IRC5-IRB1400 Prod Man 3HAC021111-001 Procedures Rev- En

Product manual (part 1 of 2), proceduresArticulated robotIRB 1400

M2000, M2004

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Product manual (part 1 of 2)Procedures3HAC 021111-001

Revision -

Articulated robotIRB 1400

M2000

M2004

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

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.

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

This manual and parts thereof must not be reproduced or copied without ABB’s written per-mission, and contents thereof must not be imparted to a third party nor be used for any unau-thorized purpose. Contravention will be prosecuted.

Additional copies of this manual may be obtained from ABB at its then current charge.

©Copyright 2004 ABB All right reserved.

ABB Automation Technologies ABRobotics

SE-721 68 VästeråsSweden

Table of Contents

0.0.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70.0.2 Product documentation, M2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90.0.3 Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

1: Safety, service 13

1.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

1.1: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141.1.1 Safety, service - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141.1.2 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141.1.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

1.2: Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151.2.1 Safety risks related to gripper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151.2.2 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151.2.3 Safety risks related to pneumatic/hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151.2.4 Safety risks during operational disturbances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161.2.5 Safety risks during installation and service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161.2.6 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

1.3: Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181.3.1 Safety fence dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181.3.2 Fire extinguishing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181.3.3 Emergency release of the manipulator’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181.3.4 Brake testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191.3.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191.3.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191.3.7 Work inside the manipulator’s working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201.3.8 Signal lamp (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

2: Installation and commissioning 21

2.0.1 Transporting and Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212.0.2 Stability / Risk of Tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222.0.3 System CD ROM and Diskette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232.0.4 Transport Locking Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

2.1: On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .252.1.1 Lifting the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .252.1.2 Turning the Manipulator (Inverted Suspension Application) . . . . . . . . . . . . . . . . . . . . . . . . .262.1.3 Assembling the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .272.1.4 Suspended Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .282.1.5 Stress Forces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292.1.6 Amount of Space required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302.1.7 Manually engaging the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312.1.8 Restricting the Working Space. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .322.1.9 Mounting Holes for Equipment on the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .352.1.10 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

2.2: Customer connections on manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .372.2.1 Air supply and signals for extra equipment to upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . .372.2.2 Connection of Extra Equipment to the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

3: Maintenance 41

3.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .413.0.2 Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

3.1: Instructions for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .433.1.1 Oil in gears 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .433.1.2 Greasing axes 5 and 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

3HAC 021111-001 3

Table of Contents

3.1.3 Lubricating spring brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453.1.4 Changing the battery in the measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463.1.5 Checking the mechanical stop, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4: Repair 49

4.1: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494.1.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494.1.2 Instructions for reading the following sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514.1.3 Caution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524.1.4 Fitting new Bearings and Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534.1.5 Instructions for tightening Screw Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554.1.6 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564.1.7 Checking for play in gearboxes and wrist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

4.2: Axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584.2.1 Changing the motor of axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584.2.2 Changing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594.2.3 Position indicator in axis 1 (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614.2.4 Replacing the mechanical stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

4.3: Axis 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634.3.1 Changing the motor of axis 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634.3.2 Changing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644.3.3 Dismantling the lower arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 654.3.4 Changing the bearings in the upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 664.3.5 Dismantling the balancing springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4.4: Axis 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 684.4.1 Changing the motor of axis 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 684.4.2 Changing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 694.4.3 Dismantling the parallel arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704.4.4 Changing the tie rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714.4.5 Dismantling the complete upper arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

4.5: Axis 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 754.5.1 Changing the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 754.5.2 Changing the intermediate gear including sealing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764.5.3 Dismantling the drive gear on the tubular shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 784.5.4 Dismantling the tubular shaft and changing bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

4.6: Cabling and serial measuring board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814.6.1 Changing serial measuring boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814.6.2 Changing the cabling in axes 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 824.6.3 Changing the cabling in axes 4, 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

4.7: The wrist and axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 844.7.1 Dismantling the wrist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 854.7.2 Dismantling the complete drive mechanism of axes 5 and 6. . . . . . . . . . . . . . . . . . . . . . . . . . 864.7.3 Changing the motor or driving belt of axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 874.7.4 Measuring play in axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

4.8: Motor units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 894.8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

5: Calibration, M2000 91

5.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

5.1: Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 925.1.1 How to calibrate the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 925.1.2 Calibration, prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

4 3HAC 021111-001

Table of Contents

5.2: Reference information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .945.2.1 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .945.2.2 Directions for all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .965.2.3 Checking the calibration position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .975.2.4 Positions and directions of sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .995.2.5 Initialization of Levelmeter 2000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

5.3: Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1035.3.1 Calibration, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1035.3.3 Calibration, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1075.3.4 Calibration, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1095.3.5 Calibration, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1115.3.6 Calibration, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1135.3.7 Fine calibration procedure on TPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1155.3.8 Resetting of Levelmeter 2000 and sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1175.3.9 Updating the revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121

5.4: After calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1235.4.1 Post calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123

6: Calibration, M2004 125

6.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

7: Alternative calibration 127

7.0.1 Alternative calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1277.0.2 Alternative calibrating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1287.0.3 New calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1297.0.4 New calibration offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1307.0.5 Retrieving offset values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131

3HAC 021111-001 5

Table of Contents

6 3HAC 021111-001

0.0.1 Overview

0.0.1 Overview

About this manual

This manual contains instructions for

• mechanical and electrical installation of the manipulator

• maintenance of the manipulator

• mechanical and electrical repair of the manipulator.

Usage This manual should be used during

• installation, from lifting the manipulator to its work site and securing it to the foundation to making it ready for operation

• maintenance work

• repair work and calibration.

Who should read this manual?

This manual is intended for:

• installation personnel

• maintenance personnel

• repair personnel.

Prerequisites The reader should...

• be a trained maintenance/repair craftsman

• have the required knowledge of mechanical and electrical installation/repair/mainte-nance work.

Organization of chapters

The manual is organized in the following chapters:

References

Chapter Contents

Safety, service Safety information

Installation and commissioning Information about installation of the manipulator.

Maintenance Information about maintenance work, including mainte-nance schedules.

Repair Information about repair work.

Calibration Information about calibration of the manipulator.

Decommissioning Environmental information about the manipulator.

Reference Document Id

3HAC 021111-001 Revision - 7

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.

8 Revision - 3HAC 021111-001

0.0.2 Product documentation, M2000


General The complete product documentation kit for the M2000 robot system, including controller,

manipulator and any hardware option, consists of the manuals listed below:

Hardware manuals

All hardware, manipulators and controller cabinets, will be delivered with a Product manual that is divided into two parts:

Product manual, procedures

• Safety information

• Installation and commissioning (descriptions of mechanical installation, electrical con-nections and loading system software)

• Maintenance (descriptions of all required preventive maintenance procedures includ-ing periodicity)

• Repair (descriptions of all recommended repair procedures including spare parts)

• Additional procedures, if any (calibration, decommissioning).

Product manual, reference information

• Reference information (article numbers for documentation refered to in Product man-ual, procedures, lists of tools, safety standards)

• Part list

• Foldouts or exploded views

• Circuit diagrams.

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 oper-

ation.

A complete listing of all available software manuals is available from ABB.

Hardware option manual

Each hardware option is supplied with its own documentation. Each document set contains

the types of information specified below:

• Installation information

• Repair information

• Maintenance information

In addition, spare part information is supplied for the entire option.

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General The robot documentation may be divided into a number of categories. This listing is based on

the type of information contained within the documents, regardless of whether the products

are standard or optional. 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.

Hardware manuals

All hardware, manipulators and controller cabinets, will be delivered with a Product manual that is divided into two parts:

Product manual, procedures

• Safety information

• Installation and commissioning (descriptions of mechanical installation, electrical con-nections and loading system software)

• Maintenance (descriptions of all required preventive maintenance procedures includ-ing periodicity)

• Repair (descriptions of all recommended repair procedures including spare parts)

• Additional procedures, if any (calibration, decommissioning).

Product manual, reference information

• Reference information (article numbers for documentation refered to in Product man-ual, procedures, lists of tools, safety standards)

• Part list

• Foldouts or exploded views

• Circuit diagrams.

RobotWare manuals

The following manuals describe the robot software in general and contain reference informa-

tion about it:

• RAPID Overview : An overview of the RAPID programming language.

• RAPID reference manual part 1 : Description of all RAPID instructions.

• RAPID reference manual part 2 : Description of all RAPID functions and data types.

• Technical reference manual - System parameters : Description of system parame-ters and configuration workflows.

Application manuals

Specific applications (e.g. software or hardware options) are described in Application man-uals . An application manual can describe one or several applications.

An application manual generally contains information about:

• The purpose of the application (what does it do and when is it useful)

• What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)

• How to use the application

• Examples of how to use the application

3HAC 021111-001 Revision - 11


Operating Manuals

This group of manuals is aimed at those having first hand operational contact with the robot,

i.e. production cell operators, programmers and trouble shooters, and include:

• Operating Manual - IRC5 with FlexPendant

• Operating Manual - RobotStudioOnline

• Trouble shooting Manual for the controller and manipulator

Miscellaneous A number of manuals provide generic descriptions of the robot and robot system. These

include:

• Robot fundamentals (describing the fundamental aspects, functions, concept and similar, of a robot system to provide a basic understanding of the robot system)

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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:

• Safety, service -general

• Limitation of liability

• Referenced documents

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 manipulator´s arm

• Brake testing

• Risk of disabling function "Reduced speed 250 mm/s"

• Safe use of the Teach Pendant Unit enabling device

• Work inside the manipulator´s working range

• Signal lamp (optional)

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1 Safety, service

1.1.1 Safety, service - General

1.1: General information

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 indus-

trial robot, described in the applicable documents, e.g. User’s 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 inter-

act 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 con-

necting safety devices between the robot and the peripheral equipment.

1.1.2 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.

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

Restricting the working space Product manual for the manipulator Installation and com-missioning

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1 Safety, service

1.2.1 Safety risks related to gripper

1.2: Safety risks

1.2.1 Safety risks related to gripper

Ensure that a gripper is prevented from dropping a workpiece, if such is used.

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).

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.

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.

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

Safe design • Gravity may cause any parts or objects held by these systems to drop.

