ABB IRB 1400 Product Manual
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ABB IRB 1400 Product Manual

Articulated robot
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Articulated robot
IRB 1400
M2004

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Summary of Contents for ABB IRB 1400

  • Page 1 Product manual Articulated robot IRB 1400 M2004...
  • Page 3 Product manual 3HAC021111-001 Revision: B Articulated robot IRB 1400 M2000 M2004...
  • Page 4 Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fit- ness for a specific purpose or the like.

  • Page 5: Table Of Contents

    Table of Contents 0.0.1 Overview ..............7 0.0.2 Product documentation, M2000.
  • Page 6 Table of Contents 4: Repair 4.1: General information ............. . 59 4.1.1 General description .
  • Page 7 8.0.7 Standard toolkit, IRB 1400 ........
  • Page 8 Table of Contents 11.0.5 Sheet 104 Motor axes 1 - 3 ..........174 11.0.6 Sheet 105 Feedback axes 1 - 3 .

  • Page 9: Overview

    Prerequisites A maintenance/repair/ installation craftsman working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Organization of The manual is organized in the following chapters: chapters...
  • Page 10 0.0.1 Overview Revisions Revision Description First edition. Replaces previous product manual 3HAC 7617-1 Changes made in the material from the previous manuals: • Model M2004 implemented. Yaskawa motors included. Changes made in: • Prerequisites in section Owerview • Oil change in section Maintenance 3HAC021111-001 Revision: B...

  • Page 11: Product Documentation, M2000

    A complete listing of all available software manuals is available from ABB. Hardware option Each hardware option is supplied with its own documentation. Each document set contains...
  • Page 12 0.0.2 Product documentation, M2000 3HAC021111-001 Revision: B...

  • Page 13: Product Documentation, M2004

    This means that any one delivery of robot products will not contain all documents listed, but only some of them. However, all documents listed may be ordered from ABB. The documents listed are valid for M2004 robot systems.
  • Page 14 0.0.3 Product documentation, M2004 Operating This group of manuals is aimed at those having first hand operational contact with the robot, Manuals i.e. production cell operators, programmers and trouble shooters, and include: • Operating Manual - IRC5 with FlexPendant • Operating Manual - RobotStudioOnline •...

  • Page 15: 1: Safety, Service

    1 Safety, service 1.0.1 Introduction 1: Safety, service 1.0.1 Introduction Definitions This chapter details safety information for service personnel i.e. personnel performing instal- lation, repair and maintenance work. Sections The chapter "Safety, service" is divided into the following sections: 1. General information contains lists of: •...

  • Page 16: General Information

    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.

  • Page 17: Limitation Of Liability

    General Any information given in this information product regarding safety, must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions have been complied with. 3HAC021111-001 Revision: B...

  • Page 18: Related Information

    1 Safety, service 1.1.3 Related information 1.1.3 Related information General The list below specifies documents which contain useful information: Documents Type of information Detailed in document Section Installation of safety devices Product manual for the manipulator Installation and com- missioning Changing robot modes User’s Guide Start-up...

  • Page 19: Safety Risks

    1 Safety, service 1.2.1 Safety risks related to gripper 1.2: Safety risks 1.2.1 Safety risks related to gripper CAUTION! Ensure that a gripper is prevented from dropping a workpiece, if such is used. 3HAC021111-001 Revision: B...

  • Page 20: Safety Risks Related To Tools/Workpieces

    1 Safety, service 1.2.2 Safety risks related to tools/workpieces 1.2.2 Safety risks related to tools/workpieces Safe handling It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that guards remain closed until the cutters stop rotating. It should be possible to release parts by manual operation (valves).

  • Page 21: Safety Risks Related To Pneumatic/Hydraulic Systems

    1 Safety, service 1.2.3 Safety risks related to pneumatic/hydraulic systems 1.2.3 Safety risks related to pneumatic/hydraulic systems General Special safety regulations apply to pneumatic and hydraulic systems. Residual energy • Residual energy may be present in these systems so, after shutdown, particular care must be taken.

  • Page 22: Safety Risks During Operational Disturbances

    1 Safety, service 1.2.4 Safety risks during operational disturbances 1.2.4 Safety risks during operational disturbances General • The industrial robot is a flexible tool which can be used in many different industrial applications. • All work must be carried out professionally and in accordance with the applicable safety regulations.

  • Page 23: Safety Risks During Installation And Service

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

  • Page 24: Risks Associated With Live Electric Parts

    1 Safety, service 1.2.6 Risks associated with live electric parts 1.2.6 Risks associated with live electric parts Voltage related • 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) risks, general when repairing faults, disconnecting electric leads and disconnecting or connecting units.

  • Page 25: Safety Actions

    1 Safety, service 1.3.1 Safety fence dimensions 1.3: Safety actions 1.3.1 Safety fence dimensions General Install a safety cell around the robot to ensure safe robot installation and operation. Dimensioning Dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed.

  • Page 26: Fire Extinguishing

    1 Safety, service 1.3.2 Fire extinguishing 1.3.2 Fire extinguishing NOTE! Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the robot (manipula- tor or controller)! 3HAC021111-001 Revision: B...

  • Page 27: Emergency Release Of The Manipulator's Arm

    1 Safety, service 1.3.3 Emergency release of the manipulator's arm 1.3.3 Emergency release of the manipulator's arm Description In an emergency situation, any of the manipulator's axes may be released manually by push- ing 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 in the Product manual for the manipulator.

  • Page 28: Brake Testing

    1 Safety, service 1.3.4 Brake testing 1.3.4 Brake testing When to test During operation the holding brakes of each axis motor wear normally. A test may be per- formed 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.

  • Page 29: Risk Of Disabling Function "Reduced Speed 250 Mm/S

    1 Safety, service 1.3.5 Risk of disabling function "Reduced speed 250 mm/s" 1.3.5 Risk of disabling function "Reduced speed 250 mm/s" Note! Do not change "Transm gear ratio" or other kinematic parameters from the Teach Pendant Unit or a PC. This will affect the safety function Reduced speed 250 mm/s. 3HAC021111-001 Revision: B...

  • Page 30: Safe Use Of The Teach Pendant Unit

    1 Safety, service 1.3.6 Safe use of the Teach Pendant Unit 1.3.6 Safe use of the Teach Pendant Unit NOTE! The enabling device is a push button located on the side of the Teach Pendant Unit (TPU) which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device is released or pushed all the way in, the robot is taken to the MOTORS OFF state.

  • Page 31: Work Inside The Manipulator's Working Range

    1 Safety, service 1.3.7 Work inside the manipulator's working range 1.3.7 Work inside the manipulator's working range Warning! If work must be carried out within the robot’s work envelope, the following points must be observed: - The operating mode selector on the controller must be in the manual mode position to render the enabling device operative and to block operation from a computer link or remote control panel.

