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Installation and Commissioning ManualIndustrial Robot IRB 940 Tricept™3HAC 16638-1 / M2000 / Rev. -
IRB 940 Tricept™
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ABB Automation Technology Products ABRoboticsS-721 68 VÄSTERÅSSWEDENTelephone: +46 (0) 21 344000Telefax: +46 (0) 21 132592
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Installation and Commissioning ManualIRB 940 Tricept™
3HAC 16638-1-
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The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no re-sponsibility for any errors that may appear in this manual.
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 permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
©Copyright 2002 ABB All rights reserved.
ABB Automation Technology Products ABRobotics
SE-721 68 VästeråsSweden
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Table of Contents
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Overview 1Product Documentation, IRB 940 Tricept™ 3
Chapter 1: Safety, service 5
Introduction 5Safety, service - General 6
Section A: References 7Limitation of Liability 7Applicable Safety Standards 7Related information 8
Section B: Safety risks 9Safety risks related to end effector 9Safety risks related to tools/workpieces 9Safety risks related to pneumatic/hydraulic systems 9Safety risks during operational disturbances 10Safety risks during installation and service 10Risks associated with live electric parts 11
Section C: Safety actions 13Safety fence dimensions 13Fire extinguishing 13Emergency release of the manipulator's arm 14Brake testing 14Risk of disabling function "Reduced speed 250 mm/s" 15Safe use of the Teach Pendant Unit 15Work inside the manipulators working range 15
Chapter 2: Reference Information 17
Introduction 17Screw joints 18Weight specifications 20
Chapter 3: Manipulator 21
Introduction 21
Section A: Unpacking 22Pre-installation procedure 22Working range, IRB 940 Tricept 26Risk of tipping/Stability 27
Section B: On-site installation 28Lifting manipulator in a horizontal orientation 28
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Lifting manipulator in a vertical orientation, using a trolley 31Lifting manipulator in a vertical orientation, using a lifting jack 35Manually releasing the brakes 39Orienting and securing the manipulator 40Fitting equipment on manipulator 44Loads 46
Section C: Electrical connections 47Installation of cabling on board the manipulator 47Connecting the manipulator to the control cabinet, manipulator cabling 49Connectors on the distribution box 52
Chapter 4: Controller 53
Introduction 53
Section A: Unpacking 54Transporting and unpacking, S4Cplus 54
Section B: On-site Installation 56Lifting the controller cabinet 56Required installation space, control cabinet 57Bolt pattern, control cabinet 58Installation of external power transformer 59Installation of Distributed Drive Unit (DDU) 64
Section C: Electrical connections 68
C - 1: Signal/Power cables 68Connecting the manipulator to the control cabinet, S4Cplus cabling 68Connectors on control cabinet, S4Cplus 70Connectors on distributed drive unit, DDU 71Connection of mains power to control cabinet, S4Cplus 72
C - 2: Signal connections 74Signal Classes 74Selecting Cables 75Interference elimination 77Connection types 79Connections to screw terminals 80Connections to connectors 81
C - 3: Customer connections on controller 81The MOTORS ON/MOTORS OFF circuit 81External customer connections on panel X1 - X4 91Connection of external safety relay 94
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C - 4: Supplies 96External 24V supply 9624V I/O supply 98115/230 VAC supply 99
C - 5: Buses 99Connection of the CAN bus 99Interbus-S, slave DSQC 351 104Profibus-DP, slave DSQC 352 110
C - 6: I/O units 114Distributed I/O units 114Distributed I/O, digital sensors 115Distributed I/O, digital I/O DSQC 328 (option) 116AD Combi I/O, DSQC 327 (optional) 120Analog I/O, DSQC 355 (optional) 124Encoder interface unit, DSQC 354 (optional) 130Relay I/O, DSQC 332 (optional) 136Digital I/O (120 VAC), DSQC 320 (optional) 140
C - 7: Communication 144Communication concept, Allen-Bradley 144RIO, remote I/O for Allen-Bradley PLC DSQC 350 146Communication, serial links 149Communication, Ethernet 154External operator’s panel 157
Section D: Start-up 159Inspection before start-up 159Start-up 160
Section E: Installation of controller software 162Loading system software 162RobotWare CD-ROM 164Installing new Robot Controller Software with RobInstall 166Create a new Robot Controller System 168Update the Robot Controller image 173Transfer Robot Controller System using Ethernet connection 175Transfer Robot Controller System using floppy disks 180RobInstall preferences 182
Section F: Robot controller 184BootImage 184Start window 185Reboot Window 187Boot Disk Window 188
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Network Settings Window 189LAN Settings Window 190Service Settings Window 192System selection window 193How to perform a Restart 194How to Start in Query Mode 198
Section G: System directory structure 200Media pool in the PC 200System pool in the PC 201File structure in the robot controller mass storage memory 202Preparation of S4Cplus software to be installed 203Handling mass memory storage capacity 204
Chapter 5: Calibration 207
When to calibrate 207
Section A: General 208How to calibrate the robot system 208Calibration tool kit, contents 210
Section B: Preliminaries 211Correct orientation of axes 211Checking the calibration position 215Updating the revolution counter 216Fine calibration procedure on TPU 219
Section C: Calibration 222Directions for all axes 222Fine calibration, all axes 224
Section D: After calibration 231Post calibration procedure 231
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Overview
About This Manual
This information product is a manual containing instructions for installing the
complete robot system, mechanically as well as electrically.
Usage This manual should be used during installation, from lifting the manipulator to its
work site through installing application software in the robot controller, making
the robot ready for operation.
Who Should Read This Manual?
This manual is intended for:
• installation personnel on the installation site.
Prerequisites The reader should...
• have the required knowledge of mechanical as well as electrical installa-tion work.
Organization of Chapters
The manual is organized in the following chapters:
Chapter Contents
1. Safety, service
2. Reference Information
3. Manipulator
4. Controller
5. Calibration
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References
Revisions
Reference Document Id
Circuit diagram, Manipulator Included in 3HAC 16640-1, Repair Manual, part 2
Circuit diagram, Controller Included in 3HAC 16640-1, Repair Manual, part 2
Revision Description
- First edition
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Product Documentation, IRB 940 Tricept™
General The complete documentation of IRB 940 Tricept™ including controller consists
of several manuals listed below:
Overview, Installation and Commissioning Manual
The Installation and Commissioning Manual contains the following main chap-
ters:
• Safety, Service
• Reference Information
• Unpacking
• On-site Installation
• Electrical connections
• Start-up
• Robot controller
• Installation of controller software
• System directory structure
• Calibration
Overview, Repair Manual
The Repair Manual contains the following main chapters:
• Safety, Service
• Reference Information
• Remove/Refitting instructions for all manipulator details considered spare parts
• Remove/Refitting instructions for all controller cabinet details considered spare parts
• Circuit Diagram for manipulator
• Circuit Diagram for controller cabinet
Overview, Maintenance Manual
The Maintenance Manual contains the following main chapters:
• Safety, Service
• Reference Information
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• Maintenance schedules
• Maintenance activities
• Disposal
The chapters for the maintenance activities include instructions for all the main-
tenance activities specified in the maintenance schedule.
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Safety, service
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Chapter 1:Safety, service
Introduction
Definitions This chapter details safety information for service personnel i.e. personnel per-
forming installation, repair and maintenance work.
Sections The chapter “Safety, service” is divided into the following sections:
A. References contains lists of:
• Limitation of liability
• applicable safety standards
• referenced documents
B. Safety risks lists dangers relevant when servicing the robot system. The dangers are split into different categories:
• Safety risks related to 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
C. 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
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Safety, service - General
Validity and responsibility
The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment, which can influence the safety
of the total system. To protect personnel, the complete system must be designed
and installed in accordance with the safety requirements set forth in the standards
and regulations of the country where the robot is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable
safety laws and regulations in the country concerned are observed and that the
safety devices necessary to protect people working with the robot system have
been designed and installed correctly. Personnel working with robots must be
familiar with the operation and handling of the industrial robot, described in the
applicable documents, e.g. 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 inter-
face for the connection of external safety devices. Via this interface, an external
safety function can interact with other machines and peripheral equipment. This
means that control signals can act on safety signals received from the peripheral
equipment as well as from the robot.
In the Product Manual - Installation and Commissioning, instructions are pro-
vided for connecting safety devices between the robot and the peripheral equip-
ment.
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Safety, serviceReferences
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Section A: References
Limitation of Liability
General Any information given in this information product regarding safety, must not be
construed as a warranty by ABB Robotics that the industrial robot will not cause
injury or damage even if all safety instructions have been complied with.
Applicable Safety Standards
Standards The robot is designed in accordance with the requirements of:
• EN 292-1, Safety of macheniry, basic terminology
• EN 292-2, Safety of machinery, technical principles/specifications, emer-gency stop
• EN 418, Safety of machinery, emergency stop equipment
• EN 563, Safety of machinery, temperatures of surfaces
• EN 614-1, Safety of machinery, ergonomic design principles
• EN 775, Robot safety
• EN 60204-1, Electrical equipment for industrial machines
• EN 50081-2EMC, Generic emission standard. Part 2: Industrial environ-ment(EN 55011 Class ARadiated emission enclosure)(EN 55011 Class AConducted emission AC Mains)
• EN 61000-6-2EMC, Generic standards - Immunity for Industrial environ-ments(EN 61000-4-2Electrostatic discharge immunity test)(EN 61000-4-3Radiated, radio-frequency, electromagnetic field immunity test)(EN 61000-4-4Electrical fast transient/burst immunity test)(EN 61000-4-5Surge immunity test)(EN 61000-4-6Immunity to conducted disturbances, induced by radio-fre-quency fields)(EN 61000-4-11Voltage dips, short interruptions and voltage variations immunity test)
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Related information
General The list below specifies documents which contain useful information:
Documents
Type of information Detailed in document Section
Installation of safety devices Installation and Commis-sioning Manual
Changing robot modes User’s Guide Start-up
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Section B: Safety risks
Safety risks related to end effector
Make sure to prevent an end effector from dropping a workpiece, if such is used.
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.
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, par-ticular care must be taken.
• The pressure in pneumatic and hydraulic systems must be released before starting to repair them.
• Note that the interior of the robot may be pressurized.
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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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 personnel
• 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.
Safety risks during installation and service
General risks dur-ing installation 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, lifting and transport of the
robot system, the regulations applicable in the country concerned and the instruc-
tions of ABB Robotics must be complied with.
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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 or when the motors or other components are removed.
• 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 temperature of the motors or oil spills that can occur on the robot.
To be observed by the supplier of the complete sys-tem
• The supplier of the complete system must ensure that all circuits used in the safety function are interlocked in accordance with the applicable stan-dards for that function.
• The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner, in accor-dance with the applicable standards for the emergency stop function.
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.
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Voltage related risks, controller, S4Cplus
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 external 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. N.B.: 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 process
• The external voltage connected to the control cabinet remains live even when the robot is disconnected from the mains.
• Additional connections
Voltage related risks, manipula-tor, IRB 940 Tri-cept™
A danger of high voltage is associated with the manipulator in:
• The distribution box for the manipulator (up to 430 VDC)
• The power supply for the motors (up to 430 VDC)
• The user connections for tools or other parts of the installation (max. 230V AC, see Product Manual - Installation and Commissioning)
Voltage related risks, tools, mate-rial handling devices, etc.
Tools, material handling devices, etc., may be live even if the robot system is in
the OFF position. Power supply cables which are in motion during the working
process may be damaged.
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Section C: Safety actions
Safety fence dimensions
General Install a safety cell around the robot to ensure safe robot installation and operation.
Dimensioning the fence or enclo-sure
Design the safety cell such that it will:
• - withstand any impact from a tool failure. Due to the high kinetic energy associated with HSM (High Speed Machining), a tool failure poses a seri-ous risk as any debris can cause serious personal injury. Both walls and ceilings must be designed and dimensioned so that they can withstand any projectiles that they may be subjected to. Windows must be made of suit-able safety glass. Study the planned process to determine the forces involved and appropriate materials.
• - insulate against sound pollution from the machining process. Typically the safety cell should be able to reduce sound from the machining process down to 75dBA, though individual installations may stipulate other values. Study the planned process to determine the allowable noise pollution lev-els and appropriate sound insulation.
• - isolate gases and mist generated by the machining process and spray mist lubrication. Study the planned process to determine the fumes involved and appropriate ventilation/filtering system.
Fire extinguishing
Use a CARBON DIOXIDE (CO 2 ) extinguisher in the event of a fire in the robot (manipulator or controller)!
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Emergency release of the manipulator’s arm
Description In an emergency situation, any of the manipulator’s axes may be released manu-
ally by pushing the brake release buttons on the distribution box for the manipu-
lator. How to release the brakes is detailed in section "Manually releasing the
brakes" in the Installation Manual.
The manipulator arms may be moved manually when the brakes has been
released.
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!
Brake testing
When to test During operation the holding brakes of each axis motor wear normally. A test may
be performed to determine whether the brake can still perform its function.
How to test The function of each axis’ motor holding brakes may be checked as detailed
below:
1. Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized (max. static load).
2. Switch the motor to the MOTORS OFF position with the Operating mode selector on the controller.
3. Check that the axis maintains its position.
If the manipulator does not change position as the motors are switched off, then the brake function is adequate.
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Risk of disabling function "Reduced speed 250 mm/s"
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.
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.
Work inside the manipulators working range
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 per-sonnel who are aware of the risks that this entails. Also be aware of any danger that may be caused by rotating tools or other devices mounted on the manipulator or inside the cell.
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Chapter 2:Reference Information
Introduction
General This chapter presents generic pieces of information, complementing the more spe-
cific information in the following chapters.
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Screw joints
General This section details how to tighten the various types of screw joints in the manip-
ulator as well as the controller.
The instructions and torque values are valid for screw joints comprising metallic
materials and do not apply to soft or brittle materials.
Any instructions given in the repair, maintenance or installation procedure
description override any value or procedure given here, i.e. these instruction are
only valid for standard type screw joints.
Tightening torque The tightening torque values for different types of screw joint are specified in the
tables below:
Screws with slotted or cross recess head
Screws with hexagon socket head
Dimension Tightening torque (Nm) Class 4.8 "dry"
M2.5 0.25
M3 0.5
M4 1.2
M5 2.5
M6 5.0
Dimension Tightening torque (Nm) Class 8.8 "dry"
Tightening torque (Nm) Class 10.9
Tightening torque (Nm) Class 12.9
M5 6 - -
M6 10 - 17
M8 24 28 40
M10 47 55 70
M12 82 95 120
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M16 200 235 300
Dimension Tightening torque (Nm) Class 8.8 "dry"
Tightening torque (Nm) Class 10.9
Tightening torque (Nm) Class 12.9
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Weight specifications
Definition In all repair and maintenance instructions, weights of the components handled are
sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in
this way.
ABB recommends handling all components with a weight exceeding 22 kg using
lifting equipment to avoid inflicting injury.
Example Below is an example of how a weight specification is presented:
The actuator with motor weighs 40 kg! All lifting equipment used must be dimen-sioned accordingly!
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Manipulator
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Chapter 3:Manipulator
Introduction
Definitions This chapter contains necessary information for installing the manipulator to the
working site.
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Section A: Unpacking
Pre-installation procedure
General This instruction is primarily intended for use when unpacking and installing the
manipulator (mechanical robot) for the first time. It also contains information use-
ful during later re-installation of the manipulator.
Checking the pre-requisites for installation
The checklist below details what must be observed before proceeding with the
actual installation of the manipulator:
1. Make sure only qualified installation personnel, conforming to all national and local codes, are allowed to perform the installation.
2. Make sure the manipulator has not been damaged, by visually inspect-ing the manipulator and control cabinet exterior.
3. Make sure the lifting device to be used is dimensioned to handle the weight of the manipulator as stated in Weight, manipulator.
4. If the manipulator is not to be installed directly, it must be stored as in Storage conditions, manipulator.
5. Make sure the appointed operating environment of the manipulator conforms to the specifications as in Operating conditions, manipulator.
6. Before taking the manipulator to its installation site, make sure the site conforms to Loads on flange, manipulator and Protection classes.
7. Before moving the manipulator, please observe Risk of tipping/Stability regarding risk of tipping!
8. When these prerequisites have been met, the manipulator may be taken to its installation site as in Lifting manipulator in a horizontal/ver-tical orientation.
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Weight, manipulator
The table below shows the weight of the manipulator:
Manipulator model Weight
IRB 940 Tricept 570 kg
Distribution box 31 kg
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Loads on flange, manipulator
The table below shows the maximum forces and torques working on the manipu-
lator during operation.
NOTE! These forces and torques are extreme values that are rarely encountered
during operation. The values also never reach their maximum simultaneously!
xx0200000362
Force Maximum stress transmitted to the mounting base
Force xy 51 kN
Force z 68 kN
Torque xy 14 kNm
Torque z 45 kNm
Tz
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Storage conditions, manipulator
The table below shows the allowed storage conditions for the manipulator and the
distribution box:
Operating conditions, manipulator
The table below shows the allowed operating conditions for the manipulator and
the distribution box:
Note! The robot must not be operated until the internal temperature of the robot is
stabilized within the prescribed operational temperature range!
Protection classes
The table below shows the protection class of the main parts of the robot system:
Parameter Value
Min. ambient temperature, storage -25°C
Max. ambient temperature, storage +55°C
Max. ambient temperature, storage (less than 24 hrs) +55°C
Max. ambient humidity, storage Max. 95% at constant temperature
Parameter Value
Min. ambient temperature, operation +5°C
Max. ambient temperature, operation, manipulator +45°C
Max. ambient humidity, operation Max. 95% at constant temperature
Equipment Protection class
Manipulator IP 66
Distribution box IP 67
Overpressure unit IP 67
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Working range, IRB 940 Tricept
Illustration The illustration below shows the unrestricted working range of IRB 940 Tricept:
xx0200000356
A Absolute Tolerance Area at the tool-coordinate system, TCP0
B Working range, centre of axis 5
(mm)
800 400 0 400 800 12001200
800
400
0
(mm)
800 400 0 400 800 12001200
800
400
0
A
B
A
B
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Risk of tipping/Stability
General The section below details how to make sure the manipulator does not tip over
before it has not been safely secured to the foundation.
Stability The figure below shows the robot in its shipping position which also is the most
stable.
The robot must be placed on a spacer, at least 100mm in height, in order to avoid
the risk of collision with the axis 2 servomotor.
xx0200000357
The table below specifies the most stable position of each axis of the manipulator.
1. DO NOT change the manipulator position before securing it to its foun-dation. The shipping position is the most stable.
A 26 mm (most stable position of axes 1, 2 and 3)
B Spacer, min. 100 mm in height
Axis Position Note
1, 2, 3 26 mm Shown in figure above!
4, 6 0°5 -90°
A
B
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Section B: On-site installation
Lifting manipulator in a horizontal orientation
General The section below details how to lift the manipulator in a horizontal orientation
from a transportation pallet to a stand.
Required equip-ment
Lifting in horizon-tal orientation
The section below details how to lift and move the manipulator from the transpor-
tation pallet, horizontally, using the lifting equipment specified above.
The IRB 940 manipulator weighs 570 kg! All lifting equipment used must be dimen-sioned accordingly!
No personnel must under any circumstances be present under the suspended load!
Failure to attach the straps correctly can cause the suspended load to tilt suddenly and cause both personal injury and severe damage to the load.
Equipment Note
Crane or hoist Lifting capacity: 1000 kg.
1 strap, length 2 m Lifting capacity: 1000 kg.
2 straps, length 1 m Lifting capacity: 1000 kg.
2 upper platform eyebolts M16
2 shackles The shackles must fit the eyebolts on the upper platform.
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Step Action Note
1. Run the overhead crane to a position above the manipulator.
2. Fit the 2 metre strap around the wrist unit, as shown in the adjacent fig-ure.
xx0200000317
3. Hook the strap to the lift, or crane, as shown in the adjacent figure.
xx0200000318
4. Unless already in posi-tion, fit the eyebolts to the upper platform.
Dimension specified above!
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5. Attach the 1 metre straps to the eyebolts using the shackles.
xx0200000319
• A: Strap, 1 m (2 pcs)
• B: Shackle (2 pcs)
• C: Eyebolt (2 pcs)
6. Attach the straps to the lift, or crane, as shown in figure above!
7. Lift the manipulator to the required location and dis-connect the lifting equip-ment.
Step Action Note
B
C
A
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Lifting manipulator in a vertical orientation, using a trolley
General The section below details how to lift the manipulator from a transportation pallet
to a stand, after turning it into a vertical orientation.
Notice that there are two different ways of turning the manipulator into a vertical
orientation. The section below details a method using a trolley or a machine skate,
that is used to wheel the front of the manipulator towards the centre of the lift as
the manipulator is hoisted.
Required equip-ment
Lifting in vertical orientation, using a trolley
The section below details how to lift and move the manipulator from the transpor-
tation pallet, vertically, using the lifting equipment specified above.
The IRB 940 manipulator weighs 570 kg! All lifting equipment used must be dimen-sioned accordingly!
No personnel must under any circumstances be present under the suspended load!
Equipment Note
Crane or hoist Lifting capacity: 1000 kg.
2 straps, length 2 m Lifting capacity: 1000 kg.
2 upper platform eyebolts M16
2 shackles The shackles must fit the eyebolts on the upper platform.
Trolley (or machine skate) Capacity: 500 kg. Height: 400 mm.
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Failure to attach the straps correctly can cause the suspended load to tilt suddenly and cause both personal injury and severe damage to the load.
- Ensure that the area around the manipulator is clear as the machine can swing round as it leaves the pallet!
- Ensure that the trolley has free movement while lifting. If the trolley gets stuck, the manipulator is likely to fall off and can cause personal injury and damage to the manipulator!
Step Action Note
1. Unless already in posi-tion, fit the eyebolts to the upper platform.
Dimension specified above!
2. Attach the 2 metre straps to the eyebolts using the shackles.
xx0200000320
• A: Strap, 2 m (2 pcs)
• B: Shackle (2 pcs)
• C: Eyebolt (2 pcs)
3. Attach the straps to the lift, or crane, as shown in figure above!
B
C
A
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4. Place the trolley under the wrist unit and guide it into the correct posi-tion as the manipulator is lifted, as shown in the adjacent figure.
xx0200000321
• A: Strap, 2 m (2 pcs)
• B: Wrist unit
• C: Trolley
• D: 125 mm
• E: 400 mm
5. When the wrist is rest-ing squarely on the trol-ley it is safe to continue lifting it off the pallet, as shown in the adjacent figure. Note! Exercise extreme care when lowering the wrist unit on to the trol-ley. Dropping the manipulator onto the trolley can cause dam-age to the manipulator and/or affect the cali-bration of the tripod.
xx0200000322
Step Action Note
AB
C
DE
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6. As the manipulator is lifted off the pallet, care-fully remove the pallet to allow free movement of the trolley towards the centre of the lift, as shown in the adjacent figure.
xx0200000323
7. Continue lifting the manipulator until it leaves the trolley and is hanging vertically, as shown in the adjacent figure.
xx0200000324
8. Lift the manipulator and move it to the required location.
Step Action Note
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Lifting manipulator in a vertical orientation, using a lifting jack
General The section below details how to lift the manipulator from a transportation pallet
to a stand, after turning it into a vertical orientation.
Notice that there are two different ways of turning the manipulator into a vertical
orientation. The section below details a method using a lifting jack.
Required equip-ment
Lifting in vertical orientation, using a lifting jack
The section below details how to lift and move the manipulator from the transpor-
tation pallet, vertically, using the lifting equipment specified above.
The IRB 940 manipulator weighs 570 kg! All lifting equipment used must be dimen-sioned accordingly!
No personnel must under any circumstances be present under the suspended load!
Failure to attach the straps correctly can cause the suspended load to tilt suddenly and cause both personal injury and severe damage to the load.
Equipment Note
Crane or hoist Lifting capacity: 1000 kg.
2 straps, length 2 m Lifting capacity: 1000 kg.
1 strap, length 1 m Lifting capacity: 1000 kg.
2 upper platform eyebolts M16
2 shackles The shackles must fit the eyebolts on the upper platform.
Lifting jack Lifting capacity: 1000 kg.
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Step Action Note
1. Unless already in posi-tion, fit the eyebolts to the upper platform.
Dimension specified above!
2. Attach the 2 metre straps to the eyebolts using the shackles.
xx0200000320
• A: Strap, 2 m (2 pcs)
• B: Shackle (2 pcs)
• C: Eyebolt (2 pcs)
3. Attach the straps to the lift, or crane, as shown in figure above.
B
C
A
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4. Attach the 1 metre strap to the wrist as shown in the adjacent figure.
xx0200000317
5. Connect one end of the lifting jack to the strap around the wrist and the other to the lift, or crane. Adjust the length so that the lifting jack is tightened, as shown in the adjacent figure.
Dimension specified above!
xx0200000325
• A: Strap around wrist unit
• B: Crane
6. Lift the whole manipula-tor using the lift, or crane, away from the pallet and remove the pallet.
Step Action Note
A
B
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7. Lower the wrist end of the manipulator using the lifting jack.
When the wrist gets near the floor, raise the whole manipulator fur-ther, as shown in the adjacent figure.
Repeat until the manip-ulator hangs vertically.
xx0200000326
8. Remove the lifting jack and lift the manipulator to the required location.
Step Action Note
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Manually releasing the brakes
General The section below details how to release the holding brakes of each axis’ motor.
This may be done by:
• using push-buttons on the distribution box (internal brake release unit). This requires either that the controller is connected to the power supply or that the R1.MP connector (at the distribution box) is supplied with +24 V on R1.MP.B16 and 0 V on B14 or B15.
Supplying power on the wrong pin may cause all brakes on the manipulator to be released!
Internal brake release unit
This section details how to release the holding brakes using the internal brake
release unit.
When releasing the holding brakes, the manipulator axes may move very quickly and sometimes in unexpected ways! Make sure no personnel is near the manipu-lator arm!
Step Action Info/Illustration
1. The push-button unit is equipped with six but-tons for controlling the axis brakes. The but-tons are numbered with the axes numbers.
The push-button unit is located on the outside of the distribution box.
2. Release the holding brake on a particular manipulator axis by pressing the appropriate button on the internal brake release panel. The brake will function again as soon as the button is released.
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Orienting and securing the manipulator
General This section details how to orient and secure the manipulator at the stand in order
to run the robot safely.
The cable harness should be installed in the stand before the manipulator is
mounted to it. Installation of the cabling is described in chapter "Electrical con-
nections".
Attachment screws
The table below specifies the type of securing screws and washers to be used for
securing the manipulator to the foundation. Securing screws are included in the
delivery of the manipulator.
A locating pin may be used in the mounting flange, when necessary. The dimen-
sion for the attachment hole is detailed in part "Hole configuration, mounting
flange".
Suitable screws, lightly lubricated MC6S, M16 x 55
Quality Quality 8.8
Suitable washer Thickness: 4 mm
Tightening torque 200 Nm
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Illustration, securing manipu-lator at stand
The figure below shows how to mount the manipulator to a stand. The figure
shows prepared cabling in the stand.
xx0200000348
A Manipulator attachment bolts
B Centering ring
C Mounting flange
AB
C
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Securing the manipulator
This section details how to secure the manipulator to the stand in a vertical posi-
tion, after fitting the stand to the foundation.
Step Action Info/Illustration
1. Lift and turn the manipulator to vertical orien-tation.
Detailed in "Lifting the manipulator in a vertical orientation, using a trol-ley/lifting jack".
2. Move the manipulator to the vicinity of its installation location.
3. Pull the cabling through the stand and through the centering ring. Fit the ring to the stand.
Shown in figure above!
4. Guide the manipulator gently while lowering it into its mounting position. Make sure the manipulator mounting flange is correctly fitted onto the centering ring!If necessary, use a locating pin in the flange.
Shown in figure above!
Location of the attach-ment hole for the pin is shown in part "Hole con-figuration, mounting flange".
5. Fit the 8 bolts and washers in the mounting flange attachment holes.
Specified in "Attachment screws". Shown in figure above!
Note! Lightly lubricate the bolts before assembly!
6. Tighten the bolts in a criss-cross pattern to ensure that the flange is not distorted.
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Hole configura-tion, mounting flange
The illustration below shows the hole configuration used when securing the
manipulator. Note that the holes are not equally spaced on the flange.
xx0200000358
A-A
C-C
(Ø400)
Ø350
53
86.5
18 Through ˜8x)
Ø10 H8 Through
87.5
C
C
3
6
A
A
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Fitting equipment on manipulator
General The manipulator features mounting holes for additional equipment.
Illustration, fitting of extra equip-ment on upper platform
The illustration below shows the mounting holes available for fitting extra equip-
ment on the upper platform.
xx0200000360
309.5 4
x M8x12 Deep
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Illustration, fitting on mounting flange
The illustration below shows the mounting holes available for fitting equipment
on the mounting flange.
xx0200000359
Fastener quality When fitting tools on the mounting flange (see the figure above), use only screws
with quality 12.9. When fitting other equipment, standard screws with quality 8.8
can be used.
A guiding pin may be used when fitting equipment on to the tool flange. Attach
the pin to the extra equipment using a press fit, in order to make sure that the pin
remains in the equipment when removing it from the flange.
