on the Teach Pendant Unit (I/O window).

After a stop, the switch must be reset at the unit which caused the stop, before the robot can be ordered to start again.

The safety chains must never be bypassed, modified, or changed in any other way.

2.7.2 Emergency stops

An emergency stop should be activated if there is a danger to people or equipment. Built-in emergency stop buttons are located on the operator’s panel of the robot controller and on the Teach Pendant Unit.

External emergency stop devices (buttons, etc.) can be connected to the safety chain by the user (see Product Manual - Installation and Commissioning). They must be connected in accordance with the applicable standards for emergency stop circuits.

Before commissioning the robot, all emergency stop buttons or other safety equipment must be checked by the user to ensure their proper operation.

Before switching to MOTORS ON mode again, establish the reason for the stop and rectify the fault.

2.7.3 Mode selection using the operating mode selector

The applicable safety requirements for using robots, laid down in accordance with ISO/DIS 10218, are characterised by different modes, selected by means of control devices and with clear-cut positions.

&

&

Interlocking

EN RUN

DriveUnit M

K1 K2

LIM1 LIM2 ES2ES1

GS1 GS2 AS2AS1

TPUEn1

TPUEn2

Man2Man1

Auto1 Auto2

K1 K2

+ +

External contactors

Safety Safety

Product Manual 23

One automatic and two manual modes are available:

The manual mode, < 250 mm/s or 100%, must be selected whenever anyone enters the robot’s safeguarded space. The robot must be operated using the Teach Pendant Unit and, if 100% is selected, using Hold-to-run control.

In automatic mode, the operating mode selector is switched to , and all safety arrangements, such as doors, gates, light curtains, light beams and sensitive mats, etc., are active. Nobody may enter the robot’s safeguarded space. All controls, such as emergency stops, the control panel and control cabinet, must be easily accessible from outside the safeguarded space.

2.7.4 Programming and testing at reduced speed

Robot movements at reduced speed can be carried out as follows:

1. Set the operating mode selector to <250 mm/s

2. Programs can only be started using the Teach Pendant Unit with the enabling device activated.

The automatic mode safeguarded space stop (AS) function is not active in this mode.

2.7.5 Testing at full speed

Robot movements at programmed speed can be carried out as follows:

1. Set the operating mode selector to 100%

2. Programs can only be started using the Teach Pendant Unit with the enabling device activated.

For “Hold-to-run control”, the Hold-to-run button must be activated. Releasing the button stops program execution.

The 100% mode may only be used by trained personnel. The applicable laws and regulations of the countries where the robot is used must always be observed.

2.7.6 Automatic operation

Automatic operation may start when the following conditions are fulfilled:

1. The operating mode selector is set to

2. The MOTORS ON mode is selected

Either the Teach Pendant Unit can be used to start the program or a connected remote control device. These functions should be wired and interlocked in accordance with the applicable safety instructions and the operator must always be outside the safeguarded space.

Manual mode: < 250 mm/s - max. speed is 250mm/s

100% - full speed

Automatic mode: The robot can be operated via a remote control device

Safety Safety

24 Product Manual

2.7.7 Enabling device

When the operating mode selector is in the MANUAL or MANUAL FULL SPEED position, the robot can be set to the MOTORS ON mode by depressing the enabling device on the Teach Pendant Unit.

Should the robot revert to the MOTORS OFF mode for any reason while the enabling device is depressed, the latter must be released before the robot can be returned to the MOTORS ON mode again. This is a safety function designed to prevent the enabling device from being rendered inactive.

When the enabling device is released, the drive power to the motors is switched off, the brakes are applied and the robot reverts to the MOTORS OFF mode.

If the enabling device is reactivated, the robot changes to the MOTORS ON mode.

2.7.8 Hold-to-run control

This function is always active when the operating mode selector is in the MANUAL FULL SPEED position. It is possible to set a parameter to make this function active also when the operating mode selector is in the MANUAL position.

When the Hold-to-run control is active, the enabling device and the Hold-to-run button on the Teach Pendant Unit (TPU) must be depressed in order to execute a program. When the button is released, the axis (axes) movements stop and the robot remains in the MOTORS ON mode.

Here is a detailed description of how to execute a program in Hold-to-run control:

1. Activate the enabling device on the TPU.

2. Choose execution mode using the function keys on the TPU:

- Start (continuous running of the program)

- FWD (one instruction forwards)

- BWD (one instruction backwards)

3. Wait for the Hold-to-run alert box.

4. Activate the Hold-to-run button on the TPU.

Now the program will run (with the chosen execution mode) as long as the Hold-to-run button is pressed. Releasing the button stops program execution and activating the button will start program execution again.

For FWD and BWD execution modes, the next instruction is run by releasing and activating the Hold-to-run button.

It is possible to change execution mode when the Hold-to-run button is released and then continue the program execution with the new execution mode, by just activating the Hold-to-run button again, i.e. no alert box is shown.

If the program execution was stopped with the Stop button on the TPU, the program execution will be continued by releasing and activating the Hold-to-run button.

When the enabling device on the TPU is released, the sequence described above must be repeated from the beginning.

2.7.9 General Mode Safeguarded Stop (GS) connection

The GS connection is provided for interlocking external safety devices, such as light

Safety Safety

Product Manual 25

curtains, light beams or sensitive mats. The GS is active regardless of the position of the operating mode selector.

When this connection is open the robot changes to the MOTORS OFF mode. To reset to MOTORS ON mode, the device that initiated the safety stop must be interlocked in accordance with applicable safety regulations. This is not normally done by resetting the device itself.

2.7.10 Automatic Mode Safeguarded Stop (AS) connection

The AS connection is provided for interlocking external safety devices, such as light curtains, light beams or sensitive mats used externally by the system builder. The AS is especially intended for use in automatic mode, during normal program execution.

The AS is bypassed when the operating mode selector is in the MANUAL or MANUAL FULL SPEED position.

2.7.11 Limiting the working space

Note! Not valid for IRB 340 and IRB 140

For certain applications, movement about the robot’s main axes must be limited in order to create a sufficiently large safety zone. This will reduce the risk of damage to the robot if it collides with external safety arrangements, such as barriers, etc.

Movement about axes 1, 2 and 3 can be limited with adjustable mechanical stops or by means of electrical limit switches. If the working space is limited by means of stops or switches, the corresponding software limitation parameters must also be changed. If necessary, movement of the three wrist axes can also be limited by the computer software. Limitation of movement of the axes must be carried out by the user.

2.7.12 Supplementary functions

Functions via specific digital inputs:

- A stop can be activated via a connection with a digital input. Digital inputs can be used to stop programs if, for example, a fault occurs in the peripheral equipment.

Functions via specific digital outputs:

- Error – indicates a fault in the robot system.

- Cycle_on – indicates that the robot is executing a program.

- MotOnState/MotOffState – indicates that the robot is in MOTORS ON / MOTORS OFF mode.

- EmStop - indicates that the robot is in emergency stop state.

- AutoOn - indicates that the robot is in automatic mode.

Safety Safety

26 Product Manual

2.8 Safety Risks Related to End Effectors

2.8.1 Gripper

If a gripper is used to hold a workpiece, inadvertent loosening of the workpiece must be prevented.

2.8.2 Tools/workpieces

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.

Grippers must be designed so that they retain workpieces in the event of a power failure or a disturbance of the controller. It should be possible to release parts by manual operation (valves).

2.8.3 Pneumatic/hydraulic systems

Special safety regulations apply to pneumatic and hydraulic systems.

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

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

2.9 Risks during Operational Disturbances

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.

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

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 applicable safety regulations. Care must be taken at all times.

2.10 Risks during Installation and Service

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

Safety Safety

Product Manual 27

Note! 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. Special attention must be paid to the following points:

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

- 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.

- 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.

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

- 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 away from the robot’s working space.

- 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.

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.

Even if the power supply for the robot is turned off, you can still injure yourself.

- 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 tie rod.

- 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 energy (DC link) and hot parts in the controller.

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

Safety Safety

28 Product Manual

2.11 Dimensioning the safety fence

A safety fence must be fitted around the robot to ensure a safe robot installation. The fence must be dimensioned to withstand the force created if the load being handled by the robot is dropped or released at maximum speed. The maximum speed is determined from the maximum velocities of the robot axes and from the position at which the robot is working in the workcell (see Product Specification - Description, Robot Motion).

Applicable standards are ISO/DIS 11161 and prEN 999:1995.

2.12 Standards of interest when the robot is part of a cell

2.13 Risks Associated with Live Electric Parts

2.13.1 Controller

A danger of high voltage is associated with the following parts:

- The mains supply/mains switch

- The power unit

- The power supply unit for the computer system (55VAC)

- The rectifier unit (260VAC and 370V DC. NB: Capacitors!)

- The drive unit (370V DC)

- The service outlets (115/230VAC)

- The power supply unit for tools, or special power supply units for the machin-ing process

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

- Additional connections

EN 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 - Inter locking device associated with guards principles for design and selection.

Table 1 Standards of interest when the robot is part of a cell

Safety Safety

Product Manual 29

2.13.2 Manipulator

A danger of high voltage is associated with the manipulator in:

- The power supply for the motors (up to 370V DC)

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

2.13.3 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.

2.14 Emergency Release of Mechanical Arm

If an emergency situation occurs where a person is trapped by the mechanical robot arm, the brake release buttons should be pressed whereby the arms can be moved to release the person. To move the arms by manpower is normally possible on the smaller robots (1400 and 2400), but for the bigger ones it may not be possible without a mechanical lifting device such as an overhead crane.

If power is not available the brakes are applied and therefore manpower may not be sufficient for any robot.

Before releasing the brakes, be sure that the weight of the arms does not enhance the pressure on the trapped person.

2.15 Limitation of Liability

The above information regarding safety must not be construed as a warranty by ABB Robotics that the industrial robot will not cause injury or damage even if all safety instructions have been complied with.

2.16 Related Information

Described in:

Installation of safety devices Product Manual - Installation and Commissioning

Changing robot modes User’s Guide - Starting up

Limiting the working space Product Manual - Installation and Commissioning

Safety Safety

30 Product Manual

Decomissioning

Product Manual 31

3 Decommissioning

3.1 General

The components of the robot are manufactured from many different materials. Some of them are listed below to facilitate scrapping, i.e. so that the components can be disposed of in a way that does not have a detrimental effect on anyone’s health or on the environment.

