Professional Documents
Culture Documents
Industrial Robot
IRB 6600 - 225/2.55
IRB 6600 - 175/2.8
IRB 6600 - 175/2.55
IRB 6650 - 200/2.75
IRB 6650 - 125/3.2
M2000A
Product Specification
3HAC 14064-1/M2000/Rev 2
IRB 6600 - 175/2.55
IRB 6600 - 225/2.55
IRB 6600 - 175/2.8
IRB 6650 - 125/3.2
IRB 6650 - 200/2.75
The information in this document is subject to change without notice and should not be construed as a
commitment by ABB Automation Technology Products AB, Robotics. ABB Automation Technology
Products AB, Robotics assumes no responsibility for any errors that may appear in this document.
In no event shall ABB Automation Technology Products AB, Robotics be liable for incidental or
consequential damages arising from use of this document or of the software and hardware described
in this document.
This document and parts thereof must not be reproduced or copied without ABB Automation
Technology Products AB, Roboticss 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 document may be obtained from ABB Automation Technology Products AB,
Robotics at its then current charge.
Description
1 Description
1.1 Structure
A new world of possibilities opens up with ABBs IRB 6600 robot family. It comes in
five versions, 175kg /2.55m, 225kg /2.55 m, 175kg /2.8m, 125kg/3.2m, and
200kg/2.75m handling capacities.
The IRB 6600 is ideal for process applications, regardless of industry. Typical areas can
be spotwelding, material handling and machine tending.
We have added a range of software products - all falling under the umbrella designation
of Active Safety - to protect not only personnel in the unlikely event of an accident, but
also robot tools, peripheral equipment and the robot itself.
The robot is equipped with the operating system BaseWare OS. BaseWare OS controls
every aspect of the robot, like motion control, development and execution of
application programs, communication etc. See Product Specification S4Cplus.
For additional functionality, the robot can be equipped with optional software for
application support - for example spot welding, communication features - network
communication - and advanced functions such as multi-tasking, sensor control, etc.
For a complete description on optional software, see the Product Specification
RobotWare Options.
Axis 3
Axis 4 Axis 5
Axis 6
Axis 2
Axis 1
Description
Different robot versions
The IRB 6600 is available in five versions. The following different robot types are
available:
Standard:
IRB 6600 - 175 kg / 2.55 m
IRB 6600 - 225 kg / 2.55 m
IRB 6600 - 175 kg / 2.8 m
IRB 6650 - 125 kg / 3.2 m
IRB 6650 - 200 kg / 2.75 m
Definition of version designation
IRB 6600 Mounting - Handling capacity / Reach
Prefix
Mounting
Description
Floor-mounted manipulator
Handling capacity
yyy
Reach
x.x
Manipulator weight
IRB 6600-175/2,55
IRB 6600-225/2,55
IRB 6600-175/2,8
IRB 6650-125/3.2
IRB 6650-200/2.75
1700 kg
1700 kg
1700 kg
1725 kg
1700 kg
< 73 dB (A) Leq (acc. to
Machinery directive 98/37/EEC)
Description
IRB 6600
2445 IRB 6650
6600-400/2.55
R 580
R 690 with fork lift
Figure 2 View of the manipulator from the side and above (dimensions in mm).
Allow 200 mm behind the manipulator foot for cables.
Description
1.2 Safety/Standards
The robot conforms to the following standards:
EN 292-1
Safety of machinery, terminology
EN 292-2
Safety of machinery, technical specifications
EN 954-1
Safety of machinery, safety related parts of control
systems
EN 60204
Electrical equipment of industrial machines
IEC 204-1
Electrical equipment of industrial machines
ISO 10218, EN 775
Manipulating industrial robots, safety
ANSI/RIA 15.06/1999
Industrial robots, safety requirements
ISO 9787
Manipulating industrial robots, coordinate systems
and motions
IEC 529
Degrees of protection provided by enclosures
EN 50081-2
EMC, Generic emission
EN 61000-6-2
EMC, Generic immunity
ANSI/UL 1740-1996 (option) Standard for Industrial Robots and Robotic
Equipment
CAN/CSA Z 434-94 (option) Industrial Robots and Robot Systems - General
Safety Requirements
The robot complies fully with the health and safety standards specified in the EECs
Machinery Directives.
The Service Information System (SIS)
The service information system gathers information about the robots usage and by that
determines how hard the robot has been used. The usage is characterised by the speed,
the rotation angles and the load of every axis.
With this data collection, the service interval of every individual robot of this generation
can be predicted, optimising and planning ahead service activities. The collection data is
available via the teach pendant or the network link to the robot.
The Process Robot Generation is designed with absolute safety in mind. It is dedicated
to actively or passively avoid collisions and offers the highest level of safety to the
operators and the machines as well as the surrounding and attached equipment. These
features are presented in the active and passive safety system.
The Active Safety System
The active safety system includes those software features that maintain the accuracy of
the robots path and those that actively avoid collisions which can occur if the robot
leaves the programmed path accidentally or if an obstacle is put into the robots path.
The Active Brake System (ABS)
All robots run with an active brake system that supports the robots to maintain the
programmed path even in an emergency situation.
6
Description
The ABS is active during all stop modes, braking the robot to a stop with the power of
the servo drive system along the programmed path. After a specific time the mechanical
brakes are activated ensuring a safe stop even in case of a failure of the drive system or
a power interruption.
The maximal applicable torque on the most loaded axis determines the stopping
distance.
The stopping process is in accordance with a class 1 stop.
While programming the robot in manual mode a class 0 stop, with mechanical brakes
only, applies.
The Self Tuning Performance (STP)
The Process Robot Generation is designed to run at different load configurations, many
of which occur within the same program and cycle.
The robots installed electrical power can thus be exploited to lift heavy loads, create a
high axis force or accelerate quickly without changing the configuration of the robot.
Consequently the robot can run in a power mode or a speed mode which can be
measured in the respective cycle time of one and the same program but with different
tool loads. This feature is based on QuickMoveTM.
The respective change in cycle time can be measured by running the robot in NoMotionExecution with different loads or with simulation tools like RobotStudio.
The Electronically Stabilised Path (ESP)
The load and inertia of the tool have a significant effect on the path performance of a
robot. The Process Robot Generation is equipped with a system to electronically
stabilise the robots path in order to achieve the best path performance.
This has an influence while accelerating and braking and consequently stabilises the
path during all motion operations with a compromise of the best cycle time. This feature
is secured through TrueMoveTM.
Over-speed protection
The speed of the robot is monitored by two independent computers.
Restricting the working space
The movement of each axis can be restricted using software limits.
As options there are safeguarded space stops for connection of position switches to
restrict the working space for the axes 1-3.
Axes 1-3 can also be restricted by means of mechanical stops.
Collision detection (option)
In case an unexpected mechanical disturbance occurs, like a collision, electrode sticking, etc., the robot will detect the collision, stop on the path and slightly back off from
its stop position, releasing tension in the tool.
The Passive Safety System
The Process Robot Generation has a dedicated passive safety system that by hardware
construction and dedicated solutions is designed to avoid collisions with surrounding
equipment. It integrates the robot system into the surrounding equipment safely.
Compact robot arm design
The shape of the lower and upper arm system is compact, avoiding interference into the
working envelope of the robot.
Product Specification IRB 6600 M2000
Description
The lower arm is shaped inward, giving more space under the upper arm to re-orientate
large parts and leaving more working space while reaching over equipment in front of
the robot.
The rear side of the upper arm is compact, with no components projecting over the edge
of the robot base even when the robot is moved into the home position.
Moveable mechanical limitation of main axes (option)
All main axes can be equipped with moveable mechanical stops, limiting the working
range of every axis individually. The mechanical stops are designed to withstand a
collision even under full load.
Position switches on main axes (option)
All main axes can be equipped with position switches. The double circuitry to the cam
switches is designed to offer personal safety according to the respective standards.
The Internal Safety Concept
The internal safety concept of the Process Robot Generation is based on a two-channel
circuit that is monitored continuously. If any component fails, the electrical power
supplied to the motors shuts off and the brakes engage.
Safety category 3
Malfunction of a single component, such as a sticking relay, will be detected at the next
MOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the faulty
section is indicated. This complies with category 3 of EN 954-1, Safety of machinery safety related parts of control systems - Part 1.
Selecting the operating mode
The robot can be operated either manually or automatically. In manual mode, the robot
can only be operated via the teach pendant, i.e. not by any external equipment.
Reduced speed
In manual mode, the speed is limited to a maximum of 250 mm/s (600 inch/min.).
The speed limitation applies not only to the TCP (Tool Centre Point), but to all parts of
the robot. It is also possible to monitor the speed of equipment mounted on the robot.
Three position enabling device
The enabling device on the teach pendant must be used to move the robot when in
manual mode. The enabling device consists of a switch with three positions, meaning
that all robot movements stop when either the enabling device is pushed fully in, or when
it is released completely. This makes the robot safer to operate.
Safe manual movement
The robot is moved using a joystick instead of the operator having to look at the teach
pendant to find the right key.
Emergency stop
There is one emergency stop push button on the controller and another on the teach
pendant. Additional emergency stop buttons can be connected to the robots safety chain
circuit.
Safeguarded space stop
The robot has a number of electrical inputs which can be used to connect external safety
equipment, such as safety gates and light curtains. This allows the robots safety
functions to be activated both by peripheral equipment and by the robot itself.
8
Description
Delayed safeguarded space stop
A delayed stop gives a smooth stop. The robot stops in the same way as at a normal
program stop with no deviation from the programmed path. After approx. 1 second the
power supplied to the motors is shut off.
Hold-to-run control
Hold-to-run means that you must depress the start button in order to move the robot. When
the button is released the robot will stop. The hold-to-run function makes program testing
safer.
Fire safety
Both the manipulator and control system comply with ULs (Underwriters Laboratory)
tough requirements for fire safety.
Safety lamp (option)
As an option, the robot can be equipped with a safety lamp mounted on the manipulator. This is activated when the motors are in the MOTORS ON state.
Description
1.3 Installation
All versions of IRB 6600 are designed for floor mounting. Depending on the robot
version, an end effector with max. weight of 175 to 225 kg including payload, can be
mounted on the mounting flange (axis 6). See Load diagram for IRB 6600 generation
robots on page 14, page 16, page 18, page 20 and page 22.
Extra loads (valve packages, transformers) can be mounted on the upper arm with a
maximum weight of 50 kg. On all versions an extra load of 500 kg can also be mounted
on the frame of axis 1. Holes for mounting extra equipment on page 26.
The working range of axes 1-3 can be limited by mechanical stops. Position switches
can be supplied on axes 1-3 for position indication of the manipulator.
External Mains Transformer
The robot system requires a 400 - 475 VAC power supply. Therefore an external
transformer will be included when a mains voltage other than 400-475V is selected.
Operating requirements
Protection standards
Standard and Foundry Manipulator
IP67
Cleanroom standards
Cleanroom class 100 for manipulator according to:
DIN EN ISO 14644: Cleanrooms and associated controlled environments
US Federal Standard 209 e - Air-clean-classes
Explosive environments
The robot must not be located or operated in an explosive environment.
Ambient temperature
Manipulator during operation
For the controller: standard
option
Complete robot during transportation and storage, -25oC (13oF) to +55oC (131oF)
for short periods (not exceeding 24 hours)
up to +70oC (158oF)
Relative humidity
Complete robot during transportation and storage Max. 95% at constant temperature
Complete robot during operation
Max. 95% at constant temperature
Mounting the manipulator
Maximum load in relation to the base coordinate system.
Force xy
Force z
Torque xy
Torque z
10
Endurance load
in operation
Max. load at
emergency stop
10.1 kN
18.0 13.8 kN
20.7 kN
18.0 22.4 kN
27.6 kNm
7.4 kNm
50.6 kNm
14.4 kNm
Product Specification IRB 6600 M2000
88 0.3
Description
11
Description
B
5
325
D
B
37,5 o
15
C
o
10
50
522
0.1
A
A-A
1.5
B-B
C-C
D
Two guiding pins required, dimensions see Figure 5
12
Description
200
Figure 6 Centre of gravity for 50 kg extra load at arm housing (dimensions i mm).
13
Description
Load diagram for IRB 6600-175/2.55
0,80
80 kg
0,70
100 kg
0,60
120 kg
Z-distance (m)
0,50
135 kg
0,40
150 kg
175 kg
0,30
180 kg
185 kg
0,20
200 mm
0,10
0,00
0,00
0,10
0,10
0,20
0,30
0,40
0,50
L-distance (m )
Figure 7 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity).
14
Description
Load diagram for IRB 6600-175/2.55 Vertical Wrist (10o)
Vertical wrist
10o 10o
200 mm
L-distance (m)
0,0
0,2
0,20
0,4
0,40
0,6
0,60
Pay
load
0,8
0,80
1,0
1,00
1,2
1,20
1,4
1,40
0,0
0,2
0,20
210 kg
190 kg
0,40
0,4
Z-distance (m)
150 kg
0,60
0,6
100 kg
0,80
0,8
75 kg
1,00
1,0
1,20
1,2
1,40
1,4
Figure 8 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity) at Vertical Wrist (10o), J0 =15 kgm2.
15
Description
Load diagram for IRB 6600-225/2.55
0,90
100 kg
0,80
0,70
120 kg
0,60
Z-distance (m)
150 kg
0,50
175 kg
200 kg
0,40
215 kg
220 kg
0,30
225 kg
230 kg
0,20
200 mm
0,10
0,00
0,00
0,10
0,10
0,20
0,20
0,30
0,40
0,50
0,60
L-distance (m)
Figure 9 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity).
16
Description
Load diagram for IRB 6600-225/2.55 Vertical Wrist (10o)
Vertical wrist
Pay
load
10o 10o
200 mm
Z
L-distance (m)
0,00
0,20
0,40
0,60
0,80
1,00
1,20
1,40
0,00
0,20
260 kg
235 kg
0,40
200 kg
Z-distance (m)
0,60
150 kg
0,80
100 kg
1,00
1,20
1,40
1,60
Figure 10 Maximum permitted load mounted on the robot tool flange at different positions (centre of
gravity) at Vertical Wrist (10o).
17
Description
Load diagram for IRB 6600-175/2.8
1,10
1,00
80 kg
0,90
100 kg
0,80
Z-distance (m)
0,70
120 kg
0,60
150 kg
0,50
170 kg
0,40
175 kg
0,30
180 kg
185 kg
0,20
200 mm
0,10
0,00
0,00
0,10
0,10
0,20
0,20
0,30
0,40
0,50
0,60
0,70
L-distance (m )
Figure 11 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity)..
18
Description
Load diagram for IRB 6600-175/2.8 Vertical Wrist (10o)
Vertical wrist
Pay
load
200 mm
10o 10o
L-distance (m )
0,00
0,20
0,40
0,60
0,80
1,00
1,20
1,40
0,00
0,20
210 kg
190 kg
0,40
Z-distance (m)
170 kg
125 kg
0,60
100 kg
0,80
1,00
1,20
Figure 12 Maximum permitted load mounted on the robot tool flange at different positions (centre of
gravity) at Vertical Wrist (10o).
19
Description
Load diagram for IRB 6650-125/3.2
1,10
1,00
80 kg
0,90
90 kg
0,80
100 kg
0,70
Z-distance (m)
110 kg
0,60
115 kg
0,50
120 kg
0,40
125 kg
0,30
130 kg
0,20
200 mm
0,10
0,00
0,00
0,10
0,20
0,20
0,30
0,40
0,50
0,60
0,70
L-distance (m)
Figure 13 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity)..
20
Description
Load diagram for IRB 6650-125/3.2 Vertical Wrist (10o)
Vertical wrist
Pay
load
10o 10o
L-distance (m)
Z
0,0
0,2
0,20
0,4
0,40
0,6
0,60
0,8
0,80
1,0
1,00
1,2
1,20
1,4
1,40
1,6
1,60
0,0
150 kg
0,20
0,2
135 kg
0,40
0,4
120 kg
Z-distance (m)
110 kg
0,6
0,60
100 kg
0,8
0,80
1,0
1,00
1,2
1,20
1,40
1,4
1,60
1,6
Figure 14 Maximum permitted load mounted on the robot tool flange at different positions (centre of
gravity) at Vertical Wrist (10o).
21
Description
Load diagram for IRB 6650-200/2.75
0,90
0,80
100 kg
0,70
120 kg
135 kg
0,60
Z-distance (m)
150 kg
0,50
175 kg
195 kg
0,40
200 kg
0,30
205 kg
210 kg
0,20
200 mm
0,10
0,00
0,00
0,10
0,10
0,20
0,30
0,40
0,50
0,60
L-distance (m)
Figure 15 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity).
22
Description
Load diagram for IRB 6650-200/2.75 Vertical Wrist (10o)
Vertical wrist
Pay
load
10o 10o
Z
200 mm
L-distance (m)
0,0
0,2
0,20
0,4
0,40
0,6
0,60
0,8
0,80
1,0
1,00
1,2
1,20
1,4
1,40
0,0
235 kg
0,20
0,2
210 kg
Z-distance (m)
0,4
0,40
175 kg
0,60
0,6
125 kg
0,80
0,8
100 kg
1,0
1,00
1,2
1,20
1,4
1,40
Figure 16 Maximum permitted load mounted on the robot tool flange at different positions (centre of
gravity) at Vertical Wrist (10o).
23
Description
Maximum load and moment of inertia for full and limited axis 5 (centre line down)
movement.
Note. Load in kg, Z and L in m and J in kgm2
Full movement of axis 5 (120o):
Axis 5
Maximum moment of inertia:
Ja5 = Load ((Z + 0,200)2 + L2) + J0L 250 kgm2 for: -225/2.55, -175/2.8, -125/3.2 and
-200/2.75
Centre of gravity
J0L = Maximum own moment of inertia
around the maximum vector in the X-Y-plane
J0Z = Maximum own moment of inertia around Z
kgm2
-200/2.75
for: -175/2.55
Centre of gravity
J0L = Maximum own moment of inertia
around the maximum vector in the X-Y-plane
J0Z = Maximum own moment of inertia around Z
Z
Figure 18 Moment of inertia when axis 5 centre line down.
24
Description
Mounting equipment
Extra loads can be mounted on the upper arm housing, the lower arm, and on the frame.
Definitions of distances and masses are shown in Figure 19 and Figure 20.
The robot is supplied with holes for mounting extra equipment (see Figure 21).
Maximum permitted arm load depends on centre of gravity of arm load and robot
payload.
Upper arm
Permitted extra load on upper arm housing plus the maximum handling
weight (See Figure 19):
M1 50 kg with distance a 500 mm, centre of gravity in axis 3 extension.
/
M1
Mass
centre
M1
JH0
R
M4
527
457
790
1195
25
Description
Mounting of hip load
The extra load can be mounted on the frame. Holes for mounting see Figure 21 and
Figure 22. When mounting on the frame all the four holes (2x2, 16) on one side must
be used.
Figure 21 Holes for mounting extra equipment on the upper and the lower arm, and the frame
(dimensions in mm).
26
Description
Figure 22 Holes for mounting of extra load on the upper arm (dimensions in mm).
27
Description
IRB 6600-175/2.55
1,6
0,04 A
12 H7 Depth 15
15
A
)
o (12x
30
A-A
0,02 CD
99
100 H7 Depth 8 min
160
0,02 A
B-B
M12 ( 11x )
0,2 A B
28
Description
IRB 6600-225/2.55
IRB 6600-175/2.8
IRB 6650-125/3.2
IRB 6650-125/3.2
2
0,04 A
1,6
12 H7 Depth 15
15
A
1,6
B
0,02 C D
A-A
0,02 A
M12 ( 11x )
0,2 A B
160
B-B
29
Description
30
Description
Range of movement
Axis 1
Axis 2
Axis 3
Axis 4
Axis 5
Axis 6
+180o
+85o
+70o
+300o
+120o
+300o
Rotation motion
Arm motion
Arm motion
Wrist motion
Bend motion
Turn motion
to
to
to
to
to
to
-180o
-65o
-180o
-300o
-120o
-300o
IRB 6600-175/2.55
IRB 6600-225/2.55
Figure 25 The extreme positions of the robot arm specified at the wrist centre (dimensions in mm).
31
Description
IRB 6600-175/2.8
Figure 26 The extreme positions of the robot arm specified at the wrist centre (dimensions in mm).
32
Description
IRB 6650-125/3.2
Figure 27 The extreme positions of the robot arm specified at the wrist centre (dimensions in mm).
IRB 6650-200/2.75
Figure 28 The extreme positions of the robot arm specified at the wrist centre (dimensions in mm).
33
Description
Performance according to ISO 9283
At rated maximum load, maximum offset and 1.6 m/s velocity (for IRB 6600-225/2.55,
1.0 m/s velocity) on the inclined ISO test plane, 1 m cube with all six axes in motion.
Data for IRB 6650 not yet available.
IRB 6600
-175/2.55
Pose accuracy, AP
0.09 mm
Pose repeatability, RP
0.18 mm
Path repeatability, RT
1.05 mm
Pose stabilization time, Pst 0.03 s
-225/2.55
0.11 mm
0.18 mm
0.36 mm
0.55 s*
-175/2.8
0.13 mm
0.20 mm
0.32 mm
0.21 s
Axis no.
1
2
3
4
5
6
IRB 6600-175/2.55
IRB 6600-225/2.55
IRB 6600-175/2.8
IRB 6650-200/2.75
IRB 6650-125/3.2
100/s
90/s
90/s
150/s
120/s
190/s
110/s
90/s
90/s
150/s
120/s
235/s
The maximum allowed average speed for axis 1-3 at the maximum ambient
temperature of 50oC according to Table 1. IP 54 for cooling fan.
Table 1
Variant
34
Maximum
average speed
axis 1 (rpm)
Maximum
average speed
axis 2 (rpm)
Maximum
average speed
axis 3 (rpm)
IRB 6600-175/2.55
8.1 - 10.5
2.4 - 2.6
4.7 - 6.1
IRB 6600-225/2.55
7.8 - 10.1
2.1 - 2.3
3.1 - 4.0
IRB 6600-175/2.8
7.8 - 10.1
2.1 - 2.3
3.1 - 4.0
IRB 6650-125/3.2
4.9 - 6.3
2.1 - 2.3
3.1 - 4.0
IRB 6650-200/2.75
7.8 - 10.1
2.1 - 2.3
3.1 - 4.0
Description
Pedestal Gun
Type HS
Material Handling
Type H
35
Description
The SpotPack for IRB6600/6650 is modular based and contains the main modules
shown in the schematic picture below. Option description specifies different module
combinations.
Robot
gun/gripper
Upper arm
harness
Lower arm
harness
Power
unit
Water and
air unit
Control
Cabinet
Pedestal
gun
Floor
harness
The modules Upper arm harness, Lower arm harness and Floor harness are in
different combinations described as DressPack. The DressPack for upper and lower
arm harness contains signals, process media (water and air) and power feeding (for
Spotwelding power) for customer use. The floor harness for DressPack contains
customer signals.
To form a complete SpotPack also a Water and Air unit with hoses, Power unit with
power cable and signal cables between these units are required.
36
Description
Description of DressPack
The DressPack contains the maximum wire and media capacity as described below.
The number of signals that are available in each case depends on the choice of different
option combinations (see option description). The interface connectors for the signals
are also specified under each option description.
Material handling application
The cables and hose which are used to form the DressPack for the Material Handling
application has the following specification and capacity:
Table 2
Type
Pcs
Area
Allowed capacity
2+2
1
0,5 mm2
1,0 mm2
19
4
0,23 mm2
0,23 mm2
50 VAC/DC, 1 A rms
50 VAC/DC, 1 A rms
2
2
4
4
0,18 mm2
0,18 mm2
0,18 mm2
0,23 mm2
Media
Air (PROC 1)
12,5 mm
inner
diameter
Quad twisted under separate screen. Can also be used for very sinsitive signals
37
Description
Spot Welding application
The cables and hoses used for the DressPack for the Spot Welding application has the
following specification and capacity:
Table 3
Type
Pcs
Area
Allowed capacity
3
2+2
1
1,5 mm2
0,5 mm2
1,5 mm2
19*
4
0,23 mm2
0,23 mm2
50 VAC/DC, 1 A rms
50 VAC/DC, 1 A rms
2
2
4
4
0,18 mm2
0,18 mm2
0,18 mm2
0,23 mm2
2
1
35mm2
35mm2
600 VAC***
2
1
25mm2
25mm2
600 VAC****
12,5 mm
inner
diameter
3-4
If servo gun application (S or HS) is used some signals will be occupied for motor
control.
** Quad twisted under separate screen. Can also be used for very sensitive signals.
*** 150 A rms at + 20C (68F) ambient temp, 120 A rms at + 50C (122F) ambient
temp
**** 135 A rms at + 20C (68F) ambient temp, 100 A rms at + 50C (122F) ambient
temp
38
Description
Description of Water and Air unit
The Water and Air unit contains components for water and air distribution and control
within the SpotPack. The water and air unit is via the process software controlled from
the robot controller. Wiring is made via the power unit.
The capacity and functionality depends on the choice of different option combinations,
see option description.
The unit is mounted at the manipulator base. Control cables to the unit has quick
connectors in both ends and has the same cable length as the one specified for the robot
control cable. The unit is only used for the spot welding applications.
Table 4
Type
Pcs
1
1
1
1
Specification
Parker PushLock fitting, M22 (conical angle 24)*
Parker PushLock fitting, M22 (conical angle 24)*
Parker PushLock fitting, M22 (conical angle 24)*
1/2" connection. **
Max air pressure 16 bar / 230 PSI, max water pressure 10 bar / 145 PSI. (Parker
Pushlock reference 3C382-15-8BK, brass version)
** Plugged at delivery (to be used for tip-dresser or other equipment). (Fitting 1/2"
BSP 1,5).
Signals for water and air unit:
Electrical connections to robot I/O board are made via the splitbox on the water and air
unit. Total 6 x M12 connections (4 pins) are available. The number in use depends on
option choices but minimum 2 are in use within the SpotPack. Free connections can be
used for customer purpose like tip-dresser control (Max 0,5 amp, 24 DC Volt).
39
Description
Description of Power Unit
The Power unit contains components for power distribution and control within the
SpotPack. The power unit with the welding controller built in, is controlled from the
robot controller via the process software.. Wiring is made between robot controller
(I/O-board and internal cabling in the DressPack) and the power unit.
The capacity and functionality depends by the choice of different option combinations.
All cables are connected on the left hand side of the power unit.
The unit is placed on top of the robot controller. The unit is only used for the spot
welding applications. Two basic versions are available, Type S for Spotwelding with
robot handled gun and Type HS for Spotwelding with pedestal gun.
Table 5
Type
Pcs
Area
Allowed capacity
Floor cable
Floor cable protective earth
2
1
Signals
Water and Air unit
Pedestal gun
1
1
** 150 A rms at + 20C (68F) ambient temp and 120 A rms at + 50C (122F) ambient
temp
*** The connector type at the power unit is Han compact, HD insert..
Protection class for the power unit is IP54.
40
Description
41
Description
SpotPack Type HS with servo requires the following additional options:
Option 381
Option 702
Option 686-689
Option 625
42
Description
1.9.2 DressPack options
Dress Pack options includes options for Upper arm harness, Lower arm harness and
Floor harness. These are described separated below but are designed and meant to be
seen as a complete package for either Material handling or Spot welding application.
The Upper Arm Harness consists of a process cable package and supports, clamps,
brackets and a retractor arm. The process cable package contains special designed
cables and hoses that have been long term tested. The cables and hoses are partly
placed in a protective hose to extend the lifetime.
The Upper Arm Harness is designed to follow the robot arm movements and minimise
damages to the harness or the robot manipulator. The interface to the lower arm harness
is located well protected below the motor for axis 3.
The complete harness is tested and proven to be well suited for both spot welding
applications and other applications with the same type of movements and very high
requirements. The cable and hose package has a 1000-mm free length at axis 6 for
connection to a spot welding gun or a gripper. A tension arm unit keeps hose package
in the right position for the robot arm movement approved for the SpotPack. An arm
protection will prevent wear on the protective hose and on the robot itself. Please note
that when the robot is operating, some multiply axis movement might end up with an
overstraining of the hose package. These movements must be avoided.
For more information see the Installation and Maintenance Manual.
Process Cable package
Harness support axis 6
Tension arm unit
Arm protection
Note. The upper arm harness specification is based on the sselection of lower arm
harness.
The Lower Arm Harness consists of a process cable package and supports, clamps
and brackets. The process cable package, containing special designed cables and hoses,
has been long term tested.
The process cable package is routed along the lower arm to minimise space required
and to give no limitation in the robot working envelope. The cables and hoses are partly
placed in a protective hose to extend the lifetime.
Product Specification IRB 6600 M2000
43
Description
The lower arm harness is connected to the upper arm harness at the connection point
under the axis 3 motor. The interface plate at the manipulator base is the place where
the floor harness and the process media are connected.
The Floor Harness consists of signal cables for customer signals. The floor harness is
connected to the lower arm harness at the interface plate at the manipulator base and to
the left side of the robot control cabinet. The signal connection inside the robot control
cabinet depends on chosen options. As example will servo gun option, bus option and
parallel option mean different connections.
Process cable package
For material handling and spot welding the DressPack can be chosen in different
configurations. The part of the DressPack changing between different options are
basically the process cable package and the brackets etc are the same. Initially general
configurations for the process cable package is specified. With this as a base, the details
of the application signals and media are added.
Option 056 Connection to manipulator
No floor cables for the DressPack are chosen. The connector at the base for interfacing
is specified in installation and maintenance manual. Terminal connections could be
found in the circuit diagrams.
Option 057 Connection to cabinet
Floor cables for the DressPack are chosen. Number of cables and cable type depends
on chosen options. The length of the process cable package at the floor is specified
under the options below:
- Option 675-678 for parallel communication
- Option 660-663 for bus communication with Can/DeviceNet
- Option 665-668 for bus communication with Profibus
- Option 670-673 for bus communication with Interbus
The connection inside the cabinet depends on communication type.
- If parallel communication is chosen, signals are found at terminals inside the
cabinet (XT5.1, XT5.2 and XT6)
- If bus communication is chosen, signals are routed both to valid bus card. The
remaining are found at terminals inside the cabinet (XT5.1, XT5.2 and XT6).
44
Description
Communication
Option 2063 Parallel communication
The process cable package has been chosen for parallel communication. The number
as well as the type of signals are defined under Material handling application (Option
2204,2205) and Spot welding application (Option 2200).
Option 2064 Bus communication
The process cable package has been chosen for bus communication. This alternative
includes both the signals for the bus communication as well as some parallel signals.
The number as well as the type of signals are defined under Material handling
application (Option 2204,2205) and also Spot welding application (Option 2200). This
option can not be combined with servo gun application. The type of bus are defined by
choice of floor cabling (see also option 057)
Option 2204 Material Handling axis 1 to axis 3
The Lower arm harness for the Material Handling has been chosen. This includes the
process cable package as well as brackets, connectors etc to form a complete dressing
package from manipulator base until connectors on axis 3. Depending on the choice
above the process cable package will have different content. See tables below.
For all process cable packages some of the content is common. These common parts
for Material Handling application are shown in Table 6 below. Unique parts for
different option combinations are shown in Table 7, Table 8, Table 9 and Table 10.
These tables are valid for option 2204 and 2205.
Table for Common content Material Handling (with option 2063/2064)
Table 6
Type
Pcs at
Connection point
Note
Allowed capacity
12,5 m inner
diameter
Media
Air (PROC 1)
45
Description
Table for Material Handling with option 2063 with or without Servo gun option
701
Table 7
Type
Customer Power (CP)
Utility Power
Protective earth
Customer Signals (CS)
Signals twisted pair
Signals twisted pair and
separate shielded
Pcs at
Terminal*
Pcs at Connection
point**
Allowed capacity
2+2
1
2+2
1
19
4
19
4
50 VAC, 1 A rms
50 VAC, 1 A rms
Type
Customer Power (CP)
Utility Power
Protective earth
Customer Bus (CBus)
Bus signals
Bus signals
Signals twisted pair
Utility signals
Pcs at
Terminal*
Pcs at Connection
point**
Allowed capacity
2+2
1
2+2
1
4
4
2
2
4
4
Can/DeviceNet spec
50 VAC, 1 A rms
50 VAC, 1 A rms
50 VAC, 1 A rms
46
Description
Type
Customer Power (CP)
Utility Power
Protective earth
Customer Bus (CBus)
Bus signals
Bus signals
Signals twisted pair
Utility signals
Pcs at
Terminal*
Pcs at Connection
point**
Allowed capacity
2+2
1
2+2
1
4
3
4
1
4
3
Interbus spec
50 VAC, 1 A rms
50 VAC, 1 A rms
50 VAC, 1 A rms
Type
Customer Power (CP)
Utility Power
Protective earth
Customer Bus (CBus)
Bus signals
Bus signals
Signals twisted pair
Utility signals
Pcs at
Terminal*
Pcs at Connection
point**
Allowed capacity
2+2
1
2+2
1
4
4
2
2
4
4
47
Description
Option 2200 Spot Welding to axis 3, and option 2201 Spot Welding to axis 6
The Lower arm harness and the Upper arm harness for Spot Welding has been chosen.
This includes the process cable package as well as brackets, connectors etc to form a
complete dressing package from manipulator base to the connectors on axis 6.
Depending on the earlier choice above the process cable package will have different
content. See tables below. For further details see Installation and maintenance manual
and circuit diagrams
For all process cable packages some of the content are common. These common parts
for Spot Welding application are shown in table 11 below. Unique parts for different
option combinations are showed in Table 12, Table 13, Table 14, Table 15 and Table 16.
Table for common content Spot Welding (with option 2063/2064)
Table 11
Type
Welding Power (WP)
Lower arm harness
Lower arm harness
protective earth
Upper arm harness
Upper arm harness
protective earth
Media
Water/Air (PROC 1-3)
Pcs at Connection
point*
Note
Allowed capacity
2
1
35 mm2
35 mm2
600 VAC**
2
1
25 mm2
25 mm2
600 VAC***
12,5 mm
inner
diameter
*
**
48
Description
Table for Spot Welding with option 2063
Table 12
Type
Customer Power (CP)
Utility Power
Protective earth
Customer Signals (CS)
Signals twisted pair
Signals twisted pair and
separate shielded
Pcs at
Terminal*
Pcs at Connection
point**
Allowed capacity
2+2
1
2+2
1
19*
4*
19*
4*
50 VAC, 1 A rms
50 VAC, 1 A rms
Type
Customer Power (CP)
Servo motor Power
Utility Power
Protective earth
Customer Signals (CS)
Signals twisted pair
Signals twisted pair and
separate shielded
Pcs at
Terminal*
Pcs at Connection
point**
Allowed capacity
2+2
1
3
2+2
1
4*
4*
4*
4*
50 VAC, 1 A rms
50 VAC, 1 A rms
Terminals inside the cabinet if option 057 is chosen. Signals needed for servo gun
motor control are not specified above.
** At manipulator base or axis 6.
49
Description
Table for Spot Welding with option 2064 and CAN/DeviceNet
Table 14
Type
Customer Power (CP)
Utility Power
Protective earth
Customer Bus (CBus)
Bus signals
Bus signals
Signals twisted pair
Utility signals
Pcs at
Terminal*
Pcs at Connection
point**
Allowed capacity
2+2
1
2+2
1
4
4
2
2
4
4
CAN/DeviceNet spec
50 VAC, 1 A rms
50 VAC, 1 A rms
50 VAC, 1 A rms
Type
Customer Power (CP)
Utility Power
Protective arth
Customer Bus (CBus)
Bus signals
Bus signals
Signals twisted pair
Utility signals
Pcs at
Terminal*
Pcs at Connection
point**
Allowed capacity
2+2
1
2+2
1
4
3
4
1
4
3
Interbus spec
50 VAC, 1 A rms
50 VAC, 1 A rms
50 VAC, 1 A rms
50
Description
Table for Spot Welding with option 2064 and Profibus
Table 16
Type
Pcs at
Terminal*
Pcs at Connection
point**
Allowed capacity
2+2
1
2+2
1
4
4
2
2
4
4
51
Description
1.9.3 Power Unit
The standard Power unit for SpotPack contains the electric components and circuits
needed for spot welding. The power unit cabinet is designed to be placed on top of the
robot control cabinet, see picture below, and secured with four attachment plates. The
power unit should be seen as a main part of the complete SpotPack (type S and HS) and
normally not handled as a separate unit.
The electrical circuits of the power unit consist of weld power circuit and control
circuits to control the welding.
Weld power circuit
The welding power for the welding gun is fed through a circuit breaker and welding
thyristor (for AC welding) or inverter (for MFDC welding) and further out to the welding power cable. The welding power cable is connected directly to the thyristor/
inverter.
Control Circuits
Power 240 V AC and 24 V DC for the control circuits is fed from the robot cabinet.
Also the safety circuits in the robot cabinet is used to interlock the welding timer.
A welding timer (Bosch), integrated with the air cooled thyristor or inverter, controls
the welding current. The welding timer includes control program which gives
possibility to program different weld sequence. The programming is normally done on
a PC that is connected directly to the welding timer. The interface between the robot
system and the welding timer is handled via a digital signal interface. Example of
signals are weld start, weld ready, weld program choice and error.
Also cross connections, of interface signals and interlocking between the robot system
(I/O-boards), the water and air unit, signals to DressPack and pedestal / stationary gun
(type HS), are done within the power unit.
For further information see Installation and Maintenance manual and separate manuals
for the Bosch equipment.
Programming device for the welding timer is not included.
Option 2087 Power unit, AC welding type S
The basic power unit for type S is equipped for a robot handled AC Spotwelding gun
and with the following components:
- Cable gland for incoming power (X100)
- Circuit Breaker type ABB SACE, T1 160 A
- Welding Timer and Thyristor type Bosch PST 6100.100L 76kVA
- Fuse terminal for 24 V distribution
- Connector to Water and air unit, Modular Harting. (XS103)
- Cable gland for outgoing power (X101). (For power cable see option 2095/
2096)
For further information see Installation and Maintenance manual, circuit diagrams and
separate manuals for the Bosch equipment.
52
Description
Option 2088 Power unit, AC welding type HS
The basic power unit for type HS is equipped for a stationary / pedestal mounted
AC Spotwelding gun and with the following components:
- Cable gland for incoming power (X100)
- Circuit Breaker type ABB SACE, T1160 A
- Welding Timer and Thyristor type Bosch PST 6100.100L76kVA
- Fuse terminal for 24 V distribution
- Connector to Water and air unit, Modular Harting. (XS103)
- Connector to pedestal gun, Modular Harting (XS 104). (For process cables to
Stationary gun see option 2117, 2118 and 2119)
- Cable gland for outgoing power (X101). For power cable (see option 2095/
2096)
For further information see Installation and Maintenance manual, circuit diagrams and
separate manuals for the Bosch equipment.
Option 2090 MFDC welding S and HS
This option replaces the thyristor unit in option 2087 or 2088, with a MFDC inverter
type Bosch PSI 6100.100L. This option requires forced air cooling (option 2091).
Option 2091 Forced air cooling
This option adds a cooling fan with housing placed on the rear of the power unit. This
forces air on the cooling surface for the thyristor or MFDC converter. For the MFDC
converter this is mandatory. For the AC thyristor the need of the forced air cooling
depends on the load and the ambient temperature.
For further information see separate manuals for the Bosch equipment.
Option 2092 Earth fault protection
This option adds an earth fault protection to the circuit breaker. This protection could
be used for AC welding or MFDC welding. The sensitivity of the earth fault protection
could be adjusted. If and earth fault occurs the circuit breaker is tripped.
For further information see Installation and Maintenance manual, circuit diagrams and
separate specifications of the earth fault protection.
Option 2093 Contactor for weld power
This option adds a contactor with necessary wiring and relays inside the power unit.
This contactor could be used to disconnect power to the gun at for example tool change.
Option 2095 Weld power cable, 7m
This option includes floor cable of 7 m length for weld power. This is connected at
terminals inside the control cabinet and with an MC connector at manipulator base. The
cable has an allowed capacity of 150 A rms at + 20C (68F) ambient temp and 120 A
rms at + 50C (122F) ambient temp.
53
Description
Option 2096 Weld power cable, 15 m
This option includes floor cable of 15 m length for weld power. See description for
option 2095.
Option 2117 Process cable to stationary gun, 7m
This option includes floor cable of 7 m length for process signals to the pedestal/
stationary gun.
This cable is connect to the Power unit (option 2088) with a modular harting. The cable
ends also with a modular harting where the customer could connect control signals for
the gun.
For further information about connector and available signals see Installation and
Maintenance manual and circuit diagrams.
Option 2118 Process cable to stationary gun, 15m
This option includes floor cable of 15 m length for weld power. See description for
option 2117.
Option 2119 Process cable to stationary gun, 30m
This option includes floor cable of 30 m length for weld power. See description for
option 2117.
1.9.4 Water and Air Unit
The water and air unit is the connection point for cooling water and compressed air to
the spot welding gun. All standard features and options are the same for types S and
HS. Water and air unit is not included for type H.
The standard water and air unit is mounted at the base of the robot.
The standard water and air unit consists of four main assemblies:
- Water in circuit
- Water return circuit
- Air supply circuit
- Split box
Cables and hoses required for Water and Air unit are defined and described under each
option for water and air unit.
Water in circuit
The function of the water in circuit is to open / close the cooling water supply to the
Spot welding gun. An electrically controlled valve with indication led is used. The
valve is controlled by a digital signal from the robot control system.
The circuit start from left with an Parker Puchlock 33482-8-8BK fitting for hose
(hose assembled by customer), manual shut off valve for the cooling water flow,
electrical shut off valve and ends with a Parker Pushlock adapter. (Suitable for a Parker
Puchlock DIN 20 078 A, we recommend a Parker Pushlock 39C82-15-8BK fitting).
From this point the water is led to the gun/robot.
54
Description
Water return circuit
The water return circuit monitors the flow of the returning cooling water from the Spot
welding gun. The flow switch detects if the water flow is too low in the cooling water
circuit.
The flow switch gives a digital signal to the robot control system, which automatically
shuts the electrical shut off valve in the water in circuit off if the flow is too low. The
system and the supply of cooling water are then automatically stopped to minimise any
risk of damage to the system.
The water return circuit is delivered with a pre-set flow limit, set to approx. 3,5 litres
per minute.
The water return circuit started from right with a Parker Pushlock adapter (Suitable for
a Parker Puchlock DIN 20 078 A, we recommend a Parker Pushlock 39C82-15-8BK
fitting), flowswitch with a switching point between 2-12 litres per minute.
Its also equipped with a flow control valve; the flow control can adjust the water flow
to a wanted flow level. The flow-value can be monitored through a small window on
the flow control valve. This will serve as a rough function check in the approximate
flow range of 2-8 litres per minute. The circuit ends with a check-valve that will stop
any reversing water flow, manual shut off valve and an Parker Puchlock 33482-8-8BK
fitting for hose (hose assembled by customer). From this point the water is led to
the factory water system.
Air supply circuit
The air supply circuit provides the robot and option: proportional valve with air supply.
The air supply circuit started with a Parker Puchlock 39C82-15-8BK fitting (hose
assembled by customer). Manually operated shut off valve to vent the system through
a silencer, air filter 25 microns and a water separator equipped with a metal bowl
protection, distribution block containing plugged air outlet ports.
The air supply circuit ends with a Parker Pushlock adapter. (Suitable for a Parker
Puchlock DIN 20 078 A, we recommend a Parker Pushlock 39C82-15-8BK fitting).
Maximum flow capacity is 3000 litres per minute at 6.3 bar and P = 1.0 bar. Maximum
allowed pressure is 16 bar.
Split box
With the split box, the 24VDC supply and signals are connected and distributed to the
different units on the water and air unit, see picture below. The design makes disconnection of separate items for service and repair on the water and air unit very easy. The
split box has a protection class IP68. Brand: Woodhead, Brad Harrison.
The split box has six connections prepared for the following units.
- Electric water shut off valve
- Flow switch 1
- Flow switch 2 (Option 2177 Second Water Return)
- Pressure switch (Option 2179 Pressure switch and Regulator
for air)
- Proportional valve (Option 2181 Electrical proportional valve for air)
- Spare
Product Specification IRB 6600 M2000
55
Description
The cable and cable length between the Split box and the Power unit has to be specified
(see option 2183, 2184 and 2185).
XS 101.1
Flow switch 1
XS 101.2
Flow switch 2
Proportonal Valve
Option
Option
Option
Spare
XS 101.3
XS 101.4
XS 101.5
XS 101.6
Description
Hoses between water in circuit and water return circuit are not supplied. These have to
be arranged by the customer.
Option 2177 Second water return
When the water pressure drop is to high because of too long hoses or because of any
other reason, an additional water return circuit can be the best solution to solve this
problem. For this extra water return circuit this option is required. It contains an extra
flow switch to monitor the water coming from the second circuit. Two cooling water
circuits also have the advantage of a more even cooling of the two sides of the
Spotwelding gun compared to a single circuit system. For more information see under
Flow switch in water return circuit.
Please note that this option can not be combined with option 2181, Electrical
proportional valve for air normally used together with a pneumatic robot mounted
welding gun. The additional used water hose in this option is normally used for
compressed air for pneumatic moved welding guns. Additional 1/2" water hose (PROC
4) to manipulator base is included.
Option 2192 Digital flow meter, One water return
If a digital flow meter is requested instead of a flow switch, this option should be
chosen. This option is valid for one water return (if two water return see option 2193).
This option means that the flow switch and the flow control valve with visible flow
indication is replaced by the digital flow meter and a flow control valve without visible
flow indication (not required as adjustments could be seen on the digital flow meter).
The digital flow meter gives the following advantages compared to flow switch:
- The biggest advantage is that the flow switch is mechanical function safe, that
means if something damage the flow switch you will notice that immediacy
- The actual flow could be seen direct on the display
- The flow switch level and the tolerance could be set with high tolerance
- The flow value could been monitored at distance with a remote display.
Option 2193 Digital flow meter, Two water returns
If the option second water return (option 2177) is chosen and the digital flow meter is
requested this option should be chosen. For more information see option 2192.
Option 2179 Pressure switch and regulator for air
Option 2179, Filter regulator and pressure switch includes a manually operated
pressure regulator to set the incoming pressure to the Spot welding gun. The pressure
can be monitored on the included pressure gauge. This option also includes a Pressure
Switch to monitor the air pressure and to give a signal to the control system if the
pressure becomes to low.
The 2179 include same components as Air Supply Circuit except that the filter changes
to a filter regulator plus we add pressure gauge 0-16 bar and pressure Switch with
belonging cable to splitbox.
57
Description
Option 2181 Electrical proportional valve for air
The option includes a proportional valve with integrated control circuit and connection
cable to the splitbox. The proportional valve controls the pinching force of the
pneumatic spot welding gun and is designed to obtain optimal performance during long
operation time. The proportional valve is controlled by the weldtimer in the Power unit.
The included distribution block can be used for two additional non-regulated
compressed air circuits.
An analogue signal 0-10V, controls the proportional valve and the air pressure is in the
range of 0-12 bar.
Option 2183 Cable to split box, 7m
This option includes floor cable of 7 m length for signals to the split box sitting on the
water and air unit. This cable is connect to the Power unit (option 2087/2088) with a
modular harting (Han Compact with insert type HD). The cable ends also with a quick
connector at the split box end.
Option 2184 Cable to split box, 15m
This option includes floor cable of 15 m length for the split box. See description for
option 2183.
Option 2185 Cable to split box, 30m
This option includes floor cable of 30 m length for the split box. See description for
option 2183.
58
Description
Name / Note
DressPack options
057
Connection to cabinet.
Includes floor cables with signals to terminals inside controller
2064
2204
2205
660
Example 2: SpotPack for SpotWelding with pneumatic gun and parallel interface
Option no
Name / Note
General options
122
201
251
206
553
Connection to cabinet
Includes floor cables with signals to terminals inside controller
2063
2200
SpotWelding to axis 6
Lower arm and Upper arm harness to get the signals to axis 6
2065
Extended media SW
Additional hose for regulated air via option 2181
675
59
Description
2087
2095
2174
2181
2183
Example 3: SpotPack for SpotWelding with servo gun gun and parallel interface.
Option no
Name / Note
General options
122
201
251
206
702
Robot Gun
681
625
60
057
Connection to cabinet
Includes floor cables with signals to terminals inside controller
2063
2200
SpotWelding to axis 6
Lower arm and Upper arm harness to get the signals to axis 6
675
2087
2090
2091
2095
Description
2174
2183
Example 4: SpotPack for SpotWelding with pedestal servo gun and Interbus
interface to robot handled gripper.
Option no
Name / Note
General options
122
201
251
206
701
Stationary Gun.
686
625
Connection to cabinet
Includes floor cables with signals to terminals inside controller
2064
2200
SpotWelding to axis 6
Lower arm and Upper arm harness to get the signals to axis 6
670
248
Interbus Master/Slave,
Copper wire. Interbus board in cabinet
2087
2095
2117
2175
2183
61
Description
M1
M2
CB1
D1
option 381
D2
DDU-V
(options 641-644)
option 701
M7C1B1.CFG
options 686-689
Option
62
Description
Product Spec.
381
S4Cplus
686-689
S4Cplus
701
S4Cplus
625
RobotWare Options
Description
1.11.2 Robot Gun (RG)
option 702
M1
M2
CB1
D1
D2
option 381
option 702
options 2063
DDU-V
options 697-699
(options 641-644)
Option
Description
Product Spec.