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Loads
General Any loads mounted on the manipulator must be defined correctly and carefully
(with regard to the position of centre of gravity and inertia factor) in order to avoid
jolting movements and overloading the motors. If this is not done correctly oper-
ational stops may result.
References Load diagrams, permitted extra loads (equipment) and their positions are speci-
fied in the Product Specification. The loads must also be defined in the software
as detailed in the User’s Guide.
Brake perfor-mance
Manipulator motor brake performance depends on any loads attached. For further
information about brake performance, please contact ABB Robotics.
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Section C: Electrical connections
Installation of cabling on board the manipulator
General The manipulator is connected to the control cabinet via a distribution box, after
mounting it on the stand.
The section below describes how to install the cabling on board the manipulator.
All the necessary cabling is included in the delivery of the robot but must be con-
nected both to the manipulator and to the distribution box.
All cabling is specified in the part "Connecting the manipulator to the control
cabinet, manipulator (/controller) cabling"
The figure below shows how the cabling is installed to the manipulator.
xx0200000349
A Cabling in one of the two grooves in the upper platform
A
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Installation of cabling on board the manipulator Step Action Note/Illustration
1. Attach the cables, axes 1-2-3, with straps in the cable grooves on the upper platform, as shown in the figure above. The cabling is marked with a red ring at the correct attachment point. The ring is then located behind the straps.
When installing the cabling in the robot it is very important to adjust its looseness correctly.
2. Connect the cables, axes 1-2-3, to the motors of axes 1-2-3. Fit the cables to the brackets mounted nearby the motors and secure with straps.
Connection points detailed in "Con-necting the manipulator to the con-trol cabinet, manipulator cabling".
3. Fit the cables, axis 4-5-6, inside the cable chain.
4. Connect the cables on top of the housing, at the upper end of the center unit.
Connection points detailed in "Con-necting the manipulator to the con-trol cabinet, manipulator cabling".
5. Fasten the cable chain with attachment screws in the cable bracket at axis 2 and at top of the housing.
xx0200000428
4x4x
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Connecting the manipulator to the control cabinet, manipulator cabling
General The manipulator is to be connected to the control cabinet via a distribution box,
after mounted to the stand. This section specifies the cabling to be used and their
connection points.
How to install the manipulator cables on board the manipulator is detailed in the
part "Installation of cabling on board the manipulator".
Main cable cate-gories
Cable category Description
Manipulator cables The cables between the distribution box and the manip-ulator motors are specially manufactured with extra strong screening. The cabling for each motor consists of two separate cables, one power cable and one signal cable. The cabling contains conductors for:
The power cable contains conductors for: • Motor phases
• Earth connection
• Motor brake
• Motor temperature sensors
The signal cable contains conductors for: • Resolvers
Distribution box cables Handles power supply to and control of the manipula-tor's motors as well as feedback from the serial mea-surement board.
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Manipulator cables
The manipulator cables are included in the standard delivery. They are completely
pre-manufactured and ready to plug in.
The cabling transfers drive power and resolver data for drive and control of the six
axes.
Distribution box cables
These cables are included in the standard delivery. They are completely pre-man-
ufactured and ready to plug in.
Cable sub-category Connection point, distribution box
Connection point, manipulator
Manipulator cable, power, axis 1 XM1 XM1.1
Manipulator cable, signal, axis 1 XR1 XR1.1
Manipulator cable, power, axis 2 XM2 XM2.1
Manipulator cable, signal, axis 2 XR2 XR2.1
Manipulator cable, power, axis 3 XM3 XM3.1
Manipulator cable, signal, axis 3 XR3 XR3.1
Manipulator cable, power, axis 4 XM4 XM4.1
Manipulator cable, signal, axis 4 XR4 XR4.1
Manipulator cable, power, axis 5 XM5 XM5.1
Manipulator cable, signal, axis 5 XR5 XR5.1
Manipulator cable, power, axis 6 XM6 XM6.1
Manipulator cable, signal, axis 6 XR6 XR6.1
Cable sub-category
Description Connection point, cabinet
Connection point, distribution box
Distribution box cable, power
Transfers drive power from the drive units in the control cabinet to the manipulators distribution box.
XS1 R1.MP
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Distribution box cable, power
Distribution box cable, signals
Distribution box cable, signals
Transfers resolver data from the serial measurement board and power supply to the SMB in the distribution box.
XS2 R1.SMB
Cable sub-category
Description Connection point, cabinet
Connection point, distribution box
Cable Article number
Distribution box cable, power, 7 m 3HAC 11818-1
Distribution box cable, power, 15 m 3HAC 11818-2
Distribution box cable, power, 30 m 3HAC 11818-4
Cable Article number
Distribution box cable, signal, shielded, 7 m 3HAC 7998-1
Distribution box cable, signal, shielded, 15 m 3HAC 7998-2
Distribution box cable, signal, shielded, 30 m 3HAC 7998-4
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Connectors on the distribution box
General Section "Connecting the distribution box to the control cabinet" specifies which
cables to use in order to connect the manipulators distribution box to the control-
ler.
Connectors on the distribution box
All distribution box connectors are shown in the figure below.
xx0200000430
The connectors on the controller cabinet are located as detailed in part "Connec-
tors on the controller cabinet, S4CPlus".
XM1
XM2
XM3
XM4
XM5
XM6
XR1XR2XR3
XR4XR5XR6
R1.SMBR1.MP
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Chapter 4:Controller
Introduction
Definitions This chapter contains necessary information for installing the controller to the
working site.
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Section A: Unpacking
Transporting and unpacking, S4Cplus
General Before starting to unpack and install the robot system, 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 must be done by qualified installation personnel and should con-
form to all national and local codes.
When you have unpacked the cabinet, check that it has not been damaged during
transport or while unpacking.
Weight, controller cabinet
The table below shows the weights for the controller cabinet:
Storage conditions, controller cabinet
The table below shows the allowed storage conditions for the controller:
Controller Weight
S4Cplus controller cabinet 240 kg
Distributed Drive Unit (option) 30 kg
Parameter Value
Min. ambient temperature -25°C
Max. ambient temperature +55°C
Max. ambient temperature (less than 24 h) +70°C
Max. ambient humidity Max. 95% at constant temperature
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Operating condi-tions, controller cabinet
The table below shows the allowed operating conditions for the controller:
Protection class, controller
The table below shows the protection class of the controller:
Parameter Value
Min. ambient temperature +5°C
Max. ambient temperature +45°C
Max. ambient humidity Max. 95% at constant temperature
Equipment Protection class
Control cabinet IP 54
Programming unit IP 54
Distributed Drive Unit (option) IP 54
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Section B: On-site Installation
Lifting the controller cabinet
Lifting device Use the four lifting devices on the cabinet or a fork lift when lifting the controller
cabinet S4Cplus as shown below.
The figure below shows the minimum angle between the lifting straps and the
cabinet when lifting the controller.
xx0100000153
Cabinet delivered without top cover
If the controller is delivered without its top cover, a fork lift must be used. Do not
use lifting devices!
A Min. 60°when lifting with straps
B Fork lift
B
A
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Required installation space, control cabinet
Dimensions The figure below shows the required installation space for the S4CPlus control
cabinet:
xx0100000156
A Air distance to wall
B Cabinet extension (Option 124)
* Castor wheels (Option 126)
500
70
620
820
950980*
800
800
200200
A
B
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Bolt pattern, control cabinet
Dimensions The figure below shows the bolt pattern for the S4CPlus control cabinet:
xx0100000157
400
720
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Installation of external power transformer
Location of exter-nal power trans-former
The external power transformer (option) is located outside the controller as shown
in the figure below:
xx0100000154
Required equip-ment
A Cable glands for input and output cables (large gland; input cable, small gland; output cable)
B Locking screws/lifting lugs
A
B
Equipment, etc. Spare part no. Art. no. Note
External power trans-former unit
3HAC 11668-1
Input cables Rec. 16 mm 2
Output cables Rec. 6 mm 2
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Connections The procedure below details how to connect the external power transformer unit.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supply to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Fuse and holder Mains voltage 200 VAC: 63 A Mains voltage 600 VAC: 25 A
Circuit breaker Dimensioned for the expected cur-rents
Standard toolkit 3HAC 15571-1 The contents are defined in section "Standard toolkit"!
Other tools and proce-dures may be required. See references to these procedures in the step-by-step instruc-tions below.
These procedures include references to the tools required.
Circuit Diagram, con-troller
3HAC 5582-2
Circuit Diagram, exter-nal power transformer
3HAC 11668-11
Equipment, etc. Spare part no. Art. no. Note
Step Action Note/Illustration
1. Connect the shop mains power supply Detailed in "Shop mains power supply" below!
2. Connect the external power transformer input.
Detailed in "Transformer input" below!
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Shop mains power supply
The procedure below details how to connect the Shop mains power supply.
Please observe the following before commencing any repair work on the controller: Turn off all electric power supply to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Transformer input The procedure below details how to connect the Transformer input.
Please observe the following before commencing any repair work on the controller: Turn off all electric power supply to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
3. Connect the external power transformer out-put.
Detailed in "Transformer output" below!
4. Connect the controller input. Detailed in "Controller input" below!
Step Action Note/Illustration
Step Action Note/Illustration
1. Make sure the shop supply is fitted with suit-able circuit breakers and fuses.
Fuse size specified in the table above!
Step Action Note/Illustration
1. Run a cable from the shop supply outlet through the input cable inlet on the trans-former unit.
Shown in the figure above!
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Transformer output
The procedure below details how to connect the Transformer output.
Please observe the following before commencing any repair work on the controller: Turn off all electric power supply to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
2. Open the transformer unit by removing the lock screws on top of the unit.
Shown in the figure above!
3. Connect the input cable earth conductor to the earth terminal.
4. Connect the three input phases to the long terminal. Make sure the cables are connected to the terminals marked with the voltage value cor-responding to the voltage supplied.
Terminal: X1
5. Make sure all terminals are tightened to ensure good electric contact.
Tightening torque: approx. 2 Nm
Step Action Note/Illustration
Step Action Note/Illustration
1. Run a cable from the transformer unit through the output cable outlet to the robot controller.
Shown in the figure above!
2. Connect the output cable earth conductor to the transformer unit earth terminal.
3. Connect the three output phases to the out-put terminals. The terminals are marked with "475" for the output voltage.
Terminals: X1.1, X1:2 and X1:3
4. Make sure all terminals are tightened to ensure good electric contact.
Tightening torque: approx. 2 Nm
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Controller input The procedure below details how to connect the Controller input.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supply to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Step Action Note/Illustration
1. Remove the left cover plate under the robot controller top lid.
2. Route the transformer output cable through the gland located on the left cabinet wall.
3. Connect the cable inside the robot controller (not depen-dent on phase sequence):
• Phase 1 to L1
• Phase 2 to L2
• Phase 3 to L3
• 0 to XT26.N
• Earth to the cabinet earth connection (C in the figure). The earth connection is marked with a "PE" sticker.
xx0100000155
• A: Terminal X26
• B: Connectors
• C: Earth connection (PE)
• D: Cable glands
4. Make sure all terminals are tightened to ensure good elec-tric contact.
Tightening torque: approx. 2 Nm
A
C
B
D
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Installation of Distributed Drive Unit (DDU)
Required installa-tion space, DDU
The external DDU (option) is located outside the control cabinet. The figure
below shows the required installation space for the DDU.
xx0200000340
A 50 mm, required free area for the exhaust air
A300
A A
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Bolt pattern, DDU The DDU is to be suspended nearby the control cabinet, using the bolt pattern
shown in the figure below.
xx0200000374
Connection to earth
If the difference of potential between the control system and the DDU is too large
or there are suspicions of shorter drops in voltage, the DDU must be connected to
earth. This is done at the connection point GND (see the part "Connectors on the
DDU").
Fan cooling The main power from the control cabinet also feeds two fans in the DDU via an
internal transformer with three input taps.
The transformer wires are connected as
• 0 - 400V for nominal mains input 400V
• 0 - 440V for nominal mains input 440V
• 0 - 480V for nominal mains input 480V
260
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Overheating Overheating of the DDU may be caused by the following:
• A line voltage lower than 480V is used, while the fans are connected as 480V. This causes a reduced fan cooling. See “Changing the connection of the transformer” below.
• The fuse, located at the screw terminal, has caused the fans to stop.
• Insufficient airflow. See “Increasing the airflow” below.
• Too heavy drive at too high ambient temperature. See the manual “Exter-nal axes”.
Changing the connection of the transformer
The default connection of the transformer is the nominal mains input 480V. The
cooling is, however, reduced, when a lower line voltage is used and there may be
a risk that the drive unit is triggered at a high surrounding temperature. Therefore,
if the line voltage differs from 480V, it is recommended to switch over the default
connection to 440V or 400V instead.
To change the voltage, remove the lid of the DDU and switch the connections on
the screw terminals (see the part "Connections to screw terminals").
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Increasing the airflow
If there appears to be an overheating of the DDU, without suspicion of reduced
fan cooling, the airflow may be increased by replacing the two covering plates
with vents, see figure below. This gives four openings instead of the normal two.
xx0200000373
Cabling Section "Connecting the manipulator to the control cabinet" specifies which
cables to use and to which connectors these are to be connected, in order to con-
nect the DDU to either the controller, the manipulator or to the external axis.
A Vent
B Covering plate
A
A
B
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Section C: Electrical connections
C - 1: Signal/Power cables
Connecting the manipulator to the control cabinet, S4Cplus cabling
General Connect the manipulator and control cabinet to each other after securing them to
the foundation. The lists below specify which customer cables to be used.
Manipulator cabling is specified in chapter “Manipulator”, section “Electrical
connections”.
Customer cables These cables are not included in the standard delivery, but are included in the
delivery of each specific option. The cables are not ready to plug in, but require
connection to terminals inside the control cabinet as well as keying. These activ-
ities are detailed in Customer Connection Kit.
Cable Art. no.Connection point, cabinet
Connection point, manipulator
Fieldbus cable, CAN, 7 m 3HAC 13173-1 XT/XP5.1 XT/XP6 XS6
R1.CP/CS
Fieldbus cable, CAN, 15 m 3HAC 13173-2 XT/XP5.1XT/XP6 XS6
R1.CP/CS
Fieldbus cable, CAN, 30 m 3HAC 13173-4 XT/XP5.1
XT/XP6 XS6
R1.CP/CS
Fieldbus cable, Profibus, 7 m 3HAC 13174-1 XT/XP5.1 XT/XP6
DP/M
R1.CP/CS
Fieldbus cable, Profibus, 15 m 3HAC 13174-2 XT/XP5.1 XT/XP6 DP/M
R1.CP/CS
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Fieldbus cable, Profibus, 30 m 3HAC 13174-4 XT/XP5.1 XT/XP6
DP/M
R1.CP/CS
Harness CP/CS, CAN, 7 m 3HAC 14890-4 XT/XP5.1 - XT/XP5.2 - XT/XP6.1 XS13
R1.CP/CS
Harness CP/CS, CAN, 15 m 3HAC 14890-1 XT/XP5.1 - XT/XP5.2 - XT/XP6.1 XS13
R1.CP/CS
Harness CP/CS, CAN, 30 m 3HAC 14890-6 XT/XP5.1 - XT/XP5.2 - XT/XP6.1
XS13
R1.CP/CS
Harness CP/CS, Interbus, 7 m 3HAC 15644-4 XT/XP5.1 - XT/XP5.2 - XT/XP6.1 XS13
R1.CP/CS
Harness CP/CS, Interbus, 15 m
3HAC 15644-1 XT/XP5.1 - XT/XP5.2 - XT/XP6.1 XS13
R1.CP/CS
Harness CP/CS, Interbus, 30 m
3HAC 15644-5 XT/XP5.1 - XT/XP5.2 - XT/XP6.1
XS13
R1.CP/CS
Cable Art. no.Connection point, cabinet
Connection point, manipulator
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Connectors on control cabinet, S4Cplus
General Section "Connecting the manipulator to the control cabinet" specifies which
cables to use and to which connectors these are to be connected, in order to con-
nect the controller to the manipulator.
Connections to the cabinet
All control cabinet connectors are shown in the figure below.
xx0100000247
* For 6400S/640 and Can Bus
** Option for 66X0 and 7600
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Connectors on distributed drive unit, DDU
General The section "Connecting the manipulator to the control cabinet" specifies which
cables to use and to which connectors these are to be connected, in order to con-
nect the DDU (distributed drive unit) to either the controller, the manipulator or
to the external axis.
Connections to the DDU
All DDU connectors are shown in the figure below.
xx0200000372
The connections on the manipulator are located on the rear of the robot base.
S77 XS78 XP40
GND
XP49
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Connection of mains power to control cabinet, S4Cplus
General Connect the power supply either inside the cabinet, or to a optional socket on the
left-hand side of the cabinet or the lower section of the front. The cable connector
is supplied but not the cable.
Dimension the mains supply cables and fuses in accordance with the rated power
and line voltage, see rating plate on the controller.
Connections to the mains switch
Also see the Circuit Diagram.
The instruction below details how to make all the required connections to the
mains switch:
xx0100000248
A XT 26
B Protective Earth connection
C Cable gland
D Connector
Step Action Info/Illustration
1. Remove the left cover plate under the top lid.
A
B
C
D
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Connection through a power socket
It is possible to connect the mains supply via an industrial Harting connector (DIN
41 640). See the figure below:
Cable connectors are supplied (option 132 - 134).
xx0100000162
2. Pull the mains cable (outer diam. 10.2 mm) through the gland located on the left cabinet wall.
Shown in the figure above!
3. Release the connector from the knob by pushing the release buttons located on the side of the connector.
4. Connect phase: • 1 to L1 (Not dependent on phase
sequence)
• 2 to L2
• 3 to L3
• 0 to XT26.N (line neutral is needed only for option 432)
• and protective earth to the protective earth connection.
Shown in the figure above!
NOTE! Max. conductor size is 6 mm2 (AWG 10). Tighten to a torque of 2.3-2.5 Nm. Retighten after approx. 1 week.
5. Snap the breaker on to the knob again and check that it is fixed properly in the correct position.
6. Tighten the cable gland.
7. Fasten the cover plate.
Step Action Info/Illustration
A DIN connector
A
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C - 2: Signal connections
Signal Classes
Overview Different rules apply to the different classes when selecting and laying cable. Sig-
nals from different classes must not be mixed.
Signals • Power Signals: Supplies external motors and brakes.
• Control signals: Digital operating and data signals (digital I/O, safety stops, etc.).
• Measuring signals: Analog measuring and control signals (resolver and analog I/O).
• Data communication signals: Gateway (Field bus) connection, computer link.
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Selecting Cables
Controller cables: All cables laid in the controller must be capable of withstanding +70°C.
Power Signal: Shielded cable with an area of at least 0.75mm 2 or AWG 18.
Note that any local standards and regulations concerning insulation and area must always be complied with.
Control signals: Shielded cables.
Measuring signals:
Shielded cable with twisted pair conductors.
Data communica-tion signals:
Shielded cable with twisted pair conductors.
A specific cable should be used for Gateway (Field bus) connections.
CAN bus with DeviceNet for dis-tributing I/O units:
A thin cable according to DeviceNet specification release 1.2, must be used, e.g.
ABB article no. 3HAB 8277-1. The cable is shielded and has four conductors, two
for electronic supply and two for signal transmission.
Note that a separate cable for suppling I/O loads is required.
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Allen-Bradley Remote I/O:
Cables according to Allen-Bradley specification, e.g. "Blue hose", should be used
for connections between DSQC 350 and the Allen-Bradley PLC bus.
Interbus-S: Cables according to Phoenix specification, e.g. "Green type", should be used for
connections between the DSQC 351 and external Interbus-S bus.
Profibus DP: Cables according to Profibus DP specification should be used for connections
between the I/O unit DSQC 352 and the external Profibus DP bus.
Ethernet: Shielded twisted pair conductors (10 Base T STP).
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Interference elimination
External units External relay coils, solenoids, and other units that will be connected to the con-
troller must be neutralized. The figure below illustrates how this can be done.
The turn-off time for DC relays increases after neutralization, especially if a diode is connected across the coil. Varistors give shorter turn-off times. Neutralizing the coils lengthens the life of the switches that control them.
Clamping with a diode
The diode should be dimensioned for the same current as the relay coil, and a
voltage of twice the supply voltage.
xx0100000163
Clamping with a varistor
The varistor should be dimensioned for the same current as the relay coil, and a
voltage of twice the supply voltage.
xx0100000164
+24V 0V
+24V 0V
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Clamping with an RC circuit
R 100 ohm, 1W C 0.1 - 1 mF.
>500V max. voltage, 125V nominal voltage.
xx0100000165
+24V DC,or AC voltage 0VR C
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Connection types
General I/O, external emergency stops, safety stops, etc. can be supplied on screw connec-
tions or as industrial connectors.
Connections
Designation Connection type
X(T) Screw terminal
XP Pin (male)
XS Sockets (female)
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Connections to screw terminals
Overview This section describes how to connect conductors to screw terminals. Detailed
information about connection location and functions will be found in the circuit
diagram (Service Manual).
Installation The installation should comply with the IP54 (NEMA 12) protective standard.
1. Bend unused conductors backwards and attach them to the cable using a clasp, or similar.
To prevent interference, ensure that unused conductors are not connected at the other end of the cable (antenna effect). In environments with much interference, disconnected conductors should be grounded (0V) at both ends.
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Connections to connectors
Location of con-nectors
If ordered, industrial connectors can be found on the left-hand side or front of the
control cabinet (depending on the customer order). Also see the figure in section
"Connectors on control cabinet"!
The manipulator arm (not IRB 940 Tricept) is equipped with round Burndy/Fram-
atome connectors (customer connector not included).
Connectors, description
Each industrial connector has accommodation for four rows of 16 conductors with
a maximum conductor area of 1.5 mm 2. The pull-relief clamp must be used when
connecting the shield to the case.
Making the con-nection
The section below details how to crimp cable connections to pins:
1. Using a special crimp tool, crimp a pin or socket on to each non-insu-lated conductor.
When two conductors are be connected to the same pin or socket, both of them must be crimped into the same pin or socket. A maximum of two conductors may be crimped into the same pin or socket.
2. Snap the pin into the connector housing.
3. Push the pin into the connector until it locks.
4. A special extractor tool must be used when removing pins or sockets from industrial connectors.
C - 3: Customer connections on controller
The MOTORS ON/MOTORS OFF circuit
Outline diagram The MOTORS ON/MOTORS OFF circuit is made up of two identical chains of
switches.
The diagram shows the available customer connections, AS, GS and ES.
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xx0100000174
A ES (emergency stop)
B LS (Limit switch)
C Solid state switches
D Contactor
E Mains
F Drive unit
G Second chain interlock
H GS (general mode safeguarded space stop)
J AS (Automatic mode safeguarded space stop)
K ED (TPU enabling device)
L Manual mode
M Motor
N Automatic mode
P Operating mode selector
R RUN
S EN1
G
CD
E
A
F
T
LN
P
M
H
J
K
B
R S
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Function of the MOTORS ON/MOTORS OFF cir-cuit
The circuit monitors all safety related equipment and switches. If any of the
switches is opened, the MOTORS ON/MOTORS OFF circuit switches the power
to the motors off.
As long as the two chains are not identical, the robot will remain in MOTORS
OFF mode.
Connection of safety chains
The diagram below shows the two-channel safety chain.
The supply from internal 24V (X3/X4:12) and 0 V (X3/X4:7) is displayed. For an
external supply of GS and AS, X3/X4:10,11 is connected to 24V and X3/X4:8,9
is connected to external 0V. Connection tables for X1-X4 are given in "External
customer connections on panel X1 - X4".
T EN2
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xx0100000166
Technical data per chain
Limit switch Load: 300 mV
Max. voltage drop: 1 V
External connectors Load: 10 mA Max. voltage drop: 4 V
GS/AS load at 24 V 25 mA
GS/AS closed "1" >18 V
GS/AS open "0" < 5 V
External supply of GS/AS Max. + 35 VDC Min. - 35 VDC
24VX3:12X4:12
24VExt LIM1
X1:11 12
X3:10
8
11
9
Optoisol.
Optoisol.
Optoisol.
Optoisol.
GS1
AS1
ES1
TPU En1
Internlocking
EN
Run
Auto1 Man1
Man2
&
&
External contactors
0 V24 V
X3:3X4:3
44
CONT1CONT2
Ext LIM20 V X2:11 12
K1
K2
K10 V
K224 V
Drive Unit
M
X4:10
8
11
9AS2
GS2
TPU En2
Auto2
ES2
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Max. potential in relation to the cabinet earthing and other signal groups
300 V
Signal class Control signals
Technical data per chain
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Connection of ES1/ES2 on panel unit
The diagram below shows the terminals for the emergency circuits.
The supply from internal 24V (X1/X2:10) and 0V (X1/X2:10) is displayed. For
an ext. supply, X1/X2:3 is connected to ext. 24V and X1/X2:8 is connected to ext.
0V (dotted lines).
xx0100000191
24V
24V
0V
0V
1:4
X1:10
X1:3
X1:9
X1:7
X1:8
X1:1
X1:2 24V
A
B C D
D
X1:6
E24V
X2:7
X2:8
X2:1
X2:224V
X2:6
FB
24VX2:4X2:5
C
2:4
G
H
J
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A Internal
B Ext shop
C TPU
D Cabinet
E ES1 internal
F Run chain 1 top
G Internal
H ES2 internal
J Run chain 2 top
Technical data
ES1 and ES2 max output voltage 120 VAC or 48 VDC
ES1 and ES2 max output current 120 VAC: 4 A
48 VDC L/R: 50 mA 24 VDC L/R: 2 A 24 VDC R load: 8 A
External supply of ES relay Min. 22 V between terminals X1:9, 8 and X2:9, 8 respectively
Rated current per chain 40 mA
Max. potential in relation to the cabinet earthing and other signal groups
300 V
Signal class Control signals
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Connection to MOTORS ON/MOTORS OFF contactor
The diagram below shows the connection of terminals for customer use.
xx0100000193
A K1 (Motor on/off 1)
B K1 (Motor on/off 2)
Technical data
Max. voltage 48 VDC
Max. current 4 A
Max. potential in relation to the cabinet earthing and other signal groups
300 V
Signal class Control signals
A
B
X3:2
X4:21
1
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Connection to operating mode selector
The diagram below shows the connection of terminals for customer use.
xx0100000197
A Auto 1
B MAN1
C 100% (Option)
D Auto 2
E MAN2
F 100% (Option)
Technical data
Max. voltage 48 VDC
Max. current 4 A
Max. potential in relation to the cabinet earthing and other signal groups
300 V
Signal class Control signals
A
B C
D
E F1
2
3
4
5
6
7
8S1.1.x1
S1.1.x1
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Connection to brake contactor
The diagram below shows the connection of terminals for customer use.
xx0100000199
A K3 (Brake)
Technical data
Max. voltage 48 VDC
Max. current 4 A
Max. potential in relation to the cabinet earthing and other signal groups
300 V
Signal class Control signals
X4:56
A
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External customer connections on panel X1 - X4
Outline diagram The diagram shows the customer connections X1 - X4 located on the panel unit.
xx0100000205
Connection of X1: 12-pole type Phoenix COM-BICON connector
The table below shows the signal descriptions for X1.
The signal names refer to the Circuit Diagram.
grey field Jumper
WARNINGREMOVE JUMPERS BEFORE CONNECTINGANY EXTERNAL EQUIPMENT
Signal Terminal no. Comment
ES1 out: A 1 Emergency stop out chain 1
ES1 out: B 2 Emergency stop out chain 1
ES1 top 3 Top of emergency stop chain 1
24 V panel 4 + 24 V emergency stop chain 1 and run chain 1
Run ch1 top 5 Top of run chain 1
ES1 internal 6 Internal signal from emergency stop relay chain 1
Sep. ES1: A 7 Separated emergency stop chain 1
Sep. ES1: B 8 Separated emergency stop chain 1
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Connection of X2: 12-pole type Phoenix COM-BICON connector
The table below shows the signal descriptions for X2.
The signal names refer to the Circuit Diagram.
Connection of X3: 12-pole type Phoenix COM-BICON connector
The table below shows the signal descriptions for X3.
The signal names refer to the Circuit Diagram.
ES1 bottom 9 Bottom of emergency stop chain 1
0 V 10 0 V emergency stop chain 1
Ext. LIM1: A 11 External limit switch chain 1
Ext. LIM1: B 12 External limit switch chain 1
Signal Terminal no. Comment
Signal Terminal no. Comment
ES2 out: A 1 Emergency stop out chain 2
ES2 out: B 2 Emergency stop out chain 2
ES2 top 3 Top of emergency stop chain 2
0 V 4 0 V emergency stop chain 2
Run ch2 top 5 Top of run chain 2
ES2 internal 6 Internal signal from emergency stop relay chain 2
Sep. ES2: A 7 Separated emergency stop chain 2
Sep. ES2: B 8 Separated emergency stop chain 2
ES2 bottom 9 Bottom of emergency stop chain 2
24 V panel 10 + 24 V emergency stop chain 1 and run chain 2
Ext. LIM2: A 11 External limit switch chain 2
Ext. LIM2: B 12 External limit switch chain 2
Signal Terminal no. Comment
Ext. MON 1: A 1 Motor contactor 1
Ext. MON 1: B 2 Motor contactor 1
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Connection of X4: 12-pole type Phoenix COM-BICON connector
The table below shows the signal descriptions for X4.