3.1.1 Hazardous material

3.1.2 Oil and Greases

Where possible, arrange for the oil and grease to be recycled. Dispose of via an authorized person/contractor in accordance with local regulations. Do not dispose of oil and grease near lakes, ponds, ditches, down drains or on to soil. Incineration must be carried out under controlled conditions in accordance with local regulations.

Also note the following:

o Spills may form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired.

o Spillage may penetrate the soil causing ground water contamination.

Material Example application

Lithium or NiCad Batteries Serial meausurement board

Copper Cables, motors

Cast iron/Nodular iron Base, lower arm, upper arm, parallel bar/arm

Steel Gears, screws, baseframe

Neodymium Brakes, motors

Plastic/Rubber (PVC)/Composites Cables, connectors, parallel bars

Oil, Grease Gearboxes

Aluminium Covers, sync. brackets

Decomissioning Decommissioning

32 Product Manual

Installation and Commissioning

Product Manual 33

4 Installation and Commissioning

4.1 Transporting and Unpacking

NB!Before starting to unpack and install the robot, read the safety regulations and other instructions very carefully. These are found in separate sections in the User’s Guide and Product manual.

The installation shall be made by qualified installation personnel and should conform to all national and local codes.

When you have unpacked the robot, check that it has not been damaged during transport or while unpacking.

Check especially following items:

- Composite arms (upper arms and bar system); no hacks

- Joint balls; no scratches

- Ventilation hose; no holes

Operating Conditions

Ambient temperature + 5°C (41°F) to +52°C (125°F) (manipulator)

Relative humidity Max. 95% at constant temperature

Storage Conditions

If the equipment is not going to be installed straight away, it must be stored in a dry area at an ambient temperature between -25°C (13°F) and +55°C (131°F).

When air transport is used, the robot must be located in a pressure-equalized area.

The net weight of the different variants of the manipulator is approximately:

- Standard and WashDown : 140 kg (308.4 pounds)

- Stainless : 165 kg (364 pounds)

Whenever the manipulator is transported, it must be in mounting position, it’s not allowed to turn the manipulator up side down.

4.1.1 System CD ROM and Diskette

The system CD ROM and the manipulator parameter disk are delivered with the robot system.

See Product Manual for S4Cplus or IRC5 Procedures, “Installation and Commis-sioning”.

Installation and Commissioning

34 Product Manual

Product Manual 35

4.2 On-Site Installation

4.2.1 Lifting the Manipulator and Controller

Never walk under a suspended load!

The best way to lift the manipulator is to use lifting straps and a traverse crane. Attach the straps to the three lifting eyes on the base box (see Figure 15). The lifting strap dimensions must comply with the applicable standards for lifting.

Figure 15 Lifting the Manipulator using a Traverse Crane.

L=1000 mm / 40 inchVentilation hose

Crane lift

36 Product Manual

It is also possible to lift the manipulator using a fork lift. To do that let the manipulator rest in its standard delivery loading stool.

Figure 16 Lifting the Manipulator using a Fork Lift.

4.2.2 Assembling the Robot

Manipulator

The three support points of the manipulator base box shall be mounted against three flat surfaces with a flatness within the specification. Use shims if necessary. The rest of the surface must be flat within ± 2 mm. Footprint diagram, see Figure 17. The levelness requirement for the surface is as follows:

Fork lift

0.5

Product Manual 37

Figure 17 Bolting the Manipulator (Dimensions in mm).

The manipulator is fixed with three M16 bolts, tightened alternately.

Suitable bolts:Standard and Stainless versions:

M16x45 8.8 Socket screw with washer(The length of the screws depends on the design of the frame.)

Wash Down version:

The bolts’ length shall be selected to protrude through themounting flange, and shall be sealed with Loctite or equal.

67 o

26

39Axis 3

Axis 1

Axis 2

A A

A

AA

A

R 370

120 o(3x)

M16

A - A

4012

25 H

8 (+

0.03

3 )

Clamping plane

30o

Y

X0

= Available footprint of frame

Area for calibration tool

The amount ofspace is shownin Figure 4.

38 Product Manual

Tightening torque:150 Nm (oil lubricated)

Guide sleeves (Art.No 3HAC9519-1) can be added to two optional holes of the three bolt holes, to allow the same manipulator to be re-mounted without program adjustment (see Figure 17).

The screw joint must be able to withstand the stress loads defined in Section 4.2.3 below.

Mounting the Arm System and movable Plate

After the manipulator has been mounted, as described in Section above, the arm system and movable plate are assembled according to Repairs chapter Section 6.4.

Mounting the Telescopic Shaft, Axis 4

After the arm system has been mounted, as described in Section above, the telescopic shaft is assembled as described in Repairs chapter, Section 6.3.3.

Mounting the Ventilation Hose

Standard

Mount the ventilation hose (see Figure 15) with two hose clips, 3HAC 4428-1, supplied with the robot.

Wash Down and Stainless

Wash Down ventilation hose is already fitted. If External Air Connection (option 061) is ordered, the Wash Down ventilation has to be exchanged and the same screws will be used to mount the new, tightening torque 4 Nm.

Hose to Tool Point

Mount the hose from the air filter down to the movable plate as described in foldout 7. See Foldouts in part 2 of this manual, Reference Information.

4.2.3 Stress Forces

Stiffness

The stiffness of the frame must be designed to minimize the influence on the dynamic behaviour of the robot. For optimal performance the frequency of the frame with the robot weight must be higher than 17 Hz.

TuneServo can be used for adapting the robot tuning to a non-optimal foundation.

Forces

Maximum force in each fixing point are 500 N referring to the z-direction in the base coordinate system, regarding coordinate system see the Product Specification for IRB 340.

A robot frame is not included in the delivery.

Product Manual 39

4.2.4 Amount of Space required

The amount of space required to operate the manipulator is illustrated in Figure 18.

Manipulator

Figure 18 The amount of Space required for the Manipulator.

4.2.5 Manually engaging the Brakes

All axes (except ax 4) come equipped with holding brakes. When the position of a manipulator axis needs to be changed without connecting the controller, an external voltage supply (24 V D.C.) must be connected to enable engagement of the brakes. The voltage supply should be connected to the FCI connector under the cover (see Figure 19).

Figure 19 Connection of External Voltage to enable Engagement of the Brakes.

When the controller or the voltage device is connected, illustrated above, the brakes can be engaged by means of the push-button, location shown in Figure 20.

324

270

795

1160

∅ 1246

39734

R=362.5

12

4 5 6

78 9 1

10 11 12

13 14 15

3

Internal connectorFCI connector: R1.MP4-6

0 V

+ 24 V D.C.

NOTE!Be careful not to interchange the 24 V- and 0 V pins. If they are mixed up, damage can be caused to electrical components.

40 Product Manual

Figure 20 Location of Brake Release Button.

4.2.6 Mounting Equipment on the Manipulator

External equipment, for example hoses and wiring mounted on the arms of the manipulator must have a maximum weight of 300 g/m, see also the Product Specification for IRB 340.

NB! Never drill a hole in the manipulator without first consulting maintenance staff or the design department at ABB.

Figure 21 The mechanical Interface (Mounting Flange).

Table 2 Location of Brake Release Button

A Brake Release Button

A

Mounting flange R3/8”, depth 14 mmØ25

Ø52

2xR1/4”

Key grip = Width 22/h7 mmHeight 6 mm

(Whitworth ISO-228/1)

Product Manual 41

4.2.7 Loads

It is important to define the loads properly (with regard to the position of centre of gravity and inertia factor) in order to avoid breakdown of arm system.

For more information see the Product Specification for IRB 340 for load diagrams, permitted extra loads (equipment) and their positions. The loads must also be defined in the software, see User’s Guide.

4.2.8 Moving the Robot by hand

Note! If any emergency situation occurs and the robot has to be moved by hand, please follow the suggestions below!

Overview

Moving the IRB 340 by hand may cause sever damage to the robot. If the robot is moved by hand outside it´s working envelope, parts on the robot may be damaged. Below are some examples of parts that can be damaged.

Extreme Position of Robot Arm

In order to prevent damage it is important not to step over the extreme position of the robot arm or exceed the extreme values of the angles. See illustration below!

Figure 22 Extreme values of angles

Mechanical Stop

When angle V = -57° is mechanical stop reached.

Table 3

Position P1 Position P2

U = 100° U = -46.1°

V = 95.5° V = -50.6°

W = 134.5° W = 43.9°

42 Product Manual

Below are some examples of parts that can be damaged if the instructions above not are followed!

Universal Joints

Upper and/or lower universal joints may be damaged if the angle is greater than 45 degrees. When the robot is moved by hand outside the working area, the universal joint is forced to be the mechanical stop of the axis. The universal joint is not designed to operate at angles greater than 45 degrees. As a result of the applied forces to the bearings and other parts, the universal joint(s) can be destroyed.

Forks on the Spring Units

The forks on the spring units, can be bent apart, when the robot is moved by hand. This occurs when the cylinder of the spring unit gets jammed against the upper arms. This will force the forks to spread apart.

A broken fork cannot keep the rollers in place and secure a proper function of the robot arm. When the forks are destroyed the roller caps may fall out the next time the robot is moved by hand. This can also occur randomly during production.

Product Manual 43

Using the Teach Pendant to move the Robot

Using the teach pendant to move the robot, will assure that the robot never exceeds the working envelope.

A sticker according to the picture below can be ordered from ABB After Sales. Article no. 3HAC 4613-1.

We recommend operators to use the teach pendant to move the robot. If the operators normally not are using the teach pendant, the bottom part of the sticker can be cut away.

WashDown cleaning

WashDown cleaning and procedures according to the Maintenance chapter in this Product Manual, should be followed! See Section 5.3.2

44 Product Manual

4.2.9 Connecting the controller to the manipulator

Two cables are used to connect the controller to the manipulator, one for measuring signals and the other for motor and brakes.

The connection on the manipulator is located on the rear of the robot base.

Connection on left-hand side of cabinet

The cables are connected to the left side of the cabinet using an industrial connector and a Burndy connector (see Figure 23). A connector is designated XP when it has pins (male) and XS when it has sockets (female). A screwed connection is designated XT.

Figure 23 Connections on the cabinet wall.