  • Page 32: Signal Lamp (Optional)

    1 Safety, service 1.3.8 Signal lamp (optional) 1.3.8 Signal lamp (optional) Description A signal lamp with an yellow fixed light can be mounted on the manipulator, as a safety device. The signal lamp is required on an UL/UR approved robot. Function The lamp is active in MOTORS ON mode.

  • Page 33: 2: Installation And Commissioning

    2 Installation and commissioning 2.0.1 Transporting and Unpacking 2: Installation and commissioning 2.0.1 Transporting and Unpacking Before starting to unpack and install the robot, read the safety regulations and other instructions very carefully. These are found in separate sections in the User’s Guide and Product manual.

  • Page 34: Stability / Risk Of Tipping

    2 Installation and commissioning 2.0.2 Stability / Risk of Tipping 2.0.2 Stability / Risk of Tipping When the manipulator is not fastened to the floor and standing still, the manipulator is not stable in the whole working area. When the arms are moved, care must be taken so that the centre of gravity is not displaced, as this could cause the manipulator to tip over.

  • Page 35: System Cd Rom And Diskette

    2 Installation and commissioning 2.0.3 System CD ROM and Diskette 2.0.3 System CD ROM and Diskette The system CD ROM and the manipulator parameter disk are delivered with the robot system. See section RobotWare CD-ROM in the Product manual for the controller. Art.

  • Page 36: Transport Locking Device

    2 Installation and commissioning 2.0.4 Transport Locking Device 2.0.4 Transport Locking Device At delivery, axis 2 (= lower arm) is equipped with a transport locking device (see figure below). Remove the transport locking device before operating the robot. Transport locking device Transport Locking Device, Axis 2.

  • Page 37: On-Site Installation

    2 and 3 (see figure below). The lifting strap dimensions must comply with the applicable standards for lifting. Never walk under a suspended load. Lifting eye IRB 1400H Lifting eye IRB 1400 Lifting the Manipulators using a Traverse Crane. 3HAC021111-001 Revision: B...

  • Page 38: Turning The Manipulator (Inverted Suspension Application)

    N.B! Only possible with IRB 1400H. A special tool is recommended when the manipulator is to be turned for inverted mounting (ABB article number 3HAB 3397-1). The tool is attached to the outsides of the gearboxes for axes 2 and 3 using six (M8x25) bolts and washers.

  • Page 39: Assembling The Robot

    Tightening torque 190 Nm Two guide sleeves, ABB art. no. 2151 0024-169, can be fitted to the two rear bolt holes, to allow the same robot to be re-mounted without having to re-adjust the program. When bolting a mounting plate or frame to a concrete floor, follow the general instructions for expansion-shell bolts.

  • Page 40: Suspended Mounting

    2 Installation and commissioning 2.1.4 Suspended Mounting 2.1.4 Suspended Mounting The method for mounting the manipulator in a suspended position is basically the same as for floor mounting. With inverted installation, make sure that the gantry or corresponding structure is rigid enough to prevent unacceptable vibrations and deflections, so that optimum perfor- mance can be achieved.

  • Page 41: Stress Forces

    The stiffness of the foundation must be designed to minimize the influence on the dynamic behaviour of the robot. TuneServo can be used for adapting the robot tuning to a non-optimal foundation. IRB 1400 and IRB 1400H Force Endurance load (in operation) Max. load (emergency stop) ±...

  • Page 42: Amount Of Space Required

    2 Installation and commissioning 2.1.6 Amount of Space required 2.1.6 Amount of Space required The amount of working space required to operate the manipulator is illustrated in the figures below. The working range for axis 1 is +/- 170°. NB! There are no software or mechanical limits for the working space under the base of the manipulator.

  • Page 43: Manually Engaging The Brakes

    2 Installation and commissioning 2.1.7 Manually engaging the brakes 2.1.7 Manually engaging the brakes All axes are equipped with holding brakes. If the positions of the manipulator axes are to be changed without connecting the controller, an external voltage supply (24 V d.c.) must be connected to enable engagement of the brakes.

  • Page 44: Restricting The Working Space

    2 Installation and commissioning 2.1.8 Restricting the Working Space 2.1.8 Restricting the Working Space When installing the manipulator, make sure that it can move freely within its entire working space. If there is a risk that it may collide with other objects, its working space should be limited, both mechanically and using software.
  • Page 45 2 Installation and commissioning 2.1.8 Restricting the Working Space Axis 2 The working range of axis 2 can be limited mechanically by fitting extra stop lugs to the under arm (see Figure ). The lugs limit the arm movements in intervals of 20°. (20° = 1 lug, 40° = 2 lugs, etc.) Instructions for doing this are supplied with the kit.
  • Page 46 2 Installation and commissioning 2.1.8 Restricting the Working Space Axis 3 The working range of axis 3 can be limited mechanically by fitting a stop lug under the parallel arm (see Figure ). Axis 3 is limited upwards to 0 or -10 degrees above the horizontal plane.

  • Page 47: Mounting Holes For Equipment On The Manipulator

    2 Installation and commissioning 2.1.9 Mounting Holes for Equipment on the Manipulator 2.1.9 Mounting Holes for Equipment on the Manipulator NB! Never drill a hole in the manipulator without first consulting ABB. Mounting holes for equipment M8 (2x) IRB 1400H...

  • Page 48: Loads

    2.1.10 Loads 2.1.10 Loads Regarding load diagram, permitted extra loads (equipment) and locations of extra loads (equipment), see the Product Specification for IRB 1400. The loads must also be defined in the soft ware, see User’s Guide. 3HAC021111-001 Revision: B...

  • Page 49: Customer Connections On Manipulator

    2 Installation and commissioning 2.2.1 Air supply and signals for extra equipment to upper arm 2.2: Customer connections on manipulator 2.2.1 Air supply and signals for extra equipment to upper arm Option 041 Hose for compressed air is integrated into the manipulator. There is an inlet at the base and an outlet on the upper arm housing.
  • Page 50 To connect power and signal conductors to the manipulator base and to the upper arm connectors, the following parts are recommended: • ABB’s recommended contact set, for connector R2.CS, has Art. No. 3HAC 12583-1. • ABB’s recommended contact set, for connector R1.CS, has Art. No. 3HAC 12493-1.

  • Page 51: Connection Of Extra Equipment To The Manipulator

    2 Installation and commissioning 2.2.2 Connection of Extra Equipment to the Manipulator 2.2.2 Connection of Extra Equipment to the Manipulator Technical data for customer connections. Signals Conductor resistance < 3 ohm, 0.154 mm Max. voltage 50 V AC/DC Max. current 250 mA Connections on Upper Arm...
  • Page 52 2 Installation and commissioning 2.2.2 Connection of Extra Equipment to the Manipulator Connection of Signal Lamp on R3.H1 + Upper Arm R3.H2 - Signal lamp (Option) Location of Signal Lamp. 3HAC021111-001 Revision: B...

  • Page 53: 3: Maintenance

    3 Maintenance 3.0.1 Introduction 3: Maintenance 3.0.1 Introduction The robot is designed to be able to work under very demanding circumstances with a mini- mum of maintenance. Nevertheless, certain routine checks and preventative maintenance must be carried out at given periodical intervals, see the table below. •...