The signal names refer to the Circuit Diagram.
0 V 3 External contactor 1 0 V
CONT1 4 External contactor 1
5 No connection
6 No connection
0 V 7 0 V to auto stop (AS) and general stop (GS)
GS1- 8 General stop minus chain 1
AS1- 9 Auto stop minus chain 1
GS1+ 10 General stop plus chain 1
AS1+ 11 Auto stop plus chain 1
24 V panel 12 24 V to auto stop and general stop
Signal Terminal no. Comment
Signal Terminal no. Comment
Ext. MON 2: A 1 Motor contactor 2
Ext. MON 2: B 2 Motor contactor 2
24 V panel 3 External contactor 2 24 V
CONT2 4 External contactor 2
Ext. BRAKE A 5 Contactor for external brake
Ext. BRAKE B 6 Contactor for external brake
0 V 7 0 V to auto stop (AS) and general stop (GS)
GS2- 8 General stop minus chain 2
AS2- 9 Auto stop minus chain 2
GS2+ 10 General stop plus chain 2
AS2+ 11 Auto stop plus chain 2
24 V panel 12 24 V to auto stop and general stop
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Connection of external safety relay
Description The motor contactors K1 and K2 in the controller can operate with external equip-
ment if external relays are used.
The figure below shows two examples of how to connect the external safety
relays:
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Connection examples
xx0100000246
A Panel unit
K2
K1
X3:4X3:3
X3:1
X3:2
X4:1
X4:2
X4:3X4:4
0 VCONT 1
Ext MON 1
Ext MON 224 V
CONT 2
24 V
0 V
A B
AS GSAS GS
E
E
F F
G
H
K
J
C D
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C - 4: Supplies
External 24V supply
When is an exter-nal supply recom-mended?
An external supply is recommended to make use of the advantages offered by the
galvanic insulation on the I/O units or on the panel unit.
An external supply must be used in the following cases:
• When the internal supply is insufficient
• When the emergency stop circuits must be independent of whether or not the robot has power on, for example.
• When there is a risk that major interference can be carried over into the internal 24V supply.
How to connect the external sup-ply
The external supply neutral wire must be connected to the chassis such that the
maximum permitted potential difference in the chassis earth is not exceeded. For
example, a neutral wire can be connected to the chassis earth of the controller, or
some other common earthing point.
Technical data
B Relays with positive action
C Robot 1
D Robot 2
E External supply
F ES (emergency stop) out
G Safety relay
H To other equipment
J Safety gate
K Cell ES (emergency stop)
Potential difference to chassis earth Max. 60 V continuously Max. 500 V during 1 minute
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Permitted supply voltage I/O units 19 VDC - 35 VDC incl. ripple
Panel unit 20.6 VDC - 30 VDC incl. ripple
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24V I/O supply
General The 24V I/O is not galvanically separated from the rest of the controller voltages.
24 VDC supply for internal and external use
24 VDC supply available at XT 31
24V I/O available for customer connections at XT 31 is shown in the figure in
"Connections to screw terminals".
Voltage 24.0 - 26.4V
Ripple Max. 0.2V
Permitted customer load Max. 7A
Current limit 13,5 ~0A.
XT.31.2 24 V (through a 2 A fuse)
XT.31.1 for own fuses
XT.31.4 0 V (connected to cabinet structure)
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115/230 VAC supply
General This voltage is used in the robot for supplying optional service outlets. The AC
supply is not galvanically separated from the rest of the controller voltages.
115/230 VAC sup-ply for internal and external use
115/230 VAC sup-ply available at XT 21
115 VAC/230 VAC available for customer connections at XT 21 is shown in the
figure in "Connection to screw terminals".
C - 5: Buses
Connection of the CAN bus
Illustration The illustration below shows an example of how to connect the CAN bus:
Voltage 115 VAC or 230 VAC
Permitted customer load Max. 500 VA
Fuse size, 115 V 6.3 A
Fuse size, 230 V 3.15 A
XT.21.1-5 230 VAC
XT.21.6-8 115 VAC
XT.21.9-13 N (connected to cabinet structure)
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xx0100000241
A Base connector unit
B CAN bus
X15 CAN1.1 (Internal I/O)
X7 CAN1.3
X6 CAN1.2
A
B
C
D
D
G
D
D D
D D
E
F
D D
1. 0V_CAN2. CAN_L3. drain4. CAN_H5. 24V_I/O
X15, X6, X7 1.2.3.4.5.
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CAN 1.1 Used for internal I/O unit mounted inside the cabinet. No terminating resistor is
fitted on CAN 1.1 regardless of whether any I/O units are used or not. CAN 1.1 is
connected to socket X15 on the Base connector unit (see Connection of the CAN
bus).
CAN 1.2 If CAN 1.2 is not used, a terminating resistor must be connected to the X6 socket
(exceptional case see below!).
If CAN 1.2 is used, the terminating resistor should be moved to the last I/O unit
on the CAN 1.2 chain.
If CAN 1.2, for example, is not connected at the end of any CAN chain but some-where between the end points of the chain, then no terminating resistor should be mounted in CAN 1.3. This is in accordance with the basic rule, i.e. the CAN chain should be terminated in both end points.
CAN 1.3 If CAN 1.3 is unused, a terminating resistor must be connected to the X7 socket.
If CAN 1.3 is used, the terminating resistor should be moved to the last I/O unit
on the CAN 1.3 chain.
If CAN 1.2, for example, is not connected at the end of any CAN chain but some-where between the end points of the chain, then no terminating resistor should be mounted in CAN 1.3. This is in accordance with the basic rule, i.e. the CAN chain should be terminated in both end points.
C Control cabinet
D I/O
E Termination of last unit
F 120 ohm, 1%, 0.25 W metal film resistor
G See figure in section "CAN 2" below!
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Termination resistors in CAN bus
The CAN chain must be terminated with terminating resistors at each end!
If CAN 1.2, for example, is not connected at the end of any CAN chain but some-
where between the end points of the chain, then no terminating resistor should be
mounted in CAN 1.3.
CAN 2 The illustration below shows an example of how to connect the CAN 2 bus:
xx0100000242
A Controller
B Base connector unit
C See figure in section "Illustration" above!
D I/O
E Termination of last unit
F 120 ohm, 1%, 0.25 W metal film resistor
D D
B
1. 0V_CAN2. CAN_L3. drain4. CAN_H5. 24V_I/O
X8 1. 0V_CAN2. CAN_L3. drain4. CAN_H5. 24V_I/O
1.2.3.4.5.
A
X8 CAN 2
C
E
F
D
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The illustration below shows CAN connections on base connector unit:
xx0100000243
A X6 CAN 1.2 (external I/O)
B X7 CAN 1.3 (external I/O)
C X8 CAN 2 (external I/O)
D X15 CAN 1.1 (internal I/O)
A
B
C
D
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Interbus-S, slave DSQC 351
General The unit can be operated as a slave for an Interbus-S system.
Supply The Interbus-S slave must be fed externally to avoid shutting down the Interbus-
S net if a robot cell is switched off. The 24V power supply must be fed from
outside the control cabinet and be connected to pin 2 on the Phoenix connector
located on the Interbus-S card’s front panel marked 24V.
Technical data Also see the Interbus-S specification.
Further informa-tion
For setup parameters, see User’s Guide - System Parameters, Topic: Controller.
Also see the Circuit Diagram.
Unit ID The unit ID to be entered in the Interbus-S master is 3. The length code depends
on the selected data. Width between 1 and 4.
Layout, DSQC 351
The figure below shows the layout of the DSQC 351 board:
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xx0100000225
Communication concept
The Interbus-S system is able to communicate with a number of external devices,
depending on the number of process words occupied by each unit. The robot may
be equipped with one or two DSQC 351. The Interbus-S inputs and outputs are
accessible in the robot as general inputs and outputs.
For application data, refer to Interbus-S, International Standard, DIN 19258.
An outline diagram of the communication concept is shown below:
X3 Power connector
X5 DeviceNet connector
X20 Interbus-S, input
X21 Interbus-S, output
X20
X5 X3
X21
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xx0100000224
Termination link A link is connected between pins 5 and 9 in the plug on the interconnection cable
connected to the OUT connector of each unit. The link informs the Interbus-S unit
that more units are connected further out in the chain. (The last unit in the chain
does not have a cable connected and therefore no link).
Connections, X5 DeviceNet con-nectors
See DeviceNet Connectors.
A Master PLC
B Robot 1, word 1:3
C Robot 1, word 4:7
D Robot 2, word 8:11
E 128 inputs/128 outputs
F 64 inputs/64 outputs
*1 xx
A B DC
E F
In Out In Out In Out
*1 *1
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Connections, connector X20, Interbus-S IN
The figure below shows the pin configuration of the connector:
xx0100000220
The table below shows the connections to connector X20, Interbus-S IN:
Connections, connector X21, Interbus-S OUT
The figure below shows the pin configuration of the connector:
xx0100000220
The table below shows the connections to connector X21, Interbus-S OUT:
Signal name X20 pin Function
TPDO1 1 Communication line TPDO1
TPDI1 2 Communication line TPDI1
GND 3 Ground connection
NC 4 Not connected
NC 5 Not connected
TPDO1-N 6 Communication line TPDO1-N
TPDI1-N 7 Communication line TPDI1-N
NC 8 Not connected
NC 9 Not connected
5
1 9
6
5
1 9
6
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Connections, connector X3
The figure below shows the pin configuration of the connector:
xx0100000221
The table below shows the connections to connector X3:
Bus status LEDs The designations refer to LEDs shown in the figure in section "Layout, DSQC
352" above.
Signal name X21 pin Function
TPDO2 1 Communication line TPDO2
TPDI2 2 Communication line TPDI2
GND 3 Ground connection
NC 4 Not connected
+ 5 V 5 + 5 VDC
TPDO2-N 6 Communication line TPDO2-N
TPDI2-N 7 Communication line TPDI2-N
NC 8 Not connected
RBST 9 Synchronization
Signal name X3 pin Function
0 VDC 1 External supply of Interbus-S
NC 2 Not connected
GND 3 Ground connection
NC 4 Not connected
+ 24 VDC 5 + 24 VDC
15
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The figure and table below show the location and significance of the LEDs on the
board.
Designation Color Description
POWER-24 VDC Green Indicates that a supply voltage is present, and has a level above 12 VDC.
NS/MS Green/red See section "CAN bus status LED descrip-tion".
CAN Tx/CAN Rx Green/red See section "CAN bus status LED descrip-tion".
POWER- 5 VDC Green Lit when both 5 VDC supplies are within lim-its, and no reset is active.
RBDA Red Lit when this Interbus-S station is last in the Interbus-S network.
If it is not (which is required), check parame-ter setup.
BA Green Lit when Interbus-S is active.
If there is no light, check network, nodes and connections.
RC Green Lit when Interbus-S communication runs without errors.
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Profibus-DP, slave DSQC 352
General The unit can be operated as a slave for a Profibus-DP system.
Supply The Profibus does not need any external power supply. All the robot cells are
connected to the trunk cable through a special D-sub connector which works as a
very short drop cable. Because of this the profibus will work correctly even if a
robot cell is turned off.
Technical data Also see the Profibus-DP specification, International Standard DIN E 19245, part
3.
Further informa-tion
For setup parameters, see User’s Guide - System Parameters, Topic: I/O Signals.
Also see the Circuit diagram.
Layout, DSQC 352
The figure below shows the layout of the DSQC 352 board:
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xx0100000223
Communication concept
The Profibus-DP system is able to communicate with a number of external
devices, depending on the number of process words occupied by each unit. The
robot may be equipped with one or two DSQC 352. The Profibus-DP inputs and
outputs are accessible in the robot as general inputs and outputs.
An outline diagram of the communication concept is shown below:
xx0100000222
X3 Power connector
X5 DeviceNet connector
X20 Profibus connection
X20
X5 X3
A B
E F
C D
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Termination The Profibus cable must be terminated in both ends.
Connections, X5 DeviceNet con-nectors
See "Device Net Connectors".
Connections, connector X20, Profibus-DP
The figure below shows the pin configuration of the connector:
xx0100000220
The table below shows the connections to connector X20, Interbus-S IN:
A Master PLC
B Robot 1, word 1:8
C Robot 1, word 9:16
D Robot 2, word 17:24
E 256 inputs/256 outputs
F 128 inputs/128 outputs
Signal name X20 pin Function
Shield 1 Cable screen
NC 2 Not connected
RxD/TxD-P 3 Receive/Transmit data P
Control-P 4
GND 5 Ground
+5 VDC 6
5
1 9
6
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Connections, connector X3
The figure below shows the pin configuration of the connector:
xx0100000221
The table below shows the connections to connector X3:
Bus status LEDs The figure and table below show the location and significance of the LEDs on the
board.
The designations refer to LEDs shown in the figure in section "Layout, DSQC
352" above.
NC 7 Not connected
RxD/TxD-N 8 Receive/Transmit data N
NC 9 Not connected
Signal name X20 pin Function
Signal name X3 pin Function
0 VDC 1 External supply of Profibus-DP
NC 2 Not connected
GND 3 Ground connection
NC 4 Not connected
+ 24 VDC 5 External supply of Profibus-DP
15
Designation Color Description
Profibus active Green Lit when the node is communicating with the master.
If there is no light, check system messages in robot and in Profibus net.
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C - 6: I/O units
Distributed I/O units
General Up to 20 units can be connected to the same controller but only four of these can
be installed inside the controller. Normally a distributed I/O unit is placed outside
the controller.
Connection The maximum total length of the distributed I/O cable is 100 m (from one end of
the chain to the other end).
The controller can be one of the end points or be placed somewhere in the middle
of the chain.
Parameter setup For setup parameters, see User’s Guide, section System Parameters, Topic: I/O
Signals.
NS/MS Green/red See section "CAN bus status LED descrip-tion".
CAN Tx/CAN Rx Green/red See section "CAN bus status LED descrip-tion".
POWER, 24 VDC Green Indicates that a supply voltage is present, and has a level above 12 VDC. If there is no light, check that voltage is present in the power unit and in the power connector. If not, check cables and connec-tors.
If power is applied to the unit but it does not work, replace the unit.
Designation Color Description
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Distributed I/O, digital sensors
General Digital sensors are connected to one optional digital unit.
Technical data See Product Specification for Controller S4Cplus.
Allowed types of digital sensors
The table below shows the allowed types of digital sensors to be used, and their
signal levels respectively:
Sensor type Signal level
Digital one bit sensor High, "1"
Low, "0"
Digital two bit sensor High, "01" No signal, "00" Low, "10"
Error status, "11" (stop program running)
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Distributed I/O, digital I/O DSQC 328 (option)
General The digital I/O unit handles digital communication between the robot system and
any external systems.
Technical data
Also see Product Specification for controller S4Cplus.
Further informa-tion
For setup parameters, see Users Guide - System Parameters, Topic: Controller.
Also see the Circuit Diagram.
Layout, DSQC 328
The figure below show the layout of the DSQC328 board:
xx0100000240
No. of inputs 16 (divided into two groups of 8, galvanically isolated from each other)
No. of outputs 16 (divided into two groups of 8, galvanically isolated from each other)
Supply voltage 24 VDC
Supply source 24 V I/O or separate external supply
A Status LEDs
OUT
INNS
MS16151413121110987654321
OUT
IN
X1
X3
X2
X4
101101
101 101
X5
112
A
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Connections, connector X1
If supervision of the supply voltage is required, a bridge connection can be made
to an optional digital input. The supervision instruction must be written in the
RAPID program. This is described in the User’s Guide.
The table below shows the connections to connector X1:
Connections, connector X2
If supervision of the supply voltage is required, a bridge connection can be made
to an optional digital input. The supervision instruction must be written in the
RAPID program. This is described in the User’s Guide.
The table below shows the connections to connector X2:
Unit function Signal name X1 pin
Optically isolated output Out ch 1 1
Optically isolated output Out ch 2 2
Optically isolated output Out ch 3 3
Optically isolated output Out ch 4 4
Optically isolated output Out ch 5 5
Optically isolated output Out ch 6 6
Optically isolated output Out ch 7 7
Optically isolated output Out ch 8 8
Optically isolated output 0 V for outputs 1-8 9
Optically isolated output 24 V for outputs 1-8 10
Unit function Signal name X2 pin
Optically isolated output Out ch 9 1
Optically isolated output Out ch 10 2
Optically isolated output Out ch 11 3
Optically isolated output Out ch 12 4
Optically isolated output Out ch 13 5
Optically isolated output Out ch 14 6
Optically isolated output Out ch 15 7
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Connections, connector X3
The table below shows the connections to connector X3:
The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected
to ground, to prevent disturbances, causes a short rush of current when setting the
input.
When connecting outputs, sensitive to pre-oscillation current, a series resistor
(100 W) may be used.
Connections, connector X4
The table below shows the connections to connector X4:
Optically isolated output Out ch 16 8
Optically isolated output 0 V for outputs 9-16 9
Optically isolated output 24 V for outputs 9-16 10
Unit function Signal name X2 pin
Unit function Signal name X3 pin
Optically isolated input In ch 1 1
Optically isolated input In ch 2 2
Optically isolated input In ch 3 3
Optically isolated input In ch 4 4
Optically isolated input In ch 5 5
Optically isolated input In ch 6 6
Optically isolated input In ch 7 7
Optically isolated input In ch 8 8
Optically isolated input 0 V for inputs 1-8 9
Optically isolated input Not used 10
Unit function Signal name X4 pin
Optically isolated input In ch 9 1
Optically isolated input In ch 10 2
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The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected
to ground, to prevent disturbances, causes a short rush of current when setting the
input.
When connecting outputs, sensitive to pre-oscillation current, a series resistor
(100 W) may be used.
Optically isolated input In ch 11 3
Optically isolated input In ch 12 4
Optically isolated input In ch 13 5
Optically isolated input In ch 14 6
Optically isolated input In ch 15 7
Optically isolated input In ch 16 8
Optically isolated input 0 V for inputs 9-16 9
Optically isolated input Not used 10
Unit function Signal name X4 pin
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AD Combi I/O, DSQC 327 (optional)
General The digital I/O unit handles digital and analog communication between the robot
system and any external systems.
Technical data
Also see Product Specification for controller S4Cplus.
Further informa-tion
For setup parameters, see User’s Guide - System Parameters, Topic: Controller.
Also see the Circuit Diagram.
Layout, DSQC 327
The figure below shows the layout of the DSQC327 board:
No. of digital inputs 16 (divided into two groups of 8, galvanically isolated from each other)
No. of digital outputs 16 (divided into two groups of 8, galvanically isolated from each other)
No. of analog outputs 2 (galvanically isolated from the controller electron-ics)
Supply voltage 24 VDC
Supply source, digital I/O 24 V I/O or separate external supply
Supply source, analog I/O 24 V_CAN (with galvanically isolated DC/AC con-verter)
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xx0100000239
Connector X5 is a CAN connector further described in section "Connection and
address keying of the CAN bus".
Connections, connector X1
If supervision of the supply voltage is required, a bridge connection can be made
to an optional digital input. The supervision instruction must be written in the
RAPID program. This is described in the User’s Guide.
The table below shows the connections to connector X1:
A Status LEDs
OUT
INNS
MS16151413121110987654321
OUT
IN
X1
X3
X2
X4
X6
1 10 101
1 6101 101
X5
112
A
Unit function Signal name X1 pin
Optically isolated output Out ch 1 1
Optically isolated output Out ch 2 2
Optically isolated output Out ch 3 3
Optically isolated output Out ch 4 4
Optically isolated output Out ch 5 5
Optically isolated output Out ch 6 6
Optically isolated output Out ch 7 7
Optically isolated output Out ch 8 8
Optically isolated output 0 V for outputs 1-8 9
Optically isolated output 24 V for outputs 1-8 10
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Connections, connector X2
If supervision of the supply voltage is required, a bridge connection can be made
to an optional digital input. The supervision instruction must be written in the
RAPID program. This is described in the User’s Guide.
The table below shows the connections to connector X2:
Connections, connector X3
The table below shows the connections to connector X3:
Unit function Signal name X2 pin
Optically isolated output Out ch 9 1
Optically isolated output Out ch 10 2
Optically isolated output Out ch 11 3
Optically isolated output Out ch 12 4
Optically isolated output Out ch 13 5
Optically isolated output Out ch 14 6
Optically isolated output Out ch 15 7
Optically isolated output Out ch 16 8
Optically isolated output 0 V for outputs 9-16 9
Optically isolated output 24 V for outputs 9-16 10
Unit function Signal name X3 pin
Optically isolated input In ch 1 1
Optically isolated input In ch 2 2
Optically isolated input In ch 3 3
Optically isolated input In ch 4 4
Optically isolated input In ch 5 5
Optically isolated input In ch 6 6
Optically isolated input In ch 7 7
Optically isolated input In ch 8 8
Optically isolated input 0 V for inputs 1-8 9
Optically isolated input Not used 10
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Connections, connector X4
The table below shows the connections to connector X4:
Connections, connectors X6
The table below shows the connections to connectors X6:
The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected
to ground, to prevent disturbances, causes a short rush of current when setting the
input.
When connecting outputs, sensitive to pre-oscillation current, a series resistor
(100 W) may be used.
Unit function Signal name X4 pin
Optically isolated input In ch 9 1
Optically isolated input In ch 10 2
Optically isolated input In ch 11 3
Optically isolated input In ch 12 4
Optically isolated input In ch 13 5
Optically isolated input In ch 14 6
Optically isolated input In ch 15 7
Optically isolated input In ch 16 8
Optically isolated input 0 V for inputs 9-16 9
Optically isolated input Not used 10
Signal name: X6 pin: Explanation:
AN_ICH1 1 For test purposes only
AN_ICH2 2 For test purposes only
0 V 3 0 V for In channels 1-2
0 VA 4 0 V for Out channels 1-2
AN_OCH1 5 Out channels 1
AN_OCH2 6 Out channels 2
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Analog I/O, DSQC 355 (optional)
General The analog I/O unit handles communication between the robot system and any
external systems through analog sensors.
Technical data
Also see Product Specification for controller S4Cplus.
Further informa-tion
For setup parameters, see User’s Guide - System Parameters, Topic: Controller.
Also see the Circuit Diagram.
Layout, DSQC 355
The figure below shows the layout of the DSQC 355 board:
No. of analog inputs 4 (-10 V/+10 V)
No. of analog outputs 3 (-10 V/+10 V) 1 (4-20 mA))
No. of analog outputs 2 (galvanically isolated from the controller electronics)
Supply voltage 24 VDC
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xx0100000238
Connections, connectors X7 analog output
The figure below shows the pin configuration of the connector:
xx0100000236
X3 Not used
X5 DeviceNet input and ID connector
X7 Analog outputs
X8 Analog inputs
DS QC 355 AB B F lexible Automation
Bus s tatus
Analog I/O
X8
X8
S 3S 2
X3
X3
X5
X5
X2
X7
X7
1
12
13
24
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The table below shows the connections to connector X7:
The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected
to ground, to prevent disturbances, causes a short rush of current when setting the
input.
Connect a resistor (100 W) in series when connecting outputs, sensitive to pre-
oscillation current.
Signal name: X7 pin: Explanation:
ANOUT_ 1 Analog output 1, -10 V/+10 V
ANOUT_ 2 Analog output 2, -10 V/+10 V
ANOUT_ 3 Analog output 3, -10 V/+10 V
ANOUT_ 4 Analog output 4, 4-20 mA
Not used 5
Not used 6
Not used 7
Not used 8
Not used 9
Not used 10
Not used 11
Not used 12
Not used 13
Not used 14
Not used 15
Not used 16
Not used 17
Not used 18
GND 19 Analog output 1, 0 V
GND 20 Analog output 2, 0 V
GND 21 Analog output 3, 0 V
GND 22 Analog output 4, 0 V
GND 23
GND 24
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Connections, connectors X8 analog input
The figure below shows the pin configuration of the connector:
xx0100000237
The table below shows the connections to connector X8:
Signal name: X8 pin: Explanation:
ANIN_1 1 Analog input 1, -10 V/+10 V
ANIN_2 2 Analog input 2, -10 V/+10 V
ANIN_3 3 Analog input 3, -10 V/+10 V
ANIN_4 4 Analog input 4, -10 V/+10 V
Not used 5
Not used 6
Not used 7
Not used 8
Not used 9
Not used 10
Not used 11
Not used 12
Not used 13
Not used 14
Not used 15
Not used 16
+24 V out 17 +24 VDC supply
1 17
3216
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The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected
to ground, to prevent disturbances, causes a short rush of current when setting the
input.
Connect a resistor (100 W) in series when connecting outputs, sensitive to pre-
oscillation current.
Bus status LEDs The figure and table below show the location and significance of the LEDs on the
board.
+24 V out 18 +24 VDC supply
+24 V out 19 +24 VDC supply
+24 V out 20 +24 VDC supply
+24 V out 21 +24 VDC supply
+24 V out 22 +24 VDC supply
+24 V out 23 +24 VDC supply
+24 V out 24 +24 VDC supply
GND 25 Analog input 1, 0 V
GND 26 Analog input 2, 0 V
GND 27 Analog input 3, 0 V
GND 28 Analog input 4, 0 V
GND 29
GND 30
GND 31
GND 32
Signal name: X8 pin: Explanation:
Designation Color Description
NS/MS Green/red
See section 4.1.
RS232 Rx Green Indicates the state of the RS232 Rx line. LED is active when receiving data. If there is no light, check communication line and connections.
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RS232 Tx Green Indicates the state of the RS232 Tx line. LED is active when transceiving data. If there is no light when transmission is expected, check error messages and check also system boards in rack.
+5VDC / +12VDC /
-12VDC Green Indicates that supply voltage is present and at correct level. If there is no light, check that voltage is present on power unit and that power is present in power connector. If not, check cables and connectors. If power is applied to the unit but it does not work, replace the unit.
Designation Color Description
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Encoder interface unit, DSQC 354 (optional)
General The encoder interface unit handles communication with an external conveyor:
• One encoder input (synchronization of conveyor position with robot move-ments). The encoder is supplied with 24 V and 0 V, and sends position information on two channels. This information is computed by the on-board computer using quadrature decoding (QDEC) to determine position and direction.
• One digital input (external start signal/conveyor synchronization point)
Technical data
Also see Product Specification for controller S4Cplus.
Further informa-tion
User reference Description Conveyor Tracking. For setup parameters, see User’s
Guide - System Parameters, Topic: Controller. Also see the Circuit Diagram.
No. of encoder inputs 1
No. of digital inputs 1 (24 VDC)
Supply voltage 24 VDC
Supply source 24 V I/O or external supply
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Layout, DSQC 354
The figure below shows the layout of the DSQC 354 board:
xx0100000233
X3 Not used
X5 DeviceNet input and ID connector
X20 Conveyor connection
X20
X5 X3
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Encoder connec-tions
The figure below shows the encoder connections:
xx0100000234
AA 24 V I/O or external supply
AB 0 V I/O or external supply
AC Encoder
AD Sync switch
AE 10-16 not used
AF Encoder unit
AG Galvanic isolation
12345678910111213141516
OptoOpto
Opto
OptoOpto
Opto
B
A
24 VDC
24 VDC
0V
0V
AA
AB
AC
AD
AE
AF
AG
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Connections, connectors X20 encoder and digi-tal input connec-tions
The table below shows the connections to connector X20:
The figure below shows the layout of the pins in connector X20:
xx0100000235
Signal name: X20 pin: Explanation:
24 VDC 1 24 VDC supply
0 V 2 0 V
ENC 3 Encoder 24 VDC
ENC 4 Encoder 0 VDC
ENC_A 5 Encoder phase A
ENC_B 6 Encoder phase B
DIGIN 7 Synchronization switch 24 VDC
DIGIN 8 0 V
DIGIN 9 Synchronization switch digital input
Not used 10
Not used 11
Not used 12
Not used 13
Not used 14
Not used 15
Not used 16
116
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Bus status LEDs The figure and table below show the location and significance of the LEDs on the
board.
Designation Color Description
POWER, 24 VDC Green Indicates that a supply voltage is present, and has a level above 12 VDC.
If there is no light, check that voltage is present on power unit and in connector X20. If not, check cables and connectors. If power is applied to the unit but it does not work, replace the unit.
NS/MS Green/red See section "CAN bus status LED description".
CAN Tx/CAN Rx Green/red See section "CAN bus status LED description".
ENC 1A/1B Green Indicates phase 1 and 2 from encoder. Flashes at each Encoder pulse. At frequencies higher than a few Hz, flashing can no longer be observed (light will appear weaker).
If there is no light, there is an error due to one or more of the following reasons:
• Faulty power supply for input circuit (internal or external).
• Defective input circuit on board.
• Short circuit or broken wire in external wiring or connectors.
• Internal error in unit.
Constant light indicates constant high level on input and vice versa. No light on one LED indicates fault in one encoder phase.
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DIGIN1 Green Digital input. Lit when digital input is active. The input is used for external start signal/conveyor synchronization point.
If there is no light, there is an error due to one or more of the following reasons:
• Faulty power supply for input circuit (internal or external).
• Faulty limit switch, photocell etc.
• Short circuit or broken wire in external wiring or connectors.
• Defective input circuit on board.