• Dump valves should be used in case of emergency.

• Shot bolts should be used to prevent tools, etc., from falling due to gravity.

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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.

• Care must be taken at all times.

Qualified per-sonnel

• 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.

Extraordinary risks

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.

1.2.5 Safety risks during installation and service

General risks during instal-lation and service

• 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.

Nation/region specific regula-tions

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.

Non-voltage related risks

• Safety zones, which have to be crossed before admittance, must be set up in front of the robot's working space. Light beams or sensitive mats are suitable devices.

• Turntables or the like should be used to keep the operator 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 parallel arm.

• Energy, stored in the robot for the purpose of counterbalancing certain axes, may be released if the robot, or parts thereof, is dismantled.

• When dismantling/assembling mechanical units, watch out for falling objects.

• Be aware of stored heat energy in the controller.

• 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 tempera-ture of the motors or oil spills that can occur on the robot.

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1 Safety, service

1.2.6 Risks associated with live electric parts

To be observed by the supplier of the complete system

• 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 emer-gency stop function are interlocked in a safe manner, in accordance with the applica-ble standards for the emergency stop function.

1.2.6 Risks associated with live electric parts

Voltage related risks, general

• 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 robot’s working space.

Voltage related risks, controller

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

• Be aware of stored electrical energy (DC link) in the controller.

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

• The mains supply/mains switch

• The power unit

• The power supply unit for the computer system (230 VAC)

• The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)

• The drive unit (700 VDC)

• The service outlets (115/230 VAC)

• The power supply unit for tools, or special power supply units for the machining pro-cess

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

• Additional connections

Voltage related risks, manipu-lator

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

• The power supply for the motors (up to 800 VDC)

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

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 dam-

aged.

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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. 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.

1.3.2 Fire extinguishing

Use a CARBON DIOXIDE (CO 2 ) extinguisher in the event of a fire in the robot (manipula-tor or controller)!

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.

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, further increasing any injury!

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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. Run each manipulator axis to a position where the combined weight of the manip-ulator 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.

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.

1.3.6 Safe use of the Teach Pendant Unit

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.

To ensure safe use of the Teach Pendant Unit, the following must be implemented:

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

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

The programmer must always bring the Teach Pendant Unit with him/her, when entering the robot’s working space. This is to prevent anyone else taking control over the robot without the programmer knowing.

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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.

- The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in posi-tion < 250 mm/s. This should be the normal position when entering the working space. The position 100% ”full speed”may only be used by trained personnel who are aware of the risks that this entails.

- Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in order not to get entangled with hair or clothing. Also be aware of any danger that may be caused by rotating tools or other devices mounted on the manipulator or inside the cell.

- Test the motor brake on each axis, according to section Brake testing on page 19.

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.

Further information

Further information about the MOTORS ON/MOTORS OFF mode may be found in the chap-

ter Description, Control System in the Product manual for the controller.

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2 Installation and commissioning

2.0.1 Transporting and Unpacking

2: Installation and commissioning

2.0.1 Transporting and Unpacking

NB!Before starting to unpack and install the robot, read the safety regulations and other instructions very carefully. These are found in separate sections in the User’s Guide and Product manual.The installation shall be made by qualified installation personnel and should conform to all national and local codes.When you have unpacked the robot, check that it has not been damaged during trans-port or while unpacking.

Operating conditions

Storage conditions

If the equipment is not going to be installed straight away, it must be stored in a dry area at

an ambient temperature between -25°C and +55°C.

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

Weight The net weight of the manipulator is approximately: 225 kg

Parameter Value

Ambient temperature +5º to +45º

Relative humidity Max. 95% at constant temperature

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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.

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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. no. for the manual is detailed in section Document references in the Product manual,

reference information.

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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.

Figure 1: Transport Locking Device, Axis 2.

Transport locking device

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2.1.1 Lifting the Manipulator

2.1: On-site installation

2.1.1 Lifting the Manipulator

The best way to lift the manipulator is to use lifting straps and a traverse crane. Attach the

straps to the special eye bolts on the gear boxes for axes 2 and 3 (see figure below). The lifting

strap dimensions must comply with the applicable standards for lifting.

Never walk under a suspended load.

Figure 2: Lifting the Manipulators using a Traverse Crane.

IRB 1400H

IRB 1400

Lifting eye

Lifting eye

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2.1.2 Turning the Manipulator (Inverted Suspension Application)

2.1.2 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. Tightening torque 25 Nm.

The manipulator is lifted with a fork lift or a crane (see figure below).

Note also the positions of the arm system.

Figure 3: Turning the Manipulator.

(Fork lift)

M8x25 (x3) on both sides

Tool 3HAB 3397-1

Appr. R=580

Appr. R=860

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2.1.3 Assembling the robot

2.1.3 Assembling the robot

Manipulator The manipulator must be mounted on a level surface with the same hole layout as shown in

Figure 4. The levelness requirement of the surface is as follows:

.

Figure 4: Bolting down the Manipulator.

The manipulator is bolted down by means of three M16 bolts.

Two guide sleeves, ABB art. no. 2151 0024-169, can be fitted to the two rear bolt holes, to

allow the same robot to be re-mounted without having to re-adjust the program.

When bolting a mounting plate or frame to a concrete floor, follow the general instructions

for expansion-shell bolts. The screw joint must be able to withstand the stress loads defined

in this chapter, section Stress Forces on page 29.

Suitable bolts M16 8.8

Tightening torque 190 Nm

0.5

� 18,5

� 35 H8

38

20

455

210

35

� 18.5 H7

200

400

245

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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.

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2.1.5 Stress Forces

2.1.5 Stress Forces

Stiffness 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

Fxy and Mxy are vectors that can have any direction in the xy plane.

Figure 5: The Directions of the Stress Forces.

Force Endurance load (in operation) Max. load (emergency stop)

Fxy ± 1500 N ± 2000 N

Fz (upright) 2800 ± 500 N 2800 ± 700 N

Fz (suspended) -2800 ± 800 N -2800 ± 1000 N

Torque Endurance load (in operation) Max. load (emergency stop)

Mxy ± 1800 Nm ± 2000 Nm

Mz ± 400 Nm ± 500 Nm

X

Z

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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.

Manipulator

Figure 6: The Amount of working Space required for the Manipulator.

1051150

2541282733

1645

770

11271221

150

Axis 1 ± 170o

Axis 1 +145o

-135o

1195

1008 1444

150511

1793

50

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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. The voltage supply should be connected to the

contact at the base of the manipulator (see figure below).

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

Figure 7: Connection of External Voltage to enable Engagement of the Brakes.

External power must be connected according to Figure 7. Incorrectly connected power can release all brakes, causing simultaneously movement of all axes.

When the controller or the voltage supply is connected as illustrated above, the brakes can be

engaged using the push-button on the manipulator, see Figure 8.

WARNING: Be very careful when engaging the brakes. The axes become activated very quickly and may cause damage or injury.

Figure 8: Location of the Brake Release Button.

+24 V B8

0 V C10

Brake release button

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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. Installation of an optional extra stop for the

main axes 1, 2 and 3 is described below.

Limiting the working space using software is described in the System Parameters in the

User’s Guide.

Axis 1 The range of rotation for axis 1 can be limited mechanically by fitting extra stop lugs to the

base, see Figure 9.

Instructions for necessary machining and mounting are supplied with the kit.

NB! The original stop lug must never be removed.

Figure 9: Mechanically limiting Axis 1.

Extra stop lug for axis 1

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Axis 2 The working range of axis 2 can be limited mechanically by fitting extra stop lugs to the under

arm (see Figure 10). 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.

Figure 10: Mechanically limiting Axis 2.

Under arm

Extra stop lugs

3HAC 021111-001 Revision - 33



Axis 3 The working range of axis 3 can be limited mechanically by fitting a stop lug under the

parallel arm (see Figure 11). Axis 3 is limited upwards to 0 or -10 degrees above the horizon-

tal plane.

Instructions for doing this are supplied with the kit.

Figure 11: Extra Stop Lug for limiting Axis 3.

Extra stop lug

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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.

Figure 12: Mounting Holes for Customer Equipment.

Figure 13: The mechanical Interface (Mounting Flange).

135Mounting holesfor equipmentM8 (2x) Depth 16

120

A A

Mounting holesfor equipment, both sidesM8 (3x), R=75Depth 16

15o

120o(3x)

IRB 1400

120

135

for equipment

Depth 16

Mounting holes

M8 (2x)

A A

IRB 1400H

D=

25

D=

50

H8 h8

45oD=6 H7

M6 (4x)

R 20

A

A

4

10

A - A

2

� 0.05

� 0.3

BC B

0.06 B(4x)90o

C

D=

12

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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.

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2.2.1 Air supply and signals for extra equipment to upper arm

2.2: Customer connections on manipulator


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. Connections: R1/4” in the upper arm housing and at the

base. Max. 8 bar. Inner hose diameter: 6.5 mm.

For connection of extra equipment on the manipulator, there are cables integrated into the

manipulator’s cabling.

Option 042 Control cabling to arc welding wire-feeder is integrated into the manipulator’s cabling.

This option (042) is not available for IRB 1400H.

Number of signals 12 signals, 49V, 500 mA

Connector on upper arm: FCI 12-pin UT001412SHT

Connector on robot base: FCI 12-pin UT001412PHT

Control signals

Number of signals: 16 signals, 49V, 500 mA

Connector on upper arm housing: FCI 23-pin UTG61823PN

Connector on robot base: FCI 23-pin UT001823SHT

Power signals

Number of signals: 12 signals, 300V, 4A

Connector on upper arm housing: FCI 12-pin socket UTG61412SN

Connector on robot base: FCI 12-pin UT001412PHT

3HAC 021111-001 Revision - 37



Figure 14: Location of Customer Connections.

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.

The complete contact set (option) contains:

• Pins for cable area 0.13 - 0.25 mm2

• Shrinking hose bottled shaped

• Shrinking hose, angled,

• which corresponds to item 4, 5, 6, 7, 8 and 9 according to Figure 15.

Figure 15: FCI Connector

R2.CSR1.CS

Air (only option 041)R2.CP (only option 042)

Air (only option 041)R2.CP (only option 042)

1, 3

4, 5

86

2

Manipulator sideCustomer side

7

9

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2.2.2 Connection of Extra Equipment to the Manipulator


Technical data for customer connections.