  • Page 54: Maintenance Intervals

    3 Maintenance 3.0.2 Maintenance Intervals 3.0.2 Maintenance Intervals Check Check Maintenance Maintenance Equipment twice/ once/ every 2000 hrs every 4000 hrs Others year year or 6 months or 1 year Mechanical stop axis 1 Cabling Gears axis 1-4 Maintenance free Lubrication of spring brackets Lubrication of...

  • Page 55: Instructions For Maintenance

    3.1: Instructions for maintenance 3.1.1 Oil in gears 1-4 The gearboxes are lubricated for life. ABB’s oil, Mobil Gear 600 XP 320 art. No. 1171 2016-604, corresponds to: BP: Energol GR-XP 320 Castrol: Alpha SP 320 Esso: Spartan EP 320 Klüber: Lamora 320...

  • Page 56: Greasing Axes 5 And 6

    Grease is pressed through the 3 nipples (1), see Figure . The tip nozzle of the greasing gun should be of type Orion 1015063, or equivalent. Volume: 2 ml (0.00053 US gallon) Greasing Positions for Axes 5 and 6. Type of grease: ABB’s art. No. 3HAB 3537-1, corresponds to: Shell Alvania WR2 3HAC021111-001 Revision: B...

  • Page 57: Lubricating Spring Brackets

    3 Maintenance 3.1.3 Lubricating spring brackets 3.1.3 Lubricating spring brackets There are four lubrication places, located over and under the two balancing springs. Type of grease: ABB’s art. No. 3HAA 1001-294, corresponds to: Optimol PDO 3HAC021111-001 Revision: B...

  • Page 58: Changing The Battery In The Measuring System

    3 Maintenance 3.1.4 Changing the battery in the measuring system 3.1.4 Changing the battery in the measuring system The battery to be replaced is located inside the base under the flange cover (see Figure ). The robot is delivered with a rechargeable Nickel-Cadmium (Ni-Cd) battery with article number 4944 026-4.
  • Page 59 3 Maintenance 3.1.4 Changing the battery in the measuring system User type Exchange 3-cell Exchange 6-cell 1. Vacation (4 weeks) power off Every 5 years Every 5 years 2. Weekend power off + user type 1 Every 2 years Every 4 years 3.

  • Page 60: Checking The Mechanical Stop, Axis 1

    3 Maintenance 3.1.5 Checking the mechanical stop, axis 1 3.1.5 Checking the mechanical stop, axis 1 Check regularly, as follows: • That the stop pin is not bent. If the stop pin is bent, it must be replaced by a new one. See section Replacing the mechanical stop on page 71.

  • Page 61: 4: Repair

    The industrial robot system comprises two separate units: the control cabinet and the manip- ulator. The IRB 1400 is also available in a suspended version, IRB 1400H. Servicing the mechanical unit is described in the following sections. Servicing the manipulator is described in this manual.

  • Page 62: Instructions For Reading The Following Sections

    Some maintenance jobs require special experience or specific tools and are therefore not described in this manual. These jobs involve replacing the faulty module or component on-site. The faulty component is then transported to ABB for service.

  • Page 63: Caution

    4 Repair 4.1.3 Caution 4.1.3 Caution The mechanical unit contains several parts which are too heavy to lift manually. As these parts must be moved with precision during any maintenance and repair work, it is important to have a suitable lifting device available. The robot should always be switched to MOTORS OFF before anybody is allowed to enter its working space.

  • Page 64: Fitting New Bearings And Seals

    Bearings throughout. High quality lubricating grease, such as Shell Alvania WR2 (ABB’s art. No. 3537-1), should be used. 2. Grooved ball bearings should be greased on both sides. 3. Tapered roller bearings and axial needle bearings should be greased when they are split.
  • Page 65 8. Grease the seal just before it is fitted – not too early as otherwise dirt and foreign particles may stick to the seal. The space between the dust tongue and sealing lip should 2/3-filled with grease of type Shell Alvania WR2 (ABB’s art. No. 3537- 1). The rubber coated external diameter must also be greased.

  • Page 66: Instructions For Tightening Screw Joints

    4 Repair 4.1.5 Instructions for tightening Screw Joints 4.1.5 Instructions for tightening Screw Joints General It is extremely important that all screw joints are tightened using the correct torque. Application The following tightening torques must be used, unless otherwise specified in the text, for all screw joints made of metallic materials.

  • Page 67: Tightening Torques

    4 Repair 4.1.6 Tightening Torques 4.1.6 Tightening Torques Screws with slotted or cross recessed head, Dimension Tightening Torque Nm property class 4.8 Without Oil M2.5 0.25 Screws with hexagon socket head, property Dimension Tightening Torque Nm Tightening Torque Nm class 8.8 Without Oil With Oil 3HAC021111-001 Revision: B...

  • Page 68: Checking For Play In Gearboxes And Wrist

    4 Repair 4.1.7 Checking for play in gearboxes and wrist 4.1.7 Checking for play in gearboxes and wrist When checking for play in gearboxes the brakes must be disengaged. When trying to move an arm manually when the brakes are engaged, some play can be felt. The play that can be felt is between the brake disk and the motor shaft, not in the gearbox itself.

  • Page 69: Axis 1

    4 Repair 4.2.1 Changing the motor of axis 1 4.2: Axis 1 4.2.1 Changing the motor of axis 1 See foldouts 1 and 5 (6 for IRB 1400H) in the list of spare parts. The motor and the drive gear constitute one unit. NOTE! There are two different types of motors, (Elmo and Yaskawa) The different motors are not compatible.

  • Page 70: Changing The Gearbox

    4 Repair 4.2.2 Changing the gearbox 4.2.2 Changing the gearbox Axis 1 gearbox is of the conventional type, manufactured with a high degree of precision and, together with the gearboxes for axes 2 and 3, forms a complete unit. The gearbox is not normally serviced or adjusted. Note! If the gearbox on any of the axes 1, 2 or 3 is changed, the whole unit must be changed.
  • Page 71 4 Repair 4.2.2 Changing the gearbox To assemble 1. Place a new gear unit on the table. 2. Raise the base. 3. Screw in the screws <1/4> together with their washers <1/3>. Tighten using a torque of 68 Nm ±10%. 4.

  • Page 72: Position Indicator In Axis 1 (Optional)

    4 Repair 4.2.3 Position indicator in axis 1 (optional) 4.2.3 Position indicator in axis 1 (optional) See foldouts 3 and 4 (6 for IRB 1400H) in the list of spare parts. To dismantle 1. Remove the flange plate <4/138>. 2. Loosen the connector R1.LS. 3.

  • Page 73: Replacing The Mechanical Stop

    4 Repair 4.2.4 Replacing the mechanical stop 4.2.4 Replacing the mechanical stop See foldout 1 in the list of spare parts. If the stop pins are bent, they must be replaced. Remove the old stop pin. Fit the new pin as illustrated in Figure below. Loctite 242 or 243 Fit the new Pin as illustrated.

