ABB IRB1410, Product Manual

Page 1: ...Product manual Articulated robot IRB1410 M2004 ...

Page 2: ......

Page 3: ...Product manual IRB 1410 M2004 ID 3HAC026320 001 Revision A ...

Page 4: ...s for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written per mission and contents thereof must not be imparted to a third party nor be used for any unau thorized purpose Contravention will be prosecute...

Page 5: ...ls 27 1 5 Safety related instructions 28 1 5 1 Safety signals general 28 1 5 2 DANGER Moving manipulators are potentially lethal 30 1 5 3 DANGER First test run may cause injury or damage 31 1 5 4 WARNING The unit is sensitive to ESD 32 1 5 5 WARNING Safety risks during work with gearbox oil 33 2 Installation and commissioning 35 2 0 1 Transporting and Unpacking 35 2 0 2 Stability Risk of Tipping 3...

Page 6: ...the gearbox 81 4 3 3 Dismantling the lower arm 82 4 3 4 Changing the bearings in the upper arm 84 4 3 5 Dismantling the balancing springs 85 4 4 Axis 3 86 4 4 1 Changing the motor of axis 3 86 4 4 2 Changing the gearbox 88 4 4 3 Dismantling the parallel arm 89 4 4 4 Changing the tie rod 90 4 4 5 Dismantling the complete upper arm 92 4 5 Axis 4 95 4 5 1 Changing the motor 95 4 5 2 Changing the inte...

Page 7: ... 130 6 0 7 Standard toolkit IRB 1400 131 6 0 8 Performing a leak down test 132 6 0 9 Lifting equipment and lifting instructions 133 7 Recommended Spare parts 135 7 0 1 Spare parts 135 8 Foldouts 137 8 0 1 Introduction 137 9 Circuit diagram 139 9 0 1 Introduction 139 9 0 2 Sheet 101 List of contents 140 9 0 3 Sheet 102 Connection point location 141 9 0 4 Sheet 103 Serial measurement board 142 9 0 5...

Page 8: ...Table of Contents 6 ...

Page 9: ...stallation personnel maintenance personnel repair personnel Prerequisites A maintenance repair installation craftsman working with an ABB Robot must be trained by ABB and have the required knowledge of mechanical and electrical installation repair maintenance work Organization of chapters The manual is organized in the following chapters Chapter Contents Safety service Safety information Installat...

Page 10: ...Overview 8 3HAC026320 001 Revision A References Revisions Reference Document Id Revision Description First edition A Changes made in Prerequisites in section Overview Oil change in section Maintenance ...

Page 11: ...nclud ing periodicity Repair descriptions of all recommended repair procedures including spare parts Additional procedures if any calibration decommissioning Product manual reference information Reference information article numbers for documentation refered to in Product man ual procedures lists of tools safety standards Part list Foldouts or exploded views Circuit diagrams Technical reference ma...

Page 12: ...t hand operational contact with the robot i e production cell operators programmers and trouble shooters and include Operating Manual IRC5 with FlexPendant Operating Manual RobotStudio Online Operating Manual Trouble shooting for the controller and manipulator Miscellaneous A number of manuals provide generic descriptions of the robot and robot system These include ...

Page 13: ... any service work on the robot These are applicable for all service work and are found in section General safety information on page 12 specific safety information pointed out in the procedure at the moment of the danger How to avoid and eliminate the danger is either detailed directly in the procedure or further detailed in separate instructions found in section Safety related instructions on pag...

Page 14: ...ndustrial robot described in the applicable documents e g Operating manual IRC5 with FlexPendant M2004 and Product manual Connection of external safety devices Apart from the built in safety functions the robot is also supplied with an interface for the connection of external safety devices Via this interface an external safety function can interact with other machines and peripheral equipment Thi...

Page 15: ...ring the installation of the robot system the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with Non voltage related risks Safety zones which have to be crossed before admittance must be set up in front of the robot s working space Light beams or sensitive mats are suitable devices Turntables or the like should be used to keep the operator ou...

Page 16: ...ccordance with the applicable standards for the emergency stop function Complete robot Cabling Safety risk Description Hot components Caution Motors and gears are HOT after running the robot Touching the motors and gears may result in burns Removed parts may result in collapse of robot Warning Take any necessary measures to ensure that the robot does not collapse as parts are removed e g secure th...

Page 17: ...and service work on robot 3HAC026320 001 Revision A 15 Gearboxes and motors Safety risk Description Gears may be damaged if excessive force is used Caution Whenever parting mating motor and gearbox the gears may be damaged if excessive force is used ...

Page 18: ...ch as milling cutters etc Make sure that guards remain closed until the cutters stop rotating It should be possible to release parts by manual operation valves Safe design Grippers end effectors must be designed so that they retain workpieces in the event of a power failure or a disturbance of the controller CAUTION Ensure that a gripper is prevented from dropping a workpiece if such is used ...

Page 19: ...lic systems Residual energy Residual energy may be present in these systems After shutdown particular care must be taken The pressure in pneumatic and hydraulic systems must be released before starting to repair them Safe design Gravity may cause any parts or objects held by these systems to drop Dump valves should be used in case of emergency Shot bolts should be used to prevent tools etc from fa...

Page 20: ... and in accordance with the applicable safety regulations Care must be taken at all times Qualified personnel Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts Extraordinary risks If the working process is interrupted extra care must be taken due to risks other than t...

Page 21: ...e mains supply mains switch The transformers The power unit The control power supply 230 VAC The rectifier unit 400 480 VAC and 700 VDC Note Capacitors The drive unit 700 VDC The drive system power supply 230 VAC The service outlets 115 230 VAC The customer power supply 230 VAC The power supply unit for tools or special power supply units for the machining process The external voltage connected to...

Page 22: ...le it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed Determine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot is working in the work cell see Product Specification IRB 1400 Section 1 5 Description Robot Motion Also consider the maximum possible impact caused by a breaking or mal...

Page 23: ...1 Safety 1 4 2 Fire extinguishing 3HAC026320 001 Revision A 21 1 4 2 Fire extinguishing NOTE Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the robot manipulator or controller ...