Connections on Upper Arm

Figure 16: Customer Connections on Upper Arm.

Signals

Conductor resistance < 3 ohm, 0.154 mm2

Max. voltage 50 V AC/DC

Max. current 250 mA

Signal Name

Customer Terminal Controller (optional)

Customer Contacton Upper Arm, R2

Customer Contact on Manipulator Base(Cable not supplied)

CSA XT5.1 R2.CS.A R1.CS.A

CSB XT5.2 R2.CS.B R1.CS.B

CSC XT5.3 R2.CS.C R1.CS.C

CSD XT5.4 R2.CS.D R1.CS.D

CSE XT5.5 R2.CS.E R1.CS.E

CSF XT5.6 R2.CS.F R1.CS.F

CSG XT5.7 R2.CS.G R1.CS.G

CSH XT5.8 R2.CS.H R1.CS.H

CSJ XT5.9 R2.CS.J R1.CS.J

CSK XT5.10 R2.CS.K R1.CS.K

CSL XT5.11 R2.CS.L R1.CS.L

CSM XT5.12 R2.CS.M R1.CS.M

R2.CS

3HAC 021111-001 Revision - 39



Connection of Signal Lamp on Upper Arm (Option)

Figure 17: Location of Signal Lamp.

Signal lampR3.H1 +R3.H2 -

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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.

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

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

3HAC 021111-001 Revision - 41

3 Maintenance

3.0.2 Maintenance Intervals

3.0.2 Maintenance Intervals

1) Check that the “mechanical stop” is not bent.2) Inspect all visible cabling. Change if damaged.3) See section Changing the battery in the measuring system on page 46.

EquipmentCheck twice/year

Check once/year

Maintenance every 2000 hrs or 6 months

Maintenance every 4000 hrs or 1 year

Others

Mechanical stop axis 1

X1

Cabling X2

Gears axis 1-4 Maintenance free

Lubrication of spring brackets

X

Lubrication of gears axis 5-6

X

Replacement of accumulator for measuring sys-tem

3 years3

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3 Maintenance

3.1.1 Oil in gears 1-4

3.1: Instructions for maintenance

3.1.1 Oil in gears 1-4

The gearboxes are lubricated for life.

ABB’s oil, art. No. 1171 2016-604, corresponds to:

Oil volume (BP), floor-mounted robot

Oil volume (BP), suspended robot

BP: Energol GR-XP 320 Castrol: Alpha SP 320

Esso: Spartan EP 320 Klüber: Lamora 320

Optimol: Optigear 320 Shell: Omala Oil 320

Texaco: Meropa 320 Statoil: Loaway EP

Gearbox Volume

Axis 1 2,000 ml

Axis 2 and 3 1,700 ml

Axis 4 30 ml

Gearbox Volume

Axis 1 2,700 ml

Axis 2 and 3 1,700 ml

Axis 4 30 ml

3HAC 021111-001 Revision - 43

3 Maintenance

3.1.2 Greasing axes 5 and 6

3.1.2 Greasing axes 5 and 6

Grease is pressed through the 3 nipples (1), see Figure 18. The tip nozzle of the greasing gun

should be of type Orion 1015063, or equivalent.

Volume: 2 ml (0.00053 US gallon)

Figure 18: Greasing Positions for Axes 5 and 6.

Type of grease: ABB’s art. No. 3HAB 3537-1, corresponds to:

Shell Alvania WR2

(1)

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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

3HAC 021111-001 Revision - 45

3 Maintenance

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 19).

The robot is delivered with a rechargeable Nickel-Cadmium (Ni-Cd) battery with article

number 4944 026-4.

The battery must never be just thrown away; it must always be handled as hazardous waste.

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

• Remove the flange cover. All connections on the flange cover, except for the sig-nal contact for the serial link, R1.SMB, can be disconnected.

• Remove one of the screws and loosen the two other screws holding the serial measurement board. Push the unit to the side and remove it backwards. All cables and contacts must remain intact. Note the ESD-protection (ESD = Electro-static Discharge).

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

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

• Refit the serial measurement board, flange cover and connections.

• The Ni-Cd battery takes 36 hours to recharge; the mains supply must be switched on during this time.

Figure 19: The Battery is located Inside the Base under the Flange Cover.

Alternative Battery

As an alternative to the Ni-Cd battery a lithium battery of primary type can be installed. The

lithium battery needs no charging and has for that reason a blocking diode which prevents

charging from the serial measurement board.

The benefit with a lithium 10.8 V battery is the lifetime, which can be up to 5 years in service,

compare with the Ni-Cd battery’s maximum life time of 3 years in service.

Two lithium batteries exists:

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

• A 6-cell battery, art.No. 3HAB 9999-2

The life time of the lithium battery depends on how frequently the user switches off the

power. The estimated max. life time in years for the different lithium batteries and the recom-

mended exchange interval is shown below:

Flange cover

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3 Maintenance


1) Because of material aging, the maximum life in service is 5 years.

Voltage of batteries, measured at power off:

Exchange of the battery is done according to the beginning of this section.

User type Exchange 3-cell Exchange 6-cell

1. Vacation (4 weeks) power off Every 5 years Every 5 years1

2. Weekend power off + user type 1 Every 2 years Every 4 years

3. Nightly power off + user type 1 and 2 Every year Every 2 years

Min. Max.

Ni-Cd 7.0 V 8.7 V

Lithium 7.0 V -

3HAC 021111-001 Revision - 47

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 62.

The article number of the pin is 3HAB 3258-1.

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4 Repair

4.1.1 General description

4: Repair

4.1: General information


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.

When service on the IRB1400H is contemplated, a decision must be made in each particular

case whether the work can be carried out with the manipulator suspended or whether it must

be removed and the work done on the floor.

Lifting and turning the manipulator is described in section Lifting the Manipulator on page

25.

When servicing the manipulator, it is helpful to service the following parts separately:

• The Electrical System

• The Motor Units

• The Mechanical System

The Electrical System is routed through the entire manipulator and is made up of two main

cabling systems; the power cabling and signal cabling. The power cabling feeds the motor

units of the manipulator axes. The signal cabling feeds the various control parameters, such

as axis positions, motor revs, etc.

The AC Motor Units provide the motive power for the various manipulator axes by means of

gears. Mechanical brakes, electrically released, lock the motor units when the robot is inop-

erative for more than 3 minutes during both automatic and manual operation.

The manipulator has 6 axes which makes its movements very flexible.

Axis 1 rotates the manipulator. Axis 2 provides the lower arm’s reciprocating motion. The

lower arm, together with the parallel arm and the parallel bracket, forms a parallelogram rel-

ative to the upper arm. The parallel bracket is mounted on bearings in the parallel arm and in

the upper arm.

Axis 3 raises the upper arm of the manipulator. Axis 4, located on the side of the upper arm,

rotates the upper arm. The wrist is bolted to the tip of the upper arm and includes axes 5 and

6. These axes form a cross and their motors are located at the rear of the upper arm.

Axis 5 is used to tilt and axis 6 to turn. A connection is supplied for various customer tools

on the tip of the wrist in the turn disc. The tool (or manipulator) can be pneumatically con-

trolled by means of an external air supply (optional extra). The signals to/from the tool can

be supplied via internal customer connections (optional extras).

Note that the control cabinet must be switched off during all maintenance work on the manipulator. The accumulator power supply must always be disconnected before per-forming any work on the manipulator measurement system (measurement boards, cabling, resolver unit).When any type of maintenance work is carried out, the calibration position of the manipulator

must be checked before the robot is returned to the operational mode.

3HAC 021111-001 Revision - 49

4 Repair


Take special care when manually operating the brakes. Make sure also that the safety instructions described in this manual are followed when starting to operate the robot.

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4.1.2 Instructions for reading the following sections

4.1.2 Instructions for reading the following sections

The subsequent sections describe the type of on-site maintenance that can be performed by

the customer’s own maintenance staff. 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.

Calibration The robot must be re-calibrated when a mechanical unit or part of one is replaced, when the

motor and feedback unit is disconnected, when a resolver error occurs, or when the power

supply between a measurement board and resolver is interrupted. This procedure is described

in detail in section Calibration, M2000 on page 91.

Any work on the robot signal cabling may cause the robot to move to the wrong posi-tions.After performing such work, the calibration position of the robot must be checked as described in section Calibration, M2000 on page 91.

Tools Two types of tools are required for the various maintenance jobs. It may be necessary to use

conventional tools, such as sockets and ratchet spanners, etc., or special tools, depending on

the type of servicing. Conventional tools are not discussed in this manual, since it is assumed

that maintenance staff have sufficient basic technical competence. Maintenance jobs which

require the use of special tools are, on the other hand, described in this manual.

Foldouts The chapter on spare parts comes with a number of foldouts which illustrate the parts of the

robot. These foldouts are provided in order to make it easier for you to quickly identify both

the type of service required and the make-up of the various parts and components. The item

numbers of the parts are also shown on the foldouts.

In the subsequent sections, these numbers are referred to in angle brackets < >. If a reference

is made to a foldout, other than that specified in the paragraph title, the foldout’s number is

included in the numeric reference to its item number; for example:

<5/19> or <10:2/5>. The digit(s) before the stroke refer to the foldout number.

The foldouts also include other information such as the article number, designation and

related data.

NB! This manual is not considered as a substitute for a proper training course. The informa-

tion in the following chapters should be used only after an appropriate course has been com-

pleted.

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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.

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4.1.4 Fitting new Bearings and Seals


Bearings 1. Do not unwrap new bearings until just before assembly, in order to prevent dust and grit getting into the bearing.

2. Make sure that all parts of the bearing are free from burr dust, grinding dust and any other contamination. Cast parts must be free from foundry sand.

3. Bearing rings, races and roller parts must not under any circumstances be sub-jected to direct impact. The roller parts must not be subjected to any pressure that is created during the assembly.

Tapered Bearings 1. The bearing should be tightened gradually until the recommended pre-tensioning is attained.

2. The roller parts must be rotated a specified number of turns both before pre-tensioning and during pre-tensioning.

3. The above procedure must be carried out to enable the roller parts to slot into the correct position with respect to the racer flange.