  • Page 74: Axis 2

    4 Repair 4.3.1 Changing the motor of axis 2 4.3: Axis 2 4.3.1 Changing the motor of axis 2 See foldouts 1 and 5 (6 for IRB 1400H) in the list of spare parts. The motor and the drive gear constitute one unit. NOTE! There are two different types of motors, (Elmo and Yaskawa) The different motors are not compatible.

  • Page 75: Changing The Gearbox

    4 Repair 4.3.2 Changing the gearbox 4.3.2 Changing the gearbox Axis 2 gearbox is of a conventional type, manufactured with a high degree of precision and, together with the gearbox for axes 1 and 3, forms a complete unit. The gearbox is not normally serviced or adjusted. Note! If the gearbox of any of the axes 1, 2 or 3 needs to be changed, the whole unit must be changed.

  • Page 76: Dismantling The Lower Arm

    4 Repair 4.3.3 Dismantling the lower arm 4.3.3 Dismantling the lower arm See foldouts 1 (6 for IRB 1400H) in the list of spare parts. To dismantle 1. Remove the balancing springs as described in section Dismantling the balancing springs on page 76 (not valid for IRB 1400H). 2.

  • Page 77: Changing The Bearings In The Upper Arm

    4 Repair 4.3.4 Changing the bearings in the upper arm 4.3.4 Changing the bearings in the upper arm See foldout 1 (6 for IRB 1400H) in the list of spare parts. To dismantle 1. Loosen the upper bracket of the tie rod as described in section Changing the tie rod on page 80.

  • Page 78: Dismantling The Balancing Springs

    4 Repair 4.3.5 Dismantling the balancing springs 4.3.5 Dismantling the balancing springs See foldouts 1 and 2 in the list of spare parts. Note! Not valid for IRB 1400H. To dismantle 1. Place the lower arm in a vertical position. 2.

  • Page 79: Axis 3

    4 Repair 4.4.1 Changing the motor of axis 3 4.4: Axis 3 4.4.1 Changing the motor of axis 3 See foldouts 1 and 5 (6 for IRB 1400H) in the list of spare parts. The motor and the drive gear constitute one unit. NOTE! There are two different types of motors, (Elmo and Yaskawa) The different motors are not compatible.

  • Page 80: Changing The Gearbox

    4 Repair 4.4.2 Changing the gearbox 4.4.2 Changing the gearbox Axis 3’s gearbox is of a conventional type, manufactured with a high degree of precision and, together with the gearbox for axes 1 and 2, forms a complete unit. The gearbox is not normally serviced are adjusted. Note! If the gearbox of any of the axes 1, 2 or 3 needs to be changed,the whole unit must be changed.

  • Page 81: Dismantling The Parallel Arm

    4 Repair 4.4.3 Dismantling the parallel arm 4.4.3 Dismantling the parallel arm See foldout 1 (6 for IRB 1400H) in the list of spare parts. To dismantle 1. Loosen the upper bracket of the tie rod as described in this chapter, section Changing the tie rod on page 80.

  • Page 82: Changing The Tie Rod

    4 Repair 4.4.4 Changing the tie rod 4.4.4 Changing the tie rod See foldout 2 in the list of spare parts. To dismantle Lock the upper arm in a horizontal position with the help of a crane or similar. 1. Unscrew screw <74>. 2.

  • Page 83: Dismantling The Complete Upper Arm

    4 Repair 4.4.5 Dismantling the complete upper arm 4.4.5 Dismantling the complete upper arm See foldout 2 in the list of spare parts. To dismantle Attach a crane to the upper arm. 1. Unscrew the upper bracket of the tie rod as specified in section Changing the tie rod on page 80.
  • Page 84 16.If the old armhouse is mounted, adjust the calibration washer according to the punch mark. If the armhouse is new adjust the washer according to Figure and make new punch marks for axes 3 and 4, according to section Calibration scales, IRB 1400 on page 134. 3HAC021111-001 Revision: B...
  • Page 85 4 Repair 4.4.5 Dismantling the complete upper arm Calibration Mark for Axis 3. Tools pressing tool for bearings: 3HAB 1200-1 Measuring instrument: 3HAB 1205-1 Withdrawing tool for shaft spindles: 3HAB 1259-1 3HAC021111-001 Revision: B...

  • Page 86: Axis 4

    4 Repair 4.5.1 Changing the motor 4.5: Axis 4 4.5.1 Changing the motor See foldouts 5 and 8 in the list of spare parts. The motor and the drive gear constitute one unit. Position the arm system in such a way that the motor of axis 4 points upwards. NOTE! There are two different types of motors, (Elmo and Yaskawa) The different motors are not compatible.

  • Page 87: Changing The Intermediate Gear Including Sealing

    4 Repair 4.5.2 Changing the intermediate gear including sealing 4.5.2 Changing the intermediate gear including sealing See foldout 8 in the list of spare parts. To dismantle 1. Dismantle the wrist as described in section Dismantling the wrist on page 94. 2.
  • Page 88 4 Repair 4.5.2 Changing the intermediate gear including sealing Tightening torque Screws for the large drive gear, item <18>: 8.3 Nm ±10% Screws for the intermediate gear of axis 4, item <12>: 20 Nm ±10% 3HAC021111-001 Revision: B...

  • Page 89: Dismantling The Drive Gear On The Tubular Shaft

    4 Repair 4.5.3 Dismantling the drive gear on the tubular shaft 4.5.3 Dismantling the drive gear on the tubular shaft See foldout 8 in the list of spare parts. To dismantle 1. Dismantle the wrist as described in section Dismantling the wrist on page 94. 2.
  • Page 90 4 Repair 4.5.3 Dismantling the drive gear on the tubular shaft 7. Mount the drive mechanism as specified in section Dismantling the complete drive mechanism of axes 5 and 6 on page 95. 8. Mount the wrist according to section Dismantling the wrist on page 94. 9.

  • Page 91: Dismantling The Tubular Shaft And Changing Bearings

    4 Repair 4.5.4 Dismantling the tubular shaft and changing bearings 4.5.4 Dismantling the tubular shaft and changing bearings See foldout 8 in the list of spare parts. To dismantle 1. Dismantle the drive gear as described in section Dismantling the drive gear on the tubular shaft on page 87.

  • Page 92: Cabling And Serial Measuring Board

    4 Repair 4.6.1 Changing serial measuring boards 4.6: Cabling and serial measuring board 4.6.1 Changing serial measuring boards See foldout 4 in the list of spare parts. To dismantle 1. Remove flange plate <138>. 2. Cut tie around bundle <144>. 3.

  • Page 93: Changing The Cabling In Axes 1, 2 And 3

    4 Repair 4.6.2 Changing the cabling in axes 1, 2 and 3 4.6.2 Changing the cabling in axes 1, 2 and 3 See foldouts 3 and 4 (7 for IRB 1400H) in the list of spare parts. To dismantle 1. Remove the cover of the motors. 2.

