Table Of Contents - ABB IRB 14000 Product Manual

Table of Contents

Table Of Contents5
Organization Of Chapters9
Overview Of This Manual9
References10
Product Documentation, Irc512
Categories For User Documentation From Abb Robotics12
Product Manuals12
Technical Reference Manuals12
Application Manuals13
Operating Manuals13
How To Read The Product Manual14
Safety Information14
Illustrations14
Network Security15
Introduction To Safety Information17
General Safety Information18
Introduction To General Safety Information18
Sections18
Safety In The Robot System19
Validity And Responsibility19
Connection Of External Safety Devices19
Limitation Of Liability19
Safety In Collaborative Operation20
Mechanical Design Measures20
Certified Safety Functions20
Personal Protective Equipment20
Design Of Work Pieces And End Effectors21
Safety Risks During Installation And Service Work On Robots22
General Risks During Installation And Service22
Spare Parts And Special Equipment22
Complete Robot23
Cabling23
Gearboxes And Motors23
Elimination24
Caution - Hot Parts May Cause Burns24
Safety Risks Related To Tools/Work Pieces25
Safe Handling25
Safe Design25
Safety Risks Related To Pneumatic Systems26
Pneumatic System Related Risks26
Safety Risks With Pressure Relief Valve27
Safety Risks During Operational Disturbances28
Qualified Personnel28
Extraordinary Risks28
Risks Associated With Live Electric Parts29
Voltage Related Risks, General29
Voltage Related Risks, Irc5 Controller29
Voltage Related Risks, Robot29
Voltage Related Risks, Tools, Material Handling Devices, Etc.30
Safety Risks For Collaborative Robots31
Safety Risks In Collaborative Operation31
Safe Design Of The Robot Cell31
Safety Actions32
Fire Extinguishing32
Emergency Release Of The Robot Arm33
Increased Injury33
Manually Stopping Or Overriding The Arm34
Brake Testing35
How To Test35
Risk Of Disabling Function "Reduced Speed 250 Mm/S36
Handling Of The Flexpendant37
Handling And Cleaning37
Cabling And Power Supply37
Three-Position Enabling Device38
Waste Disposal38
Work Inside The Working Range Of The Robot39
Signal Lamp (Optional)40
Safety Stops41
What Is An Emergency Stop41
Definition Of Emergency Stop41
Emergency Stop Buttons41
What Is A Safety Stop Or Protective Stop?42
Definition Of Safety Stops42
What Is Cartesian Speed Supervision?43
Definition Of Cartesian Speed Supervision43
Safety Signals In The Manual44
Introduction To Safety Signals44
Danger Levels44
Safety Symbols On Product Labels46
Types Of Labels46
Symbols On Safety Labels46
Danger - Moving Robots Are Potentially Lethal52
Safety Related Instructions52
Danger - First Test Run May Cause Injury Or Damage53
Elimination, Controller54
Danger - Make Sure That The Main Power Has Been Switched Off54
Warning - The Unit Is Sensitive To Esd55
Warning - Safety Risks During Handling Of Batteries56
Warning - Safety Risks During Work With Gearbox Lubricants (Oil Or Grease)57
Installation And Commissioning59
Introduction59
Unpacking60
Pre-Installation Procedure60
Checking The Pre-Requisites For Installation60
Weight, Robot61
Loads On Foundation, Robot61
Table Mounted61
Requirements, Foundation62
Storage Conditions, Robot62
Operating Conditions, Robot62
Protection Classes, Robot63
Dimensions64
Working Range65
Illustration, Working Range Irb 1400065
Front View65
Side View66
Top View66
Isometric View67
Robot Motion67
Risk Of Tipping/Stability68
Shipping And Transport Position68
On-Site Installation69
Lifting The Robot With Lifting Accessories69
Required Equipment69
Lifting The Robot By Two Persons72
Attachment Screws And Pins72
Lifting And Transporting The Robot72
Orienting And Securing The Robot74
Hole Configuration, Base74
Specification, Attachment Screws And Pins75
Manually Releasing The Brakes77
Introduction To Manually Releasing The Brakes77
Location Of Brake Release Button77
Releasing The Brakes78
Loads Fitted To The Robot79
Installing The Signal Lamp80
Location Of Signal Lamp80
Required Parts80
Required Tools And Equipment81
Removing The Body Covers81
Refitting The Body Covers83
Electrical Connections86