4.2.10 Dimensioning the safety fence

A safety fence must be fitted around the robot to ensure a safe robot installation. The fence must be dimensioned to withstand the force created if the load being handled by the robot is dropped or released at maximum speed. The maximum speed is determined from the max. velocities of the robot axes and from the position at which the robot is working in the workcell. See Product Specification, section 3.8. The max. speed for a load mounted on the IRB 340 is 10 m/s.

Applicable standards are ISO/DIS 11161 and prEN 999:1995.

4.2.11 Mains power connection

Before starting to connect the mains, make sure that the other end of the cable is disconnected from the line voltage.

The power supply can be connected either inside the cabinet, or to a optional socket on the left-hand side of the cabinet or the lower section of the front. The cable connector is supplied but not the cable. The mains supply cables and fuses should be dimensioned in accordance with rated power and line voltage, see rating plate on the controller.

Connection to the mains switch

Remove the left cover plate under the top lid. Pull the mains cable (outer diameter

XS2XS1

Motor cable, XP1

Measurement cable, XP2

Product Manual 45

10.20 mm) through the gland (see Figure 24) located on the left cabinet wall.

Figure 24 Mains connection inside the cabinet.

Connect as below: For more information, also see Circuit Diagram in part 2 of this manual, Reference Information.

1. Release the connector from the knob by depressing the red button located on the upper side of the breaker (see Figure 24).

2. Connect phase:

NOTE!

Max. conductor size is 6 mm2 (AWG 10). Tighten torque 2.3-2.5 Nm.

Retighten after approx. 1 week.

3. Snap the breaker on the knob again and check that it is fixed properly in the right position.

4. Tighten the cable gland.

5. Fasten the cover plate.

Connection via a power socket

You can also connect the mains supply via an optional wall socket of type CEE 3x16 and 3x32 A, or via an industrial Harting connector (DIN 41 640). See Figure 25.

Table 4

1 to L1 N.B. Not dependent on phase sequence.

2 to L2

3 to L3

0 to XT26.N line neutral is needed only for option 432

Protective earth to earth sign

PE

Cable gland

Connector

XT 26

46 Product Manual

Cable connectors are supplied (option 133 - 134).

Figure 25 Mains connection via an optional wall socket.

4.2.12 Inspection before start-up

Before switching on the power supply, check that the following have been performed:

1. The robot has been properly mechanically mounted and is stable

2. The controller mains section is protected with fuses.

3. The electrical connections are correct and corresponds to the identification plate on the controller.

4. The teach pendant and peripheral equipment are properly connected.

5. That limiting devices that establish the restricted space (when utilized) are installed.

6. The physical environment is as specified.

7. The operating mode selector on the operator’s panel is in Manual mode position.

When external safety devices are used check that these have been connected or that the following circuits in either XS3 (connector on the outside left cabinet wall) or X1-X4 (screw terminals on the panel unit) are strapped:

For more information, see Product Manual for S4Cplus or IRC5.

Table 5

XS3 Panel unit

External limit switches A5-A6, B5-B6 X1.3-4, X2.3-4

External emergency stop A3-A4, B3-B4 X1.9-10, X2.9-10

External emergency stop internal 24 V

A1-A2, B1-B2 X1.7-8, X2.7-8

General stop + A11-A12, B11-B12 X3.10-12, X4.10-12

General stop - A13-A14, B13-B14 X3.7-8, X4.7-8

Auto stop + A7-A8, B7-B8 X3.11-12, X4.11-12

Auto stop - A9-A10, B9-10 X3.7-9, X4.7-9

Motor off clamping A15-A16, B15-16 X1.5-6, X2.5-6

CEE connector DIN connector

Product Manual 47

4.2.13 Start-up

General

1. Switch on the mains switch on the cabinet.

2. The robot performs its self-test on both the hardware and software. This test takes approximately 1 minute.

If the robot is supplied with software already installed, proceed to pos. 3 below. Otherwise continue as follows (no software installed):

- Connect the batteries for memory backup (see Figure 26).

Install the software as described in Product Manual for S4Cplus or IRC5.

Figure 26 Location of batteries, view from above.

3. A welcome message is shown on the teach pendant display.

4. To switch from MOTORS OFF to MOTORS ON, press the enabling device on the teach pendant.

5. Update the revolution counters according to Section .

6. Check the calibration position according to Section .

7. When the controller with the manipulator electrically connected are powered up for the first time, ensure that the power supply is connected for at least 36 hours continuously, in order to fully charge the batteries for the serial measurement board.

After having checked the above, verify that

8. the start, stop and mode selection (including the key lock switches) control devices function as intended.

9. each axis moves and is restricted as intended.

10. emergency stop and safety stop (where included) circuits and devices are functional.

11. it is possible to disconnect and isolate the external power sources.

12. the teach and playback facilities function correctly.

13. the safeguarding is in place.

14. in reduced speed, the robot operates properly and has the capability to handle the

Batteries

Connect the batteries to the connectors X3 and X4, situated below the batteries.

48 Product Manual

product or work piece, and

15. in automatic (normal) operation, the robot operates properly and has the capability to perform the intended task at the rated speed and load.

16. The robot is now ready for operation.

Updating the revolution counter

When pressing the enabling device on a new robot, a message will be displayed on the teach pendant telling you that the revolution counters are not updated. When such a message appears, the revolution counter of the manipulator must be updated using the calibration marks on the manipulator (see Figure 31).

Examples of when the revolution counter must be updated:

- when one of the manipulator axes has been manually moved with the control-ler disconnected.

- when the battery (on the manipulator) is empty.

- when there has been a resolver error

- when the signal between the resolver and the measuring panel unit has been interrupted

WARNING: Working inside the robot working range is dangerous.

Press the enabling device on the teach pendant and, using the joystick, manually move the robot so that the calibration marks lie within the tolerance zone. For axes 1-3 the pin should be inside the nut and for axis 4, the marks must be in line (see Figure 31).

When all axes have been positioned as above, the revolution counter settings are stored using the teach pendant, as follows:

1. Press the Misc. window key (see Figure 27).

Figure 27 The Misc. window key from which the Service window can be chosen.

2. Select Service in the dialog box shown on the display.

3. Press Enter .

21

2 3

0

1

4 5 6

7 8 9

P3

P1 P2

Product Manual 49

4. Then, choose View: Calibration. The window in Figure 28 appears.

Figure 28 This window shows the status of the revolution counters.

If there are several units connected to the robot, these will be listed in the window.

5. Select the desired unit in the window, as in Figure 28. Choose Calib: Rev. Counter Update. The window in Figure 29 appears.

Figure 29 The dialog box used to select axes whose revolution counters are to be updated.

6. Press the function key All to select all axes if all axes are to be updated. Otherwise, select the desired axis and press the function key Incl (the selected axis is marked with an x).

IRB Not rev. counter update

File Edit View Calib

1(1)

Service Calibration

Unit Status

X 1 Not updated Rev. CounterX 2 Not updated Rev. Counter

3 Calibrated4 Calibrated

X 5 Not updated Rev. CounterX 6 Not updated Rev. Counter

Incl All Cancel OK

1(6)

Rev. Counter Update!IRBTo calibrate, include axes and press OK.

Axis Status

50 Product Manual

7. Confirm by pressing OK. A window like the one in Figure 30 appears.

Figure 30 The dialog box used to start updating the revolution counter.

8. Start the update by pressing OK.

If a revolution counter is incorrectly updated, it will cause incorrect positioning. Thus, check the calibration very carefully after each update. Incorrect updating can damage the robot system or injure someone.

9. Check the calibration position as described in Section .

10.Save the system parameters on floppy disk.

Cancel OK

Rev. Counter Update!IRB

The Rev. Counter for all marked axes will be update.It cannot be undone.

OK to continue?

Product Manual 51

Figure 31 Calibration marks on the manipulator.

These marks are intended only for resolver counter update. See Section 6.8 in Repairs chapter.

Checking the calibration position

There are two ways to check the calibration position and they are described below.

Using the diskette, Controller Parameters:

Run the program \ SERVICE \ CALIBRAT \ CAL 340 on the diskette, follow instructions displayed on the teach pendant. When the robot stops, switch to MOTORS OFF. Check that the calibration marks for each axis are at the same level, see Figure 31. If they are not, the setting of the revolution counters must be repeated.

Using the Jogging window on the teach pendant:

Open the Jogging window and choose running axis-by-axis. Using the joystick, move the robot so that the read-out of the positions is equal to -13,2 degrees. Check that the calibration marks for each axis are at the same level, see Figure 31. If they are not, the setting of the revolution counters must be repeated.

Calibration mark, axes 1-3

Calibration mark, axis 4

Nut

Pin

Calibration marks

52 Product Manual

Operating the robot

Starting and operating the robot is described in the User’s Guide. Before start-up, make sure that the robot cannot collide with any other objects in the working space.

Defining working area

To Define the Working area.

• Press the Miscellaneous key to open the System Parameters window.

• Select System Parameters from the dialog box that appears.

• Press OK or Enter .

• Choose Topics: Manipulator


• Choose Types: Robot


Type the desired values for Upper and Lower work area on axes x, y, and z.

Work area restrictions in x and y directions, (max. 0.566 m) and (min. -0.566 m) and in z direction (max. 1.11 m) and (min. 0.86 m).

The default working areas for the x and y directions are ± 0.4 m.

Figure 32 Working area restrictions for x and y directions

x

y

Axis 1

Axis 2

Axis 3R = 0.566

Upper Work Area y

Lower Work Area y

Upper work area xLower work area x

Marked area = actual working areawith this configuration

Product Manual 53

The default working area in the z direction is +860 mm to +1160 mm.

Figure 33 Working area restrictions for z direction

z

Marked area = actual working arear 1014

+1160 mm

+1110 mm+.860 mm

ø967mm

ø1132 mm

54 Product Manual

Customer connections

Product Manual 55

4.3 Customer Connections on Manipulator

Two Options of Customer Connections are available.

1. Option 218-5Signals and power. Number of signals: 23 signals (49 V, 250 mA), 10 power signals (250 V, 2 A). Cable between manipulator and controller not supplied.Also see Section 4.3.1 below.

2. Option 218-9A vacuum system, including three signals: grip, drop and vacuum level guard. The signals are connected to one 12-pole screw terminal in the controller. The cable between the manipulator and the controller is included. See the Product Specification for IRB 340, Chapter 2, Specification of Variants and Options for further information.

Air supply: Regarding air quality, only use dry and clean air. Maximum particle size 5 µm

Figure 34 Location of Customer Connections.