Designation Color Description
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Relay I/O, DSQC 332 (optional)
General The unit handles communication between the robot system and any external sys-
tems through relay outputs and digital inputs.
Technical data
Also see Product Specification for controller S4Cplus.
Further informa-tion
For setup parameters, see User’s Guide - System Parameters, Topic: Controller.
Also see the Circuit Diagram.
Layout, DSQC 332
The figure below shows the layout of the DSQC 332 board:
xx0100000232
No. of digital inputs 16 (divided into two groups of 8, galvanically isolated from each other)
No. of relay outputs 16 (a single normally open contact, isolated from each other)
Supply voltage 24 VDC
Supply source 24 V I/O or separate external supply
A Status LEDs
OUT
INNS
MS16151413121110987654321
OUT
IN
X1
X3
161
X2
X4
161
161 161
A
X5
112
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Connections, connector X1
The table below shows the connections to connector X1:
Connections, connector X2
The table below shows the connections to connector X2:
X1 See below for connection tables!
X2 See below for connection tables!
X3 See below for connection tables!
X4 See below for connection tables!
X5 CAN connection detailed in section "Connection of CAN bus"!
Signal name X1 pin Function
Out ch 1a 1 Contact, relay 1
Out ch 1b 2 Contact, relay 1
Out ch 2a 3 Contact, relay 2
Out ch 2b 4 Contact, relay 2
Out ch 3a 5 Contact, relay 3
Out ch 3b 6 Contact, relay 3
Out ch 4a 7 Contact, relay 4
Out ch 4b 8 Contact, relay 4
Out ch 5a 9 Contact, relay 5
Out ch 5b 10 Contact, relay 5
Out ch 6a 11 Contact, relay 6
Out ch 6b 12 Contact, relay 6
Out ch 7a 13 Contact, relay 7
Out ch 7b 14 Contact, relay 7
Out ch 8a 15 Contact, relay 8
Out ch 8b 16 Contact, relay 8
Signal name X2 pin Function
Out ch 9a 1 Contact, relay 9
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Connections, connector X3
The table below shows the connections to connector X3:
Out ch 9b 2 Contact, relay 9
Out ch 10a 3 Contact, relay 10
Out ch 10b 4 Contact, relay 10
Out ch 11a 5 Contact, relay 11
Out ch 11b 6 Contact, relay 11
Out ch 12a 7 Contact, relay 12
Out ch 12b 8 Contact, relay 12
Out ch 13a 9 Contact, relay 13
Out ch 13b 10 Contact, relay 13
Out ch 14a 11 Contact, relay 14
Out ch 14b 12 Contact, relay 14
Out ch 15a 13 Contact, relay 15
Out ch 15b 14 Contact, relay 15
Out ch 16a 15 Contact, relay 16
Out ch 16b 16 Contact, relay 16
Signal name X2 pin Function
Signal name X3 pin
In ch 1 1
In ch 2 2
In ch 3 3
In ch 4 4
In ch 5 5
In ch 6 6
In ch 7 7
In ch 8 8
0 v for In ch 1-8 9
Not used 10
Not used 11
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Connections, connector X4
The table below shows the connections to connector X4:
Not used 12
Not used 13
Not used 14
Not used 15
Not used 16
Signal name X3 pin
Signal name X4 pin
In ch 9 1
In ch 10 2
In ch 11 3
In ch 12 4
In ch 13 5
In ch 14 6
In ch 15 7
In ch 16 8
0 v for In ch 9-16 9
Not used 10
Not used 11
Not used 12
Not used 13
Not used 14
Not used 15
Not used 16
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Digital I/O (120 VAC), DSQC 320 (optional)
General The unit handles communication between the robot system and any external sys-
tems through galvanically isolated outputs and inputs.
Technical data
Also see Product Specification for controller S4Cplus.
Further informa-tion
For setup parameters, see User’s Guide - System Parameters, Topic: Controller.
Also see the Circuit Diagram.
Layout, DSQC 320
The figure below shows the layout of the DSQC 320 board:
xx0100000231
No. of inputs 16 (galvanically isolated from each other)
No. of outputs 16 (galvanically isolated from each other)
Supply voltage 120 VAC
A Status LEDs
X1 See below for connection tables!
X2 See below for connection tables!
OUT
INNS
MS16151413121110987654321
OUT
IN
X1
X3
161
X2
X4
161
161 161
A
X5
112
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Connections, connector X1
The table below shows the connections to connector X1:
Connections, connector X2
The table below shows the connections to connector X2:
X3 See below for connection tables!
X4 See below for connection tables!
X5 CAN connection detailed in section "Connection of CAN bus"!
Signal name X1 pin Function
Out ch 1a 1 AC voltage to switch 1/AC output signal from switch 1
Out ch 1b 2 AC voltage to switch 1/AC output signal from switch 1
Out ch 2a 3 AC voltage to switch 2/AC output signal from switch 2
Out ch 2b 4 AC voltage to switch 2/AC output signal from switch 2
Out ch 3a 5 AC voltage to switch 3/AC output signal from switch 3
Out ch 3b 6 AC voltage to switch 3/AC output signal from switch 3
Out ch 4a 7 AC voltage to switch 4/AC output signal from switch 4
Out ch 4b 8 AC voltage to switch 4/AC output signal from switch 4
Out ch 5a 9 AC voltage to switch 5/AC output signal from switch 5
Out ch 5b 10 AC voltage to switch 5/AC output signal from switch 5
Out ch 6a 11 AC voltage to switch 6/AC output signal from switch 6
Out ch 6b 12 AC voltage to switch 6/AC output signal from switch 6
Out ch 7a 13 AC voltage to switch 7/AC output signal from switch 7
Out ch 7b 14 AC voltage to switch 7/AC output signal from switch 7
Out ch 8a 15 AC voltage to switch 8/AC output signal from switch 8
Out ch 8b 16 AC voltage to switch 8/AC output signal from switch 8
Signal name
X2 pin Function
Out ch 9a 1 AC voltage to switch 9/AC output signal from switch 9
Out ch 9b 2 AC voltage to switch 9/AC output signal from switch 9
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Connections, connector X3
The table below shows the connections to connector X3:
Out ch 10a 3 AC voltage to switch 10/AC output signal from switch 10
Out ch 10b 4 AC voltage to switch 10/AC output signal from switch 10
Out ch 11a 5 AC voltage to switch 11/AC output signal from switch 11
Out ch 11b 6 AC voltage to switch 11/AC output signal from switch 11
Out ch 12a 7 AC voltage to switch 12/AC output signal from switch 12
Out ch 12b 8 AC voltage to switch 12/AC output signal from switch 12
Out ch 13a 9 AC voltage to switch 13/AC output signal from switch 13
Out ch 13b 10 AC voltage to switch 13/AC output signal from switch 13
Out ch 14a 11 AC voltage to switch 14/AC output signal from switch 14
Out ch 14b 12 AC voltage to switch 14/AC output signal from switch 14
Out ch 15a 13 AC voltage to switch 15/AC output signal from switch 15
Out ch 15b 14 AC voltage to switch 15/AC output signal from switch 15
Out ch 16a 15 AC voltage to switch 16/AC output signal from switch 16
Out ch 16b 16 AC voltage to switch 16/AC output signal from switch 16
Signal name
X2 pin Function
Signal name
X3 pin Function
In ch 1a 1 AC input signal from switch 1/Neutral voltage to switch 1
In ch 1b 2 AC input signal from switch 1/Neutral voltage to switch 1
In ch 2a 3 AC input signal from switch 2/Neutral voltage to switch 2
In ch 2b 4 AC input signal from switch 2/Neutral voltage to switch 2
In ch 3a 5 AC input signal from switch 3/Neutral voltage to switch 3
In ch 3b 6 AC input signal from switch 3/Neutral voltage to switch 3
In ch 4a 7 AC input signal from switch 4/Neutral voltage to switch 4
In ch 4b 8 AC input signal from switch 4/Neutral voltage to switch 4
In ch 5a 9 AC input signal from switch 5/Neutral voltage to switch 5
In ch 5b 10 AC input signal from switch 5/Neutral voltage to switch 5
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Connections, connector X4
The table below shows the connections to connector X4:
In ch 6a 11 AC input signal from switch 6/Neutral voltage to switch 6
In ch 6b 12 AC input signal from switch 6/Neutral voltage to switch 6
In ch 7a 13 AC input signal from switch 7/Neutral voltage to switch 7
In ch 7b 14 AC input signal from switch 7/Neutral voltage to switch 7
In ch 8a 15 AC input signal from switch 8/Neutral voltage to switch 8
In ch 8b 16 AC input signal from switch 8/Neutral voltage to switch 8
Signal name
X3 pin Function
Signal name
X4 pin Function
In ch 9a 1 AC input signal from switch 1/Neutral voltage to switch 1
In ch 9b 2 AC input signal from switch 1/Neutral voltage to switch 1
In ch 10a 3 AC input signal from switch 2/Neutral voltage to switch 2
In ch 10b 4 AC input signal from switch 2/Neutral voltage to switch 2
In ch 11a 5 AC input signal from switch 3/Neutral voltage to switch 3
In ch 11b 6 AC input signal from switch 3/Neutral voltage to switch 3
In ch 12a 7 AC input signal from switch 4/Neutral voltage to switch 4
In ch 12b 8 AC input signal from switch 4/Neutral voltage to switch 4
In ch 13a 9 AC input signal from switch 5/Neutral voltage to switch 5
In ch 13b 10 AC input signal from switch 5/Neutral voltage to switch 5
In ch 14a 11 AC input signal from switch 6/Neutral voltage to switch 6
In ch 14b 12 AC input signal from switch 6/Neutral voltage to switch 6
In ch 15a 13 AC input signal from switch 7/Neutral voltage to switch 7
In ch 15b 14 AC input signal from switch 7/Neutral voltage to switch 7
In ch 16a 15 AC input signal from switch 8/Neutral voltage to switch 8
In ch 16b 16 AC input signal from switch 8/Neutral voltage to switch 8
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C - 7: Communication
Communication concept, Allen-Bradley
General The robot may communicate with the Allen Bradley system only, or be used in
combination with the I/O system in the robot. For example, the inputs to the robot
may come from the Allen Bradley system while the outputs from the robot control
external equipment go via general I/O addresses and the Allen Bradley system
only reads the outputs as status signals.
Definitions The Allen Bradley system can communicate with up to 64 external systems. Each
of these systems is called a Rack and is given a Rack Address 0-63. Basically, each
robot connected to the Allen Bradley system will occupy one rack.
Each rack is divided into four sections called Quarters. Each quarter provides 32
inputs and 32 outputs and a rack will subsequently provide 128 inputs and 128
outputs. A rack may also be shared by 2, 3, or 4 robots. Each of these robots will
then have the same rack address, but different starting quarters must be specified.
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Illustration The illustration below shows a block diagram of the Allen-Bradley system, where
Robot 1 uses a full rack while robot 2 and robot 3 share one rack. The rack address,
starting quarter, and other required parameters such as baud rate, LED status etc.
are entered in the configuration parameters.
en0100000255
Allen Bradleycontrol system
Robot 1 - 128 in / 128 out Robot 2 - 64 in / 64 out
128 in / 128 out
64 in / 64 out
Quarter 2
Quarter 3
Quarter 4
Quarter 1
Rack ID 12 (example)Rack size 4Starting quarter 1
Quarter 2
Quarter 1
Rack ID 13 (example)Rack size 2Starting quarter 1
Robot 3 - 64 in / 64 out
64 in / 64 out
Quarter 4
Quarter 3
Rack ID 13 (example)Rack size 2Starting quarter 3
Quarter 2
Quarter 3
Quarter 4
Quarter 1
Other systems
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RIO, remote I/O for Allen-Bradley PLC DSQC 350
General The unit handles communication between the robot system and the Allen Bradley
system.
Technical data
Also see the Allen-Bradley RIO specification.
Further informa-tion
For setup parameters, see User’s Guide - System Parameters, Topic: I/O Signals.
Also see Circuit Diagram.
Connection The RIO-unit should be connected to an Allen-Bradley PLC using a screened, two
conductor cable.
Layout, DSQC 350
The figure below shows the layout of the DSQC 350 board:
xx0100000226
No. of digital inputs Unit is programmable for 32, 64, 96 or 128 digital inputs
No. of digital outputs Unit is programmable for 32, 64, 96 or 128 digital outputs
DS QC 350 ABB F lexible Automation
X8
X9X5
X3
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Connections, connector X8
The figure below shows the pin configuration of the connector:
xx0100000221
The table below shows the connections to connector X8:
Connections, connector X9
The figure below shows the pin configuration of the connector:
xx0100000221
The table below shows the connections to connector X9:
X3 Not used
X5 DeviceNet and ID connector
X8 RIO in
X9 RION out
Signal name X8 pin Function
LINE1 (blue) 1 Remote I/O in
LINE2 (clear) 2 Remote I/O in
Shield 3 Remote I/O in
Cabinet ground 4 Remote I/O in
15
Signal name X9 pin Function
Blue 1 Remote I/O out
Clear 2 Remote I/O out
Shield 3 Remote I/O out
Cabinet ground 4 Remote I/O out
15
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Termination When the robot is last in a RIO loop, the loop must be terminated with a termina-
tion resistor according to Allen-Bradley’s specification.
Warranty This product incorporates a communications link which is licensed under patents
and proprietary technology of the Allen-Bradley Company, Inc. The Allen-Brad-
ley Company, Inc. does not warrant or support this product. All warranty and sup-
port services for this product are the responsibility of and provided by ABB
Flexible Automation.
Bus status LEDs The figure and table below show the location and significance of the LEDs on the
board.
The designations refer to LEDs shown in the figure in section "Layout, DSQC
350" above.
Designation Color Description
POWER-24 VDC Green Indicates that a supply voltage is present, and has a level above 12 VDC. If there is no light, check that voltage is present on power unit and in power connector. If not, check cables and connectors. If power is applied to the unit but it does not work, replace the unit.
NS/MS Green/red See section "CAN bus status LED description".
CAN Tx/CAN Rx Yellow See section "CAN bus status LED description".
NAC STATUS Green Steady green indicates RIO link in operation. If there is no light, check network, cables and connections. Also check that PLC is operational. Flashing green indicates that communication is established, but the INIT_COMPLETE bit is not set in NA chip, or configuration, rack size etc. does not match configuration set in PLC. If LED keeps flashing continuously, check setup
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Communication, serial links
General The robot has three serial channels, which can be used by the customer to com-
municate with printers, terminals, computers, and other equipment (see the figure
in "Connections" below).
• COM1 (computer system) - RS 232 115 kbps. This was formerly referred to as Com2.
• COM2 - RS 232 with RTS-CTS-control and support for XON/XOFF, trans-mission speed 300 - 38 400 bps. This was formerly referred to as SIO1.
• COM3 - RS 422 full duplex TXD4, TXD4-N, RXD4, RXD4-N, transmission speed 300 - 38 400 bps. This was formerly referred to as SIO2.
• For temporary use: MC/CONSOLE - RS 232 115 kbps. This was formerly referred to as Com1.
Further informa-tion
• For setup parameters, see User's Guide - System Parameters, Topic: I/O Signals.
• Circuit Diagram.
• Location in the cabinet (see figure in section "Connection to screw termi-nals").
Technical data See Product Specification for controller S4Cplus. Separate documentation is
included when the option RAP Serial link is ordered.
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Connections The figure below shows the connection of serial channels:
xx0100000219
Customer terminals, on base connector board: X10 (COM2) and X9 (COM3), see
section "Connection to screw terminals".
Connections on DSQC 504, COM1
Standard RS232 port.
The figure below shows the pin configuration of the connector:
xx0100000220
The table below shows the signals from the COM1 (RS232):
A External computer
A
Signal Pin Description
DCD 1 Data carrier Detect
RX 2 Receive Data
TX 3 Transmit Data
5
1 9
6
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Connections on DSQC 504, D-sub connector X10, COM2
The figure below shows the pin configuration of the connector:
xx0100000220
The table below shows the connections to connector X10:
DTR 4 Data Terminal Ready
GND 5 Signal Ground
DSR 6 Data Set Ready
RTS 7 Request To Send
CTS 8 Clear To Send
RI 9 Ring Indicator
NC 10 Not Connected
Signal Pin Description
COM2 Signal name X10 pin
1
RxD (Receive Data) 2
TxD (Transmit Data) 3
DTR (Data Terminal Ready) 4
0 V 5
DSR (Data Ready Set) 6
RTS N (Request To Send N) 7
CTS (Clear To Send) 8
9
5
1 9
6
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Connections on DSQC 504, D-sub connector X9, COM3
The figure below shows the pin configuration of the connector:
xx0100000220
The table below shows the connections to connector X9:
Connections to MC/CONSOLE
The figure below shows the MC/CONSOLE connection behind the service hatch:
xx0100000218
COM3 Signal name X9 socket
TxD (Transmit Data) 1
TxD N (Transmit Data N) 2
RxD (Receive Data) 3
RxD N (Receive data N) 4
0 V 5
DATA (Data Signals in Half Duplex Mode) 6
DATA N (Data Signals in Half Duplex Mode N) 7
DCLK (Data Transmission Clock) 8
DCLK N (Data Transmission Clock N) 9
5
1 9
6
A
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Standard RS232 port intended for temporary use, e.g. connection of laptop/PC.
The table below shows the signals on the MC/CONSOLE (RS232):
A External computer
Signal Pin Description
RX 2 Receive Data
TX 3 Transmit Data
GND 5 Signal Ground
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Communication, Ethernet
General The robot has two Ethernet channels available:
• LAN (connected to the Main computer)
• Service (connected to the I/O computer)
Connection of LAN (Main com-puter)
The figure below shows an outline diagram of the Ethernet TCP/IP:
xx0100000217
Used for connection of shielded twisted-pair Ethernet (TPE), or as defined in
IEEE 802.3: 10/100 BASE-T. Maximum node-to-node distance 100 meter. The
main computer board has no termination for a cable shield. The cable shield must
be grounded at the cabinet wall with a cable gland. 10BASE-T is a point-to-point
net, connected via a HUB, see the figure above.
A External computer
B Controller Robot 1
C Controller Robot 2
Signal X1 Pin Description
TX+ 1 Transmit data line +
E thernet hub
A B C
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The figure below shows the main computer board front:
xx0100000216
TX- 2 Transmit data line -
RX+ 3 Receive data line +
NC 4 Not Connected
NC 5 Not Connected
RX- 6 Receive data line -
NC 7 Not Connected
NC 8 Not Connected
Signal X1 Pin Description
X1LAN
PWR
HDD
STATUS
X2
1
8
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Connection of Service (I/O Com-puter)
Used for connection of a laptop to the service outlet on the front of the controller
cabinet (behind service hatch).
The figure below shows how to connect a laptop to the service outlet:
xx0100000215
For setup parameters, see User’s Guide - System Parameters, Topic: I/O Signals.
Also see the Circuit Diagram. Separate documentation is included when the
option Ethernet services is ordered.
E thernet
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External operator’s panel
General All necessary components are supplied, except for the external enclosure.
Dimensions for installation
Install the assembled panel in a housing which satisfies protection class, IP 54, in
accordance with IEC 144 and IEC 529!
The figure below shows the main dimensions of the external operator’s panel:
xx0100000214
A Holes for operator’s panel
B Holes for flange
184200
70
45°
62
D
E
90
155
C
A
M4 (x4)
ø5 (x2)
F
G
B
140
M8 (x4)
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C Required depth: 200 mm
D External panel enclosure (option)
E Holes for teach pendant unit (TPU) holder
F Teach pendant unit (TPU) connector
G Connection to the controller
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Section D: Start-up
Inspection before start-up
General Perform the following checks before starting up the robot system:
Check that: 1. the controller mains section is protected with fuses.
2. the electrical connections are correct and correspond to the identifica-tion plate on the controller.
3. the teach pendant and peripheral equipment are properly connected.
4. any limiting devices that establish the restricted space (when utilized) are installed.
5. the physical environment is as specified.
6. the operating mode selector on the operator’s panel is in the Manual mode position.
7. when external safety devices are used, check that these have been connected or that the following circuits in either XS3 (connector on the outside left cabinet wall) or X1-X4 (screw terminals on the panel unit) are strapped:
Device XS3 Panel unit
External limit switches A5-A6, B5-B6 X1.3-4, X2.3-4
External emergency stop A3-A4, B3-B4 X1.9-10, X2.9-10
External emergency stop internal 24 V
A1-A2, B1-B2 X1.7-8, X2.7-8
General stop + A11-A12, B11-B12 X3.10-12, X4.10-12
General stop - A13-A14, B13-B14 X3.7-8, X4.7-8
Auto stop + A7-A8, B7-B8 X3.11-12, X4.11-12
Auto stop - A9-A10, B9-10 X3.7-9, X4.7-9
Motor off clamping A15-A16, B15-16 X1.5-6, X2.5-6
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Start-up
General 1. Switch on the mains switch on the cabinet.
1. The robot performs its self-test on both the hardware and software, which takes approximately 1 minute.
2. If the robot is not supplied with the software already installed, install the software as described in chapter "Robot Controller".
A welcome message is shown on the Teach Pendant Unit display.
3. To switch from MOTORS OFF to MOTORS ON, press the enabling device on the teach pendant.
4. Update the revolution counters as described in the Calibration chapter, section "Updating the revolution counters".
5. IRB 940: Check the position of the spiral cable in the centre tube sleeve. Correct position is described in the Calibration chapter, section "Correct orientation of axes".
6. Check the calibration position as described in the Calibration chapter, section "Checking the calibration position".
7. When the controller, with the manipulator electrically connected, is powered up for the first time, ensure that the power supply is connected for at least 36 hours continuously, in order to fully charge the batteries for the serial measurement board. It takes approx. 4 hours to fully charge a computer system battery.
8. After having checked the above, verify that:
• the start, stop and mode selection (including the key lock switches) control devices work as intended.
• each axis moves and is restricted (if possible) as intended.
• emergency stop and safety stop (where included) circuits and devices are functional.
• it is possible to disconnect and isolate the external power sources.
• the teach and playback facilities work correctly.
• the safeguarding is in place.
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• at reduced speed, the robot operates properly and has the capability to handle the product or workpiece.
• in automatic (normal) operation, the robot operates properly and has the capability to perform the intended task at the rated speed and load.
9. The robot is now ready for operation.
Operating the robot
Starting and operating the robot is described in the User’s Guide. Before start-up,
make sure that the robot cannot collide with any other objects in the working
space.
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Section E: Installation of controller software
Loading system software
General The robot system may be delivered with or without system software. When the
system is not delivered with software, this must be downloaded in one of a number
of ways.
Software installed on delivery
If the robot controller is ordered with the software installed on delivery, the con-
troller software and settings are already stored in the storage memory and the
system is ready to use.
Software not installed on deliv-ery
If the robot controller is ordered and delivered without software or if you want to
reconfigure your system, the RobInstall tool must be used to install the controller
software. The RobInstall tool is included on the RobotWare CD-ROM (see section
"RobotWare CD-ROM"). The RobInstall tool can be used both for creation of the
controller software and for downloading it to the controller system.
Types of software loading
xx0100000192
AB
C
DE
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When downloading, the controller software can be transferred to the controller
storage memory in three ways as shown in the figure above.
• using floppy disks,
• using Ethernet connected direct to the IO computer (IOC) service outlet on the front of the controller cubicle,
• using Ethernet connected via a local area network (LAN) to the main com-puter (MC).
Boot Image The transfer and installation of the controller software to the controller storage
memory via Ethernet or floppy disks is executed by a basic program named Boot
Image.
This basic program must always be in the storage memory. When starting the
controller, with no controller software installed, Boot Image will start and ask the
operator for controller software installation instructions. If the controller software
is already installed and a warm start is performed, Boot Image is not used. The
installed controller software can be deleted by a cold start and then the Boot Image
will be reactivated.
A RobotWare CD-ROM to install RobInstall and System Pack on PC
B Floppy Disks
C IOC Ethernet (service) with delivered boot cable UTP-X
D Connected to IOC
E MC Ethernet (LAN) network in workshop
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RobotWare CD-ROM
The CD contains all the System software and should therefore be treated and stored carefully.
RobotWare CD-ROM contents
The RobotWare CD-ROM contains the following:
Contents Description
1. RobInstall A PC tool used to create and install the control-ler operating system in the robot control sys-tem.
2. Documentation On-line documentation for the RobInstall appli-cation and the Controller Operating System Package.
3. Controller OS Package Controller Operating System Package for S4Cplus. This package includes all the soft-ware needed to create the controller operating system with any ordered options. Please note that it is possible to install different releases with different versions of the same system package (see section "Media Pool in the PC").
4. Test Signal Viewer A tool (created in LabView) for viewing Motion-Test Signals (oscilloscope function) and also for logging these signals.
5. FTP Client On the CD is also included a so called FTP cli-ent named Voyager. Please note that this is not an ABB product but a shareware program, which means that it can be installed and used for a limited time, but that it has to be regis-tered for permanent use. Registering means that a certain fee must be paid to the vendor.
The FTP client is used to transport files manu-ally between the PC and the robot controller storage memory. These actions are carried out in the same way as in a file manager or in Win-dows Explorer.
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Installation of the RobotWare on the PC (except FTP Client)
This section describes how to install the software delivered on the RobotWare
CD-ROM onto a PC hard drive, to be transferred to the robot system.
1. Insert the CD in your reader.
1. The Install Shield will automatically start and guide you through the install process (if it does not start, double-click the CD icon on your PC). When the setup type window is displayed, it is recommended to select the Custom button. Then Next button will open the Select Components window, where normally all the four options, RobInstall, Documenta-tion, Controller OS Package and Test Signal Viewer should be marked as selected.
Installation of the FTP Client on the PC
This section describes how to install the FTP Client onto a PC hard drive.
1. In the Explorer, select and open the directory "ftp" on the CD.
2. Double-click the file ftpvsetup.exe.
The Install Shield for the FTP client will start and guide you through the instal-lation. Please read the "Readme" file for information about license regulations.
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Installing new Robot Controller Software with RobInstall
General Since most systems have the operating system installed already on delivery, the
RobotWare CD-ROM is normally not needed. However it should be used when:
• creating a new controller operating system,
• changing the current operating system configuration, e.g. concerning included options.
Nomenclature In the text dealing with RobInstall, the following nomenclature is used:
How to use Rob-Install
Robinstall is used to create and install the controller software in the S4Cplus robot
controller. With RobInstall, you can:
• create a new system,
• update an existing system,
• download a system to the controller using the Ethernet connection,
• create Boot Disks to transfer the system to the Controller.
Concept: Means:
System pack This is the RobotWare Controller Operating System Package for S4Cplus, including all options, even if they are not ordered and activated.
Key This is a text string, or a special file with the text string, which is used to define and open both the BaseWare and all ordered RobotWare options.
System This is a complete controller software, i.e. controller operating system, based on the system pack and the key. It can also include any user files to be added to the home directory on the controller storage memory.
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Step Action Illustration/Info
1. Make sure RobInstall is installed. If not, install it according to the instruc-tions in section "Installa-tion of the RobotWare on the PC".
2. Click the start button on your PC and select pro-grams/ABB Robotics/Rob-Install/RobInstall.
3. The RobInstall start win-dow will open.
xx0100000185
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Create a new Robot Controller System
Setting up the system
Step Action Illustration/Info
1. Start RobInstall as described in section "How to use Robinstall".
2. Choose New to create a new Robot Controller sys-tem as shown in the fig-ure.
xx0100000179
3. Enter a name for the new controller system. Select a saving location or use the default directory, nor-mally "Program Files\ABB Robotics\sys-tem" (see the figure below, position 1).
xx0100000180
4. Enter the RobotWare key or add from file. If added from a file, files with the extension .kxt should be used (see the figure above, position 2).
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Add or remove external options
5. Press OK. The configured system will be displayed in the next window (see the figure below).
xx0100000181
6. If no external options or parameters are to be added or changed, press Finish to create the new controller system. Other-wise press Next to con-tinue to "Additional Keys" (see section "Add or remove external options").
Step Action Illustration/Info
Step Action Illustration/Info
1. To add or remove external options, press Next in the screen shown in the last fig-ure in section "Setting up the system" or click on "Additional Keys" in the menu to the left.
xx0100000182
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Add or remove additional system parameters
2. Enter the key string for the selected option and press Add Key to list, or pressAdd key from file to select a key string file.
3. To remove additional keys, select the key in the Included Additional Keys list and press Remove Key.
4. Press Finish to create the controller system or press Next to continue to "Parame-ter Data" (see section "Add or remove additional system parameters).
Step Action Illustration/Info
Step Action Illustration/Info
1. To add or remove addi-tional parameters, press Next in the screen shown in the last figure in section "Add or remove external options" or click on "Parameter Data" in the menu to the left.
xx0100000183
2. Press Add to load manipu-lator calibration data (see the figure above, position 1). This is the calib.cfg file delivered on the Manipula-tor Parameter disk (see section "The manipulator parameter disk").
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Change options or system pack revision
3. To remove manipulator calibration data, press Remove.
4. Press Add to load addi-tional system parameters, see pos. 2. All system parameter files added here will be automatically loaded together with the system, when the control-ler is restarted with the new system.
5. To remove additional parameters, select the parameter in the "Loaded Additional Parameters" list and press Remove.
6. Press Finish to create the controller system or press Next to continue to "Options" (see section "Change options or sys-tem pack revision").