Robot Cabling And Connection Points86
Main Cable Categories86
Main Power Cable86
Controller87
Overview87
Controller Interface, Left Side88
Controller Interface, Right Side89
Connecting Power And The Flexpendant90
Connecting Power Supply90
Line Fusing90
Rated Power90
Connecting Power To The Controller91
Connecting A Flexpendant91
Connecting A Pc And Ethernet Based Options92
Multiple Ethernet Based Options92
Connectors On The Computer Unit93
Service Port93
Wan Port94
Lan Ports94
Isolated Lan 3 Or Lan 3 As Part Of The Private Network95
Usb Ports96
Connecting I/O Signals97
Tool I/O97
Tool I/O, Left And Right Arm97
Digital Inputs97
Digital Inputs And Outputs98
Connecting Fieldbuses99
Expansion Board For Fieldbus Adapters100
Fieldbus Adapters100
Devicenet Master/Slave Board101
Termination Resistors In The Devicenet Bus101
Connecting Safety Signals102
Standalone Safety102
Safety When Connected To External Devices103
Safety Plc103
Rt6 Safety Relay (Option 1526-X)104
Memory Functions105
Sd-Card Memory105
Connecting An Usb Memory106
Location On The Controller106
Location On The Flexpendant106
Maintenance107
Structure Of This Chapter107
Maintenance Schedule108
Specification Of Maintenance Intervals108
Scheduled And Non-Predictable Maintenance109
Life Of Each Component109
Activities And Intervals, Standard Equipment109
Activities And Intervals, Optional Equipment110
Inspection Activities111
Inspecting The Information Labels111
Location Of Labels111
Required Spare Parts113
Inspecting, Labels114
Inspecting, Signal Lamp115
Inspecting, Cable Harness117
Location Of Cable Harness117
Inspecting The Cable Harness118
Inspecting, Plastic And Padding119
Location Of Plastic And Padding119
Replacement/Changing Activities121
Replacing The Battery Pack121
Location Of Battery Pack121
Removing The Battery Pack122
Preparations Before Removing The Battery Pack122
Refitting The Battery Pack124
Cleaning The Irb 14000126
Cleaning Activities126
Repair127
General Procedures128
Mounting Instructions For Seals128
Rotating Seals128
Flange Seals And Static Seals129
O-Rings129
Replacing The Complete Arm130
Arm And Arm Covers130
Location Of The Complete Arm130
Covers To Be Removed For Access131
Preparations Before Removing The Arm132
Removing The Axis-1 Covers133
Removing The Arm From The Body With Cabling Still Connected135
Disconnecting The Arm Cabling From The Controller137
Refitting The Arm138
Refitting The Arm To The Body138
Connecting The Arm Cabling To The Controller139
Refitting The Remaining Screws Between The Arm And The Body140
Refitting The Axis-1 Covers141
Concluding Procedure144
Replacing The Encapsulation And Covers145
Location Of Arm Covers145
Replacing The Arm Covers145
Information For Replacement145
Replacing The Axis-1 Motor148
Location Of The Axis-1 Motor148
Replacing The Axis-2 Motor149
Location Of The Axis-2 Motor149
Consumables150
Preparations Before Removing The Motor152
Removing The Motor152
Removing The Axis-2 Covers157
Removing The Axis-2 Motor157
Removing The Wave Generator From The Motor159
Refitting The Motor159
Fitting A New O-Ring On The Motor159
Fitting The Wave Generator To The Motor160
Refitting The Axis-2 Motor164
Replacing The Axis-7 Motor171
Location Of The Axis-7 Motor171
Replacing The Axis-3 Motor172
Location Of The Axis-3 Motor172
Removing The Axis-3 Motor175
Replacing The Axis-4 Motor185
Location Of The Axis-4 Motor185
Checking The O-Ring On The Motor190
Replacing The Axis-5 Motor199
Location Of The Axis-5 Motor199
Replacing The Axis-6 Motor211
Location Of The Axis-6 Motor211
Hall Sensors226
Replacing The Axis-1 Hall Sensor226
Location Of The Hall Sensor226
Removing The Hall Sensor227
Preparations Before Removing The Hall Sensor227
Replacing The Axis-2 Hall Sensor241
Replacing The Axis-7 Hall Sensor248
Replacing The Axis-3 Hall Sensor255
Replacing The Axis-4 Hall Sensor262
Mechanical Stops270
Replacing The Axis-1 Mechanical Stop270
Preparations Before Removing The Mechanical Stop271
Refitting The Mechanical Stop276
Replacing The Axis-2 Mechanical Stop281
Location Of The Mechanical Stop281