381
S4Cplus
697-699
S4Cplus
702
S4Cplus
2063
IRB 6600
625
RobotWare Options
63
Description
1.11.3 Stationary and Robot Gun (SG + RG)
M1
M2
CB1
options 697-699
options 2063
D1
M1
M2
CB2
D2
D1
D2
option 382
option 703
DDU-VW
SMB
M7C1B1.CFG
(options 641-644)
options 686-689
Option
64
Description
Product Spec.
382
S4Cplus
686-689
S4Cplus
697-699
S4Cplus
703
S4Cplus
2063
IRB 6600
625
RobotWare Options
Description
1.11.4 Twin Stationary Guns (SG + SG)
M1
M2
CB1
D1
M1
M2
CB2
D2
D1
option 382
D2
DDU-VW
(options 641-644)
M7C1B1.CFG
SG 1
options 686-689
SMB
SG 2
option 704
Option
Description
Product Spec.
382
S4Cplus
686-689
S4Cplus
704
S4Cplus
625
RobotWare Options
65
Description
1.11.5 Stationary Gun and Track Motion (SG + TM)
M1
M2
M1
CB1
D1
M2
CB2
D2
D1
option 382
D2
DDU-VW
(options 641-644)
SMB
M7C1B1.CFG
options 686-689
option 705
Option
66
Description
Product Spec.
382
S4Cplus
686-689
S4Cplus
705
S4Cplus
Incl. in TM
delivery
IRBT 6003S
625
RobotWare Options
Description
1.11.6 Robot Gun and Track Motion (RG + TM)
M1
M2
CB1
D1
M1
M2
CB2
D2
D1
option 382
D2
option 706
options 2063
DDU-VW
SMB
M7C1B1.CFG
(options 641-644)
options 697-699
Option
Description
Product Spec.
382
S4Cplus
697-699
S4Cplus
706
Cable between the cabinet and TM, and between SMB and
the manipulator
S4Cplus
2063
IRB 6600
Incl. in TM
delivery
IRBT 6003S
625
RobotWare Options
67
Description
M1
M2
CB1
D1
M1
M2
CB2
D2
D1
option 383
D2
DDU-W
M7C1B1.CFG
TM delivery
(options 641-644)
Option
68
Description
Product Spec.
383
S4Cplus
2204 or 2200
IRB 6600
TM delivery
IRBT 6003S
1 MANIPULATOR
VARIANTS
022
023
024
025
027
IRB 6600-175/2.8
IRB 6600-225/2.55
IRB 6600-175/2.55
IRB 6650-125/3.2
IRB 6650-200/2.75
Manipulator colour
330 Standard
The manipulator is painted in ABB orange.
352 RAL code
Colours according to RAL-codes.
Protection
035 Standard (IP 67)
036 Foundry
Robot adapted for foundry or other harsh environments.
The robot has the FoundryPlus protection which means that the whole manipulator is
steam washable. The excellent corrosion protection is obtained by a
special coating. The connectors are designed for severe environment, and bearings,
gears and other sensitive parts are highly protected.
69
option 2204
option 2205
option 2200
option 2201
Figure 40 Spot Welding from base to axis 3 , and Spot Welding from axis 3 to axis 6.
Communication
2063 Parallel
Includes customer power CP, customer signals CS and Air for MH-process cable
package.
Includes CP, CS, Air and two Media hoses for SW-process cable package.
2064 Bus
Includes CP, CS, Air and CAN/DeviceNet or Interbus for MH-process cable package.
Includes CP, CS, Air, two Media hoses and CAN/DeviceNet or Interbus for SW-cable
package.
70
R3.FB7
R1.SW2/3
R1.MP
R1.SMB
R1.PROC1 1 x 1/2
R1.CP/CS
R2.CP/CS
R2.PROC1 1 x 1/2
R2.MP 5/6
R1.CP/CS
R1.SW1
R3.FB7
R1.MP
R1.SMB
R1.SW2/3
R1.PROC1-3 3 x 1/2
71
7m
15m
30m
EQUIPMENT
691 Safety lamp
A safety lamp with an orange fixed light can be mounted on the manipulator.
The lamp is active in MOTORS ON mode.
The safety lamp is required on a UL/UR approved robot.
092 Fork lift device
Lifting device on the manipulator for fork-lift handling.
Note. When Cooling Fan for axis 1 motor unit is used, this must be disassembled in order
to use fork lift device.
087 Base plate
Can also be used for IRB 7600. See chapter 1.3 Installation, for dimension drawing.
091 Brake release cover
A cover for the break release buttons.
113 Cooling fan for axis 1 motor (IP 54)
Cannot be combined with Cooling fan for axis 2 motor option 114.
For in use recommendations see 1.7 Cooling fan for axis 1-3 motor (option 113-115).
See Figure 44.
Not for protection Foundry.
72
Option 115
Option 113
Option 088
73
CONNECTION KITS
The connectors fit to the connectors at the manipulator base, axis 3 and 6 respectively.
The kit consists of connectors, pins and sockets.
2220 R1.CP/CS and PROC1
For the Customer Power/Customer Signal connector and one Process connector on the
manipulator base. Sockets for bus communication are included.
2221 R1.WELD and PROC2-4
For the Weld connector and three Process connectors on the manipulator base.
2222 R1.SW1 and SW2/3
For the position switch asis 1 connector and the position axis 2/3 connector on the
manipulator base.
74
POSITION SWITCHES
Position switches indicating the position of the three main axes. Rails with separate
adjustable cams are attached to the manipulator. The cams, which have to be adapted
to the switch function by the user, can be mounted in any position in the working range
for each switch. No machining operation of the cams is necessary for the adaptation,
simple hand tools can be used.
For axis 1, there are three redundant position zones available, each with two
independent switches and cams. For axes 2 and 3, two chanals position zones are
available, each with two independent switches and cams.
For axis 1 it is possible to mount a second set of position switches, doubling the number
of redundant zones to six.
Each position zone consists of two switches mechanically operated by separate cams.
Each switch has one normally open and one normally closed contact. See Product
Specification S4Cplus.
The design and components fulfill the demands to be used as safety switches.
These options may require external safety arrangements, e.g. light curtains, photocells
or contact mats.
The switches can be connected either to the manipulator base (R1.SW1 and R1.SW2/
3, (see Figure 41 and Figure 43), or to the controller. In the controller the signals are
connected to screw terminal XT8 Phoenix MSTB 2.5/12-ST-5.08.
Switch type Balluff Multiple position switches BNS, according to EN 60947-5-1 and
EN 60947-5-2.
Connection to
075 Manipulator
Connection on the manipulator base with one/two FCI 23-pin connector.
076 Cabinet
Connection on the cabinet wall. Limit switch cables are included.
Not available for second set of position switches, which have to be connected at the
manipulator base.
071 Position switches axis 1
Three redundant position zones are available, each with two independent switches and
cams.
Product Specification IRB 6600 M2000
75
SPOTPACK
Power Unit
For more information see chapter 1.9.3 Power Unit
2087 Power unit AC welding type S
2088 Power unit AC welding type HS
2090 MFDC welding S and HS
2091 Forced air cooling
2092 Contactor for welding power
76
7m
2118
15m
2119
30m
77
78
Accessories
3 Accessories
There is a range of tools and equipment available, specially designed for the robot.
Basic software and software options for robot and PC
For more information, see Product Specification S4Cplus, and Product Specification
RobotWare Options.
Robot Peripherals
- Track Motion
- Tool System
- Motor Units
- Spot welding system for transformer gun
Tools
Brake release box
Includes six brake release buttons and 24V battery unit which can be connected to
R1.BU on the manipulator frame. The brake release box can be ordered from
ABB Automation Technology Products, Robotics, department S.
Calibration Cube
This calibration tool can be ordered from ABB Automation Technology Products,
Robotics, department S.
79
Accessories
80
Index
4 Index
A
accessories 79
Active Brake System 6
C
Collision detection 7
colours 69
cooling device 4
E
Electronically Stabilised Path 7
emergency stop 8
enabling device 8
equipment
mounting 25
permitted extra load 25
F
fire safety 9
fork lift device 72
motion 31
mounting
extra equipment 25
robot 10
mounting flange 28, 29
N
noise level 4
O
operating requirements 10
options 69
overspeed protection 7
P
Passive Safety System 7
payload 10
position switches 8, 10, 75
protection 69
protection standards 10
R
hold-to-run control 9
hole configuration 11
holes for mounting extra equipment 26
humidity 10
range of movement 31
reduced speed 8
Robot Gun 63
Robot Gun and Track Motion 67
Robot Peripherals 79
robot tool flange 28, 29
robot versions 4
installation 10
Internal Safety Concept 8
L
lifting device 72
limit switches 8, 10, 75
load 10
load diagrams 13
M
maintenance 30
manipulator colour 69
mechanical interface 28, 29
81
Index
T
temperature 10
troubleshooting 30
Twin Stationary Guns 65
V
variants 69
W
weight 4
working space
restricting 7, 10, 76
Z
zone switches 8
82
27
29
31
51
Description
1 Description
1.1 Structure
The controller contains the electronics required to control the manipulator, external
axes and peripheral equipment.
The controller also contains the system software, i.e. the BaseWare OS (operating
system), which includes all basic functions for operation and programming.
Controller weight
250 kg
Controller volume:
Teach pendant
Operators panel
Mains switch
Disk drive
Figure 1 The controller is specifically designed to control robots, which means that optimal
performance and functionality is achieved.
Description
200
200
800
Cabinet extension
800
Option 124
820
Extended cover
500
Option 123
250
950
980 *
Lifting points
for forklift
500
52
623
Figure 2 View of the controller from the front, from above and from the side (dimensions in mm).
Description
1.2 Safety/Standards
The robot conforms to the following standards:
EN 292-1
Safety of machinery, terminology
EN 292-2
Safety of machinery, technical specifications
EN 954-1
Safety of machinery, safety related parts of control
systems
EN 60204
Electrical equipment of industrial machines
IEC 204-1
Electrical equipment of industrial machines
ISO 10218, EN 775
Manipulating industrial robots, safety
ANSI/RIA 15.06/1999
Industrial robots, safety requirements
ISO 9787
Manipulating industrial robots, coordinate systems
and motions
IEC 529
Degrees of protection provided by enclosures
EN 50081-2
EMC, Generic emission
EN 61000-6-2
EMC, Generic immunity
ANSI/UL 1740-1996 (option) Standard for Industrial Robots and Robotic
Equipment
CAN/CSA Z 434-94 (option) Industrial Robots and Robot Systems - General
Safety Requirements
The robot complies fully with the health and safety standards specified in the EECs
Machinery Directives.
The robot controller is designed with absolute safety in mind. It has a dedicated safety
system based on a two-channel circuit which is monitored continuously. If any
component fails, the electrical power supplied to the motors shuts off and the brakes engage.
Safety category 3
Malfunction of a single component, such as a sticking relay, will be detected at the next
MOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the faulty
section is indicated. This complies with category 3 of EN 954-1, Safety of machinery
- safety related parts of control systems - Part 1.
Selecting the operating mode
The robot can be operated either manually or automatically. In manual mode, the robot
can only be operated via the teach pendant, i.e. not by any external equipment.
Reduced speed
In manual mode, the speed is limited to a maximum of 250 mm/s (600 inch/min.).
The speed limitation applies not only to the TCP (Tool Centre point), but to all parts of
the robot. It is also possible to monitor the speed of equipment mounted on the robot.
Three position enabling device
The enabling device on the teach pendant must be used to move the robot when in
manual mode. The enabling device consists of a switch with three positions, meaning
that all robot movements stop when either the enabling device is pushed fully in, or
when it is released completely. This makes the robot safer to operate.
Description
Safe manual movement
The robot is moved using a joystick instead of the operator having to look at the teach
pendant to find the right key.
Over-speed protection
The speed of the robot is monitored by two independent computers.
Emergency stop
There is one emergency stop push button on the controller and another on the teach
pendant. Additional emergency stop buttons can be connected to the robots safety chain
circuit.
Safeguarded space stop
The controller has a number of electrical inputs which can be used to connect external
safety equipment, such as safety gates and light curtains. This allows the robots safety
functions to be activated both by peripheral equipment and by the robot itself.
Delayed safeguarded space stop
A delayed stop gives a smooth stop. The robot stops in the same way as at a normal
program stop with no deviation from the programmed path. After approx. 1 second the
power supplied to the motors shuts off.
Collision detection
In case an unexpected mechanical disturbance like a collision, electrode sticking, etc.
occurs, the robot will stop and slightly back off from its stop position.
Restricting the working space
The movement of each axis can be restricted using software limits.
There are safeguarded space stops for connection of limit switches to restrict the working
space.
For some robots the axes 1-3 can also be restricted by means of mechanical stops.
Hold-to-run control
Hold-to-run means that you must depress the start button in order to move the robot. When
the button is released the robot will stop. The hold-to-run function makes program testing
safer.
Fire safety
Both the manipulator and control system comply with ULs (Underwriters Laboratory)
tough requirements for fire safety.
Safety lamp
As an option, the robot can be equipped with a safety lamp mounted on the manipulator.
This is activated when the controller is in the MOTORS ON state.
Description
1.3 Operation
All operations and programming can be carried out using the portable teach pendant
(see Figure 3) and operators panel (see Figure 5).
.
Hold-to-run
Menu keys
Motion keys
Display
P5
P4
7
4
1
Window
keys
1
2
P1
8
5
2
0
9
6
3
Joystick
Enabling
device
P2
P3
Function keys
Emergency stop
button
Navigation keys
Cable 10 m
Figure 3 The teach pendant is equipped with a large display, which displays prompts,
information, error messages and other information in plain English.
Description
- File management
- System configuration
- Service and troubleshooting
- Automatic operation
User-defined keys (P1-P5)
Five user-defined keys that can be configured to set or reset an output (e.g. open/close
gripper) or to activate a system input.
Hold-to-run
A push button which must be pressed when running the program in manual mode with
full speed.
Enabling device
A push button which, when pressed halfway in, takes the system to MOTORS ON.
When the enabling device is released or pushed all the way in, the robot is taken to the
MOTORS OFF state.
Joystick
The joystick is used to jog (move) the robot manually; e.g. when programming the
robot.
Emergency stop button
The robot stops immediately when the button is pressed in.
Menu keys
File
Edit
View
1 Goto ...
Inputs/Outputs
2 Goto Top
3 Goto Bottom
Name
Value
I/O list
di1
di2
grip1
grip2
clamp3B
feeder
progno
1
1
0
1
0
1
1
13
Menu
4(6)
Line indicator
Cursor
Function keys
Using the joystick, the robot can be manually jogged (moved). The user determines the
speed of this movement; large deflections of the joystick will move the robot quickly,
smaller deflections will move it more slowly.
The robot supports different user tasks, with dedicated windows for:
- Production
8
Description
- Programming
- System setup
- Service and installation
Operators panel
MOTORS ON button
and indicating lamp
Emergency stop
If pressed in,
pull to release
MOTORS ON
Continuous light
Fast flashing light (4Hz)
Slow flashing light (1 Hz) = One of the safeguarded space stops is active
Note: The motors have been switched off
100%
Automatic mode
= Running production
Manual mode
at reduced speed
Optional:
Manual mode
= Testing at full program speed
at full speed
Equipped with this mode,
the robot is not approved
according to ANSI/UL
Figure 5 The operating mode is selected using the operators panel on the controller.
Description
Both the operators panel and the teach pendant can be mounted externally, i.e.
separated from the cabinet. The robot can then be controlled from there.
The robot can be remotely controlled from a computer, PLC or from a customers panel,
using serial communication or digital system signals.
For more information on how to operate the robot, see the Users Guide.
10
Description
1.4 Memory
Available memory
The controller has two different memories:
- a fixed DRAM memory of size 32 MB, used as working memory
- a flash disk memory, standard 64 MB, used as mass memory. Optional 128 MB.
The DRAM memory is used for running the system software and the user programs and
it is thus divided into three areas:
- system software
- system software execution data
- user RAPID programs, about 5.5 MB, see Figure 6 (when installing different
options, the user program memory will decrease, at most by about 0.7 MB).
The flash disk is divided into four main areas:
- a base area of 5 MB, with permanent code for booting
- a release area of 20 MB, where all the code for a specific release is stored
- a system specific data area of 10 MB, where all the run time specific data
including the user program for a system is stored at backup
- a user mass memory area which can be used for storing RAPID programs, data,
logs etc.
The flash disk is used for backup, i.e. when a power failure occurs or at power off, all
the system specific data including the user program, see Figure 6, will be stored on the
flash disk and restored at power on. A backup power system (UPS) ensures the
automatic storage function.
DRAM memory
32 MB
System
soft ware
Release storage
20 MB
Data
User RAPID
program 5.5 MB
Power
off store
11
Description
Several different systems, i.e. process applications, may be installed at the same time
in the controller, of which one can be active. Each such application will occupy another
10 MB of the flash memory for system data. The release storage area will be in common
as long as the process applications are based on the same release. If two different
releases should be loaded, the release storage area must also be doubled.
For RAPID memory consumption, see RAPID Developers Manual. As an example, a
MoveL or MoveJ instruction consumes 236 bytes when the robtarget is stored in the
instruction (marked with *) and 168 bytes if a named robtarget is used. In the latter
case, the CONST declaration of the named robtarget consumes an additional 280 bytes.
Additional software options will reduce the available user program memory, most of
them however only marginally, i.e. the user program area will still be about 5.5 MB.
Only the SpotWare option will reduce memory significantly, i.e. down to about 4.8 MB
depending on the number of simultaneous welding guns.
1.5 Installation
The controller is delivered with a standard configuration for the corresponding
manipulator, and can be operated immediately after installation. Its configuration is
displayed in plain language and can easily be changed using the teach pendant.
Operating requirements
Protection standards
Controller electronics
IEC529
IP54
Explosive environments
The controller must not be located or operated in an explosive environment.
Ambient temperature
Controller during operation
with option 473
Controller during transportation and storage,
for short periods (not exceeding 24 hours)
Relative humidity
Transportation, storage and operation
Vibration
Controller during transportation and storage
Bumps
Controller during transportation and storage
10-55 Hz:
55-150 Hz:
Max. 0.15 mm
Max. 20 m/s2
Power supply
Mains voltage
12
Mains frequency
48.5 to 61.8 Hz
Description
Rated power:
IRB 140, 1400, 2400
IRB 340, 14001, 24001,4400, 6400, 940
IRB 6600
IRB 7600
External axes cabinet
Computer system backup capacity
at power interrupt
Configuration
The robot is very flexible and can, by using the teach pendant, easily be configured to
suit the needs of each user:
Authorisation
Most common I/O
Instruction pick list
Instruction builder
Operator dialogs
Language
Date and time
Power on sequence
EM stop sequence
Main start sequence
Program start sequence
Program stop sequence
Change program sequence
Working space
External axes
Brake delay time
I/O signal
Serial communication
For a detailed description of the installation procedure, see the Product Manual Installation and Commissioning.
1.6 Programming
Programming the robot involves choosing instructions and arguments from lists of
appropriate alternatives. Users do not need to remember the format of instructions,
since they are prompted in plain English. See and pick is used instead of remember
and type.
13
Description
The programming environment can be easily customized using the teach pendant.
- Shop floor language can be used to name programs, signals, counters, etc.
- New instructions can be easily written.
- The most common instructions can be collected in easy-to-use pick lists.
- Positions, registers, tool data, or other data, can be created.
Programs, parts of programs and any modifications can be tested immediately without
having to translate (compile) the program.
Movements
A sequence of movements is programmed as a number of partial movements between
the positions to which you want the robot to move.
The end position of a movement is selected either by manually jogging the robot to the
desired position with the joystick, or by referring to a previously defined position.
The exact position can be defined (see Figure 7) as:
- a stop point, i.e. the robot reaches the programmed position
or
- a fly-by point, i.e. the robot passes close to the programmed position. The size
of the deviation is defined independently for the TCP, the tool orientation and
the external axes.
Stop point
Fly-by point
User-definable distance (in mm)
Figure 7 The fly-by point reduces the cycle time since the robot does not have to stop at
the programmed point. The path is speed independent.
Description
a standard PC.
Editing programs
Programs can be edited using standard editing commands, i.e. cut-and-paste, copy,
delete, find and change, undo etc. Individual arguments in an instruction can also be
edited using these commands.
No reprogramming is necessary when processing left-hand and right-hand parts, since
the program can be mirrored in any plane.
A robot position can easily be changed either by
- jogging the robot with the joystick to a new position and then pressing the
ModPos key (this registers the new position)
or by
- entering or modifying numeric values.
To prevent unauthorised personnel from making program changes, passwords can be
used.
Testing programs
Several helpful functions can be used when testing programs. For example, it is
possible to
- start from any instruction
- execute an incomplete program
- run a single cycle
- execute forward/backward step-by-step
- simulate wait conditions
- temporarily reduce the speed
- change a position
- tune (displace) a position during program execution.
For more information, see the Users Guide and RAPID Reference Manual.
15
Description
Other
Service
A special input can be set to order the robot to go to a service position. After service,
the robot is ordered to return to the programmed path and continue program execution.
You can also create special routines that will be automatically executed when the power
is switched on, at program start and on other occasions. This allows you to customise
each installation and to make sure that the robot is started up in a controlled way.
The robot is equipped with absolute measurement, making it possible to operate the
robot directly when the power is switched on. For your convenience, the robot saves
the used path, program data and configuration parameters so that the program can be
easily restarted from where you left off. Digital outputs are also set automatically to the
value prior to the power failure.
Description
1.9 Exception handling
Many advanced features are available to make fast error recovery possible.
Characteristic is that the error recovery features are easy to adapt to a specific
installation in order to minimise down time. Examples:
- Error Handlers (automatic recovery often possible without stopping
production).
- Restart on Path.
- Power failure restart.
- Service routines.
- Error messages: plain text with remedy suggestions, user defined messages.
- Diagnostic tests.
- Event logging.
17
Description
18
Description
Tool coordinates
Z
Base coordinates
X
Y
Axis 3
Axis 2
Axis 3
X
Base coordinates
Axis 1
Axis 1
Y
Tool coordinates
Z
Tool Centre Point (TCP)
Z User
coordinates
Object
coordinates
Y
X
World coordinates
X
X
Figure 9 The coordinate systems, used to make jogging and off-line programming easier.
The world coordinate system defines a reference to the floor, which is the starting
point for the other coordinate systems. Using this coordinate system, it is possible to
relate the robot position to a fixed point in the workshop. The world coordinate system
is also very useful when two robots work together or when using a robot carrier.
The base coordinate system is attached to the base mounting surface of the robot.
The tool coordinate system specifies the tools centre point and orientation.
The user coordinate system specifies the position of a fixture or workpiece
manipulator.
The object coordinate system specifies how a workpiece is positioned in a fixture or
workpiece manipulator.
The coordinate systems can be programmed by specifying numeric values or jogging
the robot through a number of positions (the tool does not have to be removed).
Each position is specified in object coordinates with respect to the tools position and
orientation. This means that even if a tool is changed because it is damaged, the old
program can still be used, unchanged, by making a new definition of the tool.
If a fixture or workpiece is moved, only the user or object coordinate system has to be
redefined.
19
Description
Stationary TCP
When the robot is holding a work object and working on a stationary tool, it is possible
to define a TCP for that tool. When that tool is active, the programmed path and speed
are related to the work object.
Program execution
The robot can move in any of the following ways:
- Joint motion (all axes move individually and reach
the programmed position at the same time).
- Linear motion (the TCP moves in a linear path).
- Circle motion (the TCP moves in a circular path).
Soft servo - allowing external forces to cause deviation from programmed position can be used as an alternative to mechanical compliance in grippers, where imperfection
in processed objects can occur.
If the location of a workpiece varies from time to time, the robot can find its position
by means of a digital sensor. The robot program can then be modified in order to adjust
the motion to the location of the part.
Jogging
The robot can be manually operated in any one of the following ways:
- Axis-by-axis, i.e. one axis at a time.
- Linearly, i.e. the TCP moves in a linear path (relative to one of the coordinate
systems mentioned above).
- Reoriented around the TCP.
It is possible to select the step size for incremental jogging. Incremental jogging can be
used to position the robot with high precision, since the robot moves a short distance
each time the joystick is moved.
During manual operation, the current position of the robot and the external axes can be
displayed on the teach pendant.
Singularity handling
The robot can pass through singular points in a controlled way, i.e. points where two
axes coincide.
Motion Supervision
The behaviour of the motion system is continuously monitored as regards position and
speed level to detect abnormal conditions and quickly stop the robot if something is not
OK. A further monitoring function, Collision Detection, is optional (see option Load
Identification and Collision Detection).
20
Description
External axes
Very flexible possibilities to configure external axes. Includes for instance high
performance coordination with robot movement and shared drive unit for several axes.
Big Inertia
One side effect of the dynamic model concept is that the system can handle very big
load inertias by automatically adapting the performance to a suitable level. For big,
flexible objects it is possible to optimise the servo tuning to minimise load oscillation.
Soft Servo
Any axis (also external) can be switched to soft servo mode, which means that it will
adopt a spring-like behaviour.
21
Description
External axes for robot types IRB 140, IRB 1400, and IRB 2400:
When more than three external axes are used, the drive units for external axis 4 and
upwards must be located in a separate cabinet as shown in Figure 10.
External axes for robot types IRB 6600 and IRB 7600:
The drive units for all external axes must be located in a separate cabinet as shown in
Figure 10.
Not supplied on delivery
Motor channel
Serial signals for
measurement and
drive system
SMB
Measurement
System 1
SMB
alt.
Measurement
System 2
Drive System 2
ABB Drives
22
Description
thick/thin cable
S4Cplus
multiport-tap
trunk line
R
node
thick/thin cable
node
node
I/O CPU
node
Daisy chain
node
node
node
node
R = terminating resistor
short drop max. 6m each
Figure 11 Example of a general DeviceNet bus.
23
Description
- Program controlled enabling/disabling of I/O units.
- Scaling of analog signals.
- Filtering.
- Polarity definition.
- Pulsing.
- TCP-proportional analog signal.
- Programmable delays.
- Simulated I/O (for forming cross connections or logical conditions without need
the for physical hardware).
- Accurate coordination with motion.
Signals can be assigned to special system functions, such as program start, so as to be
able to control the robot from an external panel or PLC.
The robot can function as a PLC by monitoring and controlling I/O signals:
- I/O instructions are executed concurrent to the robot motion.
- Inputs can be connected to trap routines. (When such an input is set, the
trap routine starts executing. Following this, normal program execution
resumes. In most cases, this will not have any visible effect on the robot motion,
i.e. if a limited number of instructions are executed in the trap routine.)
- Background programs (for monitoring signals, for example) can be
run in parallel with the actual robot program. Requires Multitasking option, see
Product Specification RobotWare.
Manual functions are available to:
- List all the signal values.
- Create your own list of your most important signals.
- Manually change the status of an output signal.
- Print signal information on a printer.
I/O signals can for some robots also be routed parallel or serial to connectors on the
upper arm of the robot.
Types of connection
The following types of connection are available:
- Screw terminals on the I/O units
- Industrial connectors on cabinet wall
- Distributed I/O-connections inside or on cabinet wall
For more detailed information, see Chapter 2, Specification of Variants and Options.
ABB I/O units (node types)
Several I/O units can be used. The following table shows the maximum number of
physical signals that can be used on each unit. Data rate is fixed at 500 Kbit/s.
24
Description
Digital
Analog
DSQC
Option
no.
In
Out
328
20x
16
16
Internal/External1
320
25x
16
16
Internal/External
Analog I/O
355
22x
AD Combi I/O
327
23x
16
16
Relay I/O
332
26x
16
16
Allen-Bradley
Remote I/O Slave
350
241
1282
128
Interbus Slave
351
242-285
642
64
Profibus DP Slave
352
243-287
1282
128
100
100
Type of unit
Simulated I/O3
Encoder interface
unit4
Encoder interface
unit5
354
244
377
249
Voltage
inputs
Voltage
output
3
2
Current
output
Power supply
Internal
Internal/External1
Internal/External1
30
30
1. The digital signals are supplied in groups, each group having 8 inputs or outputs.
2. To calculate the number of logical signals, add 2 status signals for Allen-Bradley Remote I/O unit and 1
for Interbus and Profibus DP.
3. A non physical I/O unit can be used to form cross connections and logical conditions without
physical wiring. No. of signals are to be configured. Some ProcessWares include SIM unit.
4. Dedicated for conveyor tracking only.
5. Only for PickMaster 4.0
Distributed I/O
The maximum number of logical signals is 1024 in total for the CAN/DeviceNet buses
(inputs or outputs, group I/O, analog and digital including field buses)
CAN1
Max. total no of units*
Data rate (fixed)
Max. total cable length
Cable type (not included)
CAN2 (option)
25
Description
Signal data
Permitted customer 24 V DC load
Digital inputs
24 V DC
max. 7,5 A
(option 201/203)
Optically-isolated
Rated voltage:
24 V DC
Logical voltage levels: 1
15 to 35 V
0
-35 to 5 V
Input current at rated input voltage:
6 mA
Potential difference:
max. 500 V
Time delays:
hardware
515 ms
software
3 ms
Time variations:
2 ms
Digital inputs
120 V AC
26
(option 205)
Single pole relays with one make contact (normally open)
Rated voltage:
24 V DC, 120 VAC
Voltage range:
19 to 35 V DC
24 to 140 V AC
Output current:
max. 2 A
Potential difference:
max. 500V
Time intervals: hardware (set signal)
typical 13 ms
hardware (reset signal) typical 8 ms
software
4 ms
(option 204)
Optically isolated
Rated voltage
Input voltage range: 1
Input voltage range: 0
Input current (typical):
Time intervals: hardware
software
120 V AC
90 to 140 V AC
0 to 45 V AC
7.5 mA
20 ms
4 ms
Description
Digital outputs
120 V AC
(option 204)
Optically isolated, voltage spike protection
Rated voltage
120 V AC
Output current:
max. 1A/channel, 12 A
16 channels
or
max. 2A/channel, 10 A
16 channels
(56 A in 20 ms)
min. 30mA
Voltage range:
24 to 140 V AC
Potential difference:
max. 500 V
Off state leakage current:
max. 2mA rms
On state voltage drop:
max. 1.5 V
Time intervals: hardware
12 ms
software
4 ms
Analog inputs (option 202)
Voltage Input voltage:
+10 V
Input impedance:
>1 Mohm
Resolution:
0.61 mV (14 bits)
Accuracy:
+0.2% of input signal
Analog outputs
Analog outputs
(option 202)
VoltageOutput voltage:
Load impedance:
Resolution:
CurrentOutput current:
Load impedance:
Resolution:
Accuracy:
min.
min.
+10 V
2 kohm
2.44 mV (12 bits)
4-20 mA
800 ohm
4.88 A (12 bits)
+0.2% of output signal
(option 203)
Output voltage (galvanically isolated):
Load impedance:
min.
Resolution:
Accuracy:
Potential difference:
Time intervals: hardware
software
0 to +10 V
2 kohm
2.44 mV (12 bits)
25 mV 0.5% of output
voltage
max. 500 V
2.0 ms
4 ms
System signals
Signals can be assigned to special system functions. Several signals can be given the
same functionality.
Digital outputs
Motors on/off
Executes program
Error
Automatic mode
Emergency stop
Restart not possible
Run chain closed
27
Description
Digital inputs
Motors on/off
Starts program from where it is
Motors on and program start
Starts program from the beginning
Stops program
Stops program when the program cycle is ready
Stops program after current instruction
Executes trap routine without affecting status of stopped
regular program1
Loads and starts program from the beginning1
Resets error
Resets emergency stop
System reset
Analog output
For more information on system signals, see Users Guide - System Parameters.
28
Description
1.14 Communication
The controller has three serial channels for permanent use - two RS232 and one
RS422 Full duplex - which can be used for communication point to point with
printers, terminals, computers and other equipment. For temporary use, like service,
there are two more RS 232 channels.
The serial channels can be used at speeds up to 19,200 bit/s (max. 1 channel with speed
19,200 bit/s).
The controller has two Ethernet channels and both can be used at 10 Mbit/s or
100 Mbit/s. The communication speed is set automatically.
Temporary
Main CPU console
Ethernet 10 Mbit/s
Permanent
Ethernet or serial
Figure 12 Point-to-point communication.
29
Description
30
1 SAFETY STANDARDS
EU - Electromagnetic Compatibility
693 The controller complies with the European Union Directive Electromagnetic
Compatibility 89/336/EEC. This option is required by law for end users in the
European Union.
UNDERWRITERS LABORATORY
695 UL/CSA
The robot is certified by Underwriters Laboratory to comply with the Safety Standard
ANSI/UL 1740-1996 Industrial Robots and Robotic Equipment and
CAN/CSA Z 434-94.
UL/UR certification is required by law in some US states and Canada.
UL (UL/CSA) means certification of complete product and UR (UL recognized
Component) means certification of component or not complete product.
Safety lamp (691) Door interlock (145 or 142) Operating mode selector standard
2 modes (193) are mandatory.
Not with Cabinet height 950 mm no cover (122), Cabinet height 1200 mm (123),
Cabinet height 1750 mm (124), Cabinet variant Prepared for Arcitec (112), Mains
connection type CEE17 connector (132, 133), Service outlet type 230V Europe (412).
696 UR (UL Recognized)
The robot is certified by Underwriters Laboratory to comply with the Safety Standard
UL 1740 Industrial Robots and Robotic Equipment. UL/UR certification is required
by law in some US states and Canada. UL (UL listed) means certification of complete
product and UR (UL Recognized Component) means certification of component or not
complete product.
Safety lamp (691), Door interlock (145 or 142), Operating mode selector standard 2
modes (193) are mandatory.
Not with Cabinet variant Prepared for Arcitec (112), Mains connection type CEE17
connector (132, 133), Service outlet type 230V Europe (412).
31
665
9 (x4)
690
730
20
705
Figure 14 Mounting plate for mounting of equipment (dimensions in mm)
M4 (x4)
M8 (x4)
o
45
196
193
223
70
62
140
96
Holes for
flange
184
200
Holes for
operators panel
Holes for
teach pendant holder
Teach pendant
connection
Connection to
the controller
90
5 (x2)
155
33
337
Connection flange
370
Figure 16 Operators panel mounted in a box (all dimensions in mm).
DOOR KEYS
461
462
463
464
466
Standard
Doppelbart
Square outside 7 mm
EMKA DB
Locking cylinder 3524
CONTROLLER COOLING
472 Ambient temperature up to 45oC (113oF)
Standard design. The computer unit is provided with a passive heat exchanger (cooling
fins on the rear part of the box).
473 Ambient temperature up to 52oC (125oF)
The computer unit is provided with an active Peltier cooling equipment (replaces the
cooling fins from option 472.
34
English
Swedish
German
French
Spanish
Portuguese
Danish
Italian
Dutch
Japanese
Czech
Finnish
Extension cable for the teach pendant:
606 10 m
An extension cable can be connected between the controller and the teach pendant.
The total length of cable between the controller and the teach pendant should not
exceed 30 m.
Note that the length of the optional operators panel cable must be included in the
limitation.
607 20 m
MAINS VOLTAGE
The control system can be connected to a rated voltage of between 200 V and 600 V,
3-phase and protective earthing. A voltage fluctuation of +10% to -15% is permissible.
151
152
153
154
155
156
157
158
200V
220V
400V
440V
475V
500V
525V
600V
For all robots except for IRB 6600/7600 the voltage range must be specified. This gives
the possibility to select between three different transformers.
35
560
300
398
MAINS SWITCH
141 Rotary switch 40 A in accordance with the standard in section 1.2 and IEC 337-1,
VDE 0113. Customer fuses for cable protection required.
142 Flange disconnector in accordance with the standard in section 1.2.
Includes door interlock for flange disconnector and a 20A circuit breaker with interrupt capacity
14 kA.
0058 Flange disconnector in accordance with the standard in section 1.2.
Includes door interlock for flange disconnector and a 20A circuit breaker with interrupt
36
145
147
37
X8 (CAN 2)
Ph.5-Pol
X7
CAN 1.3
X10 SIO1
Test
9-Pol D-sub
X20 DRIVE
SYSTEM 2
R
E
L
Ph.5-Pol
8-Pol
DB-44
9-Pol D-sub
X1 I/O COMPUTER
X11 CONSOLE
X9 SIO2
Ph.5-Pol
15-Pol D-sub
9-Pol D-sub
X9 (COM3, RS422)
X8
CAN 2
Ph.5-Pol
X5 MEASUREMENT SYSTEM 2
X2 AXIS COMPUTER
X6
CAN 1.2
25-Pol D-sub
CAN 2
NS MS
X4 MEASUREMENT SYSTEM 1
15-Pol D-sub
15-Pol D-sub
15-Pol
Female
FCI
X3 DRIVE SYSTEM 1
15-Pol
Male
FCI
25-Pol D-sub
Computer system
(COM1, RS232)
XT 31
(24V I/O)
Panel Unit
WARNING
DSQC 509
Manipulator connections
X1-X4
Safety Signals
115/230 VAC
MS NS
X3 X1-X4
CUSTOMER
CONNECTIONS
X1
X2
X4
XP5
XP58
XP6
RL2
XT21
Connection to
Position switches
RL1
XP8
Connection to
Customer power
Customer signals
Figure 20 I/O unit and screw terminal locations.
38
SAFETY SIGNALS
206 Internal connection
The signals are connected directly to screw terminals in the upper part of the cabinet
(see Figure 20).
207 External connection
The signals are connected via 64-pole standard industrial connector in accordance
with DIN 43652. The connector is located on the left-hand side of the controller.
Corresponding customer part is included.
39
GATEWAY UNITS
For more details, see I/O System on page 23.
241 Allen-Bradley Remote I/O
Up to 128 digital inputs and outputs, in groups of 32, can be transferred serially to a
PLC equipped with an Allen Bradley 1771 RIO node adapter. The unit reduces the
number of I/O units that can be mounted in cabinet by one. The field bus cables are
connected directly to the A-B Remote I/O unit in the upper part of the cabinet (see
Figure 20). Connectors Phoenix MSTB 2.5/xx-ST-5.08 or equivalent are included.
242 Interbus Slave
Up to 64 digital inputs and 64 digital outputs can be transferred serially to a PLC
equipped with an InterBus interface. The unit reduces the number of I/O units that
can be mounted in the cabinet by one. The signals are connected directly to the
InterBus slave unit (two 9-pole D-sub) in the upper part of the cabinet.
40
41
195
203
49
170
49
115
Figure 22 Dimension for units 231-234.
43
45
46
Drive unit GT, for 4 or 6 motors. Recommended motor types see Figure 23.
Drive unit ECB, for 3 or 6 motors. Recommended motor types see Figure 23.
Drive unit GT + ECB
Drive unit GT + GT + ECB
Drive unit
identity
Motor max
current Arms
Suitable motor
type
11.5-57
30
XL
5.5-26
14.5
XL
11 - 55A
24A
M, L
6 - 30A
16A
S, M, L
7.5-37
20
S, M, L, XL
4 - 19A
8,4A
S, M
2,5 - 11A
5A
1,5 - 7A
4A
Figure 23 Motor selection table. Motor types according to external axes Motor Unit.
47
7m
15 m, not available for IRB 140
22 m, not available for IRB 140
30 m, not available for IRB 140
3 m, only available for IRB 140
Manipulator connection (only available for IRB 340)
SERVICE OUTLET
Any of the following standard outlets with protective earthing can be chosen for
maintenance purposes.
The maximum load permitted is 500 VA (max. 100 W can be installed inside the
cabinet).
411 120 V in accordance with American standard; single socket, Harvey Hubble.
412 230 V mains outlet in accordance with DIN VDE 0620; single socket suitable for
EU countries.
MEMORY
Removable mass memory
320 Floppy drive
The disk drive normally works well at temperatures up to 40oC (104oF). The disk drive
48
49
50
Index
3 Index
A
absolute measurement 16
Allen-Bradley Remote I/O 23, 25, 40
analog signals 23, 27
automatic operation 15
B
backup
computer system backup 13
memory 11
base coordinate system 19
Big Inertia 21
bumps 12
C
cabinet wheels 32
CAN/DeviceNet 39
collision detection 6
communication 29
concurrent I/O 24
configuration 12, 13, 23
connection 48
mains supply 36
cooling device 3
coordinate systems 18
cross connections 23
cursor 7
event routine 16
explosive environments 12
extended memory 11
external axes 21
external panel 33
F
fire safety 6
flash disk memory 11
fly-by point 14
function keys 7
H
hold-to-run 8
hold-to-run control 6
humidity 12
I
I/O units 24
I/O-system 23
incremental jogging 20
inputs 23
installation 12
Interbus Slave 23, 25, 40
interrupt 24
J
jogging 20
joystick 8
diagnostics 17
digital signals 23, 26
display 7
distributed I/O 25
LAN/Ethernet 39
language 13
lighting
connection 48
teach pendant 35
E
editing
position 15
programs 15
emergency stop 6, 7
emergency stop button 8
enabling device 5, 8
display 7
Encoder interface unit 25, 41
M
mains supply 36
mains switch 36
mains voltage 35
maintenance 17
manipulator cable 48
length 48
protection 48
51
Index
mass memory 11
memory
backup 11
extended 11
flash disk 11
mass storage 11
RAM memory 11
menu keys 7
mirroring 15
motion 18
motion keys 7
motion performance 18
Motion Supervision 20
Multitasking 24
N
navigation keys 7
noise level 3
O
object coordinate system 19
operating mode 9
operating mode selector 9, 34
operating requirements 12
operation 7
operator dialogs 13
operators panel 9, 33
options 31
outputs 23
over-speed protection 6
P
password 13, 15
performance 18
PLC functionality 24
position
editing 15
execution 20
programming 14, 19
position fixed I/O 24
power supply 12
production window 15
Profibus 39
Profibus DP Slave 23, 25, 41
program
editing 15
testing 15
52
programming 13
protection standards 12
Q
QuickMove 18
R
RAPID Language 16
reduced speed 5
S
safe manual movements 6
safeguarded space stop 6
delayed 6
safety 5
safety lamp 6
serial communication 29
service 17
service outlets 48
signal data 26
singularity handling 20
Soft Servo 21
space requirements 3
standards 5
stationary TCP 20
stop point 14
structure 3
system signals 27
T
TCP 19
teach pendant 7
cable 35
language 35
lighting 35
temperature 12
testing programs 15
tool coordinate system 19
tools centre point 19
trap routines 24
troubleshooting 17
TrueMove 18
U
user coordinate system 19
user-defined keys 8
Product Specification S4Cplus M2000/BaseWare OS 4.0
Index
V
variants 31
vibration 12
volume 3
W
window keys 7
windows 7
working space
restricting 6
world coordinate system 19
53
Index
54
Product Specification
RobotWare Options
3HAC 9218-1/Rev.2
BaseWare OS 4.0
The information in this document is subject to change without notice and should not be construed as a
commitment by ABB Automation Technology Products AB, Robotics. ABB Automation Technology
Products AB, Robotics assumes no responsibility for any errors that may appear in this document.
In no event shall ABB Automation Technology Products AB, Robotics be liable for incidental or
consequential damages arising from use of this document or of the software and hardware described
in this document.
This document and parts thereof must not be reproduced or copied without ABB Automation Technology Products AB, Robotics 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 document may be obtained from ABB Automation Technology Products AB,
Robotics at its then current charge.
Introduction
1 Introduction
RobotWare is a family of software products from ABB Automation Technology
Product AB, Robotics, designed to make you more productive and lower your cost of
owning and operating a robot.
ABB Automation Technology Product AB, Robotics has invested many man-years
into the development of these products and they represent knowledge and experience
based on several thousand robot installations.
Within the RobotWare family there are three classes of products:
BaseWare OS - This is the operating system of the robot and constitutes the kernel of
the RobotWare family. BaseWare OS provides all the necessary features for
fundamental robot programming and operation. It is an inherent part of the robot but
can be provided separately for upgrading purposes.
For the description of BaseWare OS, see Product Specification S4Cplus.
BaseWare Options - These products are options that run on top of BaseWare OS of the
robot. They represent functionality for robot users that need additional functionality,
for example run multitasking, transfer information from file to robot, communicate
with a PC, perform advanced motion tasks etc.
ProcessWare - ProcessWare products are designed for specific process applications
like welding, gluing and painting. They are primarily designed to improve the process
result and to simplify installation and programming of applications. These products
also run on top of BaseWare OS.
Introduction
2 BaseWare Options
[544] Absolute Accuracy
Absolute Accuracy (AbsAcc) is a calibration concept, which ensures a TCP absolute
accuracy of better than 1 mm in the entire working range.
The user is supplied with robot calibration data (error parameter file) and a certificate
that shows the performance (Birth Certificate).
The difference between an ideal robot and a real robot can be typically 8 mm, resulting
from mechanical tolerances and deflection in the robot structure. Absolute Accuracy
option is integrated in the controller algorithms for compensation of this difference,
and does not need external equipment or calculation.
Features
Compensation of mechanical tolerances.
Compensation of deflection due to load (tool, object and equipment on arm).
Applications
Any application where Absolute Accuracy is needed to facilitate:
- Exchangeability of robots
- Off-line programming with minimum touch-up.
- On-line programming with accurate linear movement as well as accurate
reorientation of tool
- Re-use of programs between applications
Controller algorithms
Inherent mechanical tolerances and deflection due to load in the robot structure
decrease the robots absolute accuracy. Practical compensation of such errors is a
complex and highly non-linear problem. The ABB solution is to compensate positions
internally in the controller, resulting in a defined and measurable robot TCP (Tool
Center Point) accuracy. A generic robot control model is used for each robot family and
robot individuals are described by a set of error parameters, generated during
calibration at ABB Automation Technology Products, Robotics. Accuracy of each
robot will be ascertained and verified through the Birth Certificate which statistically
describes the robot accuracy in a large sample of robot positions.
[542] ScreenViewer
[542] ScreenViewer
This option adds a user window to display user defined screens with advanced display
functions. The user window can be displayed at any time, regardless of the execution
state of the RAPID programs.
User defined screens
The user defined screens are composed of:
A fixed background with a size of 12 lines of 40 characters each. These characters
can be ASCII and/or horizontal or vertical strokes (for underlining, separating or
framing).
1 to 5 function keys.
1 to 4 pop-up menus containing from 1 to 10 choices.
1 to 30 display and input fields defined by:
- Their position and size.
- Their type (display, input).
- Their display format (integer, decimal, binary, hexadecimal, text).
- A possible boundary with minimum and maximum limits.
Example of a user defined screen. The ### represent the fields.
SpotTim
Program number: ###
PHASES
SQUEEZE
PREHEAT
COOLING
## HEAT
COLD
LASTCOLD
POSTHEAT
HOLD
Next
View
File
|
|
|
|
|
|
|
|
|
XT
##
##
##
##
##
##
##
##
|
|
|
|
|
|
|
|
|
|
CURENT (A)
START | END
|
####
|
| ####
####
|
|
|
####
| ####
|
Prev.
(Copy)
Valid
[542] ScreenViewer
A screen event can occur
- When a new screen is displayed (to initialize the screen contents).
- After a chosen interval (to refresh a screen).
- When a menu choice or a function key is selected (to execute a specific action,
or change the screen).
- When a new value is entered in a field, or when a new field is selected (to execute some specific action).
The commands that can be executed on screen events are
- Reading/writing RAPID or I/O data.
- Reading/writing fields contents.
- Arithmetical (+, -, /, *, div) or logical (AND, OR, NOT, XOR) operations on the
data read.
- Comparing data read (=, <, >) and carrying out a command or not, depending
on the comparison result.
- Displaying a different screen.
Capacities
The user screens can be grouped in a screen package file under a specific name. Up to
8 packages can be loaded at the same time.
A certain amount of memory (approx. 50 kbytes) is reserved for loading these screen
packages.
- The screen package to be displayed is selected using the far right hand menu
View (which shows a list of the screen packages installed).
ScreenMaker
ScreenMaker is a complete tool for creating and editing screens for the ScreenViewer
on desktop computers running Windows 95/98 or Windows NT.
See ScreenMaker Product Specification.
10
[532] Multitasking
[532] Multitasking
Up to 10 programs (tasks) can be executed in parallel with the normal robot program.
- These additional tasks start automatically at power on and will continue until
the robot is powered off, i.e. even when the main process has been stopped and
in manual mode.
- They are programmed using standard RAPID instructions, except for motion
instructions.
- They can be programmed to carry out various activities in manual or automatic
mode, and depending on whether or not the main process is running.
- Communication between tasks is carried out via I/O or global data.
- Priorities can be set between the processes.
Examples of applications:
- The robot is continuously monitoring certain signals even when the robot
program has stopped, thus taking over the job traditionally allocated to a PLC.
- An operator dialogue is required at the same time as the robot is doing, for
example, welding. By putting this operator dialogue into a background task, the
operator can specify input data for the next work cycle without having to stop
the robot.
- The robot is controlling a piece of external equipment in parallel with the
normal program execution.
Performance
When the various processes are programmed in the correct way, no performance
problems will normally occur:
- When the priorities for the various processes are correctly set, the normal
program execution of the robot will not be affected.
- Because monitoring is implemented via interrupts (instead of checking
conditions at regular intervals), processor time is required only when
something actually happens.
- All input and output signals are accessible for each process.
Note that the response time of Multitasking does not match that of a PLC. Multitasking
is primary intended for less demanding tasks. The normal response time is about 5 ms,
but in the worst cases, e.g. when the processor is computing new movements, it can be
up to 120 ms.