  • Page 94: Changing The Cabling In Axes 4, 5 And 6

    4 Repair 4.6.3 Changing the cabling in axes 4, 5 and 6 4.6.3 Changing the cabling in axes 4, 5 and 6 See foldouts 2, 3 and 4 (6 for IRB 1400H) in the list of spare parts. To dismantle 1.

  • Page 95: The Wrist And Axes 5 And 6

    It is of such a complex design that it is not normally serviced on-site, but should be sent to ABB to be serviced. ABB recommends its customers to carry out only the following servicing and repair work on the wrist.

  • Page 96: Dismantling The Wrist

    4 Repair 4.7.1 Dismantling the wrist 4.7.1 Dismantling the wrist See foldouts 1 (6 for IRB 1400H) and 9 in the list of spare parts. To dismantle 1. Remove the 2 plastic plugs on the rear of the wrist. 2. Release the brake in axes 5 and 6. 3.

  • Page 97: Dismantling The Complete Drive Mechanism Of Axes 5 And 6

    4 Repair 4.7.2 Dismantling the complete drive mechanism of axes 5 and 6 4.7.2 Dismantling the complete drive mechanism of axes 5 and 6 See foldouts 8 and 9 in the list of spare parts. To dismantle 1. Dismantle the wrist according to section Dismantling the wrist on page 94. 2.

  • Page 98: Changing The Motor Or Driving Belt Of Axes 5 And 6

    4 Repair 4.7.3 Changing the motor or driving belt of axes 5 and 6 4.7.3 Changing the motor or driving belt of axes 5 and 6 See foldout 9 in the list of spare parts. To dismantle 1. Dismantle the wrist as described in section Dismantling the wrist on page 94. 2.

  • Page 99: Measuring Play In Axes 5 And 6

    4 Repair 4.7.4 Measuring play in axes 5 and 6 4.7.4 Measuring play in axes 5 and 6 Axis 5 Axis 4 shall be turned 90 . The maximum accepted play in axis 5 is 4.7 arc.minutes when loading axis 5 with a moment of 4.8 Nm in one direction, unloading to 0.24 Nm and start measuring the play, loading in the other direction with 4.8 Nm unloading to 0.24 Nm and reading the play.

  • Page 100: Motor Units

    4 Repair 4.8.1 General 4.8: Motor units 4.8.1 General General Each axis (6 axes) of the manipulator has its own motor unit, and is regarded as one complete unit, comprising: • A synchronous motor • A brake (built into the motor) •...

  • Page 101: 5: Calibration, M2000

    5 Calibration, M2000 5.0.1 Introduction 5: Calibration, M2000 5.0.1 Introduction Calibration This chapter details how to calibrate the robot with the Wyler calibration equipment, using methods Levelmeter 2000, when the robot is part of an M2000 robot system (S4Cplus controller). The robot can also be calibrated with the Calibration Pendulum equipment, as detailed in the Calibration Pendulum Instruction, enclosed with the Pendulum toolkit.

  • Page 102: Overview

    5 Calibration, M2000 5.1.1 How to calibrate the robot system 5.1: Overview 5.1.1 How to calibrate the robot system General This section provides an overview of the procedures to perform when calibrating the robot system. Many of the steps in this overview are detailed in other sections to which references are given.

  • Page 103: Calibration, Prerequisites

    5 Calibration, M2000 5.1.2 Calibration, prerequisites 5.1.2 Calibration, prerequisites Peripheral The robot must be free from any peripheral equipment during calibration. Fitted tools and equipment similar will cause erroneous calibration positions. Calibration order The axes must be adjusted in increasing sequence, i.e. 1 - 2 - 3 - 4 - 5 - 6. Location of The positions where the calibration sensor and reference sensor should be fitted during cali- sensors...

  • Page 104: Reference Information

    5 Calibration, M2000 5.2.1 Calibration scales and correct axis position 5.2: Reference information 5.2.1 Calibration scales and correct axis position Introduction This section specifies the calibration scale positions and/or correct axis position for all robot models. Safety Read the safety information below. information If work must be carried out within the robot’s work envelope, the following points must be observed:...
  • Page 105 5 Calibration, M2000 5.2.1 Calibration scales and correct axis position Calibration The illustration below shows the calibration scale positions: scales, IRB 1400 en0200000272 3HAC021111-001 Revision: B...

  • Page 106: Directions For All Axes

    5 Calibration, M2000 5.2.2 Directions for all axes 5.2.2 Directions for all axes Calibration When calibrating, the axis must consistently be run towards the calibration position in the movement same direction, in order to avoid position errors caused by backlash in gears etc. Positive directions directions are shown in the figure below.

  • Page 107: Checking The Calibration Position

    5 Calibration, M2000 5.2.3 Checking the calibration position 5.2.3 Checking the calibration position General Check the calibration position before beginning any programming of the robot system. This may be done in one of two ways: • Using the program CALxxxx in the system software (xxxx signifying the robot type; IRB xxxx) •...

  • Page 108: Positions And Directions Of Sensor

    5 Calibration, M2000 5.2.4 Positions and directions of sensor 5.2.4 Positions and directions of sensor General This section details the mounting positions and directions for the • reference sensor • calibration sensor When calibrating an axis with only one sensor, the sensor must first be positioned at the base of the manipulator in order to create reference values.
  • Page 109 5 Calibration, M2000 5.2.4 Positions and directions of sensor Axis 4 Axis 3 Direction for sensor at reference plane, axis 2, 3 and 5 Direction for sensor at reference plane, axis 4 and 6 3HAC021111-001 Revision: B...

  • Page 110: Initialization Of Levelmeter 2000

    5 Calibration, M2000 5.2.5 Initialization of Levelmeter 2000 5.2.5 Initialization of Levelmeter 2000 Overview Whenever Levelmeter 2000 is used for calibrating the robot, the equipment must first be initialized as detailed in this section. Shown below is an outline of how to initialize the Levelmeter 2000. Detailed procedures are given further down.
  • Page 111 5 Calibration, M2000 5.2.5 Initialization of Levelmeter 2000 Step Action Info/Illustration If type 5 does not flash, press ZERO/SELECT to select filter type 5 and press ENTER . Measuring units Step Action Info/Illustration Press ON/MODE until the dot flashes under UNIT . Shown in the figure Level- meter 2000 on page 108! Press ENTER.

  • Page 112: Calibration

    5 Calibration, M2000 5.3.1 Calibration axis 1 5.3: Calibration 5.3.1 Calibration axis 1 Location of axis 1 The axis 1 is located as shown in the figure below The special calibration equipment is fitted to the base of the manipulator as shown in the figure below.
  • Page 113 5 Calibration, M2000 5.3.1 Calibration axis 1 Calibration, axis 1 The procedure below details how to calibrate axis 1 NOTE! Make sure the sensors and sensor positions on the manipulator are clean and free from metal- lic materials! Step Action Info/Illustration Move the robot to its calibration position corre- sponding to the calibration scales.