Page 24: ...he brake release buttons on the robot How to release the brakes is detailed in section Emergency release of the robot s arm on page 22 The robot arm may be moved manually on smaller robot models but larger models may require using an overhead crane or similar Increased injury Before releasing the brakes make sure that the weight of the arms does not increase the pressure on the trapped person furt...

Page 25: ...nction of the holding brake of each axis motor may be checked as detailed below 1 Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized max static load 2 Switch the motor to the MOTORS OFF position with the Operating mode selector on the controller 3 Check that the axis maintains its position If the manipulator does not change position a...

Page 26: ...eed 250 mm s 24 3HAC026320 001 Revision A 1 4 5 Risk of disabling function Reduced speed 250 mm s NOTE Do not change Transm gear ratio or other kinematic parameters from the FlexPendant or a PC This will affect the safety function Reduced speed 250 mm s ...

Page 27: ...he way in the robot is taken to the MOTORS OFF state To ensure safe use of the FlexPendant the following must be implemented The enabling device must never be rendered inoperative in any way During programming and testing the enabling device must be released as soon as there is no need for the robot to move The programmer must always bring the FlexPendant with him her when entering the robot s wor...

Page 28: ...speed is limited to max 250 mm s when the operating mode selector is in position manual mode with reduced speed This should be the normal position when entering the working space The position manual mode with full speed 100 may only be used by trained personnel who are aware of the risks that this entails Pay attention to the rotating axes of the manipulator Keep a distance to the axes in order no...

Page 29: ...for adding a fourth language underneath the three standard languages English German and French Add a local language to the label by using a transparent sticker over the standard label with text added in a fourth language Drawings detailing the design text figure dimensions of the standard labels can be ordered from ABB Notice that each label is identified according to the article number located in...

Page 30: ...ple contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc warning WARNING Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electr...

Page 31: ...harge ESD symbol indicates electrostatic hazards which could result in severe damage to the product Note NOTE Note symbols alert you to important facts and conditions Tip TIP Tip symbols direct you to specific instructions where to find additional information or how to perform a certain operation in an easier way Symbol Designation Signification ...

Page 32: ...in the manipulator working range Elimination Action Note Illustration 1 Before attempting to run the manipulator make sure all emergency stop equipment is correctly installed and connected Emergency stop equipment such as gates tread mats light curtains etc 2 If possible use the hold to run button whenever possible The hold to run button is used in manual mode not in automatic mode How to use the ...

Page 33: ...eration before the first test run Elimination Follow the procedure below when performing the first test run after a service activity repair installation or maintenance Action 1 Remove all service tools and foreign objects from the robot and its working area 2 Install all safety equipment properly 3 Make sure all personnel are standing at a safe distance from the robot i e out of its reach behind s...

Page 34: ...eld When handling parts or their containers personnel not grounded may potentially transfer high static charges This discharge may destroy sensitive electronics Elimination Action Note 1 Use a wrist strap Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly 2 Use an ESD protective floor mat The mat must be grounded through a current limiting resist...

Page 35: ...vity Possible pressure build up in gearbox When opening the oil plug there may be pressure present in the gearbox causing oil to spray from the opening Open oil plug carefully and keep away from the opening Do not overfill the gearbox when filling Do not overfill Overfilling of gearbox oil can lead to internal over pressure inside the gearbox which in turn may damage seals and gaskets completely p...

Page 36: ...the robot for a time to heat up the oil Specified amount depends on drained volume The specified amount of oil is based on the total volume of the gearbox When changing the oil the amount of refilled oil may differ from the specified amount depending on how much oil has previously been drained from the gearbox After refilling check the oil level Warning Description Elimination Action ...

Page 37: ...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 Operating conditions 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 and 55 C When air transport is used the robot must be located in a pressure eq...

Page 38: ...2 0 2 Stability Risk of Tipping When the manipulator is not fastened to the floor and standing still the manipulator is not stable in the whole working area When the arms are moved care must be taken so that the centre of gravity is not displaced as this could cause the manipu lator to tip over ...

Page 39: ...0 3 System CD ROM and Diskette The system CD ROM and the manipulator parameter disk are delivered with the robot system See section RobotWare CD ROM in the Product manual for the controller Art no for the manual is detailed in section Document references in the Product manual ref erence information ...

Page 40: ...C026320 001 Revision A 2 0 4 Transport Locking Device At delivery axis 2 lower arm is equipped with a transport locking device see figure below Remove the transport locking device before operating the robot Figure 1 Transport Locking Device Axis 2 Transport locking device ...

Page 41: ...t way to lift the manipulator is to use lifting straps and a traverse crane Attach the straps to the special eye bolts on the gear boxes for axes 2 and 3 see figure below The lifting strap dimensions must comply with the applicable standards for lifting Never walk under a suspended load Figure 2 Lifting the Manipulators using a Traverse Crane Lifting eye ...

Page 42: ... is bolted down by means of three M16 bolts Two guide sleeves ABB art no 2151 0024 169 can be fitted to the two rear bolt holes to allow the same robot to be re mounted without having to re adjust the program When bolting a mounting plate or frame to a concrete floor follow the general instructions for expansion shell bolts The screw joint must be able to withstand the stress loads defined in this...

Page 43: ...unting The method for mounting the manipulator in a suspended position is basically the same as for floor mounting With inverted installation make sure that the gantry or corresponding struc ture is rigid enough to prevent unacceptable vibrations and deflections so that optimum performance can be achieved ...

Page 44: ...can be used for adapting the robot tuning to a non optimal foundation IRB 1400 Fxy and Mxy are vectors that can have any direction in the xy plane Figure 4 The Directions of the Stress Forces Force Endurance load in operation Max load emergency stop Fxy 1500 N 2000 N Fz upright 2800 500 N 2800 700 N Fz suspended 2800 800 N 2800 1000 N Torque Endurance load in operation Max load emergency stop Mxy ...

Page 45: ... the manipulator is illustrated in the figures below The working range for axis 1 is 170 NB There are no software or mechanical limits for the working space under the base of the manipulator Manipulator Figure 5 The Amount of working Space required for the Manipulator 1051 150 254 1282 733 1645 770 1127 1221 150 Axis 1 170o Axis 1 145o 135o 1195 1008 1444 150 511 1793 50 ...