To connect to power and signal conductors from the connection unit to the manipulator, the following parts are recommended:

Table 6 Connector R2.CS - Recommended connecting Parts

Connector R2.CS. Signals on Manipulator. (Regarding Item No. see Figure 35)

Item Name ABB Art. No. Type Comments

1 Socket con. 23p 3HAC 7446-4 UTO 018 23 SHT FCI

Option 218-5

R2.CP

R2.CS

R1.CS

Air

Vacuum system, option 218-9

Note! R1.CS are not the same contact for option 218-5 and 218-9

R1.CPR1.CS(undercover)


56 Product Manual

2 Gasket 2152 0363-5 UTFD 16 B FCI

3 Socket See Table 8 below

4 Pin con. 23p 3HAA 2602-3

5217 649-34

UTG 061823 P04T

UTG 61823 PN

FCI EMC

FCI

5 Pin See Table 8 below

6 Adaptor 3HAA 2601-3 UTG 18 ADT FCI EMC

7 Cable clamp 5217 649-36 UTG 18 PG FCI

8 Shrinking hose

Shrinking hose

3HAA 2614-3

5217 1032-5

Bottled shaped

Angled

Table 6 Connector R2.CS - Recommended connecting Parts

Connector R2.CS. Signals on Manipulator. (Regarding Item No. see Figure 35)



Product Manual 57

Table 7 Connector R2.CP - Recommended connecting Parts

Connector R2.CP. Power Signals on Manipulator. (Regarding Item No. see Figure 35)


1 Socket con. 12p 3HAC 7446-4 UTO 014 12 SHT FCI

2 Gasket 21520363-3 UTFD 13 B FCI

3 Socket See Table 8 below

4 Pin con. 12p 3HAA 2602-2

5217 649-7

UTO 61412 PN04

UTO 61412 PN

FCI EMC

FCI

5 Pin See Table 8 below

6 Adaptor 3HAA 2601-2 UTG 14 ADT FCI EMC

7 Cable clamp 5217 649-8 UTG 14 PG FCI

8 Shrinking hose

Shrinking hose

3HAA 2614-2

5217 1032-4

Bottled shaped

Angled

Table 8 Recommended Pins and Sockets

Name ABB Part No. Type Comments

Pin 5217 649-72

5217 649-25

5217 649-70

5217 649-3

5217 649-68

5217 649-10

5217 649-31

24/26

24/26

20/22

20/22

16/20

24/26

16/20

FCI Machine tooling

FCI Hand tooling

FCI Machine tooling

FCI Hand tooling

FCI Machine tooling

FCI Ground

FCI Ground

Socket 5217 649-73

5217 649-26

5217 649-71

5217 649-69

5217 1021-4

5217 1021-5

24/26

24/26

20/22

16/18

DIN 43 652

DIN 43 652

FCI Machine tooling

FCI Hand tooling

FCI Machine tooling

FCI Machine tooling

Tin bronze (CuSu)

0.14 - 0.5mm2 AWG 20-26

Tin bronze (CuSu)

0.5 - 1.5mm2 AWG 16-20


58 Product Manual

Figure 35 FCI Connector

4.3.1 Connection of Extra Equipment to the Manipulator

Technical data for customer connections.

Customer Power CP

Conductor resistance<0,5 ohm, AWG 20 0,56 mm2

Max. voltage250V A.C.Max. current2 A

Customer Signals CS

Conductor resistance<3 ohm, AWG 20 0.56 mm2Max. voltage50V A.C. / D.C.Max. current250 mA

Connections on Manipulator

Figure 36 Customer Connections.

Customer side 4, 5

1, 3

2

7

68

Manipulator side

R2.CS

R2.CP


Product Manual 59

Table 9

Signal Name Customer Terminal Controller

(see Chapter 8, Installation and Commissioning, 2.6 Connection to Screw Terminal)

Customer Contact on Manipulator

(Cable not supplied)

Power supply

CPA XT6:1 R2.CP:A

CPB XT6:2 R2.CP:B

CPC XT6:3 R2.CP:C

CPD XT6:4 R2.CP:D

CPE XT6:5 R2.CP:E

CPF XT6:6 R2.CP:F

CPJ XT6:7 R2.CP:J

CPK XT6:8 R2.CP:K

CPL XT6:9 R2.CP:L

CPM XT6:10 R2.CP:M

PE R2.CP:G

Signals

CSA XT5.1:1 R2.CS:A

CSB XT5.1:2 R2.CS:B

CSC XT5.1:3 R2.CS:C

CSD XT5.1:4 R2.CS:D

CSE XT5.1:5 R2.CS:E

CSF XT5.1:6 R2.CS:F

CSG XT5.1:7 R2.CS:G

CSH XT5.1:8 R2.CS:H

CSJ XT5.1:9 R2.CS:J

CSK XT5.1:10 R2.CS:K

CSL XT5.1:11 R2.CS:L

CSM XT5.1:12 R2.CS:M

CSN XT5.2:13 R2.CS:N

CSP XT5.2:14 R2.CS:P

CSR XT5.2:15 R2.CS:R

CSS XT5.2:16 R2.CS:S

CST XT5.2:17 R2.CS:T

CSU XT5.2:18 R2.CS:U

CSV XT5.2:19 R2.CS:V

CSW XT5.2:20 R2.CS:W

CSX XT5.2:21 R2.CS:X

CSY XT5.2:22 R2.CS:Y

CSZ XT5.2:23 R2.CS:Z


60 Product Manual

Maintenance

Product Manual 61

5 MaintenanceThe robot is designed to be able to work under very demanding conditions with a minimum of maintenance. Time between services can vary depending on the influence of the environment the robot is exposed for. Always check that joints and rods are well lubricated.

We strongly recommend that at every stop in production and after every wash down, the robot is inspected concerning the following parts:

Nevertheless, certain routine checks and preventative maintenance must be carried out at specified periodic intervals, as shown in the table below.

• The exterior of the robot should be cleaned as required. Use a vacuum cleaner or wipe it with a cloth. Compressed air and harsh solvents that can damage the sealing joints, bearings, lacquer or cabling, must not be used.

• Check that the sealing joints and cable glands are really airtight so that dust and dirt are not sucked into the cabinet.

• Lubricate sealings at regular intervals and when needed, recommended lubrication see 5.2.5.

Tabell 10

Inspect regularly:

Telescopic shaft

Spring Units

Rollers

Bars

Joint Balls

Universal Joints

Maintenance

62 Product Manual

5.1 Maintenance Schedule

5.2 Instructions for Maintenance

Numbers inside < > refers to maintenance points on the manipulator, see Figure 39.

5.2.1 General Instructions for the Manipulator

Check regularly:

• Wear of plain bearings in telescopic shaft (SA, SAS versions).

• Wear of bearing ring in joints of the arm system, lubricate.

• For any oil leaks. If a major oil leak is discovered, call for service personnel.

• For excessive play in gears. If play develops, call for service personnel.

• That the cabling between the control cabinet and robot is not damaged.

Cleaning:

• Clean the robot exterior with a cloth when necessary. Do not use aggressive solvents which may damage paint or cabling.

• Cleaning instructions for Wash Down version see 5.3.

5.2.2 Telescopic Shaft, Axis 4, Plain Bearings.

Interval 500 h

Table 11 Maintenance Intervals

Prescribed Maintenance Maintenance Intervals

Checkevery 500 h

4,000 h or 2 years

12,000 hor 3years

30,000 h or5years

Telescopic shaft, axis 4 X X

Vacuum system X 1

1. Only if option is chosen. Change interval is depending on the material in picked objects. Porous objects may cause shorter cleaning intervals.

X

Bar system X X

Upper arms X

Spring unit X

Movable plate with swivel X

Gearboxes, axes 1, 2, and 3 X X

Manipulator fan X 2

2. Check roller bearing.

Accumulator for measur-ing system Exchange

3 years 3

3. See section 5.2.15.

Maintenance

Product Manual 63

Apply grease at <1>.

Type of grease: Mobilgrease FM 102 (see 5.2.6)Optimol Obeen UF 2 (see 5.2.6)

Volume: 1.3 ml

Check and retighten set screws.

Interval 4,000 h or 2 Years

Exchange the part as described in Repairs chapter, section 6.3.4.

5.2.3 Telescopic Shaft, WashDown and Stainless, Axis 4, Plain Bearing

The wear on the bearings depends on the payload, cycle, environment, and lubrication.

Interval 500 h

Rods

Check the wear of the rods on the inside of the plain bearing. If the rods are damaged or worn out, replace the telescopic shaft as described in Repairs chapter section 6.3.3.

Apply a small amount of grease on the rods.

Plain Bearing

If the plain bearings are worn out or if the backlash is excessive, replace the plain bearings as described in Repairs chapter section 6.3.4.


If necessary, replace the parts as described in Repairs chapter.

Type of grease: Mobilgrease FM 102 (see 5.2.6)Optimol Obeen UF 2 (see 5.2.6)

5.2.4 Vacuum System

Use only unlubricated air.

Interval 500 h

Empty air filter <3> and check the position of the clamps <4> for the hose. The correct position for the outer clamps is 150 mm from joints.

Check that the air supply is dry and clean. Particle size must not exceed 5 µm!


Replace pneumatic valves <16>. The service life of the valves is 4x107 cycles.

Article number for:

Air filter: 3HAC 3718-1

Pneumatic valve unit: 3HAC 8030-4, PIAB

Maintenance

64 Product Manual

5.2.5 Bar System

The wear on the wear rings depends on the payload, cycle, environment, and lubrication.

Interval 500 hrs or 1 year.

Check wear rings <5>. Listen for screeching. If necessary apply grease.

Type of grease: Mobilgrease FM 102Optimol Obeen UF 2

Volume: 0.5 ml

Interval 4,000 hrs or 2 Years

Check surface of tube <10> for cracks or damages.

Check the distance between the wear ring holders <11>.

Normal dimension should be 126 mm. If distance is less than 124 mm, the ring is worn out and must be replaced, see Figure 37.

If necessary, replace parts as described in Chapter 6, Repairs in this manual.