  • Page 114: Calibration, Axis 2

    5 Calibration, M2000 5.3.2 Calibration, axis 2 5.3.2 Calibration, axis 2 General This section details how to perform the actual fine calibration of axis 2 using the Wyler cali- bration equipment. Required equipment Equipment Art. no. Note Levelmeter 2000 cali- 6369 901-347 Includes one sensor.
  • Page 115 5 Calibration, M2000 5.3.2 Calibration, axis 2 Step Action Illustration Manually run axis 2 in with the joystick to the Correct measurement on the level- correct position as indicated by the levelme- meter: ter. 0 ±0.40 mm/m Tip! Reduce the jogging velocity in order to easily position the axis as close to zero as possi- ble! Update only axis 2.

  • Page 116: Calibration, Axis 3

    5 Calibration, M2000 5.3.3 Calibration, axis 3 5.3.3 Calibration, axis 3 General This section details how to perform the actual fine calibration of axis 3 using the Wyler cali- bration equipment. Required equipment Equipment Art. no. Info Levelmeter 2000 calibra- 6369 901-347 Includes one sensor.
  • Page 117 5 Calibration, M2000 5.3.3 Calibration, axis 3 Step Action Illustration/Info Fit the calibration sensor unit (sensor and Shown in the section Positions plate) on the turning disk fixture. and directions of sensor on page 106! Carefully tighten the securing screws with approximately same tightening torque that used at the reference plane.

  • Page 118: Calibration, Axis 4

    5 Calibration, M2000 5.3.4 Calibration, axis 4 5.3.4 Calibration, axis 4 General This section details how to perform the actual fine calibration of axis 4 using the Wyler cali- bration equipment. Required equipment Equipment Art. no. Info Levelmeter 2000 calibra- 6369 901-347 Includes one sensor.
  • Page 119 5 Calibration, M2000 5.3.4 Calibration, axis 4 Step Action Illustration Fit the calibration sensor unit (sensor and plate) on Shown in the section Posi- the turning disk fixture. tions and directions of sen- sor on page 106! Carefully tighten the securing screws with approxi- mately same tightening torque that used at the refer- ence plane.

  • Page 120: Calibration, Axis 5

    5 Calibration, M2000 5.3.5 Calibration, axis 5 5.3.5 Calibration, axis 5 General This section details how to perform the actual fine calibration of axis 5 using the Wyler cali- bration equipment. Required equipment Equipment Art. no. Info Levelmeter 2000 cali- 6369 901-347 bration kit with one sen- Sensor plate...
  • Page 121 5 Calibration, M2000 5.3.5 Calibration, axis 5 Step Action Illustration Fit the calibration sensor on the turning disk fixture. Shown in the section Posi- tions and directions of sen- Carefully tighten the securing screws with approxi- sor on page 106! mately same tightening torque that used at the refer- ence plane.

  • Page 122: Calibration, Axis 6

    5 Calibration, M2000 5.3.6 Calibration, axis 6 5.3.6 Calibration, axis 6 General This section details how to perform the actual fine calibration of axis 6 using the Wyler cali- bration equipment. Required equipment Equipment Art. no. Info Levelmeter 2000 calibra- 6369 901-347 tion kit with one sensor Sensor plate...
  • Page 123 5 Calibration, M2000 5.3.6 Calibration, axis 6 Step Action Illustration Update only axis 6. Detailed in section Fine cali- bration procedure on TPU on page 122. Remove the sensor. Check the calibration according to section Post cal- ibration procedure on page 129. Refit the cover plate on the reference surface at the base.

  • Page 124: Fine Calibration Procedure On Tpu

    5 Calibration, M2000 5.3.7 Fine calibration procedure on TPU 5.3.7 Fine calibration procedure on TPU General This section details how to use the Teach Pendant Unit (TPU) when performing a fine cali- bration of the robot. The method of fitting the calibration equipment to each axis is detailed in the calibration instruction for the axis.
  • Page 125 5 Calibration, M2000 5.3.7 Fine calibration procedure on TPU Step Action Note/Illustration Select the desired unit and choose Fine Cali- brate from the Calib menu. A Warning window appears. xx0100000203 Move the desired robot axis according to the cali- bration procedure for cur- rent axis.

  • Page 126: Resetting Of Levelmeter 2000 And Sensor

    5 Calibration, M2000 5.3.8 Resetting of Levelmeter 2000 and sensor 5.3.8 Resetting of Levelmeter 2000 and sensor General The equipment must first be reset before calibrating each axis. This section details how to reset the Levelmeter 2000 and make the one sensor ready for calibration.
  • Page 127 5 Calibration, M2000 5.3.8 Resetting of Levelmeter 2000 and sensor Reference sensor, fitted to the sensor plate (actual direction differs) Sensor fixture, fitted on manipulator base Attachment screws, sensor plate Required equipment Equipment Art. no. Note Levelmeter, one sensor 6369 901-347 Includes one sensor.
  • Page 128 5 Calibration, M2000 5.3.8 Resetting of Levelmeter 2000 and sensor Step Action Info/Illustration Clean the sensor plate attachment area on the fixture with isopropanol. Fit the sensor unit (sensor plate and sensor) on Correct direction is shown in to the sensor fixture and connect the sensor to Positions and directions of sen- the Levelmeter 2000.

  • Page 129: Updating The Revolution Counters

    5 Calibration, M2000 5.3.9 Updating the revolution counters 5.3.9 Updating the revolution counters Manually running This section details the first step when updating the revolution counter; manually running the the manipulator manipulator to the calibration position. to the calibration position Step Action Illustration...
  • Page 130 5 Calibration, M2000 5.3.9 Updating the revolution counters Step Action Illustration Select the desired unit and choose Rev Counter Update from the Calib menu. The Revolution Counter Update window appears. xx0100000202 Select the desired axis and press Incl to include it (it will be marked with an x) or press All to select all axes.

  • Page 131: After Calibration

    5 Calibration, M2000 5.4.1 Post calibration procedure 5.4: After calibration 5.4.1 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 Action Illustration Run the calibration home position program twice.
  • Page 132 5 Calibration, M2000 5.4.1 Post calibration procedure 3HAC021111-001 Revision: B...

  • Page 133: 6: Calibration Information

    The resolver val- If resolver values are changed, the robot must be recalibrated using the calibration methods ues are changed supplied from ABB. Calibrate the robot carefully with standard calibration. The different methods are briefly described in section Calibration methods on page 133, and further detailed in separate Calibration manuals.

  • Page 134: Calibration Methods

    6 Calibration information 6.0.2 Calibration methods 6.0.2 Calibration methods Overview This section specifies the different types of calibration and the calibration methods that are supplied from ABB. Types of cali- bration Type of Description Calibration method calibration Standard calibra- The calibrated robot is positioned at home...
  • Page 135 Calibration Pen- Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB dulum - standard 6400R, IRB 640, IRB 1400H and IRB 4400S) and is also the most accurate method for the method standard type of calibration.