Page 46: ...interchange the 24V and 0V pins If they are mixed up damage can be caused to electrical components Figure 6 Connection of External Voltage to enable Engagement of the Brakes External power must be connected according to Figure 6 Incorrectly con nected power can release all brakes causing simultaneously movement of all axes When the controller or the voltage supply is connected as illustrated above...

Page 47: ... range using parameters is described in the section Configuring systems in the Operating manual IRC5 with FlexPendant Axis 1 The range of rotation for axis 1 can be limited mechanically by fitting extra stop lugs to the base see Figure 8 Instructions for necessary machining and mounting are supplied with the kit NB The original stop lug must never be removed Figure 8 Mechanically limiting Axis 1 A...

Page 48: ...26320 001 Revision A Figure 9 Mechanically limiting Axis 2 Axis 3 The working range of axis 3 can be limited mechanically by fitting a stop lug under the par allel arm see Figure 10 Axis 3 is limited upwards to 0 or 10 degrees above the horizontal plane Under arm Extra stop lugs ...

Page 49: ...tallation and commissioning 2 1 7 Restricting the Working Space 3HAC026320 001 Revision A 47 Instructions for doing this are supplied with the kit Figure 10 Extra Stop Lug for limiting Axis 3 Extra stop lug ...

Page 50: ...ill a hole in the manipulator without first consulting ABB Figure 11 Mounting Holes for Customer Equipment Figure 12 The mechanical Interface Mounting Flange 135 Mounting holes for equipment M8 2x Depth 16 120 A A Mounting holes for equipment both sides M8 3x R 75 Depth 16 15o 120o 3x IRB 1400 D 25 D 50 H8 h8 45o D 6 H7 M6 4x R 20 A A 4 10 A A 2 0 05 0 3 B C B 0 06 B 4x 90o C D 12 ...

Page 51: ... 001 Revision A 49 2 1 9 Loads Regarding load diagram permitted extra loads equipment and locations of extra loads equipment see the Product Specification for IRB 1400 The loads must also be defined in the software see Operating manual IRC5 with FlexPendant ...

Page 52: ...m For connection of extra equipment on the manipulator there are cables integrated into the manipulator s cabling Option 042 Control cabling to arc welding wire feeder is integrated into the manipulator s cabling Number of signals 12 signals 49V 500 mA Connector on upper arm FCI 12 pin UT001412SHT Connector on robot base FCI 12 pin UT001412PHT Control signals Number of signals 16 signals 49V 500 m...

Page 53: ...s recommended contact set for connector R2 CS has Art No 3HAC 12583 1 ABB s recommended contact set for connector R1 CS has Art No 3HAC 12493 1 The complete contact set option contains Pins for cable area 0 13 0 25 mm2 Shrinking hose bottled shaped Shrinking hose angled which corresponds to item 4 5 6 7 8 and 9 according to Figure 14 Figure 14 FCI Connector R2 CS R1 CS Air only option 041 R2 CP on...

Page 54: ...hm 0 154 mm2 Max voltage 50 V AC DC Max current 250 mA Signal Name Customer Terminal Controller optional Customer Contact on Upper Arm R2 Customer Contact on Manipulator Base Cable not supplied CSA XT5 1 R2 CS A R1 CS A CSB XT5 2 R2 CS B R1 CS B CSC XT5 3 R2 CS C R1 CS C CSD XT5 4 R2 CS D R1 CS D CSE XT5 5 R2 CS E R1 CS E CSF XT5 6 R2 CS F R1 CS F CSG XT5 7 R2 CS G R1 CS G CSH XT5 8 R2 CS H R1 CS ...

Page 55: ...ation and commissioning 2 2 2 Connection of Extra Equipment to the Manipulator 3HAC026320 001 Revision A 53 Connection of Signal Lamp on Upper Arm Option Figure 16 Location of Signal Lamp Signal lamp R3 H1 R3 H2 ...

Page 56: ...2 Installation and commissioning 2 2 2 Connection of Extra Equipment to the Manipulator 54 3HAC026320 001 Revision A ...

Page 57: ...s and preventative maintenance must be carried out at given periodical intervals see 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 joint and cable bushings are really airtight so that dust and...

Page 58: ...ed 3 See section Changing the battery in the measuring system on page 60 Equipment Check twice year Check once year Maintenance every 2000 hrs or 6 months Maintenance every 4000 hrs or 1 year Others Mechanical stop axis 1 X1 Cabling X2 Gears axis 1 4 Maintenance free Lubrication of spring brackets X Lubrication of gears axis 5 6 X Replacement of accumulator for measuring sys tem 3 years3 ...

Page 59: ...0 art No 1171 2016 604 corresponds to Oil volume BP floor mounted robot Oil volume BP suspended robot BP Energol GR XP 320 Castrol Alpha SP 320 Esso Spartan EP 320 Klüber Lamora 320 Optimol Optigear 320 Shell Omala Oil 320 Texaco Meropa 320 Statoil Loaway EP Gearbox Volume Axis 1 2 000 ml Axis 2 and 3 1 700 ml Axis 4 30 ml Gearbox Volume Axis 1 2 700 ml Axis 2 and 3 1 700 ml Axis 4 30 ml ...

Page 60: ... and 6 Grease is pressed through the 3 nipples 1 see Figure 17 The tip nozzle of the greasing gun should be of type Orion 1015063 or equivalent Volume 2 ml 0 00053 US gallon Figure 17 Greasing Positions for Axes 5 and 6 Type of grease ABB s art No 3HAB 3537 1 corresponds to Shell Alvania WR2 1 ...

Page 61: ...g spring brackets 3HAC026320 001 Revision A 59 3 1 3 Lubricating spring brackets There are four lubrication places located over and under the two balancing springs Type of grease ABB s art No 3HAA 1001 294 corresponds to Optimol PDO ...