The available program memory can be divided up arbitrarily between the processes.
However, each process in addition to the main process will reduce the total memory,
see Product Specification S4Cplus.
11
13
14
15
16
17
18
19
GetNextSym
GetDataVal
Get the value of a data, specified with a string for the name
SetDataVal
Set the value of a data, specified with a string for the name
20
AliasIO
ArgName
BookErrNo
TextTabGet
TextGet
Function used to get a text string from the system text tables
(installed at cold start).
TextTabInstall
TextTabFreeToUse
IsSysId
SetSysData
ReadCfgData
WriteCfgData
PFDOVal
Get the value of the specified digital output signal at the time
for power failure.
PFGOVal
Get the value of the specified digital output group at the time
for power failure.
PFRestart
Trigg Functions
TriggSpeed
StepBwdPath
TriggStopProc
21
22
22
23
24
[547]Sensor Synchronization
Start/stop synchronization
Connect to an object in the start window
Disconnect from current object
25
26
27
28
29
30
31
32
Ethernet
RS232/RS422
Examples of applications:
- Production is controlled from a superior computer. Information about the robot
status is displayed by the computer. Program execution is started and stopped
from the computer, etc.
- Transferring programs and parameters between the robot and a PC. When many
different programs are used in the robot, the computer helps in keeping track of
them and by doing back-ups.
RAPID instruction included in this option
SCWrite
33
34
35
36
[551] ArcWare
3 ProcessWare
[551] ArcWare
ArcWare comprises a large number of dedicated arc welding functions, which make the
robot well suited for arc welding. It is a simple yet powerful program since both the
positioning of the robot and the process control and monitoring are handled in one and
the same instruction.
I/O signals, timing sequences and weld error actions can be easily configured to meet
the requirements of a specific installation.
ArcWare functions
A few examples of some useful functions are given below.
Adaptation to different equipment
The robot can handle different types of weld controllers and other welding equipment.
Normally communication with the welding controller uses parallel signals but a serial
interface is also available.
Advanced process control
Voltage, wire feed rate, and other process data can be controlled individually for each
weld or part of a weld. The process data can be changed at the start and finish of a
welding process in such a way that the best process result is achieved.
Testing the program
When testing a program, welding, weaving or weld guiding can all be blocked. This
provides a way of testing the robot program without having the welding equipment
connected.
Automatic weld retry
A function that can be configured to order one or more automatic weld retries after a
process fault.
Weaving
The robot can implement a number of different weaving patterns up to 10 Hz
depending on robot type. These can be used to fill the weld properly and in the best
possible way. Weaving movement can also be ordered at the start of the weld in order
to facilitate the initial striking of the arc.
37
[551] ArcWare
Wire burnback and rollback
These are functions used to prevent the welding wire sticking to the work object.
Fine adjustment during program execution
The welding speed, wire feed rate, voltage and weaving can all be adjusted whilst
welding is in progress. This makes trimming of the process much easier because the
result can be seen immediately on the current weld. This can be done in both manual
and automatic mode.
Seam finding and tracking
Seam finding and tracking can be implemented using a number of different types of
sensors. Please contact your nearest local ABB office for more information.
Interface signals
The following process signals are, if installed, handled automatically by ArcWare. The
robot can also support dedicated signals for workpiece manipulators and sensors.
38
Digital outputs
Power on/off
Gas on/off
Wire feed on/off
Wire feed direction
Weld error
Error information
Weld program number
Description
Turns weld on or off
Turns gas on or off
Turns wire feed on or off
Feeds wire forward/backward
Weld error
Digital outputs for error identification
Parallel port for selection of program number, or
3-bit pulse port for selection of program number, or
Serial CAN/Devicenet communication
Digital inputs
Arc OK
Voltage OK
Current OK
Water OK
Gas OK
Wire feed OK
Manual wire feed
Weld inhibit
Weave inhibit
Stop process
Wirestick error
Supervision inhibit
Torch collision
Description
Arc established; starts weld motion
Weld voltage supervision
Weld current supervision
Water supply supervision
Gas supply supervision
Wire supply supervision
Manual command for wire feed
Blocks the welding process
Blocks the weaving process
Stops/inhibits execution of arc welding instructions
Wirestick supervision
Program execution without supervision
Torch collision supervision
Analog outputs
Voltage
Wire feed
Current
Voltage adjustment
Current adjustment
Description
Weld voltage
Velocity of wire feed
Weld current
Voltage synergic line amplification
Current synergic line amplification
[551] ArcWare
Analog inputs (cont.)
Description (cont.)
Voltage
Current
39
40
[556] Arcitec
[556] Arcitec
This option is intended to be used in combination with the Arcitec power sources.
It shall only be ordered by the supplying unit of Arcitec.
The package is a special software, used together with the ArcWare package, to be able
to control not only the robot program but also the set up, configuration and
programming of the power source. Thus the robot teach pendant will be used for
programming and tuning both the robot and the power source.
The package also includes a special aid for easy welding programming, i.e. the synergic
function. This means that there is a pre-programmed relationsship between the wire
feed rate and all other data components in the power source, making it easy to control
the entire welding process, just by tuning the wire feed rate.
41
[553] SpotWare
[553] SpotWare
The Spotweld options are general and flexible software platforms for creation of
customized and easy to use function packages for different types of spotweld systems
and process equipments.
The SpotWare option is used for sequential welding with one or several pneumatic gun
equipments. If welding with several pneumatic guns at the same time is desired then
the SpotWare Plus option has to be used instead.
The SpotWare option provides dedicated spotweld instructions for fast and accurate
positioning combined with gun manipulation, process start and supervision of the weld
equipment.
Communication with the welding equipment is normally carried out by means of
digital inputs and outputs but a serial interface is also available for some type of weld
timers.
It should be noted that the SpotWare options are general and can be extensively
customized. They have a default ready to use functionality directly after install but it
is intended that some configuration data, RAPID data and RAPID routines has to be
changed during the customizing.
SpotWare features
Some examples of useful functions are given below:
- Fast and accurate positioning using the unique QuickMove and TrueMove
concept.
- Gun pre-closing.
- Quick start after a weld.
- Handling of an on/off gun with two strokes.
- Dual/single gun.
- Manual actions for welding and gun control.
- Simulation possibilities for test purposes.
- Reverse execution with gun control.
- Spot counters.
- User-defined supervision and error recovery. Weld error recovery with
automatic rewelding.
- User-defined continuous supervision of the weld equipment, such as weld
current signal and water cooling start. Note: This feature requires the
MultiTasking option.
- Wide customizing possibilities.
42
[553] SpotWare
Principles of SpotWare
The SpotWare functions will be controlled by separate internal program processes,
which will run in parallel. For instance the robot movements, the continuous supervision and the spot welding will be handled in different independent processes. This
means that if for instance the program execution and thus the robot movements is
stopped, then the welding and supervision will continue until they come to a well
defined process stop. For example, the welding process will carry on and finish the
weld and open the gun, although the program has been stopped during the weld phase.
For well defined points in the welding sequence and movements, calls to user routines
offer adaptations to the plant environment. A number of predefined parameters are also
available to shape the behaviour of the SpotWare instructions.
Programming principles
Both the robot movement and the control of the spot weld equipment are embedded in
the basic spot weld instructions SpotL and SpotJ.
The spot welding process is specified by:
- Spotdata: spot weld process data
- Gundata: spot weld equipment data
- The system modules SWUSRC and SWUSRF: RAPID routines and global data
for changing of process and test behaviour.
- System parameters: the I/O Signal configuration.
Spot welding instructions
Instruction
Used to:
SpotL
SpotJ
Used to define:
spotdata
gundata
43
44
Used to:
SpotML
SpotMJ
Used to define:
spotmdata
gunmdata
45
46
47
Used to:
SpotL
SpotJ
SetForce
CalibL
CalibJ
Calibrate
STTune
STTuneReset
48
Data type
Used to define:
spotdata
gundata
forcedata
simdata
Simulation modes
49
50
Instruction
Used to:
SpotML
SpotMJ
[569] DispenseWare
[569] DispenseWare
The DispenseWare package provides support for different types of dispensing
processes such as gluing and sealing.
The DispenseWare application provides fast and accurate positioning combined with a
flexible process control.
Communication with the dispensing equipment is carried out by means of digital and
analog outputs.
DispenseWare is a package that can be extensively customized. The intention is that
the user adapts some user data and routines to suit a specific dispensing equipment and
the environmental situation.
Dispensing features
The DispenseWare package contains the following features:
- Fast and accurate positioning.
- Handling of on/off guns as well as proportional guns.
- Speed proportional or constant analog outputs.
- Up to five different guns can be handled simultaneously, controlled by 1 - 5
digital output signals (for gun on/off control) and 1 - 2 analog output signals
(for flow control).
- Four different gun equipment, each controlled by 1 - 5 digital output signals
and 1 - 2 analog output signals, can be handled in the same program.
- Possibility to use different anticipated times for the digital and analog signals.
- Possibility to use equipment delay compensation for the TCP speed
proportional analog signals.
- Global or local flow rate correction factors.
- Dispensing instructions for both linear and circular paths.
- Dispensing in wet or dry mode.
- Wide opportunities of customizing the functionality to adapt to different types
of dispensing equipment.
- Possibility to restart an interrupted dispense sequence.
Programming principles
Both the robots movement and the dispensing process control are embedded in the
instructions, DispL and DispC respectively.
51
[569] DispenseWare
The gluing process is specified by:
- Bead specific dispensing data. See Data types - beaddata.
- Equipment specific dispensing data. See Data types - equipdata.
- RAPID routines and global data for customizing purposes. See Predefined Data
and Programs - System Module DPUSER.
- The I/O configuration. See System Parameters - DispenseWare
Dispensing instructions
Instruction
Used to:
DispL
Move the TCP along a linear path and perform dispensing with
the given data
DispC
Dispensing data
52
Data type
Used to define:
beaddata
equipdata
[571] PalletWare
[571] PalletWare
General
PalletWare is a ready-to-use software package for the S4Cplus controller, focused on
palletizing. PalletWare imports data created with PalletWizard, the included off-line
PC-tool, to execute the defined palletizing cycles. PalletWare has a predefined
interface for connecting PLC (Programmable Logic Controller), which is the most
common way to control external equipment such as infeeders, outfeeders and sensor
equipment. The standard package includes software components such as priority and
scheduling routines that are ready to use. The package also includes components that
can be customized, e.g. grip tool control routines.
PalletWare supports system integrators who want to customize the system, by
presenting a standardized interface.
What is included
Included in the PalletWare package is software components to control robot motion,
and to communicate with the user and external equipment.
In order to minimize commissioning time, PalletWare is equipped with a standardized
set of modules, referred to as the Standard Package Add-On. Advanced users can
replace these modules with their own if special customizing is needed. PalletWare is
also delivered with template user routines that handles the most common solutions.
PalletWare offers a standardized interface where to connect all external equipment
such as infeeders, PLC, signal board, grip tool, sensor equipment etc. The package
includes a set of predefined signals connected to a simulated board. The integrator has
to implement the signal board and connect the signals. The configuration file for the
signals has also to be modified depending on what type of board is used. Because of
the large amount of signals, it is recommended to use a field bus such as for example
Profibus.
PalletWare features
PalletWare offers for example following functionality:
- Multiplacing
- Parallel processing, up to 5 stations simultaneously
- Multistationary production
- User dialogue interface with Screen Viewer
- On-line tuning of geometrical data
- Safety functionality
- Prepared PLC interface
- Prepared MMI interface
53
[571] PalletWare
- Tool control
- Standardized error handling
- Predefined user routines
Programming principles
PalletWare is added to the BaseWare system. PalletWare consists of predefined motion
principles and communication routines for communicating with external equipment. It
is not necessarily needed to implement any RAPID code. However, the system supports
integrators for customizing by standardized functions and instructions.
Customizing PalletWare
PalletWare can be up-and-running without any need for implementing RAPID code,
but it must be adapted to the current robot cell and its physical lay-out. For instance,
there are a number of steps which are compulsory, e.g:
- Connect external equipment such as infeeders, tool, PLC etc., via the predefined
interface.
- Connect safety equipment such as emergency stop, safety fences etc.
- Define tooldata if the tool does not match the templates
- Check the set-up in the configuration module PAL_CFG.
- Define/teach work objects to the stations
- Define/teach robtarget with tool in zero orientation
- Create and load pallet cycles with PalletWizard.
In addition to this, PalletWare offers a great deal of customizing possibilities for
advanced users, e.g.
- Using tools with suction cups or mechanical gripper
- Sliding uppermost layer to gain pallet height
- Controlling orientation on infeeder
- Add or skip safety height movements between stations
- Set priority when working with several pallet cycles in parallel.
- Etc.
Pallet Wizard
Pallet Wizard is a complete and easy to use stand alone tool running on a PC under
Windows 95/98 or Windows NT, for off line programming of palletizing or
depalletizing processes. It is delivered as a part of the PalletWare option package.
In PalletWizard the complete cell with its different components like the products, the
tools, the in/out feeders and pallet stations as well as the pallet cycles with the layers
and the pattern descriptions can be defined.
54
[571] PalletWare
PalletWizard offers for example the following features:
- Detailed On-line help
- Wizards for defining the products, tools, cell definition, station configurations,
pallet composition and the pallet cycles
- Automatic pick- and place definition
- Automatic calculating of grip zones to be used for the tool
- Software based collision detection
- Library of predefined patterns
Several different pallet cycles can be combined into a production cycle and saved into
a file, which can be downloaded to the robot. At the robot the operator can then select
what specific pallet cycle to run and on which infeeder and pallet station.
55
Index
INDEX
4 Index
A
AbsAcc 5
Absolute Accuracy 5
Advanced functions 14
arc welding 37, 40
Arcitec 41
ArcWare 37
ArcWare Plus 40
B
BaseWare 5
BaseWare Options 3
BaseWare OS 3
C
Collision Detection 7
communication
robot and PC 33
continuous movement 13
Contour tracking 12
Conveyor Tracking 23, 27, 29
coordinated motion 12
cross-connection
locigal conditions 16
output 15
procedure call 15
Friction Compensation 13
FTP 32
I
I/O Plus 36
independent movement 13
input or output signals
interrupts 17
Interbus Configuration Tool 34
interrupt routine movement 16
interrupts
from analog input or output signals 17
L
Load Identification 7
logical conditions
cross connections 16
N
NFS 32
O
output
in fixed position 15
P
D
data
read and write 14, 33
transfer 14
Discrete Applications Platform 22
DispenseWare 51
E
electronically linked motors 24
error handler movement 16
Ethernet Services 32
F
file
read and write 14, 33
fixed position
PalletWare 53
parallel processing 11
PLC functionality 16
printout 14
ProcessWare 3, 37
Profibus Configuration Tool 35
Profibus DP 35
program
back-up 33
transfer 33
R
RAP Communication 31
read
data 14
file 14
57
Index
58
Table of Contents
0.0.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
0.0.2 Product Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Chapter 1: Safety, service
1.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Section 1.1: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
17
27
35
3HAC 16245-1
Table of Contents
4.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.2.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.2.3 Mechanically restricting the working range of axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.2.4 Mechanically restricting the working range of axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.2.5 Position switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Section 4.3: On-site installation, controller cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
75
139
ii
3HAC 16245-1
Table of Contents
141
157
169
175
3HAC 16245-1
iii
Table of Contents
205
iv
3HAC 16245-1
0.0.1 Overview
0.0.1 Overview
About This
Manual
This information product is a manual containing instructions for installing the complete robot
system, mechanically as well as electrically.
Usage
This manual should be used during installation, from lifting the manipulator to its work site
thru installing application software in the robot controller, making the robot ready for operation.
Prerequisites
Organization of
Chapters
Contents
Safety, Service
Reference Information
Unpacking
On-site Installation
Electrical connections
Start-up
Robot controller
10
Calibration
11
Decommissioning
References
3HAC 16245-1
Reference
Document Id
3HAC 13347-1
3HAC 14189-2
0.0.1 Overview
Revisions
Revision
Description
First edition
Various corrections in text and in figures due to reconstructions, new options, etc.
3HAC 16245-1
General
The complete product documentation kit for the robot, including controller, manipulator and
any hardware option, consists of the manuals listed below:
Installation and
Commissioning
Manual
Repair Manual
Maintenance
Manual
Safety, Service
Reference Information
Unpacking
On-site Installation
Electrical connections
Start-up
Calibration
Safety, Service
Reference Information
Remove/Refitting instructions for all controller cabinet details considered spare parts
Safety, Service
Reference Information
Maintenance schedules
Instructions for all maintenance activities specified in the maintenance schedule, for
example cleaning, lubrication, inspection etc.
The information is generally divided into separate chapters for the manipulator and the controller, respectively.
Software manuals
The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during operation.
A complete listing of all available software manuals is available from ABB Robotics.
3HAC 16245-1
Hardware option
manual
Each hardware option is supplied with its own documentation. Each document set contains
the types of information specified above:
Installation information
Repair information
Maintenance information
3HAC 16245-1
1 Safety, service
1.0.1 Introduction
Definitions
This chapter details safety information for service personnel i.e. personnel performing installation, repair and maintenance work.
Sections
2. Safety risks lists dangers relevant when servicing the robot system. The dangers are split into different categories:
Safety risks related to gripper/end effector
Safety risks related to tools/workpieces
Safety risks related to pneumatic/hydraulic systems
Safety risks during operational disturbances
Safety risks during installation and service
Risks associated with live electric parts
3. Safety actions details actions which may be taken to remedy or avoid dangers.
Safety fence dimensions
Fire extinguishing
Emergency release of the manipulators arm
Brake testing
Risk of disabling function "Reduced speed 250 mm/s"
Safe use of the Teach Pendant Unit enabling device
Work inside the manipulators working range
3HAC 16245-1
1 Safety, service
1.1.1 Safety, service - General
Validity and
responsibility
The information does not cover how to design, install and operate a complete system, nor
does it cover all peripheral equipment, which can influence the safety of the total system. To
protect personnel, the complete system must be designed and installed in accordance with the
safety requirements set forth in the standards and regulations of the country where the robot
is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable safety laws
and regulations in the country concerned are observed and that the safety devices necessary
to protect people working with the robot system have been designed and installed correctly.
Personnel working with robots must be familiar with the operation and handling of the industrial robot, described in the applicable documents, e.g. Users Guide and Product Manual.
Connection of
external safety
devices
Apart from the built-in safety functions, the robot is also supplied with an interface for the
connection of external safety devices. Via this interface, an external safety function can interact with other machines and peripheral equipment. This means that control signals can act on
safety signals received from the peripheral equipment as well as from the robot.
In the Product Manual - Installation and Commissioning, instructions are provided for connecting safety devices between the robot and the peripheral equipment.
General
Any information given in this information product 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.
General
Documents
10
Type of information
Detailed in document
Users Guide
Start-up
Section
3HAC 16245-1
1 Safety, service
1.2.1 Safety risks related to gripper
Safe handling
It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that guards
remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
Grippers/end effectors must be designed so that they retain workpieces in the event of a power
failure or a disturbance of the controller.
General
Residual energy
Safe design
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.
Shot bolts should be used to prevent tools, etc., from falling due to gravity.
General
Qualified personnel
Extraordinary
risks
3HAC 16245-1
The industrial robot is a flexible tool which can be used in many different industrial
applications.
All work must be carried out professionally and in accordance with the applicable
safety regulations.
Remedial action must only be carried out by qualified personnel who are familiar with
the entire installation as well as the special risks associated with its different parts.
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.
11
1 Safety, service
1.2.5 Safety risks during installation and service
Nation/region
specific regulations
Non-voltage
related risks
To be observed
by the supplier of
the complete system
The instructions in the Product Manual - Installation and Commissioning must always
be followed.
Emergency stop buttons must be positioned in easily accessible places so that the
robot can be stopped quickly.
Those in charge of operations must make sure that safety instructions are available
for the installation in question.
Those who install the robot must have the appropriate training for the robot system in
question and in any safety matters associated with it.
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.
Safety zones, which have to be crossed before admittance, must be set up in front of
the robot's working space. Light beams or sensitive mats are suitable devices.
Turntables or the like should be used to keep the operator out of the robot's working
space.
The axes are affected by the force of gravity when the brakes are released. In addition
to the risk of being hit by moving robot parts, you run the risk of being crushed by the
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.
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 temperature of the motors or oil spills that can occur on the robot.
The supplier of the complete system must ensure that all circuits used in the safety
function are interlocked in accordance with the applicable standards for that function.
The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner, in accordance with the applicable standards for the emergency stop function.
Voltage related
risks, general
Voltage related
risks, controller
12
Although troubleshooting may, on occasion, have to be carried out while the power
supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
The mains supply to the robot must be connected in such a way that it can be turned
off outside the robots working space.
3HAC 16245-1
1 Safety, service
1.2.6 Risks associated with live electric parts
Units inside the controller, e.g. I/O modules, can be supplied with power from an external source.
The power supply unit for the computer system (230 VAC)
The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
The power supply unit for tools, or special power supply units for the machining process
The external voltage connected to the control cabinet remains live even when the
robot is disconnected from the mains.
Additional connections
Voltage related
risks, manipulator
Voltage related
risks, tools, material handling
devices, etc
Tools, material handling devices, etc., may be live even if the robot system is in the OFF
position. Power supply cables which are in motion during the working process may be damaged.
3HAC 16245-1
The user connections for tools or other parts of the installation (max. 230 VAC, see
Installation and Commissioning Manual)
13
1 Safety, service
1.3.1 Safety fence dimensions
General
Fit a safety fence or enclosure around the robot to ensure a safe robot installation.
Dimensioning
Dimension the fence or enclosure to enable it to withstand the force created if the load being
handled by the robot is dropped or released at maximum speed. Determine the maximum
speed from the maximum velocities of the robot axes and from the position at which the robot
is working in the work cell (see Product Specification - Description, Robot Motion).
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating
tool or other device fitted to the manipulator.
Description
In an emergency situation, any of the manipulators axes may be released manually by pushing the brake release buttons on the manipulator or on an optional external brake release unit.
How to release the brakes is detailed in section "Manually releasing the brakes".
The manipulator 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, which may further increase any injury!
When to test
During operation the holding brakes of each axis motor wear normally. A test may be performed to determine whether the brake can still perform its function.
How to test
The function of each axis motor holding brakes may be checked as detailed below:
1. Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized (max. static load).
2. Switch the motor to the MOTORS OFF position with the Operating mode selector
on the controller.
3. Check that the axis maintains its position.
If the manipulator does not change position as the motors are switched off, then the brake
function is adequate.
14
3HAC 16245-1
1 Safety, service
1.3.5 Risk of disabling function "Reduced speed 250 mm/s"
3HAC 16245-1
15
1 Safety, service
1.3.7 Work inside the manipulators working range
16
3HAC 16245-1
2 Reference information
2.0.1 Introduction
General
3HAC 16245-1
This chapter presents generic pieces of information, complementing the more specific information in the following chapters.
17
2 Reference information
2.1.1 Applicable Safety Standards
Standards,
general
Standards,
robot cell
18
The following standards are applicable when the robot is part of a robot cell:
EN 811 - Safety distances to prevent danger zones being reached by the lower limbs.
EN 294 - Safety distances to prevent danger zones being reached by the upper limbs.
3HAC 16245-1
2 Reference information
2.1.2 Screw joints
General
This section details how to tighten the various types of screw joints on the manipulator as well
as the controller.
The instructions and torque values are valid for screw joints comprising metallic materials
and do not apply to soft or brittle materials.
Any instructions given in the repair, maintenance or installation procedure description override any value or procedure given here, i.e. these instruction are only valid for standard type
screw joints.
UNBRAKO
screws
UNBRAKO is a special type of screw recommended by ABB in certain screw joints. It features special surface treatment (Gleitmo as described below), and is extremely resistant to
fatigue.
Whenever used, this is specified in the instructions and in such cases no other type of replacement screw is allowed. Using other types of screw will void any warranty and may potentially
cause serious damage or injury!
Gleitmo treated
screws
Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.
Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this
the screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should
be used.
Screws lubricated
in other ways
Screws lubricated with Molycote 1000 (or another lubricant) should only be used when specified in the repair, maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1. Lubricate the thread of the screw.
2. Lubricate between the plain washer and screw head.
3. Tighten to the torque specified in section "Tightening torque" below. Screw dimensions
of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or
smaller may be tightened without a torque wrench if this is done by trained and qualified personnel.
3HAC 16245-1
Lubricant
Art. no.
1171 2016-618
19
2 Reference information
2.1.2 Screw joints
Tightening torque
Below are tables specifying the torque values for different screw joint types:
Dimension
M2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
Screws with
hexagon socket
head, dry
Screws with
hexagon socket
head, lubricated
20
Dimension
Tightening
torque (Nm)
Class 8.8 "dry"
Tightening
Tightening
torque (Nm)
torque (Nm)
Class 10.9 "dry" Class 12.9 "dry"
M5
M6
10
M8
24
34
40
M10
47
67
80
M12
82
115
140
M16
200
290
340
Dimension
M8
28
34
M10
55
66
M12
96
115
M16
235
280
3HAC 16245-1
2 Reference information
2.1.3 Weight specifications
Definition
In all repair and maintenance instructions, weights of the components handled are sometimes
specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.
ABB recommends the use of lifting equipment when handling components with a weight
exceeding 22 kg to avoid inflicting injury. A wide range of lifting tools and devices is available for each manipulator model.
Example
3HAC 16245-1
21
2 Reference information
2.1.4 Standard toolkit
General
All service (repairs, maintenance and installation) instructions contain lists of tools required
to perform the specified activity.
All special tools required are listed directly in the instructions while all the tools that are
considered standard are gathered in the Standard toolkit and defined in the table below.
In this way, the tools required are the sum of the Standard Toolkit and any tools listed in the
instruction.
Contents,
standard toolkit,
3HAC 15571-1
22
Qty
Tool
Rem.
To be shorted to 12mm
3HAC 16245-1
2 Reference information
2.1.5 Special tools
General
All service (repairs, maintenance and installation) instructions contain lists of tools required
to perform the specified activity. The required tools are a sum of standard tools, defined in
section Standard toolkit on page 22, and of special tools, listed directly in the instructions and
also gathered in the table below.
The table below is an overview of all the special tools required when performing service
activities on the IRB 6600/6650/7600. The tools are gathered in two kits: Basic Toolkit
(3HAC 15571-3) and Extended Toolkit (3HAC 15571-2).
The special tools are also listed directly in the current instructions.
3HAC 16245-1
Description
Angel bracket
68080011-LP
3HAB 3409-86
3HAB 3409-89
Cal. tool
68080011-GM
Calibration bracket
3HAC 13908-9
3HAC 13908-4
3HAC 15716-1
3HAC 12342-1
3HAC 13659-1
3HAC 13660-1
Gearbox crank
3HAC 16488-1
3HAC 13056-2
3HAC 13056-3
3HAC 13056-4
3HAC 15520-1
3HAC 15520-2
3HAC 14445-1
3HAC 14446-1
3HAC 15521-1
3HAC 15521-2
3HAC 13120-2
3HAC 13120-3
3HAC 13120-4
3HAC 13120-5
3HAC 14628-2
3HAC 14628-1
3HAC 14627-3
3HAC 14627-2
Hydraulic cylinder
3HAC 11731-1
3HAC 13086-1
23
2 Reference information
2.1.5 Special tools
Description
3HAC 13086-2
6369901-348
3HAC 15560-1
3HAC 15607-1
3HAC 15994-1
3HAC 15536-1
3HAC 16131-1
3HAC 14457-3
3HAC 14457-4
3HAC 15556-1
3HAC 13698-1
3HAC 12731-1
3HAC 14691-1
3HAC 14459-1
3HAC 15534-1
3HAC 13605-1
3HAC 12734-1
Measuring pin
3HAC 13908-5
Mech stop ax 3
3HAC 12708-1
Mech stop ax 3
3HAC 12708-2
3HAC 13527-1
3HAC 13453-1
3HAC 13452-1
3HAC 17129-1
3HAC 15767-1
3HAC 12475-1
3HAC 15814-1
3HAC 14972-1
3HAC 14631-1
3HAC 14973-1
Rotation tool
3HAC 17105-1
Sensor plate
3HAC 0392-1
Support, base
3HAC 15535-1
Sync. adapter
3HAC 13908-1
3HAC 15943-2
3HAC 15943-1
3HAC 68080011GU
3HAA 1001-186
Note a) Calibration tools for IRB 6600/6650/7600 when CalPen is not used (standard).
Note b) Special tools that may be rent from ATRP/S.
24
3HAC 16245-1
2 Reference information
2.1.6 Performing a leak-down test
General
After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil
must be tested. This is done in a leak-down test.
Required equipment
Equipment, etc.
Leakdown tester
Note
3HAC 0207-1
Procedure
Step
3HAC 16245-1
Action
Note/Illustration
1.
2.
3.
Apply compressed air, and raise the pressure Recommended value: 0.2 - 0.25
with the knob until the correct value is shown on bar (20 - 25 kPa)
the manometer.
4.
5.
Wait for approx. 8-10 minutes. No pressure loss If the compressed air is signifimust be detected.
cantly colder or warmer than the
gearbox to be tested, a slight pressure increase or decrease respectively may occur. This is quite
normal.
6.
7.
Spray suspected leak areas with leak detection Art. no. specified above!
spray .
Bubbles indicate a leak.
8.
When the leak has been localized: take the necessary measures to correct the leak.
25
2 Reference information
2.1.7 Lifting equipment and lifting instructions
General
Many repair and maintenance activities require different pieces of lifting equipment, which
are specified in each activity instruction.
However, how to use each piece of lifting equipment is not detailed in the activity instruction,
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.
26
3HAC 16245-1
3 Unpacking
3.0.1 Pre-installation procedure
Chapter 3: Unpacking
3.0.1 Pre-installation procedure
General
This instruction is primarily intended for use when unpacking and installing the manipulator
(mechanical robot) for the first time. It also contains information useful during later re-installation of the manipulator.
The checklist below details what must be observed before proceeding with the actual installation of the manipulator:
1. Make sure only qualified installation personnel conforming to all national and local
codes are allowed to perform the installation.
2. Make sure the manipulator has not been damaged, by visually inspecting the
manipulator and control cabinet exterior.
3. Make sure the lifting device to be used is dimensioned to handle the weight of the
manipulator as specified in Weight, manipulator on page 27.
4. If the manipulator is not to be installed directly, it must be stored as described in
Storage conditions, manipulator on page 28.
5. Make sure the expected operating environment of the manipulator conforms to
the specifications as described in Operating conditions, manipulator on page 28.
6. Before taking the manipulator to its installation site, make sure the site conforms
to Loads on foundation, manipulator, Requirements on foundation, manipulator
on page 28 and Protection classes, manipulator on page 29.
7. Before moving the manipulator, please observe Risk of tipping/Stability on page
34 regarding risk of tipping!
8. When these prerequisites have been met, the manipulator may be taken to its
installation site as described in Lifting manipulator with fork lift on page 36.
Weight, manipulator
3HAC 16245-1
Manipulator model
Weight
1700 kg
1700 kg
1700 kg
1725 kg
1700 kg
27
3 Unpacking
3.0.1 Pre-installation procedure
The table below shows the various forces and torques working on the manipulator during
different kinds of operation.
NOTE! These forces and torques are extreme values that are rarely encountered during operation. The values also never reach their maximum simultaneously!
Requirements on
foundation,
manipulator
28
Force
Endurance load
(in operation)
Max. load
(at emergency stop)
Force xy
10.1 kN
20.7 kN
Force z
18.0 13.8 kN
18.0 22.4 kN
Torque xy
27.6 kNm
50.6 kNm
Torque z
7.4 kNm
14.4 kNm
The table below shows the requirements for the foundation where the manipulator is to be
fitted:
Requirement
Value
Min. levelity
0.5 mm
Max. tilt
22 Hz
Note
The limit for the maximum payload on the
manipulator is reduced if the manipulator is
tilted from 0.
Contact ABB for further information about
acceptable payload.
The table below shows the allowed storage conditions for the manipulator:
Parameter
Value
-25C
+55C
+70C
The table below shows the allowed operating conditions for the manipulator:
Parameter
Value
+5C
+50C
3HAC 16245-1
3 Unpacking
3.0.1 Pre-installation procedure
Protection
classes, manipulator
3HAC 16245-1
Equipment
Protection class
IP 67
29
3 Unpacking
3.0.2 Working range, IRB 6600 - 175/2.55 and IRB 6600 - 225/2.55
3.0.2 Working range, IRB 6600 - 175/2.55 and IRB 6600 - 225/2.55
Illustration
The illustration below shows the unrestricted working range of IRB 6600 - 175/2.55 and IRB
6600 - 225/2.55:
IR B 6600-175/2,55
IR B 6600-225/2,55
903
1119
1814
2550
xx0200000025
30
3HAC 16245-1
3 Unpacking
3.0.3 Working range, IRB 6600 - 175/2.8
Illustration
The illustration below shows the unrestricted working range of IRB 6600 - 175/2.8:
IR B 6600-175/2,8
1004
1324
2061
2800
xx0200000026
3HAC 16245-1
31
3 Unpacking
3.0.4 Working range, IRB 6650 - 125/3.2
Illustration
The illustration below shows the unrestricted working range of IRB 6650 - 125/3.2:
IRB 6650-125/3.2
xx0200000338
32
3HAC 16245-1
3 Unpacking
3.0.5 Working range, IRB 6650 - 200/2.75
Illustration
The illustration below shows the unrestricted working range of IRB 6650 - 200/2.75:
RB 6650-200/2.75
xx0200000339
3HAC 16245-1
33
3 Unpacking
3.0.6 Risk of tipping/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. Moving the arms will displace the centre of gravity, which
may cause the manipulator to tip over. DO NOT change the manipulator position before
securing it to the foundation.
Stabililty
The figure below shows the manipulator in its shipping position, which also is its most stable
position.
50
m
xx0100000103
1. DO NOT change the manipulator position before securing it to its foundation. The
shipping position is the most stable.
34
3HAC 16245-1
4 On-site Installation
3HAC 16245-1
35
4 On-site Installation
4.1.1 Lifting manipulator with fork lift
General
The manipulator may be moved using a fork lift. Special aids are available.
This section applies to the IRB 7600 as well as IRB 6600.
Different designs
There are two different versions of the fork lift that fit one design of the frame respectevily.
The different designs of the frame and of the fork lift attachments are shown in the figure
below. Determine which fork lift set fits the current manipulator.
Note! The distance between the attachment holes for the fork lift pockets, shown in the figure
below, are different depending on the design of the frame. This means that the fork lift sets
are unique for one type of frame, they are in other words not compatible!
Except for the shorter distance between the attachment holes, the later design of the frame
also includes an extra oil plug, located as shown in the figure below.
2
A
xx0200000386
Frame version without oil plug on the side (C), fork lift set to be used: 3HAC 0604-2
Frame version with oil plug on the side (C), fork lift set to be used: 3HAC 0604-1
Oil plug
Required equipment
36
Equipment, etc.
Art. no.
Note
3HAC 0604-2
3HAC 0604-1
3HAC 16245-1
4 On-site Installation
4.1.1 Lifting manipulator with fork lift
Illustration, 3HAC
0604-2
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15557-1 The contents are defined in section Standard toolkit on page 18.
The figure below shows how to attach the fork lift set, 3HAC 0604-2, to the manipulator.
C
B
xx0100000102
3HAC 16245-1
Spacer (2 pcs)
37
4 On-site Installation
4.1.1 Lifting manipulator with fork lift
Illustration, 3HAC
0604-1
The figure below shows how to attach the fork lift set, 3HAC 0604-1, to the manipulator.
A
B
xx0200000379
Spacer (2 pcs)
The section below details how to secure the fork lift set to the manipulator in order to lift and
move the manipulator using the fork lift ONLY!
The IRB 6600/6650 manipulator weighs 1725 kg! All lifting equipment used must be dimensioned accordingly!
The IRB 7600 manipulator weighs 2550 kg! All lifting equipment used must be dimensioned
accordingly!
The shorter fork lift pocket weighs 22 kg while the longer version weighs 60 kg! Use a suitable
lifting device to avoid injury to personnel!
38
3HAC 16245-1
4 On-site Installation
4.1.1 Lifting manipulator with fork lift
No personnel must under any circumstances be present under the suspended load!
Step
Info/Illustration
10
1.
Action
m
xx0200000079
10
50
m
xx0200000387
3HAC 16245-1
2.
Fit the two spacers to the manipulator Shown in the figures Illustration, 3HAC
and secure.
0604-2 on page 37 or Illustration, 3HAC
0604-1 on page 38!
3.
Shown in the figure Illustration, 3HAC 06042 on page 37 or Illustration, 3HAC 0604-1
on page 38!
4 pcs; M16x60; tightening torque: 60 Nm
12 Nm (not oil lubricated screws).
Make sure the original screws are always
used (or replacements of equivalent quality:
M16, quality 12.9)!
39
4 On-site Installation
4.1.1 Lifting manipulator with fork lift
Step
Action
Info/Illustration
4.
5.
Secure the second fork lift pocket on Shown in figure Illustration, 3HAC 0604-2
the other side of the manipulator with on page 37 or Illustration, 3HAC 0604-1 on
securing screws.
page 38!
4 pcs; M16x60; tightening torque: 60 Nm
12 Nm (not oil lubricated screws).
Make sure the original screws are always
used (or replacements of equivalent quality:
M16, quality 12.9)!
6.
xx0200000380
40
3HAC 16245-1
4 On-site Installation
4.1.2 Lifting manipulator with roundslings
General
The manipulator may be lifted with roundslings according to the illustration below. The illustration is the same as the label attached to the manipulators lower arm.
L IF T ING OF R OB OT
HE B E N DE S R OB OT E R S
L E VAGE DU R OB OT
Roundsling, 2000kg
Do not strech!
Rundschlingen, 2000kg
Nicht gespannt!
lingue ronde, 2000kg
Ne doivent pas etre sous tension!
IRB 6600:
m=1700kg, 3750lbs
50
m
.
10
3HAC 16487-1
xx0200000282
3HAC 16245-1
41
4 On-site Installation
4.1.3 Lifting manipulator with lifting slings
General
Illustration, lifting
slings
The figure below shows how to lift the complete manipulator with lifting slings.
Note the recommended manipulator position shown in the following figure and in the instruction! Attempting to lift a manipulator in any other position may result in the manipulator
tipping over, causing severe damage or injury!
C
E
I
L
B
xx0200000153
42
Load hook
Shortening hook
Chain
Hook
3HAC 16245-1
4 On-site Installation
4.1.3 Lifting manipulator with lifting slings
Required equipment
Equipment
Art. no.
Slings attached
directly onto
manipulator
The section below details how to lift and move the manipulator using lifting slings when these
are to be attached directly onto the manipulator frame.
The IRB 6600/6650 manipulator weighs 1725 kg! All lifting equipment used must be dimensioned accordingly!
The IRB 7600 manipulator weighs 2550 kg! All lifting equipment used must be dimensioned
accordingly!
No personnel must under any circumstances be present under the suspended load!
Step
Action
Note
1.
2.
50
m
xx0100000103
3HAC 16245-1
3.
4.
Raise the overhead crane to lift the robot. Make sure all hooks and attachments
maintain their correct positions while lifting the manipulator!
Always move the manipulator at very low
speeds, making sure it does not tip.
43
4 On-site Installation
4.1.4 Manually releasing the brakes
General
The section below details how to release the holding brakes of each axis motor. It applies to
IRB 7600 as well as IRB 6600/6650. Differences between the versions are highlighted in the
affected sections.
The brakes may be released by:
Internal brake release unit: using push buttons on the manipulator. This requires either
that the controller is connected or that power is supplied to the R1.MP connector (on
manipulator base), 0V on pin 12 and 24V on pin 11.
IRB 7600: External brake release unit: using push-buttons on an external brake
release unit. This does NOT require the controller to be connected. The external unit
is used when there are no push-buttons on the manipulator.
Supplying power on the wrong pins may cause all brakes on the manipulator to be released!
Illustration, IRB
6600/6650
The internal brake release unit on the IRB 6600/6650 is located at the frame, as shown in the
figure below.
6
5
4
3
2
1
xx0300000044
44
Internal brake release unit with push buttons, located on the manipulator frame
3HAC 16245-1
4 On-site Installation
4.1.4 Manually releasing the brakes
Illustration, IRB
7600 base
The internal brake release unit on the IRB 7600 is located either at the base or at the frame.
The figure below shows the unit located at the base.
xx0200000375
Illustration, IRB
7600 frame
Internal brake release unit with push buttons, located on the manipulator base
The internal brake release unit on the IRB 7600 is located either at the base or at the frame.
The figure below shows the unit located at the frame.
6 5 4
3 2 1
xx0200000376
3HAC 16245-1
Internal brake release unit with push buttons, located on the manipulator frame
45
4 On-site Installation
4.1.4 Manually releasing the brakes
Internal brake
release unit,
releasing the
brakes
The procedure below details how to release the holding brakes when the robot is equipped
with an internal brake release unit.
When relasing the holding brakes, the manipulator axes may move very quickly and sometimes in unexpected ways! Make sure no personnel is near the manipulator arm!
Step
Illustration, IRB
7600 external
brake release unit
connections
Action
Info/Illustration
1.
2.
The illustration below shows where to connect the external brake release unit in order to
release the manipulators holding brakes.
C
D
xx0100000104
46
Connector R1.BU
3HAC 16245-1
4 On-site Installation
4.1.4 Manually releasing the brakes
Illustration IRB
7600, external
brake release unit
connectors
The illustration below shows the connectors on the manipulator and on the external brake
release unit.
D
E
xx0200000081
Connector R1.MP
Connector R1.BU
Connect to R1.BU
Required equipment
External brake
release unit (only
IRB 7600)
Equipment
Art. no.
3HAC 12987-1
This section details how to release the holding brakes when the robot is equipped with an
external brake release unit (only IRB 7600).
When releasing the holding brakes, the manipulator axes may move very quickly and sometimes in unexpected ways! Make sure no personnel is near the manipulator arm!
Step
1.
3HAC 16245-1
Action
Info/Illustration
Remove the rear cover plate on the base of Shown in Illustration, IRB 7600 exterthe manipulator by unscrewing its attachnal brake release unit connections on
ment screws and plain washers
page 46!
47
4 On-site Installation
4.1.4 Manually releasing the brakes
Step
48
Action
Info/Illustration
2.
Locate the free connector, connected to the Shown in Illustration IRB 7600, exterrear of connector R1.MP behind the rear
nal brake release unit connectors on
connector plate.
page 47!
Make sure it is designated R1.BU.
3.
4.
Release the holding brake of each manipulator axis by pressing the respective button
on the external brake release unit.
5.
6.
3HAC 16245-1
4 On-site Installation
4.1.5 Lifting the base plate
General
Equipment
Note
Standard toolkit
Lifting slings
Hole
configuration
xx0200000096
The base plate weighs 335 kg! All lifting equipment used must be dimensioned accordingly!
3HAC 16245-1
Action
Info/Illustration
1.
Fit lifting eyes in the three lifting holes. Shown in the figure Hole configuration on
page 49!
2.
49
4 On-site Installation
4.1.6 Securing the base plate
General
Base plate,
dimensions
2x 503
2x 453
2x 247
2x 182
2x 90 2x 90
2x 451
2x 407
2x 321
2x 273
B
B
455
A
A
540
480
A-A
B- B
xx0100000105
50
3HAC 16245-1
4 On-site Installation
4.1.6 Securing the base plate
Base plate,
grooves and
holes
The illustration below shows the orienting grooves and guide sleeve holes in the base plate.
B
xx0300000045
Required equipment
Equipment
Base plate
Standard toolkit
3HAC 16245-1
Note
51
4 On-site Installation
4.1.6 Securing the base plate
Base plate
This section details how to secure the base plate to the foundation.
The table specifies any recommendations made by ABB:
Variable
Recommendation
Step
52
Action
Info/illustration
1.
2.
3.
Lift the base plate to its mounting position. Detailed in Lifting the base plate on
page 49.
4.
Use the base plate as a template and drill If possible, observe the recommenda16 attachment holes as required by the
tions specified in the table above. ABB
selected bolt dimension.
does not assume any responsibility for
other foundation qualities, due to great
variations in the foundation properties.
5.
6.
If required, fit strips of sheet metal underneath the base plate to fill any gaps.
7.
8.
Recheck the four manipulator contact sur- Max. allowed deviation: 0.5 mm
faces on the base plate to make sure they
are level and flat.
If they are not, pieces of sheet metal or
similar may be used to bring the base plate
to a level position.
3HAC 16245-1
4 On-site Installation
4.1.7 Orienting and securing the manipulator
General
This section details how to orient and secure the manipulator to the base plate after fitting it
to the foundation, in order to run the robot safely. The requirements made on the foundations
are shown in the following tables and figures.
The section below applies to IRB 7600 as well as IRB 6600/6650. The only difference
between these robot models is that IRB 7600 is secured using 12 attachment bolts while IRB
6600/6650 uses 8 attachment bolts.
Illustration,
manipulator fitted
to base plate
The illustration below shows the IRB 7600 manipulator base fitted to the base plate. The IRB
6600/6650 manipulator base does not have the attachment holes A (4 pcs).
A B
xx0100000107
Attachment
screws
3HAC 16245-1
Manipulator attachment bolts and washers, 4 pcs M24 x 120 (IRB 7600 only)
Levelling screws
The table below specifies the type of securing screws and washers to be used for securing the
manipulator to the base plate/foundation.
M24 x 120
Quality
Quality 8.8
Suitable washer:
Thickness: 4 mm
Outer diameter: 44 mm
Inner diameter: 25 mm
Tightening torque:
775 Nm
53
4 On-site Installation
4.1.7 Orienting and securing the manipulator
Securing the
manipulator
The procedure below details how to secure the manipulator to the base plate after fitting the
plate to the foundation.
Step
Action
Info/Illustration
1.
2.
3.
Fit two guide sleeves to the guide sleeve Shown in Base plate, grooves and holes
holes in the base plate.
on page 51.
Note that one of the guide sleeve holes
is elongated!
4.
Make sure the manipulator base is correctly fitted onto the guide sleeves!
5.
6.
The illustration below shows the hole configuration used when securing the manipulator, IRB
6600.
R400
4
x
15
7,5
4x3
xx0200000029
54
3HAC 16245-1
4 On-site Installation
4.1.7 Orienting and securing the manipulator
The illustration below shows the hole configuration used when securing the manipulator, IRB
7600.
4x
10
4
5 .5
x1 x7
4
4x
37.5
xx0300000046
Cross section,
guide sleeve hole
The illustration below shows the cross section of the guide sleeve holes.
xx0100000109
3HAC 16245-1
55
4 On-site Installation
4.1.8 Fitting equipment on manipulator
General
Illustration, fitting
extra equipment
on lower arm
The illustration below shows the mounting holes available for fitting extra equipment on the
lower arm.
Make sure not to damage the manipulator cabling on the inside of the lower arm when fitting
extra equipment. Always use the appropriate attachment screws!
202
207,5*
282
154
M12 (4x)
80
125 25
110* 40*
5, 35*
75
150
53
354, 369*
xx0200000195
Illustration, fitting
extra equipment
on upper arm
IRB 6650
The illustration below shows the mounting holes available for fitting extra equipment on the
upper arm.
M12 (4x)
190
xx0200000196
56
3HAC 16245-1
4 On-site Installation
4.1.8 Fitting equipment on manipulator
Illustration, fitting
extra equipment
on frame
The illustration below shows the mounting holes available for fitting extra equipment on the
frame.
75
200
45
240
4x M16
790
1195
xx0200000198
3HAC 16245-1
57
4 On-site Installation
4.1.8 Fitting equipment on manipulator
Illustration, fitting
on mounting
flange
The illustrations below show the mounting holes available for fitting equipment on the
mounting flange. There are two different versions of the mounting flange, as shown in illustrations below.
A
30 (11x)
15
12 H7 Depth 15
A
A-A
58
Mounting flange for robot version 225/2.55, 175/2.8, 125/3.2 and 200/2.75
3HAC 16245-1
4 On-site Installation
4.1.8 Fitting equipment on manipulator
A
30 (12 x)
15
12 H7 Depth 15
Fastener quality
3HAC 16245-1
When fitting tools on the mounting flange (see the figures above), use only screws with quality 12.9. When fitting other equipment, standard screws with quality 8.8 can be used.
59
4 On-site Installation
4.1.9 Loads
4.1.9 Loads
General
Any loads mounted on the manipulator must be defined correctly and carefully (with regard
to the position of center of gravity and inertia factor) in order to avoid jolting movements and
overloading the motors. If this is not done correctly operational stops may result.
References
Load diagrams, permitted extra loads (equipment) and their positions are specified in the
Product Specification. The loads must also be defined in the software as detailed in Users
Guide.
Manipulator motor brake performance depends on any loads attached. For further information about brake performance, please contact ABB Robotics.
60
3HAC 16245-1
4 On-site Installation
4.2.1 Introduction
General
The working range of the manipulator may be limited to eliminate the risk of collisions. The
following axes may be restricted:
Axis 1, hardware (mechanical stop) and software (signal from adjustable position
switch)
Axis 2, hardware (mechanical stop) and software (signal from adjustable position
switch)
Axis 3, hardware (mechanical stop) and software (signal from adjustable position
switch)
This section describes the utilization of the mechanical stops and the position switches.
3HAC 16245-1
61
4 On-site Installation
4.2.2 Mechanically restricting the working range of axis 1
General
The working range of axes 1 is limited by fixed mechanical stops and can be reduced by
adding additional mechanical stops giving 7.5 or 15 graduation in both directions.