4. It is important to position the bearings correctly, because this directly affects the service life of the bearing.

Greasing Bearings

1. Bearings must be greased after they are fitted. Extreme cleanliness is necessary throughout. High quality lubricating grease, such as Shell Alvania WR2 (ABB’s art. No. 3537-1), should be used.

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.

4. Normally the bearings should not be completely filled with grease. However, if there is space on both sides of the bearing, it can be filled completely with grease when it is fitted, as surplus grease will be released from the bearing on start up.

5. 70-80% of the available volume of the bearing must be filled with grease during operation.

6. Make sure that the grease is handled and stored correctly, to avoid contamination.

Seals The most common cause of leakage is incorrect mounting.

Rotating Seals 1. The seal surfaces must be protected during transportation and assembly.

2. The seals must either be kept in their original packages or be protected well.

3. The seal surfaces must be inspected before mounting. If the seal is scratched or damaged in such a way that it may cause leakage in the future, it must be replaced.

3HAC 021111-001 Revision - 53

4 Repair


4. The seal must also be checked before it is fitted to ensure that:

5. The seal edge is not damaged (feel the edge with your finger nail),

6. The correct type of seal is used (has a cut-off edge),

7. There is no other damage.

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.

9. Seals and gears must be fitted on clean workbenches.

10.Fit the seal correctly. If it is fitted incorrectly, it may start to leak when pumping starts.

11.Always use an assembling tool to fit the seal. Never hammer directly on the seal because this will cause it to leak.

12.Use a protective sleeve on the sealing edge during assembly, when sliding over threads, key-ways, etc.

Flange Seals and Static Seals

1. Check the flange surfaces. The surface must be even and have no pores. The evenness can be easily checked using a gauge on the fitted joint (without sealing compound).

2. The surfaces must be even and free from burr dust (caused by incorrect machin-ing). If the flange surfaces are defective, they must not be used as they will cause leakage.

3. The surfaces must be cleaned properly in the manner recommended by ABB.

4. Distribute the sealing compound evenly over the surface, preferably using a brush.

5. Tighten the screws evenly around the flange joint.

6. Make sure that the joint is not subjected to loading until the sealing compound hasattained the hardness specified in the materials specification.

O-rings 1. Check the O-ring grooves. The grooves must be geometrically correct, without pores and free of dust and grime.

2. Check the O-ring for surface defects and burrs, and check that it has the correct shape, etc.

3. Make sure the correct O-ring size is used.

4. Tighten the screws evenly.

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

6. If any of the parts fitted are defective, they will cause leakage. Grease the O-ring with Shell Alvania WR2 (ABB’s art. No. 3537-1) before fitting it.

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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.

The instructions do not apply to screw joints made of soft or brittle materials.

For screws with a property class higher than 8.8, the same specifications as for class 8.8. are

applicable, unless otherwise stated.

Screws treated with Gleitmo

All screws in the manipulator that are tightened to a specified torque are treated with Gleitmo.

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

Screws treated with Gleitmo can be unscrewed and screwed in again 3-4 times before the slip

coating disappears. Screws can also be treated with Molycote 1000.

When screwing in new screws without Gleitmo, these should first be lubricated with Moly-

cote 1000 and then tightened to the specified torque.

Assembly Screw threads sized M8 or larger should preferably be lubricated with oil. Molycote 1000

should only be used when specified in the text.

Screws sized M8 or larger should be tightened with a torque wrench, if possible.

Screws sized M6 or smaller may be tightened to the correct torque by personnel with suffi-

cient mechanical training, without using torque measurement tools.

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4 Repair

4.1.6 Tightening Torques

4.1.6 Tightening Torques

Screws with slotted or cross recessed head, property class 4.8

Screws with hexagon socket head, property class 8.8

Dimension Tightening Torque Nm

Without Oil

M2.5 0.25

M3 0.5

M4 1.2

M5 2.5

M6 5.0

Dimension Tightening Torque Nm Tightening Torque Nm

Without Oil With Oil

M3 1 1

M4 2 2

M5 5.5 4

M6 10 9

M8 24 22

M10 48 45

M12 83 78

M16 200 190

M20 410 400

M24 750 740

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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. This is because the rotating brake disk is connected to the motor shaft by splines. This

is why the brakes must be disengaged before testing for play in the gearboxes and wrist. The

brakes are disengaged by pressing the enable button on the teach pendant.

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

3HAC 021111-001 Revision - 57

4 Repair

4.2.1 Changing the motor of axis 1

4.2: 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.

To dismantle 1. Remove the cover of the motor.

2. Loosen connectors R4.MP1 and R4.FB1.

3. Remove the connection box by unscrewing <5/160>.

4. Note the position of the motor before removing it.

5. Loosen the motor by unscrewing <1/10>.

To assemble 1. Check that the assembly surfaces are clean and the motor unscratched.

2. Release the brake, apply 24V DC to terminals 7 and 8 in the 4.MP1 connector.

3. Install the motor, tighten screws <1/10> using a torque of approximately 2 Nm.

Note the position of the motor!

4. Adjust the motor in relation to the gear in the gearbox.

5. Screw the 3HAB 1201-1 crank tool into the end of the motor shaft.

6. Make sure there is very small play by turning axis 1 at least 45o.

7. Tighten screws <1/10> using a torque of 8.3 Nm ±10%.

8. Connect the cabling.

9. Calibrate the robot as specified in section Calibration, M2000 on page 91.

Tightening torque The motor attaching screws, item10:8.3 Nm ±10%

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4 Repair

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 mustbe changed.See foldout 1 (6 for IRB 1400H) in the list of spare parts.

To dismantle 1. Remove the motors in axes 1, 2 and 3 as described in section Changing the motor of axis 1 on page 58, section Changing the motor of axis 2 on page 63 and section Changing the motor of axis 3 on page 68.

2. Remove the cabling and serial measuring boards according to section Changing the cabling in axes 1, 2 and 3 on page 82 and section Changing serial measuring boards on page 81.

3. Remove the tie rod as described in this chapter, section Changing the tie rod on page 71.

4. Remove the parallel arm according to section Dismantling the parallel arm on page 70.

5. Remove the balancing springs in accordance with section Dismantling the bal-ancing springs on page 67 (not valid for IRB 1400H).

6. Dismantle the upper arm as described in section Dismantling the complete upper arm on page 72.

7. Dismantle the lower arm according to section Dismantling the lower arm on page 65.

8. Place the remaining parts of the manipulator upside-down on a table or similar surface and remove the bottom plate <1/5>. See Figure 20.

Make sure that the foot is stable.

Figure 20: How to Position the Foot when dismantling Axes 1, 2 and 3.

9. Undo screws <1/4>.

10.Separate the base from the gear unit.

3HAC 021111-001 Revision - 59

4 Repair


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. Replace the bottom plate <1/5> using screws <1/7>.

5. Turn the foot.

6. Replace the lower arm as described in section Dismantling the lower arm on page 65.

7. Replace the parallel arm according to section Dismantling the parallel arm on page 70.

8. Replace the upper arm as described in section Dismantling the complete upper arm on page 72.

9. Replace the cabling in accordance with section Changing the cabling in axes 1, 2 and 3 on page 82 and section Changing serial measuring boards on page 81.

10.Replace the tie rod as described in section Changing the tie rod on page 71.

11.Replace the balancingd springs according to section Dismantling the balancing springs on page 67 (not valid for IRB 1400H).

12.Calibrate the robot as described in section Calibration, M2000 on page 91.

Tightening Torque

Screwed joint of base/gear unit, item <4>:68 Nm ±10%

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4 Repair

4.2.3 Position indicator in axis 1 (optional)

4.2.3 Position indicator in axis 1 (optional)


To dismantle 1. Remove the flange plate <4/138>.

2. Loosen the connector R1.LS.

3. Dismantle the two limit switches <3/174>.

4. Loosen the cables from the switches.

5. Remove the cabling through the base.

To assemble 1. Assemble in the reverse order.

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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 21 below.

Figure 21: Fit the new Pin as illustrated.

Loctite 242 or 243

68 ±

1

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4 Repair


4.3: Axis 2




To dismantle

Lock the arm system before dismantling the motor; the brake is located in the motor.

1. Remove the cover of the motor.




5. Loosen the motor by unscrewing <1/10>. N.B! The oil will start to run out.


2. Release the brake, apply 24 V DC to terminals 7 and 8 on the R3.MP2 connector.

3. Install the motor, tighten screws <1/10> to a torque of approximately 2 Nm.


4. Adjust the motor in relation to the drive in the gearbox.


6. Make sure there is no play.

7. Tighten screws <1/10> to a torque of 8.3 Nm ±10%.

8. Fill with oil. See section Oil in gears 1-4 on page 43.


10.Calibrate the robot as specified in section Calibration, M2000 on page 91.

Tightening torque The motor’s fixing screws, item10: 8.3 Nm ±10%

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4 Repair



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.See foldout 1 in the list of spare parts.

To dismantle See section Changing the gearbox on page 59.

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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 67 (not valid for IRB 1400H).

2. Remove the cabling down to axis 1 according to section Cabling and serial mea-suring board on page 81.

3. Dismantle the upper arm as specified in section Dismantling the complete upper arm on page 72.

4. Attach the crane to the lower arm.

5. Remove the parallel arm in accordance with section Dismantling the parallel arm on page 70.

6. Loosen screws <1/13>.

7. Remove the lower arm.

To assemble 1. Transfer the damping element and calibration marking to the new lower arm.

2. Lift the lower arm into position.

3. Fix the lower arm to gear 2 using screws <1/13> and tighten them to a torque of 68 Nm ±10%.

To prevent clicking during operation of the robot, grease the bearing seating of the par-allel arm in the lower arm.

4. Replace the parallel arm as described in section Dismantling the parallel arm on page 70.

5. Replace the upper arm as specified in section Dismantling the complete upper arm on page 72.

6. Replace the balancing springs in accordance with section Dismantling the balanc-ing springs on page 67 (not valid for IRB 1400H).

7. Replace the cabling as described in section Cabling and serial measuring board on page 81.

8. Calibrate the robot according to section Calibration, M2000 on page 91.

Tightening torque Screwed joint of lower arm/gear 2, item <13>:68 Nm ±10%

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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 71.