Page 62: ...rom 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 mea suring board Refit the serial measurement board flange cover and connections The Ni Cd battery takes 36 hours to recharge the mains supply must be switched on during this time Figure 18 The Battery is located Inside the Base under t...

Page 63: ...f batteries measured at power off Exchange of the battery is done according to the beginning of this section User type Exchange 3 cell Exchange 6 cell 1 Vacation 4 weeks power off Every 5 years Every 5 years1 2 Weekend power off user type 1 Every 2 years Every 4 years 3 Nightly power off user type 1 and 2 Every year Every 2 years Min Max Ni Cd 7 0 V 8 7 V Lithium 7 0 V ...

Page 64: ...26320 001 Revision A 3 1 5 Checking the mechanical stop axis 1 Check regularly as follows That the stop pin is not bent If the stop pin is bent it must be replaced by a new one See Replacing the mechanical stop on page 78 The article number of the pin is 3HAB 3258 1 ...

Page 65: ...nipulator Axis 2 provides the lower arm s reciprocating motion The lower arm together with the parallel arm and the parallel bracket forms a parallelogram rel ative to the upper arm The parallel bracket is mounted on bearings in the parallel arm and in the upper arm Axis 3 raises the upper arm of the manipulator Axis 4 located on the side of the upper arm rotates the upper arm The wrist is bolted ...

Page 66: ...al description 64 3HAC026320 001 Revision A WARNING Take special care when manually operating the brakes Make sure also that the safety instructions described in this manual are followed when starting to operate the robot ...

Page 67: ...jobs It may be necessary to use conventional tools such as sockets and ratchet spanners etc or special tools depending on the type of servicing Conventional tools are not discussed in this manual since it is assumed that maintenance staff have sufficient basic technical competence Maintenance jobs which require the use of special tools are on the other hand described in this manual Foldouts The ch...

Page 68: ...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 anybody is allowed to enter its working space ...

Page 69: ...ns both before pre tensioning and during pre tensioning 3 The above procedure must be carried out to enable the roller parts to slot into the correct position with respect to the racer flange 4 It is important to position the bearings correctly because this directly affects the ser vice life of the bearing Action 1 Bearings must be greased after they are fitted Extreme cleanliness is necessary thr...

Page 70: ...gs and Seals 68 3HAC026320 001 Revision A 6 Bearings must be greased after they are fitted Extreme cleanliness is necessary throughout High quality lubricating grease such as Shell Alvania WR2 ABB s art No 3537 1 should be used Action ...

Page 71: ...should 2 3 filled with grease of type Shell Alvania WR2 ABB s art No 3537 1 1 The rubber coated external diameter must also be greased 7 Fit the seal correctly If it is fitted incorrectly it may start to leak when pumping starts 8 Always use an assembling tool to fit the seal Never hammer directly on the seal because this will cause it to leak 9 Use a protective sleeve on the sealing edge during a...

Page 72: ...of dust and grime 2 Check the O ring for surface defects and burrs and check that it has the correct shape etc 3 Make sure the correct O ring size is used 4 Tighten the screws evenly 5 Defective O rings and O ring grooves must not be used 6 If any of the parts fitted are defective they will cause leakage Grease the O ring with Shell Alvania WR2 ABB s art No 3537 1 before fitting it ...

Page 73: ...t are tightened to a specified torque are treated with Gleitmo WARNING 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 screwing in new screws without Gleitmo these should first be lubricat...

Page 74: ...d head property class 4 8 Screws with hexagon socket head property class 8 8 Dimension Tightening Torque Nm Without Oil M2 5 0 25 M3 0 5 M4 1 2 M5 2 5 M6 5 0 Dimension Tightening Torque Nm Tightening Torque Nm Without Oil With Oil M3 1 1 M4 2 2 M5 5 5 4 M6 10 9 M8 24 22 M10 48 45 M12 83 78 M16 200 190 M20 410 400 M24 750 740 ...

Page 75: ...ngaged 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...

Page 76: ...e foldout pos 1 10 Action Note Illustration 1 Check that the assembly surfaces are clean and the motor unscratched 2 Release the brake apply 24V DC to terminals 7 and 8 in the 4 MP1 connector 3 Install the motor tighten screws using a Torque approximately 2 Nm See foldout pos 1 10 NOTE Note the position of the motor 4 Adjust the motor in relation to the gear in the gearbox 5 Screw the 3HAB 1201 1 ...

Page 77: ...e 79 Changing the motor of axis 3 on page 86 2 Remove the cabling and serial measuring boards Described in section Changing the cabling in axes 1 2 and 3 on page 103 Changing serial measuring boards on page 102 3 Remove the tie rod Described in section Changing the tie rod on page 90 4 Remove the parallel arm Described in section Dismantling the parallel arm on page 89 5 Remove the balancing sprin...

Page 78: ...5 and 1 7 5 Turn the foot 6 Replace the lower arm Described in section Dismantling the lower arm on page 82 7 Replace the parallel arm Described in section Dismantling the parallel arm on page 89 8 Replace the upper arm Described in section Dismantling the complete upper arm on page 92 9 Replace the cabling Described in section Changing the cabling in axes 1 2 and 3 on page 103 Changing serial mea...

Page 79: ...ts 3 and 4 in chapter Foldout To dismantle To assemble Action Note Illustration 1 Remove the flange plate See foldout pos 4 138 2 Loosen the connector R1 LS 3 Dismantle the two limit switches See foldout pos 3 174 4 Loosen the cables from the switches 5 Remove the cabling through the base Action Note Illustration 1 Assemble in the reverse order ...

Page 80: ...eplacing the mechanical stop General If the stop pins are bent they must be replaced See foldout 1 in chapter Foldout Replacement Action Note Illustration 1 Remove the old stop pin 2 Fit the new pin according to the illustration Figure 20 Fit the new stop pin Loctite 242 or 243 68 1 ...

Page 81: ...and R3 FB2 5 Remove the connection box by unscrewing the screws See foldout pos 5 160 6 Note the position of the motor before removing it NOTE The oil will start to run out when loosen the motor 7 Loosen the motor by unscrewing the motor screws See foldout pos 1 10 Action Note Illustration 1 Check that the assembly surfaces are clean and the motor unscratched 2 Release the brake apply 24 V DC to t...