  • Page 136: Calibration Scales And Correct Axis Position

    6.0.3 Calibration scales and correct axis position Introduction This section specifies the calibration scale positions and/or correct axis position for all robot models. Calibration The illustration below shows the calibration scale positions on IRB 1400: scales, IRB 1400 en0200000272 3HAC021111-001 Revision: B...

  • Page 137: Calibration Movement Directions For All Axes

    6 Calibration information 6.0.4 Calibration movement directions for all axes 6.0.4 Calibration movement directions for all axes Overview 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.

  • Page 138: Updating Revolution Counters

    Flex- Action Pendant On the ABB menu, tap Calibration. All mechanical units connected to the system are shown along with their calibration status. Tap the mechanical unit in question. A screen is displayed: tap Rev. Counters.
  • Page 139 6 Calibration information 6.0.5 Updating revolution counters Action Tap Update Revolution Counters..A dialog box is displayed, warning that updating the revolution counters may change programmed robot positions: Tap Yes to update the revolution counters. Tap No to cancel updating the revolution counters. Tapping Yes displays the axis selection window.

  • Page 140: Checking The Calibration Position

    FlexPendant, Action Note IRC5 On ABB menu tap Program Editor. Create a new program. Use MoveAbsJ in the Motion&Proc menu. Create the following program: MoveAbsJ [[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E 9]]\NoEOffs, v1000, z50, Tool0 Run the program in manual mode.
  • Page 141 6 Calibration information 6.0.6 Checking the calibration position 3HAC021111-001 Revision: B...

  • Page 143: 7: Alternative Calibration

    7 Alternative calibration 7.0.1 Alternative calibration position 7: Alternative calibration 7.0.1 Alternative calibration position General The manipulator may be calibrated in alternative positions. The regular calibration instruc- tions detailed for each axis are intended for calibration position 0, i.e. the normal position Calibration instructions for alternative positions are detailed in Alternative calibrating on page 128.

  • Page 144: Alternative Calibrating

    7 Alternative calibration 7.0.2 Alternative calibrating 7.0.2 Alternative calibrating General The manipulator may be calibrated in any of three positions, shown in Alternative calibration position on page 127. Procedure Step Action Illustration Calibrate the robot in position 0 for all axes. Set an alternative calibration position before installation if the final installation makes it impossible to reach the calibration 0 position.

  • Page 145: New Calibration Position

    7 Alternative calibration 7.0.3 New calibration position 7.0.3 New calibration position Procedure Use these instructions to change to a new calibration position for axis 1 during definition of a new calibration position. Step Action Illustration Press the "Miscellaneous" button xx0100000194 Select the System parameters window by pressing ENTER.

  • Page 146: New Calibration Offset

    7 Alternative calibration 7.0.4 New calibration offset 7.0.4 New calibration offset Procedure Use these instructions when changing to a new calibration offset for axis 1 during definition of a new calibration position. Step Action Illustration Press the "Miscellaneous" button. xx0100000194 Select the Service window by press- ing ENTER.

  • Page 147: Retrieving Offset Values

    7 Alternative calibration 7.0.5 Retrieving offset values 7.0.5 Retrieving offset values Procedure Use these instructions when retrieving new offset values for axis 1 during definition of a new calibration position. Step Action Illustration Press the “Micellaneous” button. xx0100000194 Select the system parameters window by pressing ENTER.
  • Page 148 7 Alternative calibration 7.0.5 Retrieving offset values 3HAC021111-001 Revision: B...

  • Page 149: 8: Reference Information, Irb 1400

    8 Reference information, IRB 1400 8.0.1 Introduction 8: Reference information, IRB 1400 8.0.1 Introduction General This chapter includes general information, complementing the more specific information in the following chapters. 3HAC021111-001 Revision: B...

  • Page 150: Applicable Safety Standards

    8 Reference information, IRB 1400 8.0.2 Applicable Safety Standards 8.0.2 Applicable Safety Standards Standards, The robot is designed in accordance with the requirements of: general • EN ISO 10218-1 : 2006, Robots for industrial environments - Safety requirements - Part 1 Robot •...

  • Page 151: Unit Conversion

    8 Reference information, IRB 1400 8.0.3 Unit conversion 8.0.3 Unit conversion Converter table Use the table below to convert units used in this manual. Quantity Units Length 3.28 ft 39.37 in Weight 1 kg 2.21 lb Pressure 1 bar 100 kPa 14.5 psi...

  • Page 152: Screw Joints

    The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials. UNBRAKO UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It screws features special surface treatment (Gleitmo as described below), and is extremely resistant to fatigue.
  • Page 153 8 Reference information, IRB 1400 8.0.4 Screw joints Tightening torque Before tightening any screw, note the following: • Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure description.
  • Page 154 8 Reference information, IRB 1400 8.0.4 Screw joints The table below specify the recommended standard tightening torque for Molycote-lubri- cated screws with Allen head screws. Tightening torque (Nm) Tightening torque (Nm) Dimension Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated The table below specify the recommended standard tightening torque for water and air con- nectors when one or both connectors are made of brass.

  • Page 155: Weight Specifications

    All components exceeding 22 kg (50 lbs) are high-lighted in this way. To avoid injury, ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each manipulator model.

  • Page 156: Document References

    8 Reference information, IRB 1400 8.0.6 Document references 8.0.6 Document references General The contents of this manual may include references to additional documentation necessary to perform certain procedures. This section specifies the article numbers for the referenced doc- umentation. Product specifi- The product specification includes generic technical data.

  • Page 157: Standard Toolkit, Irb 1400

    8 Reference information, IRB 1400 8.0.7 Standard toolkit, IRB 1400 8.0.7 Standard toolkit, IRB 1400 General All service (repair, maintenance and installation) instructions contain lists of tools required to perform the specified activity. All special tools, i.e. all tools that are not considered stan- dard as defined below, are listed in their instructions respectively.

  • Page 158: Performing A Leak-Down Test

    8 Reference information, IRB 1400 8.0.8 Performing a leak-down test 8.0.8 Performing a leak-down test General After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test.

  • Page 159: Lifting Equipment And Lifting Instructions

    8 Reference information, IRB 1400 8.0.9 Lifting equipment and lifting instructions 8.0.9 Lifting equipment and lifting instructions General Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each procedure. The use of each piece of lifting equipment is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting equipment.
  • Page 160 8 Reference information, IRB 1400 8.0.9 Lifting equipment and lifting instructions 3HAC021111-001 Revision: B...

  • Page 161: 9: Spare Part List

    9 Spare part list 9.0.1 Introduction 9: Spare part list 9.0.1 Introduction Item number refers to item number on the foldouts. Article numbers marked with bold text are specially designed as spare parts (painted etc.). 3HAC021111-001 Revision: B...