2. Unscrew screws <13> which hold the parallel arm to gear 3.

3. Remove the bearings from the parallel arm.

To assemble 1. Fit new bearings to the parallel arm.

2. Replace the parallel arm using screws <13> and tighten to a torque of 68 Nm ±10%.

3. Attach the upper bracket of the tie rod as specified in section Changing the tie rod on page 71.

4. Calibrate the robot according to section Calibration, M2000 on page 91.

Tightening torque Screwed joint of parallel arm/gear 3, pos. <13>:68 Nm ±10%

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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. Loosen the locking nut <1/76>.

3. Release the spring using tool 3HAB 1214-6 and undo screw <1/13> at the same time.

If the tool 3HAB 1214-6 is not available, but there are two persons, then the spring can be released manually.

4. Unscrew <2/65> in the upper bracket of the spring.

5. Remove the springs.

To assemble 1. Before installing new springs, make sure that the distance between the attach-ment points is correct, see Figure 22. Lock the link heads using Loctite 242 or 243.

Figure 22: Distance between the Attachment Points.

2. Lubricate the link heads with grease.

3. Attach the springs to the top bracket using screws <2/65> and tighten to a torque of 68 Nm ±10%.

4. Pull the springs down using tool 3HAB 1214-6 and attach screws <1/13>, together with lifting lug <1/23> and washer <1/17>.

5. Attach the locking nut <1/76>.

Tightening torque Screws of upper bracket, position <65>:68 Nm ±10%.

C C 377

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4 Repair


4.4: Axis 3








5. Loosen the motor by unscrewing <1/10>. N.B! The oil will start to run out.


2. Release the brake, apply 24 V d.c. to terminals 7 and 8 on the 4.MP1 connector.



4. Adjust the motor in relation to the drive in the gearbox.


6. Make sure there is no play.


8. Fill with oil. See section Oil in gears 1-4 on page 43.



Tightening torque The motor’s fixing screws, item 10:8.3 Nm ±10%

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4 Repair



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.See foldout 1 in the list of spare parts.

To dismantle See this chapter, section Changing the gearbox on page 64.

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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 71.

2. Unscrew screws <13> which fix the parallel arm to gear 3.

3. Remove the bearings from the parallel arm.

To assemble 1. Fit the bearings on the parallel arm.

2. Replace the parallel arm using screws <13> and tighten to a torque of 68 Nm ±10%.

3. Attach the upper bracket of the tie rod according to section Changing the tie rod on page 71.


Tightening torque Screwed joint of parallel arm/gear 3, item <13>:68 Nm ±10%

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4 Repair

4.4.4 Changing the tie rod

4.4.4 Changing the tie rod


To dismantle

Lock the upper arm in a horizontal position with the help of a crane or similar.

1. Unscrew screw <74>.

2. Undo the two screws for fixing the cabling bracket of the upper arm housing.Fold back the cabling bracket.

3. Screw the screw <74> back into the shaft <71>.

4. Carefully knock the shaft out.

5. Remove housing <72>.

6. Unscrew <70> on the lower bracket.

7. Carefully tap the rod off the shaft.

8. Change the bearings.

To assemble 1. Fit bearings on the parallel arm.

2. Make sure you replace the rod the correct way up. See foldout 1 (1:1).

3. Install grommets: (3 x) <68> and (1 x) <75>.

Note! The grommet <75> is bevelled and must be inserted the right way up in the lower bearing.

4. Place the lower bearing of the tie rod on the parallel arm.

5. Screw in screw <70> and its washer <69>. Lock using Loctite 242 or 243.

6. Replace shaft <71>. N.B! Do not forget the sleeve <72>.

7. Mount washer <73> and tighten the shaft using a temporary screw, M8x35.

8. Replace this screw by screw <74> and mount the cable bearer <163>. Lock using Loctite 242 or 243.

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4 Repair

4.4.5 Dismantling the complete upper arm



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 71.

2. Loosen the connectors of the motors of axes 4, 5 and 6.

3. Disconnect the connection box from the motors.

4. Detach the balancing springs as described in section Dismantling the balancing springs on page 67 (not valid for IRB 1400H).

5. Undo the KM nuts <64>.

6. Remove washers <63> and shims <61-62> on the same side as axis 3.

7. Attach the withdrawing tool 3HAB 1259-1 and pull the axes off.

To assemble 1. Raise the upper arm into assembly position.

2. Install shaft spindles <59> (both sides), use two temporary screws M10x90.

3. Insert bearings <60> (both sides) using tool 3HAB 1200-1 and screws <65>.

4. Detach the tool and tighten the screws once more, only to prevent rotation of the axis when the KM nut is tightened.

N.B! Assemble the same side as axis 2 first.

5. Mount two washers <63> and calibration washer <50>.

6. Tighten using the KM nut <64>.

7. Attach the measuring instrument 3HAB 1205-1 to the shaft spindle on axis 3.

N.B! If measuring instrument 3HAB 1205-1 is not available, you can use a micrometer thickness gauge.

8. Hold the tool against the shoulder of the shaft spindle and measure the dimension “A”. See Figure 23.(If you are not using the measuring instrument, tighten using the KM nut and, before measuring with the micrometer thickness gauge, then undo it again.)

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4 Repair


Figure 23: Measuring the Shim Thickness when preloading the Bearing.

9. Make a note of the dimension “A”. Fit one washer <63> and shims <61-62>, and using the micrometer, measure the thickness so that the total thickness is 0.10 - 0.20 mm more than the noted dimension “A”. This will result in a preloading of the bearing of 0.10 - 0.20 mm.

10.Fit the shims and washer and tighten the KM nut <64>.

11.Replace the upper attachment of the tie rod as specified in section Changing the tie rod on page 71.

12.Replace the balancing springs as described in section Dismantling the balancing springs on page 67 (not valid for IRB 1400H).

13.Reconnect the connection boxes and the cabling.

14.Calibrate the robot in accordance with section Calibration, M2000 on page 91.

15.Undo the KM-nut on the axis 2 side, just to be able to adjust the calibration washer <50>.

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 24 and make new punch marks for axes 3 and 4, according to section Calibration scales and correct axis position on page 94.

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4 Repair


Figure 24: Calibration Mark for Axis 3.

Tools pressing tool for bearings: 3HAB 1200-1

105o

Measuring instrument: 3HAB 1205-1

Withdrawing tool for shaft spindles: 3HAB 1259-1

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4 Repair

4.5.1 Changing the motor

4.5: Axis 4

4.5.1 Changing the motor



Position the arm system in such a way that the motor of axis 4 points upwards.





5. Loosen the motor by unscrewing <8/23>.


2. Put O-ring <8/21> on the motor.

3. Release the brake, apply 24 V DC to terminals 7 and 8 on the R3.MP4 connector.



5. Adjust the position of the motor in relation to the drive in the gearbox.


7. Make sure there is a small clearance.

8. Unscrew one screw at a time, apply Loctite 242 or 243 and tighten to a torque of 4.1 Nm ±10%.



Tightening torque The motor’s fixing screws, item <23>:4.1 Nm ±10%

Tool

Crank tool for checking the play: 3HAB 1201-1

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4 Repair

4.5.2 Changing the intermediate gear including sealing



To dismantle 1. Dismantle the wrist as described in section Dismantling the wrist on page 85.

2. Dismantle the drive mechanism according to section Dismantling the complete drive mechanism of axes 5 and 6 on page 86.

3. Dismantle the motor of axis 4 as specified in section Changing the motor on page 75.

4. Remove the cover <25>.

5. Undo screws <18> fixing the large drive gear <17> and dismantle it.

N.B! Put the shims in a safe place.

6. Undo screws <12>.

7. Push the intermediate gear out of the arm housing.

To assemble 1. Grease the seating of the arm housing to provide radial sealing.

2. Push the gear unit down into the arm housing.

3. Screw in screws <12> together with their washers <13> and pull the gear down.

4. Mount the drive gear <17> using screws <18> and tighten to a torque of 8.3 Nm ±10%.

N.B! Do not forget to insert shims <14, 15, 16> under the drive gear.

5. Tighten screws <12> to a torque of approximately 5 Nm.

6. Bend the pinion towards the large drive gear and then rotate it around the tubular shaft a couple of times so that the clearance in the gears can adjust itself in rela-tion to the highest point of the large drive gear.

7. Then tighten screws <12> to a torque of 20 Nm ±10%.

8. Check the clearance in relation to the tightening torque.

9. Replace the cover <25> using screws <26>. Use a drop of Loctite 242 or 243.

10.Position the manipulator so that the tubular shaft points upwards.

11.Fill (30 ml) oil into the gear of axis 4. See section Oil in gears 1-4 on page 43.

12.Install the motor of axis 4 in accordance with section Changing the motor on page 75.

13.Install drive mechanism <28> as described in section Dismantling the complete drive mechanism of axes 5 and 6 on page 86.

14.Replace the wrist in accordance with section Dismantling the wrist on page 85.


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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%

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4 Repair

4.5.3 Dismantling the drive gear on the tubular shaft




2. Dismantle the drive mechanism in accordance with section Dismantling the com-plete drive mechanism of axes 5 and 6 on page 86.

3. Dismantle the motor of axis 4 as specified in section Changing the motor on page 75.

4. Remove the cover <25>.

5. Unscrew screws <12> that hold the intermediate gear in place.

6. Unscrew screws <18> that hold the large drive gear <17> and then dismantle it.

N.B! Put the shims from under the drive gear in a safe place.

To assemble Shim between drive gear <17> and the rear bearing <3>.

Shim thickness = B - A + 0.05 mm, see Figure 25.

Figure 25: Measuring the Shim Thickness of the Drive Gear of Axis 4.

1. Install the drive gear using screws <18> and tighten to a torque of 8.3 Nm ±10%.

N.B! Do not forget the shims.

2. Screw screw <19> and 2 washers <20> into the drive gear. Lock using Loctite 242 or 243.

3. Mount the intermediate gear according to section Changing the intermediate gear including sealing on page 76.

4. Lubricate the drive gear with grease (30 g).

5. Install the motor of axis 4 as described in section Changing the motor on page 75.

6. Replace the cover <25> using screws <26>. Lock using a drop of Loctite 242 or 243.

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4 Repair


7. Mount the drive mechanism as specified in section Dismantling the complete drive mechanism of axes 5 and 6 on page 86.