Page 82: ...tool into the end of the motor shaft 6 Make sure there is no play 7 Tighten screws See foldout pos 1 10 Torque of 8 3 Nm 10 8 Fill with oil Detailed in section Oil in gears 1 4 on page 57 9 Connect the cabling 10 Calibrate the robot as specified in Calibration methods on page 115 Action Note Illustration ...

Page 83: ...ufactured with a high degree of precision and together with the gearbox for axes 1 and 3 forms a complete unit See foldout 1 in chapter Foldout The gearbox is not normally serviced or adjusted NOTE Note If the gearbox of any of the axes 1 2 or 3 needs to be changed the whole unit must be changed To dismantle See Changing the gearbox on page 75 ...

Page 84: ...ng slings to the lower arm 1 Remove the parallel arm in accordance with Described in section Dismantling the parallel arm on page 89 1 Loosen screws See foldout pos 1 13 1 Remove the lower arm Action Note Illustration 1 Transfer the damping element and calibration mark ing to the new lower arm 2 Lift the lower arm into position 3 Fix the lower arm to gear 2 using screws 1 13 and tighten them to a ...

Page 85: ...alancing springs Detailed in section Dismantling the balancing springs on page 85 7 Replace the cabling as described in Detailed in section Cabling and serial measur ing board on page 102 8 Calibrate the robot Detailed in section Calibration methods on page 115 Action Note Illustration ...

Page 86: ...ection Changing the tie rod on page 90 2 Unscrew screws which hold the parallel arm to gear 3 See foldout pos 1 13 3 Remove the bearings from the parallel arm 1 Fit new bearings to the parallel arm 2 Replace the parallel arm using screws and tighten See foldout pos 1 13 Torque of 68 Nm 10 3 Attach the upper bracket of the tie rod as specified in Described in section Changing the tie rod on page 90...

Page 87: ...ased manually 4 Unscrew the screw in the upper bracket of the spring See foldout pos 2 65 5 Remove the springs Action Note Illustration 1 Before installing new springs make sure that the distance between the attachment points is correct see Figure 21 Lock the link heads using Loctite 242 or 243 Figure 21 Distance between the Attachment Points 2 Lubricate the link heads with grease 3 Attach the spr...

Page 88: ...start to run out when loosing the motor 5 Loosen the motor by unscrewing the motor screws See foldout pos 1 10 Action Note Illustration 1 Check that the assembly surfaces are clean and the motor unscratched 2 Release the brake apply 24 V d c to terminals 7 and 8 on the 4 MP1 connector 3 Install the motor tighten screws See foldout pos 1 10 Torque approximately 2 Nm NOTE Note the position of the mo...

Page 89: ...4 Repair 4 4 1 Changing the motor of axis 3 3HAC026320 001 Revision A 87 9 Connect the cabling 10 Calibrate the robot Detailed in section Calibration methods on page 115 Action Note Illustration ...

Page 90: ...rbox is of a conventional type manufactured with a high degree of precision and together with the gearbox for axes 1 and 2 forms a complete unit See foldout 1 in chapter Foldout The gearbox is not normally serviced or adjusted NOTE Note If the gearbox of any of the axes 1 2 or 3 needs to be changed the whole unit must be changed To dismantle See Changing the gearbox on page 75 ...

Page 91: ... the tie rod on page 90 2 Unscrew screws which fix the parallel arm to gear 3 See foldout pos 1 13 3 Remove the bearings from the parallel arm Action Note Illustration 1 Fit the bearings on the parallel arm 2 Replace the parallel arm using screws and tighten See foldout pos 1 13 Torque 68 Nm 10 3 Attach the upper bracket of the tie rod Detailed in section Changing the tie rod on page 90 4 Calibrat...

Page 92: ...s 2 72 7 Unscrew on the lower bracket See foldout pos 2 70 8 Carefully tap the rod off the shaft Action Note Illustration 1 Fit bearings on the parallel arm 2 Make sure you replace the rod the correct way up See foldout pos 1 1 3 Install grommets 3 x and 1 x See foldout pos 1 68 and 1 75 NOTE The grommet is bevelled and must be inserted the right way up in the lower bearing See foldout pos 2 75 4 ...

Page 93: ...4 Repair 4 4 4 Changing the tie rod 3HAC026320 001 Revision A 91 9 Lock using Loctite 242 or 243 Action Note Illustration ...

Page 94: ...ings on page 85 5 Undo the KM nuts See foldout pos 2 64 6 Remove washers and shims on the same side as axis 3 See foldout pos 2 61 2 62 and 2 63 7 Attach the withdrawing tool 3HAB 1259 1 and pull the axes off Action Note Illustration 1 Raise the upper arm into assembly position 2 Install shaft spindles both sides use two tem porary screws M10x90 See foldout pos 2 59 3 Insert bearings both sides us...

Page 95: ...dimension A Fit one washer and shims and using the micrometer measure the thickness so that the total thick ness is 0 10 0 20 mm more than the noted dimension A This will result in a preloading of the bearing of 0 10 0 20 mm See foldout pos 2 63 2 61 and 2 62 11 Fit the shims and washer and tighten the KM nut See foldout pos 2 64 12 Replace the upper attachment of the tie rod as specified in Detai...

Page 96: ...st the cal ibration washer according to the punch mark If the arm house is new adjust the washer according to Figure 24 and make new punch marks for axes 3 and 4 accordiong to Calibra tion scales IRB 1400 on page 117 Figure 23 Calibration Mark for Axis 3 Action Note Illustration 105o Measuring instrument 3HAB 1205 1 Withdrawing tool for shaft spindles 3HAB 1259 1 ...

Page 97: ...removing it 5 Loosen the motor by unscrewing the screw See foldout pos 8 23 Action Note Illustration 1 Check that the assembly surfaces are clean and the motor unscratched 2 Put O ring on the motor See foldout pos 8 21 3 Release the brake apply 24 V DC to terminals 7 and 8 on the R3 MP4 connector 4 Install the motor tighten screws See foldout pos 8 23 Torque approximately 2 Nm NOTE Note the positi...