  • Page 162: Manipulator Complete

    9 Spare part list 9.0.2 Manipulator complete 9.0.2 Manipulator complete Manipulator See foldouts 1, 2, 3, 4 and 5 to locate the item numbers. complete Item Qty Name Art. no. Remark Foot 3HAB 3443-1 Gears, axes 1-3 3HAB 3272-1 Plain washer 9ADA 312-9 13x24x2.5 Screw...
  • Page 163 9 Spare part list 9.0.2 Manipulator complete Item Qty Name Art. no. Remark Motor unit axis 3 3HAC 1618-1 Elmo, Gear box Samp- ingranaggi Motor unit axis 3 3HAC 021963-001 Yaskawa Lifting eye 2179 090-25 Sync.marker 3HAB 3296-1 Stop pin 3HAB 3258-1 Cushion axis 3 3HAB 3254-1...
  • Page 164 9 Spare part list 9.0.2 Manipulator complete Item Qty Name Art. no. Remark Shaft 3HAB 3256-1 Spacer 3HAB 3264-1 M5x140 Washer 3HAA 2355-11 Screw 9ADA 183-36 MC6S, M8x20 Sealing washer 3HAB 3767-1 9ADA 267-8 Bracket 3HAB 3225-1 Bracket 3HAB 9387-1 Spring 3HAB 3291-1 Cable guide...
  • Page 165 9 Spare part list 9.0.2 Manipulator complete Item Qty Name Art. no. Remark Tapping screw 2121 2477-291 M4x12 Bracket SK 616 013-F Actuator 1SFA616100R1006 Black Protective cover 1SFA616920R8010 Sealing 3HAB 3293-1 Straps (outdoor) 2166 2055-1 L=92 mm Tapping screw 9ADA 624-44 M5x12 Dust cap 5217 649-9...

  • Page 166: Arm Housing, Complete

    9 Spare part list 9.0.3 Arm housing, complete 9.0.3 Arm housing, complete Arm housing, See foldout 6 to locate the item numbers. complete Item Name Art. no. Remark Tubular shaft 3HAB 3270-1 Back-up ring 3HAB 6354-1 Ball bearing 2213 253-12 61821-2RS1 Housing axis 4 3HAB 3201-1...

  • Page 167: Drive Unit, Axes 5-6

    9 Spare part list 9.0.4 Drive unit, axes 5-6 9.0.4 Drive unit, axes 5-6 Drive unit, axes 5- See foldouts 7, 8 and 9 to locate the item numbers. Item Name Art. no. Remark Driving shaft, 5-6 3HAC 11305-1 Motor unit, axes 5 - 6 3HAC 11865-1 Elmo Motor unit, axes 5 - 6...

  • Page 168: Serial Measurement Unit

    9 Spare part list 9.0.5 Serial measurement unit 9.0.5 Serial measurement unit Serial mea- See foldout 10 to locate the item numbers. surement unit Item Name Art. no. Remark Battery 4944 026-4 Straps, outdoor 2166 2055-6 L=368 mm Serial measurement board 3HAC021905-001 DSQC 633 Signal cable 3HAB 3774-1...

  • Page 169: 10: Foldouts

    10 Foldouts 10.0.1 Introduction 10: Foldouts 10.0.1 Introduction Overview This chapter includes foldouts with illustrations of the robot. The item numbers are specified in chapter Spare part list on page 159. 3HAC021111-001 Revision: B...
  • Page 170 10 Foldouts 10.0.1 Introduction 3HAC021111-001 Revision: B...
  • Page 181 11 Circuit diagram 11.0.1 Introduction 11: Circuit diagram 11.0.1 Introduction Overview This chapter includes the complete circuit diagram for the robot. 3HAC021111-001 Revision: B...
  • Page 182 11 Circuit diagram 11.0.1 Introduction 3HAC021111-001 Revision: B...
  • Page 183 11 Circuit diagram 11.0.2 Sheet 101 List of contents 11.0.2 Sheet 101 List of contents 3HAC021111-001 Revision: B...

  • Page 184: Sheet 102 Connection Point Location

    11 Circuit diagram 11.0.3 Sheet 102 Connection point location 11.0.3 Sheet 102 Connection point location 3HAC021111-001 Revision: B...

  • Page 185: Sheet 103 Serial Measurement Board

    11 Circuit diagram 11.0.4 Sheet 103 Serial measurement board 11.0.4 Sheet 103 Serial measurement board 3HAC021111-001 Revision: B...

  • Page 186: Sheet 104 Motor Axes 1 - 3

    11 Circuit diagram 11.0.5 Sheet 104 Motor axes 1 - 3 11.0.5 Sheet 104 Motor axes 1 - 3 3HAC021111-001 Revision: B...

  • Page 187: Sheet 105 Feedback Axes 1 - 3

    11 Circuit diagram 11.0.6 Sheet 105 Feedback axes 1 - 3 11.0.6 Sheet 105 Feedback axes 1 - 3 3HAC021111-001 Revision: B...

  • Page 188: Sheet 106 Motor Axes 4 - 6

    11 Circuit diagram 11.0.7 Sheet 106 Motor axes 4 - 6 11.0.7 Sheet 106 Motor axes 4 - 6 3HAC021111-001 Revision: B...

  • Page 189: Sheet 107 Feedback Axes 4 - 6

    11 Circuit diagram 11.0.8 Sheet 107 Feedback axes 4 - 6 11.0.8 Sheet 107 Feedback axes 4 - 6 3HAC021111-001 Revision: B...

  • Page 190: Sheet 108 Customer Connection (Option)

    11 Circuit diagram 11.0.9 Sheet 108 Customer connection (Option) 11.0.9 Sheet 108 Customer connection (Option) 3HAC021111-001 Revision: B...

  • Page 191: Sheet 109 Integrated Wirefeed Cabling (Option)

    11 Circuit diagram 11.0.10 Sheet 109 Integrated wirefeed cabling (Option) 11.0.10 Sheet 109 Integrated wirefeed cabling (Option) 3HAC021111-001 Revision: B...

  • Page 192: Sheet 110 Position Indicator Axis 1

    11 Circuit diagram 11.0.11 Sheet 110 Position indicator axis 1 11.0.11 Sheet 110 Position indicator axis 1 3HAC021111-001 Revision: B...

  • Page 193: Sheet 111 External Connections (Option)

    11 Circuit diagram 11.0.12 Sheet 111 External connections (Option) 11.0.12 Sheet 111 External connections (Option) 3HAC021111-001 Revision: B...
  • Page 194 11 Circuit diagram 11.0.12 Sheet 111 External connections (Option) 3HAC021111-001 Revision: B...
  • Page 195 Index robot position Absolute Accuracy, calibration scales on robot sync marks calibrating roughly, calibration Updating revolution counters Absolute Accuracy type, updating revolution counters alternative method, Calibration Pendulum, Levelmeter calibration, marks/scales, rough, standard method, standard type, when to calibrate, calibration manuals Calibration Pendulum Calibration position calibration position...
  • Page 196 Index...
  • Page 198 ABB AB Robotics Products S-721 68 VÄSTERÅS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592...

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