8. Mount the wrist according to section Dismantling the wrist on page 85.


Tightening torque Screws of drive gear, item <18>: 8.3 Nm ±10%

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4 Repair

4.5.4 Dismantling the tubular shaft and changing bearings

4.5.4 Dismantling the tubular shaft and changing bearings


To dismantle 1. Dismantle the drive gear as described in section Dismantling the drive gear on the tubular shaft on page 78.

2. Push out the tubular shaft.

To assemble 1. Fit a new bearing <3> on the tubular shaft using tool 6896 134-V.

2. Push the tube into the housing of the upper arm.

3. Insert the rear bearing <3> using tool 6896 134-JB.

4. Mount the drive gear in accordance with section Dismantling the drive gear on the tubular shaft on page 78.


Tools Pressing tool for front bearing: 6896 134-V

Pressing tool for rear bearing: 6896 134-JB

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4 Repair

4.6.1 Changing serial measuring boards

4.6: Cabling and serial measuring board

4.6.1 Changing serial measuring boards


To dismantle 1. Remove flange plate <138>.

2. Cut tie around bundle <144>.

3. Unscrew the serial measuring board <135> using screws <7>.

4. Remove the board and loosen the contacts.


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4 Repair

4.6.2 Changing the cabling in axes 1, 2 and 3



To dismantle 1. Remove the cover of the motors.

2. Remove the flange plate <4/138>.

3. Loosen connectors R1.MP, R2.FB1-3.

4. Cut tie around bundle and detach the cable brackets.

5. Detach the cable guides <3/104 and 105> and undo screws <3/149>.

6. Loosen the connectors in the motors.

7. Disconnect the connection boxes in the motors.

8. Feed the cabling up through the middle of axis 1.


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4 Repair



See foldouts 2, 3 and 4 (6 for IRB 1400H) in the list of spare parts.

To dismantle 1. Remove the cover of the motors.

2. Remove the flange plate <4/138>.

3. Loosen connectors R2.MP4-6 and R2.FB4-6, including customer connector R1.CS (if there is one) and the air hose.

4. Detach the cable guides <3/104, 105>.

5. Loosen the cable brackets <3/149> between gears 2 and 3 and cut the tie around them.

6. Feed the cabling and air hose up through axis 1.

7. Loosen the cable bracket on the lower arm and undo screws <3/147>.

8. Undo screw <2/74> which fixes the shaft of the tie rod.

9. Disconnect the connection boxes in the motors.

10.Loosen the remaining cable brackets and remove the cabling.


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4 Repair


4.7: The wrist and axes 5 and 6The wrist, which includes axes 5 and 6, is a complete unit, comprising drive units and gears.

It is of such a complex design that it is not normally serviced on-site, but should be sent to

ABB to be serviced.

ABB recommends its customers to carry out only the following servicing and repair work on

the wrist.

• Grease the wrist according to the table in section Maintenance Intervals on page 42.

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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. Rotate axes 5 and 6 so that you can see screws <9/15> in the clamping sleeve through the hole.

4. Disconnect the clamping sleeve.

5. Undo screws <1/53> and remove the wrist.

To assemble 1. Mount the wrist, tighten screws <1/53> to a torque of 8.3 Nm ±10%.

Note! The grease nipple on the tilt house should be pointing against the basewhen the axis 4 is in the calibration position.

2. Screw the clamping sleeves together using screws <9/15>.

3. Replace the plastic plugs.

4. Calibrate the robot as described in section Calibration, M2000 on page 91.

Tightening torque Screwed joint of wrist/tubular shaft, item <1/53>:8.3 Nm ±10%

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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


To dismantle 1. Dismantle the wrist according to section Dismantling the wrist on page 85.

2. Loosen the connectors on the motors of axes 5 and 6.

3. Undo screws <8/29>.

4. Squeeze the drive shafts (<9/1>) together at the tip of the tubular shaft, in order that they can pass through the tube.

5. Pull out the complete drive mechanism of axes 5 and 6.

To assemble 1. Install the drive mechanism in the tubular shaft.


3. Insert the cabling.

4. Mount the wrist as described in section Dismantling the wrist on page 85.

Tightening torque Screwed joint of the drive mechanism, item <8/29>:8.3 Nm ±10%

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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



2. Dismantle the drive mechanism according to section Dismantling the complete drive mechanism of axes 5 and 6 on page 86.

3. Undo screws <9> and remove the appropriate motor.

4. If the driving belt is to be changed, both motors must be removed.

5. Undo screws <9> and remove plate <7>.

To assemble 1. Install the driving belts.

2. Mount the plate <7> using screws <9>.

N.B! Do not forget the nuts of the motors.

3. Install the motors.

4. Push the motors in sideways to tension the belts. Use tool 3HAA 7601-050. Tighten screws <9> to a torque of 4.1 Nm.

5. Rotate the drive shafts. Check the tension on the belt.

6. Install the drive mechanism as described in section Dismantling the complete drive mechanism of axes 5 and 6 on page 86.

7. Mount the wrist according to section Dismantling the wrist on page 85.


Tightening torque Screws for motors and plate, item <9>: 4.1 Nm.

Tool

To adjust the belt tension: 3HAA 7601-050

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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 90o. 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 mea-

suring the play, loading in the other direction with 4.8 Nm unloading to 0.24 Nm and reading

the play. This correspond to play of 0.27 mm on a radius of 200 mm when the load is F=40

N and 2 N on radius 120 mm. See Figure 26.

Figure 26: Measuring Play in Axis 5.

Axis 6 The maximum accepted play in axis 6 is 12.8 arc.minutes when loading axis 6 with a moment

of 4.2 Nm in one direction, unloading to 0.2 Nm and start measuring the play, loading in the

other direction with 4.2 Nm unloading to 0.2 Nm and reading the play. This correspond to a

play of 0.37 mm on a radius of 100 mm when the load is F=42 N and 2 N. See Figure 27.

Figure 27: Measuring Play in Axis 6.

F

200

12035

100 F

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4 Repair

4.8.1 General

4.8: Motor units

4.8.1 General

General

Each axis of the manipulator has its own motor unit, comprising:

• A synchronous motor

• A brake (built into the motor)

• A feedback device.

There are a total of six motors mounted in the manipulator.

The power and signal cables are run to the respective motor from the cable connector points

on the manipulator. The cables are connected to the motor units by connectors.

The drive shaft of the electric motor forms a part of the gearbox of the manipulator axis. A

brake, operated electromagnetically, is mounted on the rear end of the motor shaft and a pin-

ion is mounted on its drive end. The brake releases when power is supplied to the electromag-

nets.

N.B!There is a feedback device mounted on each motor unit. The device is installed by the supplier

of the motor and should never be removed from the motor. The motor need never be commu-

tated.

The commutation value of the motors is: 1.570800.

The motor, resolver and brakes are regarded as one complete unit.

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4 Repair

4.8.1 General

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5 Calibration, M2000

5.0.1 Introduction

5: Calibration, M2000

5.0.1 Introduction

Calibration methods

This chapter details how to calibrate the robot with the Wyler calibration equipment, using

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.

When to calibrate The system must be calibrated if any of the below occurs.

Changed resolver values

Calibrate the measurement system carefully as detailed in section Calibration on page 103 if

any of the resolver values have changed. This may occur when parts affecting the calibration

position are replaced on the robot.

Contents of the revolution counter memory are lost

Calibrate the system roughly as detailed in section Updating the revolution counters on page

121 if the contents of the revolution counter memory are lost. This may occur when:

• the battery is discharged

• a resolver error occurs

• the signal between a resolver and measurement board is interrupted

• a robot axis is moved with the control system disconnected

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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.

Method -Wyler Calibration

The calibration procedure with Wyler equipment may be performed with either one or two

sensors. The procedure detailed here is performed with only one sensor and may be described

as checking an pre-adjusted sensor, trying to obtain the same measurement value on every

axis as when adjusted at the reference plane.

All article numbers of relevant equipment are specified in their instructions respectively.

Overview, calibration

Additional information

In addition to the basic calibration procedure detailed above, a number of calibration related

actions may be performed:

Step Action Note

1. Check that all required hardware is avail-able for calibrating the robot.

Required hardware is specified in the calibrating procedures for each axis.

2. Manually run the robot axes to a position close to the correct calibration position.

Use the calibration scales fitted to each robot axis to locate this position. These are shown in the section Calibration scales and correct axis position on page 94.

3. Initialize the Levelmeter. Detailed in section Initialization of Lev-elmeter 2000 on page 101.

4. Start the calibration procedure on the TPU. Detailed in section Fine calibration pro-cedure on TPU on page 115.

5. Calibrate each axis. Detailed in each axis’ calibration instruction.

6. Verify that the calibration was successfully carried out.

Detailed in section Post calibration pro-cedure on page 123.

Action Detailed in section:

How to update the robot revolution counter without per-forming a complete calibration.

Updating the revolution counters on page 121

How to manually check the current calibration position. Checking the calibration position on page 97

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5.1.2 Calibration, prerequisites

5.1.2 Calibration, prerequisites

Peripheral equipment

The robot must be free from any peripheral equipment during calibration. Fitted tools and

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 sensors

The positions where the calibration sensor and reference sensor should be fitted during cali-

bration, are specified in Positions and directions of sensor on page 99.

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5.2.1 Calibration scales and correct axis position

5.2: Reference information


Introduction This section specifies the calibration scale positions and/or correct axis position for all robot

models.

Safety information

Read the safety information below.

If work must be carried out within the robot’s work envelope, the following points must be

observed:

• The operating mode selector on the controller must be in the manual mode position to

render the enabling device operative and to block operation from a computer link or

remote control panel.

• The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in

position < 250 mm/s. This should be the normal position when entering the working

space. The position 100% ”full speed” may only be used by trained personnel who are

aware of the risks that this entails.

• Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in

order not to get entangled with hair or clothing. Also be aware of any danger that may

be caused by rotating tools or other devices mounted on the manipulator or inside the

cell.

• Test the motor brake on each axis, according to section Brake testing on page 19.