Page 98: ...4 Repair 4 5 1 Changing the motor 96 3HAC026320 001 Revision A 10 Calibrate the robot Detaild in section Calibration methods on page 115 Action Note Illustration ...

Page 99: ...the motor on page 95 4 Remove the cover See foldout pos 8 25 5 Undo screws fixing the large drive gear and dis mantle it See foldout pos 8 18 and 8 17 NOTE Put the shims in a safe place 6 Undo screws See foldout pos 8 12 7 Push the intermediate gear out of the arm housing Action Note Illustration 1 Grease the seating of the arm housing to provide radial sealing 2 Push the gear unit down into the a...

Page 100: ...ng screws Use a drop of Loctite 242 or 243 See foldout pos 8 25 and 8 26 10 Position the manipulator so that the tubular shaft points upwards 11 Fill 30 ml oil into the gear of axis 4 Detailed in section Oil in gears 1 4 on page 57 12 Install the motor of axis 4 Detailed in section Changing the motor on page 95 13 Install drive mechanism See foldout pos 8 28 Detailed in section Dismantling the com...

Page 101: ...ntle the drive mechanism in accordance with Detailed in section Dismantling the complete drive mechanism of axes 5 and 6 on page 107 3 Dismantle the motor of axis 4 as specified in Detailed in section Changing the motor on page 95 4 Remove the cover See foldout pos 8 25 5 Unscrew screws that hold the intermediate gear in place See foldout pos 8 12 6 Unscrew screws that hold the large drive gear an...

Page 102: ...crew and 2 washers into the drive gear Lock using Loctite 242 or 243 See foldout pos 8 19 and 8 20 4 Mount the intermediate gear Detailed in section Changing the intermediate gear including sealing on page 97 5 Lubricate the drive gear with grease 30 g 6 Install the motor of axis 4 Detailed in section Changing the motor on page 95 7 Replace the cover using screws Lock using a drop of Loctite 242 o...

Page 103: ...g the drive gear on the tubular shaft on page 99 2 Push out the tubular shaft Action Note Illustration 1 Fit a new bearing on the tubular shaft using the tool See foldout pos 8 3 Tool no 6896 134 V 2 Push the tube into the housing of the upper arm 3 Insert the rear bearing using the tool See foldout pos 8 3 Tool no 6896 134 JB 4 Mount the drive gear Detailed in section Dismantling the drive gear o...

Page 104: ...eneral See foldout 4 in chapter Foldout To dismantle To assemble Action Note Illustration 1 Remove flange plate See foldout pos 4 138 2 Cut tie around bundle See foldout pos 4 144 3 Unscrew the serial measuring board using screws See foldout pos 4 135 and 4 7 4 Remove the board and loosen the contacts Action Note Illustration 1 Assemble in the reverse order ...

Page 105: ...e motors 2 Remove the flange plate See foldout pos 4 138 3 Loosen connectors R1 MP R2 FB1 3 4 Cut tie around bundle and detach the cable brack ets 5 Detach the cable guides and undo screws See foldout pos 3 104 and 105 cable guides See foldout pos 3 149 screw 6 Loosen the connectors in the motors 7 Disconnect the connection boxes in the motors 8 Feed the cabling up through the middle of axis 1 Act...

Page 106: ... connector R1 CS if there is one and the air hose 4 Detach the cable guides See foldout pos 3 104 105 5 Loosen the cable brackets between gears 2 and 3 and cut the tie around them See foldout pos 3 149 6 Feed the cabling and air hose up through axis 1 7 Loosen the cable bracket on the lower arm and undo screws See foldout pos 3 147 8 Undo screw which fixes the shaft of the tie rod See foldout pos ...

Page 107: ... and 6 is a complete unit comprising drive units and gears It is of such a complex design that it is not normally serviced on site but should be sent to ABB to be serviced NOTE ABB recommends to carry out only the following servicing and repair work on the wrist 1 Grease the wrist according to the table in section Maintenance Intervals on page 56 ...

Page 108: ...leeve through the hole See foldout pos 9 15 4 Disconnect the clamping sleeve 5 Undo screws and remove the wrist See foldout pos 1 53 Action Note Illustration 1 Mount the wrist tighten screws See foldout pos 1 53 Torque 8 3 Nm 10 NOTE The grease nipple on the tilt house should be pointing against the base The grease nipple on the tilt house should be pointing against the base 2 Screw the clamping s...

Page 109: ...ist on page 106 2 Loosen the connectors on the motors of axes 5 and 6 3 Undo screws See foldout pos 8 29 4 Squeeze the drive shafts together at the tip of the tubular shaft in order that they can pass through the tube See foldout pos 9 1 5 Pull out the complete drive mechanism of axes 5 and 6 Action Note Illustration 1 Install the drive mechanism in the tubular shaft 2 Tighten screws See foldout p...

Page 110: ...os 9 9 4 If the driving belt is to be changed both motors must be removed 5 Undo screws and remove plate See foldout pos 9 9 and 9 7 Action Note Illustration 1 Install the driving belts 2 Mount the plate using screws See foldout pos 9 7 and 9 9 NOTE Do not forget the nuts of the motors 3 Install the motors 4 Push the motors in sideways to tension the belts using the tool Tighten screws See foldout...

Page 111: ...4 Repair 4 7 4 Changing the motor or driving belt of axes 5 and 6 3HAC026320 001 Revision A 109 8 Calibrate the robot Detailed in section Calibration methods on page 115 Action Note Illustration ...

Page 112: ...ading the play This correspond to play of 0 27 mm on a radius of 200 mm when the load is F 40 N and 2 N on radius 120 mm See Figure 25 Figure 25 Measuring Play in Axis 5 Axis 6 The maximum accepted play in axis 6 is 12 8 arc minutes when loading axis 6 with a moment of 4 2 Nm in one direction unloading to 0 2 Nm and start measuring the play loading in the other direction with 4 2 Nm unloading to 0...