Mechanical
stops, axis 1
The illustration below shows the mounting position of the mechanical stops on axis 1.
B
xx0300000049
Required equipment
Equipment, etc.
62
Note
Standard toolkit
3HAC 16245-1
4 On-site Installation
4.2.2 Mechanically restricting the working range of axis 1
Installation,
mechanical stops
axis 1
The procedure below details how to mount the mechanical stops on axis 1. An assembly
drawing is also enclosed with the product.
The addititonal mechanical stop must be replaced after a hard collision if the mechanical stop
has been deformed!
Step
3HAC 16245-1
Action
Note/Illustration
1.
2.
63
4 On-site Installation
4.2.3 Mechanically restricting the working range of axis 2
General
The working range of axis 2 is limited by fixed mechanical stops and can be reduced by
adding up to six additional mechanical stops with 15 graduation in respective direction.
Mechanical
stops, axis 2
The illustration below shows the mounting position of the mechanical stops on axis 2.
A
B
xx0300000047
Required equipment
Equipment, etc.
64
Note
3HAC 13787-1 Includes six stops, 3HAC 137861, each one restricting the working range by 15.
Includes attachment screws.
3HAC 11077-1 Includes six stops, 3HAC 114071, each one restricting the working range by 15.
Includes attachment screws.
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18.
3HAC 16245-1
4 On-site Installation
4.2.3 Mechanically restricting the working range of axis 2
Installation,
mechanical stops
axis 2
The procedure below details how to mount the mechanical stops on axis 2. An assembly
drawing is also enclosed with the product.
The addititonal mechanical stop must be replaced after a hard collision if the mechanical stop
has been deformed!
Step
3HAC 16245-1
Action
Note/Illustration
1.
Mount and tighten the additional stops in a row, Tightening torque: 115 Nm.
starting from the fixed stop.
Shown in the figure Mechanical
stops, axis 2 on page 64.
2.
65
4 On-site Installation
4.2.4 Mechanically restricting the working range of axis 3
General
The working range of axis 3 is limited by fixed mechanical stops and can be reduced by
adding additional mechanical stops with 20 graduation in respective direction.
Mechanical
stops, axis 3
The illustration below shows the mounting position of the mechanical stops on axis 3.
xx0300000048
Required equipment
Equipment, etc.
66
Note
Standard toolkit
3HAC 16245-1
4 On-site Installation
4.2.4 Mechanically restricting the working range of axis 3
Installation,
mechanical stops
axis 3
The procedure below details how to mount the mechanical stops on axis 3. An assembly
drawing is also enclosed with the product.
The addititonal mechanical stop must be replaced after a hard collision if the mechanical stop
has been deformed!
Step
3HAC 16245-1
Action
Note/Illustration
1.
2.
67
4 On-site Installation
4.2.5 Position switches
General
Position switches can be installed on axes 1-3. The position switches include cams as shown
in the figures below (all illustrations show IRB 7600 unless otherwise stated).
The position switch kits may be delivered in one of two ways:
Axis 1
Fitted by ABB Robotics on delivery. In this case, the cams must still be fitted and
locked by the user. For axis 1, the cover for the cams must also be fitted.
Description
Art. no.
3HAC 14118-1
3HAC 15710-1
3HAC 15709-1
A
F
C
E
xx0100000158
68
Cam
Protection sheet
Rail
Rail attachment
3HAC 16245-1
4 On-site Installation
4.2.5 Position switches
Axis 2
E
B
C
F
xx0100000159
3HAC 16245-1
Cam
Rail
Rail Attachment
69
4 On-site Installation
4.2.5 Position switches
Axis 3
C
B
xx0100000160
Specifications
Connections
70
Cam
Rail
Rail attachment
Parameter
Value
Voltage
Max. 50 V DC
Current
Max. 1 A
The position switches may be connected to different points on the robot system:
R1.SW1 at the manipulator base. Customer connection kit is recommended! Also see
"Customer Connection Kit"!
3HAC 16245-1
4 On-site Installation
4.2.5 Position switches
Fitting and
adjusting cams
and stops
The instruction below details how to fit and adjust the parts of the position switches:
Step
Illustration,
adjust and secure
cams
Action
Info/Illustration
1.
2.
3.
4.
Make sure the ends of the profile are chamfered to enable the cam to run through the profile.
5.
Fit the cam with the M5 screw and nut. Tighten Shown in Illustration, adjust and
the M5 screw to secure the cam.
secure cams on page 71.
The illustration below show how to adjust and secure the position switch cams and profiles.
C
30
xx0100000113
3HAC 16245-1
Adjustable cam
Profile
71
4 On-site Installation
4.2.5 Position switches
The illustration below show how to cut the position switch cam.
o
30
o
90
xx0100000114
72
3HAC 16245-1
4 On-site Installation
4.3.1 Lifting the controller cabinet
Lifting device
Use the four lifting devices on the cabinet or a fork lift when lifting the controller cabinet
S4Cplus M2000A as shown below.
60
xx0100000153
3HAC 16245-1
Fork lift
73
4 On-site Installation
4.3.2 Required installation space, control cabinet
Dimensions
The figure below shows the required installation space for the S4Cplus M2000A control cabinet:
A
A
xx0100000156
Dimensions
The figure below shows the bolt pattern for the S4Cplus M2000A control cabinet:
720
400
xx0100000157
74
3HAC 16245-1
5 Electrical connections
3HAC 16245-1
75
5 Electrical connections
5.1.1 Connecting the manipulator to the control cabinet
General
Connect the manipulator and control cabinet to each other after securing them to the foundation. The lists below specify which cables to be used in each application.
Location of connectors
XS
Application interface
XS20
I/O connections
XS8
X13/X5
Operators panel
XS78
XS77/X7
DeviceNet
LAN/XTDF
Mains connection
X24VE/VS
External axes
IBS
Position switches
XS41
Manipulator cables
XS58
XS2
Ext. contr. panel
Main cable
categories
All cables between manipulator and control cabinet are divided into the following categories:
Cable category
Description
Manipulator cables
Position switch cables (option) Handles supply to and feedback from any position switches
and cooling fans on the manipulator.
76
Handles communication with equipment fitted on the manipulator by the customer, including databus communication,
low voltage signals and high voltage power supply + protective earth.
3HAC 16245-1
5 Electrical connections
5.1.1 Connecting the manipulator to the control cabinet
These categories are divided into sub-categories which are specified below:
Manipulator
cables
These cables are included in the standard delivery. They are completely premanufactured and ready to plug in.
Cable subcategory
Connection Connection
point,
point,
cabinet
manipulator
Description
Manipulator
cable, power
R1.MP
Manipulator
cable, signals
R1.SMB
XP2
Manipulator
cable, power
Cable
Article number
3HAC 11818-1
3HAC 11818-2
3HAC 11818-4
Cable
Article number
3HAC 7998-1
3HAC 7998-2
3HAC 7998-4
Manipulator
cable, signals
Position switch
cables
3HAC 16245-1
These cables are not included in the standard delivery, but can be included in the delivery if
the Position switch option is ordered. (The position switches can also be ordered without
cables.) The cables are completely pre-manufactured and ready to plug in.
Cable
Article
number
Connection Connection
point,
point,
cabinet
manipulator
3HAC 13175-1
XP8
R1.SW
3HAC 13175-2
XP8
R1.SW
3HAC 13175-4
XP8
R1.SW
XP58
R1.SW2/3
XP58
R1.SW2/3
XP58
R1.SW2/3
77
5 Electrical connections
5.1.1 Connecting the manipulator to the control cabinet
Customer cables
External axes
cables
These cables are not included in the standard delivery, but can be included in the delivery of
each specific option. The cables are not ready to plug in, but requires connection to terminals
inside the control cabinet as well as keying. These activities are detailed in Customer Connection Kit.
Connection
point,
cabinet
Connection
point,
manipulator
3HAC 13173-1
XT/XP5.1
XT/XP6
XS6
R1.CP/CS
3HAC 13173-2
XT/XP5.1
XT/XP6
XS6
R1.CP/CS
3HAC 13173-4
XT/XP5.1
XT/XP6
XS6
R1.CP/CS
3HAC 13174-1
XT/XP5.1
XT/XP6
DP/M
R1.CP/CS
3HAC 13174-2
XT/XP5.1
XT/XP6
DP/M
R1.CP/CS
3HAC 13174-4
XT/XP5.1
XT/XP6
DP/M
R1.CP/CS
Cable
Article number
These cables are not included in the standard delivery, but can be included if the External
axes option is ordered. The cables are ready to plug in.
78
Connection Connection
point,
point,
cabinet
manipulator
XS45
XS47
XP41
3HAC 16245-1
5 Electrical connections
5.1.2 Connection of manipulator cables to control cabinet, S4Cplus M2000A
General
Section "Connecting the manipulator to the control cabinet" specifies which cables to use and
to which connectors these are to be connected in order to to connect the controller to the
manipulator.
Connections to
the cabinet
xx0100000247
The connections on the manipulator are located on the rear of the robot base.
3HAC 16245-1
79
5 Electrical connections
5.1.3 Connection of mains power to control cabinet, S4Cplus M2000A
General
Connect the power supply 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.
Dimension the mains supply cables and fuses in accordance with the rated power and line
voltage, see rating plate on the controller.
Connections to
the mains switch
xx0100000248
Cable gland
Step Action
80
Info/Illustration
1.
2.
3.
3HAC 16245-1
5 Electrical connections
5.1.3 Connection of mains power to control cabinet, S4Cplus M2000A
Step Action
4.
Connection
through a power
socket
Info/Illustration
Connect phase:
1 to L1 (Not dependent on phase sequence)
2 to L2
3 to L3
5.
6.
7.
It is also possible to connect the mains supply through an optional wall socket of type 3x32A
or 4x32A or via an industrial Harting connector (DIN 41 640). See the figure below. Cable
connectors are supplied (option 132 - 134).
A
xx0100000162
3HAC 16245-1
DIN connector
81
5 Electrical connections
5.2.1 Signal Classes
Overview
Signals
82
Different rules apply to the different classes when selecting and laying cable. Signals from
different classes must not be mixed.
Control signals: Digital operating and data signals (digital I/O, safety stops, etc.).
Measuring signals: Analog measuring and control signals (resolver and analog I/O).
3HAC 16245-1
5 Electrical connections
5.2.2 Selecting Cables
Controller cables:
All cables laid in the controller must be capable of withstanding 70o C. In addition.
Power Signal:
Control signals:
Shielded cables.
Measuring
signals:
Thin cable according to DeviceNet specification release 1.2, must be used, e.g. ABB article
no. 3HAB 8277-1. The cable is shielded and has four conductors, two for electronic supply
and two for signal transmission.
Note that a separate cable for supply of I/O loads is required.
Allen-Bradley
Remote I/O:
Cables according to Allen-Bradley specification, e.g. "Blue hose", should be used for connections between DSQC 350 and the Allen-Bradley PLC bus.
Interbus-S:
Cables according to Phnix specification, e.g. "Green type", should be used for connections
between the DSQC 351 and external Interbus-S bus.
Profibus DP:
Cables according to Profibus DP specification should be used for connections between the I/
O unit DSQC 352 and the external Profibus DP bus.
Ethernet:
3HAC 16245-1
83
5 Electrical connections
5.2.3 Interference elimination
External units
External relay coils, solenoids, and other units that will be connected to the controller must
be neutralized. The figure below illustrates how this can be done.
The turn-off time for DC relays increases after neutralisation, especially if a diode is connected
across the coil. Varistors give shorter turn-off times. Neutralising the coils lengthens the life of
the switches that control them
Clamping with a
diode
The diode should be be dimensioned for the same current as the relay coil, and a voltage of
twice the supply voltage.
+24V
0V
xx0100000163
Clamping with a
varistor
The varistor should be be dimensioned for the same current as the relay coil, and a voltage of
twice the supply voltage.
+24V
0V
xx0100000164
Clamping with an
RC circuit
R 100 ohm, 1W C 0.1 - 1 mF. >500V max. voltage, 125V nominal voltage.
+24V DC,
or AC voltage
0V
xx0100000165
84
3HAC 16245-1
5 Electrical connections
5.2.4 Connection types
General
I/O, external emergency stops, safety stops, etc. can be supplied on screw connections or as
industrial connectors.
Connections
3HAC 16245-1
Designation
Connection type
X(T)
Screw terminal
XP
Pin (male)
XS
Sockets (female)
85
5 Electrical connections
5.2.5 Connections to screw terminals
Overview
This section describes how to connect conductors to screw terminals. Detailed information
about connection location and functions will be found in the circuit diagram (Service Manual).
Installation
The installation should comply with the IP54 (NEMA 12) protective standard.
1. Bend unused conductors backwards and attach them to the cable using a clasp,
or similar.
To prevent interference, ensure that unused conductors are not connected at the other end of
the cable (antenna effect)
In environments with much interference, disconnected conductors should be grounded (0V) at
both ends.
86
3HAC 16245-1
5 Electrical connections
5.2.6 Connections to connectors (option)
Location of connectors
The industrial connectors can be found on the front of the control cabinet. See the figure
below and the figure in section "Control cabinet connections manipulator"!
The manipulator arm is equipped with round Burndy/Framatome connectors (customer connector not included).
xx0100000249
XS
Application interface
XS20
I/O connections
XS8
X13/X5
Operators panel
XS78
XS77/X7
DeviceNet
LAN/XTDF
Mains connection
X24VE/VS
External axes
IBS
Position switches
XS41
Manipulator cables
XS58
XS2
Ext. contr. panel
Connectors,
description
Each industrial connector has accomodations for four rows of 16 conductors with a maximum
conductor area of 1.5 mm 2 . The pull-relief clamp must be used when connecting the shield
to the case.
3HAC 16245-1
87
5 Electrical connections
5.3.1 Signal connections, SpotWelding Specification
General
The section below specifies the signal connections on manipulator arm housing for material
handling.
Customer Power
(CP)
Servo motor power
Utility power
Protective earth
min. 1,5 mm 2
Signals
20
Sensitive signals
10
Bus signals
Bus signals
CAN/DeviceNet spec*
Bus signals
Interbus spec*
Fibre Optics
Hose
Weld power
Protective earth
35 mm 2
Customer Signal
(CS)
Customer BUS
(CBUS)
Air/Water (PROC)
Welding power
(WELD)
Further
information
88
See Circuit Diagram in the "Repairs Manual, part 2" for further information.
3HAC 16245-1
5 Electrical connections
5.3.2 Signal connections, Material Handling Specification
General
The section below specifies the signal connections on manipulator arm housing for material
handling.
Customer Power
(CP)
Servo motor power
Utility power
Protective earth
min. 1,5 mm 2
Signals
20
Sensitive signals
10
Bus signals
Bus signals
CAN/DeviceNet spec*
Bus signals
Interbus spec*
Fibre Optics
Customer Signal
(CS)
Customer BUS
(CBUS)
* Twisted pair under separate screen. Can also be used for very sensitive signals.
Air/Water (PROC)
Hose
Further
information
3HAC 16245-1
See Circuit Diagram in the "Repairs Manual, part 2" for further information.
89
5 Electrical connections
5.4.1 The MOTORS ON/MOTORS OFF circuit
Outline diagram
The MOTORS ON/MOTORS OFF circuit is made up of two identical chains of switches.
The diagram shows the available customer connections, AS, GS and ES.
A
E
C
D
H
J
R
N
P
xx0100000174
Function of the
MOTORS ON/
MOTORS OFF
circuit
90
ES (emergency stop)
LS (Limit switch)
Contactor
Mains
Drive unit
Manual mode
Motor
Automatic mode
RUN
EN1
EN2
The circuit monitors all safety related equipment and switches. If any of the switches is
opened, the MOTORS ON/MOTORS OFF circuit switches the power to the motors off.
As long as the two chains are not identical, the robot will remain in MOTORS OFF mode.
3HAC 16245-1
5 Electrical connections
5.4.1 The MOTORS ON/MOTORS OFF circuit
Connection of
safety chains
24V
X3:12
X4:12
Ext LIM1
24V
K1
0V
X1:11 12
ES1
X3:10
Opto GS1
isol.
TPU En1
&
11
Opto AS1
isol.
Auto1
K1
EN
Run
Intern
locking
K2
Man1
External contactors
0V
24 V
0V
X3:3
X4:3
4
4
CONT1
CONT2
Ext LIM2
X2:11 12
K2
Drive Unit
ES2
X4:10
Opto GS2
isol.
TPU En2
&
11
9
24 V
Opto AS2
isol.
Auto2
Man2
xx0100000166
Connection of
ES1/ES2 on panel
unit
3HAC 16245-1
Limit switch
External connectors
GS/AS load at 24 V
25 mA
>18 V
<5V
Max. + 35 VDC
Min. - 35 VDC
300 V
Signal class
Control signals
The diagram below shows the terminals for the emergency circuits.
Supply from internal 24V (X1/X2:10) and 0V (X1/X2:10) is displayed. When ext. supply,
X1/X2:3 is connected to ext. 24V and X1/X2:8 is connected to ext. 0V (dotted lines).
91
5 Electrical connections
5.4.1 The MOTORS ON/MOTORS OFF circuit
A
24V 0V
B
X1:3
1:4
X1:7
X1:10
X1:9
X1:8
X1:1
X1:2
24V
X1:6
E
24V
G
24V 0V
F
B
2:4
X2:7
X2:8
X2:1
X2:2
24V
X2:6
H
24V
X2:4
X2:5
J
xx0100000191
Internal
Ext shop
Internal
TPU
ES2 internal
Cabinet
ES1 internal
Technical data
92
120 VAC: 4 A
48 VDC L/R: 50 mA
24 VDC L/R: 2 A
24 VDC R load: 8 A
40 mA
300 V
Signal class
Control signals
3HAC 16245-1
5 Electrical connections
5.4.1 The MOTORS ON/MOTORS OFF circuit
Connection to
MOTORS ON/
MOTORS OFF
contactor
The diagram below shows the connection of terminals for customer use.
A
B
X3:2
1
X4:2
1
xx0100000193
K1 (Motor on/off 1)
K1 (Motor on/off 2)
Technical data
Max. voltage
48 VDC
Max. current
4A
Max. potential in relation to the cabinet earthing and other signal groups 300 V
Signal class
Connection to
operating mode
selector
Control signals
The diagram below shows the connection of terminals for customer use.
S1.1.x1 8
A
7
6
5
S1.1.x1 4
D
3
2
1
xx0100000197
Auto 1
MAN1
100 % (Option)
Auto 2
MAN2
100% (Option)
Technical data
3HAC 16245-1
Max. voltage
48 VDC
Max. current
4A
93
5 Electrical connections
5.4.1 The MOTORS ON/MOTORS OFF circuit
Technical data
Connection to
brake contactor
300 V
Signal class
Control signals
The diagram below shows the connection of terminals for customer use.
A
X4:5
6
xx0100000199
K3 (Brake)
Technical data
94
Max. voltage
48 VDC
Max. current
4A
300 V
Signal class
Control signals
3HAC 16245-1
5 Electrical connections
5.4.2 External customer connections on panel X1 - X4
Outline diagram
The diagram shows the customer connections X1 - X4 located on the panel unit
WARNING
REMOVE JUMPERS BEFORE CONNECTING
ANY EXTERNAL EQUIPMENT
xx0100000205
Connection of X1:
12-pole type
Phoenix COMBICON connector
Connection of X2:
12-pole type
Phoenix COMBICON connector
3HAC 16245-1
Signal
Terminal
Comment
number
ES1 out: A
ES1 out: B
ES1 top
24 V panel
ES1 internal
Sep. ES1: A
Sep. ES1: B
ES1 bottom
0V
10
Ext. LIM1: A
11
Ext. LIM1: B
12
Signal
Terminal
Comment
number
ES2 out: A
95
5 Electrical connections
5.4.2 External customer connections on panel X1 - X4
Connection of X3:
12-pole type
Phoenix COMBICON connector
Connection of X4:
12-pole type
Phoenix COMBICON connector
96
Signal
Terminal
Comment
number
ES2 out: B
ES2 top
0V
ES2 internal
Sep. ES2: A
Sep. ES2: B
ES2 bottom
24 V panel
10
Ext. LIM2: A
11
Ext. LIM2: B
12
Signal
Terminal
Comment
number
Ext. MON 1: A
Motor contactor 1
Ext. MON 1: B
Motor contactor 1
0V
External contactor 1 0 V
CONT1
External contactor 1
No connection
No connection
0V
GS1-
AS1-
GS1+
10
AS1+
11
24 V panel
12
Signal
Terminal
Comment
number
Ext. MON 2: A
Motor contactor 2
Ext. MON 2: B
Motor contactor 2
24 V panel
External contactor 2 24 V
CONT2
External contactor 2
Ext. BRAKE A
Ext. BRAKE B
3HAC 16245-1
5 Electrical connections
5.4.2 External customer connections on panel X1 - X4
3HAC 16245-1
Signal
Terminal
Comment
number
0V
GS2-
AS2-
GS2+
10
AS2+
11
24 V panel
12
97
5 Electrical connections
5.4.3 Connection of external safety relay
Description
The motor contactors K1 and K2 in the controller can operate with external equipment if
external relays are used.
The figure below shows two examples of how to connect the external safety relays:
Connection
examples
X4:4
CONT 2
24 V X4:3
E xt MON 2
X4:2
0V
K2
X4:1
X3:2
K1
E xt MON 1
X3:1
24 V
0 V X3:3
CONT 1 X3:4
E
AS
AS
GS
GS
F
G
E
K
H
J
xx0100000246
98
Panel unit
Robot 1
Robot 2
External supply
Safety relay
3HAC 16245-1
5 Electrical connections
5.4.3 Connection of external safety relay
3HAC 16245-1
To other equipment
Safety gate
99
5 Electrical connections
5.5.1 External 24V supply
How to connect
the external supply
An external supply is recommended to make use of the advantages offered by the galvanic
insulation on the I/O units or on the panel unit.
An external supply must be used in the following cases:
When the emergency stop circuits must be independent of whether or not the robot
has power on, for example.
When there is a risk that major interference can be carried over into the internal 24V
supply.
The external supply neutral wire must be connected to the chassis such that the maximum
permitted potential difference in the chassis earth is not exceeded. For example, a neutral wire
can be connected to the chassis earth of the controller, or some other common earthing point.
Technical data
100
Max. 60 V continuously
Max. 500 V during 1 minute
3HAC 16245-1
5 Electrical connections
5.5.2 24V I/O supply
General
24 VDC supply
available at XT 31
3HAC 16245-1
The 24V I/O is not galvanically separated from the rest of the controller voltages.
Voltage
24.0 - 26.4V
Ripple
Max. 0.2V
Max. 7A
Current limit
13,5 ~0A.
24V I/O available for customer connections at XT 31 is shown in the figure in "Connections
to screw terminals".
XT.31.2
24 V (through a 2 A fuse)
XT.31.1
XT.31.4
101
5 Electrical connections
5.5.3 115/230 VAC supply
General
102
This voltage is used in the robot for supplying optional service outlets. The AC supply is not
galvanically separated from the rest of the controller voltages.
Voltage
Max. 500 VA
6.3 A
3.15 A
115 VAC/230 VAC available for customer connections at XT 21 is shown in the figure in
"Connection to screw terminals".
FU2 - 201
230 VAC
FU1 - 202
115 VAC
N - 203
3HAC 16245-1
5 Electrical connections
5.6.1 Connection of the CAN bus
Illustration
The illustration below shows an example of how to connect the CAN bus:
C
A
X6 CAN1.2
X7 CAN1.3
G
D
D
E
X15, X6, X7
1.
2.
3.
4.
5.
1. 0V_CAN
2. CAN_L
3. drain
4. CAN_H
5. 24V_I/O
xx0100000241
CAN bus
Control cabinet
I/O
CAN 1.1
Used for internal I/O unit mounted inside the cabinet. No terminating resistor is to be
mounted on CAN 1.1 regardless of whether any I/O units are used or not. CAN 1.1 is connected to socket X15 on the Base connector unit (see Connection of the CAN bus).
CAN 1.2
If CAN 1.2 is not used, a terminating resistor must be connected to the X6 socket (exceptional
case see below!).
3HAC 16245-1
103
5 Electrical connections
5.6.1 Connection of the CAN bus
If CAN 1.2 is used, the terminating resistor should be moved to the last I/O unit on the CAN
1.2 chain.
If CAN 1.2, for example, is not connected in the end of any CAN chain but somewhere between
the end points of the chain, then no terminating resistor should be mounted in CAN 1.3. This
is in accordance with the basic rule, i.e. the CAN chain should be terminated in both end points.
CAN 1.3
Termination
resistors in CAN
bus
The CAN chain must be terminated with terminating resistors in each end!
CAN 2
The illustration below shows an example of how to connect the CAN 2 bus:
If CAN 1.2, for example, is not connected in the end of any CAN chain but somewhere
between the end points of the chain, then no terminating resistor should be mounted in CAN
1.3.
B
D
X8 CAN 2
X8
1. 0V_CAN
2. CAN_L
3. drain
4. CAN_H
5. 24V_I/O
1. 0V_CAN
2. CAN_L
3. drain
4. CAN_H
5. 24V_I/O
1.
2.
3.
4.
5.
xx0100000242
104
Controller
I/O
3HAC 16245-1
5 Electrical connections
5.6.1 Connection of the CAN bus
A
B
C
D
xx0100000243
3HAC 16245-1
105
5 Electrical connections
5.6.2 Interbus-S, slave DSQC 351
General
Supply
The Interbus-S slave must be fed externally to avoid shutting down the Interbus-S net if a
robot cell is switched off. The 24V power supply must be fed from outside the control cabinet
and be connected to pin 2 Phoenix connector located on the Interbus-S cards front panel
marked 24V.
Technical data
Further information
For setup parameters, see Users Guide - System Parameters, Topic: Controller. Also see the
Circuit Diagram.
Unit ID
Unit ID to be entered in the Interbus-S master is 3. The length code depends on the selected
data. Width between 1 and 4.
Layout, DSQC
351
The figure below show the layout of the DSQC 351 board:
X20
X21
X5
X3
xx0100000225
106
X3
Power connector
X5
DeviceNet connector
X20
Interbus-S, input
X21
Interbus-S, output
3HAC 16245-1
5 Electrical connections
5.6.2 Interbus-S, slave DSQC 351
Communication
concept
The Interbus-S system is able to communicate with a number of external devices, depending
on the number of process words occupied by each unit. The robot may be equipped with one
or two DSQC 351. The Interbus-S inputs and outputs are accessible in the robot as general
inputs and outputs.
For application data, refer to Interbus-S, International Standard, DIN 19258.
Below is shown an outline diagram of the communication concept:
E
A
B
In
C
Out
In
*1
D
Out
In
Out
*1
xx0100000224
Master PLC
64 inputs/64 outputs
*1
Termination link
A link is connected between pins 5 and 9 in the plug on the interconnection cable connected
to the OUT connector of each unit. The link informs the Interbus-S unit that more units are
connected further out in the chain. (The last unit in the chain does not have a cable connected
and therefore no link).
Connections, X5
DeviceNet connectors
Connections,
connector X20,
Interbus-S IN
6
9
xx0100000220
The table below show the connections to connector X20, Interbus-S IN:
3HAC 16245-1
Signal name
X20 pin
Function
TPDO1
TPDI1
GND
Ground connection
NC
Not connected
107
5 Electrical connections
5.6.2 Interbus-S, slave DSQC 351
Connections,
connector X21,
Interbus-S OUT
Signal name
X20 pin
Function
NC
Not connected
TPDO1-N
TPDI1-N
NC
Not connected
NC
Not connected
6
9
xx0100000220
The table below show the connections to connector X21, Interbus-S OUT:
Connections,
connector X3
Signal name
X21 pin
Function
TPDO2
TPDI2
GND
Ground connection
NC
Not connected
+5V
+ 5 VDC
TPDO2-N
TPDI2-N
NC
Not connected
RBST
Synchronization
1
xx0100000221
Signal name
X3 pin
Function
0 VDC
NC
Not connected
GND
Ground connection
NC
Not connected
+ 24 VDC
+ 24 VDC
The designations refer to LEDs shown in the figure in section "Layout, DSQC 352" above.
The figure and table below show the location and significance of the the LEDs on the board.
108
3HAC 16245-1
5 Electrical connections
5.6.2 Interbus-S, slave DSQC 351
3HAC 16245-1
Designation
Color
Description
POWER-24 VDC
Green
NS/MS
Green/red
CAN Tx/CAN Rx
Green/red
POWER- 5 VDC
Green
RBDA
Red
BA
Green
RC
Green
109
5 Electrical connections
5.6.3 Profibus-DP, slave DSQC 352
General
Supply
The Profibus does not need any external power feed. All the robot cells are connected to the
trunk cable through a special D-sub connector which works as a very short drop cable.
Because of this the profibus will work correctly even if a robot cell is turned off.
Technical data
Also see the Profibus-DP specification, Internation Standard DIN E 19245 part 3.
Further
information
For setup parameters, see Users Guide - System Parameters, Topic: I/O Signals. Also see the
Circuit diagram.
Layout, DSQC
352
The figure below show the layout of the DSQC 352 board:
X20
X5
X3
xx0100000223
Communication
concept
X3
Power connector
X5
DeviceNet connector
X20
Profibus connection
The Profibus-DP system is able to communicate with a number of external devices, depending on the number of process words occupied by each unit. The robot may be equipped with
one or two DSQC 352. The Profibus-DP inputs and outputs are accessible in the robot as
general inputs and outputs.
Below is shown an outline diagram of the communication concept:
E
A
F
C
xx0100000222
110
3HAC 16245-1
5 Electrical connections
5.6.3 Profibus-DP, slave DSQC 352
Master PLC
Termination
Connections, X5
DeviceNet
connectors
Connections,
connector X20,
Profibus-DP
6
9
xx0100000220
The table below show the connections to connector X20, Interbus-S IN:
Connections,
connector X3
Signal name
X20 pin
Function
Shield
Cable screen
NC
Not connected
RxD/TxD-P
Receive/Transmit data P
Control-P
GND
+5 VDC
NC
Not connected
RxD/TxD-N
Receive/Transmit data N
NC
Not connected
Ground
1
xx0100000221
3HAC 16245-1
Signal name
X3 pin
Function
0 VDC
111
5 Electrical connections
5.6.3 Profibus-DP, slave DSQC 352
Signal name
X3 pin
Function
NC
Not connected
GND
Ground connection
NC
Not connected
+ 24 VDC
The figure and table below show the location and significance of the the LEDs on the board.
The designations refer to LEDs shown in the figure in section "Layout, DSQC 352" above.
Designation
Color
Description
Profibus active
Green
NS/MS
Green/red
CAN Tx/CAN Rx
Green/red
112
3HAC 16245-1
5 Electrical connections
5.7.1 Distributed I/O units
General
Up to 20 units can be connected to the same controller but only four of these can be installed
inside the controller. Normally a distributed I/O unit is placed outside the controller.
Connection
The maximum total length of the distributed I/O cable is 100 m (from one end of the chain to
the other end).
The controller can be one of the end points or be placed somewhere in the middle of the chain.
Parameter setup
3HAC 16245-1
For setup parameters, see Users Guide, section System Parameters, Topic: I/O Signals.
113
5 Electrical connections
5.7.2 Distributed I/O, digital sensors
General
Technical data
Allowed types of
digital sensors
The table below shows the allowed types of digtal sensors to be used, and their signal levels
respectively:
114
Sensor type
Signal level
High, "1"
Low, "0"
High, "01"
No signal, "00"
Low, "10"
Error status, "11" (stop program running)
3HAC 16245-1
5 Electrical connections
5.7.3 Distributed I/O, digital I/O DSQC 328 (option)
General
The digital I/O unit handles digital communication between the robot system and any external
systems.
Technical data
No. of inputs
No. of outputs
Supply voltage
24 VDC
Supply source
Further information
For setup parameters, see Users Guide - System Parameters, Topic: Controller. Also see the
Circuit Diagram.
Layout, DSQC
328
OUT
MS
IN
NS
X1
X3
10
11
12
13
14
15
16
OUT
IN
X2
1
10
10
X4
1
10
10
12
X5
xx0100000240
Connections,
connector X1
Status LEDs
3HAC 16245-1
Unit function
Signal name
X1 pin
Out ch 1
Out ch 2
Out ch 3
Out ch 4
115
5 Electrical connections
5.7.3 Distributed I/O, digital I/O DSQC 328 (option)
Connections,
connector X2
Unit function
Signal name
X1 pin
Out ch 5
Out ch 6
Out ch 7
Out ch 8
10
Connections,
connector X3
Unit function
Signal name
X2 pin
Out ch 9
Out ch 10
Out ch 11
Out ch 12
Out ch 13
Out ch 14
Out ch 15
Out ch 16
10
Signal name
X3 pin
In ch 1
In ch 2
In ch 3
In ch 4
In ch 5
In ch 6
In ch 7
In ch 8
Not used
10
The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected to ground,
to prevent disturbances, causes a short rush of current when setting the input.
When connecting outputs, sensitive to pre-oscillation current, a series resistor (100 W) may
be used.
116
3HAC 16245-1
5 Electrical connections
5.7.3 Distributed I/O, digital I/O DSQC 328 (option)
Connections,
connector X4
Signal name
X4 pin
In ch 9
In ch 10
In ch 11
In ch 12
In ch 13
In ch 14
In ch 15
In ch 16
Not used
10
The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected to ground,
to prevent disturbances, causes a short rush of current when setting the input.
When connecting outputs, sensitive to pre-oscillation current, a series resistor (100 W) may
be used.
3HAC 16245-1
117
5 Electrical connections
5.7.4 AD Combi I/O, DSQC 327 (optional)
General
The digital I/O unit handles digital and analog communication between the robot system and
any external systems.
Technical data
No. of digital inputs
Supply voltage
24 VDC
Supply source, analog I/O 24 V_CAN (with galvanically isolated DC/AC converter)
Further information
For setup parameters, see Userss Guide - System Parameters, Topic: Controller. Also see the
Circuit Diagram.
Layout, DSQC
327
OUT
MS
IN
NS
X1
X3
OUT
9
10
11
12
13
14
15
IN
X2
1
10
X4
10
X6
1
10
16
10
12
X5
xx0100000239
Status LEDs
Connector X5 is a CAN connector further described in section "Connection and address keying of the CAN bus".
Connections,
connector X1
118
3HAC 16245-1
5 Electrical connections
5.7.4 AD Combi I/O, DSQC 327 (optional)
Connections,
connector X2
Unit function
Signal name
X1 pin
Out ch 1
Out ch 2
Out ch 3
Out ch 4
Out ch 5
Out ch 6
Out ch 7
Out ch 8
10
Connections,
connector X3
3HAC 16245-1
Unit function
Signal name
X2 pin
Out ch 9
Out ch 10
Out ch 11
Out ch 12
Out ch 13
Out ch 14
Out ch 15
Out ch 16
10
Unit function
Signal name
X3 pin
In ch 1
In ch 2
In ch 3
In ch 4
In ch 5
In ch 6
In ch 7
In ch 8
Not used
10
119
5 Electrical connections
5.7.4 AD Combi I/O, DSQC 327 (optional)
Connections,
connector X4
Connections,
connectors X6
Unit function
Signal name
X4 pin
In ch 9
In ch 10
In ch 11
In ch 12
In ch 13
In ch 14
In ch 15
In ch 16
Not used
10
Signal name
X6 pin
Explanation
AN_ICH1
AN_ICH2
0V
0 VA
AN_OCH1
Out channels 1
AN_OCH2
Out channels 2
The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected to ground,
to prevent disturbances, causes a short rush of current when setting the input.
When connecting outputs, sensitive to pre-oscillation current, a series resistor (100 W) may
be used.
120
3HAC 16245-1
5 Electrical connections
5.7.5 Analog I/O, DSQC 355 (optional)
General
The analog I/O unit handles communication between the robot system and any external systems through analog sensors.
Technical data
No. of analog inputs
4 (-10 V/+10 V)
3 (-10 V/+10 V)
1 (4-20 mA))
Supply voltage
24 VDC
Further information
For setup parameters, see Users Guide - System Parameters, Topic: Controller. Also see the
Circuit Diagram.
Layout, DSQC
355
The figure below show the layout of the DSQC 355 board:
X7
X8
X7
X8
Bus s tatus
S2S3
X2
X5 X3
Analog I/O
DS QC 355
X5
AB B F lexible Automation
X3
xx0100000238
3HAC 16245-1
X3
Not used
X5
X7
Analog outputs
X8
Analog inputs
121
5 Electrical connections
5.7.5 Analog I/O, DSQC 355 (optional)
Connections,
connectors X7
analog output
13
xx0100000236
Signal name
X7 pin
Explanation
ANOUT_
ANOUT_
ANOUT_
ANOUT_
Not used
Not used
Not used
Not used
Not used
Not used
10
Not used
11
Not used
12
Not used
13
Not used
14
Not used
15
Not used
16
Not used
17
Not used
18
GND
19
Analog output 1, 0 V
GND
20
Analog output 2, 0 V
GND
21
Analog output 3, 0 V
GND
22
Analog output 4, 0 V
GND
23
GND
24
The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected to ground,
to prevent disturbances, causes a short rush of current when setting the input.
Connect a resistor (100 W) in series when connecting outputs, sensitive to pre-oscillation
current.
122
3HAC 16245-1
5 Electrical connections
5.7.5 Analog I/O, DSQC 355 (optional)
Connections,
connectors X8
analog input
xx0100000237
3HAC 16245-1
Signal name
X7 pin
Explanation
ANIN_1
ANIN_2
ANIN_3
ANIN_4
Not used
Not used
Not used
Not used
Not used
Not used
10
Not used
11
Not used
12
Not used
13
Not used
14
Not used
15
Not used
16
+24 V out
17
+24 V out
18
+24 V out
19
+24 V out
20
+24 V out
21
+24 V out
22
+24 V out
23
+24 V out
24
GND
25
Analog input 1, 0 V
GND
26
Analog input 2, 0 V
GND
27
Analog input 3, 0 V
GND
28
Analog input 4, 0 V
GND
29
GND
30
GND
31
123
5 Electrical connections
5.7.5 Analog I/O, DSQC 355 (optional)
Signal name
X7 pin
GND
32
Explanation
The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected to ground,
to prevent disturbances, causes a short rush of current when setting the input.
Connect a resistor (100 W) in series when connecting outputs, sensitive to pre-oscillation
current.
The figure and table below show the location and significance of the the LEDs on the board.
Designation
Color
Description
NS/MS
Green/red
RS232 Rx
Green
RS232 Tx
Green
Green
+5VDC / +12VDC /
-12VDC
124
3HAC 16245-1
5 Electrical connections
5.7.6 Encoder interface unit, DSQC 354 (optional)
General
One encoder input (synchronisation of conveyor position with robot movements). The
encoder is supplied with 24 V and 0 V, and sends position information in two channels.
This information is computed by the on-board computer using quadrature decoding
(QDEC) to determine position and direction.
Technical data
No. of encoder inputs
1 (24 VDC)
Supply voltage
24 VDC
Supply source
Further information
User reference Description Conveyor Tracking. For setup parameters, see Users Guide - System Parameters, Topic: Controller. Also see the Circuit Diagram.
Layout, DSQC
354
The figure below show the layout of the DSQC 354 board:
X20
X5
X3
xx0100000233
3HAC 16245-1
X3
Not used
X5
X20
Conveyor connection
125
5 Electrical connections
5.7.6 Encoder interface unit, DSQC 354 (optional)
Encoder
connections
A
B
24 VDC
AD
0V
AE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Opto
Opto
Opto
Opto
Opto
Opto
AG
xx0100000234
Connections,
connectors X20
encoder and
digital input
connections
126
AA
AB
AC
Encoder
AD
Sync switch
AE
AF
Encoder unit
AG
Galvanic isolation
Signal name
X20 pin
Explanation
24 VDC
24 VDC supply
0V
0V
ENC
Encoder 24 VDC
ENC
Encoder 0 VDC
ENC_A
Encoder phase A
ENC_B
Encoder phase B
DIGIN
DIGIN
0V
DIGIN
Not used
10
Not used
11
Not used
12
3HAC 16245-1
5 Electrical connections
5.7.6 Encoder interface unit, DSQC 354 (optional)
Signal name
X20 pin
Not used
13
Not used
14
Not used
15
Not used
16
Explanation
The figure below show the layout of the pins in connector X20:
16
xx0100000235
The figure and table below show the location and significance of the the LEDs on the board.
Designation
Color
Description
NS/MS
Green/red
ENC 1A/1B
Green
3HAC 16245-1
127
5 Electrical connections
5.7.6 Encoder interface unit, DSQC 354 (optional)
128
Designation
Color
Description
DIGIN1
Green
Digital input. Lit when digital input is active. The input is used
for external start signal/conveyor synchronisation point.
If there is no light, there is an error due to one or more of the
following reasons:
Faulty power supply for input circuit (internal or
external).
3HAC 16245-1
5 Electrical connections
5.8.1 Allen-Bradley, general
General
The robot may communicate with the Allen Bradley system only, or be used in combination
with the I/O system in the robot. For example, the inputs to the robot may come from the
Allen Bradley system while the outputs from the robot control external equipment via general
I/O addresses and the Allen Bradley system only reads the outputs as status signals.
Definitions
The Allen Bradley system can communicate with up to 64 external systems. Each of these
systems is called a Rack and is given a Rack Address 0-63. Basically, each robot connected
to the Allen Bradley system will occupy one rack.
Each rack is divided into four sections called Quarters. Each quarter provides 32 inputs and
32 outputs and a rack will subsequently provide 128 inputs and 128 outputs. A rack may also
be shared by 2, 3, or 4 robots. Each of these robots will then have the same rack address, but
different starting quarters must be specified.
Illustration
The following illustration shows a block diagram of the Allen-Bradley system, where Robot
1 uses a full rack while robot 2 and robot 3 share one rack. The rack address, starting quarter,
and other required parameters such as baud rate, LED status etc. are entered in the configuration parameters.
Allen Bradley
control system
Robot 2 - 64 in / 64 out
Quarter 1
64 in / 64 out
Quarter 4
Rack ID 12 (example)
Rack size 4
Starting quarter 1
Quarter 1
Quarter 2
Quarter 2
Rack ID 13 (example)
Rack size 2
Starting quarter 1
Quarter 3
Other systems
Quarter 3
Quarter 4
Robot 3 - 64 in / 64 out
Quarter 3
64 in / 64 out
Quarter 4
Rack ID 13 (example)
Rack size 2
Starting quarter 3
en0100000255
3HAC 16245-1
129
5 Electrical connections
5.8.2 RIO, remote I/O for Allen-Bradley PLC DSQC 350
General
The unit handles communication between the robot system and the Allen Bradley system.
Technical data
No. of digital inputs
Further information
For setup parameters, see Users Guide - System Parameters, Topic: I/O Signals. Also see
Circuit Diagram.
Connection
The RIO-unit should be connected to an Allen-Bradley PLC using a screened, two conductor
cable.
Layout, DSQC
350
The figure below show the layout of the DSQC 350 board:
X5
X9
X3
X8
DS QC 350
xx0100000226
Connections,
connector X8
X3
Not used
X5
X8
RIO in
X9
RION out
1
xx0100000221
130
3HAC 16245-1
5 Electrical connections
5.8.2 RIO, remote I/O for Allen-Bradley PLC DSQC 350
Connections,
connector X9
Signal name
X8 pin
Function
LINE1 (blue)
Remote I/O in
LINE2 (clear)
Remote I/O in
Shield
Remote I/O in
Cabinet ground
Remote I/O in
1
xx0100000221
Signal name
X9 pin
Function
Blue
Clear
Shield
Cabinet ground
Termination
When the robot is last in a RIO loop, the loop must be terminated with a termination resistor
according to Allen-Bradleys specification.
Warranty
This product incorporates a communications link which is licensed under patents and proprietary technology of Allen-Bradley Company, Inc. Allen-Bradley Company, Inc. does not
warrant or support this product. All warranty and support services for this product are the
responsibility of and provided by ABB Flexible Automation.
The figure and table below show the location and significance of the the LEDs on the board.
The designations refer to LEDs shown in the figure in section "Layout, DSQC 350" above.
Designation
Color
Description
NS/MS
3HAC 16245-1
131
5 Electrical connections
5.8.2 RIO, remote I/O for Allen-Bradley PLC DSQC 350
132
Designation
Color
Description
NAC STATUS
Green
3HAC 16245-1
5 Electrical connections
5.8.3 Communication, serial links
General
T he robot has three serial channels, which can be used by the customer to communicate with
printers, terminals, computers, and other equipment (see the figure in "Connections" below).
Further
information
COM1 (computer system) - RS 232 115 kbps. This was formerly referred to as Com2.
COM3 - RS 422 full duplex TXD4, TXD4-N, RXD4, RXD4-N, transmission speed 300 38 400 b/s. This was formerly referred to as SIO2.
For temporary use : MC/CONSOLE - RS 232 115 kb/s. This was formerly referred to
as Com1.
For setup parameters, see User's Guide - System Parameters, Topic: I/O Signals.
Circuit Diagram.
Technical data
See Product Specification for controller S4Cplus. Separate documentation is included when
the option RAP Serial link is ordered.
Connections
xx0100000219
External computer
Customer terminals, on base connector board: X10 (COM2) and X9 (COM3), see section
"Connection to screw terminals".
Connections on
DSQC 504, COM1
6
9
xx0100000220
3HAC 16245-1
133
5 Electrical connections
5.8.3 Communication, serial links
The table below shows the signals from the COM1 (RS232):
Connections on
DSQC 504, D-sub
connector X10,
COM2
Signal
Pin
Description
DCD
RX
Receive Data
TX
Transmit Data
DTR
GND
Signal Ground
DSR
RTS
Request To Send
CTS
Clear To Send
RI
Ring Indicator
NC
10
Not Connected
6
9
xx0100000220
X10 pin
1
0V
8
9
Connections on
DSQC 504, D-sub
connector X9,
COM3
6
9
xx0100000220
134
X9 socket
3HAC 16245-1
5 Electrical connections
5.8.3 Communication, serial links
Connections to
MC/CONSOLE
X9 socket
0V
The figure below shows the MC/CONSOLE connection behind the service hatch:
xx0100000218
External computer
Standard RS232 port intended for temporary use, e.g. connection of laptop/PC.
The table below shows the signals on the MC/CONSOLE (RS232):
3HAC 16245-1
Signal
Pin
Description
RX
Receive Data
TX
Transmit Data
GND
Signal Ground
135
5 Electrical connections
5.8.4 Communication, Ethernet
General
Connection of
LAN (Main computer)
E thernet hub
xx0100000217
External computer
Controller Robot 1
Controller Robot 2
Used for connection of shielded twisted-pair Ethernet (TPE), or as defined in IEEE 802.3: 10/
100 BASE-T. Maximum node-to-node distance 100 meter. The main computer board has no
termination for a cable shield. The cable shield must be grounded at the cabinet wall with a
cable gland. 10BASE-T is a point-to-point net, connected via a HUB, see the figure above.
Signal
X1 Pin
Description
TX+
TX-
RX+
NC
Not Connected
NC
Not Connected
RX-
NC
Not Connected
NC
Not Connected
136
3HAC 16245-1
5 Electrical connections
5.8.4 Communication, Ethernet
X1
LAN
PWR
HDD
STATUS
X2
xx0100000216
Connection of
Service
(I/O Computer)
Used for connection of a laptop to the service outlet on cabinet front (behind service hatch)
on the controller.
The figure below shows how to connect a laptop to the service outlet:
E thernet
xx0100000215
For setup parameters, see Users Guide - System Parameters, Topic: I/O Signals. Also see the
Circuit Diagram. Separate documentation is included when the option Ethernet services is
ordered.
3HAC 16245-1
137
5 Electrical connections
5.8.5 External operators panel
General
All necessary components are supplied, except for the external enclosure.
Dimensions for
installation
Install the assembled panel in a housing which satisfies protection class, IP 54, in accordance
with IEC 144 and IEC 529!
The following figure shows the main dimensions of the external operators panel:
B
M8 (x4)
M4 (x4)
62
C
45
70
140
184
200
E
90
5 (x2)
155
F
G
xx0100000214
138
3HAC 16245-1
6 Start-up
6.0.1 Inspection before start-up
Chapter 6: Start-up
6.0.1 Inspection before start-up
General
Check:
3HAC 16245-1
Device
XS3
Panel unit
A5-A6, B5-B6
X1.3-4, X2.3-4
A3-A4, B3-B4
X1.9-10, X2.9-10
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
A15-A16, B15-16
X1.5-6, X2.5-6
139
6 Start-up
6.0.2 Start-up
6.0.2 Start-up
General
4. To switch from MOTORS OFF to MOTORS ON, press the enabling device on the
teach pendant.
5. Update the revolution counters as described in "Updating the revolution
counters".
6. Check the calibration position as described in "Checking the calibration position".
7. When the controller, with the manipulator electrically connected, is 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. It takes approx. 4 hours to fully charge a computer system battery.
8. After having checked the above, verify that:
the start, stop and mode selection (including the key lock switches) control devices
work as intended.
each axis moves and is restricted as intended.
emergency stop and safety stop (where included) circuits and devices are functional.
it is possible to disconnect and isolate the external power sources.
the teach and playback facilities work correctly.
the safeguarding is in place.
at reduced speed, the robot operates properly and has the capability to handle the
product or workpiece.
in automatic (normal) operation, the robot operates properly and has the capability to
perform the intended task at the rated speed and load.