Figure 37 Wear Ring Holder Distance

5.2.6 Substitute greases

Robots installed in application that not requires FDA approwed grease can use greases stated below as substitute (the grease should be of type NLGI 2):

Type of grease: Mobilgrease SpecialMobilegrease XHP 222

Olista Longtime 2Optimol Longlife PD 2

5.2.7 Joint Balls

Check surface of joint balls <13, 14> for cracks or burrs. If necessary replace the part as described in Chapter 6, Repairs in this manual.

126 mm

Maintenance

Product Manual 65

5.2.8 Upper Arms

Check the surface of tube <12>, no cracks.

If necessary exchange the part as described in Chapter 6, Repairs in this manual.

5.2.9 Hoses

Interval 500 hrs

Check the entire hose <6> so that there are no folds or surface damage.


5.2.10 Spring Units

Check the roller <7> for wear.


5.2.11 Movable Plate with Swivel

Check the axis rotation joint <15> so that the rotation is smooth.

If necessary, replace the part as described in Chapter 6, Repairs in this manual.

5.2.12 Gearboxes, Axes 1-3


Check for backlash in outgoing shafts <17>. Total backlash should be < ±0.0167o (1 minute of arc).



Oil should only be changed after the first 12,000 h.

Change the oil as follows.

Type of oil: Mobil DTE FM 220

Volume: 0.9l (per gearbox)

Drain the Gearbox, alt. No. 1:

• Unscrew base cover.

Maintenance

66 Product Manual

• Remove oil plugs (see Figure 38).

Figure 38 Location of Oil Plugs.

• Suck up the oil with a smooth hose.

• The oil is filled through the plug holes, with specified volume.

• Mount base cover.

Drain the Gearbox, alt. No. 2:

• Remove the transmission cover and arms.

• The oil is drained through the lower drain plug <18> holes (see Figure 39).

• The oil is filled through the upper plug holes, with specified volume.

• Mount transmission cover and arms.

• Calibrate axes 1-3, as described in Repairs chapter, section in this manual.

5.2.13 Manipulator Fan


Check roller bearings.

If necessary, replace the part as described Chapter 6, Repairs in this manual.

Motor/gear box for axis 4 must be removed

board must be removedSerial measurementOil plug (3x)

Maintenance

Product Manual 67

5.2.14 Location of Maintenance Points

Figure 39 Maintenance Points.

13

5, 11 (12x)

19

16

3

4 (2x)

14

Lower oil plug, 1817

12 (3x)

Upper oil plug9 (2x)

10

1

7

15

2 (2x)

8

6

Maintenance

68 Product Manual

5.2.15 Changing the Battery in the Measuring System

The robot is delivered with a 3-cell lithium battery. The lithium battery of primary type, needs no charging. For this reason there is a blocking diode, which prevents charging from the serial measurement board.

The battery to be replaced is located under the cover in the base box. (See Figure 40).

• Set the robot to the MOTORS OFF operating mode. (This means that it will not have to be coarse-calibrated after the change.)

• Loosen the battery terminals from the serial measuring board and cut the clasps that keep the battery unit in place.

• Install a new battery with two clasps and connect the terminals to the serial measuring board.

Used batteries must never be thrown away! They must be handled as hazardous waste!

The length of life of the Lithium Battery

The battery is used as a back-up when the robot system is switched off. Hence the life of a lithium battery depends on how frequently the power to the system is switched off and also if the environment temperature is higher than recommended operating temperature.

The length of life of the lithium battery varies from 12 - 36 months, depending on current situations. An alert is given on the TPU when the battery is nearly discharged and must then be replaced within a month.

Figure 40 The Battery is located Inside the Base Box.

Lithium battery available:

- A 3-cell battery, art. No. 3HAB 9999-1

Battery

Maintenance

Product Manual 69

Voltage of batteries, measured at power off:

The battery is replaced as described in the first paragraph of this section.

Tabell 12

Min. Max.

Lithium 7.0 V 12.0 V

Maintenance

70 Product Manual

5.3 Cleaning of Robot

The manipulator is tested to fulfil IP55 (Standard) and IP 67 (Wash Down, Stainless Wash Down) according to IEC 529.

The test is performed under the following conditions:

IP55The capping is sprayed with water from all possible angles with a nozzle.

- Nozzle inside diameter: 6,3 mm.

- Water flow: 12,5 l/min. ± 5%.

- Water pressure to be adjusted to achive the specified delivery rate.

- Test time / m² of the capping area: 1 min.

- Shortest test time: 3 min.

- Distance from the nozzle to the capping: approx. 3 m.

IP67The capping is lowered into water to fulfil the following conditions.

- The water surface should be min. 150 mm above the highest part of the capping.

- The lowest part of the capping should be at least 1 m below the water surface.

- The length of the test should be at least 30 min.

- The water temperature should not deviate more than 5°C from the temperature of the material. This requirement could be changed by the technical committee in question if the test is to be done when the material is powered or in motion.

5.3.1 Standard Cleaning

The standard version of IRB 340 is not manufactured for wash down applications and should only be cleaned by wiping off the dirt and dust using a dry or moistened cloth.

5.3.2 Wash Down Cleaning

Note! This applies for IRB 340 SA, and IRB 340 SAS, Wash Down version.

1. Flush with water max. 60°C, low pressure, see Figure 41 for sensitive points.

2. Foam with “P3-Topax 12” with a concentration of approximately 3% depending on the type of dirt. The water temperature should be 40-60°C. The solvent should be applied to the whole external surface.

3. Wait about 15 minutes so the solvent takes effect. To retain effective cleaning prop-erties, ensure that the solvent does not dry on the surface.

4. Flush thoroughly with water.

Maintenance

Product Manual 71

5. Apply the disinfectant, we recommend “P3-Topax 99”. Time, concentration, and water temperature are chosen to reach the desired effect.

- Concentration = 1-2%

- Temperature = 10-40°C

- Time approx. 20 min.

6. Flush thoroughly with water. Sealings and joints should be lubricated after cleaning, for good functionality.

Figure 41 Sensitive Points

Be careful flushing sealings.

Due to the risk of damaging the roller

Only with any detergentdo not cleanis removed.

bearing when the “swivel cup” use a moistened cloth.

After cleaning bearing races and“swivel cup” sealing, lubricate them with provision classified grease.

Maintenance

72 Product Manual

Repairs

Product Manual 73

6 Repairs

6.1 General Description

IRB 340 are avalailable in the following versions:

The industrial robot system IRB 340 comprises two separate units; the control cabinet and the mechanical unit. The service of the mechanical unit is described in this document.

As regards service, the mechanical unit is divided into the following main parts:

• Electrical System

• Motor Units

• Mechanical System

The Electrical System is routed for longevity. The power cabling feeds the robot axes' motor units. The signal cabling feeds the various controlling parameters like axis positions, motor revs, etc.

The AC type Motor Units provide the motive power for the various robot axes via gears. Mechanical brakes, electrically released, lock the motor units when the robot is inoperative for more than 1000 hours.

Table 13

Pay load Standard WashDown WashDown Stainless

1 kg IRB 340 IRB 340 SA IRB 340 SAS

2 kg IRB 340/2 IRB 340 SA/2 IRB 340 SAS/2

Repairs

74 Product Manual

The Mechanical System is available in six version. All versions are equipped with 4 axes, enabling the flexible robot motions.

Figure 42 The Robot Axes and Working Space.

Axis No. 1, 2 and 3 moves the end effector parallel with the working surface.

Axis No. 4 is a telescopic shaft that rotates the tool.

The Control Cabinet must be switched off during all service work on the robot! Before doing any work on the robot measurement system (measurement board, cabling), the accumulator power supply must always be disconnected.

When service work is finished, the calibration position should always be checked with the system disc.

The Brake Release Button should be connected as indicated in Chapter, Installation and Commissioning, (See Product Manual for S4Cplus or IRC5) to enable movements of the axes. See also Section 4.2.5 Manually engaging the Brakes in this manual.

Special care must be taken when the brakes are operated manually. This applies particularly when the robot is started up, either for the first time or after a stoppage. The safety instructions in the manual must be complied with at all times.

6.1.1 Document Guidance

The subsequent chapters describe the type of service work that can be carried out by the Customer’s own service staff on site. Certain types of work, requiring special experience or special aids, are not dealt with in this manual. In such cases, the defective module or component should be replaced on site. The faulty item should be sent to ABB for service.

Calibration. Re-calibration of the robot may have to be carried out after replacing mechanical unit parts or when the motor and feedback unit have been separated; or when a resolver error has occurred or the power supply between a measurement board and resolver has been interrupted. The procedure is described in detail in Section 6.8

Axis 1

Axis 2

Axis 4

Axis 3

TCP

Repairs

Product Manual 75

Calibration.

IMPORTANT! When work is done on the robot signal cabling, this may result in the robot moving to incorrect positions.

After doing such work, it is important that the robot calibration position is checked as described in this chapter, Section 6.8.2 Checking the Calibration Posi-tion. If a calibration fault is discovered, the robot must be re-calibrated as described in Section 6.8 Calibration.

Tools. Two types of tools are required for various service jobs involving dismantling; on the one hand, conventional tools like socket and ratchet spanners, etc.; on the other hand, special tools may be necessary, depending on what type of service is being carried out. The conventional tools are not dealt with in this manual, based on the assumption that the service personnel have sufficient technical basic competence. However, service work requiring the use of special tools is described in this manual.

Foldouts. In the Spare Parts chapter which can be found in the “Reference Information” part 2 of this manual, there are a number of foldouts illustrating the robot parts, intended to facilitate quick identification of both the type of service required and the composition of the various components. The parts are item numbered on the foldouts. The foldouts are referred to in the Manual text within “arrow heads” (< >) as exploded view numbers. Where reference is made to foldouts, other than those specified in the paragraph title, the foldout number is included in the item number reference, for example <5/19> or <10:2/5>, the digit(s) before the stroke referring to the foldout number.

Numbers in brackets ( ) refer to figures in the text.

The foldouts also include information such as article number, designation and relevant data.

N.B. This manual is not to be considered as a substitute for a proper training course. This document is intended for use after the course has been completed.

6.1.2 Caution

The mechanical unit contains several parts which are too heavy to lift manually. As these parts must be moved with precision during any maintenance and repair work, it is important to have a suitable lifting device available.

The robot should always be switched to MOTORS OFF before allowing anyone to enter its working space.