Step Action Illustration/Info
Step Action Illustration/Info
1. To change the option con-figuration, press Next in the screen shown in the figure below or click on "Options" in the menu to the left.
xx0100000184
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2. To change the Teach Pen-dant Unit language, robot type, or software options, press Options (see the fig-ure above, position 1).
3. Normally the latest release or revision of all system packages and option packages stored in the media pool (see sec-tion "Media Pool in the PC") will be used. If an earlier revision should be used, uncheck the check mark and press Rev. Select (see the figure above, position 2). In the new window select the system package to use and press OK.
4. If you want the system to start up in query mode, put a mark in the query mode selection square. For fur-ther details of the query mode, see section "Start in Query Mode".
5. Press Finish to create the controller system or press Next to view the current configuration.
Step Action Illustration/Info
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Update the Robot Controller image
Actions
Step Action Illustration/Info
1. To update an existing con-troller system, press Update, see the figure below.
xx0100000189
2. Select a system in the sys-tem list and press OK, see the figure above. Please note that a pop up menu can be shown by clicking right mouse button. With this menu Copy, Rename or Delete can be selected for the marked system.
xx0100000190
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3. The window displaying the current configuration of the system will be shown. Fol-low the instructions in sec-tions "Add or remove external options", "Add or remove additional system parameters" or "Change options or system pack revi-sion" to modify the system.
Step Action Illustration/Info
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Transfer Robot Controller System using Ethernet connection
Selecting type of set-up
Before a system can be downloaded to a robot controller using the RobInstall tool
some preparations and set up must be done. This may be done in one of two ways:
If using a direct connection between PC and IOC service outlet on controller
If you are using: ...then see instructions in section:
...and continue in section:
a direct connection between PC and IOC service outlet on controller
"If using a direct connection between PC and IOC service outlet on controller" below!
"Download Robot Controller System" below!
Network Intranet connection with fixed IP addresses
"If using Network Intranet connection with fixed IP addresses " below!
"Download Robot Controller System" below!
Network Intranet connection with DHCP (Dynamic Host Configuration Protocol)
"If using Network Intranet connection with DHCP " below!
"Download Robot Controller System" below!
Step Action Illustration/Info
1. Connect a patch-cable between the Ethernet con-nection on the front of the controller and the corre-sponding connection on the PC/Laptop.
2. Make sure that the Net-work protocol is set for TCP/IP properties.
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If using Network Intranet connec-tion with fixed IP addresses
3. Change the TCP/IP Prop-erties in accordance with the following table and fig-ure:
xx0100000178
Step Action Illustration/Info
Step Action Illustration/Info
1. Make sure that the Network protocol is set for TCP/IP properties.
2. Change the TCP/IP Properties in accordance with the values to be used for IP address, Subnet mask and Gateway.
3. Perform a X-START (see section "x-START") or C-START (see section "C-start") on the S4Cplus con-troller.
4. Configure the IP address to be used for the robot controller from the TPU.
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If using Network Intranet connec-tion with DHCP
Download Robot Controller Sys-tem
Before downloading, check the following: Make sure there is at least 25 Mb free disk space on the controller mass storage memory. For information on how to perform a manual storage capacity check, see section "Check Storage Capacity". Make sure that the robot controller displays the Start Window on the Teach Pen-dant Unit (see section "Start window").
Step Action Illustration/Info
1. Read Ethernet MAC-id on the Teach Pendant Unit (see section "LAN settings").
Step Action Illustration/Info
1. To download a controller system, press Download as in the figure below:
xx0100000176
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2. Select a target system as in the figure, position 1.
If a direct connection is used with the patch cable between the PC and the controller front, then just select the default IP address (192.168.125.1) and "Direct" option. In other cases, write the correct IP address for the robot controller and select "Host-name or IP-address". RobInstall will store already used IP addresses, which can later be selected with the down arrow.
3. Type your username and password if required by the robot controller as in the fig-ure below, position 2.
xx0100000177
4. Test the connection by pressing Test Connection and press OK if a connec-tion is established.
5. Select a system in the list on the left and press OK as in the figure below. Please note that it is possible to select another system pool than the shown one (in such case be sure to select the system pool directory, not the system itself on the lower level).
xx0100000175
Step Action Illustration/Info
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6. RobInstall will now create a system file and download it to the controller.
After downloading it is possible to restart the controller with the new downloaded controller system. Otherwise, the controller may be restarted from the Teach Pendant Unit as detailed in section "Reboot".
Step Action Illustration/Info
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Transfer Robot Controller System using floppy disks
Before downloading, make sure: there is at least 25 Mb free disk space on the controller mass storage memory. For information on how to perform a manual storage capacity check, see section "Check Storage Capacity".
that the robot controller displays the Start Window on the Teach Pendant Unit (see section "Start Window").
an optional floppy disk drive is installed in the robot controller.
Create Boot Dis-kettes from Rob-Install Step Action Illustration/Info
1. Press Create Boot Disk as in the figure below.
xx0100000173
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2. Select a system in the list on the left and press OK as in the figure below.
RobInstall will now create an image file and estimate the number of disks needed.
xx0100000175
xx0100000188
3. Insert a formatted 1.44 Mb diskette into the disk drive.
4. Press Continue to start copy the Robot Controller System image to the disks.
5. Use the finished floppy disks to boot your system as described in section "Boot Disks".
Step Action Illustration/Info
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RobInstall preferences
Customizing Rob-Install
RobInstall may be customized to suit particular requirements.
Step Action Illustration/Info
1. To customize RobInstall for new programs and optional products, press Preferences as shown in the figure. See also chap-ter "System Directory Structure".
xx0100000186
2. To select another media pool (see section "Media Pool in the PC"), press Select Media Pool as shown in the figure, posi-tion 1.
xx0100000187
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3. To add a new system pack-age or option package to the media pool, press Import Program as shown in the figure, position 2. Also see chapter "System Directory Structure".
Step Action Illustration/Info
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Section F: Robot controller
BootImage
General The BootImage is a basic program which is used to start up the system from
"scratch".
Purpose of the program
This program is already installed in the controller at delivery and is used to:
• restart the system
• load the system from boot disks or network connections
• set or check network settings
• choose a system from the mass storage memory.
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Start window
When is it shown?
xx0100000168
The start window displays the start menu and will appear in the following cases:
• When no controller operating system is installed at power on.
• After X-START (see the part "How to perform a Restart").
• After C-START (see the part "How to perform a Restart").
Possible actions From this window you can choose to do one of the following:
Restart the sys-tem, Reboot
The BootImage will be re-executed, used to apply changes in the system settings
(see the part "Reboot Window").
Load a system from diskettes, Boot Disks
(See the part "Boot Disk Window".)
Set the network settings, Network Settings
Set network settings for the Main Computer or check how to configure your PC
(see the part "Network Settings Window").
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Choose a system from the mass storage memory, Select System
If there is one or more systems in the mass storage memory, you can choose to
activate one of them (see the part "System selection window").
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Reboot Window
When is it shown?
The Reboot window will be displayed if any of the system settings are changed or
when Reboot is pressed in the Start window as shown in the figure below:.
xx0100000169
Button Function
YES Restarts the system
NO Returns to the start window
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Boot Disk Window
When is it shown?
The Boot Disk window will be displayed when Boot Disks is pressed in the Start
window as shown in the figure in section "Start window".
How to create boot disks
Information on how to create boot disks from RobInstall can be found in section
"Create Boot Diskettes from Robinstall".
Load the system
Step Action Illustration/Info
1. Insert the correct diskette in the floppy disk drive and press OK. If the diskette is alright, the system will be loaded. CANCEL removes all previ-ously loaded data and returns to the Start window as shown in the figure in section "Start window".
xx0100000170
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Network Settings Window
When is it shown?
The Network Settings window will be displayed when Network Settings is
pressed in the Start window as shown below.
xx0200000209
LAN Settings Press to configure the Main Computer for communication with a PC on a Local Area Network (LAN). Also see "LAN settings"!
Service Settings Press to view the required settings for the PC to communicate with the I/O Computer. Also see "Service settings"!
CANCEL Press to return to the Start window as shown in figure "Start window".
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LAN Settings Window
When is it shown?
The LAN Settings window will be displayed when LAN Settings is pressed in the
Network Settings window as shown in the figure in section "Network Settings".
en0100000256.gif
Node identifica-tion
NONE will, after the system is rebooted, remove the IP settings.
CANCEL returns to the Start window, as shown in the figure in section "Start Window", without changing any settings.
Parameter Type Description
MAC ID Node identification The Main Computer’s ethernet address.
Current IP Node identification The Main Computer’s current IP address. This row is blank if the LAN Settings have not been defined.
IP Network setting Space for typing in a new IP address, for the Main Computer or the DHCP server. See Configure for fixed IP network and Configure for DHCP distributed IP network below.
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Configure for fixed IP network
1. Press FIX IP.
2. Fill in the assigned IP address for the Main Computer, and the Subnet Mask and Gateway for the Network and press OK.
You will be asked to reboot the system.
3. Press YES to make the new setting take effect.
Configure for DHCP distributed IP network
1. Press DHCP.
1. The value for IP will change to DHCP.
2. Press OK.
You will be asked to reboot the system.
3. Press YES to make the new setting take effect.
(Subnet mask) Network setting Shows the subnet mask of the network. Only visible when configured for fixed IP.
(Gateway) Network setting Shows the gateway IP for the network.
Only visible when configured for fixed IP.
Parameter Type Description
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Service Settings Window
When is it shown?
The Service Settings window will be displayed when Service Settings is pressed
in the Network Settings window as shown in the figure in section "Network Set-
tings".
en0100000257
Service Setting
OK returns to the Start window as shown in the figure in section "Start Win-dow".
Parameter Description
IP (service setting) The IP Address for the I/O Computer
IP Required to configure your PC’s network settings for com-munication between RobInstall and the I/O Computer.
Subnet mask Required to configure your PC’s network settings for com-munication between RobInstall and the I/O Computer.
Gateway Required to configure your PC’s network settings for com-munication between RobInstall and the I/O Computer.
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System selection window
When is it shown?
The Select System window will be displayed when Select System is pressed in the
Start window, as shown in the figure in section "Start Window".
xx0100000171
How to select system
The window shows all systems installed on the controller mass storage memory.
CANCEL returns to the Start window as shown in the figure in section "Start Window".
Step Action Illustration/Info
1. Select by moving the X to a desired system and press OK. The system will reboot with the new system and then display the Welcome window as shown in the figure.
xx0100000172
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How to perform a Restart
General Performing a restart may be done in a number of ways. These are detailed below:
Reboot (Warm start), apply changed settings
When executing a Warm start, the system reboots with the current system, e.g. to
make new or changed settings take effect.
P-START, reinstal-lation of RAPID
A P-Start will warm start the current system, with a reinstallation of the RAPID
language and all auto-loaded modules. This means that all RAPID program and
system modules currently loaded in the working memory will be closed, and thus
have to be reloaded again after the P-Start, with the exception of such modules that
are automatically loaded, due to settings in the System Parameters/Controller/
Task Modules.
Step Action Illustration/Info
1. Press the button Miscellaneous and select Service window or System Parameter win-dow
Miscellaneous button:
xx0100000194
2. Select Restart from the File menu and press OK. The system reboots and returns to the Wel-come window as shown in the second figure in section "Select System".
Step Action Illustration/info
1. Press the button Miscellaneous and select Service window.
Miscellaneous button:
xx0100000194
2. Select Restart from the File menu.
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X-START, change active controller system
An X-start will exit the running system, store system data on the mass storage
memory, and then execute the BootImage to display the Start window. Any system
stored in the mass storage memory may then be selected as described in section
"Select System".
When performing an X-Start all stored system data will be restored (similar to
performing a warm start).
I-START, start in Query mode
An I-start can be done if "Use Query Mode at System Boot" was selected when
creating the running system in RobInstall (see section "Change options or system
pack revision"). An I-Start will restart the current system and give the opportunity
3. Enter the numbers: 2_5_8 (the fifth function key changes to P-START)
4. Press P-START. The system will reboot, reinstall RAPID and its auto-loaded modules, and return to the Welcome window as shown in the second fig-ure in section "Select System".
Step Action Illustration/info
Step Action Illustration/Info
1. Press the button Miscellaneous and select Service window.
Miscellaneous button:
xx0100000194
2. Select Restart from the File menu.
3. Enter the numbers: 1_5_9 (the fifth function key changes to X-START)
4. Press X-START. The system will reboot and return to the Start window as shown in the figure in section "Start Window".
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to set some values at start-up, e.g. language, IRB type (within the same model) or
options (see section "Start in Query Mode").
C-START (Cold start), delete the active system
When executing a C-Start, the system exits the running system and deletes it from
the mass storage memory. The BootImage is then executed and the Start window
as shown in the figure in section "Start Window" is displayed.
Use C-start with caution. Since it deletes the current system, it should not be used to just switch between installed systems. For this purpose, use X-Start (see section "X-start").
It will take quite some time to implement a Cold start. Just wait until the robot shows the Start window. When the Start window is shown, a new system can be selected if available in the mass storage memory (see section "Select System) or a new system can be downloaded and started (see section "Transfer Robot Controller System using Ethernet connection" or "Transfer Robot Controller System using floppy disks"). Do not touch any key, joystick, enable device, or emergency stop during the cold start until the Start window is shown as in the figure in section "Start Window".
Step Action Illustration/Info
1. Press the button Miscellaneous and select-Service window.
Miscellaneous button:
xx0100000194
2. Select Restart from the File menu.
3. Enter the numbers: 1_4_7 (the fifth function key changes to I-START).
4. Press I-START.
The system will start to reboot, then pause to ask for Silent, Easy, or Query mode. For more information on the different modes, continue to section "Start in Query Mode".
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Step Action Illustration/Info
1. Press the button Miscellaneous and select-Service window.
Miscellaneous button:
xx0100000194
2. Select Restart from the File menu.
3. Enter the numbers: 1_3_4_6_7_9 (the fifth function key changes to C-START)
4. Press C-START.
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How to Start in Query Mode
Pre-conditions for selecting Query Mode start
If "Use Query Mode at System Boot" was selected when creating the system in
RobInstall (see section "Change options or system pack revision"), it is possible
to set some values, e.g. language, IRB type (within the same model) or options, at
the first start-up of the system, using a C-Start (see section "C-start"), or later on
when performing an I-Start (see section "I-start").
Types of Query Mode
The first question from the system is which Query Mode to start. Depending on
your needs, you should select one of the following three:
• Silent Mode, pushbutton Silent. If Silent Mode is selected, the operating system will be installed with the system configured as defined in RobIn-stall.
• Easy Query Mode, pushbutton Easy Query. In Easy Query Mode you can change language, remove selected options and select service or standard mode (see section "Easy Query Mode").
• Query Mode, pushbutton Query. In Query Mode you can, as well as the things in Easy Query, select DC-link, change Robot type (within the same family) and for IRB 7600, select balancing unit (see section "Query Mode").
Easy Query Mode If Easy Query was chosen as start-up query mode, the following steps will be
required to start the system:
Step Action Illustration/Info
1. Select Service/Standard motion param. Choose between standard or service motion parameters (pushbutton Stand / pushbutton Service).
2. Choose TP Language. If there was another language than English selected in RobInstall (see section "Change options or system pack revision"), it will be possible to choose the language (pushbutton English /pushbutton "Other").
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Query Mode If Query Mode was chosen as start-up query mode, the following steps will be
required to start the system:
3. Install xxx? For every option that was selected in RobInstall (see section "Change options or system pack revision") it is now possible to select Yes to keep the option, or No to remove it from the system.
Step Action Illustration/Info
Step Action Illustration/info
1. Select Service/Standard motion param. See section "Easy Query Mode", step 1.
2. Choose TP Language. See section "Easy Query Mode", step 2.
3. Select external axes config.
You can find the article number of the DC-link used on the unit inside the controller, then use the table below to find out the configura-tion ID for that DC-link.
4. Select xxxx model. Choose Robot model type within in the same family, e.g. 1400, 6400 etc. If there are more than three options, press pushbutton SCAN to view them.
5. Install xxx. See section "Easy Query Mode", step 3.
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Section G: System directory structure
Media pool in the PC
Directory All RobotWare System Packages and Option Packages are stored in a media pool
directory (folder) as shown in the table below.
Two revisions of the same system package may exist in the pool. By default, after
having installed RobInstall, a directory "MediaPool" will be found in the directory
Program Files\ABB Robotics\, and will also be the current one. However any
directory in the structure can be set up as the current media pool in the Preference
window (see section "Robinstall Preferences").
xx0100000259
Naming conven-tions
Each package is stored in a directory, the name of which is an article number
ending with the sub-number and with the revision number as shown in the table
above. All the system packs and option packs in one media pool must have the
correct revision numbers in their directory names. Thus a later revision can be
loaded into the program pool, to be added to the old one, without changing the
article number.
Art. no./folder name Description
3HAXaaaa-1.00 RobotWare System Pack 3HAXaaaa-1, rev 00
3HAXbbbb-1.02 RobotWare System Pack 3HAXbbbb-1, rev 02
3HAXcccc-1.01 ABB Robotics external option program 3HAXcccc-1, rev 01
3HYZdddd-1.00 OEM customer external option program 3XYZdddd-1, rev 00
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System pool in the PC
Directory All systems created with the RobInstall will be stored in a system pool. The
default name of such a system pool is "system" as shown below. Each system
stored in the system pool is a directory with the name of the system as shown in
the table below.
By default, after installing RobInstall, a directory "system" will be found in Pro-
gram Files\ABB Robotics\ and will also be the current one. However any direc-
tory in the structure can be set up as the current system directory in the Create New
System window or Select System window.
File system requirements
The system directory must hold these files and directories to allow software instal-
lation:
• key.id (encrypted key file for the actual controller)
• program.id (file with paths to selected programs in the media pool)
• A syspar directory containing .cfg files to be included in the software instal-lation procedure. All system parameter files, included when creating a sys-tem with RobInstall, are stored in this syspar directory as shown in the table in section "System Pool Directory".
• A directory called Home. In this home directory the user can include any file or files, which should be downloaded to the controller together with the operating system. Such files will then be placed in the home directory of the system in the controller.
Directory view Folder "System 1"
xx0100000260
xx0100000261
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File structure in the robot controller mass storage memory
Files in root direc-tory, hd0a
The root directory of the mass storage memory is called hd0a. This includes sev-
eral components:
Directories and subdirectories
Each system directory holds a number of subdirectories, defining for instance lan-
guage, options, robots, etc.
"Home" directory The system directory is the "home" directory for the system. When using the
address "home:" in the RAPID program, this directory will be addressed.
"Bin" subdirec-tory
The subdirectory bin, containing the storage area for all system data, e.g. at power
break. This means that at warm start, in addition to restoring the operating system
from the control system package, all system data is restored from this directory
and reloaded into the working memory.
Never change these directories!
Never delete or change the \bin or BootRom.sys directories in the root directory.
If this is done, the controller cannot be restarted and it will be impossible to use
the mass storage memory.
File name Description
E.g. 3HAC6811-1.00 Control system package, named as an article number
bin BootImage code
BootRom.sys System configuration and description file for the mass storage memory
MC.cfg Network configuration for the main computer
ctrl.bin Holds e.g. revolution counter values
system.dir Holds information on the current system
system directories Different systems stored in the mass storage memory
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Preparation of S4Cplus software to be installed
Illustration
xx0100000262
Files to be pre-pared
The list details what happens during preparation:
• RobInstall creates a file named Key.id from the key strings specifying the options to be installed from the System Pack and the external option pro-grams to be installed.
• Unless deselected in RobInstall, the latest revision of the System Pack and External Option Programs is selected as default (see section "Change options or system pack revisions").
• These are copied from the media pool and concatenated into one target file that also holds the key.id and the syspar directory. This may then be downloaded to the controller via Ethernet or a set of diskettes. The target file is temporarily stored in the system directory before downloading or cre-ating diskettes.
Media pool S ystem pool
S ystem Pack in/3haxbbbb-1.nn*.* signature no
Ext Option in/3haxcccc-1.nn*.* relkey.txt
Created fileskey.idprogram.id
My system/system_nkey.idprogram.idkeystr.txt/syspar
*.cfg
Inserted key stringsare saved in keystr.txt
S ystem Pack fromRobotWare CD-ROM
External option fromdisk or CD-ROM
RobotWare keystrings define the optionsto be included from the S ystem Packthey belong to and Ext opt keystrings defineadded external option packages.All keys must have the same serial number.
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Handling mass memory storage capacity
General In some cases it is very important that there is enough free space in the mass
storage memory, before attempting to download new system software. How to
check its capacity, and if required increase it, is detailed below.
A manual check on the free space can be done in one of the following ways:
Checking storage capacity from the Teach Pendant Unit
1. Press the button Miscellaneous to select Service window.
2. Select Storage Capacity from the System Info menu. The Mass Storage Memory is called hd0a.
Checking storage capacity through connection to the MC/CONSOLE port
1. Connect a console to the MC/CONSOLE outlet on the controller and execute the command dosFsShow.
There should always be at least 25 Mb free disk space on the controller mass storage memory before attempting to download a new system. For information on how to increase storage capacity, see below!
Increasing stor-age capacity
If the capacity of the mass storage memory is less than 25 Mb when a new con-
troller system is to be downloaded, storage memory must be released by removing
old systems from the mass storage memory. This can be done in one of the follow-
ing ways:
1. Boot up on the system you would like to remove and then make a C-START (see section "C-start").
2. Use the FileManager in the Teach Pendant Unit, see User’s Guide - File Manager, for more information on how to use the FileManager.
3. Use a third-party "ftp" client (like FTPVoyager supplied on the Robot-Ware CD).
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Removing systems using the FileManager or FTP-client may be hazardous since the \bin and BootRom.sys directories must be kept intact. Proceed with the utmost care to avoid accidentally removing such files or directo-ries!
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Chapter 5:Calibration
When to calibrate
Types of calibra-tion procedures
Calibrate the measurement system carefully if any of the resolver values has been
changed. This may occur when parts affecting the calibration position have been
replaced on the robot.
Calibrate the system roughly as detailed in section "Updating the revolution
counter" 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 has been moved with the control system disconnected
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Section A: General
How to calibrate the robot system
General This section provides an overview of the procedure required when calibrating the
robot system. Many of the steps in the procedure are detailed in other sections to
which references are given.
Procedure
Step Action Note/Illustration
1. Check that all required hardware is available for calibrating the robot.
Required hardware is specified in the calibrating procedures for each axis.
2. Check the correct orientation of axis 4. Incorrect orientation of the axis may cause damage on cabling!
Detailed in "Correct orientation of axes".
3. Manually, run the robot axes to a posi-tion close to the correct calibration position.
Use the calibration scales or dis-tances to locate this position, detailed in "Correct orientation of axes".
4. Start the calibration procedure on the TPU.
Detailed in "Fine calibration pro-cedure on TPU".
5. Calibrate each axis. Detailed in "Fine calibration, all axes".
6. Verify that the calibration was suc-cessfully carried out.
Detailed in "Post calibration pro-cedure".
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Additional information
In addition to the basic calibration procedure detailed above, a number of calibra-
tion related actions may be performed:
Action Detailed in section:
How to update the robot revolution counter without performing a complete calibration.
Updating the revolution counter
How to manually check the current calibration position.
Checking the calibration position
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Calibration tool kit, contents
Calibration tool kit, 3HAC xxxxx-x
The calibration tool kit, 3HAC xxxxx-x, can be ordered from ABB Automation
Technologies AB, Robotics.
The kit contains:
• Digital indicator
• Magnetic stand
• Calibration tool for actuator
• Calibration tool for wrist
• Tool case
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Section B: Preliminaries
Correct orientation of axes
General This section details the correct orientation of all axes.
The orientation of axis 4 must be especially checked and corrected if necessary
before performing any calibration!
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Index marks The figure below shows the index marks of axes 4-5-6 and the correct position of
the spiral cable. It also shows the calibration distance on axes 1-2-3.
xx0200000341
A Axis 4 (center tube) E Index marks for axis 5
B Spiral cable inspection cover F Index marks for axis 6
C Correct orientation of the spiral cable (and axis 4)
G Calibration distance for axes 1-2-3: 26 mm on each axis
D Index marks for axis 4
B
A
C
D
E F
G
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Correct position of axes 1-2-3
The axes 1-2-3 should be positioned with an approximate distance of 26 mm
between the actuator and the calibration spacer above the lower joint, shown in
figure above. This distance is set exactly during the fine calibration procedure.
Correct orienta-tion of axis 4
The procedure below details how to check and eventually correct the orientation
of axis 4.
Axis 4 has no mechanical limitation! Cabling inside the manipulator may be dam-aged if axis 4 is oriented incorrectly when performing calibration of the robot!
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 person-nel who are aware of the risks that this entails.
Step Action Note
1. Remove the spiral cable inspection cover on the center tube sleeve by removing its 4 attachment screws.
Shown in figure above!
2. Make a visual check of the numbers, marked on the spiral cable.
The numbers 4-3-2-1 must be positioned in a straight line, as shown in figure above!
In case the index marks are not present: make sure that the normal vector of the face of the gearbox, axis 5, is pointing in approxi-mate (+ / - a couple of degrees) +Y direction!
Directions detailed in part “Directions for all axes”.
3. In case correction is necessary, turn axis 4 with the TPU into the approximate calibration position by positioning the numbers into a straight line!
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Correct orienta-tion of axes 5-6
The procedure below details the correct orientation of axes 5-6.
4. Refit the spiral cable inspection cover with the 4 attachment screws!
Step Action Note
Step Action Note/Illustration
1. Make sure that the index marks of axis 5 are roughly aligned.
In case the index marks are not present: make sure that the normal vector of the face of the tool flange is pointing approximately (+ / - a couple of degrees) in the +Z direction (positive)!
Location shown in figure above!
Directions detailed in part “Directions for all axes”.
2. Make sure that the index marks of axis 6 are roughly aligned.In case the index marks are not present: make sure that the hole for the guide pin in the tool flange is pointing approximately (+ / - a couple of degrees) in the -X direction (neg-ative)!
Location shown in figure above! Directions detailed in part “Directions for all axes”.
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Checking the calibration position
General Check the calibration position before beginning any programming of the robot
system. This may be done as detailed below.
Using the Jog-ging window on the teach pendant Step Action Note/Illustration
1. Open the Jogging window.
xx0100000195
2. Choose running axis-by-axis.
xx0100000196
3. Check that the positions of axes 1-2-3 are reached and that the calibration marks on axes 4-5-6 are aligned correctly. If they are not, update the revolution counters as detailed in "Update the revolution counter".
Calibration positions and marks for each axis are shown in section "Correct orientation of axes".
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Updating the revolution counter
Manually running the manipulator to the sync posi-tion
This section details the first step when updating the revolution counter; manually
running the manipulator to the synchronization position.
Axis 4 has no mechanical limitation! Cabling inside manipulator may be damaged
if axis 4 is oriented incorrectly when performing calibration of the robot!the
Storing the revo-lution counter setting
This section details the second step when updating the revolution counter; storing
the revolution counter settings.
If a revolution counter is incorrectly updated, it will cause incorrect robot position-ing, which in turn may cause damage or injury!
Step Action Illustration
1. Select axis-by-axis motion mode
2. Press the enabling device on the teach pen-dant and, using the joystick, move the robot manually so that the calibration marks or dis-tances lie within the tolerance zone.
Calibration marks shown in section "Correct orien-tation of axes".
3. Note that axis 6 does not have any mechani-cal stop and can thus be calibrated at the wrong faceplate revolution. Do not operate axis 6 manually before the robot has been calibrated.
4. When all axes have been positioned as above, store the revolution counter settings using the Teach Pendant Unit as detailed below:
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Step Action 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 Calibration window appears.
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.
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6. Press OK when all axes that are to be updated are marked with an x.
CANCEL returns to the Cali-bration window.
7. Press OK again to confirm and start the update.CANCEL returns to the Rev-olution Counter Update win-dow.
8. At this point, it is recom-mended that the revolution counter values are saved to a diskette.
Not required.
9. Recheck the calibration posi-tion as described in "Check-ing the calibration position".
Step Action Illustration
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Fine calibration procedure on TPU
General The section below details how to use the Teach Pendant Unit (TPU) when per-
forming a fine-calibration of the robot.
Procedure
Step Action Note/Illustration
1. Press the button "Miscella-neous".
xx0100000194
2. Select the Service window by pressing ENTER.
xx0100000200
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3. Choose Calibration from the View menu. The Calibration window appears.
xx0100000201
Explanation of status: • Synchronized: all axes are cali-
brated 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 described in "Updating the revolution counter".
• Not calibrated: one (or more) of the axis is NOT fine-calibrated. This axis, or these axes, must therefore be fine-calibrated as described in "Fine calibration".
4. Select the desired unit and choose Fine Calibrate from the Calib menu. A Warning window appears.
xx0100000203
Step Action Note/Illustration
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5. Move the manipulator to its calibration position and press OK. The Fine Cali-brate window appears.
Calibration positions for the manipulator detailed in "Checking the calibration posi-tion".
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 Cali-bration 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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Section C: Calibration
Directions for all axes
Calibration move-ment directions
The figure below shows the positive and negative directions for each axis.
xx0200000355
1
2
3
4
5
6
+
- +
++
+
+
-
-
---
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Jogging directions
The figure below shows the linear directions when jogging the robot.
xx0200000378
+Y +X
+Z +Z
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Fine calibration, all axes
Introduction This section details how to calibrate the complete robot, using calibration tools.