Operating the
robot
140
Starting and operating the robot is described in the Users Guide. Before start-up, make sure
that the robot cannot collide with any other objects in the working space.
3HAC 16245-1
General
The robot system may delivered with or without system software. When the system is not
delivered with software, this must be downloaded in one of a number of ways.
Software installed
on delivery
If the robot controller is ordered with the software installed on delivery, the controller software and settings are already stored in the storage memory and the system is ready to use.
Software not
installed on
delivery
If the robot controller is ordered and delivered without software or if you want to reconfigure
your system, the RobInstall tool must be used to install the controller software. The RobInstall tool is included on the RobotWare CD-ROM (see section "RobotWare CD-ROM"). The
RobInstall tool can be used both for creation of the controller software and for downloading
it to the controller system.
Types of software
loading
Rob Install
A
B
D
C
E
xx0100000192
Floppy Disks
Connected to IOC
When downloading, the controller software can be transferred to the controller storage memory in three ways as shown in the figure above.
3HAC 16245-1
using Ethernet connected direct to the IO computer (IOC) service outlet on the front of
the controller cubicle,
using Ethernet connected via a local area network (LAN) to the main computer (MC).
141
Boot Image
The transfer and installation of the controller software to the controller storage memory via
Ethernet or floppy disks is executed by a basic program named Boot Image.
This basic program must always be in the storage memory. At start-up of the controller, without any controller software installed, Boot Image will start and ask the operator for controller
software installation instructions. If the controller software is already installed and a warm
start is performed, Boot Image is not used. The installed controller software can be deleted
by cold start and then the Boot Image will be reactivated.
142
3HAC 16245-1
RobotWare
CD-ROM contents
Installation of the
RobotWare on the
PC (except FTP
Client)
Contents
Description
1.
RobInstall
2.
Documentation
3.
Controller OS Package
4.
5.
FTP Client
This section describes how to install the software delivered on the RobotWare CD-ROM onto
a PC hard drive, to be transferred to the robot system.
1. Insert the CD in your reader.
1. The Install Shield will automatically start and guide you through the install process
(if it does not start, double-click the CD icon on your PC). When the setup type
window is presented, it is recommended to select the Custom button. Then Next
button will open the Select Components window, where normally all the four
options, RobInstall, Documentation, Controller OS Package and Test Signal
Viewer should be marked as selected.
Installation of the
FTP Client on the
PC
This section describes how to install the FTP Client onto a PC hard drive.
1. In the Explorer, select and open the directory "ftp" on the CD.
2. Double-click the file ftpvsetup.exe.
The Install Shield for the FTP client will start and guide you through the installation. Please
read the "Readme" file for information about license regulations.
3HAC 16245-1
143
General
Nomenclature
How to use
RobInstall
Since most systems have the operating system installed already on delivery, the RobotWare
CD-ROM is normally not needed. However it should be used when:
Concept
Means
System pack
Key
This is a text string, or a special file with the text string, which is used
to define and open both the BaseWare and all ordered RobotWare
options.
System
This is a complete controller software, i.e. controller operating system, based on the system pack and the key. It can also include any
user files to be added to the home directory on the controller storage
memory.
Robinstall is used to create and install the controller software in the S4Cplus robot controller.
With RobInstall, you can:
Step Action
144
Illustration/Info
1.
2.
3HAC 16245-1
Step Action
3.
Illustration/Info
xx0100000185
3HAC 16245-1
145
Setting up the
system
Step Action
Illustration/info
1.
2.
3.
Enter a name for the new controller system. Select a saving location or use the default directory,
normally "Program Files\ABB
Robotics\system" (see the figure
below, position 1).
4.
5.
xx0100000179
xx0100000180
xx0100000181
146
3HAC 16245-1
Step Action
6.
Illustration/info
Add or remove
external options
Step Action
1.
Illustration(info
xx0100000182
Add or remove
additional system
parameters
2.
3.
4.
Press Finish to create the controller system or press Next to continue to "Parameter Data" (see
section "Add or remove additional
system parameters).
Step Action
1.
Illustration/Info
xx0100000183
3HAC 16245-1
147
Step Action
Change options
or system pack
revision
Illustration/Info
2.
3.
4.
5.
6.
Press Finish to create the controller system or press Next to continue to "Options" (see section
"Change options or system pack
revision").
Step Action
1.
Illustration/Info
xx0100000184
148
2.
3.
3HAC 16245-1
Step Action
3HAC 16245-1
Illustration/Info
4.
5.
149
Actions
Step Action
1.
Illustration/Info
xx0100000189
2.
3.
xx0100000190
150
3HAC 16245-1
Selecting type of
set-up
Before a system can be downloaded to a robot controller using the RobInstall tool some preparations and set up must be done. This may be done in one of two ways:
If using a direct
connection
between PC and
IOC service outlet
on controller
...and continue in
section:
"Download Robot Controller System" below!
Network Intranet
connection with fixed IP
addresses
"If using Network Intranet con"Download Robot Controlnection with fixed IP addresses " ler System" below!
below!
Network Intranet
connection with DHCP
(Dynamic Host
Configuration Protocol)
Step Action
Illustration/Info
1.
2.
Make sure that the Network protocol is set for TCP/IP properties.
3.
xx0100000178
3HAC 16245-1
151
If using
Network Intranet
connection with
fixed IP
addresses
If using Network
Intranet connection with DHCP
Step Action
Illustration/Info
1.
2.
3.
Perform a X-START (see section "x-START") or CSTART (see section "C-start") on the S4Cplus controller.
4.
Configure the IP address to be used for the robot controller from the TPU.
Step Action
1.
Illustration/Info
Download Robot
Controller
System
Before downloading, check the following:
Make sure there is at least 25 Mb free disk space on the controller mass storage memory. For
information on how to perform a manual storage capacity check, see section "Check Storage
Capacity".
Make sure that the robot controller displays the Start Window on the Teach Pendant Unit (see
section "Start window").
Step Action
1.
Illustration/Info
xx0100000176
152
3HAC 16245-1
Step Action
Illustration/Info
2.
Select a target system as in the fig- If a direct connection is used with the patch
ure, position 1.
cable between the PC and the controller front,
then just select the default IP address
(192.168.125.1) and "Direct" option.
In other cases, write the correct IP address for
the robot controller and select "Hostname or IPaddress". RobInstall will store already used IP
addresses, which can later be selected with the
down arrow.
3.
4.
5.
6.
RobInstall will now create a system After downloading it is possible to restart the
file and download it to the controller. controller with the new downloaded controller
system. Otherwise, the controller may be
restarted from the Teach Pendant Unit as
detailed in section "Reboot".
xx0100000177
xx0100000175
3HAC 16245-1
153
Create Boot
Diskettes from
RobInstall
Step Action
1.
Illustration/Info
xx0100000173
2.
xx0100000175
xx0100000188
154
3.
4.
3HAC 16245-1
Step Action
5.
3HAC 16245-1
Illustration/Info
155
Customizing RobInstall
Step Action
1.
Illustration/Info
xx0100000186
2.
xx0100000187
3.
156
3HAC 16245-1
8 Robot controller
8.0.1 BootImage
General
The BootImage is a basic program which is used to start up the system from "scratch".
Purpose of the
program
This program is already installed in the controller at delivery and is used to:
3HAC 16245-1
157
8 Robot controller
8.0.2 Start window
When is it
shown?
xx0100000168
The start window displays the start menu and will appear in the following cases:
Possible actions
Restart the
system, Reboot
The BootImage will be re-executed, used to apply changes in the system settings (see section
"Reboot").
Load a system
from diskettes,
Boot Disks
Set network settings for Main Computer or check how to configure your PC (see section
"Network Settings").
Choose a system
from the mass
storage memory,
Select System
If there are one or more systems in the mass storage memory, you can choose to activate one
of them (see section "Select System).
158
3HAC 16245-1
8 Robot controller
8.0.3 Reboot Window
When is it
shown?
The Reboot window will be displayed if any of the system settings are changed or when
Reboot is pressed in the Start window as shown in the figure below:.
xx0100000169
3HAC 16245-1
Button
Function
YES
NO
159
8 Robot controller
8.0.4 Boot Disk Window
When is it
shown?
The Boot Disk window will be displayed when Boot Disks is pressed in the Start window as
shown in the figure in section "Start window".
How to create
boot disks
Information on how to create boot disks from RobInstall can be found in section "Create Boot
Diskettes from Robinstall".
Illustration/Info
xx0100000170
160
3HAC 16245-1
8 Robot controller
8.0.5 LAN Settings Window
When is it
shown?
The LAN Settings window will be displayed when LAN Settings is pressed in the Network
Settings window as shown in the figure in section "Network Settings".
en0100000256
NONE
CANCEL
returns to the Start window, as shown in the figure in section "Start Window", without changing any settings.
Parameter
Type
Description
MAC ID
Node identification
Current IP
Node identification
IP
Network setting
(Subnet mask)
Network setting
(Gateway)
Network setting
Node
identification
Configure for
fixed IP network
1. Press FIX IP .
2. Fill in the assigned IP address for the Main Computer, and the Subnet Mask and
Gatway for the Network and press OK .
You will be asked to reboot the system.
Configure for
DHCP distributed
IP network
1. Press DHCP .
2. The value for IP will change to DHCP.
3. Press OK.
You will be asked to reboot the system.
161
8 Robot controller
8.0.6 Service Settings Window
When is it
shown?
The Service Settings window will be displayed when Service Settings is pressed in the Network Settings window as shown in the figure in section "Network Settings".
en0100000257
OK
returns to the Start window as shown in the figure in section "Start Window".
Parameter
Description
Service Setting
162
IP
Subnet mask
Gateway
3HAC 16245-1
8 Robot controller
8.0.7 System selection window
When is it
shown?
The Select System window will be displayed when Select System is pressed in the Start
window as shown in the figure in section "Start Window".
xx0100000171
CANCEL
How to select
system
returns to the Start window as shown in the figure in section "Start Window".
The window shows all systems installed on the controller mass storage memory.
Step Action
1.
Illustration/Info
xx0100000172
3HAC 16245-1
163
8 Robot controller
8.0.8 How to perform a Restart
General
Performing a restart may be done in a number of ways. These are detailed below:
Reboot (Warm
start), apply
changed settings
When executing a Warm start, the system reboots with the current system, e.g. to make new
or changed settings take effect.
Step Action
Illustration/Info
1.
Press the button Miscellaneous and select Service window or System Parameter window
2.
Miscellaneous button:
xx0100000194
A P-Start will warm start the current system, with a reinstallation of the RAPID language and
all auto loaded modules. This means that all RAPID program and system modules currently
loaded in the working memory will be closed, and thus have to be reloaded again after the PStart, with exception for such modules which are automatically loaded, due to settings in the
System Parameters/Controller/Task Modules.
Step Action
1.
Illustration/info
Miscellaneous button:
xx0100000194
X-START, change
active controller
system
2.
3.
4.
Press P-START .
The system will reboot, reinstall RAPID and its auto
loaded modules, and return to the Welcome window as
shown in the second figure in section "Select System".
An X-start will exit the running system, store system data on the mass storage memory, and
then execute the BootImage to present the Start window. Any system stored in the mass storage memory, may then be selected as described in section "Select System".
When performing an X-Start all stored system data will be restored (similar to performing a
warm start).
Step Action
1.
Illustration/Info
Press the button Miscellaneous and select Service win- Miscellaneous button:
dow.
xx0100000194
164
3HAC 16245-1
8 Robot controller
8.0.8 How to perform a Restart
Step Action
I-START, start in
Query mode
Illustration/Info
2.
3.
4.
Press X-START .
The system will reboot and return to the Start window as
shown in the figure in section "Start Window".
If "Use Query Mode at System Boot" was selected when creating the running system in RobInstall (see section "Change options or system pack revision"), an I-Start can be done. An IStart will restart the current system and give the opportunity to set some values at start-up,
e.g. language, IRB type (within the same model) or options (see section "Start in Query
Mode").
Step Action
Illustration/Info
1.
2.
3.
4.
Press I-START .
The system will start to reboot, then pause to ask for
Silent, Easy, or Query mode. For more information on the
different modes, continue to section "Start in Query
Mode".
xx0100000194
C-START (Cold
start), delete the
active system
When executing a C-Start, the system exits the running system and deletes it from the mass
storage memory. The BootImage is then executed and the Start window as shown in the figure
in section "Start Window" is presented.
Use C-start with caution. Since it deletes the current system, it should not be used to just
switch between installed systems. For this purpose, use X-Start (see section "X-start").
It will take quite some time to implement a Cold start. Just wait until the robot shows the Start
window. When the Start window is shown, a new system can be selected if available in the
mass storage memory (see section "Select System) or a new system can be down loaded and
started (see section "Transfer Robot Controller System using Ethernet connection" or "Transfer Robot Controller System using floppy disks").
Do not touch any key, joystick, enable device, or emergency stop during the cold start until the
Start window is shown as in the figure in section "Start Window".
Step Action
1.
Illustration/Info
2.
3HAC 16245-1
165
8 Robot controller
8.0.8 How to perform a Restart
Step Action
166
Illustration/Info
3.
4.
Press C-START .
3HAC 16245-1
8 Robot controller
8.0.9 How to Start in Query Mode
Preconditions for
selecting Query
Mode start
It is possible to set some values, e.g. language, IRB type (within the same model) or options,
at the first start-up of the system, using a C-Start (see section "C-start"), or later on when
performing an I-Start (see section "I-start") if "Use Query Mode at System Boot" was
selected when creating the system in RobInstall (see section "Change options or system pack
revision").
Types of Query
Mode
The first question from the system is what Query Mode to start. Depending on your needs,
you should select one of the following three:
Silent Mode, pushbutton Silent . If Silent Mode is selected, the operating system will
be installed with the system configured as defined in RobInstall.
Easy Query Mode, pushbutton Easy Query . In Easy Query Mode you can change
language, remove selected options and select service or standard mode (see section
"Easy Query Mode").
Query Mode, pushbutton Query . In Query Mode you can, on top of the things in Easy
Query, select DC-link, change Robot type (within the same family) and for IRB 7600,
select balancing unit (see section "Query Mode").
If Easy Query was chosen as start-up query mode, the following steps will be required to start
the system:
Step Action
Query Mode
Illustration/Info
1.
2.
3.
Install xxx? For every option that was selected in RobInstall (see section "Change options or system pack revision") it is now possible to select Yes to keep the option,
or No to remove it from the system.
If Query Mode was chosen as start-up query mode, the following steps will be required to
start the system:
Step Action
3HAC 16245-1
Illustration/info
1.
2.
167
8 Robot controller
8.0.9 How to Start in Query Mode
Step Action
3.
Illustration/info
168
4.
5.
3HAC 16245-1
Directory
All RobotWare System Packages and Option Packages are stored in a media pool directory
as shown in the table below.
Two revisions of the same system package may exist in the pool. By default, after having
installed RobInstall, a directory "MediaPool" will be found in the directory Program
Files\ABB Robotics\, and will also be the current one. However any directory in the structure
can be set up as the current media pool in the Preference window (see section "Robinstall
Preferences").
xx0200000156
Naming
conventions
3HAC 16245-1
Art. no./folder
name
Description
3HAXaaaa-1.00
3HAXbbbb-1.02
3HAXcccc-1.01
3HYZdddd-1.00
Each package is stored in a directory, the name of which is an article number ending with the
sub-number and with the revision number as shown in the table above. All the system packs
and option packs in one media pool must have the correct revision numbers in their directory
names. Thus a later revision can be loaded into the program pool, to be added to the old one,
without changing the article number.
169
Directory
All systems created with the RobInstall will be stored in a system pool. The default name of
such a system pool is "system" as shown below. Each system stored in the system pool is a
directory with the name of the system as shown in the table below.
By default, after installing RobInstall, a directory "system" will be found in Program
Files\ABB Robotics\ and will also be the current one. However any directory in the structure
can be set up as the current system directory in the Create New System window or Select
System window.
File system
requirements
170
Directory view
xx0100000260
xx0100000261
The system directory must hold these files and directories to allow software installation:
A syspar directory containing .cfg files to be included in the software installation procedure. All system parameter files, included when creating a system with RobInstall,
are stored in this syspar directory as shown in the table in section "System Pool Directory".
A directory called Home. In this home directory the user can include any file or files,
which should be downloaded to the controller together with the operating system.
Such files will then be placed in the home directory of the system in the controller.
3HAC 16245-1
Files in root
directory, hd0a
The root directory of the mass storage memory is called hd0a. This includes several components:
File name
Description
E.g. 3HAC6811-1.00
bin
BootImage code
BootRom.sys
MC.cfg
ctrl.bin
system.dir
system directories
Directories and
subdirectories
Each system directory holds a number of subdirectories, defining for instance language,
options, robots, etc.
"Home" directory
The system directory is the "home" directory for the system. When using the address "home:"
in the RAPID program, this directory will be addressed.
"Bin"
subdirectory
The subdirectory bin, containing the storage area for all system data, e.g. at power break. This
means that at warm start, in addition to restoring the operating system from the control system
package, all system data is restored from this directory and reloaded into the working memory.
Never change
these directories!
Never delete or change the \bin or BootRom.sys directories in the root directory. If this is
done, the controller cannot be restarted and the mass storage memory will be impossible to
use.
3HAC 16245-1
171
Illustration
Media pool
S ys tem Pack in
/3haxbbbb-1.nn
*.* s ignature no
S ys tem pool
E xt Option in
/3haxcccc-1.nn
*.* relkey.txt
Created files
key.id
program.id
My s ys tem
/s ys tem_n
key.id
program.id
keys tr.txt
/s ys par
*.cfg
xx0100000262
Files to be
prepared
172
RobInstall creates a file named Key.id from the key strings specifying the options to
be installed from the System Pack and the external option programs to be installed.
Unless deselected in RobInstall, the latest revision of the System Pack and External
Option Programs is selected as default (see section "Change options or system pack
revisions").
These are copied from the media pool and concatenated into one target file that also
holds the key.id and the syspar directory. This may then be downloaded to the controller via Ethernet or a set of diskettes. The target file is temporarily stored in the system
directory before downloading or creating diskettes.
3HAC 16245-1
General
In some cases it is very important that there is enough free space in the mass storage memory,
before attempting to download new system software. How to check its capacity, and if
required increase it, is detailed below.
A manual check on the free space can be done in one of the following ways:
Checking storage
capacity from the
Teach Pendant
Unit
Checking storage
capacity through
connection to the
MC/CONSOLE
port
1. Connect a console to the MC/CONSOLE outlet on the controller and execute the
command dosFsShow .
There should always be at least 25 Mb free disk space on the controller mass storage memory
before attempting to download a new system. For information on how to increase storage
capacity, see below!
Increasing
storage capacity
If the capacity of the mass storage memory is less than 25 Mb when a new controller system
is to be downloaded, storage memory must be released by removing old systems from the
mass storage memory. This can be done in one of the following ways:
1. Boot up on the system you would like to remove and then make a C-START (see
section "C-start").
2. Use the FileManager in the Teach Pendant Unit, see Users Guide - File Manager,
for more information on how to use the FileManager.
3. Use a third-party "ftp" client (like FTPVoyager supplied on the RobotWare CD).
Removing systems using the FileManager or FTP-client may be hazardous since the \bin and
BootRom.sys directories the must be kept intact.
Proceed with utmost care to avoid accidentally removing such files or directories!
3HAC 16245-1
173
174
3HAC 16245-1
10 Calibration
10.1.1 Types of calibration procedures
When to calibrate
Calibrate the measurement system carefully if any of the resolver values has been
changed. This may occur when parts affecting the calibration position have been
replaced on the robot.
Calibrate the system roughly as detailed in section Updating the revolution
counter on page 183 if the contents of the revolution counter memory are lost.
This may occur when:
3HAC 16245-1
a robot axis has been moved with the control system disconnected
175
10 Calibration
10.1.2 How to calibrate the robot system
General
This section provides an overview of the procedure required when calibrating the robot system. Many of the steps in the procedure are detailed in other sections to which references are
given.
Procedure
Step
176
Action
Illustration
1.
2.
Check that all required hardware is available for calibrating the robot.
3.
4.
Manually, run the robot axes to be caliUse the calibration scales fitted to each
brated to a position close to the correct cal- robot axis to locate this position.
ibration position.
5.
6.
7.
Verify that the calibration was successfully Detailed in Post calibration procedure
carried out.
on page 198.
3HAC 16245-1
10 Calibration
10.1.2 How to calibrate the robot system
Additional information
In addition to the basic calibration procedure detailed above, a number of calibration related
actions may be performed:
Action
Detailed in section:
How to update the robot revolution counter without per- Updating the revolution counter on
forming a complete calibration
page 183
How to manually check the current calibration position Checking the calibration position on
page 181
An alternative calibration position for axis 1 may be
defined
How to change to a new offset value for the alternative New calibration offset, axis 1 on
calibration position
page 202
How to retrieve a new calibration offset for the alterna- Retrieving offset values on page
tive calibration position
203
How to change to a new calibration position
3HAC 16245-1
177
10 Calibration
10.1.3 Calibration, prerequisites
General
The calibration procedure may be described as comparing the direction of two sensors, the
reference sensor and the calibration sensor, while running the robot to its calibration position,
thus reducing the sensor difference to close to zero.
All article numbers of relevant equipment are specified in their instructions respectively.
Peripheral equipment
The robot must be free from any peripheral equipment during calibration. Fitted welding guns
and similar will cause erroneous calibration positions.
Calibration order
When calibrating, the axis must consistently be run towards the calibration position in the
same direction, in order to avoid position errors caused by backlash in gears etc. Positive
directions are shown in the figure below.
This is normally handled by the robot calibration software.
NOTE The figure shows an IRB 7600, but the positive direction is the same for all robots!
6+
4+
5+
3+
2+
1+
xx0200000089
Location of sensors
The positions where the calibration sensor and reference sensor should be fitted during calibration, are specified in Calibration sensor mounting positions on page 188.
Where to find the calibration sensor and reference sensor respectively during calibration in
Calibration scales on page 194.
178
3HAC 16245-1
10 Calibration
10.1.4 Calibration pendulum kit, contents
General
The calibration pendulum kit contains all required hardware to calibrate all robot models
(except IRB 6400R) using the calibration pendulum method.
These kits may be rented from ABB at this time, but not purchased.
3HAC 16245-1
Qty
Contents
Art. no.
3HAC 12837-7
3HAC 15144-1
Leveltronic NT/41
3HAC 15732-1
Calibration pendulum
3HAC 4540-1
3HAC 16423-1
3HAC 14034-1
Batteries
Thread tap, M8
Location pin
3HAC 14137-1
58 mm long
For IRB 6600 and IRB 7600, axis
1
Location pin
3HAC 14137-2
68 mm long
For IRB 140, IRB 1400, IRB
2400 and IRB 4400, axis 1
User documentation
Rem.
All required cables
179
10 Calibration
10.1.4 Calibration pendulum kit, contents
May be turned both ways to fit IRB 140, IRB 1400, IRB 2400 and IRB 4400.
xx0200000276
Illustration,
adapter turning
disk
Guide pin, 8 mm
Guide pin, 6 mm
Screw, M10
Screw, M6
xx0200000278
180
Locating shaft
Hand wheel
3HAC 16245-1
10 Calibration
10.2.1 Checking the calibration position
General
3HAC 16245-1
Check the calibration position before any programming of the robot system can begin. This
may be done in one of two ways:
Using the program CALxxxx in the system software (xxxx signifying the robot type;
IRB xxxx)
Step
Action
Button
1.
Run the program \SYSTEM\UTILITY\SERVICE\CALIBRAT\CALxxxx in the system and follow the instructions displayed on the teach
pendant.
2.
3.
181
10 Calibration
10.2.1 Checking the calibration position
Step
Action
Illustration
1.
2.
3.
4.
Check that the calibration marks for that particular axis align correctly. If they do not,
update the revolution counters !
xx0100000195
xx0100000196
182
3HAC 16245-1
10 Calibration
10.2.2 Updating the revolution counter
Manually running
the manipulator
to the calibration
position
This section details the first step when updating the revolution counter; manually running the
manipulator to the calibration position.
Step
3HAC 16245-1
Action
Illustration
1.
2.
Press the enabling device on the teach pendant and, using Shown in Calibration
the joystick, move the robot manually so that the calibra- scales on page 194.
tion marks lie within the tolerance zone.
3.
Note that axis 6 does not have any mechanical stop and
can thus be calibrated at the wrong faceplate revolution.
Do not operate axis 6 manually before the robot has been
calibrated.
4.
183
10 Calibration
10.2.2 Updating the revolution counter
This section details the second step when updating the revolution counter; storing the revolution counter setting.
If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, which in
turn may cause damage or injury!
Step
1.
Action
Illustration
xx0100000194
2.
3.
xx0100000201
4.
5.
6.
7.
8.
Not required.
9.
xx0100000202
184
3HAC 16245-1
10 Calibration
10.2.3 Calibration procedure on TPU
General
This section details how to use the Teach Pendant Unit (TPU) when calibrating the robot
using the calibration pendulum method.
Procedure
Step
Action
Illustration
1.
2.
3.
4.
5.
xx0300000009
xx0200000188
xx0200000190
3HAC 16245-1
6.
7.
Proceed to calibrate the individual robot axes. Detailed in the calibration instructions for the robot axes.
185
10 Calibration
10.2.4 Initialization of calibration pendulum
General
Whenever calibration pendulum is used for calibrating the robot, the equipment must first be
initialized as detailed below.
The Levelmeter 2000 is shown for reference below:
+
0000000
00000
oo
GON
Port/Sensor
50
BATT
LEVELMETER 2000
+
ON/MODE
ZERO SELECT
ENTER
SEND/ESC
HOLD
WYLER
OUT
xx0200000126
Overview
Selection pointer
Measuring unit
Shown below is an outline of how to initialize the Levelmeter 2000. Detailed procedures are
specified in the manual supplied by the manufacturer.
Step
186
Action
Info/Illustration
1.
2.
Connect the Levelmeter 2000 to the COM2 port in the Shown in the figure in seccontrol cabinet through the connector marked OUT . tion General on page 186.
3.
4.
Detailed in Connection of
sensors on page 187.
3HAC 16245-1
10 Calibration
10.2.4 Initialization of calibration pendulum
Address
Step
1.
Action
Info/Illustration
Connection of
sensors
Step
Result
3HAC 16245-1
Action
Info/Illustration
1.
2.
Press ON/MODE .
3.
4.
Press ENTER.
5.
6.
Press ENTER.
Wait until the "A B" flashes again.
7.
Press ENTER.
187
10 Calibration
10.3.1 Calibration sensor mounting positions
Introduction
This section specifies the mounting positions and directions of all calibration sensors on all
robot systems using the Calibration Pendulum method.
Additional information on calibration, alternative calibration positions etc, may be found in
the Installation Manual.
Reference sensor
The illustrations below show the mounting position and direction for the reference sensor :
xx0200000183
188
Calibration pendulum in reference sensor position NOTE! The pendulum is only fitted
in one position at a time!
3HAC 16245-1
10 Calibration
10.3.1 Calibration sensor mounting positions
Axis 1
The illustrations below show the mounting position and direction for the calibration sensor,
axis 1:
B
A
C
xx0200000177
3HAC 16245-1
Calibration pendulum NOTE! The pendulum is only fitted in one position at a time!
Locating pin
189
10 Calibration
10.3.1 Calibration sensor mounting positions
Axis 2
The illustrations below show the mounting position and direction for the calibration sensor,
axis 2:
xx0200000178
190
3HAC 16245-1
10 Calibration
10.3.1 Calibration sensor mounting positions
Axis 3
The illustrations below show the mounting position and direction for the calibration sensor,
axis 3:
xx0200000179
Calibration sensor, axis 3 NOTE! The pendulum is only fitted in one position at a time!
NOTE! The IRB 7600/2.3/500 version requires a slightly different sensor mounting position
than the other versions, the sensor being turned 90. This is shown in the following figure.
xx0300000016
Any special considerations to be taken when calibrating this robot version is detailed in section Calibrating axes 3-4, IRB 7600/2.3/500 on page 197.
3HAC 16245-1
191
10 Calibration
10.3.1 Calibration sensor mounting positions
Axis 4
The illustrations below show the mounting position and direction for the calibration sensor,
axis 4:
xx0200000179
Calibration sensor, axis 4 NOTE! The pendulum is only fitted in one position at a time!
NOTE! The IRB 7600/2.3/500 version requires a slightly different sensor mounting position
than the other versions, the sensor being turned 90. This is shown in the figure below.
xx0300000016
Any special considerations to be taken when calibrating this robot version is detailed in section Calibrating axes 3-4, IRB 7600/2.3/500 on page 197.
192
3HAC 16245-1
10 Calibration
10.3.1 Calibration sensor mounting positions
Axis 5
The illustrations below show the mounting position and direction for the calibration sensor,
axis 5:
xx0200000180
Axis 6
Calibration sensor, axis 5 NOTE! The pendulum is only fitted in one position at a time!
The illustrations below show the mounting position and direction for the calibration sensor,
axis 6:
xx0200000180
3HAC 16245-1
Calibration sensor, axis 6 NOTE! The pendulum is only fitted in one position at a time!
193
10 Calibration
10.3.2 Calibration scales
Introduction
This section specifies the calibration scale positions for all robot models.
IRB 6600
xx0200000176
IRB 7600
xx0100000198
194
3HAC 16245-1
10 Calibration
10.3.3 Calibration, all axes
General
This section is valid for all robot models using the calibration pendulum procedure except
IRB 6400R.
It details how to perform the actual fine calibration of each axis using special calibration
equipment. The position to fit calibration sensors differ between different models and different axes.
Sensor mounting
positions
Equipment
Article no.
Note
Calibration pendulum,
complete set
3HAC 15716-1
3HAC 16423-1
3HAC 14034-1
Isopropanol
1177 1012-208
The position of the calibration sensors are shown in Calibration sensor mounting positions
on page 188.
Procedure
Step
3HAC 16245-1
Action
Illustration
1.
2.
3.
4.
Remove any protective covers from the reference sensor, calibration sensor and locating
pin attachment points.
The same calibration pendulum is used as a
"calibration sensor" and as a "reference sensor" depending on its function at the time. In
the instruction below, the pendulum will be
called "calibration sensor" or reference sensor" depending on the function.
5.
Clean the reference sensor, calibration sensor and locating pin attachment points with
isopropanol .
6.
195
10 Calibration
10.3.3 Calibration, all axes
Step
7.
Action
Illustration
Connect the measurement cable from the calibration sensor to the Levelmeter 2000 unit.
00 0 0 0 0 0 0 0 0 0
oo
GON
Port/Sensor
A o o
"1/12"
mRAD
"1/10"
mm/m
"/REL"
DEG
mm/REL
50
A
B
B AT T
LE V E LM E T E R 2 00 0
+
Z E R O
O N /M O D E
S E LE C T
E N TE R
S E N D /E S C
H O L D
W YL ER
O U T
xx0200000126
8.
9.
Click OK .
A number of menus will flash by briefly on the
TPU, but no action is required on behalf of the
operator until a specific action is displayed.
D: Measuring unit
E: Selection pointer
The position where to fit the reference sensor and calibration sensor
respectively, are shown in Calibration sensor mounting positions on
page 188.
NOTE that no additional tool is
required for fitting the calibration
pendulum for axes 1-3!
Fitting the pendulum to the turning
disk requires an adapter (included in
the complete set). NOTE that there
are two adapters! Article number
specified in section General on page
195.
The way of handling the calibration
program prior to the actual calibration of each axis is detailed in Calibration procedure on TPU on page
185.
196
3HAC 16245-1
10 Calibration
10.3.4 Calibrating axes 3-4, IRB 7600/2.3/500
General
Due to the fact that the upper arm tube is slightly shorter on the version than on others, the
calibration sensor position on the upper arm is changed. This applies to calibrating axes 3 and
4 of the IRB 7600/2.3/500 only.
xx0300000020
Procedure
Step
3HAC 16245-1
Action
Info/Illustration
1.
Remove any cable holders by unscrew- Shown in the figure in section General on
ing their respective attachment screws. page 197.
This is to facilitate fitting the calibration
sensor.
2.
197
10 Calibration
10.4.1 Post calibration procedure
General
Perform the following procedure after calibrating any manipulator axes. The procedure is
intended to verify that all calibration positions are correct.
Procedure
Step
198
Action
Illustration
1.
2.
3.
4.
5.
6.
7.
3HAC 16245-1
10 Calibration
10.5.1 Alternative calibration position
General
Illustration
C
xx0100000258
3HAC 16245-1
Calibration position 0
199
10 Calibration
10.5.2 Alternative calibrating
General
The manipulator may be calibrated in any of three positions, shown in Alternative calibration
position on page 199.
Procedure
Step
200
Action
Illustration
1.
2.
3.
Select Normal position, and check the calibration marks for each
axis.
4.
Run the calibration program again and select the desired calibration position (Left or Right) as shown in Alternative calibration
position on page 199.
5.
6.
Note the new calibration offset on the label, located on the frame
to the left of motor axis 1 (remove the cover between axes 2 and
3). The new calibration offset values can be found as detailed in
Retrieving offset values on page 203.
7.
8.
9.
Move the sync marks for axis 1 on the base to the new position.
10.
3HAC 16245-1
10 Calibration
10.5.3 New calibration position, axis 1
Procedure
Use this instruction to change to a new calibration position for axis 1 during definition of a
new calibration position.
Step
1.
Action
Illustration
xx0100000194
2.
3.
4.
5.
Select axis 1.
6.
xx0100000200.
3HAC 16245-1
201
10 Calibration
10.5.4 New calibration offset, axis 1
Procedure
Use this instruction when changing to a new calibration offset for axis 1 during definition of
a new calibration position.
Step
Action
Illustration
1.
2.
xx0100000194
xx0100000200
3.
4.
5.
6.
xx0100000201
202
3HAC 16245-1
10 Calibration
10.5.5 Retrieving offset values
Procedure
Use this instruction when retrieving new offset values for axis 1 during definition of a new
calibration position.
Step
Action
Illustration
1.
2.
3.
4.
5.
xx0100000194
xx0100000200
xx0100000200
3HAC 16245-1
203
10 Calibration
10.5.5 Retrieving offset values
204
3HAC 16245-1
11 Decommissioning
11.0.1 Balancing device, IRB 7600 and IRB 6600/6650
General
This information is valid for all versions of IRB 6600/6650 as well as IRB 7600!
There is much energy stored in the balancing device. Therefore a special procedure is
required to dismantle it. The coil springs inside the balancing device exert a potentially lethal
force unless dismantled properly.
Required equipment
Equipment, etc.
Standard toolkit
3HAC 15571-1
Note
The contents are defined in
section Standard toolkit on
page 22!
Cutting torch
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!
Procedure
The instruction below details how to cut open the balancing device housing and removing the
tension in the coil springs before opening the device.
Step
3HAC 16245-1
Action
Info/Illustration
1.
2.
205
11 Decommissioning
11.0.1 Balancing device, IRB 7600 and IRB 6600/6650
Step
3.
Action
Info/Illustration
450-500 mm
4.
206
5.
6.
3HAC 16245-1
Table of Contents
0.0.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
0.0.2 Product Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Chapter 1: Safety, service
1.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Section 1.1: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
13
23
3HAC 16247-1
Table of Contents
155
181
ii
3HAC 16247-1
Table of Contents
201
3HAC 16247-1
iii
Table of Contents
iv
3HAC 16247-1
0.0.1 Overview
0.0.1 Overview
About This
Manual
This information product is a manual containing instructions for repairing the complete robot
system, mechanically as well as electrically.
Usage
Prerequisites
Organization of
Chapters
Chapter
Contents
Safety
Reference information
Manipulator
Controller
Appendix
References
Reference
Document Id
3HAC 13347-1
3HAC 14189-2
Revisions
Revision
Description
First edition
3HAC 16247-1
Various corrections in text and in figures due to reconstructions, new spare part numbers, new tools, etc.
Manual completed with references to pagenumbers and numbering of sections (manipulator sections).
0.0.1 Overview
3HAC 16247-1
General
The complete product documentation kit for the robot, including controller, manipulator and
any hardware option, consists of the manuals listed below:
Installation and
Commissioning
Manual
Repair Manual
Maintenance
Manual
Safety, Service
Reference Information
Unpacking
On-site Installation
Electrical connections
Start-up
Calibration
Safety, Service
Reference Information
Remove/Refitting instructions for all controller cabinet details considered spare parts
Safety, Service
Reference Information
Maintenance schedules
Instructions for all maintenance activities specified in the maintenance schedule, for
example cleaning, lubrication, inspection etc.
The information is generally divided into separate chapters for the manipulator and the controller, respectively.
Software manuals
The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during operation.
A complete listing of all available software manuals is available from ABB Robotics.
3HAC 16247-1
Hardware option
manual
Each hardware option is supplied with its own documentation. Each document set contains
the types of information specified above:
Installation information
Repair information
Maintenance information
3HAC 16247-1
1 Safety, service
1.0.1 Introduction
Definitions
This chapter details safety information for service personnel i.e. personnel performing installation, repair and maintenance work.
Sections
2. Safety risks lists dangers relevant when servicing the robot system. The dangers are split into different categories:
Safety risks related to gripper/end effector
Safety risks related to tools/workpieces
Safety risks related to pneumatic/hydraulic systems
Safety risks during operational disturbances
Safety risks during installation and service
Risks associated with live electric parts
3. Safety actions details actions which may be taken to remedy or avoid dangers.
Safety fence dimensions
Fire extinguishing
Emergency release of the manipulators arm
Brake testing
Risk of disabling function "Reduced speed 250 mm/s"
Safe use of the Teach Pendant Unit enabling device
Work inside the manipulators working range
3HAC 16247-1
1 Safety, service
1.1.1 Safety, service - General
Validity and
responsibility
The information does not cover how to design, install and operate a complete system, nor
does it cover all peripheral equipment, which can influence the safety of the total system. To
protect personnel, the complete system must be designed and installed in accordance with the
safety requirements set forth in the standards and regulations of the country where the robot
is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable safety laws
and regulations in the country concerned are observed and that the safety devices necessary
to protect people working with the robot system have been designed and installed correctly.
Personnel working with robots must be familiar with the operation and handling of the industrial robot, described in the applicable documents, e.g. Users Guide and Product Manual.
Connection of
external safety
devices
Apart from the built-in safety functions, the robot is also supplied with an interface for the
connection of external safety devices. Via this interface, an external safety function can interact with other machines and peripheral equipment. This means that control signals can act on
safety signals received from the peripheral equipment as well as from the robot.
In the Product Manual - Installation and Commissioning, instructions are provided for connecting safety devices between the robot and the peripheral equipment.
General
Any information given in this information product 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.
General
Documents
Type of information
Detailed in document
Users Guide
Start-up
Section
3HAC 16247-1
1 Safety, service
1.2.1 Safety risks related to gripper
Safe handling
It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that guards
remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
Grippers/end effectors must be designed so that they retain workpieces in the event of a power
failure or a disturbance of the controller.
General
Residual energy
Safe design
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.
Shot bolts should be used to prevent tools, etc., from falling due to gravity.
General
Qualified personnel
Extraordinary
risks
3HAC 16247-1
The industrial robot is a flexible tool which can be used in many different industrial
applications.
All work must be carried out professionally and in accordance with the applicable
safety regulations.
Remedial action must only be carried out by qualified personnel who are familiar with
the entire installation as well as the special risks associated with its different parts.
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.
1 Safety, service
1.2.5 Safety risks during installation and service
Nation/region
specific regulations
Non-voltage
related risks
To be observed
by the supplier of
the complete system
The instructions in the Product Manual - Installation and Commissioning must always
be followed.
Emergency stop buttons must be positioned in easily accessible places so that the
robot can be stopped quickly.
Those in charge of operations must make sure that safety instructions are available
for the installation in question.
Those who install the robot must have the appropriate training for the robot system in
question and in any safety matters associated with it.
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.
Safety zones, which have to be crossed before admittance, must be set up in front of
the robot's working space. Light beams or sensitive mats are suitable devices.
Turntables or the like should be used to keep the operator out of the robot's working
space.
The axes are affected by the force of gravity when the brakes are released. In addition
to the risk of being hit by moving robot parts, you run the risk of being crushed by the
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.
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 temperature of the motors or oil spills that can occur on the robot.
The supplier of the complete system must ensure that all circuits used in the safety
function are interlocked in accordance with the applicable standards for that function.
The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner, in accordance with the applicable standards for the emergency stop function.
Voltage related
risks, general
Voltage related
risks, controller
Although troubleshooting may, on occasion, have to be carried out while the power
supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
The mains supply to the robot must be connected in such a way that it can be turned
off outside the robots working space.
3HAC 16247-1
1 Safety, service
1.2.6 Risks associated with live electric parts
Units inside the controller, e.g. I/O modules, can be supplied with power from an external source.
The power supply unit for the computer system (230 VAC)
The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
The power supply unit for tools, or special power supply units for the machining process
The external voltage connected to the control cabinet remains live even when the
robot is disconnected from the mains.
Additional connections
Voltage related
risks, manipulator
Voltage related
risks, tools, material handling
devices, etc
Tools, material handling devices, etc., may be live even if the robot system is in the OFF
position. Power supply cables which are in motion during the working process may be damaged.
3HAC 16247-1
The user connections for tools or other parts of the installation (max. 230 VAC, see
Installation and Commissioning Manual)
1 Safety, service
1.3.1 Safety fence dimensions
General
Fit a safety fence or enclosure around the robot to ensure a safe robot installation.
Dimensioning
Dimension the fence or enclosure to enable it to withstand the force created if the load being
handled by the robot is dropped or released at maximum speed. Determine the maximum
speed from the maximum velocities of the robot axes and from the position at which the robot
is working in the work cell (see Product Specification - Description, Robot Motion).
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating
tool or other device fitted to the manipulator.
Description
In an emergency situation, any of the manipulators axes may be released manually by pushing the brake release buttons on the manipulator or on an optional external brake release unit.
How to release the brakes is detailed in section "Manually releasing the brakes".
The manipulator 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, which may further increase any injury!
When to test
During operation the holding brakes of each axis motor wear normally. A test may be performed to determine whether the brake can still perform its function.
How to test
The function of each axis motor holding brakes may be checked as detailed below:
1. Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized (max. static load).
2. Switch the motor to the MOTORS OFF position with the Operating mode selector
on the controller.
3. Check that the axis maintains its position.
If the manipulator does not change position as the motors are switched off, then the brake
function is adequate.
10
3HAC 16247-1
1 Safety, service
1.3.5 Risk of disabling function "Reduced speed 250 mm/s"
3HAC 16247-1
11
1 Safety, service
1.3.7 Work inside the manipulators working range
12
3HAC 16247-1
2 Reference information
2.0.1 Introduction
General
3HAC 16247-1
This chapter presents generic pieces of information, complementing the more specific information in the following chapters.
13
2 Reference information
2.1.1 Applicable Safety Standards
Standards, general
Standards, robot
cell
14
The following standards are applicable when the robot is part of a robot cell:
EN 811 - Safety distances to prevent danger zones being reached by the lower limbs.
EN 294 - Safety distances to prevent danger zones being reached by the upper limbs.
3HAC 16247-1
2 Reference information
2.1.2 Screw joints
General
This section details how to tighten the various types of screw joints on the manipulator as well
as the controller.
The instructions and torque values are valid for screw joints comprising metallic materials
and do not apply to soft or brittle materials.
Any instructions given in the repair, maintenance or installation procedure description override any value or procedure given here, i.e. these instruction are only valid for standard type
screw joints.
UNBRAKO
screws
UNBRAKO is a special type of screw recommended by ABB in certain screw joints. It features special surface treatment (Gleitmo as described below), and is extremely resistant to
fatigue.
Whenever used, this is specified in the instructions and in such cases no other type of replacement screw is allowed. Using other types of screw will void any warranty and may potentially
cause serious damage or injury!
Gleitmo treated
screws
Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.
Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this
the screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should
be used.
Screws lubricated
in other ways
Screws lubricated with Molycote 1000 (or another lubricant) should only be used when specified in the repair, maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1. Lubricate the thread of the screw.
2. Lubricate between the plain washer and screw head.
3. Tighten to the torque specified in section "Tightening torque" below. Screw dimensions
of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or
smaller may be tightened without a torque wrench if this is done by trained and qualified personnel.
3HAC 16247-1
Lubricant
Art. no.
1171 2016-618
15
2 Reference information
2.1.2 Screw joints
Tightening torque
Below are tables specifying the torque values for different screw joint types:
Dimension
M2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
Dimension
Tightening torque
(Nm)
Class 8.8 "dry"
Tightening torque
(Nm)
Class 10.9 "dry"
Tightening torque
(Nm)
Class 12.9 "dry"
M5
M6
10
M8
24
34
40
M10
47
67
80
M12
82
115
140
M16
200
290
340
Dimension
M8
28
34
M10
55
66
M12
96
115
M16
235
280
Screws with
hexagon socket
head, dry
Screws with
hexagon socket
head, lubricated
16
3HAC 16247-1
2 Reference information
2.1.3 Weight specifications
Definition
In all repair and maintenance instructions, weights of the components handled are sometimes
specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.
ABB recommends the use of lifting equipment when handling components with a weight
exceeding 22 kg to avoid inflicting injury. A wide range of lifting tools and devices is available for each manipulator model.
Example
3HAC 16247-1
17
2 Reference information
2.1.4 Standard toolkit
General
All service (repairs, maintenance and installation) instructions contain lists of tools required
to perform the specified activity.
All special tools required are listed directly in the instructions while all the tools that are
considered standard are gathered in the Standard toolkit and defined in the table below.
In this way, the tools required are the sum of the Standard Toolkit and any tools listed in the
instruction.
Contents,
standard toolkit,
3HAC 15571-1
18
Qty
Art. no.
Tool
Rem.
3HAC 16247-1
2 Reference information
2.1.5 Special tools, IRB 6600/6650/7600
General
All service (repairs, maintenance and installation) instructions contain lists of tools required
to perform the specified activity. The required tools are a sum of standard tools, defined in
section Standard toolkit on page 18, and of special tools, listed directly in the instructions and
also gathered in the table below.
The table below is an overview of all the special tools required when performing service
activities on the IRB 6600/6650/7600. The tools are gathered in two kits: Basic Toolkit
(3HAC 15571-3) and Extended Toolkit (3HAC 15571-2).
The special tools are also listed directly in the current instructions.
3HAC 16247-1
Description
Angel bracket
68080011-LP
3HAB 3409-86
3HAB 3409-89
Cal. tool
68080011-GM
Calibration bracket
3HAC 13908-9
3HAC 13908-4
3HAC 15716-1
3HAC 12342-1
3HAC 13659-1
3HAC 13660-1
Gearbox crank
3HAC 16488-1
3HAC 13056-2
3HAC 13056-3
3HAC 13056-4
3HAC 15520-1
3HAC 15520-2
3HAC 14445-1
3HAC 14446-1
3HAC 15521-1
3HAC 15521-2
3HAC 13120-2
3HAC 13120-3
3HAC 13120-4
3HAC 13120-5
3HAC 14628-2
3HAC 14628-1
3HAC 14627-3
3HAC 14627-2
Hydraulic cylinder
3HAC 11731-1
19
2 Reference information
2.1.5 Special tools, IRB 6600/6650/7600
Description
3HAC 13086-1
3HAC 13086-2
6369901-348
3HAC 15560-1
3HAC 15607-1
3HAC 15994-1
3HAC 15536-1
3HAC 16131-1
3HAC 14457-3
3HAC 14457-4
3HAC 15556-1
3HAC 13698-1
3HAC 12731-1
3HAC 14691-1
3HAC 14459-1
3HAC 15534-1
3HAC 13605-1
3HAC 12734-1
Measuring pin
3HAC 13908-5
Mech stop ax 3
3HAC 12708-1
Mech stop ax 3
3HAC 12708-2
3HAC 13527-1
3HAC 13453-1
3HAC 13452-1
3HAC 17129-1
3HAC 15767-1
3HAC 12475-1
3HAC 15814-1
3HAC 14972-1
3HAC 14631-1
3HAC 14973-1
Rotation tool
3HAC 17105-1
Sensor plate
3HAC 0392-1
Support, base
3HAC 15535-1
Sync. adapter
3HAC 13908-1
3HAC 15943-2
3HAC 15943-1
3HAC 68080011-GU
3HAA 1001-186
Note a) Calibration tools for IRB 6600/6650/7600 when CalPen is not used (standard).
Note b) Special tools that may be rent from ATRP/S.
20
3HAC 16247-1
2 Reference information
2.1.6 Performing a leak-down test
General
After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil
must be tested. This is done in a leak-down test.
Required equipment
Equipment, etc.
Leakdown tester
Note
3HAC 0207-1
Procedure
Step
3HAC 16247-1
Action
Note/Illustration
1.
2.
Remove the topmost oil plug on the gear in Art. no. specified above!
question, and replace it with the leakdown
tester .
Adapters may be required, which are
included in the leakdown tester kit.
3.
Apply compressed air, and raise the pres- Recommended value: 0.2 - 0.25 bar
sure with the knob until the correct value is (20 - 25 kPa)
shown on the manometer.
4.
5.
Wait for approx. 8-10 minutes. No pressure If the compressed air is significantly
loss must be detected.
colder or warmer than the gearbox to
be tested, a slight pressure increase or
decrease respectively may occur. This
is quite normal.
6.
7.
8.