Replacing The Axis-7 Mechanical Stop289
Replacing The Axis-3 Mechanical Stop294
Replacing The Computer302
Location Of The Computer302
Product Manual - Irb303
Replacing The Controller Fan310
Location Of The Controller Fan310
Preparations Before Removing The Fan311
Removing The Fan311
Replacing The Fan312
Refitting The Fan312
Replacing The Capacitor Bank314
Location Of The Capacitor Bank314
Removing The Capacitor Bank315
Pulling The Controller Out Partially315
Replacing The Power Supply321
Location Of The Power Supply321
Removing The Power Supply322
Preparations Before Removing The Power Supply322
Refitting The Power Supply323
Replacing The Power Distribution Board325
Location Of The Power Distribution Board325
Removing The Power Distribution Board326
Replacing The External Power Distribution Board332
Location Of The External Power Distribution Board332
Removing The External Power Distribution Board333
Refitting The External Power Distribution Board335
Refitting The External Power Supply335
Replacing The Axis Computer338
Location Of The Axis Computer338
Removing The Axis Computer339
Refitting The Axis Computer341
Pushing The Controller In And Fastening It342
Replacing The Left Arm's Drive Board345
Location Of The Drive Board345
Removing The Left Arm's Drive Board346
Removing The I/O Board347
Removing The Smb Board347
Refitting The Left Arm's Drive Board349
Refitting The Smb Board351
Refitting The I/O Board351
Replacing The Right Arm's Drive Board354
Removing The Right Arm's Drive Board355
Refitting The Right Arm's Drive Board357
Replacing The I/O Board361
Location Of The I/O Board361
Remove The Body Cover362
Replacing The Smb Boards366
Location Of The Smb Board366
Replacing The Ethernet Switch372
Location Of The Ethernet Switch372
Removing The Ethernet Switch373
Replacing The Mass Memory Card376
Location Of The Mass Memory Card376
Removing The Mass Memory Card377
Replacing The Expansion Board Complete379
Location Of The Expansion Board Complete379
Removing The Computer380
Removing The Expansion Board Complete383
Removing The Fieldbus Adapter383
Refitting The Expansion Board Complete385
Replacing The Devicenet Master393
Location Of The Devicenet Master393
Removing The Devicenet Master397
Replacing The Fieldbus Adapter404
Location Of The Fieldbus Adapter404
Brake Release Harness409
Replacing The Brake Release Harness409
Location Of The Brake Release Harness409
Removing The Brake Release Harness410
Calibration417
When To Calibrate417
The Resolver Values Are Changed417
The Revolution Counter Memory Is Lost417
Calibration Method418
Type Of Calibration418
Calibration Scale And Correct Axis Position419
Calibrating The Robot420
Synchronization Position420
Illustration Of Robot In Synchronization Position420
Exact Axis Positions In Degrees420
Calibrating The Robot With Fine Calibration Procedure421
Moving The Robot To Its Calibration Position421
Setting The Running Speed To 100%421
Selecting The Calibration With Hall Sensors (Calhall) Routine421
Selecting The Function Fine Calibration422
Updating Revolution Counters428
Manually Moving The Manipulator To The Calibration Position428
Selecting The Function Update Of Revolution Counters429
Storing The Revolution Counter Setting431
Calibration Movement Directions For All Axes434
Calibration Movement Directions, 7 Axes434
Verifying The Calibration Position435
Using A Moveabsj Instruction435
Using The Jogging Window435
Decommissioning437
Environmental Information438
Hazardous Material438
Oil And Grease438
Scrapping Of Robot439
Important When Scrapping The Robot439
Reference Information441
Applicable Safety Standards442
Standards, En Iso442
Deviations From Iso 10218-1:2011442
Unit Conversion444
Converter Table444
Specification Of Screws445
Screws Handled As Spare Part445
Screws Not Handled As Spare Parts445
Screw Joints447
Unbrako Screws447
Gleitmo Treated Screws447
Screws Lubricated In Other Ways447
Weight Specifications448
Definition448
Standard Toolkit449
Contents, Standard Toolkit449
Special Tools450
Lifting Accessories And Lifting Instructions452
Index453