The section is divided into the following parts:
• Before calibration
• Required equipment
• Calibration order
• Calibration, axes 1, 2 and 3
• Calibration, axis 5
• Calibration, axis 6
• Calibration, axis 4
Before calibration Before calibrating the robot, make sure that the requirements in the previous sec-
tions "General" and "Preliminaries" are met!
Required equip-ment
Calibration order The order of calibration of the axes 1, 2 and 3 is of no importance, but the remain-
ing axes must be calibrated in the following sequence: 5 - 6 - 4.
Equipment, etc. Art. no. Note
Calibration tool kit - Contains tools for calibration of complete robot. May be ordered from ABB Automa-tion Technologies AB, Robotics.
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Calibration axis 1, 2 and 3
The procedure below details how to calibrate axis 1, but it is the same for axes 2
and 3. Calibrate one axis at a time and then repeat the procedure for the remaining
axes.
Step Action Note/Illustration
1. Turn the operating mode selector to MAN-UAL MODE AT REDUCED SPEED.
2. Operate current axis (axis 1, 2 or 3) in man-ual mode with the joystick until only 40-50 mm of the movable part of the actuator is visible.
3. Insert the gauge block between the plat-form and the actuator cover (see adjacent figure) and then gently contract the actua-tor until the gauge block fits exactly but is not jammed.Note! All three actuators should have approximately the same length when one of them is calibrated.
xx0200000351
• A: 26 mm
4. Update only the current axis (axis 1, 2 or 3) as detailed in "Fine calibration procedure on TPU".
5. Remove the calibration tools.
A
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Calibration, axis 5 The procedure below details how to calibrate axis 5.
Step Action Note/Illustration
1. Put a dial gauge (mounted on a sup-port positioned on a flat surface external to the robot) against the edge of the tool flange as shown in the adjacent figure. The purpose of this procedure is to adjust axis 5 so that it is possible to rotate axis 4 without reading any off-set on the indicator.
xx0200000352
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2. Lock all other axes when jogging axis 4.
• Rotate axis 4 in joint +180 degrees.
• Rotate axis 5 to compensate for half the value read on the indicator (i.e. the indicator shows 0.58 mm, move axis 5 gently until the indicator shows 0.29).
• Rotate axis 4 -180 degrees (=back to the starting posi-tion, 0 degrees).
• Repeat until it is possible to rotate axis 4 180 degrees without reading any error on the gauge. Normally, it requires 2-4 attempts.
3. Update only axis 5, as detailed in "Fine calibration procedure on TPU".
4. Remove the calibration tools.
Step Action Note/Illustration
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Calibration axis 6 The procedure below details how to calibrate axis 6.
Step Action Note/Illustration
1. Run the following axis to the specified position:
• Axis 5: -90 degrees.
2. Fit the wrist calibration tool at the tool flange and put a dial gauge (mounted on as support positioned on a flat sur-face external to the robot) against the edge of the tool, see the adjacent fig-ure.
xx0200000353
3. Lock all other linear directions except for Z.
Directions shown in “Directions for all axes”.
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Calibration, axis 4 The procedure below details how to calibrate axis 4.
4. Move the robot in +/-Z (in base) and adjust axis 6 until the indicator shows minimum change (usually a few hun-dredths of a millimeter) while travel-ling from the middle of the tool to one end (i.e. if the indicator shows 0.46 mm while travelling from the center of the tool to one end of the tool, rotate axis 6 by 0.46 mm).
Directions shown in “Directions for all axes”.
5. Update only axis 6, as detailed in "Fine calibration procedure on TPU".
6. Remove the calibration tools.
Step Action Note/Illustration
Step Action Note/Illustration
1. Run the following axes to the specified positions:
• Axis 5: -90 degrees.
• Axis 6: +90 degrees.
• Axis 4: 0 degrees.
2. Put a dial gauge (mounted on a support positioned on a flat surface external to the robot) against the ground face of the tool, see the adja-cent figure.
xx0200000354
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3. Lock all other linear direc-tions except for Y.
Directions shown in “Directions for all axes”.
4. Move the robot in +/-Y (in base) and adjust axis 4 until the indicator shows mini-mum change (usually a few hundredths of a millimeter) while travelling from the mid-dle of the tool to one end (i.e. if the indicator shows 0.52 mm while travelling from the center of the tool to one end of the tool, rotate axis 4 by 0.52 mm).
Directions shown in “Directions for all axes”.
5. Update only axis 4, as detailed in "Fine calibration procedure on TPU".
6. Remove the calibration tools.
Step Action Note/Illustration
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Section D: After calibration
Post calibration procedure
General Perform the following procedure after calibrating any manipulator axes. The pro-
cedure is intended to verify that all calibration positions are correct.
Procedure
Step Action Illustration
1. Run the calibration home position program twice.
Do not change the position of the manipulator axes after running the program!
Detailed in "Checking the calibration position".
2. Check all calibration positions. Detailed in "Checking the calibration position".
3. Repeat the check as above.
4. Adjust the calibration marks when the calibra-tion is done.
Shown in section "Cor-rect orientation of axes".
5. The system parameters will be saved to the storage memory at power off.
6. Remove any calibration equipment from the manipulator.
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Index
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Repair ManualIndustrial Robot IRB 940 Tricept™3HAC 16640-1 / M2000 / Rev. -
IRB 940 Tricept™
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ABB Automation Technology Products ABRoboticsS-721 68 VÄSTERÅSSWEDENTelephone: +46 (0) 21 344000Telefax: +46 (0) 21 132592
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Repair Manual, IRB 940 Tricept™ 3HAC 16640-1
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The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no re-sponsibility for any errors that may appear in this manual.
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 permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
©Copyright 2002 ABB All rights reserved.
ABB Automation Technology Products ABRobotics
SE-721 68 VästeråsSweden
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Table of Contents
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Overview 1 Product Documentation, IRB 940 Tricept™ 3
Chapter 1: Safety, service 5
Introduction 5Safety, service - General 6
Section A: References 7Limitation of Liability 7Applicable Safety Standards 7Related information 8
Section B: Safety risks 9Safety risks related to end effector 9Safety risks related to tools/workpieces 9Safety risks related to pneumatic/hydraulic systems 9Safety risks during operational disturbances 10Safety risks during installation and service 10Risks associated with live electric parts 11
Section C: Safety actions 13Safety fence dimensions 13Fire extinguishing 13Emergency release of the manipulator's arm 14Brake testing 14Risk of disabling function "Reduced speed 250 mm/s" 15Safe use of the Teach Pendant Unit 15Work inside the manipulators working range 15
Chapter 2: Reference Information 17
Introduction 17Screw joints 18Weight specifications 20
Chapter 3: Manipulator 21
Introduction 21
Section A: Manipulator repairs 22Removal of actuator, including motor 22Refitting of actuator, including motor 27Removal of servomotor, axes 1-3 34Refitting of servomotor, axes 1-3 38Removal of servomotor, axis 4 43
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Refitting of servomotor, axis 4 49Removal of lower joint 55Refitting of lower joint 58Removal of wrist 62Refitting of wrist 67Removal of center unit 72Refitting of center unit 77Removal of spiral cable 82Refitting of spiral cable 85
Section B: Distribution box repairs 89Replacement of battery, distribution box 89Replacement of serial measurement card, distribution box 92Replacement of brake release card, distribution box 95
Chapter 4: Controller 99
Introduction 99Putting the computer unit in the service position 100Replacement of air filter, controller 103Replacement of battery unit, controller 106Replacement of I/O and gateway units 109Replacement of bleeder resistor 113Replacement of mass storage memory 116Replacement of internal cooling fan 120Replacement of drive units and rectifier 125Replacement of system fan unit 129Replacement of power supply unit 132
Chapter 5: Circuit Diagram, IRB 940 Tricept™ 135
Introduction 135=M1/2, Potentials from control 136=M1/3, Axis 1 137=M1/4, Axis 2 138=M1/5, Axis 3 139=M1/6, Axis 4 140=M1/7, Axis 5 141=M1/8, Axis 6 142=M1/9, Serial Measure board, Earth connections 143=M/10, Brake release unit 144
144
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Chapter 6: Circuit Diagram, S4Cplus 145
Introduction 145
System 1: General information 146Sheet 1-1. Block Diagram 146Sheet 1-2. View of Control Cabinet 147Sheet 1-3. View of Control Cabinet 148Sheet 1-4. Designation 149Sheet 1-5. Designation 150
System 2: Mains Connection and Power Supply 151Sheet 2-1. Mains Connection 151Sheet 2-2. Transformer Unit 152Sheet 2-3. Power Supply 153Sheet 2-4. Power Supply 154Sheet 2-5. External transformer unit 200-500V IRB6600/7600 155Sheet 2-6. Transformer unit 400-475V IRB 6600/7600 156
System 3: Computer Unit and Connector Unit 157Sheet 3-1. Block Diagram/Computer Unit 157Sheet 3-2. Cabling in Computer Unit 158Sheet 3-3. Main Computer and Hard Disk / Flash Disk Drive 159Sheet 3-4. Compute Cooling 160Sheet 3-5. Base Connector Board and I/O Computer 161Sheet 3-6. Connector Board and I/O Computer 162Sheet 3-7. Connector Board and Axis Computer 163Sheet 3-8. Base Connector Unit 164Sheet 3-9. Connector Plate on Controller Panel 165
System 4: Emergency Stops and Run Chain 166Sheet 4-1. Emergency Stop 166Sheet 4-2. Run Chain 167Sheet 4-3. Run Chain 168Sheet 4-4. Power Unit Servo Disconnector 169
System 5: Drive System and Robot Cable 170Sheet 5-1. Block Diagram 170Sheet 5-2. Rectifier, Fans and Bleeder 171Sheet 5-3. Drive System Signal Connection 2 Drive Units 172Sheet 5-4. Drive System Signal Connection 3 Drive Units 173Sheet 5-5. Servo Drive Units / IRB 140 174Sheet 5-6. Servo Drive Units / IRB 340 175Sheet 5-7. Servo Drive Units / IRB 640, 840 176Sheet 5-8. Servo Drive Units / IRB 1400, 2400 177
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Sheet 5-9. Servo Drive Units / IRB 4400, 6400S/PE 178Sheet 5-10. Servo Drive Units / IRB 6400R 179Sheet 5-11. Control Cable IRB 140 180Sheet 5-12. Control Cable IRB 340, 1400 and 2400 181Sheet 5-13. Control Cable IRB 640, 840, 4400 and 6400S/PE 182Sheet 5-14. Control Cable IRB 6400R 183Sheet 5-15. Rectifier, fans and bleeder 184Sheet 5-16. Servo Drive System 185Sheet 5-17. Control cable 186
System 6: External axes 187Sheet 6-1. External axes 187Sheet 6-2. Axes Computer 2 and Connector Board 188Sheet 6-3. Expansion Board Axis Connector Board 189Sheet 6-4. Drive System Signal Connection External Axes 190Sheet 6-5. External axes no. 7th - 9th Control Signal Connection 191Sheet 6-6. Axis Computer 2 and Axis Connector Unit if External Axis Cabinet 192Sheet 6-7. Connection to External Axis Cabinet 193Sheet 6-8. Servogun-SMB power/signals cable 194
System 7: I/O Units and Field Bus Modules 195Sheet 7-1. I/O Unit Position 195Sheet 7-2. Digital Part of Combi I/O and Digital I/O Unit Input Part 196Sheet 7-3. Digital I/O Unit Output Part 197Sheet 7-4. Combi I/O Unit Digital and Analogue Output Part 198Sheet 7-5. Digital Input Part of 120V AC I/O Unit 199Sheet 7-6. Digital Output Part of 120V AC I/O Unit 200Sheet 7-7. Relay I/O Unit Input 1-16 201Sheet 7-8. Digital with Relays I/O Output 1-8 202Sheet 7-9. Digital with Relays I/O Output 9-16 203Sheet 7-10. Analogue I/O Unit 204Sheet 7-11. Remote I/O Unit For Allen Bradley PLC 205Sheet 7-12. Interbus-S Master/Slave - Interbus-S Master 206Sheet 7-13. Profibus DP SLave 207Sheet 7-14. Encoder Unit 208Sheet 7-15. Profibus DP Master/Slave 209Sheet 7-16. Interbus master/slave optical fibre and copper wire 210
System 8: Other options 211Sheet 8-1. Floppy Disk 211Sheet 8-2. Service Equipment Supply 212Sheet 8-3. External Connections System Signals 213Sheet 8-4. Position Switches on Manipulator 214
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Sheet 8-5. Customer Signals 215Sheet 8-6. Sustomer Power/SIgnal IRB 2400, 4400, 6400S/PE 216Sheet 8-7. Customer Cable Power/Signal/CAN IRB 6400R 217Sheet 8-8. External Control Panel 218Sheet 8-9. Extension Cable Teach Pendant 219Sheet 8-10. Time Relay 220Sheet 8-11. Customer Precess / Power / Signal / Profibus DP M/S 221Sheet 8-12. Optional customer power/signal Profibus IRB 6400R 222Sheet 8-13. LAN Ethernet connection 223Sheet 8-14. Customer power/CAN-BUS IRB 640/6400S 224Sheet 8-15. Customer cable power/signal CAN-BUS IRB 6600/7600 225Sheet 8-16. Customer cable power/signal Profibus IRB 6600/7600 226Sheet 8-17. Optional customer power/signal Profibus IRB 6400R 227
System 9: External Axis Cabinet 228Sheet 9-1. Block Diagram 228Sheet 9-2. View of External Axis Cabinet 229Sheet 9-3. Designation 230Sheet 9-4. Mains Connection 231Sheet 9-5. Transformer Unit 232Sheet 9-6. Power Supply, I/O Supply 233Sheet 9-7. Power Unit 234Sheet 9-8. Rectifier, Fans and Bleeder 235Sheet 9-9. Drive Unit Signal Connection 1 External Drive Unit 236Sheet 9-10. Drive Unit Signal Connection 2 External Drive Units 237Sheet 9-11. Drive Unit Signal Connection 3 External Drive Units 238Sheet 9-12. Drive Unit and Control Cable Drive Unit GT 239Sheet 9-13. Drive Unit and Control Cable Drive Unit GT+CCB 240Sheet 9-14. Drive Unit and Control Cable 241Sheet 9-15. Service Equipment Supply 242
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Overview
About This Manual
This information product is a manual containing instructions for repairing the
complete robot system, mechanically as well as electrically.
Usage This manual should be used during repair work.
Who Should Read This Manual?
This manual is intended for:
• repair personnel in the user´s organization.
• repair personnel in other organizations.
Prerequisites The reader should...
• be a trained repair craftsman
• have the required knowledge of mechanical repair work OR
• have the required knowledge of electrical repair work.
Organization of Chapters
The manual is organized in the following chapters:
References
Chapter Contents
1. Safety
2. Reference information
3. Manipulator
4. Controller
Reference Document Id
Circuit diagrams, Manipulator Included in Repair Manual, 3HAC 16640-1
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Revisions
Circuit diagrams, Controller Included in Repair Manual, 3HAC 16640-1
Reference Document Id
Revision Description
- First edition
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Product Documentation, IRB 940 Tricept™
General The complete documentation of IRB 940 Tricept™ including controller consists
of several manuals listed below:
Overview, Installation and Commissioning Manual
The Installation and Commissioning Manual contains the following main chap-
ters:
• Safety, Service
• Reference Information
• Unpacking
• On-site Installation
• Electrical connections
• Start-up
• Robot controller
• Installation of controller software
• System directory structure
• Calibration
Overview, Repair Manual
The Repair Manual contains the following main chapters:
• Safety, Service
• Reference Information
• Remove/Refitting instructions for all manipulator details considered spare parts
• Remove/Refitting instructions for all controller cabinet details considered spare parts
• Circuit Diagram for manipulator
• Circuit Diagram for controller cabinet
Overview, Maintenance Manual
The Maintenance Manual contains the following main chapters:
• Safety, Service
• Reference Information
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• Maintenance schedules
• Maintenance activities
• Disposal
The chapters for the maintenance activities include instructions for all the main-
tenance activities specified in the maintenance schedule.
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Safety, service
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Chapter 1:Safety, service
Introduction
Definitions This chapter details safety information for service personnel i.e. personnel per-
forming installation, repair and maintenance work.
Sections The chapter "Safety, service" is divided into the following sections:
A. References contains lists of:
• Limitation of liability
• applicable safety standards
• referenced documents
B. Safety risks lists dangers relevant when servicing the robot system. The dangers are split into different categories:
• Safety risks related to 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
C. 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
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Safety, service - General
Validity and responsibility
The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment, which can influence the safety
of the total system. To protect personnel, the complete system must be designed
and installed in accordance with the safety requirements set forth in the standards
and regulations of the country where the robot is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable
safety laws and regulations in the country concerned are observed and that the
safety devices necessary to protect people working with the robot system have
been designed and installed correctly. Personnel working with robots must be
familiar with the operation and handling of the industrial robot, described in the
applicable documents, e.g. 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 inter-
face for the connection of external safety devices. Via this interface, an external
safety function can interact with other machines and peripheral equipment. This
means that control signals can act on safety signals received from the peripheral
equipment as well as from the robot.
In the Product Manual - Installation and Commissioning, instructions are pro-
vided for connecting safety devices between the robot and the peripheral equip-
ment.
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Safety, serviceReferences
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Section A: References
Limitation of Liability
General Any information given in this information product regarding safety, must not be
construed as a warranty by ABB Robotics that the industrial robot will not cause
injury or damage even if all safety instructions have been complied with.
Applicable Safety Standards
Standards The robot is designed in accordance with the requirements of:
• EN 292-1, Safety of macheniry, basic terminology
• EN 292-2, Safety of machinery, technical principles/specifications, emer-gency stop
• EN 418, Safety of machinery, emergency stop equipment
• EN 563, Safety of machinery, temperatures of surfaces
• EN 614-1, Safety of machinery, ergonomic design principles
• EN 775, Robot safety
• EN 60204-1, Electrical equipment for industrial machines
• EN 50081-2EMC, Generic emission standard. Part 2: Industrial environ-ment(EN 55011 Class ARadiated emission enclosure)(EN 55011 Class AConducted emission AC Mains)
• EN 61000-6-2EMC, Generic standards - Immunity for Industrial environ-ments(EN 61000-4-2Electrostatic discharge immunity test)(EN 61000-4-3Radiated, radio-frequency, electromagnetic field immunity test)(EN 61000-4-4Electrical fast transient/burst immunity test)(EN 61000-4-5Surge immunity test)(EN 61000-4-6Immunity to conducted disturbances, induced by radio-fre-quency fields)(EN 61000-4-11Voltage dips, short interruptions and voltage variations immunity test)
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Related information
General The list below specifies documents which contain useful information:
Documents
Type of information Detailed in document Section
Installation of safety devices Installation and Commis-sioning Manual
Changing robot modes User’s Guide Start-up
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Safety, serviceSafety risks
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Section B: Safety risks
Safety risks related to end effector
Make sure to prevent an end effector from dropping a workpiece, if such is used.
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.
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, par-ticular care must be taken.
• The pressure in pneumatic and hydraulic systems must be released before starting to repair them.
• Note that the interior of the robot may be pressurized.
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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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 personnel
• 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.
Safety risks during installation and service
General risks dur-ing installation 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, lifting and transport of the
robot system, the regulations applicable in the country concerned and the instruc-
tions of ABB Robotics must be complied with.
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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 or when the motors or other components are removed.
• 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 temperature of the motors or oil spills that can occur on the robot.
To be observed by the supplier of the complete sys-tem
• The supplier of the complete system must ensure that all circuits used in the safety function are interlocked in accordance with the applicable stan-dards for that function.
• The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner, in accor-dance with the applicable standards for the emergency stop function.
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.
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Voltage related risks, controller, S4Cplus
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 external 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. N.B.: 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 process
• The external voltage connected to the control cabinet remains live even when the robot is disconnected from the mains.
• Additional connections
Voltage related risks, manipula-tor, IRB 940 Tri-cept™
A danger of high voltage is associated with the manipulator in:
• The distribution box for the manipulator (up to 430 VDC)
• The power supply for the motors (up to 430 VDC)
• The user connections for tools or other parts of the installation (max. 230V AC, see Product Manual - Installation and Commissioning)
Voltage related risks, tools, mate-rial handling devices, etc.
Tools, material handling devices, etc., may be live even if the robot system is in
the OFF position. Power supply cables which are in motion during the working
process may be damaged.
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Section C: Safety actions
Safety fence dimensions
General Install a safety cell around the robot to ensure safe robot installation and operation.
Dimensioning the fence or enclo-sure
Design the safety cell such that it will:
• - withstand any impact from a tool failure. Due to the high kinetic energy associated with HSM (High Speed Machining), a tool failure poses a seri-ous risk as any debris can cause serious personal injury. Both walls and ceilings must be designed and dimensioned so that they can withstand any projectiles that they may be subjected to. Windows must be made from suitable safety glass. Study the planned process to determine the forces involved and appropriate materials.
• - insulate against sound pollution from the machining process. Typically the safety cell should be able to reduce sound from the machining process down to 75dBA, though individual installations may stipulate other values. Study the planned process to determine the allowable noise pollution lev-els and appropriate sound insulation.
• - isolate gases and mist generated by the machining process and spray mist lubrication. Study the planned process to determine the fumes involved and appropriate ventilation/filtering system.
Fire extinguishing
Use a CARBON DIOXIDE (CO 2 ) extinguisher in the event of a fire in the robot (manipulator or controller)!
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Emergency release of the manipulator’s arm
Description In an emergency situation, any of the manipulator’s axes may be released manu-
ally by pushing the brake release buttons on the distribution box for the manipu-
lator. How to release the brakes is detailed in section "Manually releasing the
brakes" in the Installation Manual.
The manipulator arms may be moved manually when the brakes has been
released.
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!
Brake testing
When to test During operation the holding brakes of each axis motor wear normally. A test may
be performed to determine whether the brake can still perform its function.
How to test The function of each axis’ motor holding brakes may be checked as detailed
below:
1. Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized (max. static load).
2. Switch the motor to the MOTORS OFF position with the Operating mode selector on the controller.
3. Check that the axis maintains its position.
If the manipulator does not change position as the motors are switched off, then the brake function is adequate.
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Risk of disabling function "Reduced speed 250 mm/s"
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.
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.
Work inside the manipulators working range
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 per-sonnel who are aware of the risks that this entails. Also be aware of any danger that may be caused by rotating tools or other devices mounted on the manipulator or inside the cell.
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Chapter 2:Reference Information
Introduction
General This chapter presents generic pieces of information, complementing the more spe-
cific information in the following chapters.
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Screw joints
General This section details how to tighten the various types of screw joints in the manip-
ulator as well as the controller.
The instructions and torque values are valid for screw joints comprising metallic
materials and does not apply to soft or brittle materials.
Any instructions given in the repair, maintenance or installation procedure
description override any value or procedure given here, i.e. these instruction are
only valid for standard type screw joints.
Tightening torque The tightening torque values for different types of screw joint are specified in the
tables below:
Screws with slotted or cross recess head
Screws with hexagon socket head
Dimension Tightening torque (Nm) Class 4.8 "dry"
M2.5 0.25
M3 0.5
M4 1.2
M5 2.5
M6 5.0
Dimension Tightening torque (Nm) Class 8.8 "dry"
Tightening torque (Nm) Class 10.9
Tightening torque (Nm) Class 12.9
M5 6 - -
M6 10 - 17
M8 24 28 40
M10 47 55 70
M12 82 95 120
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M16 200 235 300
Dimension Tightening torque (Nm) Class 8.8 "dry"
Tightening torque (Nm) Class 10.9
Tightening torque (Nm) Class 12.9
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Weight specifications
Definition Within all repair and maintenance instructions, weights of the components han-
dled are sometimes specified. All components exceeding 22 kg (50 lbs) are high-
lighted in this way.
ABB recommends handling all components with a weight exceeding 22 kg using
lifting equipment to avoid inflicting injury.
Example Below is an example of how a weight specification is presented:
The actuator with motor weighs 40 kg! All lifting equipment used must be dimen-sioned accordingly!
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Chapter 3:Manipulator
Introduction
Definitions This chapter details all repair activities recommended for the manipulator, includ-
ing the manipulator´s distribution box.
It is made up of separate units, each detailing a specific repair activity, e.g.
Removal or Refitting of a certain component on the manipulator. Each unit con-
tains all information required to perform the activity, e.g. spare parts numbers,
required special tools and materials.
The chapter is divided into:
• Removal/refitting instructions for all the spare parts on the manipulator
• Replacement instructions for all the spare parts in the manipulators distri-bution box
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Section A: Manipulator repairs
Removal of actuator, including motor
Location The three actuators are located on the manipulator as shown in the figure below.
xx0200000296
A
B
C
D
E
F
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Required equip-ment
xx0200000350
Safety Please read the following notations before the removal.
Please observe the following before commencing any repair work on the manipu-lator:
- Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them!
- Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot!
A Actuator
B Actuator servomotor
C Lower joint
D Actuator fork
E Center tube
F Wrist
Equipment, etc. Spare part no. Art. no. Note
Hook wrench 3 mm pin, shown in figure the below!
- Hook wrench with 3 mm pin
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- When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures.
- Before removing, clean the work area and the components to be removed. - Place the removed components in a clean container.
The actuator with motor weighs 40 kg! All lifting equipment used must be dimen-sioned accordingly!
Preparatory work Follow the instructions below for preparatory work, before commencing to
remove an actuator.
Step Action Note/Illustration
1. Run the actuators to half way in length, and ensure all the actuators are of equal length. This is done in order to allow the actuator to retract when the lower joint is unscrewed.
2. Switch off the power supply.
3. The weight of an actuator is around 40kg (88lb). Before removal, the actuator must therefore be secured using straps, as the center unit will tend to move away from the corner with the removed actuator.
If the manipulator is vertically orientated, it is important to anchor the center tube to the sur-rounding equipment in order to prevent this. For other orientations, try to anticipate the movement and secure accordingly.
Shown in the figure above!
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Removal of actua-tor
The procedure below details how to remove an actuator, including the motor. The
procedure is the same for all actuators. Make sure the preparatory work above is
done before removing an actuator!
Step Action Note/Illustration
1. Remove the eletric cabling from the servo-motor located on the actuator to be removed. Move and secure the cabling so it can not get damaged during removal of the actua-tor.
2. Secure the actuator from above using straps from a hoist or from the forks of a fork lift.
3. Use a heating gun to loosen the thread-locking substance, before unscrewing the lower joint from the lower platform.
4. To release the bottom end of the actuator from the lower platform, unscrew the lower joint using thehook wrench. Make sure the center tube and wrist are anchored as detailed in the preparatory work above!
Shown in the figure above!
Specified above!
5. Unscrew the four attachment screws hold-ing the actuator to the actuator fork.
Shown in the figure above!
6. Gently remove the actuator and lift it safely to a flat surface.
7. Inspect the actuator fork and the thread in the lower platform for damage.
8. If only the actuator is to be replaced, remove the servomotor as detailed below.
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Removal of motor The procedure below details how to remove the motor from a dismounted actua-
tor.
Step Action Note/Illustration
1. Unscrew the four fixing screws that hold the servomotor to the actuator housing.
xx0200000302
• A: Servomotor
• B: Fixing screws (4 pcs)
• C: Toothed wheel ring
• D: Backlash-free coupling
2. Remove the servomotor from the actuator.
3. If the toothed wheel ring stays with the backlash-free coupling attached to the actuator (shown in the figure above), detach it and fit it to the coupling on the servomotor.
4. Remove the coupling from the actuator shaft.
A
B
CD
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Refitting of actuator, including motor
Location The actuators are located as shown in the figure below.
xx0200000296
A Actuator
B Actuator servomotor
A
B
C
D
E
F
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Required equip-ment
xx0200000350
Safety Please read the following notations before refitting.
Please observe the following before commencing any repair work on the manipu-lator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them!
C Lower joint
D Actuator fork
E Center tube
F Wrist
Equipment, etc. Spare part no. Art. no. Note
Actuator with motor 3HAC 17151-1
Thread-locking sub-stance
e.g. Loctite 242. Used when securing the lower joint to the lower platform.
Hook wrench 3 mm pin
- Hook wrench with 3 mm pin
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- Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! - When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures.
Please observe the following when refitting components: - Carefully clean the mating surfaces.
- Ensure that there are no damaged surfaces or other parts that need rectifying or replacing.
- Replace all gaskets.
The actuator with motor weighs 40 kg! All lifting equipment used must be dimen-sioned accordingly!
Refitting of motor In case the servomotor has been removed from the actuator, refit it as detailed in
procedure below.
Step Action Note/Illustration
1. Fit the backlash-free coupling onto the new actuator. Make sure the shaft lies flush with the coupling surface, as shown in figure to the right.
xx0200000303
• A: Actuator shaft
• B: 0mm
B
A
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Refitting of actua-tor
The procedure below details how to refit the actuator, including the motor. The
procedure is the same for all actuators.