21
2 Reference information
2.1.7 Lifting equipment and lifting instructions
General
Many repair and maintenance activities require different pieces of lifting equipment, which
are specified in each activity instruction.
However, how to use each piece of lifting equipment is not detailed in the activity instruction,
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.
22
3HAC 16247-1
Definitions
This chapter details all repair activities recommended for the manipulator, including for any
external units of the manipulator.
It is made up of separate units, each detailing a specific repair activity, e.g. Removal or Refitting of a certain component on the manipulator. Each unit contains all information required
to perform the activity, e.g. spare parts numbers, required special tools and materials.
The chapter is divided into:
3HAC 16247-1
Remaining instructions for all the spare parts in e.g. the manipulators external units, if
any.
23
The cable harness is located throughout the manipulator as shown in the figure below.
E
H
J
O
C
K
A
xx0200000210
24
Connectors at motor 3; R2.FB3 and R2.MP3 and for signal lamp R2.H1 and R2.H2
Connectors at cable harness division, inside of upper arm tube; R3.FB5 and R3.MP5.
Connectors at motor 5; R4.FB5 and R4.MP5.
Connector R1.MP
Connector R1.SMB
Velcro strap that secures the cable harness to the arm house
3HAC 16247-1
Required equipment
Equipment, etc.
Circuit Diagram
Standard toolkit
Removal, cable
harness, axes 1-4
Note
The procedure below details how to remove the cable harness, axes 1-4.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The cable harnesses are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!
Step
1.
3HAC 16247-1
Action
Note/Illustration
In order to facilitate refitting of cable harness, Axes 2 and 3 may be tilted slightly to
run the manipulator to the specified position: improve access.
Axis 1: 0
Axis 2: 0
Axis 3: 0
Axis 4: 0
Axis 5: +90
Axis 6: no significance
2.
Remove the rear cover plate on the manipulator by unscrewing its attachment screws.
3.
4.
5.
6.
25
Step
Action
Note/Illustration
7.
8.
R 2.S MB
R 1.S MB1-3
R 1.S MB4-6
R 1.G
R 2.G
xx0200000118.wmf
9.
FB3 FB4
FB5 FB6
MP3
MP4
MP5
MP6
xx0100000142.wmf
MP6
MP3
FB6
FB5
MP5
MP
FB3
FB4
xx0100000143.wmf
26
3HAC 16247-1
Location of cable
harness ax 5-6
The location of the cable harness, axes 5-6, is shown in the figure below.
B
A
F
xx0200000213
3HAC 16247-1
27
Removal, cable
harness, axes 5-6
The procedure below details how to remove the upper cable harness. The separate cable that
goes from the connection point inside of the upper arm tube to the motor, axis 5, is not
included in this procedure. The removal of that cable is described further down in section
Removal, cable harness, axis 5 on page 29.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The cable harnesses are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!
Axis 5 must be oriented in the correct position (+90 ) to allow opening the motor 6 cover!
Step
1.
Action
Note/Illustration
A
B
xx0200000214
2.
Remove the cover of motor, axis 6 and dis- Specified in the figure Location of cable
connect all connectors beneath.
harness ax 5-6 on page 27!
3.
28
4.
5.
Loosen the cable bracket in the upper arm Shown in the figure Location of cable
tube by unscrewing the two screws on top harness ax 5-6 on page 27!
of the tube.
6.
7.
3HAC 16247-1
Step
Action
Note/Illustration
8.
9.
Removal, cable
harness, axis 5
Step
3HAC 16247-1
Action
Note/Illustration
1.
2.
3.
4.
5.
29
Location of cable
harness
The cable harness is located throughout the manipulator as shown in the figure below.
E
H
J
O
C
K
A
xx0200000210
30
Connectors at motor 3; R2.FB3 and R2.MP3 and for signal lamp R2.H1 and R2.H2
Connectors at cable harness division, inside of upper arm tube; R3.FB5 and R3.MP5.
Connectors at motor 5; R4.FB5 and R4.MP5.
Connector R1.MP
Connector R1.SMB
Velcro strap that secures the cable harness to the arm house
3HAC 16247-1
Required equipment
Equipment, etc.
Note
3HAC 14940-1
IRB 6600
3HAC 16331-1
IRB 6650
3HAC 14140-1
3HAC 14139-1
Circuit Diagram
3HAC 13347-1
Standard toolkit
3HAC 15571-1
Refitting, cable
harness, axes 1-4
The procedure below details how to refit the cable harness, axes 1-4.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The cable harnesses are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!
Step
1.
3HAC 16247-1
Action
Note/Illustration
In order to facilitate refitting of cable harness, Axes 2 and 3 may be tilted slightly to
run the manipulator to the specified position: improve access.
Axis 1: 0 degrees
Axis 2: 0 degrees
Axis 3: 0 degrees
Axis 4: 0 degrees
Axis 6: no significance
2.
Pull the cable and connectors down through Make sure the cables are not twisted
the center of the frame.
with each other or with eventual customer harnesses!
Make a note of the correct positions
of the connectors!
3.
4.
31
Step
Action
Note/Illustration
5.
6.
7.
MP2 MP1
MP4
SMB
MP3
MP5 MP6
xx0100000141
8.
R2.S MB
R1.S MB1-3
R1.S MB4-6
R1.G
R 2.G
xx0200000118
9.
10.
Secure the correct adapter plate to the harness with its two attachment screws.
11.
12.
FB3 FB4
FB5 FB6
MP3
MP4
MP5
MP6
xx0100000142
13.
MP6
MP3
FB6
FB5
MP5
MP
FB3
FB4
xx0100000143
14.
32
3HAC 16247-1
Step
Location of cable
harness axes 5-6
Action
Note/Illustration
The cable harness of the axes 5-6 is located as shown in the figure below.
B
A
F
xx0100000145
Refitting, cable
harness, axes 5-6
3HAC 16247-1
The procedure below details how to refit the upper arm cable harness. The separate cable that
goes from the connection point inside of the upper arm tube to the motor, axis 5, is not
included in this procedure. The refitting of that cable is described further down in section
Refitting, cable harness axis 5 on page 35.
A
33
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The cable harnesses are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!
Axis 5 must be oriented in the correct position (+90 ) to allow opening the motor 6 cover!
Step
1.
Action
Note/Illustration
Axis 6: no significance
2.
3.
Connect the two connectors inside the upper Shown in the figure Location of cable
arm tube, R3.FB5 and R3.MP5 and secure harness axes 5-6 on page 33!
the cable bracket with the two attachment
screws to the tube.
4.
xx0200000185
5.
xx0200000254
6.
34
3HAC 16247-1
Step
7.
Action
Note/Illustration
Refitting, cable
harness axis 5
8.
9.
10.
Reconnect connector R2.M5/6 gently at the Shown in the figure Location of cable
rear cable division point with two screws, M6. harness axes 5-6 on page 33!
Be careful not to bend the attachment plate
when fastening the screws!
Step
Action
Note/Illustration
1.
2.
3.
4.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind
any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
3HAC 16247-1
35
Location of arm
system
The complete arm system is defined as the complete manipulator except for the base and
gearbox axis 1, i.e. the upper and lower arms, balancing device and frame. This is shown in
the figure below.
F
G
H
E
xx0200000224
Upper arm
Lower arm
Frame
Gearbox, axis 1
Balancing device
Motor axis 1
Required equipment
Equipment, etc.
36
Note
3HAC 16247-1
Equipment, etc.
Standard toolkit
Note
Removal, arm
system
The procedure below details how to lift and remove the complete arm system.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The complete arm system weighs 1300 kg! All lifting equipment used must be dimensioned
accordingly!
Step
1.
Action
Note/Illustration
50
m
xx0100000103
3HAC 16247-1
2.
3.
4.
37
Step
38
Action
Note/Illustration
5.
6.
Remove the block for calibration from Shown in the figure Location of arm system
the bottom of the frame.
on page 36!
7.
Remove the arm system from the base Shown in the figure Location of arm system
by unscrewing its 24 attachment
on page 36!
screws.
8.
3HAC 16247-1
Location of arm
system
The complete arm system is defined as the complete manipulator except for the base and
gearbox axis 1, i.e. the upper and lower arms, balancing device and frame. This is shown in
the figure below.
F
G
H
E
xx0200000224
Upper arm
Lower arm
Frame
Gearbox, axis 1
Balancing device
Motor axis 1
Required equipment
Equipment, etc.
3HAC 16247-1
Note
39
Equipment, etc.
Note
Standard toolkit
Refitting, arm
system
The procedure below details how to lift and refit the complete arm system.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The complete arm system weighs 1300 kg! All lifting equipment used must be dimensioned
accordingly!
Step
Action
Note/Illustration
1.
Fit the lifting device as detailed in enclosed Art. no. specified in Required equipinstruction.
ment on page 36!
2.
Lift the complete arm system and move it Make sure all the hooks and attachat very low speed, making sure it does not ments maintain in correct position
tip!
while lifting the manipulator!
Make sure the lift is done completely level,
adjust the length of the chains as detailed
in enclosed instruction!
3.
A
A
B
xx0300000070
40
3HAC 16247-1
Step
Action
Note/Illustration
4.
Look through the empty mounting hole of This is a complex task to be performed
motor 1 to assist in aligning the assembly with utmost care in order to avoid injury
during refitting of the arm system.
or damage!
The guiding pin in the gearbox must be fitted to the guiding hole of the frame.
Lower the arm system with guidance from
the guide pins previously fitted to the
frame.
5.
6.
Remove the guide pins and secure the arm Shown in the figure Location of arm
system to the base with its 24 attachment system on page 39!
screws and washers.
M12 x 70, 12.9 quality UNBRAKO,
tightening torque: 115 Nm.
Reused screws may be used, providing they are lubricated as detailed in
Screw joints on page 15 before fitting.
7.
Refit the block for calibration at the bottom Shown in the figure Location of arm
of the frame.
system on page 39!
8.
9.
Refill the gearbox axis 1 with lubricating oil. Detailed in "Oil change, gearbox axis
1" in the Maintenance Manual.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind
any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
3HAC 16247-1
41
The turning disk is located in the front of the wrist housing, as shown in the figure below. The
two different robot versions result in different designs of the turning disks.
A more detailed view of the component and its position may be found in the Foldout section
Wrist complete on page 211.
B
E1
D
C
xx0200000217
Turning disk
Wrist unit
E1
E2
Attachment screws, turning disk for robot version 225/2.55, 175/2.8, 125/3.2 or 200/
2.75 (12 pcs)
Required equipment
Equipment, etc.
Standard toolkit
42
Note
3HAC 16247-1
Removal, turning
disk
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Step
3HAC 16247-1
Action
Note/Illustration
1.
2.
3.
4.
43
The turning disk is located in the front of the wrist housing, as shown in the figure below. The
two different robot versions result in different designs of the turning disks.
A more detailed view of the component and its position may be found in the Foldout section
Wrist complete on page 211.
E1
D
C
xx0200000217
44
Turning disk
Wrist housing
E1
E2
Attachment screws, turning disk for robot version 225/2.55, 175/2.8, 125/3.2 or 200/
2.75 (12 pcs)
3HAC 16247-1
Required equipment
Equipment, etc.
Note
3HAC 9744-5
3HAC 13752-1
O-ring
3HAB 3772-65
(1 pc)
2152 0431-20
(6 pcs)
O-ring
3HAB 3772-64
(1 pc)
3HAB 3772-61
(12 pcs)
Grease
3HAB 3537-1
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!
Refitting, turning
disk
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
3HAC 16247-1
45
Step
1.
Action
Note/Illustration
xx0200000218
2.
3.
4.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind
any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
46
3HAC 16247-1
Location of wrist
unit
The wrist unit is located in the frontmost part of the upper arm as shown in the figure below.
A more detailed view of the component and its location may be found in the Foldout section
Wrist complete on page 211.
B
C
xx0200000184
3HAC 16247-1
Wrist unit
Turning disk
47
Required equipment
Equipment etc.
3HAC 13605-1
Circuit diagram
3HAC 13347-1
Standard toolkit
3HAC 15571-1
Removal, wrist
unit
Note
The procedure below details how to remove the complete wrist unit.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Axis 5 must be oriented in the correct position (+90 ) to allow opening the motor 6 cover!
The complete wrist unit weighs 165 kg! All lifting equipment used must be dimensioned
accordingly!
Step
48
Action
Note/Illustration
1.
2.
Turn axis 4 to a position where the cover, upper Shown in the figure Location of
arm tube and wrist unit, faces upwards. Also wrist unit on page 47!
turn axis 5 so that the turning disc faces to the
side in order to allow access to the motor 6
cover.
3.
4.
5.
Remove the cover of motor, axis 6 and disconnect all connectors beneath.
3HAC 16247-1
Step
6.
Action
Note/Illustration
Loosen the cable bracket on top of the wrist by Shown in the figure Location of
unscrewing the three attachment screws.
wrist unit on page 47!
Two of the attachment screws are located visiC
ble at the rear of the bracket (B) and the third
located at the bottom of the cable bracket, in
B
the center (C), shown in the figure to the right.
xx0200000254
7.
8.
9.
13. Pull the wrist unit out, lift it away and place it on
a secure surface.
3HAC 16247-1
49
Location of wrist
unit
The wrist unit is located in the frontmost part of the upper arm as shown in the figure below.
A more detailed view of the component and its location may be found in the Foldout section
Wrist complete on page 211.
B
C
xx0200000184
50
Wrist unit
Turning disk
3HAC 16247-1
Required equipment
Refitting, wrist
unit
Equipment etc.
Note
Wrist, 175/2.55
3HAC 16627-1
3HAC 13605-1
Standard toolkit
The procedure below details how to refit the complete wrist unit.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Axis 5 must be oriented in the correct position (+90 ) to allow opening the motor 6 cover!
The complete wrist unit weighs 165 kg! All lifting equipment used must be dimensioned
accordingly!
Step
3HAC 16247-1
Action
Note/Illustration
1.
2.
51
Step
Action
Note/Illustration
3.
4.
Secure the wrist unit with 10 of the 12 attach- Shown in the figure Location of wrist
ment screws and washers.
unit on page 50!
12 pcs: M12 x 50, 12.9 quality
UNBRAKO, tightening torque: 115
Nm.
Reused screws may be used, providing they are lubricated as detailed in
Screw joints on page 15 before fitting.
5.
6.
7.
8.
xx0200000185
Fasten the cable bracket at top of wrist unit Shown in the figure Location of wrist
with three attachment screws. Two of them unit on page 50!
are visible at the rear attachment point (B)
and the third is located on the bottom of the C
cable bracket, right in the center (C), shown
B
in the figure to the right.
xx0200000254
52
3HAC 16247-1
Step
Action
Note/Illustration
3HAC 16247-1
53
Location of upper
arm
The upper arm is located on top of the manipulator as shown in the figure below. The complete upper arm includes the wrist unit but this instruction also describes how to remove the
upper arm when there is no wrist unit mounted.
Note! The lifting device is attached differently depending on whether the wrist unit is
mounted on the upper arm or not. The attachment points are shown in the figure below.
A more detailed view of the component and its location may be found in the Foldout section
Upper arm on page 209.
B
A
H
G
E
C
D
xx0200000163
54
3HAC 16247-1
Attachment for lifting device, upper arm (2 pcs if there is no wrist unit mounted)
Motor, axis 3
Motor, axis 4
Required equipment
Equipment
3HAC 16131-1
3HAC 15994-1
3HAC 15556-1
Standard toolkit
3HAC 15571-1
Removal, upper
arm
Note/Illustration
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The complete upper arm weighs 380 kg without any additional equipment fitted! Use a suitable
lifting device to avoid injury to personnel!
Step
3HAC 16247-1
Action
Note/Illustration
1.
2.
Move the manipulator arm to a horisontal position. Shown in the figure Location of
Run axis 4 so that the attachment hole for lifting eye upper arm on page 54!
is faced upwards!
55
Step
56
Action
Note/Illustration
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Carefully remove the attachment screws and wash- Shown in the figure Location of
ers, upper arm.
upper arm on page 54!
13.
14.
Remove the sealing, axis 2/3 from the lower arm. Shown in the figure Location of
upper arm on page 54!
3HAC 16247-1
Location of upper
arm
The upper arm is located on top of the manipulator as shown in the figure below. The complete upper arm includes the wrist unit but this instruction also describes how to refit the
upper arm when there is no wrist unit mounted.
Note! The lifting device is attached differently depending on whether the wrist unit is
mounted on the upper arm or not. The attachment points are shown in the figure below.
A more detailed view of the component and its location may be found in the Foldout section
Upper arm on page 209.
B
A
H
G
E
C
D
xx0200000163
3HAC 16247-1
57
Attachment for lifting device, upper arm (2 pcs if there is no wrist unit mounted)
Motor, axis 3
Motor, axis 4
Required equipment
Equipment
3HAC 12443-2
3HAC 12703-1
To be replaced if damaged.
3HAC 16131-1
3HAC 15994-1
3HAC 15556-1
3HAC 14628-1
3HAC 14628-2
Power supply
3HAC 17105-1
Standard toolkit
3HAC 15571-1
Refitting, upper
arm
Note
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
58
3HAC 16247-1
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force
is used!
The complete upper arm weighs 380 kg without any additional equipment fitted! Use a suitable
lifting device to avoid injury to personnel!
Step
1.
Action
Note/Illustration
xx0200000166
3HAC 16247-1
2.
Fit the lifting eye, VLBG M12 to the attach- Art. no. specified in Required equipment hole on the upper arm, if there is a ment on page 58!
wrist unit mounted.
Shown in the figure Location of upper
arm on page 57!
3.
4.
Upper arm without wrist unit: Fit the lift- Art. no. specified in Required equiping device, upper arm to the attachments ment on page 58!
for the lifting device on the upper arm.
Shown in the figure Location of upper
arm on page 57!
5.
59
Step
Action
Note/Illustration
6.
Fasten the lifting tool (chain) onto the lift- Art. no. specified in Required equiping eye, the lifting device and an overhead ment on page 58!
crane.
7.
8.
xx0200000165
60
9.
10.
11.
12.
13.
14.
15.
16.
17.
3HAC 16247-1
Step
Action
Note/Illustration
18.
19.
20.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind
any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
3HAC 16247-1
61
Location of lower
arm
A
D
C
xx0200000255
62
Lower arm
3HAC 16247-1
Attachment
points, lower arm
The lower arm attachment points are located as shown in the figure below:
The figure (1) shows gearbox axis 3, but the location of sealing axis 2/3 in relation to
the gearbox is identical for axis 2.
The figure (2) shows a cut view through the lower arm pivot point in axis 2 (item B in
the figure above!).
201
A
B
(1)
(2)
404
401
202
204
406
402
403
D
405
409
E
xx0200000031
3HAC 16247-1
Gear box
Lower arm
Frame
Shaft hole
201
202
Attachment screw
204
Washer
401
Bearing
402
Thrust washer
403
Bushing
404
Retaining ring
405
Shaft
406
Protection plug
409
Protection washer
63
Required equipment
Equipment, etc.
3HAC 13452-1
Standard toolkit
Removal, lower
arm
Note
The procedure below details how to remove the complete lower arm.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The lower arm weighs 160 kg! All lifting equipment used must be dimensioned accordingly!
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!
Step
64
Action
Note/Illustration
1.
2.
Disconnect and remove the cables from Detailed in section Removal of cable harinside the lower arm.
ness on page 24.
Release any cable attachments.
3HAC 16247-1
Step
Action
Note/Illustration
3.
4.
Unload the balancing device in order to Detailed in section Unloading the balancmake the piston rod and front ear adjust- ing device on page 89.
able when pulling the front shaft out.
5.
6.
7.
8.
9.
xx0300000015
3HAC 16247-1
65
Step
Action
Note/Illustration
14.
Fit the press (/puller) tool to the shaft as Art. no. specified in Required equipment
shown in the figure to the right and
on page 64!
mount the hydraulic pump to it.
15.
16.
17.
18.
19.
Remove the sealing from the lower arm. Shown in the figure Attachment points,
lower arm on page 63!
On reassembly a new sealing must be
used!
xx0300000010
66
3HAC 16247-1
Location of lower
arm
A
D
C
xx0200000255
3HAC 16247-1
Lower arm
67
Attachment
points, lower arm
The lower arm attachment points are located as shown in the figure below:
The figure (1) shows gearbox axis 3, but the location of sealing axis 2/3 in relation to
the gearbox is identical for axis 2.
The figure (2) shows a cut view through the lower arm pivot point in axis 2 (item B in
the figure above!).
201
A
B
(1)
(2)
404
401
202
204
406
402
403
D
405
409
E
xx0200000031
68
Gear box
Lower arm
Frame
Shaft hole
201
202
Attachment screw
204
Washer
401
Bearing
402
Thrust washer
403
Bushing
404
Retaining ring
405
Shaft
406
Protection plug
409
Protection washer
3HAC 16247-1
Required equipment
Equipment, etc.
Bearing
3HAC 12441-2
3HAC 12443-2
3HAC 14691-1
Guidings
3HAC 14446-1
3HAC 17105-1
Power supply
24 VDC, 1.5 A.
For releasing the brakes.
3HAC 13452-1
3HAC 13453-1
Hydraulic pump 80
Mpa
3HAC 13086-1
Hydraulic pump 80
Mpa (Glycerin)
3HAC 13086-2
Grease
3HAB 3537-1
Isopropanol
Standard toolkit
3HAC 15571-1
Refitting, lower
arm
Note
The procedure below details how to refit the complete lower arm.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
3HAC 16247-1
69
The lower arm weighs 160 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
Fit a new VK-cover on a new lower arm Part no. specified in Required equipment
or replace the existing if damaged.
on page 69!
2.
Fit two guidings in the attachment holes Art no. specified in Required equipment
of the lower arm.
on page 69!
xx0200000262
4.
5.
6.
In case the holes of the lower arm and Connect power supply to connector
the ones of the gearbox axis 2 doesnt R2.MP2
match, use power supply to release the
+: pin 2
motor axis 2 brakes and rotate the pin -: pin 5
ion and gear with the rotational tool.
xx0200000165
70
3HAC 16247-1
Step
Action
Note/Illustration
8.
9.
E
F
A B
xx0300000014
A: Retaining ring
B: Protection washer
C: Bearing
D: Thrust washer
E: Shaft
F: Protection plug
14. Set the indicator to zero and press the Approx. force: 30-50 kN.
shaft in with the hydraulic cylinder of the
press tool.
15. Increase the pressure of the glycerin
pump to 50 kN.
16. Check the measurement dial readout.
19. Apply grease to the location of the shaft Art no. specified in Required equipment
where the bearing is to be mounted.
on page 69!
20. Press the bearing in with the press tool, Always use a new bearing when reassemaxis 2 bearing.
bling!
Art no. specified in Required equipment
on page 69!
3HAC 16247-1
71
Step
Action
Note/Illustration
23.
24.
25.
26.
27.
Refit and reconnect all cables inside the Detailed in section Refitting of cable harlower arm.
ness on page 30.
Resecure any cable attachments.
28.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind
any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
72
3HAC 16247-1
Location of SMB
related equipment
The SMB related equipment (SMB = serial measurement board) is located on the left hand
side of the frame as shown in the figure below. (IRB 7600 shown.)
Note that the manipulator is shown with the SMB cover already removed!
A B C D
E F G
xx0200000203
SMB battery
SMB cover
SMB unit
Pins
Required equipment
Equipment, etc. Spare part. no. Art. no.
Removal, battery
Note
Standard toolkit
Circuit Diagram
3HAC 16247-1
73
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Follow these instruction to prevent the unit to be damaged from ESD:
The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to electrostatic
voltages.
Before handling, make sure you are connected to earth through a special ESD wrist bracelet
or similar.
Step
Removal, SMB
unit
Action
Note/Illustration
1.
Remove the SMB battery cover by unscrew- Shown in the figure Location of
ing its attachment screws.
SMB related equipment on page 73!
2.
3.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Follow these instruction to prevent the unit to be damaged from ESD:
The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to electrostatic
voltages.
Before handling, make sure you are connected to earth through a special ESD wrist bracelet
or similar.
Step
74
Action
Note/Illustration
1.
Remove the SMB cover by unscrewing Shown in the figure Location of SMB
its attachment screws.
related equipment on page 73!
2.
3.
4.
5.
3HAC 16247-1
Location of SMB
related equipment
The SMB related equipment (SMB = serial measurement board) is located on the left hand
side of the frame as shown in the figure below. (IRB 7600 shown.)
Note that the manipulator is shown with the SMB cover already removed!
A B C D
E F G
xx0200000203
SMB battery
SMB cover
SMB unit
Pins
Required equipment
Equipment, etc. Spare part no. Art. no.
3HAC 16247-1
SMB Unit
3HAC 13149-1
SMB Battery
3HAC 16831-1
Note
Battery includes protection circuits.
Replace it only with given spare
part no. or an ABB approved eqvivalent.
Cable, battery/SMB
board
3HAC 13151-1
Circuit Diagram
Standard toolkit
75
Refitting, battery
Step
Refitting, SMB
unit
Action
Note/Illustration
1.
Reconnect the cable, battery/SMB board to Art. no. is specified in Required equipthe battery and fit the SMB battery.
ment on page 75!
Shown in the figure Location of SMB
related equipment on page 75!
2.
3.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Follow these instruction to prevent the unit to be damaged from ESD:
The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to electrostatic
voltages.
Before handling, make sure you are connected to earth through a special ESD wrist bracelet
or similar.
Step
76
Action
Note/Illustration
1.
2.
Fit the SMB unit onto the pins and con- Art. no. is specified in Required equipment
nect all connectors to the board.
on page 75!
Shown in the figure Location of SMB
related equipment on page 75!
R1.SMB1-3, R1.SMB4-6 and R2.SMB
3.
3HAC 16247-1
Step
Action
Note/Illustration
4.
5.
Secure the SMB cover with its attach- Shown in the figure Location of SMB
ment screws.
related equipment on page 75!
6.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind
any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
3HAC 16247-1
77
Location of brake
release unit
The brake release unit is located together with the SMB unit on the left hand side of the frame,
right below the gearbox, axis 2, as shown in figure below (IRB 7600 shown).
Some of the early designs are equipped with a separate box on the frame, with the brake
release unit inside, not shown in the figure.
D
xx0200000226
Buttons
SMB cover
Required equipment
Equipment, etc.
Standard toolkit
78
Note
3HAC 16247-1
Removal, brake
release unit
The procedure below details how to remove the brake release unit.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Follow these instruction to prevent the unit to be damaged from ESD:
The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to electrostatic
voltages.
Before handling, make sure you are connected to earth through a special ESD wrist bracelet
or similar.
Step
Action
Note/Illustration
1.
2.
A
2
C
xx0200000129
A: Connector X8
B: Connector X9
C: Connector X10
3HAC 16247-1
3.
4.
79
Location of brake
release unit
The brake release unit is located together with the SMB unit on the left hand side of the frame,
right below the gearbox, axis 2, as shown in figure below (IRB 7600 shown).
Some early designs are equipped with a separate box on the frame, with the brake release unit
inside, not shown in the figure.
D
xx0200000226
Buttons
SMB cover
Required equipment
Equipment, etc.
80
Note
Standard toolkit
3HAC 16247-1
Equipment, etc.
Note
Refitting, brake
release unit
The procedure below details how to refit the brake release unit.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Follow these instruction to prevent the unit to be damaged from ESD:
The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to electrostatic
voltages.
Before handling, make sure you are connected to earth through a special ESD wrist bracelet
or similar.
Step
Action
Note/Illustration
1.
Fasten the brake release unit on the plate Shown in the figure Location of brake
with the attachment screws.
release unit on page 80!
Art. no. specified in Required equipment on page 80!
2.
A
2
C
xx0200000129
3.
A: Connector X8
B: Connector X9
C: Connector X10
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind
any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
3HAC 16247-1
81
The balancing device is located on rear top of the frame as shown in the figure below.
A C
I,J
D, E
H
G
B
K
F
xx0200000223
Balancing device
Rear cover
Bearing attachment
Plug
Required equipment
Equipment, etc
82
Note
Locking screw
3HAC 14457-3
3HAC 15767-1
3HAC 12475-1
3HAC 16247-1
Equipment, etc
Note
Hydraulic cylinder
3HAC 11731-1
Hydraulic pump
3HAC 13086-1
Securing screw
9ADA 183-66
3HAC 13120-5
Standard toolkit
3HAC 15571-1
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!
The balancing device weighs 210 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
2.
xx0200000454
3HAC 16247-1
83
Step
84
Action
Note/Illustration
4.
5.
6.
7.
8.
Secure the two bearing attachments to the Shown in the figure Location of balancbalancing device by replacing the plug on ing device on page 82!
the outside of each attachment, with a
2pcs: M12 x 35.
screw.
9.
Remove the two bearing attachments from Shown in the figure Location of balancthe frame by unscrewing their four attach- ing device on page 82!
ment screws.
Make sure the parallel pins inside are
not lost!
10.
11.
Lift the balancing device gently backwards Note! Make sure not to burden the
to a secure area, allowing the bearing
guide pins with the weight of the balattachments to slide on the guide pins.
ancing device!
3HAC 16247-1
The balancing device is located on rear top of the frame as shown in the figure below.
A C
I,J
D, E
H
G
B
K
F
xx0200000223
Balancing device
Rear cover
Bearing attachment
Plug
Required equipment
3HAC 16247-1
Equipment
Note
Balancing device
3HAC 16198-1
IRB 6600.
Includes balancing device 3HAC
14678-1!
Includes o-rings 3HAB 3772-44.
Balancing device
3HAC 16907-1
IRB 6650.
Includes balancing device 3HAC
16189-1!
Includes o-rings 3HAB 3772-44.
85
Equipment
O-ring
3HAB 3772-44
Locking screw
Securing screw
9ADA 183-66
Bearing grease
3HAB 3537-1
Grease
Locking liquid
Loctite 243.
To apply to the securing screw in
the shaft.
Grease pump
3HAC 13120-5
3HAC 14457-3
3HAC 15767-1
3HAC 17129-1
Hydraulic cylinder
3HAC 11731-1
Hydraulic pump
3HAC 13086-1
Standard toolkit
3HAC 15571-1
Note
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
86
3HAC 16247-1
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!
The balancing device weighs 210 kg! All lifting equipment used must be dimensioned accordingly!
Step
1.
Action
Note/Illustration
Secure the lower arm to the frame by inserting the locking screw into the hole (1).
xx0200000454
3HAC 16247-1
2.
Secure the bearing attachments to the bal- Shown in the figure Location of balancing device with two screws, on the out- ancing device on page 85!
side of the attachments.
M12 x 35, 2 pcs.
3.
4.
5.
6.
Lift the balancing device and bring it forward, Note! Make sure not to burden the
gliding the bearing attachments on to the
guide pins with the weight of the balguide pins (upper holes).
ancing device!
7.
8.
Secure the rear of the balancing device by Shown in the figure Location of balfastening the two bearing attachments to the ancing device on page 85!
frame with their four attachment screws.
4 pcs, M16x70, 12.9 quality
UNBRAKO, tightening torque: 300
Nm 45 Nm.
Reused screws may be used, providing they are lubricated as detailed in
Screw joints on page 15 before fitting.
9.
10.
87
Step
Action
Note/Illustration
11.
12.
13.
Apply the shaft press tool to the lubricatedshaft through the hole in the frame.
Fit the shaft using the shaft press tool and
the hydraulic pump.
14.
Refit the securing screw in to the shaft using M16x180, tightening torque: 50 Nm.
locking liquid.
Locking liquid specified in Required
equipment on page 85!
15.
16.
17.
xx0200000454
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind
any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
88
3HAC 16247-1
This section implies that the lower arm is already secured according to the instruction for the
current repair activity, e.g removal of the balancing device.
The figure below shows the hydraulic cylinder mounted on the press tool.
A
C
1
0
D
xx0200000174
Bolt (4 pcs)
Hydraulic cylinder
Fix plate
Required equipment
Equipment, etc.
3HAC 16247-1
Note
3HAC 15767-1
Hydraulic cylinder
Hydraulic pump
Standard toolkit
89
Unloading the
balancing device
The procedure below details how to unload the balancing device, using the press tool 3HAC
15767-1. How to remove the press tool, is detailed in section Restoring the balancing device
on page 91.
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!
Step
1.
Action
Note/Illustration
xx0200000175
90
2.
3.
4.
5.
6.
7.
8.
Turn the fix plate to position 1 in order to See the figure Press tool and hydraulic
lock the tool in loaded condition.
cylinder on page 89!
9.
10.
3HAC 16247-1
Restoration is done after repair work that has included the unloading of the balancing device.
The figure below shows the hydraulic cylinder mounted on the press tool.
A
C
1
0
D
xx0200000174
Bolt (4 pcs)
Hydraulic cylinder
Fix plate
Required equipment
Equipment, etc. Spare part no. Art. no.
3HAC 16247-1
Note
Hydraulic cylinder
Hydraulic pump
Standard toolkit
91
The procedure below details how to restore the balancing device, i.e. removing the press tool
3HAC 15767-1.
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!
Step
92
Action
Note/Illustration
1.
2.
Press with the cylinder and the hydraulic Shown in the figure Press tool and
pump until the fix plate is movable again. hydraulic cylinder on page 91!
Turn the fix plate to position 0.
Do not apply more pressure than necessary, it could damage bearings and sealings at the shaft.
3.
4.
5.
Remove the press tool by unscrewing the Shown in the figure Press tool and
bolts.
hydraulic cylinder on page 91!
6.
7.
Refit the support shaft and the lubricated Make sure the o-rings are seated propo-ring.
erly!
8.
3HAC 16247-1
Location of motor
The motor axis 1 is located on the left hand side of the manipulator as shown in the figure
below.
xx0200000200
Motor, axis 1
Required equipment
Equipment, etc.
3HAC 14459-1
Power supply
3HAC 16247-1
Note
24 VDC, 1.5 A.
For releasing the brakes.
Circuit Diagram
Standard toolkit
93
Removal
Step Action
Note/Illustration
xx0200000199
-: pin 5
7. If required, press the motor out of position by Art. no. specified in Required equipfitting removal tool, motor to the motor attach- ment on page 93!
ment screw holes.
Always use the removal tools in pairs!
8. Lift the motor to get the pinion away from the
gear and disconnect the brake release voltage.
9. Remove the motor by gently lifting it straight
up.
94
3HAC 16247-1
Location of motor
The motor axis 1 is located on the left hand side of the manipulator as shown in the figure
below.
xx0200000200
Motor, axis 1
Required equipment
Equipment, etc.
Note
Motor, axis 1
3HAC 15879-1
O-ring
Grease
3HAB 3537-1
3HAC 14459-1
Power supply
3HAC 16247-1
Circuit Diagram
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!
95
Equipment, etc.
Refitting, motor
Note
These procedures include references to the tools required.
Step
Action
Note/Illustration
1.
Make sure the o-ring on the circumference of the Art no. specified in Required
motor is seated properly. Lightly lubricate the o- equipment on page 95!
ring with grease.
2.
Apply lifting tool, motor axis 1, 4, 5 to the motor. Art no. specified in Required
equipment on page 95!
3.
-: pin 5
4.
5.
6.
7.
8.
Refit the cable gland cover at the cable exit with Make sure the cover is tightly
its two attachment screws.
sealed!
9.
10.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind
any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
96
3HAC 16247-1
Location of motor
The motor axis 2 is located on the left hand side of the manipulator as shown in the figure
below.
B
D
A
xx0200000169
Motor axis 2
Required equipment
Equipment etc.
Locking screw
3HAC 15534-1
Power supply
3HAC 16247-1
Note
24 VDC, 1.5 A.
For releasing the brakes.
3HAC 14631-1
3HAC 15521-2
97
Equipment etc.
Circuit diagram
3HAC 13347-1
Standard toolkit
3HAC 15571-1
Removal, motor
Note
The motor weighs 27 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
Run the manipulator to a position close enough to Shown in the figure Location of
its calibration position, to allow the lock screw to motor on page 97!
be inserted into the hole for lock screw.
2.
Lock the lower arm by inserting the lock screw into Art. no. specified in Required
the hole.
equipment on page 97!
3.
4.
5.
Remove the cable gland cover at the cable exit by Shown in the figure Location of
unscrewing its two attachment screws.
motor on page 97!
Make sure the gasket is not
damaged!
6.
7.
In order to release the brake, connect the 24 VDC Connect to connector R2.MP2
power supply.
+: pin 2
8.
98
-: pin 5
Remove the motor by unscrewing its four attachment screws and plain washers.
3HAC 16247-1
Step
3HAC 16247-1
Action
Note/Illustration
9.
10.
If required, press the motor out of position by fitting removal tool, motor to the remaining motor
attachment holes.
11.
12.
Lift the motor to get the pinion away from the gear. Make sure the motor pinion
does not get damaged!
13.
99
Location of motor
The motor, axis 2, is located on the left hand side of the manipulator as shown in the figure
below.
B
D
A
xx0200000169
Motor axis 2
Required equipment
100
Equipment, etc.
Note
3HAC 15882-1
3HAC 15885-1
O-ring
2152 2012-430
Grease
3HAB 3537-1
3HAC 15521-2
3HAC 15534-1
3HAC 16247-1
Equipment, etc.
Note
Power supply
24 VDC, 1.5 A.
For releasing the brakes.
3HAC 17105-1
Circuit diagram
3HAC 13347-1
Standard toolkit
3HAC 15571-1
Refitting, motor
The motor weighs 27 kg! All lifting equipment used must be dimensioned accordingly!
Step
3HAC 16247-1
Action
Note/Illustration
1.
Make sure the o-ring on the circumference of Art. no. specified in Required equipthe motor is seated properly. Lightly lubricate ment on page 100!
the o-ring with grease.
2.
3.
4.
5.
101
Step
Action
Note/Illustration
6.
7.
xx0200000165
9.
Secure the motor with four attachment screws M10 x 40, tightening torque: 50 Nm.
and plain washers.
Reused screws may be used, providing they are lubricated as
detailed in Screw joints on page 15
before fitting.
10.
11.
12.
13.
14.
Refit the cover on top of the motor with its four Make sure the cover is tightly
attachment screws.
sealed!
15.
Remove the lock screw from the hole for lock Shown in the figure Location of
screw.
motor on page 100!
16.
17.
18.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind
any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
102
3HAC 16247-1
Location of motor
The motor axis 3 is located on the left hand side of the manipulator as shown in the figure
below.
A
B
C
xx0200000186
Motor, axis 3
Required equipment
Equipment, etc.
Power supply
3HAC 16247-1
Note
24 VDC, 1.5 A.
For releasing the brakes.
3HAC 14631-1
3HAC 15521-2
3HAC 12708-1
3HAA 1001-186
Circuit Diagram
3HAC 13347-1
103
Equipment, etc.
Standard toolkit
Note
3HAC 15571-1
Removal, motor
The motor weighs 27 kg! All lifting equipment used must be dimensioned accordingly!
Step
1.
Action
Note/Illustration
B
A
xx0300000051
The upper arm must be positioned as horizon- Fit the mechanical stop to the third
tal as possible!
and final attachment hole (A),
below the fixed stop (B) in the upper
arm. See the figure above!
104
2.
3.
4.
5.
6.
3HAC 16247-1
Step
Action
Note/Illustration
7.
8.
9.
12. Lift the motor to get the pinion away from the
gear.
13. Remove the motor by gently lifting it straight
Make sure the motor pinion is not
out and disconnect the brake release voltage. damaged!
3HAC 16247-1
105
Location of motor
The motor axis 3 is located on the left hand side of the manipulator as shown in the figure
below.
A
B
C
xx0200000186
Motor axis 3
Required equipment
106
Equipment, etc.
Note
3HAC 15882-1
3HAC 15885-1
O-ring
Grease
3HAB 3537-1
3HAC 16247-1
Equipment, etc.
Note
Power supply
Circuit Diagram
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!
Refitting, motor
The motor weighs 27 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
Make sure the o-ring on the circumference of the motor is seated properly.
Lightly lubricate it with grease .
2.
Fit the lifting tool, motor axis 2, 3, 4 to the Art no. specified in Required equipment
motor.
on page 106!
3.
4.
5.
6.
3HAC 16247-1
-: pin 5
107
Step
7.
Action
Note/Illustration
xx0200000165
9.
10.
11.
12.
13.
Refit the cover on top of the motor with its Make sure the cover is tightly sealed!
four attachment screws.
14.
Lifting slings
Mech stop
15.
16.
17.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind
any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
108
3HAC 16247-1
Location of motor
The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below.
A
B
xx0200000202
Motor, axis 4
Required equipment
Equipment, etc.
Power supply
24 VDC, 1.5 A.
For releasing the brakes.
Circuit Diagram
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!
3HAC 16247-1
Note
109
Removal, motor
Step
Action
Note/Illustration
1.
2.
Remove the cable gland cover at the cable exit Shown in the figure Location of
of the motor by unscrewing its two attachment
motor on page 109!
screws.
Make sure the gasket is not damaged!
3.
4.
5.
110
-: pin 5
6.
Unscrew the motors four attachment screws and Shown in the figure Location of
plain washers.
motor on page 109!
7.
8.
If required, press the motor out of position by fit- Art. no. specified in Required
ting removal tool, motor M10 to the motor attach- equipment on page 109!
ment screw holes.
Always use the removal tools in
pairs!
9.
10.
Remove the motor by gently lifting it straight out. Make sure the motor pinion is not
damaged!
3HAC 16247-1
Location of motor
The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below.
A
B
xx0200000202
Motor, axis 4
Required equipment
Equipment, etc.
Note
3HAC 15887-1
3HAC 15889-1
O-ring
Grease
3HAC 3537-1
3HAC 15520-1
3HAC 15520-2
3HAC 17105-1
Power supply
Circuit Diagram
3HAC 16247-1
3HAC 13347-1
111
Equipment, etc.
Standard toolkit
Note
3HAC 15571-1
Refitting, motor
Step
Action
Note/Illustration
1.
Make sure the o-ring on the circumference Art. no. specified in Required equipof the motor is seated properly. Lightly lubri- ment on page 111!
cate the o-ring with grease .
2.
112
-: pin 5
3.
4.
3HAC 16247-1
Step
5.
Action
Note/Illustration
xx0200000165
7.
8.
9.
Refit the cable gland cover at the cable exit Shown in the figure Location of motor
with its two attachment screws.
on page 111!
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind
any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
3HAC 16247-1
113
Location of motor
The motor axis 5 is located inside the upper arm tube, but attached to the wrist unit, as shown
in the figure below.
A more detailed view of the component and its location may be found in the Foldout section
Wrist complete on page 211.
xx0200000204
Motor, axis 5
Wrist unit
Required equipment
Equipment, etc.
Power supply
24 VDC, 1.5 A.
For releasing the brakes.
Measuring tool
6896 134-GN
Nipple
6896 134-AA
TREDO-washer
114
Note
Nipple
6896 901-282
Oil injector
6369 901-280
Circuit Diagram
3HAC 16247-1
Equipment, etc.
Standard toolkit
Note
Removal, motor
Step
Action
Note/Illustration
1.
2.
3.
4.
5.
6.
7.
- : pin 5
3HAC 16247-1
-: pin D
8.
9.
Fit the two guide pins in two of the motor Art. no. specified in Required equipment
attachment screw holes.
on page 114!
115
Step
116
Action
Note/Illustration
10.
If required, press the motor out of position Art. no. specified in Required equipment
by fitting removal tool, motor, M10 to the on page 114!
motor attachment screw holes.
Always use the removal tools in pairs
and diagonally!
11.
Lift the motor to get the pinion away from Make sure the motor pinion is not damthe gear and disconnect the brake
aged!
release voltage.
12.
13.
Measure the distance between the motor Art. no. specified in Required equipment
flange, included eventual shims, and the on page 114!
outer surface of the pinion, with measur- Make a note of the distance.
ing tool.
14.
3HAC 16247-1
Location of motor
The motor axis 5 is located inside the upper arm tube, but attached to the wrist unit, as shown
in the figure below.
A more detailed view of the component and its location may be found in the Foldout section
Wrist complete on page 211.
xx0200000204
Motor, axis 5
Wrist unit
Required equipment
Equipment, etc.
3HAC 16247-1
Note
3HAC 7941-28 Used to obtain the correct distance between motor flange and
outer surface of motor pinion.
O-ring
2152 2012430
Grease
3HAC 3537-1
Isopropanol
Mineral oil
CS 320
Press fixture
3HAC 4850-1
117
Equipment, etc.
Note
Measuring tool
6896 134-GN
Power supply
24 VDC, 1.5 A.
For releasing the brakes.
Circuit Diagram
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!
Refitting, motor
Step
118
Action
Note/Illustration
1.
Make sure the o-ring on the circumference Art. no. specified in Required equipof the motor is seated properly. Lightly lubri- ment on page 117!
cate the o-ring with grease.
2.
Clean the motor pinion and the motor pinion Art. no. specified in Required equiphole in the motor, with isopropanol.
ment on page 117!
3.
Apply a thin film of mineral oil to the pinion Art. no. specified in Required equipshaft and the pinion hole in order to make
ment on page 117!
the pinion run smoothly and to achieve an
even friction torque when assembling the
pinion.
4.
5.
3HAC 16247-1
Step
Action
Note/Illustration
6.
7.
-: pin 5
- : pin D
8.
9.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind
any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
3HAC 16247-1
119
Location of motor
The motor axis 6 is located in the center of the wrist unit as shown in the figure below.
A more detailed view of the component and its location may be found in the Foldout section
Wrist complete on page 211.
xx0200000222
Wrist unit
Motor, axis 6
Required equipment
Equipment, etc.
Power supply
120
Note
24 VDC, 1.5 A.
For releasing the brakes.
Circuit Diagram
Standard toolkit
3HAC 16247-1
Equipment, etc.
Removal, motor
Note
These procedures include references to the tools required.
Step
Action
Note/Illustration
1.
2.
3.
4.
In order to release the brake, connect the 24 VDC Connect to connector R3.MP6
power supply.
+: pin 2
3HAC 16247-1
-: pin 5
5.
Remove the motor by unscrewing its four attachment screws and plain washers.
6.
If required, press the motor out of position by fitting Art. no. specified in Required
removal tool, motor to the motor attachment screw equipment on page 120!
holes.
Always use the removal tools
in pairs!
7.
Lift the motor carefully to get the pinion away from Make sure the motor pinion is
the gear and disconnect the brake release voltage. not damaged!
8.
121
Location of motor
The motor axis 6 is located in the center of the wrist unit as shown in the figure below.
A more detailed view of the component and its location may be found in the Foldout section
Wrist complete on page 211.
xx0200000222
Wrist unit
Motor, axis 6
Required equipment
Equipment, etc.
122
Note
O-ring
3HAC 15520-1
3HAC 15520-2
3HAC 16247-1
Equipment, etc.
Note
Power supply
24 VDC, 1.5 A.
For releasing the brakes.
Grease
3HAB 3537-1
Circuit Diagram
3HAC 13347-1
Standard toolkit
3HAC 15571-1
Refitting, motor
Step
Action
Note/Illustration
1.
Make sure the o-ring on the circumference of Art. no. specified in Required equipthe motor is seated properly. Lightly lubricate ment on page 122!
the o-ring with grease.
2.
3HAC 16247-1
-: pin 5
3.
4.
5.
6.
Secure the motor with four attachment screws 4 pcs: M8 x 25, tightening torque:
and plain washers.
24 Nm.
7.
8.
9.
Refit the cover on top of the motor with its six Make sure the cover is tightly
attachment screws.
sealed!
10.
123
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind
any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
124
3HAC 16247-1
Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure below.
A more detailed view of the component and its location may be found in the Foldout section
Base incl. Frame on page 203.
xx0300000015
Gearbox, axis 1
Frame
Base
Required equipment
Equipment, etc.
3HAC 16247-1
Note
Standard toolkit
3HAC 15535-1
3HAC 15560-1
3HAC 15556-1
125
Equipment, etc.
Note
Removal, gearbox
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force
is used!
The gear box weighs 155 kg! All lifting equipment used must be dimensioned accordingly!
The base (without gearbox 1) weighs 263 kg! All lifting equipment used must be dimensioned
accordingly!
Step
1.
Action
Note/Illustration
xx0300000022
126
2.
3.
4.
5.
Remove the complete arm system. Detailed in section Removal of complete arm
system on page 36.
3HAC 16247-1
Step
Action
Note/Illustration
6.
7.
8.
9.
10.
A
B
C
xx0200000227
11.
C: Washers, 3 pcs
xx0200000256
12.
3HAC 16247-1
127
Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure below.
A more detailed view of the component may be found in Foldout section Base incl. Frame on
page 203.
xx0300000015
Gearbox, axis 1
Frame
Base
Required equipment
128
Equipment, etc.
Note
Gearbox, axis 1
3HAC 10828-8
O-ring
3HAB 3772-54
O-ring
3HAB 3772-55
Sealing ring
3HAC 11581-4
Grease
3HAC 3537-1
3HAC 15535-1
3HAC 16247-1
Equipment, etc.
Note
3HAC 15560-1
3HAC 15556-1
Standard toolkit
3HAC 15571-1
Refitting, gearbox
The gear box weighs 155 kg! All lifting equipment used must be dimensioned accordingly!
The base (without gearbox 1) weighs 263 kg! All lifting equipment used must be dimensioned
accordingly!
Step
1.
3HAC 16247-1
Action
Note/Illustration
If the base is not supported with Support, Mounting of the Support, base and
base and gear 1, this should be done first. gear 1 is detailed in section Removal of
gearbox, axis 1 on page 125.
129
Step
2.