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Calibration scales, IRB 1400

The illustration below shows the calibration scale positions:

en0200000272

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5.2.2 Directions for all axes

5.2.2 Directions for all axes

Calibration move-ment directions

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!

xx0200000089

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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)

• Using the Jogging window on the teach pendant

Using the pro-gram CALxxxx in the system software

Using the Jog-ging window on the teach pendant

Step Action Button

1. Run the program \SYSTEM\UTILITY\SERVICE\CAL-IBRAT\CALxxxx in the system and follow the instruc-tions displayed on the teach pendant.

2. Switch to MOTORS OFF when the robot stops. Check that the calibration marks for that particular axis align correctly. If they do not, update the revolu-tion counters.

Calibration marks are shown in section Calibration scales and correct axis position on page 94.

Detailed in section Updating the revolution counters on page 121.

3. Check that resolver offset values in the system parameters match those on the parameter disk deliv-ered with the robot or those established when cali-brating the robot (after a repair, etc).

Step Action Illustration

1. Open the Jogging window.

xx0100000195

2. Choose running axis-by-axis.

xx0100000196

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3. Manually run the robot axis to a position where the resolver offset value read, is equal to zero.

4. Check that the calibration marks for that particular axis align correctly. If they do not, update the revolu-tion counters!

Shown in section Calibration scales and correct axis posi-tion on page 94.

Detailed in section Updating the revolution counters on page 121.


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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. This is further detailed in section Reset-

ting of Levelmeter 2000 and sensor on page 117. These reference values are then used to

calibrate the axes of the manipulator.

The reference sensor and the calibration sensor is consequently the same sensor used at dif-

ferent locations.

When using the sensor as a reference at the base, it is fitted to a sensor fixture together with

a sensor plate, as shown in the figure below. The sensor has different directions, depending

on which axis is calibrated. The directions are shown in the figure below.

Calibration and reference sensor position

The calibration sensor is positioned and aligned on the axes as shown in the figure below.

Notice the different directions of the sensor when fitted to the reference plane, depending on

which axis is currently calibrated!

xx0400001019

A Axis 2 sensor

B Axis 3 sensor

C Axis 4 sensor

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D Axis 5 sensor

E Axis 6 sensor

F Direction for sensor at reference plane, axes 2, 3 and 5

G Direction for sensor at reference plane, axes 4 and 6

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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.

1. Select the correct filter type, as detailed in Levelmeter 2000 on page 101.

2. Set the measuring unit, as detailed in Measuring units on page 102.

3. Install sensor, as detailed in Installation of sensor on page 102.

4. Calibrate the robot, as detailed in the instruction for each axis respectively, in the sec-

tion Calibration on page 103!

Levelmeter 2000 The Levelmeter 2000 is shown for reference below:

xx0200000083

Select filter type

A Measuring unit

B Selection pointer

C Sensor connection

Step Action Info/Illustration

1. Press ON/MODE until the dot flashes under FILTER . Shown in the figure Level-meter 2000 on page 101!

2. Press ENTER.

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Measuring units

Installation of sensor

Result The Levelmeter 2000 is now initialized and ready for service.

3. The standard filter type no. 5 flashes. Default setting is filter type 5.

4. If type 5 does not flash, press ZERO/SELECT to select filter type 5 and press ENTER.



1. Press ON/MODE until the dot flashes under UNIT . Shown in the figure Level-meter 2000 on page 101!

2. Press ENTER.

3. Press ZERO/SELECT until mm/m flashes.

Two decimals (0.00) are shown on the display

4. Press ENTER.


1. Connect the sensor to the Sensor connection point. Shown in the figure Level-meter 2000 on page 101!

2. Press ON/MODE .

3. Press ON/MODE until the dot flashes under SEN-SOR .

4. Press ENTER.

5. Press ZERO/SELECT until a flashing "A" is shown.

6. Press ENTER.

Wait until the "A" flashes again.

7. Press ENTER.

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5.3.1 Calibration, axis 1

5.3: Calibration


Calibration of axis 1

The special calibration equipment is fitted to the base of the manipulator as shown in the

figure below.

xx0400001018

Required equipment

A Guide pin in gearbox

B Calibration tool

C Measuring pin, axis 1

Equipment, etc. Art. no . Note

Isopropanol 1177 1012-208 Used to clean the reference surface.

Calibration tool, axis 1 3HAB 1378-1

Measuring pin, axis 1 6808 0011-GR

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Calibration, axis 1 The procedure below details how to perform the actual calibration of axis 1 using the calibra-

tion equipment specified in Required equipment.

Step Action Note

1. Move the robot to its calibration position corre-sponding to the calibration scales.

Detailed in section Calibration scales and correct axis position on page 94.

2. Remove the cover plate from the reference sur-face on the base of the manipulator.

Clean the surface with isopropanol and deburr it.

Art. no. is specified in Required equipment on page 103.

3. Fit the calibration tool, axis 1 on the guide pin underneath the gearbox.


Shown in the figure Calibration of axis 1 on page 103.

4. Release the brakes and move the manipulator manually so that the measuring pin can be placed in the guide hole on the base.


5. Update only axis 1, using the TPU. Detailed in section Fine calibra-tion procedure on TPU on page 115.

6. Remove the calibration tool for axis 1.

7. Refit the cover plate to the reference surface on the base of the manipulator, if no other calibra-tion is to be performed.

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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

TIP!

Lock the axes previous to the one calibrated to minimize the risk of accidentally moving other

axes! In case of accidental movement of previous axes, the calibration procedure must be

restarted from the moved axis and continued in increasing sequence!

Procedure

Equipment Art. no. Note

Levelmeter 2000 calibration kit with one sensor

6369 901-347 Includes one sensor.

Sensor plate 3HAC 0392-1 One sensor plate is required for each sensor!

Angle bracket 6808 0011-LP For calibration sensor on manipulator lower arm.

Isopropanol 1177 1012-108 For cleaning the attachment points.

Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.

These procedures include references to the tools required.


1. Reset the levelmeter and the sensor for calibration of axis 2.

Detailed in section Resetting of Levelmeter 2000 and sensor on page 117.

2. Clean the calibration surface with isopropanol. Art. no. is specified in Required equipment on page 105!

3. Fit the angle bracket on the lower arm.

Adjust the angle of the bracket to make it level.

Art. no. is specified in Required equipment on page 105!

4. Fit the calibration sensor together with the sensor plate on the angle bracket on axis 2.

Carefully tighten the securing screws with approx-imately same tightening torque that used at the reference plane!

Shown in section Positions and directions of sensor on page 99!

3HAC 021111-001 Revision - 105



5. Manually run axis 2 in with the joystick to the cor-rect position as indicated by the levelmeter.

Tip!

Reduce the jogging velocity in order to easily posi-tion the axis as close to zero as possible!

Correct measurement on the levelmeter:

0 ± 0.40 mm/m

6. Update only axis 2. Detailed in section Fine calibra-tion procedure on TPU on page 115.

7. Remove the sensor.

8. Refit the cover plate on the calibration surface on the manipulator lower arm. Refit also the cover plate on the reference surface at the base if no further calibration is performed.

9. Check the calibration according to section Post calibration procedure on page 123 or continue with calibration of next axis.


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bration equipment.

Required equipment

TIP!




Procedure

Equipment Art. no. Info



Sensor plate 3HAC 0392-1 One sensor plate is required for each sensor.

Turning disk fixture 6808 0011-GU For fitting the calibration sensor plate to the sync adapter.


Other tools and procedures may be required. See refer-ences to these procedures in the step-by-step instructions below.


Step Action Illustration/Info

1. Clean the manipulator turning disk with isopro-panol.


2. Fit the turning disk fixture (incl. guide pin) on the turning disk.


3. Turn the tool clockwise against the pin at the same time as the screws are tightened.

4. Run the program \SYSTEM\UTILITY\SER-VICE\CALIBRAT\CALxxxx (xxxx=robot model, e.g. 7600) in the system and select Calib: CAL3.

The robot moves to the position for calibration of axis 3.

5. Reset the levelmeter with correct orientation of the sensor for calibration of axis 3.


3HAC 021111-001 Revision - 107



6. Fit the calibration sensor unit (sensor and plate) on the turning disk fixture.

Carefully tighten the securing screws with approximately same tightening torque that used at the reference plane.

Shown in the section Positions and directions of sensor on page 99!

7. Manually run axis 3 in with the joystick to the cor-rect position as indicated by the levelmeter.

Tip!

Reduce the jogging velocity in order to easily position the axis as close to zero as possible!


0 ± 0.40 mm/m

8. Update only axis 3. Detailed in section Fine calibra-tion procedure on TPU on page 115.


10. Check the calibration according to section Post calibration procedure on page 123 or continue with calibration of next axis.

11. Refit the cover plate on the reference surface on the base if no further calibration is performed.

Step Action Illustration/Info

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bration equipment.

Required equipment

TIP!




Procedure










1. Clean the manipulator turning disk with isopropanol .


2. Fit the turning disk fixture (incl. pin) on the turning disk.



4. Run the program \SYSTEM\UTILITY\SER-VICE\CALIBRAT\CALxxxx (xxxx=robot model, e.g. 7600) in the system and select Calib: CAL4A.

The robot moves to the position for calibration of axis 4.



3HAC 021111-001 Revision - 109




Carefully tighten the securing screws with approxi-mately same tightening torque that used at the ref-erence plane.


7. Manually run axis 4 in with the joystick to the correct position as indicated by the levelmeter.

Tip!



0 ± 0.80 mm/m

8. Update only axis 4. Detailed in section Fine cali-bration procedure on TPU on page 115.


10. Select Calib: CAL4B.

The axis 4 moves 90º, to a correct position.


12. Check the calibration according to section Post cal-ibration procedure on page 123 or continue with calibration of next axis.

13. Refit the cover plate on the reference surface at the base if no further calibration is performed.


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bration equipment.

Required equipment

TIP!




Procedure



6369 901-347







1. Clean the manipulator turning disk with isopropanol .


2. Fit the turning disk fixture (incl. pin) on the turning disk.



4. Run the program \SYSTEM\UTILITY\SER-VICE\CALIBRAT\CALxxxx (xxxx=robot model, e.g. 7600) in the system and select Calib: CAL5.

The robot will now move to the position for calibra-tion of axis 5.



6. Fit the calibration sensor on the turning disk fixture.

Carefully tighten the securing screws with approxi-mately same tightening torque that used at the ref-erence plane.


3HAC 021111-001 Revision - 111




Tip!