2. Assemble the servomotor, back-lash-free coupling and the actu-ator. Tighten the fixing screws of the motor.
4 pcs; tightening torque: 24 Nm.
xx0200000302
• A: Servomotor
• B: Fixing screws (4 pcs)
• C: Toothed wheel ring
• D: Backlash-free coupling
Step Action Note/Illustration
A
B
CD
Step Action Note/Illustration
1. Refit the motor, in case it has been removed, as detailed above.
2. Place the actuator in the actuator fork by lifting it with a hoist.
Shown in the figure above!
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3. Push the actuator to the left so that it is flush with the left hand side of the fork, as shown with the arrow in figure to the right. The direction is the same for all three actuators.
xx0200000304
• A: Clamp
• B: Circlip
4. Adjust the circlip so that the actua-tor remains tight against the left hand side.
5. Fit the clamps and tighten the four hexagonal screws that hold the clamps.
4 pcs; tightening torque: 10 Nm.
6. Fit the sealing caps onto either side of the actuator fork as shown in figure to the right.
xx0200000305
• A: Sealing cap
Step Action Note/Illustration
A
B
A
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Commissioning Follow the instructions below before commissioning after refitting an actuator.
When performing the first test run after a service activity (repair, installation or maintenance), it is vital that:
- all normal safety equipment is installed properly, e.g. TPU enabling device.
7. Refit the actuator by screwing the lower joint to the lower platform. Use normal thread-locking fluid.
Note that, as each turn of the lower joint will alter the length of the actuator by 10 mm, the actuator will be extended around 150 mm as the universal joint is screwed in.
Shown in the figure above!
8. Attach the supplied labels to the actuator and motor; the warning label close to the actuator fork and the appropriate axis label on the housing of the actuator.
9. Reconnect the cables to the servo-motor.
Step Action Note/Illustration
Step Action Note/Illustration
1. Check the manipulator and its surrounding equipment to ensure that all screws, nuts and bolts are tightened and that no foreign objects remain within the workspace.
2. Recalibrate the robot. Failure to calibrate the robot will seriously affect the performance and can, in the worst case, cause damage to equipment.
Detailed in Installation Manual.
3. When the spare part replacements have been completed, ensure that the machine data folder is updated, specifying all details such as what has been replaced and when, part serial numbers and other related component data.
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- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind any safety fences, etc. - special attention is paid to the function of the part previously serviced.
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Removal of servomotor, axes 1-3
Location The servomotors of axes 1, 2 and 3 are located on top of the actuators, as shown
in the figure below.
xx0200000297
A Servomotors, axes 1-3
A A
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Required equip-ment
Safety Please read the following notations before the removal.
Please observe the following before commencing any repair work on the manipu-lator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them!- Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! - When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures.
- Before removing, clean the work area and the components to be removed. - Place the removed components in a clean container.
Preparatory work Follow the instructions below for preparatory work, before commencing the
removal of a motor.
Equipment, etc. Spare part no. Art. no. Note
Circuit Diagram 3HAC 16640-1 Repair Manual, part 2
Step Action Note/Illustration
1. Support the wrist before disconnecting the servo-motor from the actuator, in order to keep the lower platform stable and reduce the risk of injury and/or damage.
2. Switch off the power supply.
3. The weight of an actuator servomotor is around 14kg (31lb). The actuator may therefore need to be secured using straps before being removed.
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Removal The procedure below details how to remove the servomotor, axes 1, 2 and 3.
4. The actuator is free to turn when the servomotor is removed. If not correctly supported, the center unit will tend to move away from the corner with the removed actuator servomotor. In a vertically orien-tated manipulator, it is important to anchor the cen-ter tube to the surrounding equipment in order to prevent this. For manipulators in other orientations, try to antic-ipate the movement and secure accordingly.
Step Action Note/Illustration
Step Action Note/Illustration
1. Remove the eletric cabling from the servomotor. Move and secure the cabling so that it can not get damaged dur-ing the removal of the actuator.
2. Unscrew the four fixing screws that hold the servomotor to the actuator housing, as shown in the figure below.
3. Lift the servomotor straight up from the actuator.
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4. If the toothed wheel ring stays with the backlash-free coupling attached to the servomotor, detach it and fit it to the coupling on the actuator.
xx0200000302
• A: Servomotor
• B: Fixing screws (4 pcs)
• C: Toothed wheel ring
• D: Backlash-free coupling on servomotor shaft
5. Remove the coupling from the servomotor shaft.
Step Action Note/Illustration
A
B
CD
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Refitting of servomotor, axes 1-3
Location The servomotors of axes 1, 2 and 3 are located on top of the actuators, as shown
in the figure below.
xx0200000297
A Servomotors, axes 1-3
A A
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Required equip-ment
Safety Please read the following notations before the refitting.
Please observe the following before commencing any repair work on the manipu-lator:
- Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them!
- Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot!
- When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures.
Please observe the following when refitting components: - Carefully clean the mating surfaces. - Ensure that there are no damaged surfaces or other parts that need rectifying or replacing. - Replace all gaskets.
Refitting The procedure below details how to refit the servomotor, axes 1-3.
Equipment, etc. Spare part no. Art. no. Note
Servomotor, axes 1-3
3HAC 17152-1
Circuit Diagram 3HAC 16640-1 Repair Manual, part 2
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Step Action Note/Illustration
1. Fit the backlash-free coupling onto the new servomotor, ensuring that the shaft enters the coupling to a depth of 10 mm, as shown in figure to the right.
Spare part no. specified above!
xx0200000308
• A: 10 ±0.5 mm
A
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2. Assemble the servomotor, backlash-free coupling and the actuator. Tighten the fixing screws. Note! The brake performance is reduced if the servomotor shaft is pushed in too far into the actuator. Make sure there is a lash. Measure the dis-tance between the coupling and the contact surface, according to the figure to the right.
4 pcs; tightening torque: 24Nm.
xx0200000302
• A: Servomotor
• B: Fixing screws (4 pcs)
• C: Toothed wheel ring
• D: Backlash-free coupling on the servomotor shaft
xx0200000447
• A: Coupling on actuator shaft
• B: Coupling on servomotor shaft
• 79 mm, required distance between coupling and contact surface on actuator.
• 51 mm, required distance between coupling and contact surface on servomotor.
3. Reconnect the cables to the servomotor.
Step Action Note/Illustration
A
B
CD
79 51
A B
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Commissioning Follow the instructions below before commissioning after refitting motor on axes
1, 2 and 3.
When performing the first test run after a service activity (repair, installation or maintenance), it is vital that:
- all normal safety equipment is installed properly, e.g. TPU enabling device. - all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind any safety fences, etc. - special attention is paid to the function of the part previously serviced.
Step Action Note/Illustration
1. Check the manipulator and its surrounding equipment to ensure that all screws, nuts and bolts are tightened and that no foreign objects remain within the workspace.
2. Recalibrate the robot. Failure to calibrate the robot will seriously affect the performance and can, in the worst case, cause damage to equipment.
Detailed in Installation Manual.
3. When the spare part replacements have been completed, ensure that the machine data folder is updated, specifying all details such as what has been replaced and when, part serial numbers and other related component data.
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Removal of servomotor, axis 4
Location The motor unit of axis 4 is located inside the center tube sleeve, at the lower part
of the center unit, as shown in the figure below.
xx0200000299
A Axis 4 motor unit (located beneath center tube sleeve)
B Center tube sleeve
C Spiral cable inspection cover
D Gimbal
E Lower platform
B
D
C
E
A
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Required equip-ment
Safety Please read the following notations before the removal.
Please observe the following before commencing any repair work on the manipu-lator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them!- Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! - When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures.
- Before removing, clean the work area and the components to be removed. - Place the removed components in a clean container.
The center unit is very heavy and in a vertically orientated robot, there is a risk of pinching between the center tube and the axis 4 motor.
Equipment, etc. Spare part no. Art. no. Note
Lifting bracket
String Attach to the cabling to be able to feed it through the center tube while lifting.
Circuit Diagram 3HAC 16640-1 Repair Manual, part 2
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Preparatory work Follow the instructions below for preparatory work, before commencing the
removal of the motor unit on axis 4.
Removal The procedure below details how to remove the motor unit on axis 4. Make sure
the preparatory work above is done before removing the actuator!
Step Action Note/Illustration
1. Run the actuators so that they are extended to around 500 mm in length. All actuators should have equal length. This is done in order to allow enough space between the center tube sleeve and the center tube.
2. Position axes 4, 5 and 6 at 0°respectively.
3. Switch off the power supply.
Step Action Note/Illustration
1. Cut the straps and disconnect the cabling to axes 4, 5 and 6, at the top of the center tube. Also remove the cable guide for the cabling.
2. Remove the top plate of the center tube. The cabling underneath the lid is still attached! Remove the lid carefully!
See the figure below!
3. Note the position of each connector and remove the cable connector hold-ers from the lid. Attach a string to the cabling in order not to drop it into the center tube when lifting.
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4. Remove the housing and the lower plate, exercising care with the cables inside the housing. See figure to the right for layout.
xx0200000306
• A: Top plate of center tube
• B: Cable connector holder
• C: Housing
• D: Lower plate
• E: Center tube
5. Fit the lifting tool to the center tube, ensuring that the cables can pass through the loop freely and not get caught.
6. Remove the spiral cable cover on the back of center tube sleeve. Remove also the spiral cable inspection cover.
Step Action Note/Illustration
ABC
D
E
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7. Unscrew the 18 screws that hold the center tube to the axis 4 motor and remove the locating pin, center tube.
xx0200000363
• A: 6 pcs: M8.
• B: 12 pcs: M6.
• C: Locating pin, center tube
• D: Locating pin, center tube sleeve
On reassembly the same locat-ing pin is refitted!
8. Lift the center tube, using a hoist or lift, until the bottom of the center tube almost reaches the gimbal. When lifting the center tube, be very careful not to stretch or squash the cables inside. Eliminate the risk of stretching the cabling by feeding it through at the top at the same rate as the center tube is lifted, with the help of a string.
Shown in the figure above!
9. Remove the cable clamp that holds the spiral cable in place.
Step Action Note/Illustration
C
D
A
B
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10. Remove the 12 screws that hold the center tube sleeve to the lower plat-form interface.
Remove the locating pin that positions the center tube sleeve.
Shown in the figure above! On reassembly the same locat-ing pin is refitted!
11. Lift the center tube sleeve, tilting the wrist slightly for increased accessibil-ity.
xx0200000307
• A: center tube sleeve
• B: Spacer
• C: Axis 4 motor unit
12. Make a note of the position of the motor unit.
13. Remove the spacer from the axis 4 motor unit.
14. Unscrew the 8 screws that attach the motor unit to the center shaft and remove the motor unit.
15. Check all surfaces to make sure they are free from damage and contamina-tion before proceeding with the assembly routine.
Step Action Note/Illustration
AB
C
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Refitting of servomotor, axis 4
Location The motor unit of axis 4 is located inside the center tube sleeve, at the lower part
of the center unit, as shown in the figure below.
xx0200000299
A Axis 4 motor unit (located inside the center tube sleeve)
B Center tube sleeve
C Spiral cable inspection cover
D Gimbal
E Lower platform
B
D
C
E
A
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Required equip-ment
Safety Please read the following notations before refitting.
Please observe the following before commencing any repair work on the manipu-lator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them!- Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! - When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures.
Please observe the following when refitting components: - Carefully clean the mating surfaces.
- Ensure that there are no damaged surfaces or other parts that need rectifying or replacing.
- Replace all gaskets.
Refitting The procedure below details how to refit the motor unit, axis 4.
Equipment, etc. Spare part no. Art. no. Note
Servomotor, axis 4 3HAC 17153-1
Lifting bracket
Circuit Diagram 3HAC 16640-1 Repair Manual, part 2
Step Action Note/Illustration
1. Fit the axis 4 motor unit to the center shaft and tighten the screws. Ensure it has the same orientation as the old one
8 pcs: tightening torque: 33 Nm.
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2. Fit and align the spacer to the axis 4 motor unit.
xx0200000307
• A: Center tube sleeve
• B: Spacer
• C: Axis 4 motor unit
3. Refit the center tube sleeve, ensuring that the locating pin, center tube sleeve, has the correct orientation. Tighten the 12 screws that hold the sleeve.
Shown in the figure above! 12 pcs; tightening torque: 17Nm. Make sure to refit the correct locating pin!
4. Refit the cable clamp for the spiral cable. Ensure that the spiral cable runs freely 360°in either direction by manually turning the wrist and watching the cable through the inspection hole in the side of the center tube.
5. Align the fixing holes in the axis 4 motor unit to the holes in the center tube sleeve by turning the wrist.
6. Feed the cabling through the center tube (with the help of the string) and lower the center tube carefully in order not to squash the cables.
Step Action Note/Illustration
AB
C
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7. Locate the center tube using the loca-tion pin, center tube, as reference and fit the 18 screws.
xx0200000363
• A: 6 pcs: M8; tightening torque: 40 Nm.
• B: 12 pcs: M6; tighten-ing torque: 17 Nm.
• C: Locating pin, center tube
• D: Locating pin, center tube sleeve
Make sure to refit the correct locating pin!
8. Refit the spiral cable inspection cover and the spiral cable cover, including their sealings.
Shown in the figure above!
9. Remove the lifting tool from the center tube.
Step Action Note/Illustration
C
D
A
B
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10. Refit the lower plate and the housing to the top of the center tube, taking extra care not to squash any cables, or sub-ject them to any undue stress.
xx0200000306
• A: Top plate
• B: Cable connector holder
• C: Housing
• D: Lower plate
• E: Center tube
11. Fit the cable connectors to the top plate, ensuring that the cables are ori-entated the same way as when they were removed.
12. Fit the top plate to the housing. Shown in the figure above!
13. Refit the cable guide for the axes 4, 5 and 6 cabling and reconnect the cabling previously disconnected.
Step Action Note/Illustration
ABC
D
E
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Commissioning Follow the instructions below before commissioning after refitting the motor, axis
4.
When performing the first test run after a service activity (repair, installation or maintenance), it is vital that:
- all normal safety equipment is installed properly, e.g. TPU enabling device. - all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind any safety fences, etc. - special attention is paid to the function of the part previously serviced.
Step Action Note/Illustration
1. Check the manipulator and its surrounding equipment to ensure that all screws, nuts and bolts are tightened and that no foreign objects remain within the workspace.
2. Recalibrate the robot. Failure to calibrate the robot will seriously affect the performance and can, in the worst case, cause damage to equipment.
Detailed in Installation Manual.
3. When the spare part replacements have been completed, ensure that the machine data folder is updated, specifying all details such as what has been replaced and when, part serial numbers and other related component data.
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Removal of lower joint
Location The lower joint is located between the actuator and the lower platform, as shown
in the figure below.
xx0200000298
A Lower joint (beneath the cover)
B Lower platform
C Actuator
D Calibration spacer
A
B
A
C
D
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Required equip-ment
xx0200000350
Safety Please read the following notations before the removal.
Please observe the following before commencing any repair work on the manipu-lator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them!- Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! - When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures.
- Before removing, clean the work area and the components to be removed.
- Place the removed components in a clean container.
Equipment, etc. Spare part no. Art. no. Note
Hook wrench 3 mm pin
- Hook wrench with 3 mm pin
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Preparatory work Follow the instructions below for preparatory work, before commencing the
removal of the lower joint.
Removal The procedure below details how to remove a lower joint. The procedure is the
same for all actuators. Make sure the preparatory work above is done before sep-
arating the parts!
Step Action Note/Illustration
1. Run actuators to half way in length. All the actua-tors should also have an equal length.
This is done in order to allow the actuator to retract when the lower joint is unscrewed.
2. Switch off the power supply.
3. In a vertically orientated manipulator the center unit will tend to move away from the corner with the removed lower joint. It is therefor important to anchor the center tube to the surrounding equip-ment in order to avoid this. For manipulators in other orientations, try to anticipate the movement and secure accordingly.
Step Action Note/Illustration
1. Use a heating gun to loosen the thread-lock-ing substance, before removing the lower joint.
2. Loosen the actuator piston from the lower joint with the hook wrenches. The actuator is top heavy and will tend to swing, once disconnected at the bottom. Ensure that the actuator is well anchored.
Shown in the figure above! Specified above!
3. Loosen the lower joint from the lower platform using a hook wrench, 3 mm pin.
Shown in figure above!
Specified above!
4. Remove the lower joint and the cover.
5. Remove the calibration spacer from the lower joint, in order to refit it onto the new joint!
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Refitting of lower joint
Location The lower joint is located between the actuator and the lower platform, as shown
in the figure below.
xx0200000298
A Lower joint (beneath the cover)
B Lower platform
C Actuator
D Calibration spacer
A
B
A
C
D
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Required equip-ment
xx0200000350
Safety Please read the following notations before refitting.
Please observe the following before commencing any repair work on the manipu-lator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them!- Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! - When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures.
Equipment, etc. Spare part no. Art. no. Note
Lower joint 3HAC 17154-1
Thread-locking sub-stance
e.g. Loctite 242. Used when secur-ing the lower joint to the lower platform.
Hook wrench 3 mm pin
- Hook wrench with 3 mm pin
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Please observe the following when refitting components: - Carefully clean the mating surfaces.
- Ensure that there are no damaged surfaces or other parts that need rectifying or replacing.
- Replace all gaskets.
Refitting The procedure below details how to refit the lower joint. The procedure is the
same for all actuators.
Commissioning Follow the instructions below before commissioning after refitting the lower joint.
Step Action Note/Illustration
1. Fit the calibration spacer and the cover to the new lower joint.
Spare part no. specified above!
2. Fit the lower joint to the actuator, using normal thread-locking fluid.
3. Refit the actuator by screwing the lower joint into the lower platform.
Note that, as each turn of the lower joint will alter the length of the actuator by 10 mm, the actuator will be extended around 150 mm as the uni-versal joint is screwed in.
Step Action Note/Illustration
1. Check the manipulator and its surrounding equipment to ensure that all screws, nuts and bolts are tightened and that no foreign objects remain within the workspace.
2. Recalibrate the robot. Failure to calibrate a robot will seriously affect the performance and can, in the worst-case, cause damage to equipment.
Detailed in Installation Manual.
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When performing the first test run after a service activity (repair, installation or maintenance), it is vital that:
- all normal safety equipment is installed properly, e.g. TPU enabling device. - all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind any safety fences, etc. - special attention is paid to the function of the part previously serviced.
3. When the spare part replacements have been completed, ensure that the machine data folder is updated, specifying all details such as what has been replaced and when, part serial num-bers and other related component data.
Step Action Note/Illustration
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Removal of wrist
Location The wrist is located on the lower platform, as shown in the figure below.
xx0200000300
A Wrist
B Center tube
C Spiral cable inspection cover
D Gimbal
E Center tube sleeve
F Lower platform
A
C
B
F
D
E
A
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Required equip-ment
Safety Please read the following notations before the removal.
Please observe the following before commencing any repair work on the manipu-lator:
- Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them!
- Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot!
- When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures.
- Before removing, clean the work area and the components to be removed. - Place the removed components in a clean container.
The wrist weighs 36 kg! All lifting equipment used must be dimensioned accord-ingly!
Equipment, etc. Spare part no. Art. no. Note
Lifting bracket
Punch tool Used for the crossed roller bearing.
Lifting jack Stroke of at least 100 mm.
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Preparatory work Follow the instructions below for preparatory work, before commencing the
removal of the wrist unit.
Step Action Note/Illustration
1. Run the actuators so that they are extended to around 500 mm in length. All the actuators should have equal length. This is done in order to allow enough space between the centre tube sleeve and the centre tube.
2. Position axes 4, 5 and 6 at 0°respectively.
3. Switch off the power supply.
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Removal The procedure below details how to remove the wrist. Make sure the preparatory
work above is done before removing the wrist!
Step Action Note/Illustration
1. Remove the 6 attachment screws that hold the axis 4 motor unit to the centre tube.
xx0200000363
• A: Attachment screws, axis 4 motor to centre tube: 6 pcs, M8 x 60.
• B: Attachment screws
• C: Locating pin, centre tube
• D: Locating pin, centre tube sleeve
2. Remove the spiral cable cover on the back of centre tube sleeve and the spi-ral cable inspection cover on the same sleeve.
Shown in the figure above!
3. Remove the cable clamp that holds the spiral cable in place.
C
D
A
B
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4. Unscrew 10 of the 12 screws in the wrist flange that hold the wrist to the lower platform. Turn the wrist to access all the screws.Leave one screw at the front and one at the rear of the wrist, but ensure that they are both accessible for removal without having to turn the wrist.
Shown in the figure above!
5. Position the lifting jack underneath the wrist housing, in its extended position, so that it can lower the wrist at least 100 mm without being repositioned.
6. Remove the final two screws.
7. Lower the wrist gently until the screws that attach the centre shaft to the wrist are accessible. If the wrist appears to be stuck, it needs to be pressed out. Use two of the fixing holes for the wrist/lower plat-form joint, that are threaded M8 and lie 180°in relation to each other. Note! Turn the wrist so that these holes are not aligned with the M6 holes in the lower platform, as this will damage the threads and hamper assembly at a later stage. If possible, insert a metal shim to protect the sur-face of the lower platform flange.Insert two M8 bolts, with at least 40 mm of thread, into the holes, and pull the wrist off the lower platform.
xx0200000364
8. Remove the screws and lower the wrist while disconnecting the cabling.
Note! When removing the wrist: make sure it is lowered carefully, following the same orientation when mounted. If tilted, the interface of the wrist and the lower platform may be damaged!
Step Action Note/Illustration
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Refitting of wrist
Location The wrist is located on the lower platform, as shown in the figure below.
xx0200000300
A Wrist
B Center tube
C Spiral cable inspection cover
D Gimbal
E Center tube sleeve
F Lower platform
A
C
B
F
D
E
A
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Required equip-ment
Safety Please read the following notations before refitting.
Please observe the following before commencing any repair work on the manipu-lator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them!- Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! - When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures.
Please observe the following when refitting components: - Carefully clean the mating surfaces.
- Ensure that there are no damaged surfaces or other parts that need rectifying or replacing.
- Replace all gaskets.
The wrist weighs 36 kg! All lifting equipment used must be dimensioned accord-ingly!
Equipment, etc. Spare part no. Art. no. Note
Wrist 3HAC 17155-1
Punch tool Used for the crossed roller bearing.
Lifting jack Stroke of at least 100 mm.
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Refitting The procedure below details how to refit the wrist.
Step Action Note/Illustration
1. Replace the o-ring on the centre shaft with the new one that is included in the spare parts kit. Ensure that the o-ring is lubricated prior to fitment.
xx0200000367
2. Ensure that the jack is correctly posi-tioned underneath the lower platform, and that it is in its lowest position. Place the wrist on the jack.
3. Reconnect the cabling.
4. Elevate the wrist with the jack and guide it so that it fits onto the centre shaft. Ensure that the cabling is guided into the correct position and does not get jammed. Note! Make sure the wrist is elevated in the same direction that the centre tube is pointing, so that the interfaces are not damaged!
5. Attach the centre shaft to the wrist using the 12 screws.
12 pcs; tightening torque: 17 Nm.
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Commissioning Follow the instructions below before commissioning after refitting.
6. Lift the wrist with the jack until it is possi-ble to fasten the attachment screws through the wrist flange into the lower platform. Press the wrist to its topmost position by tightening two of the attach-ment screws, 180°in relation to each other. Check that the bearing runs smoothly by turning the wrist manually.
12 pcs; tightening torque: 10 Nm. Shown in the figure above!
7. Refit the spiral cable clamp and ensure that the spiral cable twists freely through-out the ±360°of the axis 4 rotation.
It must not catch or have any tendency to rub or over-tighten, as this will drastically shorten the life of the cable.
8. Align the holes in the centre tube sleeve with the holes in the axis 4 motor unit by turning the wrist.
Shown in the figure above!
9. Fit the six M8 screws. Tighten them as detailed to the right.
6 pcs: M8; tightening torque: 40 Nm.
10. Refit the spiral cable cover and the spiral cable inspection cover with their seal-ings.
Shown in the figure above!
Step Action Note/Illustration
Step Action Note/Illustration
1. Check the manipulator and its surrounding equipment to ensure that all screws, nuts and bolts are tightened and that no foreign objects remain within the workspace.
2. Recalibrate the robot.
Failure to calibrate the robot will seriously affect the performance and can, in the worst case, cause damage to equipment.
Detailed in Installation Manual.
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When performing the first test run after a service activity (repair, installation or maintenance), it is vital that:
- all normal safety equipment is installed properly, e.g. TPU enabling device. - all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind any safety fences, etc. - special attention is paid to the function of the part previously serviced.
3. When the spare part replacements have been completed, ensure that the machine data folder is updated, specifying all details such as what has been replaced and when, part serial num-bers and other related component data.
Step Action Note/Illustration
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Removal of center unit
Location The center unit includes the center tube, wrist, spiral cable, linear guide and axis
4 motor unit. It is located in the center of the manipulator, as shown in the figure
below. When removed, the housing and the gimble is left mounted on the center
unit, as shown in the figure below.
xx0200000301
A Center unit F Lower joint
B Wrist unit G Upper platform
C Center tube H Gimbal
D Axis 4 motor unit (inside center tube sleeve)
I Linear guide
E Lower platform
B
D
C
G
E
F
H
I
A
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Required equip-ment
xx0200000350
Safety Please read the following notations before the removal.
Please observe the following before commencing any repair work on the manipu-lator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them!- Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! - When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures.
- Before removing, clean the work area and the components to be removed.
- Place the removed components in a clean container.
The center unit weighs over 100 kg! All lifting equipment must be dimensioned accordingly!
Equipment, etc. Spare part no. Art. no. Note
Hook wrench 3 mm pin
- Hook wrench with 3 mm pin
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Preparatory work Follow the instructions below for preparatory work, before commencing the
removal of the center unit.
Removal The procedure below details how to remove the center unit. Make sure the prepa-
ratory work above is done before removal!
Step Action Note/Illustration
1. Run the actuators so that they are extended to around 300 mm in length. All the actuators should have equal length. This is done in order to allow enough space for the center unit to be removed.
2. Position axes 4, 5 and 6 at 0°respectively.
3. Switch off the power supply.
Step Action Note/Illustration
1. Disconnect the cabling running into the center unit, at the top of the center unit.
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2. Secure the center unit with a strap attached to a hoist or lift. Fasten the strap around the body of the center tube just below the upper housing so that it hangs well balanced, in such a way that the center unit will be easy to handle. Note! The center unit weighs over 100 kg and must be secured properly when the gim-bal and actuator joints are dis-connected as the unit will tend to move suddenly as it is top heavy.
xx0200000365
3. Use a heating gun at the lower joint, to loosen the thread-lock-ing substance before removing the joint.
4. Remove the actuators from the lower platform by disconnect-ing the lower joints from the lower platform using the hook wrench. Note! The actuators are top heavy and will turn when released from the lower plat-form. Ensure that they are fas-tened before releasing them after removal.
Shown in the figure above! Specified above!
Step Action Note/Illustration
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5. Remove the center unit from the upper platform by removing the 4 attachment screws, located as shown in the figure to the right.Note! The gimbal weighs approximately 20 kg, be careful when removing the attachment screws!
Shown in the figure above!
xx0200000309
• A: Attachment screws that hold the gimbal to the upper plat-form (4 pcs)
6. Lower the gimbal to the bottom of the run of the linear guides so that it rests securely. Secure it to the center unit so that it does not turn or move suddenly when the center unit is released.
Shown in the figure above!
7. Lower the center unit with the hoist.
Step Action Note/Illustration
A A
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Refitting of center unit
Location The center unit includes the center tube, wrist and axis 4 motor unit. It is located
in the center of the manipulator, as shown in the figure below. When removed, the
housing and the gimble is left mounted on the center unit, as shown in the figure
below.
xx0200000301
A Center unit F Lower joint
B Wrist G Upper platform
C Center tube H Gimbal
D Axis 4 motor unit (inside center tube sleeve)
I Linear guide
E Lower platform
B
D
C
G
E
F
H
I
A
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Required equip-ment
xx0200000350
Safety Please read the following notations before refitting.
Please observe the following before commencing any repair work on the manipu-lator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them!- Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! - When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures.
Equipment, etc. Spare part no. Art. no. Note
Center Unit 3HAC 17156-1
Thread-locking sub-stance
e.g. Loctite 242. Used when securing the lower joint to the lower platform.
Hook wrench 3 mm pin
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Please observe the following when refitting components: - Carefully clean the mating surfaces.
- Ensure that there are no damaged surfaces or other parts that need rectifying or replacing.
- Replace all gaskets.
The center unit weighs over 100 kg! All lifting equipment must be dimensioned accordingly!
Refitting The procedure below details how to refit the center unit.
Step Action Note/Illustration
1. Lift the center unit in posi-tion with the hoist.
2. Insert the four screws that hold the gimbal to the upper platform, but do not tighten them. Just screw them in to the point where it is still pos-sible to move the gimbal in relation to the upper plat-form.
Shown in the figure above!
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3. Push the gimbal to the left (as seen when facing the front of the robot) so that the surfaces of the master lie flush, as shown in the figure to the right.
xx0200000310
• A: center unit
• B: Gimbal
• C: Upper platform
• D: Master
• E: Direction for pushing the gimbal
4. Tighten the 4 screws. 4 pcs; tightening torque: 40 Nm.
5. Refit the actuators by screwing the lower joint of each actuator to the lower platform, with the hook wrench and using normal thread-locking fluid.