Action
Note/Illustration
Make sure the two o-rings (C, D) on the cir- Art no. specified in Required equipcumference of the gearbox are seated
ment on page 128!
properly in their grooves respectively.
Lightly lubricate the o-rings with grease .
Make sure the small o-ring around the oil
hole is fitted properly!
A
D
C
xx0200000055
3.
A: Guide pin
Refit the cable guide in the center of gearbox 1 with its attachment screws.
xx0200000256
130
4.
Fit the lifting device, base and the lifting tool Art no. specified in Required equip(chain) to the gearbox.
ment on page 128!
5.
6.
Make sure the guide pin in the bottom face Shown in the figure xx0200000055
of the gearbox is properly aligned with the above!
base.
3HAC 16247-1
Step
7.
Action
Note/Illustration
Secure the gearbox and the three washers M16 x 70, 12.9 quality UNBRAKO,
with the 18 attachment screws, base to
tightening torque: 300 Nm.
gearbox (B).
Reused screws may be used, providing they are lubricated as detailed in
"Screw joints" before fitting.
A
B
C
xx0200000227
8.
9.
11.
C: Washers, 3 pcs
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind
any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
3HAC 16247-1
131
Different designs
Between the axis 2 motor and gearbox there is a motor attachment which exists in two different designs.
The early design of the motor attachment is attached directly to the gearbox, with the
front gearbox attachment screws.
The later design of the motor attachment is attached directly to the frame. This design
also includes an additional cover that overlaps the motor attachment and holds the oil
plugs.
The service work differ some between the designs. Be aware of the differences made in the
instruction.
Location of gearbox
The gearbox, axis 2, is located in the lower arm rotational center, underneath the motor attachment.
The figure below shows the later design of the motor attachment.
A more detailed view of the component and its location may be found in the Foldout section
Frame-Lower arm 1 on page 205.
D
A
C
G
xx0200000171
132
Balancing device
Motor axis 2
3HAC 16247-1
Additional cover
Motor attachment
Required equipment
Equipment etc.
3HAC 13659-1
3HAC 13698-1
3HAC 13056-2
3HAC 13056-4
3HAC 15767-1
Hydraulic cylinder
3HAC 11731-1
Hydraulic pump
3HAC 13086-1
Standard toolkit
3HAC 15571-1
Removal, gearbox
Note
Includes locking screw for
securing the lower arm.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force
is used!
The gear box weighs 52 kg! All lifting equipment used must be dimensioned accordingly!
3HAC 16247-1
133
Step
Action
Note/Illustration
1.
2.
C
xx0200000260
3.
4.
5.
134
B: Adjusters
3HAC 16247-1
Step
Action
Note/Illustration
6.
7.
8.
9.
xx0200000166
3HAC 16247-1
135
Step
Action
Note/Illustration
A
xx0200000172
14. Fit the lifting tool, gearbox axis 2 to the gear- Art. no. specified in Required equipbox.
ment on page 133!
15. Remove the gearbox axis 2 using an overhead crane or similar, with guidance from the
mounted guide pins.
16. Remove the friction washer and clean it.
17. Remove the sealing from the lower arm.
136
3HAC 16247-1
Different designs
Between the axis 2 motor and gearbox there is a motor attachment which exists in two different designs.
The early design of the motor attachment is attached directly to the gearbox, with the
front gearbox attachment screws.
The later design of the motor attachment is attached directly to the frame. This design
also includes an additional cover that overlaps the motor attachment and holds the oil
plugs.
The service work differ some between the designs. Be aware of the differences made in the
instruction.
Location of gearbox
The gearbox, axis 2, is located in the lower arm rotational center, underneath the motor attachment.
The figure below shows the later design of the motor attachment.
A more detailed view of the gearbox may be found in the Foldout section Frame-Lower arm
1 on page 205.
D
A
C
G
xx0200000171
3HAC 16247-1
Balancing device
Motor axis 2
137
Additional cover
Motor attachment
Required equipment
Equipment
Note
Gear, axis 2
3HAC 10828-12
O-ring
O-ring
Grease
3HAB 3537-1
3HAC 13698-1
3HAC 13056-2
3HAC 13056-3
Gearbox crank
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!
Refitting, gearbox
138
3HAC 16247-1
The gear box weighs 52 kg! All lifting equipment used must be dimensioned accordingly!
Step
1.
Action
Note/Illustration
xx0200000173
2.
3.
xx0200000166
3HAC 16247-1
139
Step
140
Action
Note/Illustration
4.
Fit the new sealing, axis 2/3 on the gearArt. no. specified in Required equipbox, axis 2, and on to the guide pins.
ment on page 138!
Do not remove the guide pins for the sealing
until the rear gearbox attachment screws
are secured.
5.
Fit two guide pins, M12 in 180relation to Art. no. specified in Required equipeach other in the frame, in the screw holes ment on page 138!
for the gearboxes front attachment screws.
6.
7.
8.
9.
10.
11.
12.
Insert and secure 22 of the 24 front gearbox Shown in the figure xx0200000166
attachment screws.
above!
Tightening torque: 115 Nm.
13.
14.
15.
16.
Later design of the motor attachment: Refit Shown in the figure Location of gearthe attachment screws, motor attachment. box on page 137.
15 pcs: M8 x 25, tightening torque: 24
Nm.
3HAC 16247-1
Step
Action
Note/Illustration
17.
Insert and secure 31 of the 33 rear gearbox Shown in the figure Location of gearattachment screws on the inside of the
box on page 137!
lower arm.
M12 x 50, 12.9 quality UNBRAKO,
tightening torque: 115 Nm.
Reused screws may be used, providing they are lubricated as detailed in
Screw joints on page 15 before fitting.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind
any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
3HAC 16247-1
141
Location of gearbox
The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.
A more detailed view of the component and its location may be found in the Foldout section
Upper arm on page 209.
xx0200000194
Gearbox, axis 3 (sealing, axis 2/3 between lower arm and gearbox 3)
Motor, axis 3
Upper arm
Required equipment
Equipment, etc.
142
3HAC 12708-1
3HAA 1001-186
Note
Used to secure the upper arm.
Use attachment screws 3HAB
3409-86 (M16 x 60).
3HAC 16247-1
Equipment, etc.
3HAC 13056-3
3HAC 13056-4
3HAC 14457-3
Standard toolkit
3HAC 15571-1
Removal, gearbox
Note
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force
is used!
The gear box weighs 52 kg! All lifting equipment used must be dimensioned accordingly!
Step
1.
Action
Note/Illustration
Secure the upper arm in a horizontal posi- Art. no. specified in Required equiption using a mechanical stop.
ment on page 142.
Fit the mechanical stop to the third and
final attachment hole (A), below the fixed
mechanical stop (B) in the upper arm,
shown in the figure to the right.
Tightening torqure: 115 Nm.
B
A
xx0300000051
3HAC 16247-1
2.
3.
143
Step
Action
Note/Illustration
4.
5.
6.
7.
Fit the two guide pins, M12 in 180relation Art. no. specified in Required equipto each other in the gearbox attachment ment on page 142!
screw holes.
8.
xx0200000201
144
9.
10.
3HAC 16247-1
Location of gearbox
The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.
A more detailed view of the component and its location may be found in the Foldout section
Upper arm on page 209.
xx0200000194
Gearbox, axis 3 (sealing, axis 2/3 between lower arm and gearbox 3)
Motor, axis 3
Upper arm
Required equipment
Equipment, etc.
Note
Gearbox, axis 3
3HAC 10828-12
O-ring
3HAC 16247-1
145
Equipment, etc.
Note
Grease
3HAB 3537-1
3HAC 14457-3
Standard toolkit
Refitting, gearbox
The gear box weighs 52 kg! All lifting equipment used must be dimensioned accordingly!
Step
146
Action
Note/Illustration
1.
2.
3.
3HAC 16247-1
Step
4.
Action
Note/Illustration
Make sure the o-rings are fitted to the gear- Art. no. is specified in Required equipbox. Apply grease to the o-rings to make
ment on page 145!
sure they stick in their grooves during
A
assembly.
xx0100000136
A: O-rings, gearbox ax 3
5.
6.
7.
Fit the gearbox onto the guide pins and slide Make sure the gearbox and o-ring are
it into position.
seated properly and correctly oriented!
8.
9.
10. Refit the upper arm with a new sealing, axis Art. no. is specified in Required equip2/3 .
ment on page 145!
Detailed in section Refitting of upper
arm on page 57!
11. Refit the motor.
3HAC 16247-1
147
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind
any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
148
3HAC 16247-1
Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.
The different robot versions result in two different designs of the gearbox.
A more detailed view of the component and its location may be found in the Foldout section
Wrist complete on page 211.
A
D
B2
B1
xx0200000219
Gearbox, axis 6
B1
Attachment screws and washers, gearbox for robot version 175/2.55 (8 pcs)
B2
Attachment screws and washers, gearbox for robot version 225/2.55, 175/2.8, 125/
3.2 and 200/2.75 (18 pcs)
Required equipment
Equipment, etc.
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!
3HAC 16247-1
Note
149
Removal, gearbox
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force
is used!
Step
Action
Note/Illustration
1.
2.
3.
4.
A
xx0200000220
5.
150
Remove the gearbox axis 6 by lifting it out care- Be careful not to damage the motor
fully.
pinion!
3HAC 16247-1
Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.
The different robot versions result in two different designs of the gearbox.
D
B2
B1
xx0200000219
Gearbox, axis 6
B1
Attachment screws and washers, gearbox for robot version 175/2.55 (8 pcs)
B2
Attachment screws and washers, gearbox for robot version 225/2.55, 175/2.8, 125/
3.2 and 200/2.75 (18 pcs)
Required equipment
3HAC 16247-1
Equipment, etc.
Note
3HAC 10828-10
3HAC 10828-13
Washers
3HAA 1001-172
O-ring
Grease
3HAB 3537-1
151
Equipment, etc.
Standard toolkit
Note
3HAC 15571-1
Refitting, gearbox
Step
1.
Action
Note/Illustration
Make sure the o-ring is fitted to the Art. no. specified in Required equipment on
rear of the gearbox. Lightly lubricate page 151!
the o-ring with grease.
A
xx0100000132
2.
152
3HAC 16247-1
Step
Action
Note/Illustration
3.
4.
5.
6.
7.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind
any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
3HAC 16247-1
153
154
3HAC 16247-1
Definitions
This chapter details all repair activities recommended for the controller.
It is made up of separate units, each detailing a specific repair activity, e.g. Removal or Refitting of a certain component in the controller. Each unit contains all information required to
perform the activity, e.g. spare parts numbers, required special tools and materials.
The chapter is divided into:
3HAC 16247-1
Remaining instructions
155
X1
X1
X1
X1
X2
X2
X2
X2
X1
X2
X3
Rectifier
A0
xx0200000103
Battery unit
Required equipment
Equipment, etc.
Note
Battery unit
3HAC 5393-2
To be replaced as a complete
unit
Standard toolkit
Removal, battery
unit
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supply to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will
be destroyed if subjected to it! Before handling, make sure you are connected to earth through
a special ESD wrist bracelet or similar.
156
3HAC 16247-1
Step Action
Note/Illustration
X1
X1
X2
X2
X1
X1
X2
X2
X2
X3
Rectifier
A0
xx0200000004
xx0200000005
Refitting, battery
unit
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supply to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will
be destroyed if subjected to it! Before handling, make sure you are connected to earth through
a special ESD wrist bracelet or similar.
Step Action
3HAC 16247-1
Note/Illustration
157
Location of I/O
and gateway units
The I/O and gateway units are located as shown in the figure below.
I/O-4
I/O-3
I/O-1
I/O-2
xx0200000009
I/O and gateway units located on the panel shutter on the left side of the cabinet.
Required equipment
Equipment, etc.
158
Note
3HAB 7229-1
DSQC 328
Analog I/O
3HNE 00554-1
DSQC 355
AD Combi I/O
3HAB 7230-1
DSQC 327
3HAB 7231-1
DSQC 320
3HAB 9669-1
DSQC 332
3HNE00025-1
DSQC 350
3HNE00006-1
DSQC 351
3HNE00009-1
DSQC 352
Standard toolkit
3HAC 15571-1
3HAC 16247-1
Removal
Step Action
Note/Illustration
1. Disconnect any connectors from the unit. The actual number of connectors vary
Note which connector goes where, to facil- depending on type of unit.
itate reassembly.
2. Lift the unit until the upper claw, that holds
the unit to the rail, is released. Use:
a screwdriver when replacing I/O
units (position 2a in the figure).
2a
3a
2b
3b
xx0200000010
Refitting
Step Action
Note/Illustration
1. Hook the unit back onto the mounting rail and snap it gently
in position.
2. Reconnect all connectors disconnected during removal.
3HAC 16247-1
159
Location of
bleeder resistor
The bleeder resistor is located behind the air outlet device, as shown in the figure below.
xx0200000007
Required equipment
Removal
Equipment, etc.
Bleeder resistor
3HAC 4560-5
Note
Step Action
Note/Illustration
160
3HAC 16247-1
Step Action
Note/Illustration
xx0200000015
3. Push down and pull out the bleeder resistor unit to release the bleeder resistor unit
from the enclosure. (see position 2 and 3
in the figure).
Refitting
Step Action
Note/Illustration
3HAC 16247-1
161
X1
X1
X1
X1
X2
X2
X2
X2
X1
X2
X3
Rectifier
A0
xx0200000105
Opening
Computer unit
Step Action
Note/Illustration
162
3HAC 16247-1
xx0200000018
3HAC 16247-1
163
Closing
Step Action
Note/Illustration
164
3HAC 16247-1
Location of mass
storage memory
The mass storage memory is located in the computer system, which is shown in the figure
below.
X1
X1
X1
X1
X2
X2
X2
X2
X1
X2
X3
Rectifier
A0
xx0200000105
Computer system
Required equipment
Equipment, etc.
3HAC 7519-2
Note
Removal
These procedures
include references to
the tools required.
The procedure below details how to remove the mass storage memory.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supply to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will
be destroyed if subjected to it! Before handling, make sure you are connected to earth through
a special ESD wrist bracelet or similar.
Step Action
Note/Illustration
3HAC 16247-1
165
Step Action
Note/Illustration
2. Open the cover on the right side of the computer system by unsnapping the two snaps
(item 1 in the figure).
xx0200000019
Refitting
The procedure below details how to refit the mass storage memory.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supply to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will
be destroyed if subjected to it! Before handling, make sure you are connected to earth through
a special ESD wrist bracelet or similar.
Step Action
Note/Illustration
1. Fit the mass storage memory in position and Art. no. is specified above!
secure it with its M4 attachment screw (item
1 in the figure)
1
xx0200000019
166
3HAC 16247-1
Step Action
Note/Illustration
3. Close the cover on the right side of the computer unit and secure it with the snaps (item
1 in the figure).
3HAC 16247-1
167
The internal cooling fan is located in the computer system, which is shown in the figure
below.
X1
X1
X1
X1
X2
X2
X2
X2
X1
X2
X3
A0
xx0200000105
Computer system
Required equipment
Equipment, etc.
Note
3HAC 6655-1
Removal
The procedure below details how to remove the internal cooling fan.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supply to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will
be destroyed if subjected to it! Before handling, make sure you are connected to earth through
a special ESD wrist bracelet or similar.
Step Action
Note/Illustration
168
3HAC 16247-1
Step Action
Note/Illustration
E
xx0200000020
Refitting
A: Upper fan
B: Lower fan
C: Locking tabs
D: Connector E5
E: Connector E6
The procedure below details how to refit the internal cooling fan.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supply to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will
be destroyed if subjected to it! Before handling, make sure you are connected to earth through
a special ESD wrist bracelet or similar.
3HAC 16247-1
169
Step Action
Note/Illustration
1. Tip the internal cooling fan with its top towards the cabinet wall and fit it into the hole (see the figure). Art. no.
specified above!
xx0200000021
A: Push direction
2. With the wall between the upper lock spring hooks, push See the figure above!
the fan unit up and in until the locking tab snaps to the
wall.
3. Reconnect the connector E5 or E6 respectively, depending on which fan was replaced.
4. Put the computer unit back in regular operation position. Detailed in "Putting the
computer in the service
position".
170
3HAC 16247-1
Location of drive
units and rectifier
The drive units and rectifier are located as shown in the figure below.
B
A
xx0200000007
Drive units
Required equipment
Equipment, etc.
Note
3HAB 8101-17
DSQC 545A
3HAB 8101-18
DSQC 546A
Removal
3HAC 16247-1
171
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will
be destroyed if subjected to it! Before handling, make sure you are connected to earth through
a special ESD wrist bracelet or similar.
Step Action
Note/Illustration
X1
X1
X1
X1
X2
X2
X2
X2
1
X1
2
X2
X3
X2
A0
Rectifier
xx0200000013
xx0200000014
Refitting
172
3HAC 16247-1
Step Action
Note/Illustration
1. Fit the unit into position and secure it with the spring.
3HAC 16247-1
Detailed in section
"Replacement of power
supply unit"
173
The system fan unit is located under the bleeder resistor unit, in the back of the controller as
shown in the figure below.
xx0200000007
Required equipment
Equipment, etc.
3HAC 15449-1
Removal
Note
These procedures
include references
to the tools required.
The procedure below details how to remove the system fan unit.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supply to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will
be destroyed if subjected to it! Before handling, make sure you are connected to earth through
a special ESD wrist bracelet or similar.
Step Action
174
Note/Illustration
Detailed in
"Replacement of bleeder resistor".
3HAC 16247-1
Step Action
Note/Illustration
A0
Rectifier
xx0200000008
Refitting
The procedure below details how to refit the system fan unit.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supply to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will
be destroyed if subjected to it! Before handling, make sure you are connected to earth through
a special ESD wrist bracelet or similar.
Step Action
Note/Illustration
1. Fit the system fan unit into position and secure it (see
position 2 in the figure above).
3HAC 16247-1
Detailed in section
"Replacement of bleeder
resistor".
175
Location of power
supply unit
xx0200000011
Required equipment
Equipment, etc.
Note
3HAB 4297-1
DSQC 506
Removal
These procedures
include references to
the tools required.
The procedure below details how to remove the power supply unit.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supply to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will
be destroyed if subjected to it! Before handling, make sure you are connected to earth through
a special ESD wrist bracelet or similar.
Step Action
Note/Illustration
1. Push the locking spring to the right to free the panel Shown in previous figure!
shutter, and Swing it out of the way.
176
3HAC 16247-1
Step Action
Note/Illustration
Refitting
The procedure below details how to refit the power supply unit.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supply to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will
be destroyed if subjected to it! Before handling, make sure you are connected to earth through
a special ESD wrist bracelet or similar.
Step Action
Note/Illustration
1. Fit the power supply unit into position onto its hooks and Art. no. is specified above!
secure it with the attachment screw (see position 2 in the
section Removal).
2. Reconnect all connectors disconnected during removal. See position 1 in figure.
3. Swing the panel shutter back in possition and secure it
with the locking spring.
3HAC 16247-1
177
Location of power
supply unit
The Peltier cooler power supply unit is located as shown in the figure below.
1
2
Cover
M5 screw
Required equipment
Equipment, etc.
3HAB 13398-1
Removal
Note
These procedures include
references to the tools
required.
The procedure below details how to remove the power supply unit.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will
be destroyed if subjected to it! Before handling, make sure you are connected to earth through
a special ESD wrist bracelet or similar.
Step Action
Note/Illustration
178
3HAC 16247-1
Step Action
Note/Illustration
Refitting
The procedure below details how to refit the power supply unit.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will
be destroyed if subjected to it! Before handling, make sure you are connected to earth through
a special ESD wrist bracelet or similar.
Step Action
Note/Illustration
3HAC 16247-1
179
180
3HAC 16247-1
3HAC 16247-1
181
182
Item Qty
Art. number
Description
Dimension/Note
3HAC 12812-2
Mechanical stop ax 1,
assembly
101
3HAC 12685-1
102
3HAC 10746-3
102
3HAC 10746-1
102
3HAC 10746-5
102
3HAC 10746-4
103
3HAC 8114-1
Wrist (175/2.55)
103
3HAC 8114-3
103
3HAC 8114-6
103
3HAC 8114-5
104
3HAC 14678-1
104
3HAC 16189-1
104
3HAC 17117-2
104
3HAC 17117-3
105
3HAC 10141-1
105
3HAC 13940-1
106
3HAC 14940-1
106
3HAC 16331-1
108
3HAC 13263-1
3HAC 16247-1
Item Qty
Art. number
Description
Dimension/Note
109
3HAC 13264-1
110
3HAC 13265-1
111
3HAC 12311-4
111
3HAC 12311-5
112
3HAC 12129-1
Cover plate
t=1,5 mm
112
3HAC 12129-1
Cover plate
t=1,5 mm
113
9ADA 618-56
M6x16
113
9ADA 618-56
M6x16
114
3HAC 13416-1
Protection cover
Shell size 16
Item
Qty
Art. number
Description
5.1
3HAC 12812-1
Mech stop
5.2
9ABA 142-92
Dimension
10x30
Item
Description
Dimension/Note
101.1
3HAC 13054-2
Base machining
101.2
3HAC 12684-1
101.3
3HAC 11732-2
Washer
T=3
101.4
18
3HAB 7700-5
101.5
3HAC 11529-1
101.6
3HAC 14453-1
101.7
3HAC 14453-2
Plug
101.8
3HAC 4428-2
Hose Clip
D=23-27
101.9
9ADA 618-56
M6x16
Base, machining,
3HAC 13054-2
Item
3HAC 16247-1
Qty
Art. number
Description
101.1.1 1
101.1.2 5
3HAC 4836-7
Protection plug
Dimension
16x12,3x9x7
183
Item
Frame incl ax 1
gearbox, 3HAC
12684-1
Art. number
Description
101.1.3 1
3HAC 1383-2
101.1.4 1
Item
Qty
Qty
Dimension
Art. number
Description
Dimension
101.2.1 1
3HAC 15866-1
Frame machining
101.2.2 1
3HAC 10828-8
RV 320C-224,26 assembly
101.2.3 24
3HAB 7700-73
101.2.4 24
M12x70
13x19x1,5
Item Qty
Art. number
Description
Note
102.1 1
3HAC 13350-1
Material set ax 4
102.2 1
3HAC 10139-1
102.3 1
3HAC 13351-2
Axis 3
102.4 1
3HAC 14753-1
5.1.4 Axis 3-4, (robot v. 225/2.55, 175/2.8, 125/3.2, 200/2.75), 3HAC 10746-1
184
Item Qty
Art. number
Description
Note
102.1 1
3HAC 13350-1
Material set ax 4
102.2 1
3HAC 10139-1
102.3 1
3HAC 13351-1
Axis 3
102.4 1
3HAC 14752-1
3HAC 16247-1
Item Qty
Art. number
Description
Note
102.1 1
3HAC 13350-1
Material set ax 4
102.2 1
3HAC 15859-1
102.3 1
3HAC 13351-2
Axis 3
102.4 1
3HAC 14753-1
Rot ac motor incl gearbox See Rot ac motor incl gearbox, 3HAC 14753-1 on page
188.
5.1.6 Axis 3-4, Foundry (robot v. 225/2.25, 175/2.8, 125/3.2, 200/2.75), 3HAC 10746-4
Item Qty
Art. number
Description
Note
102.1 1
3HAC 13350-1
Material set ax 4
102.2 1
3HAC 15859-1
102.3 1
3HAC 13351-1
Axis 3
102.4 1
3HAC 14752-1
Material set ax 4,
3HAC 13350-1
3HAC 16247-1
Item
Qty
Dimension/Note
102.1.1
102.1.3
9ADA 183-37
M8x25
102.1.4
9ADA 312-7
Plain washer
8,4x16x1,6
102.1.5
102.1.6
102.1.7
M8x65
102.1.8
12
9ADA 334-7
8,4x18x2
102.1.9
9ADA 267-7
Hexagon nut
M8
102.1.10 3
M10x110
102.1.11 3
9ADA 334-8
10,5x23x2,5
102.1.12 1
102.1.13 1
185
Item
Qty
Dimension/Note
102.1.14 1
102.1.15 2
M16x35
102.1.16 1
T=1
102.1.17 1
102.1.18 14
9ADA 618-56
M6x16
102.1.20 1
102.1.21 1
102.1.22 1
9ABA 135-45
170
102.1.23 2
2213 253-5
Ball bearing
170x215x22
102.1.24 1
2216 261-18
Sealing
170x200x15
102.1.25 1
2216 0086-4
Sealing (Nilos)
180x215x4
102.1.26 1
3HAB 4317-1
SEALING
102.1.27 1
3HAC 3774-7
Spacer ring
102.1.28 1
170x5
102.1.29 1
9ABA 107-56
10x20
Parallel pin
Wheel unit ax 4,
225 kg, 3HAC
12259-1
102.1.31 30 g
3HAB 3537-1
Bearing grease
102.1.32 1 ml
3HAB 7116-1
Locking liquid
102.1.33 1 ml
3HAB 7116-2
Locking liquid
102.1.34 1
Item
Qty
R 1/2
Art. number
Description
Dimension/Note
102.1.5.1 1
3HAC 11742-1
102.1.5.2 1
3HAC 12259-2
102.1.5.3 1
2126 2851-104
Lock nut
M20X1
102.1.5.4 1
2213 3802-11
40x68x19
102.1.5.5 1
3HAA 1001-129
102.1.5.6 1 ml
3HAB 7116-2
Locking liquid
186
Item
Qty
Art. number
Description
102.1.5.2.0
3HAC 12259-3
Pinion Z3 /4
102.1.5.2.0
3HAC 12259-4
Gear Z2 /4
Dimension
3HAC 16247-1
Damper axis 4,
3HAC 13564-1
Item
Description
102.1.12.2
Item
Description
102.1.17.1
3HAC 12149-3
102.1.17.2
3HAC 13564-2
Dimension
Dimension
Protection Cover
compl., 3HAC
1383-2
Qty
Art. number
Description
102.2.1 1
102.2.2 1
3HAC 1383-2
Note
See Protection Cover
compl., 3HAC 1383-2 on
page 187!
Item
Dimension
102.2.2.1
9ADA 624-69
M8x20
102.2.2.2
102.2.2.3
3HAC 1383-1
Protection Cover
102.2.2.4
3HAC 1383-3
Gasket
8x2
Axis 3, 3HAC
13351-2/1
3HAC 16247-1
Item
Qty
Art. number
Description
102.3.1
3HAC 10133-1
Axis 4 housing
102.3.2
102.3.3
24
3HAB 3409-71
M12x60
102.3.4
24
13x19x1,5
102.3.5
3HAC 14750-1
102.3.5
3HAC 14751-1
Dimension/Note
187
Item
Qty
Art. number
Description
Dimension/Note
102.3.6
3HAB 3409-50
M10x40
102.3.7
3HAB 4233-1
Washer
102.3.8
3HAC 16721-1
Magnetic plug
102.3.9
102.3.10 1
RV 410F-270, 176
assembly, 3HAC
10828-12
188
R 1/2
9ABA 142-92
10x30
Description
Dimension
Item
Qty
Art. number
102.3.2.1
102.3.2.2
3HAB 3772-68
O-ring
276 x 3,53
Item
Qty
Art. number
Description
102.3.5.1
3HAC 14673-6
Rotational ac motor M6
102.3.5.2
102.3.5.3
2152 2012-430
O-ring
89,5x3
102.3.5.4
9ADA 183-444
M8x130
102.3.5.5
3 ml
3HAB 7116-1
Locking liquid
Item
Qty
Art. number
Description
102.3.5.1
3HAC 14673-9
Rotational ac motor M6
102.3.5.2
102.3.5.3
2152 2012-430
O-ring
89,5x3
102.3.5.4
9ADA 183-444
M8x130
102.3.5.5
3 ml
3HAB 7116-1
Locking liquid
Item
Qty
Art. number
Description
102.4.1 1
3HAC 14673-7
Rotational ac motor M7
102.4.2 1
3HAC 12260-1
Pinion Z1 /4
102.4.3 0
2152 2012-430
O-ring
Dimension
Dimension
Dimension
89,5x3
3HAC 16247-1
Item
Qty
Art. number
Description
102.4.1 1
102.4.2 1
3HAC 12260-1
Pinion Z1 /4
102.4.3 0
2152 2012-430
O-ring
Dimension
89,5x3
Item
Qty
Dimension/Note
103.1
3HAC 8114-4
103.2
103.3
M16x80
103.4
3HAC 9744-1
103.5
Material set
Axis 6 complete
Item
Qty
Dimension/Note
103.1
3HAC 8114-4
103.2
See !
103.3
M16x80
103.4
See !
103.5
Material set
3HAC 16247-1
Item
Qty
Dimension/Note
103.1
3HAC 8114-4
103.2
Material set
189
Item
Qty
Dimension/Note
103.3
M16x80
103.4
103.5
5.1.10 Wrist Foundry (robot v. 225/2.55, 175/2.8, 125/3.2, 200/2.75) 3HAC 8114-5
Item
Qty
Dimension/Note
103.1
3HAC 8114-4
103.2
103.3
M16x80
103.4
103.5
Material set
Material set,
3HAC 8114-4
190
Item
Qty
103.1.1
3HAC 7956-1
103.1.2
103.1.3
103.1.4
9ADA 183-37
M8x25
103.1.5
9ADA 312-7
Plain washer
8,4x16x1,6
103.1.6
D=80 B=10
103.1.7
3HAC 4334-3
50x90x20
103.1.8
103.1.9
3HAB 7116-2
Locking liquid
103.1.10
16
9ADA 334-7
8,4x18x2
103.1.11
9ADA 267-7
Hexagon nut
M8
103.1.12
103.1.13
3HAB 7299-1
103.1.14
D=120, B=12
103.1.15
103.1.16
9ADA 183-39
M8x35
103.1.17
3HAB 4337-2
Damper axis 5
103.1.18
3HAC 9953-1
Dimension/Note
Sealing
M8x65
T=1,5
3HAC 16247-1
Support shaft
incl. bearing,
3HAC 7941-32
Interm.wheel unit/
5 225kg, 3HAC
7941-6
Item
Qty
Dimension/Note
103.1.19
R 1/2
103.1.21
27
9ADA 618-56
M6x16
103.1.22
9ADA 334-6
Plain washer
6,4x14x1,5
103.1.23
3HAB 7116-1
Locking liquid
103.1.24
103.1.25
6700
ml
103.1.26
3HAC 7941-6
103.1.27
3HAA 1001266
Screw
M16x60
103.1.28
103.1.29
3HAC 8081-8
103.1.30
3HAC 8081-3
Cable cover
103.1.31
103.1.32
2166 2055-3
Item
Description
103.1.15.1 1
3HAC 14731-1
Shaft
103.1.15.2 1
3HAB 3643-11
130x165x18
103.1.15.3 3
9ADA 618-56
M6x16
103.1.15.4 1 ml
3HAB 7116-1
Locking liquid
Description
Dimension
Dimension/Note
103.1.26.1 1
3HAC 7946-1
103.1.26.2 2
103.1.26.3 1
3HAC 7941-12
103.1.26.4 1
3HAC 13142-1
Washer
17x30x6
103.1.26.5 1
3HAC 7941-11
Locking Nut
103.1.26.6 1 ml
3HAB 7116-2
Locking liquid
Item
Qty
103.1.26.3.1 1
3HAC 16247-1
4,8x208
Art. number
Item
Qty
Dimension
191
Item
Qty
103.1.26.3.2 1
Axis 6 complete,
3HAC 9744-1/
16032-1
192
Item
Qty
Dimension
103.1.28.1 1
3HAC 7941-8
103.1.28.2 1
3HAB 4271-1
103.1.28.3 1
3HAB 6686-1
Support ring
103.1.28.4 1 ml
3HAB 7116-2
Locking liquid
110x150x20
Item
Qty
Art. number
103.2.1
103.2.2
3HAC 7941-1
103.2.3
89,5x3
Item
Qty
Art. number
Description
Dimension/Note
103.2.1
3HAC 1467310
103.2.2
3HAC 7941-1
103.2.3
Item
Qty
Art. number
Description
103.4.1
3HAC 9744-5
103.4.2
103.4.3
3HAC 9744-3
103.4.3
3HAC 16009-2
103.4.4
3HAC 14755-1
Description
Dimension
Dimension/Note
89,5x3
Dimension/Note
See RV 40E-81 assembly, 3HAC 10828-10 on
page 193!
3HAC 16247-1
Item
Qty
Art. number
Description
Dimension/Note
103.4.5
9ADA 312-7
Plain washer
8,4x16x1,6
103.4.6
9ADA 183-37
103.4.7
8,4x13x1,5
103.4.8
2522 122-1
Magnetic plug
R1/4
103.4.9
300 ml
3HAC 16843-1
103.4.10 1 ml
3HAB 7116-1
Locking liquid
103.4.11 1
3HAB 3772-65
O-ring
131x2
103.4.12 6
2152 0431-20
O-ring
15,5x1,5
103.4.13 1
3HAC 6862-2
Syncplate 175 kg
103.4.14 6
2121 2518-577
103.4.15 8
3HAB 7700-55
103.4.18 2
9ADA 618-32
103.4.20 1
3HAC 14263-1
Protection Cover
103.4.21 1
9ADA 624-69
M8x20
Item
Art. number
Description
Dimension
103.4.2.1 1
3HAC 10828-5
RV 40E, i=81
103.4.2.2 1
3HAB 3772-58
O-ring
Item
Qty
Art. number
Description
103.4.4.1
3HAC 14673-8
Rotational ac motor M8
103.4.4.2
103.4.4.3
2152 2012-430
O-ring
89,5x3
103.4.4.4
9ADA 183-20
M5x45
103.4.4.5
2 ml
3HAB 7116-1
Locking liquid
103.4.4.6
3HAC 12877-1
Gasket
Item
Qty
Art. number
Description
103.4.1
3HAC 13752-1
103.4.2
103.4.3
3HAC 16009-1
103.4.3
3HAC 11522-2
103.4.4
3HAC 14754-1
Qty
M4x8
151,99x3,53
Dimension
Axis 6 complete,
3HAC 13890-2/1
3HAC 16247-1
Dimension/Note
See RV 40E-81 assembly, 3HAC 10828-13 on
page 194!
193
Item
Qty
Art. number
Description
Dimension/Note
103.4.5
9ADA 312-7
Plain washer
8,4x16x1,6
103.4.6
9ADA 183-37
103.4.7
8,4x13x1,5
103.4.8
2522 122-1
Magnetic plug
R1/4
103.4.9
300 ml
3HAC 16843-1
103.4.10 1 ml
3HAB 7116-1
Locking liquid
103.4.11 1
3HAB 3772-64
O-ring
150,0x2,0
103.4.12 6
3HAB 3772-61
O-ring
13,1x1,6
103.4.13 1
3HAC 16862-1
Syncplate 175 kg
103.4.14 12
3HAB 7700-65
103.4.15 18
3HAB 7700-55
103.4.18 2
9ADA 618-32
103.4.20 1
3HAC 14263-1
Protection Cover
103.4.21 1
9ADA 624-69
M8x20
Item
Art. number
Description
Dimension
Qty
M4x8
103.4.2.1 1
103.4.2.2 1
3HAB 3772-57
Item
Qty
Art. number
Description
103.4.4.1
3HAC 14673-8
Rotational ac motor M8
103.4.4.2
3HAC 11173-3
Pinion RV 70F.125,8
103.4.4.3
2152 2012-430
O-ring
89,5x3
103.4.4.4
9ADA 183-415
M5x55
103.4.4.5
2 ml
3HAB 7116-1
Locking liquid
103.4.4.6
3HAC 12877-1
Gasket
O-ring
164,69x3,53
Dimension
Item
194
Qty
Art. number
Description
108.201 2
3HAC 17212-1
108.202 66
3HAB 7700-69
108.203 3
3HAC 12703-1
Washer axis3
Dimension/Note
M12x50
3HAC 16247-1
Item
Qty
Art. number
Description
Dimension/Note
108.204 33
13x19x1,5
108.206 12
3HAB 7700-69
M12x50
108.207 12
108.210 1
3HAC 14300-1
Cable protector
108.212 1
3HAC 11771-1
108.213 1
3HAC 13960-1
108.214 2
3HAC 12320-1
Damper axis 3
108.215 2
3HAC 12991-1
Damper axis 2
108.216 2
9ADA 624-65
M6x60
108.217 2
9ADA 334-7
8,4x18x2
108.218 2
9ADA 618-57
M6x20
108.220 2
3HAC 9953-1
T=1,5
108.222 1
3HAC 12719-1
T=1,5
108.223 2
9ADA 183-48
M10x16
108.224 1
3HAC 12844-1
Cable cover
108.225 14
9ADA 618-56
108.228 1
3HAC 3261-1
Cover
108.229 1
3HAC 15431-1
Cable protection
108.230 1
3HAC 14880-1
t=3
108.232 4
3HAC 16721-1
Magnetic plug
R 1/2
108.234 3
9ADA 618-56
M6x16
Art. number
Description
Dimension/Note
109.301 1
3HAC 17271-1
RV 410F-270,176 assembly
See RV 410F-270,176
assembly, 3HAC 172711 on page 197!
109.302 1
3HAC 16295-1
Cover, machining
109.302 1
3HAC 16829-1
Cover, machining
109.303 1
3HAC 14699-1
Friction washer
294x333x1,0
109.304 24
3HAB 3409-71
M12x60
109.305 24
13x19x1,5
109.306 1
3HAC 14749-1
109.307 1
3HAC 14751-1
109.307 1
3HAC 14750-1
109.308 8
3HAB 3409-50
M10x40
109.309 8
3HAB 4233-1
Washer
109.310 1
3HAC 12252-1
Bottom plate
13x19x1,5
t = 4 mm
M6x16
Item
3HAC 16247-1
Qty
T=3
195
Item
196
Qty
Art. number
Description
Dimension/Note
109.311 1
3HAC 14131-1
t=3 mm
109.312 1
3HAC 11774-3
Adapter, complete
109.313 1
3HAC 11769-1
109.314 1
3HAC 16295-3
Cover
109.315 29
9ADA 183-39
M8x35
109.316 29
9ADA 312-7
Plain washer
8,4x16x1,6
109.317 1
3HAB 3772-68
O-ring
276x3,53
109.318 1
3HAB 3772-69
O-ring
378x4
109.319 1
3HAB 3772-70
O-ring
340x3,5
109.320 1
3HAC 12671-5
109.321 1
3HAC 12671-6
109.322 1
3HAC 14024-1
Protection screw
109.324 24
9ADA 618-56
M6x16
109.325 3
9ADA 618-57
M6x20
109.326 1
3HAC 16014-1
109.327 1
3HAC 14692-3
109.328 1
3HAC 16831-1
Battery pack
34x102x63
109.329 1
3HAC 13151-1
Cable battery/SMB
L=35020
109.330 2
3HAC 11526-1
Stud screw
M6x150
109.332 1
3HAC 14791-3
109.334 4
9ADA 618-53
M6x8
109.335 1
3HAA 2166-23
VK-Cover
D=120, B=12
109.336 1
3HAC 13915-1
Attachment plate
109.337 2
3HAC 12625-1
Strap, Velcro
25x450
109.338 1
3HAC 14792-1
Bracket
T=3
109.339 1
3HAC 15619-1
109.344 1
3HAB 7116-1
Locking liquid
109.345 1
9ADA 298-4
109.346 1
3HAC 16035-1
109.347 1
3HAC 6499-1
109.348 4
9ADA 629-56
M6x16
109.349 2
9ADA 618-58
M6x25
109.350 1
3HAC 4813-1
109.351 10
9ADA 618-44
M6
M5x12
3HAC 16247-1
RV 410F-270,176
assembly, 3HAC
17271-1
Item
Description
109.301.1 1
109.301.2 2
3HAB 3772-68
Item
O-ring
276x3,53
Description
Dimension
109.306.1 1
3HAC 14673-6
Rotational ac motor M6
109.306.2 1
3HAC 11350-1
109.306.3 0
Item
Dimension
Description
89,5x3
Dimension
109.307.1 1
3HAC 14673-6
Rotational ac motor M6
109.307.2 1
109.307.3 0
2152 2012-430
O-ring
89,5x3
109.307.4 1
9ADA 183-444
M8x130
Locking liquid
Item
Description
Dimension
109.307.1 1
3HAC 14673-9
109.307.2 1
109.307.3 0
2152 2012-430
O-ring
89,5x3
109.307.4 1
9ADA 183-444
M8x130
Rotational ac motor M9
Locking liquid
Adapter, compl.,
3HAC 11774-3
3HAC 16247-1
Item
Qty
Art. number
Description
109.312.1
3HAC 11774-1
Adapter, machined
109.312.2
2152 2012-428
O-ring
109.312.3
1 ml
1234 0011-125
Acrylate adhesive
Dimension
79,5x3
197
Protection screw,
3HAC 14024-1
Item
Cover battery
box, 3HAC 147913
Qty
Art. number
Description
109.322.1 1
3HAC 13582-1
Protection Screw
109.322.2 1
3HAB 3772-32
O-ring
Item
Art. number
Description
109.327.1 1
3HAC 14692-1
Cover, casting
109.327.2 1
3HAC 14692-2
Gasket
109.327.3 1
3HAC 14692-4
Rubber cloth
Item
Art. number
Description
Dimension
109.332.1 1
3HAC 14791-1
Cover
T=4
109.332.2 1
3HAC 14791-2
Gasket
T=3
109.332.3 1
3HAC 16977-1
Qty
Qty
Dimension
17x3
Dimension
198
Item
Qty
Art. number
Description
Dimension
110.401
3HAC 12441-2
65x120x38
110.402
3HAC 12481-1
Thrust washer
110.403
3HAC 12627-1
Bushing
110.404
9ABA 135-31
110.405
3HAC 12480-1
Shaft
110.406
3HAC 4836-7
Protection plug
16x12,3x9x7
110.407
3HAB 7700-5
M16x70
110.408
9ABA 107-56
Parallel pin
10x20
110.409
3HAC 12548-1
Protection washer
T=1
110.410
3HAC 12534-1
110.411
3HAA 1001-186
Washer
110.412
50 ml
3HAA 1001-294
Grease
110.413
3HAC 4836-1
Protection plug
20x14,6x7,5x5,5
110.414
9ADA 183-490
M16x180
110.415
9ADA 312-10
Plain washer
17x30x3
65
17x25x3
3HAC 16247-1
Item
Qty
Art. number
Description
Dimension
111.501 1
3HAC 9760-3
111.501 1
3HAC 15859-2
111.503 12
3HAB 7700-69
111.504 12
13x19x1,5
111.505 1
9ABA 107-56
Parallel pin
10x20
111.506 1
3HAC 9760-9
111.507 4
9ADA 618-56
M12x50
M6x16
Item
3HAC 16247-1
Description
Dimension
111.501 1
3HAC 9760-7
111.501 1
3HAC 15859-3
111.503 12
3HAB 7700-69
111.504 12
13x19x1,5
111.505 1
9ABA 107-56
Parallel pin
10x20
111.506 1
3HAC 9760-10
111.507 6
9ADA 618-56
M12x50
M6x16
199
200
3HAC 16247-1
6 Appendix 2: Foldouts
6.0.1 Introduction
Definitions
This chapter is an appendix to the manual and contains detailed views of the components on
the manipulator.
The numbered details are specified with item numbers in the Appendix 1: Part List.
The foldouts are divided into:
3HAC 16247-1
Frame-Lower arm 1
Frame-Lower arm 2
Upper arm
Wrist complete
201
6 Appendix 2: Foldouts
6.0.1 Introduction
202
3HAC 16247-1
6 Appendix 2: Foldouts
6.0.2 Base incl. Frame
101.2.1
101.2.2
101.1
101.5
101.9
101.2.4
101.2.3
101.3
101.4
xx0200000329
3HAC 16247-1
203
6 Appendix 2: Foldouts
6.0.2 Base incl. Frame
204
3HAC 16247-1
6 Appendix 2: Foldouts
6.0.3 Frame-Lower arm 1
6.1
.30
109
6.3
.30
109
6.2
.30
109 .303
109
1.1
.30
109
5
.30
109
4
.30
109
8
.31
109
302
109. 15
3
109. 6
9
31
109.
.31
109
4
.31
109 317
.
109 32
.2
108
7.1
.30 3
109 .307.
109 .308
109 .309
109
xx0200000334
3HAC 16247-1
205
6 Appendix 2: Foldouts
6.0.3 Frame-Lower arm 1
206
3HAC 16247-1
6 Appendix 2: Foldouts
6.0.4 Frame-Lower arm 2
40
0.
4
40
0.
11 1
40
0.
2
11
11
108.201, 108.204
110.410
110.414
110.415
11
0.
40
3
11
0.
40
108.202
xx0200000335
3HAC 16247-1
207
6 Appendix 2: Foldouts
6.0.4 Frame-Lower arm 2
208
3HAC 16247-1
6 Appendix 2: Foldouts
6.0.5 Upper arm
.1
02
5
.5.
xx0200000337
3HAC 16247-1
209
6 Appendix 2: Foldouts
6.0.5 Upper arm
210
3HAC 16247-1
6 Appendix 2: Foldouts
6.0.6 Wrist complete
xx0200000336
3HAC 16247-1
211
6 Appendix 2: Foldouts
6.0.6 Wrist complete
212
3HAC 16247-1
Maintenance Manual
Industrial Robot
IRB 6600 - 225/2.55
IRB 6600 - 175/2.8
IRB 6600 - 175/2.55
IRB 6650 - 200/2.75
IRB 6650 - 125/3.2
M2000A
Table of Contents
0.0.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
0.0.2 Product Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Chapter 1: Safety, service
1.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Section 1.1: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
13
23
37
3HAC 16246-1
Table of Contents
43
5.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Section 5.1: Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
93
6.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Section 6.1: Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
ii
3HAC 16246-1
0.0.1 Overview
0.0.1 Overview
About This
Manual
This information product is a manual containing instructions for maintenance of the complete
robot system, mechanically as well as electrically.
Usage
Prerequisites
Organization of
Chapters
Chapter
Contents
Safety, service
Reference information
Maintenance Schedules
Maintenance activities
References
Reference
Document Id
3HAC 13347-1
3HAC 5582-2
Revisions
Revision
Description
First edition
3HAC 16246-1
Various corrections in text and in figures due to reconstructions, new spare part numbers, new tools, etc.
Manual completed with references to pagenumbers and numbering of sections (manipulator sections).
0.0.1 Overview
3HAC 16246-1
General
The complete product documentation kit for the robot, including controller, manipulator and
any hardware option, consists of the manuals listed below:
Installation and
Commissioning
Manual
Repair Manual
Maintenance
Manual
Safety, Service
Reference Information
Unpacking
On-site Installation
Electrical connections
Start-up
Calibration
Safety, Service
Reference Information
Remove/Refitting instructions for all controller cabinet details considered spare parts
Safety, Service
Reference Information
Maintenance schedules
Instructions for all maintenance activities specified in the maintenance schedule, for
example cleaning, lubrication, inspection etc.
The information is generally divided into separate chapters for the manipulator and the controller, respectively.
Software manuals
The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during operation.
A complete listing of all available software manuals is available from ABB Robotics.
3HAC 16246-1
Hardware option
manual
Each hardware option is supplied with its own documentation. Each document set contains
the types of information specified above:
Installation information
Repair information
Maintenance information
3HAC 16246-1
1 Safety, service
1.0.1 Introduction
Definitions
This chapter details safety information for service personnel i.e. personnel performing installation, repair and maintenance work.
Sections
2. Safety risks lists dangers relevant when servicing the robot system. The dangers are split into different categories:
Safety risks related to gripper/end effector
Safety risks related to tools/workpieces
Safety risks related to pneumatic/hydraulic systems
Safety risks during operational disturbances
Safety risks during installation and service
Risks associated with live electric parts
3. Safety actions details actions which may be taken to remedy or avoid dangers.
Safety fence dimensions
Fire extinguishing
Emergency release of the manipulators arm
Brake testing
Risk of disabling function "Reduced speed 250 mm/s"
Safe use of the Teach Pendant Unit enabling device
Work inside the manipulators working range
3HAC 16246-1
1 Safety, service
1.1.1 Safety, service - General
Validity and
responsibility
The information does not cover how to design, install and operate a complete system, nor
does it cover all peripheral equipment, which can influence the safety of the total system. To
protect personnel, the complete system must be designed and installed in accordance with the
safety requirements set forth in the standards and regulations of the country where the robot
is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable safety laws
and regulations in the country concerned are observed and that the safety devices necessary
to protect people working with the robot system have been designed and installed correctly.
Personnel working with robots must be familiar with the operation and handling of the industrial robot, described in the applicable documents, e.g. Users Guide and Product Manual.
Connection of
external safety
devices
Apart from the built-in safety functions, the robot is also supplied with an interface for the
connection of external safety devices. Via this interface, an external safety function can interact with other machines and peripheral equipment. This means that control signals can act on
safety signals received from the peripheral equipment as well as from the robot.
In the Product Manual - Installation and Commissioning, instructions are provided for connecting safety devices between the robot and the peripheral equipment.
General
Any information given in this information product 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.
General
Documents
Type of information
Detailed in document
Users Guide
Section
Start-up
On-site installation Manipulator
3HAC 16246-1
1 Safety, service
1.2.1 Safety risks related to gripper
Safe handling
It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that guards
remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
Grippers/end effectors must be designed so that they retain workpieces in the event of a power
failure or a disturbance of the controller.
General
Residual energy
Safe design
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.
Shot bolts should be used to prevent tools, etc., from falling due to gravity.