6.1.3 Mounting Instructions for Bearings and Seals

Bearing Rings

1. Let a new bearing remain in its wrapping until it is time for fitting, to avoid contamination of the bearing.

2. Ensure that all parts included in the bearing fitting are free from burrs, grinding waste and other contamination.

3. The bearing must be greased after fitting. The main reason for this is the

Repairs

76 Product Manual

requirement for cleanliness and a minimum of wear.

4. 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 surplus grease will be thrown out from the bearing when the robot is started up.

5. During operation, the bearing should be filled to 70-80% of the available volume.

6. Ensure that grease is handled and stored properly, to avoid contamination.

Seals

1. The most common cause of leakage is incorrect fitting.

Rotating Seals

2. The sealing surfaces should be protected during transport and mounting.

3. The seal should be kept in the original wrappings or be well protected.

4. Sealing surfaces must be inspected before mounting. If scratches or damage are found, that may result in future leakage, the seal must be replaced.

5. Seals should also be checked before mounting to ensure that:

• There is no damage to the sealing edge (feel with a fingernail)

• The seal is of the correct type (provided with cutting edge)

• There is no other damage.

6. Grease the seal just before fitting it, but not too early as there is a risk of dirt and foreign particles adhering to the seal. The space between the dust tongue and sealing lip should be filled to 2/3 with grease. The rubber coated external diameter must also be greased.

7. The fitting of seals and gears must be carried out on clean workbenches.

8. Mount the seal correctly. If it is misaligned, there is a risk of leakage due to the pumping effect.

9. Always mount the seal with a mounting tool. Never hammer directly on the seal, as this may result in leakage.

10. Use a protective sleeve for the sealing lip during mounting, when sliding over threads, key ways, etc.

Repairs

Product Manual 77

Flange Seals and Static Seals

11. Check the flange surfaces. They must be even and free from pores. It is easy to check flatness using a gauge on the fastened joint (without sealing compound).

12. Differences in surface level or the presence of burrs due to incorrect machining are not permissible. If flange surfaces are defective, the parts must not to be used, because leakage could result.

13. The surfaces must be properly cleaned in accordance with ABB’s recommendations.

14. Distribute the sealing compound evenly over the surface, preferably with a brush.

15. Tighten the screws evenly when fastening the flange joint.

O-rings

16. Check the O-ring grooves. The grooves must be geometrically correct and free from pores and contamination.

17. Check the O-ring with regard to surface defects, burrs, shape accuracy, etc.

18. Ensure that the correct O-ring size is used.

19. Tighten the screws evenly when assembling.

20. Defective O-rings and O-ring grooves must not be used.

21. Fitting defective parts will result in leakage. Grease the O-ring with lubricant before mounting.

6.1.4 Instructions for Tightening Screw Joints

General

It is of the utmost importance that all screw joints be tightened with the correct torque.

Application

The following tightening torques are to be used for all screw joints in metallic materials unless otherwise specified in the text.

These instructions do not apply to screw joints comprising soft or brittle materials.

For screws with a higher property class than 8.8, the data for 8.8 must be used unless otherwise specified.

Repairs

78 Product Manual

Screws treated with Gleitmo (lubricated)

When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should be used.

Screws treated with Gleitmo can be unscrewed and screwed in again 3-4 times before the slip coating disappears. Screws can also be treated with Molycote 1000.

When fastening new screws that are not Gleitmo treated, these should first be lubricated with Molycote 1000 and tightened to the specified torque.

Assembly

Lubrication with molybdenum disulphide grease (Molycote 1000) should only be used when specified in the text.

Screws lubricated with Molycote 1000 and then torque tightened, should also be lubricated between the washer and the head of the screw.

Screws must be tightened with a torque-wrench.

Screw Joints locked with Loctite

When Loctite is used in screw joints, always follow recommendations from Loctite, regarding the time it takes for a joint locked with Loctite to harden before the equipment can be used.

Disassembly of Joints locked with Loctite

When dissassembling a screw joint locked with Loctite, heat up the screw joint to approximately 100°C before dismounting. Follow recommendations from Loctite!

6.1.5 Tightening Torques

Collar Screw

Torx Screw

Tabell 14

Tightening torque - Nm

Dimension Class 8.8Coated with zinc, dry

M 6 9.0

Tabell 15


Dimension Class 8.8Gleitmo 610Molycote 1000

M 6 7.0

Repairs

Product Manual 79

Screws with Hexagon Socket Head

Special Screws

6.1.6 Checking for Play in Gearboxes and Wrist

Note! When checking for play in gearboxes the brakes must be disengaged.

When trying to move an arm manually when the brakes are engaged, some play can be felt. The play that can be felt is between the brake disk and the motor shaft, not in the gearbox itself. This is because the rotating brake disk is connected to the motor shaft by splines. This is why the brakes must be disengaged before testing for play in the gearboxes and wrist. The brakes are disengaged by pressing the enable button on the teach pendant.

Note! The play in the brake disk does not affect the robot motion or accuracy.

Tabell 16


Dimension Class 8.8Molycote 1000Gleitmo 610

Class 8.8OilLoctite

Class 12.9Molycote 1000Gleitmo 610

M 4 2.8

M 6 7 11

M 8 17

M 10 33

Tabell 17


Dimension Loctite Location

M 8 11.0 Ball joints

M12 20 Swivel

M12 18

Repairs

80 Product Manual

Product Manual 81

6.2 Axis 1, 2 and 3

6.2.1 Replacing Motor/Gearbox Unit

Refer to foldout Nos. 3 and 4.

Dismounting

1. Remove the parallel arms according to this chapter 6.5.1.

2. Dismount the upper arms according to Section 6.2.3 Replacing the Upper Arm in this chapter.

3. Dismount telescopic shaft according to Section 6.3.3 Replacing the Telescopic Shaft.

4. Remove flange cover <3/16>.

5. Dismount the transmission cover <10>.

6. Unscrew screws <4/38> for the base cover <4/33>.

7. Disconnect the cable for the fan, contact R4.FAN, and the manipulator cables.

8. Remove the base cover.

9. Disconnect the motor cabling.

If motor/gearbox for axis 3 is to be dismounted axis 4 must be dismounted first (see this chapter, Section 6.3.1 Replacing Motor/Gearbox Unit).If motor/gearbox for axis 2 is to be dismounted axis 4 and the serial measurement board must be removed first (see this chapter, Section 6.3.1 Replacing Motor/Gearbox Unit and Section 6.6.2 Replacing the Serial Measurement Board).

10. Unscrew screws <3/5> and remove the motor/gearbox unit.

Mounting

11. Place the motor/gearbox in position, 2 guide pins.

12. Mount the unit with screws <3/5> and washers <3/4>. Tightening torque 33 Nm.

13. Connect the motor cabling.

14. Remount the transmission cover <3/10> with screws >3/9>, torque 9 Nm.

15. Remount flange cover <3/16> and telescopic shaft.

16. Connect the cable for the fan, R4.FAN.

17. Tighten screws <4/38> for the base cover <4/33> with torque 14 Nm.

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18. Mount the upper arm according to 6.2.3 in this chapter.

19. Mount the parallel arms according to Section 6.5.1 Replacing Parallel Arms in this chapter.

20. Calibrate the robot as specified in this chapter, Section 6.8 Calibration.

Tightening Torque

Screw joint motor unit/base box, item <3/5>:33 NmScrew joint base cover/base box, item <4/38>:14 NmScrews for transmission cover, item <3/10>: 9 Nm

6.2.2 Exchange of Motor or Gearbox

Motor

1. Remove the transmission cover according to this chapter, 6.2.1.

2. Drain the gearbox according to Section 5.2.12 Gearboxes, Axes 1-3 in this chapter.

3. Unscrew the three screws (1) holding to motor to the gearbox (see Figure 43).

Figure 43 Motor and Gearbox Axes 1-3.

4. Remove the motor.

1

Product Manual 83

5. Mount O-ring (2) onto the motor flange (see Figure 44).

Figure 44 Mounting of Motor Axes 1-3.

6. Insert the new motor, do not tighten the screws (1).

7. Remount the upper arm temporarily, to be used to feel the backlash.

8. Push the motor gently downwards with help of a screw driver at the same time as you feel for the backlash by moving the upper arm back and forward.

9. Tighten the screws (1) with torque 11 Nm.

10. Check through the upper oil level hole that gear wheel (3) is axially movable (see Figure 44).

11. Fill the gearbox with oil according to Section 5.2.12 Gearboxes, Axes 1-3 in this chapter.

12. Remount transmission cover according to 6.2.1 in this chapter.


Gearbox

14. Dismount the motor/gear unit according to this chapter, 6.2.1.

15. Follow points 2. to 11. above.

16. Remount the unit (motor/gearbox) according to this chapter, 6.2.1.


6.2.3 Replacing the Upper Arm

Refer to foldout No. 1 and 3.

2

3

1

84 Product Manual

Dismounting

1. Unscrew screws <3/19>.

2. Remove the flange cover/flange axis 1-3 <3/16>.

3. Remove the parallel arms <1/1> according to this chapter, Section 6.5.1 Replacing Parallel Arms in this chapter.

4. Remove the VK-cover <3/42>. Knock a screw driver or similar through theVK-cover and bend it out. A new cover must be mounted back.


6. Pull the upper arm <3/40> out.

Mounting

7. Mount the flange cover/flange axis 1-3 <3/16> onto the upper arm shaft. Make sure that the sealing ring <3/17> is in the right position on the shaft.

NOTE! Flange axis 1-3 art.no. 3HAC021118-001 is designed to work as a mechanical stop on the upper arm. This flange shall only be mounted on upper arm art.no. 3HAC021121-001! It shall not be used on upper arm art.no. 3HAC2078-1! On this upper arm, use flange cover art.no. 3HAC4250-1.

8. Place the upper arm <3/40> in position, on the guide pin.

9. Tighten screws <3/41> with torque 11 Nm.

10. Tighten screws <3/19> with torque 9 Nm.

11. Remount the parallel arms according to this chapter, Section 6.5.1 Replacing Parallel Arms in this chapter.

Tightening Torque

Screw joint upper arm/gearbox, item <3/41>:7 NmScrew joint flange cover/gearbox, item <3/19>:9 Nm

6.2.4 Replacement of Joint Balls

Refer to foldout No. 1.

Dismounting

1. Remove the parallel arms according to this chapter, Section 6.5.1 Replacing Parallel Arms in this chapter.

2. Unscrew the joint balls <6> in the upper arm.

Mounting

3. Mount new joint balls, torque 11 Nm. Use Loctite 243.

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4. Mount parallel arm system according to this chapter, Section 6.5.1 Replacing Parallel Arms.