Page 113: ...ulator The cables are connected to the motor units by connectors The drive shaft of the electric motor forms a part of the gearbox of the manipulator axis A brake operated electromagnetically is mounted on the rear end of the motor shaft and a pin ion is mounted on its drive end The brake releases when power is supplied to the electromag nets The commutation value of the motors is 1 570800 NOTE Th...

Page 114: ...4 Repair 4 8 1 General 112 3HAC026320 001 Revision A ...

Page 115: ...ccuracy calibration it is also recommended but not always needed to be calibrated for new Absolute Accuracy The resolver values will change when parts affecting the calibration position are replaced on the robot e g motors wrist or part of transmission Contents of the revolution counter memory are lost If the contents of the revolution counter memory are lost the counters must be updated as detail...

Page 116: ...ndard calibra tion The calibrated robot is positioned at home position i e the axes positions angles are set to 0º Standard calibration data is found in the file calib cfg supplied with the robot at delivery The file identifies the correct resolver motor position corresponding to the robot home posi tion From deliveries together with RobotWare 5 0 5 and higher the data will instead be found on the...

Page 117: ...fferent routines further Absolute Accuracy calibration optional Based on standard calibration and besides positioning the robot at home position the Absolute Accuracy calibration also compen sates for mechanical tolerances in the robot structure deflection due to load Absolute Accuracy calibration focuses on positioning accuracy in the Cartesian coordi nate system for the robot Absolute Accuracy d...

Page 118: ... Calibration is enclosed with the Levelmeter 2000 CalibWare Abso lute Accuracy cal ibration In order to achieve a good positioning in the Cartesian coordinate system Absolute Accuracy is used as a TCP calibration The tool CalibWare guides through the calibration process and calculates new compensation parameters This is detailed further in the manual CalibWare 2 0 Users Guide M2000 If a service op...

Page 119: ...vision A 117 5 0 3 Calibration scales and correct axis position Introduction This section specifies the calibration scale positions and or correct axis position for all robot models Calibration scales IRB 1400 The illustration below shows the calibration scale positions on IRB 1400 en0200000272 ...

Page 120: ... position in the same direction in order to avoid position errors caused by backlash in gears etc Positive directions are shown in the figure below This is normally handled by the robot calibration software Calibration movement directions 6 axes NOTE The figure shows an IRB 7600 but the positive direction is the same for all 6 axis robots except the positive direction of axis 3 for IRB 6400R which...

Page 121: ... step when updating the revolution counter storing the rev olution counter setting with the FlexPendant RobotWare 5 0 Action Note 1 Select axis by axis motion mode 2 Jog the robot to place the calibration marks within the tolerance zone IRB 140 1400 2400 4400 6600ID 6650ID Axes 5 and 6 must be positioned together Shown in section Calibration scales IRB 1400 on page 117 3 When all axes are position...

Page 122: ...icking in the box to the left Tapping Select all to update all axes Then tap Update 5 A dialog box is displayed warning that the updating operation cannot be undone Tap Update to proceed with updating the revolution counters Tap Cancel to cancel updating the revolution counters Tapping Update updates the ticked revolution counters and removes the tick from the list of axes 6 If a revolution counte...

Page 123: ...reate the following program MoveAbsJ 0 0 0 0 0 0 9E9 9E9 9E9 9E9 9E9 9E 9 NoEOffs v1000 z50 Tool0 5 Run the program in manual mode 6 Check that the calibration marks for the axes align correctly If they do not update the revolution counters The calibration marks are shown in section Calibration scales IRB 1400 on page 117 How to update the revolution counters is detailed in section Updating revolu...

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Page 125: ...B 1400 6 0 1 Introduction 3HAC026320 001 Revision A 123 6 Reference information IRB 1400 6 0 1 Introduction General This chapter includes general information complementing the more specific information in the following chapters ...

Page 126: ...rrounding the robot cell ISO DIS 11161 Industrial automation systems safety of integrated manufacturing systems Basic requirements prEN 999 1995 Standards robot cell The following standards are applicable when the robot is part of a robot cell IEN 294 Safety of machinery Safety distance to prevent danger zones being reached by the upper limbs EN 349 Safety of machinery Minimum gaps to avoid crushi...

Page 127: ...evision A 125 6 0 3 Unit conversion Converter table Use the table below to convert units used in this manual Quantity Units Length 1 m 3 28 ft 39 37 in Weight 1 kg 2 21 lb Pressure 1 bar 100 kPa 14 5 psi Force 1 N 0 738 lbf Moment 1 Nm 0 738 lbf tn Volume 1 L 0 264 US gal ...

Page 128: ...screws Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint Screws treated with Gleitmo may be reused 3 4 times before the coating disappears After this the screw must be discarded and replaced with a new one When handling screws treated with Gleitmo protective gloves of nitrile rubber type should be used Screwslubricated in other ways Screws lubricated wit...

Page 129: ...joint by hand and never use pneumatical tools Use the correct tightening technique i e do not jerk Tighten the screw in a slow flow ing motion Maximum allowed total deviation from the specified value is 10 The table below specify the recommended standard tightening torque for oil lubricated screws with slotted or cross recess head screws The table below specify the recommended standard tightening ...

Page 130: ... the recommended standard tightening torque for water and air con nectors when one or both connectors are made of brass Dimension Tightening torque Nm Class 10 9 Molycote lubricated Tightening torque Nm Class 12 9 Molycote lubricated M8 28 34 M10 55 66 M12 96 115 M16 235 280 Dimension Tightening torque Nm Nominal Tightening torque Nm Min Tightening torque Nm Max 1 8 12 8 15 1 4 15 10 20 3 8 20 15 ...

Page 131: ...ified All components exceeding 22 kg 50 lbs are high lighted in this way To avoid injury ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg A wide range of lifting tools and devices are available for each manipulator model Example Below is an example of how a weight specification is presented CAUTION The motor weighs 32 kg All lifting equipment used ...

Page 132: ...e activities The table below specifies the article numbers of the product manuals for all controller models The part number 001 is the English version Operators manual The operators manual contains instructions for daily operation of robot systems The table below specifies the article numbers of the operators manuals for different robot systems Additional docu mentaion Document name Document ID Pr...