General
Qualified personnel
Extraordinary
risks
3HAC 16246-1
The industrial robot is a flexible tool which can be used in many different industrial
applications.
All work must be carried out professionally and in accordance with the applicable
safety regulations.
Remedial action must only be carried out by qualified personnel who are familiar with
the entire installation as well as the special risks associated with its different parts.
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.
1 Safety, service
1.2.5 Safety risks during installation and service
Nation/region
specific regulations
Non-voltage
related risks
To be observed
by the supplier of
the complete system
The instructions in the Product Manual - Installation and Commissioning must always
be followed.
Emergency stop buttons must be positioned in easily accessible places so that the
robot can be stopped quickly.
Those in charge of operations must make sure that safety instructions are available
for the installation in question.
Those who install the robot must have the appropriate training for the robot system in
question and in any safety matters associated with it.
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.
Safety zones, which have to be crossed before admittance, must be set up in front of
the robot's working space. Light beams or sensitive mats are suitable devices.
Turntables or the like should be used to keep the operator out of the robot's working
space.
The axes are affected by the force of gravity when the brakes are released. In addition
to the risk of being hit by moving robot parts, you run the risk of being crushed by the
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.
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 temperature of the motors or oil spills that can occur on the robot.
The supplier of the complete system must ensure that all circuits used in the safety
function are interlocked in accordance with the applicable standards for that function.
The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner, in accordance with the applicable standards for the emergency stop function.
Voltage related
risks, general
Voltage related
risks, controller
Although troubleshooting may, on occasion, have to be carried out while the power
supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
The mains supply to the robot must be connected in such a way that it can be turned
off outside the robots working space.
3HAC 16246-1
1 Safety, service
1.2.6 Risks associated with live electric parts
Units inside the controller, e.g. I/O modules, can be supplied with power from an external source.
The power supply unit for the computer system (230 VAC)
The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
The power supply unit for tools, or special power supply units for the machining process
The external voltage connected to the control cabinet remains live even when the
robot is disconnected from the mains.
Additional connections
Voltage related
risks, manipulator
Voltage related
risks, tools, material handling
devices, etc
Tools, material handling devices, etc., may be live even if the robot system is in the OFF
position. Power supply cables which are in motion during the working process may be damaged.
3HAC 16246-1
The user connections for tools or other parts of the installation (max. 230 VAC, see
Installation and Commissioning Manual)
1 Safety, service
1.3.1 Safety fence dimensions
General
Fit a safety fence or enclosure around the robot to ensure a safe robot installation.
Dimensioning
Dimension the fence or enclosure to enable it to withstand the force created if the load being
handled by the robot is dropped or released at maximum speed. Determine the maximum
speed from the maximum velocities of the robot axes and from the position at which the robot
is working in the work cell (see Product Specification - Description, Robot Motion).
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating
tool or other device fitted to the manipulator.
Description
In an emergency situation, any of the manipulators axes may be released manually by pushing the brake release buttons on the manipulator or on an optional external brake release unit.
How to release the brakes is detailed in section "Manually releasing the brakes".
The manipulator 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, which may further increase any injury!
When to test
During operation the holding brakes of each axis motor wear normally. A test may be performed to determine whether the brake can still perform its function.
How to test
The function of each axis motor holding brakes may be checked as detailed below:
1. Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized (max. static load).
2. Switch the motor to the MOTORS OFF position with the Operating mode selector
on the controller.
3. Check that the axis maintains its position.
If the manipulator does not change position as the motors are switched off, then the brake
function is adequate.
10
3HAC 16246-1
1 Safety, service
1.3.5 Risk of disabling function "Reduced speed 250 mm/s"
3HAC 16246-1
11
1 Safety, service
1.3.7 Work inside the manipulators working range
12
3HAC 16246-1
2 Reference information
2.0.1 Introduction
General
3HAC 16246-1
This chapter presents generic pieces of information, complementing the more specific information in the following chapters.
13
2 Reference information
2.1.1 Applicable Safety Standards
Standards,
general
Standards,
robot cell
14
The following standards are applicable when the robot is part of a robot cell:
EN 811 - Safety distances to prevent danger zones being reached by the lower limbs.
EN 294 - Safety distances to prevent danger zones being reached by the upper limbs.
3HAC 16246-1
2 Reference information
2.1.2 Screw joints
General
This section details how to tighten the various types of screw joints on the manipulator as well
as the controller.
The instructions and torque values are valid for screw joints comprising metallic materials
and do not apply to soft or brittle materials.
Any instructions given in the repair, maintenance or installation procedure description override any value or procedure given here, i.e. these instruction are only valid for standard type
screw joints.
UNBRAKO
screws
UNBRAKO is a special type of screw recommended by ABB in certain screw joints. It features special surface treatment (Gleitmo as described below), and is extremely resistant to
fatigue.
Whenever used, this is specified in the instructions and in such cases no other type of replacement screw is allowed. Using other types of screw will void any warranty and may potentially
cause serious damage or injury!
Gleitmo treated
screws
Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.
Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this
the screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should
be used.
Screws lubricated
in other ways
Screws lubricated with Molycote 1000 (or another lubricant) should only be used when specified in the repair, maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1. Lubricate the thread of the screw.
2. Lubricate between the plain washer and screw head.
3. Tighten to the torque specified in section "Tightening torque" below. Screw dimensions
of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or
smaller may be tightened without a torque wrench if this is done by trained and qualified personnel.
Tightening torque
3HAC 16246-1
Lubricant
Art. no.
1171 2016-618
Below are tables specifying the torque values for different screw joint types:
15
2 Reference information
2.1.2 Screw joints
Screws with
slotted or cross
recess head
Dimension
M2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
Dimension
Tightening torque
(Nm)
Class 8.8 "dry"
Tightening torque
(Nm)
Class 10.9 "dry"
Tightening torque
(Nm)
Class 12.9 "dry"
M5
M6
10
M8
24
34
40
M10
47
67
80
M12
82
115
140
M16
200
290
340
Dimension
M8
28
34
M10
55
66
M12
96
115
M16
235
280
Screws with
hexagon socket
head, dry
Screws with
hexagon socket
head, lubricated
16
3HAC 16246-1
2 Reference information
2.1.3 Weight specifications
Definition
In all repair and maintenance instructions, weights of the components handled are sometimes
specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.
ABB recommends the use of lifting equipment when handling components with a weight
exceeding 22 kg to avoid inflicting injury. A wide range of lifting tools and devices is available for each manipulator model.
Example
3HAC 16246-1
17
2 Reference information
2.1.4 Standard toolkit
General
All service (repairs, maintenance and installation) instructions contain lists of tools required
to perform the specified activity.
All special tools required are listed directly in the instructions while all the tools that are
considered standard are gathered in the Standard toolkit and defined in the table below.
In this way, the tools required are the sum of the Standard Toolkit and any tools listed in the
instruction.
Contents,
standard toolkit,
3HAC 15571-1
18
Qty
Art. no.
Tool
Rem.
3HAC 16246-1
2 Reference information
2.1.5 Special tools, IRB 6600/6650/7600
General
All service (repairs, maintenance and installation) instructions contain lists of tools required
to perform the specified activity. The required tools are a sum of standard tools, defined in
section Standard toolkit on page 18, and of special tools, listed directly in the instructions and
also gathered in the table below.
The table below is an overview of all the special tools required when performing service
activities on the IRB 6600/6650/7600. The tools are gathered in two kits: Basic Toolkit
(3HAC 15571-3) and Extended Toolkit (3HAC 15571-2).
The special tools are also listed directly in the current instructions.
3HAC 16246-1
Description
Angel bracket
68080011-LP
3HAB 3409-86
3HAB 3409-89
Cal. tool
68080011-GM
Calibration bracket
3HAC 13908-9
3HAC 13908-4
3HAC 15716-1
3HAC 12342-1
3HAC 13659-1
3HAC 13660-1
Gearbox crank
3HAC 16488-1
3HAC 13056-2
3HAC 13056-3
3HAC 13056-4
3HAC 15520-1
3HAC 15520-2
3HAC 14445-1
3HAC 14446-1
3HAC 15521-1
3HAC 15521-2
3HAC 13120-2
3HAC 13120-3
3HAC 13120-4
3HAC 13120-5
3HAC 14628-2
3HAC 14628-1
3HAC 14627-3
3HAC 14627-2
Hydraulic cylinder
3HAC 11731-1
19
2 Reference information
2.1.5 Special tools, IRB 6600/6650/7600
Description
3HAC 13086-1
3HAC 13086-2
6369901-348
3HAC 15560-1
3HAC 15607-1
3HAC 15994-1
3HAC 15536-1
3HAC 16131-1
3HAC 14457-3
3HAC 14457-4
3HAC 15556-1
3HAC 13698-1
3HAC 12731-1
3HAC 14691-1
3HAC 14459-1
3HAC 15534-1
3HAC 13605-1
3HAC 12734-1
Measuring pin
3HAC 13908-5
Mech stop ax 3
3HAC 12708-1
Mech stop ax 3
3HAC 12708-2
3HAC 13527-1
3HAC 13453-1
3HAC 13452-1
3HAC 17129-1
3HAC 15767-1
3HAC 12475-1
3HAC 15814-1
3HAC 14972-1
3HAC 14631-1
3HAC 14973-1
Rotation tool
3HAC 17105-1
Sensor plate
3HAC 0392-1
Support, base
3HAC 15535-1
Sync. adapter
3HAC 13908-1
3HAC 15943-2
3HAC 15943-1
3HAC 68080011-GU
3HAA 1001-186
Note a) Calibration tools for IRB 6600/6650/7600 when CalPen is not used (standard).
Note b) Special tools that may be rent from ATRP/S.
20
3HAC 16246-1
2 Reference information
2.1.6 Performing a leak-down test
General
After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil
must be tested. This is done in a leak-down test.
Required equipment
Equipment, etc.
Leakdown tester
Note
3HAC 0207-1
Procedure
Step
3HAC 16246-1
Action
Note/Illustration
1.
2.
Remove the topmost oil plug on the gear in question, Art. no. specified above!
and replace it with the leakdown tester .
Adapters may be required, which are included in the
leakdown tester kit.
3.
4.
5.
6.
7.
8.
When the leak has been localized: take the necessary measures to correct the leak.
21
2 Reference information
2.1.7 Lifting equipment and lifting instructions
General
Many repair and maintenance activities require different pieces of lifting equipment, which
are specified in each activity instruction.
However, how to use each piece of lifting equipment is not detailed in the activity instruction,
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.
22
3HAC 16246-1
General
This is a brief description of how to use the Service Information System, SIS. Details may be
found in:
Basic procedure
Step
3HAC 16246-1
Action
Reference
1.
2.
3.
4.
5.
6.
When a time limit, set in the parameters, How to access this is detailed in Reading
is exceeded, a message may be read on the SIS output logs on page 35.
the Tech Pendant Unit (TPU).
7.
If the log containing the message is to be These are described in Exporting the SIS
available from an external PC, or if the
data on page 36.
SIS parameters are to be entered from
an external PC, a set of software tools
are available to build such an application.
23
General
Service Information System (SIS) is a software function within the robot controller, which
simplifies maintenance of the robot system. It supervises the operating time and mode of the
robot, and alerts the operator when a maintenance activity is scheduled.
Supervised functions
Gearbox 1 operation time counter, based on percentage of the axis 1 gearbox service
interval
Gearbox 2 operation time counter, based on percentage of the axis 2 gearbox service
interval
Gearbox 3 operation time counter, based on percentage of the axis 3 gearbox service
interval
Gearbox 6 operation time counter, based on percentage of the axis 6 gearbox service
interval
xx0200000034
x OK
24
"OK" indicates that no service interval limit has been exceeded by that counter.
If any such limit was exceeded, the counter name would be followed by "NOK".
3HAC 16246-1
Calendar time
This is a clock within the control system that enables you to set a specific service interval,
based on calendar time:
xx0200000035
After this time, a message is accessible on the Tech Pendant Unit (TPU). How to access this
is detailed in section Reading the SIS output logs on page 35.
Operation time
Prev service
Date when the counter was reset last time, i.e. after the last service. This
date was entered manually as detailed in section Setting the SIS parameters on page 33.
Elapsed time
Elapsed time since the counter was reset the last time.
Next service
Date when next scheduled service is planned. This date is entered manually as detailed in section Setting the SIS parameters on page 33.
Remaining time
This is a function within the control system that counts the amount of time the "MOTORS
ON" signal is active, i.e. the amount of time the robot is in the operational mode.
xx0200000036
After this time, a message is accessible on the Teach Pendant Unit (TPU). How to access this
is detailed in section Reading the SIS output logs on page 35.
3HAC 16246-1
Service interval
The specified service interval until another service will be required. This
parameter was entered manually as detailed in section Setting the SIS
parameters on page 33.
Elapsed time
Operation time since the service interval was set the last time.
Remaining time
Remaining operation time until the time set in service interval has
expired.
25
Gearbox
Based on measurements, torque and RPM, for example, the system calculates an expected
service interval for each gearbox. When service is due, a message will be shown on the TPU.
How to access this is detailed in section Reading the SIS output logs on page 35.
en0200000037
Axis x OK
Service status for axis x, i.e. the automatically calculated time parameter
has not been exceeded.
Axis x NOK
The service interval for the axis in question has been reached.
Axis x N/A
en0200000038
This example shows the window for axis 1, but is also valid for the other axes.
26
Consumed time
Elapsed time
Remaining time
Remaining operation time for axis x until the service time parameter
value has been reached.
3HAC 16246-1
Reset values
en0200000040
Yes
No
Does not reset the counter, but returns to the previous menu.
en0200000041
3HAC 16246-1
Yes
No
Does not reset the counter, but returns to the previous menu.
27
en0200000039
Service interval
exceeded
Yes
No
Does not reset the counter, but returns to the previous menu.
When the service time has been exceeded for the selection made, a message (Service interval
exceeded!) is displayed below the data of the counter in question:
en0200000044
This window may be shown for any time mode; calendar time, operation time or gearbox
time.
In addition to this view, an error message is also displayed on the TPU when the service
interval is exceeded!
28
3HAC 16246-1
No data available
When no data is available for the selection made, a message (No data available!) is displayed
below the function in question:
en0200000043
This window may be shown for any time mode; calendar time, operation time or gearbox
time.
Exit
en0200000042
3HAC 16246-1
Yes
No
29
General
This section details the parameters that may be set with estimated values. The values can be
defined by the operating organization as knowledge of the robots working conditions are
accumulated.
Since the counters are to be used for purposes defined by the user, ABB cannot give any
recommendations regarding their definitions.
The figure below shows the options of parameters to be set.
en0200000049
Operation time
limit (service
level)
en0200000054
30
3HAC 16246-1
Operation time
warning
en0200000053
Calendar time
limit (service
level)
en0200000050
Calendar time
warning
en0200000051
3HAC 16246-1
31
Gearbox warning
other variables
en0200000052
32
3HAC 16246-1
General
If the SIS system is to function properly, a number of parameters must be set. How to do this
is detailed below.
Procedure
Step
Action
Rem.
1.
2.
Go to "System parameters/Manipulator/
types 2".
xx0200000045
en0200000046
3.
en0200000047
xx0100000200
3HAC 16246-1
33
Step
4.
Action
Rem.
en0200000048
en0200000049
5.
34
3HAC 16246-1
General
Whenever a set condition has expired (e.g. max allowed operation time before service), a
message to this effect will be shown in the Operational log.
Access to logs
How to open any log and show its contents is detailed in the "Users Guide", chapter "Service".
Available messages
Available in:
3HAC 16246-1
SIS message in
Operational log
Meaning
Calendar time
Service Message
Service is due!
X calendar days since
last service.
Calendar time
Service Message
X calendar days to
next service.
X number of calendar days remain until the manually set calendar time limit expires.
How to set the value determining when the message is to be shown, is detailed in section Setting
the SIS parameters on page 33.
Operation time
Service Message
Service is due!
X production hours
since last service.
Operation time
Service Message
X production hours to
next service.
X number of operation hours remain until the manually set operation time limit expires.
How to set the value determining when the message is to be shown, is detailed in section Setting
the SIS parameters on page 33.
Gearbox time
Service Message
Gearbox x requires
service!
Gearbox time
Service Message
X% of the service interval has expired for
gearbox x!
X percent of gearbox hours remain until the automatically calculated gearbox time limit expires.
How to set the value determining when the message is to be shown, is detailed in section Setting
the SIS parameters on page 33.
35
General
This section describes the available variables for entering SIS parameters as well as showing
any messages of exceeded time limits as detected by the SIS counters on an external PC using
"Webware SDK".
How to access these variables and how to perform the actual programming sequences are
detailed in the robot system Users Guide.
Definitions
36
The table below defines the names and functions of all software variables available for communication between the SIS and an external computer.
Signal
Unit
Counter
type
sisRestartDate
sec
Calendar time
sisCalendarT
sec
Calendar time
sisTotRunT
sec
Operation time Total number of operation seconds since the system was started. Corresponds to the operating
time counter on the control cabinet.
sisRunT
sec
sisL10h_1
hrs
Gearbox time
sisL10h_Time_1 sec
Gearbox time
sisL10h_2
hrs
Gearbox time
sisL10h_Time_2 sec
Gearbox time
sisL10h_3
hrs
Gearbox time
sisL10h_Time_3 sec
Gearbox time
sisL10h_6
hrs
Gearbox time
sisL10h_Time_6 sec
Gearbox time
Function
3HAC 16246-1
Description
3HAC 16246-1
The intervals may be specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the robot:
Calendar time: specified in months regardless of whether the robot system is run or
not.
Operating time: specified in operating hours. More frequent running of the robot
means more frequent maintenance activities.
SIS: specified by the robot's Service Information System (SIS). How to access this
information is detailed in section "Access to SIS information". A typical value is given
for a typical work cycle, but the value will differ depending on how hard each part is
run.
37
General
The robot, consisting of manipulator and controller cabinet, must be maintained regularly to
ensure its function. The maintenance activities and their respective intervals are specified in
the table below.
Non-predictable situations also give rise to inspections of the robot. If damage is discovered,
attend to it immediately!
The inspection intervals do not specify the life of each component. Values for these are specified in Expected component life, IRB 6600 on page 41.
Activities and
intervals, standard equipment
38
The section referred to in the table can be found in the different chapters for every maintenance activity.
The table below specifies the required maintenance activities and intervals:
Maintenance
Equipment
activity
Interval
Note
Inspection
12 mths
Inspection
12 mths
Inspection
12 mths
Inspection
12 mths
Inspection
12 mths
Inspection
12 mths
Inspection
"Inspection, balancing
device"
Inspection
Inspection
Information
labels
Inspection
"Inspection damper,
axes 2-5"
Inspection
Changing
48 mths
Changing
48 mths
Changing
48 mths
Changing
48 mths
Changing
48 mths
12 mths
Detailed in section
3HAC 16246-1
Maintenance
Equipment
activity
Interval
Note
Changing
48 mths
Replacement
As specified by the
SIS, or typically 96
mths
Replacement
As specified by the
SIS, or typically 96
mths
Replacement
As specified by the
SIS, or typically 96
mths
Replacement
Axis 4 gear
96 mths 2
"Remove/Refit, upper
arm without wrist unit"
in Repair Manual
Replacement
Axis 5 gear
96 mths 2
Replacement
Axis 6 gear
As specified by the
SIS, or typically 96
mths
Replacement
"Remove/Refit, cable
harness" in Repair
Manual
Replacement
SMB Battery
pack
"Removal/Refitting of
SMB related equipment" in Repair Manual
Lubrication
36 mths
Detailed in section
"Lubrication, balancing
device bearing"
1)
If the robot is run at temperatures higher than 50 C, the manipulator may require maintenance more frequently.
2) The service time for gearboxes, axes 4 and 5, is not calculated by the SIS, see expected life
in section Expected component life, IRB 6600 on page 41.
3)
Replace when damage is detected or when approaching life limit as specified in Expected
component life, IRB 6600 on page 41.
4)
The interval is the same as the interval for changing axis 2 gear oil because of the similarity
of the type and degree of operation.
Activities and
intervals, optional
equipment
3HAC 16246-1
The table below specifies the required maintenance activities and intervals for common
optional equipment. Maintenance of other external equipment for the robot is detailed in separate documentation.
39
Maintenance
Equipment
activity
40
Interval Note
Inspection
UL-lamp
Inspection
Mechanical stop
axes 1-3
12 mths
Inspection
Position switches,
axes 1-3
12 mths
Detailed in
section
"Inspection, ULlamp"
3HAC 16246-1
General
The expected life of a component can vary greatly depending on how hard it is run
Expected life
Component
Expected life
Note
Manipulator harness
2,000,000 cycles
See note 1)
2,000,000 cycles
See note 1)
Balancing device
2,000,000 cycles
See note 2)
Gearbox
40,000h
See note 3)
1)
The expected life can also be affected by assemblage of cabling other than standard options.
The given life is based on a test cycle that for every axis starts from the calibration position
to minimum angle to maximum angle and back to the calibration position. Deviations from
this cycle will result in differences in expected life!
2)
The given life for the balancing device is based on a test cycle that starts from the initial
position and goes to maximum extension, and back. Deviations from this cycle will result in
differences in expected life!
3)
The robot is dimensioned for a life of 8 years (350,000 cycles per year) in a normal spot
welding application. Depending on the actual application, the life of individual gearboxes
may vary greatly from this specification. The SIS (Service Information System) integrated in
the robot software, keeps track of the gearbox life in each individual case and will notify the
user when a service is due. The SIS is described in "SIS, Service Information System".
3HAC 16246-1
41
General
The robot controller must be maintained at regular intervals to ensure its function. The maintenance activities and their respective intervals are specified in the table below:
Intervals
Maintenance
Equipment
activity
Interval
Detailed in section
Inspection
Controller cabinet
6 mths
Cleaning
Controller cabinet
Replacement
Battery unit
12 000 h/36
mths 1
Replacement
60 mths
1)
42
Hours denote operational time while months denote the actual calender time.
3HAC 16246-1
General
3HAC 16246-1
This chapter contains information on how to maintain the equipment in question, i.e. how to
perform the preventive maintenance activities specified in the maintenance schedule for the
same equipment.
43
Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure below.
C
D
A
xx0200000228
Gearbox axis 1
Motor, axis 1
Required equipment
Equipment
Lubricating oil
3HAC 16843-1
Standard toolkit
3HAC 15571-1
44
Note
3HAC 16246-1
Inspection, oil
level gearbox
The procedure below details how to inspect the oil level in gearbox axis 1.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!
Step
3HAC 16246-1
Action
Note/Illustration
1.
2.
3.
4.
45
Different designs
Between the axis 2 motor and gearbox there is a motor attachment which exists in two different designs.
The early design of the motor attachment is attached directly to the gearbox, with the
front gearbox attachment screws.
The later design of the motor attachment is attached directly to the frame. This design
also includes an additional cover that overlaps the motor attachment and holds the oil
plugs.
The correct oil level varies, depending on the design of the motor attachment.
Location of gearbox
The gearbox, axis 2, is located in the lower arm rotational center, underneath the motor attachment.
The figure below shows the later design of the motor attachment.
A
D
B
xx0200000229
Required equipment
Equipment etc.
Lubricating oil
46
Note
3HAC 16246-1
Equipment etc.
Standard toolkit
Inspection, oil
level
Note
The procedure below details how to inspect the oil level in gearbox axis 2.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!
Step
3HAC 16246-1
Action
Note/Illustration
1.
2.
3.
4.
47
Location of gearbox
The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.
A
B
C
xx0200000230
Gearbox axis 3
Required equipment
Equipment, etc.
Lubricating oil
Standard toolkit
48
Note
3HAC 16246-1
Inspection, oil
level gearbox 3
The procedure below details how to inspect the oil level in the gearbox axis 3.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!
Step
3HAC 16246-1
Action
Note/Illustration
1.
2.
3.
4.
5.
49
Location of gearbox
The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure
below.
A
B
xx0200000231
Required equipment
Equipment, etc.
Lubricating oil
Standard toolkit
Inspection, oil
level gearbox 4
Note
The procedure below details how to inspect the oil level in gearbox axis 4.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
50
3HAC 16246-1
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!
Step
3HAC 16246-1
Action
Note/Illustration
1.
2.
3.
4.
5.
51
Location of gearbox
The axis 5 gearbox is located in the wrist unit as shown in the figure below.
B
xx0200000232
Required equipment
Equipment etc.
Lubricating oil
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!
Inspection, oil
level gearbox 5
Note
The procedure below details how to inspect the oil level in gearbox axis 5.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
52
3HAC 16246-1
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!
Step
3HAC 16246-1
Action
Note/Illustration
1.
2.
3.
4.
5.
53
Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.
B
A
C
xx0200000233
Gearbox axis 6
Required equipment
Equipment
Lubricating oil
Standard toolkit
Inspection, oil
level gearbox 6
Note
The procedure below details how to inspect the oil level in gearbox axis 6.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains
quicker than cold oil.
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
54
3HAC 16246-1
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!
Step
3HAC 16246-1
Action
Note/Illustration
1.
2.
3.
4.
55
The balancing device is located at the top rear of the frame as shown in the figure below.
If damage is detected during inspection, a maintenance or an upgrade must be performed,
depending on version of balancing device! Balancing device 3HAC 14678-1 and 3HAC
16189-1 requires maintenance, while 3HAC 12604-1 requires an upgrade.
C
A, B
E
F
xx0200000110
Balancing device
Bearing attachment
Rear cover
56
Equipment, etc.
Note
Balancing device
3HAC 16198-1
IRB 6600.
Includes balancing device
3HAC 14678-1!
3HAC 16246-1
Equipment, etc.
Note
Balancing device
3HAC 16907-1
IRB 6650.
Includes balancing device
3HAC 16189-1!
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!
If detecting damage when inspecting balancing device, version 3HAC 14678-1, 3HAC
16189-1 maintenance must be performed!
The table below specifies the equipment required when maintaining the balancing device!
Note
Maintenance kit
3HAC 16195-1
Maintenance kit
3HAC 16194-1
Documentation for
maintenance
3HAC 15864-5
3HAC 15864-4
3HAC 15943-2
Separator
If detecting damage when inspecting balancing device, version 3HAC 12604-1, an upgrade
must be performed!
The table below specifies equipment required when upgrading the balancing device!
3HAC 16246-1
Note
Upgrade kit
Documentation in
upgrade kit
3HAC 15864-6 Instruction for conversion from balancing device, 3HAC 12604-1 to
3HAC 14678-1.
57
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!
Step
58
Action
Note
1.
Check for dissonance from bearings, gear or Shown in the figure Location of balshaft.
ancing device on page 56.
Make sure the securing screw in the shaft is
positioned correctly and undamaged.
(M16x180, tightening torque: 50 Nm.)
At detected dissonance: Carry out an overhaul as detailed in Maintenance kit or
Upgrade kit, depending on the version of balancing device.
2.
3.
4.
5.
3HAC 16246-1
Location of
cabling axes 1-4
The manipulator cable harness, axes 1-4, is located as shown in the figure below.
C
A
D
xx0200000097
Lower arm
Connectors at base
Required equipment
3HAC 16246-1
Equipment, etc.
Note
3HAC 14940-1
IRB 6600
3HAC 16331-1
IRB 6650
3HAC 14140-1
3HAC 14139-1
Circuit diagram
Standard toolkit
59
Equipment, etc.
Inspection, cable
harness 1-4
Note
These procedures include
references to the tools
required.
The procedure below details how to inspect the cable harness of axes 1-4.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The cable harnesses are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!
Step
60
Action
Note/Illustration
1.
2.
3.
4.
3HAC 16246-1
Location of
cabling axes 5-6
The manipulator cable harness, axes 5-6, is located as shown in the figure below.
C
xx0200000234
Inspection, cable
harness, axes 5-6
The procedure below details how to inspect the cable harness of axes 5-6.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The cable harnesses are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!
Step
1.
3HAC 16246-1
Action
Note
61
Step
62
Action
Note
2.
Check the attachments at the rear of the upper arm and Shown in the figure Locain the upper arm tube.
tion of cabling axes 5-6 on
page 61!
Check the connectors at the cable harness division.
Make sure the attachment plate is not bent or in other
way damaged.
3.
3HAC 16246-1
Location of labels
The figures below show the location of the information labels to be inspected.
A
B
Warning
A
D
Warning
C
B
A
B
X-X
xx0200000236
3HAC 16246-1
Warning sign, a symbol of a lightning flash (located on motor cover), 3HAC 1589-1
63
E
G
Liftin g of robot
H
Warning
Warning
F
xx0200000101
Required equipment
Equipment, etc.
Note
3HAC 8711-1
Inspection, labels
Step
64
Action
Note/Illustration
1.
2.
3HAC 16246-1
Location of
mechanical stop
The mechanical stop axis 1 is located at the base as shown in the figure below.
A
xx0200000151
Required equipment
Equipment, etc.
Inspection,
mechanical stop
Note
Mechanical stop ax 1
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!
The procedure below details how to inspect the mechanical stop axis 1.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Step
3HAC 16246-1
Action
Note/Illustration
1.
2.
3.
65
Location of
mechanical stops
The figure below shows the location of the additional mechanical stops on axes 1, 2 and 3
(IRB 7600 shown).
B
A
B
A
xx0200000150
Additional stop
Fixed stop
Required equipment
Equipment etc.
66
Note
Mechanical stop ax 1
Mechanical stop ax 1
Mechanical stop ax 2
3HAC 13787-1
Mechanical stop ax 3
3HAC 13128-2
Standard toolkit
3HAC 16246-1
Inspection,
mechanical stops
The procedure below details how to inspect the additional mechanical stops on axes 1, 2 and
3.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Step
3HAC 16246-1
Action
Note/Illustration
1.
Check the additional stops on axes 1, 2 and 3 for Shown in the figure Location of
damage.
mechanical stops on page 66!
2.
3.
If any damage is detected, the mechanical stops Art. no. specified in Required
must be replaced!
equipment on page 66!
Correct attachment screws (lubricated with Molycote 1000):
Axis 1: M16 x 35
Axis 2: M16 x 50
Axis 3: M16 x 60
67
Location of
dampers
The figure below shows the location of all the dampers to be inspected.
B
A
xx0300000040
Required equipment
Equipment
68
Note
Damper axis 2
3HAC 12991-1
To be replaced if damaged!
Damper axis 3
3HAC 12320-1
To be replaced if damaged!
Damper axis 4
3HAC 13564-1
To be replaced if damaged!
Damper axis 5
3HAB 4337-2
To be replaced if damaged!
Standard toolkit
3HAC 15571-1
3HAC 16246-1
Inspection, dampers
The procedure below details how to inspect the dampers, axes 2-5
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Step
3HAC 16246-1
Action
Note/Illustration
1.
Check all dampers for damage, and for cracks or Shown in the figure Location of
existing impressions larger than 1 mm.
dampers on page 68!
To inspect the damper, axis 4, remove the two
covers on top of the upper arm!
2.
3.
69
A
F
C
E
xx0100000158
Cam
Protection sheet
Rail
Rail attachment
E
B
C
F
xx0100000159
70
3HAC 16246-1
Cam
Rail
Rail attachment
C
B
xx0100000160
Cam
Rail
Rail attachment
Required equipment
Equipment, etc.
3HAC 16246-1
Note
3HAC 15715-1
To be replaced in case of
detected damage
3HAC 16418-1
To be replaced in case of
detected damage
3HAC 16417-1
To be replaced in case of
detected damage
71
Equipment, etc.
Standard toolkit
3HAC 15571-1
Note
The contents are defined in
section Standard toolkit on
page 18!
These procedures include references to the tools required.
The procedure below details how to inspect the position switch, axes 1, 2 and 3.
See figure above to locate the different components to be inspected.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Step
Action
1.
2.
3.
4.
5.
72
Note/Illustration
If any damage is detected, the position switch must Art. no. specified in Required
be replaced!
equipment on page 71!
3HAC 16246-1
Location of UL
lamp
The UL-lamp is located as shown in the figure below. Note that the position can differ
depending on how the customer harness for axis 4-6 is mounted. See assembly drawing on
the current harness for alternative positioning.
There are two different article numbers for the UL-lamp. The difference is due to the accompanying motor cover, which is either flat or vaulted.
A
D
C
B
xx0200000240
UL signal lamp
Clamp
Required equipment
Equipment, etc.
3HAC 16246-1
Note
Signal lamp
Signal lamp
Standard toolkit
73
Equipment, etc.
Inspection, ULlamp
Note
These procedures include references to the tools required.
The procedure below details how to inspect the function of the UL-lamp.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Step
74
Action
Note/Illustration
1.
Check that the UL-lamp is lit, when the motors are put in
operation ("motors ON").
2.
3HAC 16246-1
Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure below.
C
D
A
xx0200000228
Gearbox axis 1
Motor axis 1
Required equipment
Equipment, etc.
Lubricating oil
Note
Standard toolkit
The specified amount of oil is based on the total volume of the gearbox. When changing the
oil, the amount of refilled oil may therefor differ from the specified amount, depending on how
much oil has previously been drained from the gearbox.
The correct oil level is specified in the section about inspection of oil level.
3HAC 16246-1
75
Changing, oil
The procedure below details how to change the oil in gearbox axis 1.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains
quicker than cold oil.
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!
Step
Action
Note/Illustration
1.
2.
xx0200000237
76
3.
Place an oil vessel close to the hose end. Vessel capacity specified in Required
equipment on page 75!
4.
5.
6.
Notice! The draining is time-consuming. Elapsed time depends on the temperature of the oil.
3HAC 16246-1
Step
3HAC 16246-1
Action
Note/Illustration
7.
8.
9.
10.
77
Different designs
Between the axis 2 motor and gearbox there is a motor attachment which exists in two different designs.
The early design of the motor attachment is attached directly to the gearbox, with the
front gearbox attachment screws (only some versions of IRB 6600).
The later design of the motor attachment is attached directly to the frame. This design
also includes an additional cover that overlaps the motor attachment and holds the oil
plugs.
The correct amount oil varies, depending on the design of the motor attachment.
Location of gearbox
The gearbox, axis 2, is located in the lower arm rotational center, underneath the motor attachment.
The figure below shows the later design of the motor attachment.
A
D
B
xx0200000229
78
Gearbox axis 2
3HAC 16246-1
Required equipment
Equipment, etc.
Lubricating oil
Note
1/2".
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!
The specified amount of oil is based on the total volume of the gearbox. When changing the
oil, the amount of refilled oil may therefor differ from the specified amount, depending on how
much oil has previously been drained from the gearbox.
The correct oil level is specified in the section about inspection of oil level.
Changing, oil
The procedure below details how to change the oil in gearbox axis 2.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains
quicker than cold oil.
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!
Step
1.
3HAC 16246-1
Action
Note/Illustration
79
Step
80
Action
Note/Illustration
2.
3.
4.
5.
6.
3HAC 16246-1
Location of gearbox
The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.
A
B
C
xx0200000230
Gearbox axis 3
Required equipment
Equipment, etc.
Lubricating oil
Note
1/2".
Standard toolkit
The specified amount of oil is based on the total volume of the gearbox. When changing the
oil, the amount of refilled oil may therefor differ from the specified amount, depending on how
much oil has previously been drained from the gearbox.
The correct oil level is specified in the section about inspection of oil level.
3HAC 16246-1
81
Changing, oil
The procedure below details how to change the oil in gearbox, axis 3.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains
quicker than cold oil.
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!
Step
82
Action
Note/Illustration
1.
2.
3.
4.
5.
3HAC 16246-1
Location of gearbox
The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure
below.
B
xx0200000231
Required equipment
Equipment, etc.
Lubricating oil
1171 2016-604
Note
BP Energol GR-XP 320.
This is a common oil that can be
replaced with an equivalent oil
from another manufacturer!
Total amount: 8,100 ml.
Capacity: 9,000 ml.
Standard toolkit
3HAC 15571-1
The specified amount of oil is based on the total volume of the gearbox. When changing the
oil, the amount of refilled oil may therefor differ from the specified amount, depending on how
much oil has previously been drained from the gearbox.
The correct oil level is specified in the section about inspection of oil level.
3HAC 16246-1
83
Changing, oil
The procedure below details how to change the oil in gearbox, axis 4.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains
quicker than cold oil.
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!
Step
84
Action
Note/Illustration
1.
2.
3.
4.
5.
6.
7.
3HAC 16246-1
Location of gearbox
The axis 5 gearbox is located in the wrist unit as shown in the figure below.
B
xx0200000232
Required equipment
Equipment, etc.
Lubricating oil
Note
Standard toolkit
3HAC 15571-1
The specified amount of oil is based on the total volume of the gearbox. When changing the
oil, the amount of refilled oil may therefor differ from the specified amount, depending on how
much oil has previously been drained from the gearbox.
The correct oil level is specified in the section about inspection of oil level.
Changing, oil
The procedure below details how to change the oil in gearbox, axis 5.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
3HAC 16246-1
85
When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains
quicker than cold oil.
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!
Step
86
Action
Note/Illustration
1.
2.
3.
4.
5.
6.
7.
3HAC 16246-1
Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.
The different robot versions have different gearbox designs. The amount of oil in the gearbox
therefore varies depending on robot version.
B
A
C
xx0200000233
Gearbox axis 6
Required equipment
Equipment, etc. Spare part no. Art. no.
Lubricating oil
Note
Standard toolkit
The specified amount of oil is based on the total volume of the gearbox. When changing the
oil, the amount of refilled oil may therefor differ from the specified amount, depending on how
much oil has previously been drained from the gearbox.
The correct oil level is specified in the section about inspection of oil level.
3HAC 16246-1
87
Changing, oil
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!
Step
88
Action
Note/Illustration
1.
2.
Drain the oil from gearbox 6 by removing the oil Vessel capacity specified in
plug. Collect the oil with a suitable vessel.
Required equipment on page 87!
3.
4.
5.
6.
3HAC 16246-1
Location of bearing
The figure below shows the location of the lubrication nipple etc.
Note! The balancing device must be mounted on the manipulator when lubricating the bearing!
xx0200000109
Lubrication nipple
Sealing spacer
Required equipment
Equipment, etc. Spare part no. Art. no.
Note
Grease
3HAA 1001-294
Grease pump
3HAC 16246-1
89
The procedure below details how to lubricate the spherical roller bearing.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!
Step
1.
90
Action
Note/Illustration
3HAC 16246-1
General
Activities
Periodicity
The periodicity of cleaning the manipulator varies a great deal depending on the actual environment and function of the robot. Clean a contamined manipulator as required.
Special points
xx0200000239
3HAC 16246-1
Inside of base/axis 1
91
Required equipment
Equipment, etc.
Steam cleaner
Always!
Never!
Foundry versions
92
Note
The section below specifies some special considerations when cleaning the manipulator.
Always use cleaning equipment as specified above! Any other cleaning equipment
may shorten the life of paintwork, rust inhibitors, signs, or labels!
Always check that all protective covers are fitted to the robot before cleaning!
Never point the water jet at bearing seals, contacts, and other seals!
Never remove any covers or other protective devices before cleaning the robot!
Never use any cleaning agents, e.g. compressed air or solvents, other than those
specified above!
Never spray with a high pressure cleaner onto the sealing cup at the bottom of the
motor 6 spiral cable (item A in the figure Special points on page 91)!
Although the manipulator is watertight, avoid spraying connectors and similar items
with a high pressure cleaner!
In working environments, e.g. foundries, where the manipulator may be exposed to fluids that
dry to make a crusty surface, e.g. release agents, clean the cable harnesses to prevent the crust
damaging the cables:
Clean the spiral wound cables to motor 6 (item A in the figure Special points on page
91) with water and a cloth!
3HAC 16246-1
General
3HAC 16246-1
This chapter contains information on how to maintain the equipment in question, i.e. how to
perform the preventive maintenance activities specified in the maintenance schedule for the
same equipment.
93
Inspection
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will
be destroyed if subjected to it! Before handling, make sure you are connected to earth through
a special ESD wrist bracelet or similar.
Step Action
94
Note/Illustration
1.
Inspect the cabinet interior to make sure there is no Replace any faulty seals as
contamination.
required.
If any contamination is found, the cabinet interior
must be cleaned and all gaskets and seals to the
cabinet inspected.
2.
3.
4.
3HAC 16246-1
X1
X1
X1
X1
X1
X2
X2
X2
X2
X2
X3
Rectifier
A0
xx0200000103
Battery unit
Required equipment
Equipment, etc.
Note
Battery unit
3HAC 5393-2
To be replaced as a complete
unit
Removal, battery
unit
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will
be destroyed if subjected to it! Before handling, make sure you are connected to earth through
a special ESD wrist bracelet or similar.
3HAC 16246-1
95
Step Action
Note/Illustration
X1
X1
X1
X2
X2
X2
X2
X1
X2
X3
Rectifier
A0
xx0200000004
xx0200000005
Refitting, battery
unit
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will
be destroyed if subjected to it! Before handling, make sure you are connected to earth through
a special ESD wrist bracelet or similar.
Step Action
Note/Illustration
2. Reconnect the cables and push the unit into position. See illustration above!
3. Secure it with the attachment screws.
96
3HAC 16246-1
Required equipment
Equipment, etc.
Internal cleaning
Art. no.
Note
Vacuum cleaner
ESD Safe
The procedure below details how to clean the interior of the controller cabinet.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will
be destroyed if subjected to it! Before handling, make sure you are connected to earth through
a special ESD wrist bracelet or similar.
Step
1.
Always!
Never!
3HAC 16246-1
Action
Note/Illustration
The section below specifies special considerations when cleaning the controller cabinet.
Always use cleaning equipment as specified above! Any other cleaning equipment
may shorten the life of paintwork, rust inhibitors, signs, or labels!
Always check that all protective covers are fitted to the controller before cleaning!
Never remove any covers or other protective devices before cleaning the controller!
Never use any cleaning agents, e.g. compressed air or solvents, other than those
specified above!
97
xx0200000002
Cover
Fan
Screw
Required equipment
Equipment, etc.
Note
Vacuum cleaner
Cleaning
ESD Safe
Step
1.
98
Action
Note/Illustration
3HAC 16246-1
Step
3HAC 16246-1
Action
Note/Illustration
2.
3.
4.
99
Location of drive
units
The illustration below shows the location of the drive units and air outlet device.
1
Drive units
Required equipment
Equipment, etc.
Vacuum cleaner
Cleaning
Note
ESD Safe
The following procedures detail how to clean the drive units, bleeder resistor and air outlet
device.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will
be destroyed if subjected to it! Before handling, make sure you are connected to earth through
a special ESD wrist bracelet or similar.
Step
1.
2.
100
Action
Illustration/Note
3HAC 16246-1
Step
Refitting
Action
Illustration/Note
3.
4.
5.
Clean the back side of the drive units. See Note above.
6.
7.
Step Action
Note/Illustration
1. Fit the bleeder resistor into position and secure it with the Art. no. is specified above!
spring.
Also see the figure above!
2. Secure the cable disconnected during disassembly.
3. Refit the air outlet device.
4. Tighten the M5 screws.
3HAC 16246-1
101
Location of air
outlet
The illustration below shows the location of the air outlet shaft
Air outlet
Required equipment
Equipment, etc.
Vacuum cleaner
Cleaning
Note
ESD Safe
The following procedures detail how to clean the air outlet shaft.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will
be destroyed if subjected to it! Before handling, make sure you are connected to earth through
a special ESD wrist bracelet or similar.
102
1.
2.
3.
4.
3HAC 16246-1
Refitting
The procedure below details how to refit the Drive units, bleeder resistor and system fan unit.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will
be destroyed if subjected to it! Before handling, make sure you are connected to earth through
a special ESD wrist bracelet or similar.
Step Action
Note/Illustration
2. Refit the Bleeder resistor and system fan unit. Detailed in Repairs Manual, section
Replacement of system fan unit.
3. Refit the air outlet device.
4. Tighten the M5 screws.
3HAC 16246-1
103
Location of drain
filter
Filter holder
M5 screw
Drain filter
Required equipment
Equipment, etc.
Filter
3HAC 5393-2
Standard toolkit
Removal
Note
104
3HAC 16246-1
Step Action
Note/Illustration
Refitting
Step Action
Note/Illustration
2. Fit the filter holder, (pos.1) and secure it with the See the figure above!
M5 screw, (pos. 2).
3. Put the computer system back in the regular
operation position.
3HAC 16246-1
105
106
3HAC 16246-1
0.0.1 Overview
0.0.1 Overview
About This
Manual
This information product is a manual containing circuit diagrams for both the manipulator
and the controller cabinet.
Usage
Organization of
Chapters
Chapter
Contents
Revision
Description
First edition
Revisions
3HAC 16247-1
0.0.1 Overview
3HAC 16247-1
Contents ........................................................................................................................101
Connection Point Location ...........................................................................................102
Legend ..........................................................................................................................103
Brake Release Unit .......................................................................................................104
Service brake release unit (IRB 7600).......................................................................104.1
Serial Measurement Board ...........................................................................................105
Axis 1............................................................................................................................106
Axis 2............................................................................................................................107
Axis 3............................................................................................................................108
Axis 4............................................................................................................................109
Axis 5 (IRB 7600) ........................................................................................................110
Axis 5 (IRB 6600) .....................................................................................................110.1
Axis 6............................................................................................................................111
Customer Power/Signal/Bus Connections....................................................................112
Customer Power/Signal/Bus and External axis .........................................................112.1
Customer Power/Signal/Bus Connections, ax 3-6.....................................................112.5
Switches axis 1 .......................................................................................................... ..113
Switches/ Fan axis 2 .....................................................................................................114
Switches/ Fan axis 3 .....................................................................................................115
Weld connections..........................................................................................................116
Contents
101
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20
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01
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102
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20
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01
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Legend
103
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20
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01
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No. of sheets
20
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104
01
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104.1
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20
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00
Revision
105
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20
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01
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Axis 1
106
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20
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01
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Axis 2
107
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20
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01
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Axis 3
108
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20
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01
Revision
Axis 4
109
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20
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01
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No. of sheets
20
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110
01
Revision
110.1
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20
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01
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Axis 6
111
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01
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112
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20
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01
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112.1
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20
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01
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112.5
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20
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01
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Switches axis 1
113
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01
Revision
114
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01
Revision
115
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20
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01
Revision
Weld connections
116
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20
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01
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Circuit Diagram
Contents
3HAC 5582-2/Rev. 03
Page
Circuit Diagram
Contents
3HAC 5582-2/Rev. 03
Page
Circuit Diagram
Contents
3HAC 5582-2/Rev. 03
Page
Circuit Diagram
Contents
3HAC 5582-2/Rev. 03
Page
1 General Information
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107
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1-0
04
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Block Diagram
1-1
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91
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1-2
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91
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1-3
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91
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Designation
1-4
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91
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04
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Designation
1-5
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91
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04
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No. of sheets
107
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2-0
04
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Mains Connection
2-1
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107
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04
Revision
2-2
sheet
107
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04
Revision
2-3
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107
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04
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Power Supply
2-4
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107
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04
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No. of sheets
107
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2-5
04
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107
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2-6
04
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107
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3-0
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3-1
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91
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3-2
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91
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3-3
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91
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Computer Cooling
3-4
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91
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3-5
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91
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04
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3-6
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91
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04
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3-7
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91
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04
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3-8
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91
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3-9
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91
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04
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No. of sheets
107
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4-0
04
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Emergency Stop
4-1
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107
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4-2
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107
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4-3
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107
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4-4
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107
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No. of sheets
107
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5-0
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Block Diagram
5-1
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107
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5-2
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107
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5-3
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107
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5-4
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107
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5-5
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107
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5-6
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107
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5-7
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107
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107
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107
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107
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107
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107
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107
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107
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5-15
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107
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5-16
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107
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5-17
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107
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6 External Axes
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107
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6-0
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External Axes
6-1
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107
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04
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6-2
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107
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6-3
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107
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6-4
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107
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6-5
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107
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6-6
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107
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6-7
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107
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6-8
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107
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6-9
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107
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6-10
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107
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6-11
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107
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6-12
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107
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6-13
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107
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6-14
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107
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04
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No. of sheets
107
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7-0
04
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7-1
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107
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04
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Digital Part of Combi I/O and Digital I/O Unit Input Part
7-2
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107
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04
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7-3
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107
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04
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7-4
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107
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7-5
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107
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7-6
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107
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7-7
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107
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7-8
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107
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7-9
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107
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7-10
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107
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04
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7-11
sheet
107
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04
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Interbus-S Slave
7-12
sheet
107
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04
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Profibus DP Slave
7-13
sheet
107
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04
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Encoder Unit
7-14
sheet
107
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04
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Profibus DP Master/Slave
7-15
sheet
107
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04
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7-16
sheet
107
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04
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8 Other Options
No. of sheets
107
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8-0
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Floppy Disk
8-1
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107
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8-2
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107
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8-3
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107
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8-4
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107
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8-5
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107
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8-6
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107
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8-7
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107
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8-8
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107
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8-9
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107
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Time Relay
8-10
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107
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8-11
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107
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8-12
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107
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8-13
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107
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8-14
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107
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8-15
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107
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107
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8-17
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107
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8-18
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107
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8-19
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107
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04
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No. of sheets
107
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9-0
04
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Block Diagram
9-1
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107
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04
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9-2
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107
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04
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Designation
9-3
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107
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04
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Mains Connection
9-4
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107
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04
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Transformer Unit
9-5
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107
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04
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9-6
sheet
107
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Power Unit
9-7
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107
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9-8
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107
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9-9
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107
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107
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107
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9-12
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107
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9-13
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107
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9-14
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107
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9-15
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107
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