Tightening Torque

Joint balls/upper arm, item <6>:11 Nm

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6.3 Axis 4

6.3.1 Replacing Motor/Gearbox Unit

Refer to foldout numbers. 1, 3 and 4.

Dismounting

1. Remove base cover <4/33>, screws <4/38>.


3. Disconnect the motor connectors, R3.FB4 and R3.MP4.

4. Loosen the set screw <1/12> at the upper coupling on the telescopic shaft.


6. Remove the motor/gearbox <4/22>.

Mounting

7. Mount motor and gearbox with screws <3/24>, tightening torque 9 Nm.

8. Remount the telescopic shaft, lock with set screw <1/12> and Loctite 243, tightening torque 4 Nm.

9. Connect the cables to the motor.

10. Connect the cabling and mount cover <4/33> with screws <4/38>, tightening torque 14 Nm.


Tightening Torque

Screw joint motor/basebox, item <3/24>:9 Nm

Screw joint base cover/basebox, item <4/38>:14 Nm

6.3.2 Exchange of Motor or Gearbox

Motor

1. Remove motor/gearbox unit according to this chapter, Section 6.3.1 Replacing Motor/Gearbox Unit.

2. Knock a screw driver or similar through the VK-cover (2) and bend it out. A new cover must be mounted (see Figure 45).

3. Pour out the oil.

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4. Unscrew screws (1) and remove the motor.

Figure 45 Motor/Gear Unit Axis 4.

5. Open screw (3) a bit and wind the gear (5) down.

6. Mount O-ring (4) in the gear house.

7. Mount the motor with screws (1), tightening torque 9 Nm.

8. Rotate gear (5) upwards so that there is no play between the gears.

9. Ensure that the gear is kept absolutely still. Apply Loctite 243 and tighten the screw (3), torque 9 Nm.

10. Check the play again.

11. Apply Loctite 243 to lock the shaft (see Figure 45).


13. Fill the gearbox with oil to the centre of the motor pinion (see Figure 45).

14. Unscrew screws (6) so that the sealing ring does not pop out when mounting the VK cover (2)

Note! Do not forget to carry out No. 15 and 16 below.

15. Mount the new VK cover (2).

16. Mount screws (6).

1

2

3+Loctite 243

4

5

Loctite 243

6

Sealing ring

Motor pinion

Product Manual 89

Tightening Torque

Screw joint motor/gearbox, item (1)9 Nm

Locking screw, item (3)9 Nm

6.3.3 Replacing the Telescopic Shaft

Refer to foldout numbers 1 and 3.

Dismounting

1. Lift up the seal ring (v-ring) and unscrew the lower set screw <1/12>.

2. Unscrew the upper set screw <1/12>, see Figure 46.

3. Push the shaft together and remove it.

Figure 46 Set Screws

Mounting

The set screws for the telescopic shaft must be tightened as described below, otherwise there is a risk of the shaft becoming loose and damaging the arms and causing personal injuries.

4. Tighten set screws <1/12> with torque 4 Nm. Use Loctite 243.

5. Press the seal ring back in place.

Note! Do not press the seal down too hard because this will cause heavy wear, see Figure 47.

6. Calibrate axis 4 as described in this chapter, Section 6.8 Calibration.

Set Screws

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Figure 47 Seal Ring.

6.3.4 Replacing the Plain Bearings, Washdown and Stainless Versions

Note! The following procedure of replacing the plain bearings, is not recommended to be performed by others than ABB. It requires special skills and special tools.

1. Remove the telescopic shaft as described in this chapter, Section 6.3.3 Replacing the Telescopic Shaft.

2. Unscrew the nuts (1) gently (see Figure 48).

3. Before dismounting the components, heat them up to at least 150°C. This will make it easier to disassemble parts locked with Loctite.

4. Disassemble the components apart.

5. Remove the three plain bearings in each bearing holder (see Figure 48).

6. Replace with new plain bearings. Ensure that the small notch is located so it fits in the hole.

7. Before applying adhesive, clean the parts with Loctite 7063 Super Clean and let it dry.

8. Apply Loctite 7649 Activator and let it dry.

Push againstchamfer (9 mm)Push against

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9. Apply Loctite 620.

10. Assemble the parts of the telescopic shaft. Torque 4 Nm. Check that the bars are parallel. The orientation of universal joints are crucial. Joints must be “in-line”! Notify that this is controlled when mounting shaft-pivots D11 and D12. The M5 hole on these must be perpendicularly mounted!

11. Check that the movement of the telescopic shaft is smooth along its whole length.

12. Remount the telescopic shaft as described in this chapter, Section 6.3.3 Replacing the Telescopic Shaft.

Figure 48 Plain Bearings, Wash Down and StainlessVersion.

Tightening Torque

Nuts, telescopic shaft, item (1):4 Nm

11

Plain bearing Hole with notch

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6.4 Movable Plate with Swivel

6.4.1 Dismounting Movable Plate

Refer to foldout No. 1

Dismounting

1. Remove the lower end of the telescopic shaft as described in this chapter, Section 6.3.3.

2. Pull the parallel arms apart by hand or use tool 3HAC 6194-1, and remove the plate.

Mounting

3. Mount the movable plate by pulling the parallel arms apart by hand or use tool 3HAC 6194-1.

4. Mount the lower end of the telescopic shaft according to this chapter, Section 6.3.3.

6.4.2 Replacement of Joint Balls


Dismounting

1. Dismount movable plate according to Section 6.4.1 above.

2. Unscrew joint balls <6>.

Mounting

3. Mount new joint balls, torque 11 Nm. Use Loctite 243.

4. Mount movable plate according to Section 6.4.1 above.

Tightening Torque

Joint balls/movable plate, item <6>:11 ±1 Nm

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6.5 Parallel Arm System

6.5.1 Replacing Parallel Arms


Dismounting

1. Remove the vacuum hose from the arm system.

2. Use tool 3HAC 6194-1 (or by hand), and pull the arms apart in both ends (see Figure 49).

Figure 49 Parallel Arms with Spring Units.

3. Remove the arms.

Mounting

4. Mount in reversed order.

6.5.2 Replacing the Spring Unit


Dismounting

1. Remove the affected arm system according to Section 6.5.1 above.

2. Push the bar as shown in Figure 50.

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Figure 50 Removing the Spring Unit.

3. Take out the rollers (see Figure 50).

4. Remove the spring unit.

5. Both sides identical.

Mounting

6. Place the spring unit in position.

7. Mount the rollers onto the pin (see Figure 50).

8. Pull the arm backwards into position.

9. Mount back the arm system according to Section 6.5.1 above.

6.5.3 Exchange of Wear Rings

Refer to foldout No. 1

Dismounting

1. Remove the parallel arm according to Section 6.5.1 above.

2. Insert a screw driver, and bend carefully the wear ring out (see Figure 51).

Mounting

3. Place a new wear ring into the joint socket (see Figure 51).

Rollers (x4)

Product Manual 97

4. Place the arm bar in dolly 3HAC 4182-1.

5. Put drifter 3HAC 4184-1 into the wear ring and knock it gently down to its position.

6. Apply grease according to Maintenance chapter in this manual.

Figure 51 Exchange of Wear Rings.

7. Mount the parallel arms according to Section 6.5.1 above.

Dolly 3HAC 4182-1

Drifter 3HAC 4184-1

Wear ring

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6.6 Cabling

6.6.1 Dismounting the Complete Cabling


Dismounting

1. Remove the base cover according to first points in this chapter, Section 6.3.1 Replacing Motor/Gearbox Unit.

2. Make a note or small drawing of the location of the cabling.

3. Cut all the straps holding the cabling.

4. Disconnect all contacts.

5. Dismount the transmission cover according to the first points in this chapter,Section 6.2.2 Exchange of Motor or Gearbox.

6. Disconnect the cables for the warning lamp and brake release button.

Mounting

7. In reversed order.

Note! Make sure that no cables are in the marked area according to foldout 5. See Foldouts in “Reference Information”.

6.6.2 Replacing the Serial Measurement Board


Note! When working with the serial measurement board it is important that a wrist strap is used, to avoid ESD faults.

Dismounting

1. Remove base cover <4/33>, screws <4/38>.


3. Disconnect the contacts connected to the board.

4. Loosen the screws holding the board and remove it.

Mounting


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6.6.3 Replacing Pushbutton Unit and Warning Lamp


Dismounting

1. Remove the parallel arm system according to this chapter, Section 6.5 Parallel Arm System.

2. Remove the upper arms according to this chapter, Section 6.2.3 Replacing the Upper Arm.

3. Dismount the transmission cover <3/10>, screws <3/59>.

4. Disconnect and unscrew the push button or lamp unit.

Mounting


6.6.4 Replacing the Fan


Dismounting

1. Remove the ventilation connection <46>, screws <19>.

2. Remove the base cover <33>, screws <38>.

3. Remove the fan cover <37>, screws <60>.

4. Disconnect the cable <35>, R4.FAN.

5. Unscrew screws <36> and remove the fan <34>.

Note! One of the screws <36> is hidden under the ventilation gasket.

Mounting


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6.7 Vacuum System

6.7.1 Dismounting Ejector Unit


Dismounting

1. Disconnect the air supply, vacuum hoses and signal cable.

2. Loosen the air filter plate <6/2>, screws <6/8>.

3. Unscrew screw <1/19>.

4. Lift out the ejector unit <6/1>.

Mounting


6.7.2 Exchange of Hoses

Dismount and mount according to foldout No. 6.

1. Open straps <12>.

2. Pull the hose out from the swivel

3. Pull the hose out from the air filter.

4. Mount a new hose on the swivel.

5. Fix the hose, do not tighten, against the three clamps <11> on the parallel arm.

6. Twist the hose and mount it on the air filter.

7. Then adjust the hose according to foldout no. 6.

8. Tighten the straps.

9. Make a small program (low velocity) and check that the hose runs freely.

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6.8 Calibration

6.8.1 General

The robot measurement system consists of one feedback unit for each axis and a measurement board that continuously keeps track of the current robot position.The measurement board memory has a battery backup.

If any of the resolver values has been changed, the measurement system must be carefully calibrated (as described in Section 6.8.4 Fine Calibration). This can happen when:

- Parts affecting the calibration position have been replaced on the robot.