Page 133: ...aintenance and installation instructions contain lists of tools required to perform the specified activity All special tools i e all tools that are not considered standard as defined below are listed in their instructions respectively This way the tools required are the sum of the Standard Toolkit and any tools listed in the instruction Contents Tool Rem ...

Page 134: ...ncluded in the leakdown tester kit Art no is specified above 3 Apply compressed air and raise the pressure with the knob until the correct value is shown on the manom eter Recommended value 0 2 0 25 bar 20 25 kPa 4 Disconnect the compressed air supply 5 Wait for approx 8 10 minutes No pressure loss must be detected If the compressed air is sig nificantly colder or warmer than the gearbox to be tes...

Page 135: ...air and maintenance activities require different pieces of lifting equipment which are specified in each procedure The use of each piece of lifting equipment is not detailed in the activity procedure but in the instruction delivered with each piece of lifting equipment This implies that the instructions delivered with the lifting equipment should be stored for later reference ...

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Page 137: ... unit axis 4 6 with customer connection SEFAW 3HAC2743 1 Safety lamp 3HAB3272 1 Gear axis 1 3 STEPHAN WERKE 3HAB9750 1 Gear axis 1 3 SAMPINGRANAGGI 3HAC021963 001 Motor with pinion Axis 1 3 3HAC021740 001 Motor with pinion Axis 4 3HAC021741 001 Motor with pinion Axis 5 6 3HAB3388 1 Wrist unit 3HAB3263 1 Spring 3HAA2301 12 Rod en bearing KM10 3HAB3258 1 Stop pin 3HAA2393 1 Belt 3HAC17396 1 Serial m...

Page 138: ...7 Recommended Spare parts 7 0 1 Spare parts 136 Revision A 3HAC026320 001 ...

Page 139: ...8 Foldouts 8 0 1 Introduction 3HAC026320 001 Revision A 137 8 Foldouts 8 0 1 Introduction Overview This chapter includes foldouts with illustrations of the robot ...

Page 140: ...8 Foldouts 8 0 1 Introduction 138 3HAC026320 001 Revision A ...

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Page 151: ...9 Circuit diagram 9 0 1 Introduction 3HAC026320 001 Revision A 139 9 Circuit diagram 9 0 1 Introduction Overview This chapter includes the complete circuit diagram for the robot ...

Page 152: ...9 Circuit diagram 9 0 2 Sheet 101 List of contents 140 3HAC026320 001 Revision A 9 0 2 Sheet 101 List of contents ...

Page 153: ...9 Circuit diagram 9 0 3 Sheet 102 Connection point location 3HAC026320 001 Revision A 141 9 0 3 Sheet 102 Connection point location ...

Page 154: ...9 Circuit diagram 9 0 4 Sheet 103 Serial measurement board 142 3HAC026320 001 Revision A 9 0 4 Sheet 103 Serial measurement board ...

Page 155: ...9 Circuit diagram 9 0 5 Sheet 104 Motor axes 1 3 3HAC026320 001 Revision A 143 9 0 5 Sheet 104 Motor axes 1 3 ...

Page 156: ...9 Circuit diagram 9 0 6 Sheet 105 Feedback axes 1 3 144 3HAC026320 001 Revision A 9 0 6 Sheet 105 Feedback axes 1 3 ...

Page 157: ... 3 2 U W V MU6 6 7 8 5 B PTC W 3 R3 MP4 1 2 U V 7 8 B MU4 5 6 PTC 1 2 3 6 9 12 4 7 10 R1 MP4 6 PTC 34 11 8 PE PE R S T R S T R S T M4R M4S M4T M6R M6S M6T M5R M5S M5T PTC 111 R1 MP4 6 111 5 BRPB R S1 3 R1 BU 104 13 14 15 2 1 BU 3 4 BU BU BU BU BU BU 15 14 13 GNYE 17 16 12 8 7 6 2 1 5 4 3 9 GNYE PTC 46 10 BU BU PTC 65 1 R1 H1 112 11 R3 H2 1 R3 H1 1 BRAKE REL 0V BRAKE BRAKE REL 0V BRAKE ...

Page 158: ...9 Circuit diagram 9 0 8 Sheet 107 Feedback axes 4 6 146 3HAC026320 001 Revision A 9 0 8 Sheet 107 Feedback axes 4 6 ...

Page 159: ...9 Circuit diagram 9 0 9 Sheet 108 Customer connection Option 3HAC026320 001 Revision A 147 9 0 9 Sheet 108 Customer connection Option ...

Page 160: ...Option CSA CSJ CSB CSC CSD CSE CSF CSG CSH CSP CSK CSL CSM CSN CSR CSS GY WH VT WH BU WH GN WH YE WH OG WH RD WH BN WH S R N M L H K P G F J E D C B A S R N M L H K P G F J E D C B A M L J K F G H C E B D A CPM CPL CPJ CPK CPF CPG CPH CPC CPE CPB CPD CPA CPD CPA M L J K F G H C E B D A 4 5 6 7 8 9 10 11 12 13 14 15 16 17 R2 CS R1 CS R1 CP R2 CP ...

Page 161: ...9 Circuit diagram 9 0 11 Sheet 110 Position indicator axis 1 3HAC026320 001 Revision A 149 9 0 11 Sheet 110 Position indicator axis 1 ...

Page 162: ...9 Circuit diagram 9 0 12 Sheet 111 External connections Option 150 3HAC026320 001 Revision A 9 0 12 Sheet 111 External connections Option ...

Page 163: ...Connection of external safety devices 12 D direction of axes 118 E ESD damage elimination 32 sensitive equipment 32 explanation safety symbols 28 F FlexPendant jogging to calibration position 121 MoveAbsJ instruction 121 updating revolution counters 119 L Levelmeter calibration 116 M MoveAbsJ instruction FlexPendant 121 N negative directions axes 118 O oil change safety risks 33 P position robot 1...

Page 164: ...Index 152 3HAC026320 001 ...

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Page 166: ...ABB AB Robotics Products S 721 68 VÄSTERÅS SWEDEN Telephone 46 0 21 344000 Telefax 46 0 21 132592 3HAC026320 001 Revision A en ...