0 ± 0.80 mm/m



10. Check the calibration according to section Post cal-ibration procedure on page 123 or continue with calibration of next axis.

11. Refit the cover plate on the reference surface at the base if no further calibration is performed.


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bration equipment.

Required equipment

TIP!




Procedure



6369 901-347




Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.



1. Calibrate axis 5. Detailed in section Calibration, axis 5 on page 111.




Carefully tighten the securing screws with approximately same tightening torque that used at the reference plane.

Shown in section Positions and directions of sensor on page 99!


Tip!

Reduce the jogging velocity in order to easily position the axis as close to zero as possible!

0 ± 0.80 mm/m

3HAC 021111-001 Revision - 113



5. Update only axis 6. Detailed in section Fine calibration procedure on TPU on page 115.


7. Check the calibration according to section Post calibration procedure on page 123.

8. Refit the cover plate on the reference surface at the base.


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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.

Procedure

Step Action Note/Illustration

1. Press the button "Miscella-neous".

xx0100000194

2. Select the Service window by pressing ENTER.

xx0100000200

3. Select Calibration from the View menu. The Cali-bration window appears.

If multiple units are con-nected to the robot, they will be listed in the window.

xx0100000201

The calibration status can be any of the following:

• Synchronized: all axes are calibrated and their positions are known. The unit is ready for use.

• Revolution Counter not updated: all axes are fine-calibrated but one (or more) of the axes has a counter that is NOT updated. This axis, or these axes, must therefore be updated as detailed in section Updating the revolution counters on page 121.

• Not calibrated: one (or more) of the axes is NOT fine-calibrated. This axis, or these axes, must therefore be fine-calibrated as detailed below and in the calibration instructions for each axis.

3HAC 021111-001 Revision - 115



4. Select the desired unit and choose Fine Calibrate from the Calib menu. A Warning window appears.

xx0100000203

5. Move the desired robot axis according to the calibration procedure for current axis. These procedures are found in section Calibration on page 103.

Press OK. The Fine Cali-brate window appears.

xx0100000204

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

7. Press OK when all axes that are to be updated are marked with an x.

CANCEL returns to the Cal-ibration window.

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

CANCEL returns to the Fine Calibration window.

An alert box is displayed dur-ing calibration. The Status window appears when the fine calibration is complete. The revolution counters are always updated at the same time as the calibration is per-formed.

Step Action Note/Illustration

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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.

Levelmeter 2000 The Levelmeter 2000 is shown for reference below:

xx0200000083

A Measuring unit

B Selection pointer

C Sensor connection

3HAC 021111-001 Revision - 117



Sensor mounted on fixture

When using the sensor as a reference sensor it is fitted to the sensor fixture, together with a

sensor plate, as shown below.

See the section Positions and directions of sensor on page 99 for actual positioning and ori-

entation of the fixture and the sensor, since the direction of the sensor differs depending on

which axis is calibrated.

xx0100000207

Required equipment

A Reference sensor, fitted to the sensor plate (actual direction differs)

B Sensor fixture, fitted on manipulator base

C Attachment screws, sensor plate

Equipment Art. no. Note

Levelmeter, one sensor 6369 901-347 Includes one sensor.

Sensor plate 3HAC 0392-1

Sensor fixture 6808 0011-GM

Isopropanol 1177 1012-108 For cleaning the sensor fixture.

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NOTE!

Note!

Always secure the sensor to the sensor fixture using screws and with approximately the same

torque each time!

NOTE!

Note!

Always fit the sensor in the same direction when resetting it as when performing the calibra-

tion for each axis!

NOTE!

Note!

Always reset the sensor when using it in a new direction!

Resetting


1. If the sensor and the sensor plate are sepa-rate, fit them together by first cleaning the attachment area on the sensor plate with iso-propanol and then fitting the sensor to it.

Handle the sensor plate and the sensor as a complete unit when fitting it to and moving it between the reference point and the different axes.


2. Make sure the Levelmeter is initialized according to section Initialization of Levelme-ter 2000 on page 101.

3. Remove the cover plate on the reference sur-face on the manipulator base.

Shown in the section Positions and directions of sensor on page 99.

4. Clean the area where the sensor fixture is fit-ted with isopropanol .

5. Fit the sensor fixture on the reference surface on the manipulator base.


Orientation is specified in section Positions and directions of sensor on page 99!

6. Clean the sensor plate attachment area on the fixture with isopropanol.

7. Fit the sensor unit (sensor plate and sensor) on to the sensor fixture and connect the sen-sor to the Levelmeter 2000.

Correct direction is shown in Posi-tions and directions of sensor on page 99.

Connection is shown in the figure Levelmeter 2000 on page 117.

8. Press ON/MODE on the Levelmeter 2000 until the dot flashes under REL ZERO .

Shown in the figure Levelmeter 2000 on page 117!

9. Press ENTER.

3HAC 021111-001 Revision - 119



Result The Levelmeter 2000 and the one sensor is now reset and ready for service. When moving

the sensor and the sensor plate to different axes, move it as a complete unit.

10. Wait until + or - flashes.

11. Press HOLD .

12. Wait until + or - flashes.

13. Press ENTER.


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5.3.9 Updating the revolution counters


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.

Storing the revolution counter setting

This section details the second step when updating the revolution counter; storing the revolu-

tion counter setting.

CAUTION!

If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, which

in turn may cause damage or injury!

Check the calibration very carefully after each update!


1. Select axis-by-axis motion mode.

2. Press the enabling device on the teach pendant and, using the joystick, move the robot manually so that the calibration marks lie within the tolerance zone.


3. Note that axis 6 does not have any mechanical stop and can thus be calibrated at the wrong faceplate rev-olution. Do not operate axis 6 manually before the robot has been calibrated.

4. When all axes are positioned as above, store the rev-olution counter settings using the Teach Pendant Unit as detailed below:


1. Press the button "Miscella-neous".

xx0100000194

2. Select the Service win-dow by pressing ENTER.

xx0100000200

3HAC 021111-001 Revision - 121



3. Select Calibration from the View menu.

The Calibration window appears.

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

xx0100000201

4. Select the desired unit and choose Rev Counter Update from the Calib menu.

The Revolution Counter Update window appears.

xx0100000202

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

6. Press OK when all axes that are to be updated are marked with an x.

CANCEL returns to the Calibration window.

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

CANCEL returns to the Revolution Counter Update window.

8. At this point, it is recom-mended that the revolution counter values are saved to a diskette.

Not required.

9. Recheck the calibration position.

Detailed in section Checking the calibration position on page 97


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5.4.1 Post calibration procedure

5.4: After calibration


General Perform the following procedure after calibrating any manipulator axes. The procedure is

intended to verify that all calibration positions are correct.

Procedure


1. Run the calibration home position program twice.

Do not change the position of the manipulator axes after running the program!

Detailed in section Checking the calibration position on page 97.

2. Check the calibration positions.

If the axes are outside the tolerance, start the calibra-tion procedure from the beginning, in increasing sequence of the axes.

Detailed in section Calibra-tion scales and correct axis position on page 94.

3. Repeat the check as above.

4. Adjust the calibration marks when the calibration is done.


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

6. Change the values on a new label and stick it on top of the label located

• underneath the flange plate on the base.

7. Remove any calibration equipment from the manipu-lator.

3HAC 021111-001 Revision - 123



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6.0.1 Introduction

6: Calibration, M2004

6.0.1 Introduction

Calibration This chapter will describe how to calibrate the robot with the Wyler calibration equipment,

using Levelmeter 2000, when the robot is part of an M2004 robot system (IRC5 controller).

This chapter will be completed in the upcoming revision of the manual.

3HAC 021111-001 Revision - 125


6.0.1 Introduction

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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 instructions detailed for each axis are intended for calibration posi-

tion 0, i.e. the normal position. Calibration instructions for alternative positions are detailed

in Alternative calibrating on page 128.

Illustration The illustration shows the available calibrating positions of a suspended robot.

xx0400001020

A Calibration program Normal, calibration position 0 (axes 2 and 3)

B Calibration program Hanging, calibration position -1.570796 (axes 2 and 3)

3HAC 021111-001 Revision - 127


7.0.2 Alternative calibrating

7.0.2 Alternative calibrating

General The manipulator may be calibrated in any of three positions, shown in Alternative calibra-

tion position on page 127.

Procedure


1. 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.

2. Run the calibration program CALxxx in the system\SYS-TEM\UTILITY\SERVICE\CALIBRAT\.

(xxx = robot version, e.g. CAL1400)

3. Select Normal position, and check the calibration marks for each axis.

4. Run the calibration program again and select the desired calibra-tion position (Hanging) as shown in Alternative calibration position on page 127.

5. Change to the new calibration offset, as detailed in New calibration offset on page 130.

6. Note the new calibration offset on the label, located under the flange plate on the base.

The new calibration offset values can be found as detailed in Retrieving offset values on page 131.

7. Change to the new calibration position as detailed in New calibra-tion position on page 129.

8. Restart the robot by selecting Restart from the File menu.

9. Mark the new calibration positions for axes 2 and 3, with the punch marker.

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

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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.


1. Press the "Miscellaneous" button

xx0100000194

2. Select the System parameters window by pressing ENTER.

xx0100000200.

3. Select Manipulator from the Topics menu.

4. Select Arm from the Types menu.

5. Select axes 2 and 3.

6. Change Cal pos to -1.570796.

The angle is measured in radians as shown in Alternative cal-ibration position on page 127.

3HAC 021111-001 Revision - 129


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.


1. Press the "Miscella-neous" button.

xx0100000194

2. Select the Service window by pressing ENTER.

xx0100000200

3. Select Calibration from the View menu.

The calibration win-dow appears.

xx0100000201

4. Select Calibrate from the Calib menu.

5. Select axes 2 and 3.

6. Confirm by pressing OK twice.

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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.


1. Press the "Miscellaneous" button.

xx0100000194

2. Select the System parameters window by pressing ENTER.

xx0100000200

3. Select Motor from the Types menu.

4. Select axes 2 and 3 and press ENTER.

xx0100000200

5. Note the Cal offset value.

3HAC 021111-001 Revision - 131



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Index

C

Calibration position, 121

R

Revolution counters, 121

U

Updating revolution counters, 121

3HAC 021111-001 133

Index

134 3HAC 021111-001