The system needs to be roughly calibrated (as described in Section 6.8.5 Updating Revolution Counter) if the contents of the revolution counter memory are lost. This may happen when:

- The battery is empty.

- A resolver error occurs.

- The signal between a resolver and measurement board is interrupted.

- A robot axis has been moved with the control system disconnected.

6.8.2 Checking the Calibration Position

Before any programming of the robot system can begin, a check of the calibration position must be made. There are two ways to check the calibration position.

A. Using the program CAL340 in the system software:

1. Run the program \ SYSTEM \ UTILITY \ SERVICE \ CALIBRAT \ CAL340 in the system and follow the instructions displayed on the teach pendant.

2. When the robot stops, switch to MOTORS OFF. Check that the calibration marks for each axis are at the same level, see Figure 57. If they are not, the setting of the revolution counters must be repeated.

3. Check resolver offset values in system parameters.

B. Using the Jogging window on the teach pendant:

1. Open the Jogging window and choose running axis-by-axis .

2. Using the joystick, move the robot so that the read-out of the position is equal to -13.19°.

3. Check that the calibration marks for each axis are at the same level, see Figure 57. If they are not, the setting of the revolution counters must be repeated.

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6.8.3 Fine Calibration Procedure on the Teach Pendant

1. Press and select the Service window (see Figure 52) by pressing .

Figure 52 The Misc. Window Key from which the Service Window can be chosen.

2. Choose Calibration from the View menu. The calibration window (see Figure 53) appears.

If there is more than one unit connected to the robot, they will be listed in the window.

The calibration status can be any of the following:

- SynchronisedAll axes are calibrated and their positions are known. The unit is ready for use.

- Revolution Counter not updatedAll axes are fine-calibrated but one (or more) of the axes has a counter that is NOT updated. This axis, or these axes, must therefore be updated as described in Section 6.8.5 Updating Revolution Counter.

- Not calibratedOne (or more) of the axes is NOT fine-calibrated. This axis, or these axes, must therefore be fine-calibrated as described in Section 6.8.4 Fine Calibra-tion.

3. Select the desired unit and choose Fine Calibrate from the Calib menu. A Warning window (see Figure 54) appears.

4. Place the manipulator in its calibration position and press OK. The Fine Calibrate window (see Figure 55) appears.

5. Select the desired axis and press Incl to include it (it will be marked with an x) or press All to select all axes.

6. When all axes that are to be updated are marked with an x, press OK.

Cancel returns to the Calibration window (see

21

2 30

1

4 5 6

7 8 9

P3

P1 P2

Figure 53 Calibra-

Figure 54 Fine Calibra-

Figure 55 Fine

Product Manual 105

Figure 53 Calibration Window).

7. Press OK again to confirm and start the update.

Cancel returns to the Fine Calibrate window (Figure 54).

An alert box is displayed during calibration. The Status window appears when the fine calibration is complete. The revolution counters are always updated at the same time as the calibration is performed.

6.8.4 Fine Calibration

Adjust the axes in increasing sequence, that is, 1 - 2 - 3 - 4, and one at the time.

Axis 1, 2 and 3.

See Figure 56.

1. Select the MOTORS OFF mode.

2. Remove the bar system according to this chapter, Section 6.5 Parallel Arm Sys-tem.

3. Remove cover (see Figure 56).

4. Mount calibration tool art. No. 3HAC 9596-1. Do NOT tighten the screw!

5. Release the brakes and push the upper arm towards the tool.

6. Position the tool correctly and tighten the screw.

7. Release the brakes again and push the upper arm very gently against the tool.

8. When joint ball reaches tool apply the brake.

9. The upper arm is now in calibration position.

10. Update only axis 1, as described in Section 6.8.3 Fine Calibration Procedure on the Teach Pendant.

11. Continue with the other two remaining axes in the same way, follow point 3 - 10.

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Figure 56 Calibration Positions for Axes 1-3.

Axis 4

1. Mount the bar system according to this chapter, Section 6.5 Parallel Arm System and axis 4 according to this chapter, Section 6.3 Axis 4.

Table 18 Components in Figure 15

A Tool 3HAC 9596-1

B Joint ball

C Upper arm

D Nut

E Pin

F Correct angle = -13,19º

G Cover

H Label

A

B

C

D EF

G

H

Product Manual 107

2. Run axis 4 with the joystick so that the calibration marks is in line, see Figure 57.

3. Update only axis 4, as described in Section 6.8.3 Fine Calibration Procedure on the Teach Pendant.

4. Check the calibration position as described in Section 6.8.2 Checking the Calibra-tion Position.

5. The system parameters will be saved to the storage memory at power off.

6. Change the values on the label, located in the base box under the plate for the manipulator cables (see Figure 56).

Figure 57 Calibration Marks on the Manipulator.

6.8.5 Updating Revolution Counter

When starting up a new robot, you may receive a message telling you that the manipulator is not synchronised. The message appears in the form of an error code on the teach pendant. If you receive such a message, the revolution counter of the manipulator must be updated using the calibration marks on the manipulator. See Figure 57.

Examples of when the revolution counter must be updated:

- When the battery unit (on the manipulator) is empty.

- When there has been a resolver error.

NutPin

Axis 1, 2 and 3

The pin should be inside the nut

Axis 4

Marks should be in line.

Mark

108 Product Manual

- When the signal between the resolver and the measuring system board has been interrupted.

- When one of the manipulator axes has been manually moved, while the con-troller is disconnected.

If the resolver values must be calibrated, this is described in Section 6.8.4 Fine Calibration.

Working in the robot work cell is dangerous.

Press the enabling device on the teach pendant and, using the joystick, move the robot manually so that the calibration marks lie within the tolerance zone (see Figure 57).

When all axes have been positioned as above, the revolution counter settings are stored using the Teach Pendant Unit, as follows:

1. Press and select the Service window (see Figure 52) by pressing .

Figure 58 The Misc. Window Key from which the Service Window can be chosen.

2. Choose Calibration from the View menu. The calibration window (see Figure 59) appears.

If there is more than one unit connected to the robot, they will be listed in the window.

3. Select the desired unit and choose Rev. Counter Update from the Calib menu. The Revolution Counter Update window (see Figure 60) appears.

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. When all axes that are to be updated are marked with an x, press OK.

CANCEL returns to the Calibration window (Figure 59 Calibration Window).

6. Press OK again to confirm and start the update.

CANCEL returns to the Revolution Counter Update window (Figure 60).

21

2 30

1

4 5 6

7 8 9

P3

P1 P2

Figure 59 Calibra-

Figure 60 Revolu-tion

Product Manual 109

If a revolution counter is incorrectly updated, it will cause incorrect positioning. Thus, check the calibration very carefully after each update. Incorrect updating can damage the robot system or injure someone.

7. Check the calibration as described in Section 6.8.2 Checking the Calibration Posi-tion.

6.8.6 Calibration Equipment

Axis 1 -3 3HAC 9596-1 Sync fixture for axis 1, 2 and 3

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6.9 Corrective action in case of a collision

If a collision occurs with the robot, please inspect the following parts!

6.9.1 Overview

1. Due to the fact that mechanical problems have occurred during manually moving and/or crashing with the manipulator, there are some things that has to be taken in consideration when performing service. If not, both manipulator and peripheral equipment, such as conveyors, may be affected.

2. Parts needed in case of a collision, are specified in the Spare Parts list for the manipulator. They are specially designed as Spare parts for Collision Mainte-nance. Under “Remark” the quantity of these parts are written in bold and under-lined. Ex. Qty. 6. See also, Spare Parts 1.6 Collision Maintenance Parts in “Reference Information”.

6.9.2 Telescopic Shaft

1. Verify that the 6 bars of the telescopic shaft are parallel.

2. If they appear to be twisted, remove the telescopic shaft from the robot by loosen-ing the setscrews.

3. Use a heat gun to loosen the setscrews. They are locked with Loctite 243.

4. Loosen the nuts and reset the bars back to being parallel.

5. Retighten the nuts.

6. Check that there is a smooth operation of the bars all the way, after each nut has been tightened.

7. If the bars are bent and adjustment isn´t possible, replace the telescopic shaft!

8. After replacing the telescopic shaft, apply Loctite 243 to the setscrews.

9. Tighten the setscrews to a torque of 4 Nm.

10. Wait 3 hours for the loctite to dry, before running the robot!

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6.9.3 Spring Units

1. Check that the six spring units are OK.

2. Make sure that the forks not are bent.

3. If the forks not are absolutely straight, there is risk that the rollers are falling out.

4. The forks has to be lined up, in order to complete the parallel shape.

5. Make certain that the screws on each side are tight. If not, tighten them to the spec-ification in the manual.

6. Secure the screws with Loctite 243.

6.9.4 Rollers

1. Check that all rollers are in place (24 pcs) and that they not are broken in any way.

2. Apply new grease on the axis. Use Mobile FM 102.

3. Check that each roller is pushed in the correct position on the fork.

6.9.5 Bars

1. Inspect the bars. Look for signs of any damage after a crash.

2. Look for loose hoses.

3. Look for anything else that may have damaged the bars.

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4. Check and regrease the wear rings.

6.9.6 Joint Balls

1. Check the joint balls for damage.

2. Change them if they show any sign of damage.

6.9.7 Universal Joints

1. Verify that the universal joints are running smoothly and that there is no damage.

2. If there is any obliqueness in the universal joint, replace it.

3. If the ball bearings are in a bad condition, replace the universal joint.

4. Remember to heat the screw to approximately 100 degrees Celsius (212 F) at dis-mantling.

5. Assemble the sealing ring (V-ring) against the ledge on the universal joint. See

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Repairs chapter for more information!

Product Manual 115

6.10 Special Tools List

The need for special tools has been reduced to a minimum. When tools are needed for dismounting/mounting work, a description is given in that section.

During the ordinary service training courses arranged by ABB, detailed descriptions of the tools are given together with their use.

Tabell 19

CalibrationCalibration fixture 3HAC 9596-1

Arm system

Tool for mounting the parallel arms 3HAC 6194-1

Drifter for mounting wear rings 3HAC 4184-1

Dolly for joint socket when inserting new wear rings 3HAC 4182-1

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IRC5-IRB340 Prod Man 3HAC022546-001 Procedures Rev- En Proc

Documents

serial measurement

operating

teach pendant

robots safeguarded

computer system

safety control

emergency

working space