Note that, as each turn of the lower joint will alter the length of the actuator by 10 mm, the actuator will be extended around 150 mm as the universal joint is screwed in.
Shown in the figure above!
Step Action Note/Illustration
AB
C
D
E
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Commissioning Follow the instructions below before commissioning after refitting the center unit.
When performing the first test run after a service activity (repair, installation or maintenance), it is vital that: - all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
Step Action Note/Illustration
1. Check the manipulator and its surrounding equipment to ensure that all screws, nuts and bolts are tightened and that no foreign objects remain within the workspace.
2. Recalibrate the robot. Failure to calibrate the robot will seriously affect the performance and can, in the worst case, cause damage to equipment.
Detailed in Installation Manual.
3. When the spare part replacements have been completed, ensure that the machine data folder is updated, specifying all details such as what has been replaced and when, part serial num-bers and other related component data.
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Removal of spiral cable
Location The spiral cable is located inside the center tube, running from the top of the
manipulator to the wrist unit.
xx0200000312
A Spiral cable
B Spiral cable inspection cover
C Wrist unit
B
C
A
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Required equip-ment
Safety Please read the following notations before the removal.
Please observe the following before commencing any repair work on the manipu-lator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them!- Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! - When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures.
- Before removing, clean the work area and the components to be removed.
- Place the removed components in a clean container.
The center unit is very heavy and in a vertically orientated robot, there is a risk of pinching between the center tube and the axis 4 motor.
Equipment, etc. Spare part no. Art. no. Note
Other tools and proce-dures may be required. See references to these procedures in the step-by-step instruc-tions below.
These procedures include references to the tools required.
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Preparatory work Follow the instructions below for preparatory work, before commencing the
removal of the spiral cable.
Removal The procedure below details how to remove the spiral cable. Make sure the pre-
paratory work above is done before removal!
Step Action Note/Illustration
1. Run the actuators so that they are extended to around 500 mm in length. All the actuators should have equal length. This is done in order to allow enough space for the center tube to be removed.
2. Position axes 4, 5 and 6 at 0° respectively.
3. Switch off the power supply.
Step Action Note/Illustration
1. Remove the axis 4 motor unit. Detailed in Removal of ser-vomotor, axis 4.
2. Remove the wrist unit. Detailed in Removal of wrist unit.
3. Remove the cable clamp that holds the spiral cable to the center shaft and remove the spiral cable.
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Refitting of spiral cable
Location The spiral cable is located inside the center tube, running from the top of the
manipulator down to the wrist unit.
xx0200000312
A Spiral cable
B Spiral cable inspection cover
C Wrist unit
B
C
A
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Required equip-ment
Safety Please read the following notations before refitting.
Please observe the following before commencing any repair work on the manipu-lator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them!- Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! - When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures.
Please observe the following when refitting components:
- Carefully clean the mating surfaces. - Ensure that there are no damaged surfaces or other parts that need rectifying or replacing. - Replace all gaskets.
The center unit is very heavy and in a vertically orientated robot, there is a risk of pinching between the center tube and the axis 4 motor.
Equipment, etc. Spare part no. Art. no. Note
Spiral Cable 3HAC 17157-1
Other tools and proce-dures may be required. See references to these procedures in the step-by-step instruc-tions below.
These procedures include references to the tools required.
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Refitting The procedure below details how to refit the spiral cable.
Commissioning Follow the instructions below before commissioning after refitting the spiral cable
and wrist unit.
Step Action Note/Illustration
1. Fit the new spiral cable and refit the cable clamp that holds the spi-ral cable to the centre shaft.
Make sure that the spiral cable is properly attached so that it can not run up and down on the shaft. Press down the spiral cable so that the first bend is tightly secured against the upper surface of the shaft as shown in the figure to the right!
Spare part no. specified above!
xx0200000366
2. Refit the wrist unit. Detailed in Refitting of wrist unit.
3. Refit the axis 4 motor unit. Detailed in Refitting of servomotor, axis 4.
Step Action Note/Illustration
1. Check the manipulator and its surrounding equipment to ensure that all screws, nuts and bolts are tightened and that no foreign objects remain within the workspace.
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When performing the first test run after a service activity (repair, installation or maintenance), it is vital that: - all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
2. Recalibrate the robot. Failure to calibrate the robot will seriously affect the performance and can, in the worst case, cause damage to equipment.
Detailed in Installation Manual.
3. When the spare part replacements have been completed, ensure that the machine data folder is updated, specifying all details such as what has been replaced and when, part serial num-bers and other related component data.
Step Action Note/Illustration
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Section B: Distribution box repairs
Replacement of battery, distribution box
Location The battery is located in the distribution box as shown in the figure below.
xx0200000394
A Serial measurement card
B Battery
A B
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Required equip-ment
Safety Please read the following notations before the replacement.
Please observe the following before commencing any repair work on the controller or units connected to the controller: Turn off all electric power supply to the cabinet! Many components inside the cabinet or inside any external units are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Removal The procedure below details how to remove the battery from the distribution box.
Equipment, etc. Spare part no. Art. no. Note
Battery 4944026-4
Step Action Note/Illustration
1. Note the position of the battery and cable ties. Shown in the figure above!
2. Remove the battery connector connecting the battery to the serial measurement circuit board.
3. Cut the two cable ties and remove the battery. The battery must be disposed of through the appropriate recycling channels.
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Refitting The procedure below details how to refit the battery to the distribution box.
Step Action Note/Illustration
1. Place the new battery on top of the serial measurement card cover.
Part no. specified above!Shown in the figure above!
2. Use cable ties to fix the battery.
3. Connect the electrical connector.
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Replacement of serial measurement card, distribution box
Location The serial measurement card is located in the distribution box as shown in the
figure below.
xx0200000394
A Serial measurement card
B Battery
A B
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Required equip-ment
Safety Please read the following notations before the replacement.
Please observe the following before commencing any repair work on the controller or units connected to the controller: Turn off all electric power supply to the cabinet! Many components inside the cabinet or inside any external units are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Removal The procedure below details how to remove the serial measurement card from the
distribution box.
Equipment, etc. Spare part no. Art. no. Note
Serial Measurement card 3HAC 14505-1
Step Action Note/Illustration
1. Remove the four electrical connectors attached to the serial measurement card.
2. Remove the three screws holding the card and the battery to the enclosure.
3. Remove the serial measurement card together with the battery.
Shown in the figure above!
4. Remove the battery from the card. The battery is refitted on to the new card.
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Refitting The procedure below details how to refit the serial measurement card to the dis-
tribution box.
Step Action Note/Illustration
1. Fit the battery to the new serial measurement card.
Part no. specified above!
Shown in the figure above!
2. Carefully fit the card and the battery in place.
3. Refit the three screws holding the serial mea-surement card and the battery to the enclosure.
4. Refit the four electrical connectors.
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Replacement of brake release card, distribution box
Location The brake release card is located in the distribution box as shown in the figure
below.
xx0200000393
A Brake release card
B Brake release buttons
A B
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Required equip-ment
Safety Please read the following notations before the replacement.
Please observe the following before commencing any repair work on the controller or units connected to the controller: Turn off all electric power supply to the cabinet! Many components inside the cabinet or inside any external units are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Removal The procedure below details how to remove the brake release card from the dis-
tribution box.
Equipment, etc. Spare part no. Art. no. Note
Brake Release card 3HAC 0017-1
Step Action Note/Illustration
1. Remove the three electrical connectors attached to the brake release card.
2. Remove the four screws holding the card to the enclosure.
3. Remove the brake release card. Shown in the figure above!
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Refitting The procedure below details how to refit the brake release card to the distribution
box.
Step Action Note/Illustration
1. Carefully fit the new brake release card in place.
Part no. specified above!Shown in the figure above!
2. Refit the four screws holding the brake release card to the enclosure.
3. Replace the three electrical connectors.
Note! It is very important that all screening is reconnected correctly in order to achieve maximum performance from the equipment.
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Chapter 4:Controller
Introduction
Definitions This chapter details all repair activities recommended for the controller.
It is made up of separate units, each detailing a specific repair activity, e.g.
Removal or Refitting of a certain component in the controller. Each unit contains
all information required to perform the activity, e.g. spare parts numbers, required
special tools and materials.
The chapter is divided into:
• Removal instructions for all components
• Refitting instructions for all components
• Remaining instructions
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Putting the computer unit in the service position
Location of com-puter unit
The computer unit is located as shown in the figure below.
xx0200000105
Opening The procedure below details how to open the computer unit.
Please observe the following before commencing any repair work on the manipu-lator: - Motors and gears are HOT after running the robot! Burns may result from touch-
ing the motors or gears!- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! - Take any necessary measures to ensure that the manipulator does not collapse
as parts are removed, e.g. securing the lower arm with fixtures before removing motor, axis 2.
A Computer unit
A
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Step Action Note/Illustration
1. Make sure the ESD-wrist band is worn and connected to ground.
2. Disconnect all connectors/cables and make sure they do not obstruct pulling the computer unit out.
3. Unscrew the transport locks in both corners of the com-puter unit. This is done by turning the screw two turns (see position 1 in the figure) and pushing the lock wash-ers towards the screw (see position 2). xx0200000016
4. Lift the two handles and push them together to release the computer unit (see position 1 in the figure).
xx0200000017
5. Push the locking device on the front of the computer unit to the right (see position 2 in the figure).
See the figure above!
12
1
2
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Closing The procedure below details how to close the computer unit.
Please observe the following before commencing any repair work on the manipu-lator:
- Motors and gears are HOT after running the robot! Burns may result from touch-ing the motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! - Take any necessary measures to ensure that the manipulator does not collapse
as parts are removed, e.g. securing the lower arm with fixtures before removing motor, axis 2.
6. Pull the computer unit out of the cabinet until it locks in its end position. Then swing it to the left as shown in the figure.
xx0200000018
7. If work is to be performed on the computer unit while in the service position, it must be locked in this position. This is done by placing the puck (located on the lower left side) on the metal bar. Alternatively, the computer unit may be lifted straight up and placed on a work bench.
Step Action Note/Illustration
Step Action Note/Illustration
1. Swing the computer unit back into position and secure it.
See the figure above! Also see the procedure above!
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Replacement of air filter, controller
Location of air fil-ter
The air filter is located in the air filter magazine in the front hatch.
xx0200000284
Required equip-ment
A Air filter magazine
A A
Equipment, etc. Spare part no. Art. no. Note
Air filter 3HAB 8028-1
Other tools and proce-dures may be required. See references to these procedures in the step-by-step instruc-tions below.
These proce-dures include ref-erences to the tools required.
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Removal, air filter The procedure below details how to remove the air filter.
Refitting, air filter The procedure below details how to refit the air filter.
Step Action Note/Illustration
1. Open the bottom of the air filter magazine as shown in the figure.
xx0200000001
2. Unlock the lower springs. Lower the magazine and remove.
3. Remove the old filter by releasing the lock shackle and lifting it.
Note! In cases of less contamina-tion, the air filter may be cleaned and refitted. The procedure for this is detailed in section "Clean-ing the air filter, controller" in the Maintenance Manual.
xx0200000003
1
2
Step Action Note/Illustration
1. Fit the air filter in the magazine. Art. no. is specified above!
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2. Fit the spring at the top of the air filter magazine into the cabinet door and push upwards inwards.
Push until the lower springs snap into the cabinet door.
xx0200000006
Step Action Note/Illustration
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Replacement of battery unit, controller
Location of bat-tery unit
The battery unit is located at the bottom of the controller.
xx0200000103
Required equip-ment
A Battery unit
A
Equipment, etc. Spare part no. Art no. Note
Battery unit 3HAC 5393-2 To be replaced as a complete unit
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Removal, battery unit
The procedure below details how to remove the battery unit.
Please observe the following before commencing any repair work on the controller: Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Other tools and proce-dures may be required. See references to these procedures in the step-by-step instruc-tions below.
These proce-dures include ref-erences to the tools required.
Equipment, etc. Spare part no. Art no. Note
Step Action Note/Illustration
1. Remove the battery unit by unscrewing its attachment screws (1).
xx0200000004
2. Pull the battery unit out.
X3
X2
X1
X2 X2 X2
X1 X1 X1
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Refitting, battery unit
The procedure below details how to refit the battery unit.
Please observe the following before commencing any repair work on the controller: Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
3. Disconnect the three cables from the battery unit.
xx0200000005
Step Action Note/Illustration
Step Action Note/Illustration
1. Place the battery unit close to its position. Art. no. specified above! See illustration above!
2. Reconnect the cables and push the unit into position.
See illustration above!
3. Secure it with the attachment screws. See illustration above!
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Replacement of I/O and gateway units
Location of I/O and gateway units
The I/O and gateway units are located as shown in the figure below.
xx0200000009
A I/O and gateway units located beneath the top cover of the cabinet
B Four available slots for I/O and gateway units
A
B
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Required equip-ment
Removal The procedure below details how to remove an I/O or gateway board.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Equipment, etc. Spare part no. Art. no. Note
Digital 24 VDC I/O 3HAB 7229-1 DSQC 328
Analog I/O 3HNE 00554-1 DSQC 355
AD Combi I/O 3HAB 7230-1 DSQC 327
Digital 120 VAC I/O 3HAB 7231-1 DSQC 320
Digital I/O with relays 3HAB 9669-1 DSQC 332
Gateway for Allen-Bradley, RIO
3HNE00025-1 DSQC 350
Gateway for Interbus-S 3HNE00006-1 DSQC 351
Gateway for Profibus DP, slave unit
3HNE00009-1 DSQC 352
Step Action Note/Illustration
1. Disconnect any connec-tors from the unit. Note which connector goes where, to facilitate reas-sembly.
The actual number of connectors vary depending on type of unit.
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Refitting The procedure below details how to refit an I/O or gateway board.
Please observe the following before commencing any repair work on the controller: Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
2. Lift the unit until the upper claw, that holds the unit to the rail, is released. Use:
• a screwdriver when replacing I/O units (posi-tion 2a in the fig-ure).
• by hand when replacing a gate-way unit (posi-tion 2b in the figure).
xx0200000010
3. With the upper claw released, tip the unit away from the mounting rail and remove it (posi-tions 3a and 3b in the figure).
Step Action Note/Illustration
1
1
2a 3a
3b2b
Step Action Note/Illustration
1. Hook the unit back onto the mounting rail and snap it gently in position.
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2. Reconnect all connectors disconnected during removal.
Step Action Note/Illustration
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Replacement of bleeder resistor
Location of bleeder resistor
The bleeder resistor is located behind the drive units, as shown in the figure below.
xx0200000007
A Drive units
B Bleeder resistor unit
C System fan unit
D Rectifier (drive unit)
E Power supply unit
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Required equip-ment
Removal The procedure below details how to remove the bleeder resistor.
Please observe the following before commencing any repair work on the controller: Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it!
Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Equipment, etc. Spare part no. Art. no. Note
Bleeder resistor 3HAC 4560-5
Step Action Note/Illustration
1. Swing the power supply unit out of the way.
Detailed in section "Replacement of power supply unit".
2. Remove the drive units. Detailed in section "Replacement of drive units and rectifier".
3. Disconnect the cable secured on top of the bleeder resistor unit (see position 1 in the fig-ure).
xx0200000015
4. Remove the bleeder resistor unit from the enclosure (see position 2 in the figure).
2
1
0
2
1
0
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Refitting The procedure below details how to refit the bleeder resistor.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Step Action Note/Illustration
1. Fit the bleeder resistor into position and secure it with the spring.
Art. no. specified above! Also see the figure above!
2. Secure the cable disconnected during disas-sembly.
3. Refit the drive unit. Detailed in section "Replacement of drive units and rectifier".
4. Swing the power supply unit back into posi-tion.
Detailed in section "Replacement of power supply unit".
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Replacement of mass storage memory
Location of mass storage memory
The mass storage memory is located in the computer system, which is shown in
the figure below.
xx0200000105
Required equip-ment
A Computer system
A
Equipment, etc. Spare part no. Art. no. Note
Mass storage memory, 64 MB
3HAC 7519-2
Mass storage memory, 128 MB
3HAC 7519-3
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Removal The procedure below details how to remove the mass storage memory.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Other tools and proce-dures may be required. See references to these procedures in the step-by-step instruc-tions below.
These proce-dures include ref-erences to the tools required.
Equipment, etc. Spare part no. Art. no. Note
Step Action Note/Illustration
1. Put the computer unit in the service position.
Detailed in section "Putting the com-puter in the service position".
2. Remove the cover from the right side of the computer sys-tem by unscrewing the ten M5 screws (item 1 in the figure).
xx0200000019
3. Disconnect the connectors X1 and X2 from the front of the mass storage memory (item 2 in the figure).
See figure above!
3
42
1
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Refitting The procedure below details how to refit the mass storage memory.
Please observe the following before commencing any repair work on the controller: Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
4. Remove the mass storage memory by unscrewing its M4 attachment screws as shown in the figure (items 3 and 4 in the figure).
See figure above!
Step Action Note/Illustration
Step Action Note/Illustration
1. Fit the mass storage mem-ory in position and secure it with its M4 attachment screws (items 3 and 4 in the figure)
Art. no. is specified above!
xx0200000019
2. Reconnect connectors X1 and X2 to the front of the computer unit (item 2 in the figure).
See the figure above!
3
42
1
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3. Refit the cover on the right side of the computer unit and secure it with its ten M5 attachment screws (item 1 in the figure).
See the figure above!
4. Put the computer system back in its regular operation position.
Detailed in section "Putting the computer in the service position".
Step Action Note/Illustration
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Replacement of internal cooling fan
Location of inter-nal cooling fan
The internal cooling fan is located in the computer system, which is shown in the
figure below.
xx0200000105
Required equip-ment
A Computer system
A
Equipment, etc. Spare part no. Art. no. Note
Internal cooling fan 3HAC 6655-1 Two fans required
Other tools and proce-dures may be required. See references to these procedures in the step-by-step instruc-tions below.
These procedures include references to the tools required.
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Removal The procedure below details how to remove the internal cooling fan.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Step Action Note/Illustration
1. Put the computer unit in the ser-vice position.
Detailed in "Putting the computer in the service position".
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Refitting The procedure below details how to refit the internal cooling fan.
Please observe the following before commencing any repair work on the controller: Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it!
2. Disconnect the connector E5 or E6 respectively, depending on which fan is to be replaced.
xx0200000020
• A: Upper fan
• B: Lower fan
• C: Locking tabs
• D: Connector E5
• E: Connector E6
3. Remove the internal cooling fan inwards by gently pressing the locking tabs upwards.
See the figure above!
Step Action Note/Illustration
A
CD
E
B
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Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Step Action Note/Illustration
1. Tip the internal cooling fan with its top towards the cabinet wall and fit it into the hole (see the figure).
Art. no. specified above!
xx0200000021
• A: Push direction
2. With the wall between the upper lock spring hooks, push the fan unit upward and inward until the locking tab snaps to the wall.
See the figure above!
A
A
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3. Reconnect the connector E5 or E6 respec-tively, depending on which fan was replaced.
4. Put the computer unit back in the regular operation position.
Detailed in "Putting the computer in the service position".
Step Action Note/Illustration
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Replacement of drive units and rectifier
Location of drive units and rectifier
The drive units and rectifier are located as shown in the figure below.
xx0200000007
A Drive units
B Bleeder resistor unit
C System fan unit
D Rectifier (drive unit)
E Power supply unit
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Required equip-ment
Removal The procedure below details how to remove the drive units.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Equipment, etc. Spare part no. Art. no. Note
Drive unit (rectifier) 3HAB 8101-17 DSQC 545A
Drive unit, axes 1-6 3HAB 8101-18 DSQC 546A
Other tools and proce-dures may be required. See references to these procedures in the step-by-step instruc-tions below.
These proce-dures include ref-erences to the tools required.
Step Action Note/Illustration
1. Swing the power supply unit out of the way.
Detailed in section "Replacement of power supply unit"
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2. Disconnect connectors X1 and X2, four connectors each (see position 1 in the figure).
xx0200000013
3. Remove the power supply bar in front of the drive units (see position 2 in the figure).
See figure above!
4. Lift the spring to release the drive unit and pull it slightly outwards (see position 3 in the figure).
xx0200000014
5. Tip it out and remove it (see position 4 in the fig-ure).
See figure above!
Step Action Note/Illustration
1
1
2
3 4
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Refitting The procedure below details how to refit the drive units.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Step Action Note/Illustration
1. Fit the unit into position and secure it with the spring.
Also see figure above!
2. Refit the power bar in front of the unit.
3. Reconnect all connectors X1 and X2.
4. Swing the power supply unit back into position. Detailed in section "Replacement of power supply unit"
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Replacement of system fan unit
Location of sys-tem fan unit
The system fan unit is located as shown in the figure below.
xx0200000007
A Drive units
B Bleeder resistor unit
C System fan unit
D Rectifier (drive unit)
E Power supply unit
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Required equip-ment
Removal The procedure below details how to remove the system fan unit.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Equipment, etc. Spare part no. Art. no. Note
System fan unit 3HAC 12924-2
Other tools and proce-dures may be required. See references to these procedures in the step-by-step instruc-tions below.
These proce-dures include ref-erences to the tools required.
Step Action Note/Illustration
1. Remove the bleeder resistor unit.
Detailed in "Replacement of bleeder resistor" in the Repair Manual.
2. Disconnect the cable (see position 1 in the figure).
xx0200000008
221
1
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Refitting The procedure below details how to refit the system fan unit.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
3. Pull the back of the system fan unit upwards to free it and then tip it out of the enclosure (see posi-tion 2 in the figure).
Step Action Note/Illustration
Step Action Note/Illustration
1. Fit the system fan unit into position and secure it (see position 2 in the figure above).
Art. no. specified above!
2. Reconnect the cable disconnected during disassembly (see position 1 in the figure above).
3. Refit the bleeder resistor unit. Detailed in section "Replacement of bleeder resistor" in the Repair Manual.
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Replacement of power supply unit
Location of power supply unit
The power supply unit is located as shown in the figure below.
xx0200000011
Required equip-ment
A Power supply unit locking spring (view from front)
B Power supply unit folded out from the cabinet (view from above)
B
A
Equipment, etc. Spare part no. Art. no. Note
Power supply unit 3HAB 4297-1 DSQC 506
Other tools and proce-dures may be required. See references to these procedures in the step-by-step instruc-tions below.
These proce-dures include ref-erences to the tools required.
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Removal The procedure below details how to remove the power supply unit.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Step Action Note/Illustration
1. Push the power supply unit locking spring down to release the power sup-ply unit.
Shown in figure above!
2. Swing the unit out of the cabinet.
Shown in figure above
3. Remove the cable straps on top of the power sup-ply unit (see position 1 in the figure).
xx0200000012
4. Disconnect the cables at the back of the unit (see position 2 in the figure).
5. Remove the screw (see position 3 in the figure).
2
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Refitting The procedure below details how to refit the power supply unit.
Please observe the following before commencing any repair work on the controller: Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
6. Lift the unit straight up to release it from the hooks and remove it outwards (see position 4 in the fig-ure).
Step Action Note/Illustration
Step Action Note/Illustration
1. Fit the power supply unit into position onto its hooks and secure it with the attachment screws (see position 3 and 4 in figure in the section Removal).
Art. no. specified above!
2. Reconnect all connectors disconnected during removal (see position 2 in figure).
3. Secure the cables on top of the unit with new cable straps (see position 1 in figure).
4. Swing the unit back into the cabinet and secure it with the locking spring.
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Circuit Diagram, IRB 940 Tricept™
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Chapter 5:Circuit Diagram, IRB 940 Tricept™
Introduction
Definitions This chapter contains all the circuit diagrams for the IRB 940 Tricept™.
3HAC 16640-1 - 135
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Circuit Diagram, IRB 940 Tricept™ - =M1/2, Potentials from control
3HAC 16640-1 -
en02
0000
0410
+EC
1c
on
tac
tR
1 M
P
+EC
1c
on
tac
tR
1 SM
B
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=M1/
2, P
ote
nti
als
fro
m c
on
tro
l
136
Circuit Diagram, IRB 940 Tricept™ - =M1/3, Axis 1
3HAC 16640-1 -
en02
0000
0411
-R1M
PA
1
-XM
1A
-XM
1.1
A
A2
B B
D6
A3
C C
A4
D D
D8
A5
E E
A6
F F
D10
PE
-XTP
EP
E G G
PE
PE H H
PE
PE
PE
PE
C3
J J
C1
K K
L L
M M
-XP
1-4
2
-XR
1A
-XR
1.1
A
14 B B
3 C C
15 D D
6 E E
18 F FG
4.3
+EC
14.
0
+M
1M
oto
r a
xis
1C
E
-SM
B9.
5Se
rial
me
asu
ring
bo
ard
-B1
Re
solv
er 1
AW
G16
gre
y WM
11
23
45
6
AW
G16
yel/
gr
AW
G16
yel/
gr
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AW
G20
blu
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78
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910
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G22
blu
e WR
1
R2.
SMB1
-4
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T1-Y
1M 3
UV
W PE
+ -
CE
CE
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=M1/
3, A
xis
1
137
Circuit Diagram, IRB 940 Tricept™ - =M1/4, Axis 2
3HAC 16640-1 -
en02
0000
0412-R
1MP
A7
-XM
2A
-XM
2.1
A
A8
B B
A9
C C
A10
D D
A11
E E
A12
F F
-XTP
EP
E G G
PE H H
C5
J J
C4
K K
L L
M M
-XP
1-4
4
-XR
2A
-XR
2.1
A
16 B B
5 C C
17 D D
7 E E
19 F FG
3.4
5.3
+EC
13.
0
+M
2M
oto
ra
xis
2C
E
-SM
B9.
5Se
rial
me
asu
ring
bo
ard
-B2
Re
solv
er 2
AW
G16
gre
y WM
21
23
45
6
PE1
AW
G16
yel/
gr
PE1
AW
G20
blu
e
78
AW
G20
blu
e
910
AW
G22
blu
e WR
2
R2.
SMB1
-4
Ï-R
T2-Y
2M 3
UV
W PE
+ -
CE
CE
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=M1/
4, A
xis
2
138
Circuit Diagram, IRB 940 Tricept™ - =M1/5, Axis 3
3HAC 16640-1 -
en02
0000
0414
-R1M
PA
13
-XM
3A
-XM
3.1
A
A14
B B
C13
A15
C C
A16
D D
C14
B1 E E
B2 F F
C15 -XTP
EP
E G G
PE H H
C7
J J
C6
K K
L L
M M
-XP
1-4
9
-XR
3A
-XR
3.1
A
21 B B
10 C C
22 D D
8 E E
20 F FG
4.3
6.3
+EC
13.
0
+M
3M
oto
ra
xis
3C
E
-SM
B9.
5Se
rial
me
asu
ring
bo
ard
-B3
Re
solv
er 3
AW
G16
gre
y WM
31
23
45
6
PE1
AW
G16
yel/
gr
PE1
AW
G20
blu
e
78
AW
G20
blu
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910
AW
G22
blu
e WR
3
R2.
SMB1
-4
Ï-R
T3-Y
3M 3
UV
W PE
+ -
CE
CE
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=M1/
5, A
xis
3
139
Circuit Diagram, IRB 940 Tricept™ - =M1/6, Axis 4
3HAC 16640-1 -
en02
0000
0415
-R1M
PB3
-XM
4A
-XM
4.1
A
-XM
TR4
1
D11
B4 C C 2
D12
B5 E E 3
D13
-XTP
EP
E G G 4
C9
J J 8
C8
K K 9
L L 5
M M 6
-XP
3-6
2
-XR
4A
-XR
4.1
A
-XM
TR4
12
14 B B 13
3 C C 15
15 D D 14
6 E E 11
18 F F 10
G 7
5.3
7.3
+EC
13.
0
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4M
oto
ra
xis
4
CE
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B9.
5Se
rial
me
asu
ring
bo
ard
-B4
Re
solv
er 4
AW
G16
gre
y WM
4
Wm
oto
r4
Wm
oto
r4.1
13
5
PE1
AW
G16
yel/
gr
PE1
AW
G20
blu
e
78
AW
G20
blu
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910
AW
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4
Wm
oto
r4.1
R2.
SMB3
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Ï-R
T4-Y
4M 3
UV
W PE
+ -
CE
CE
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=M1/
6, A
xis
4
140
Circuit Diagram, IRB 940 Tricept™ - =M1/7, Axis 5
3HAC 16640-1 -
en02
0000
0416
-R1M
PB7
-XM
5A
-XM
5.1
A
-XM
TR5-
61
D15
B6 C C 2
D14
B8 E E 3
D9
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EP
E G G 12
C11
J J 10
C10
K K 11
L L 9
-X5
1
M M 18 2
-XP
3-6
4
-XR
5A
-XR
5.1
A
-XM
TR5-
621
16 B B 22
5 C C 24
17 D D 23
7 E E 20
19 F F 19
G 25
6.3
8.3
+EC
13.
0
+M
5M
oto
ra
xis
5
CE
-SM
B9.
5Se
rial
me
asu
ring
bo
ard
-B5
Re
solv
er 5
AW
G16
gre
y WM
5
Wm
oto
r_5-
6Sp
iral 2
8x
Wm
oto
r518
x
13
5
PE1
AW
G16
yel/
gr
PE1
AW
G20
blu
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78
AW
G20
blu
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Wm
oto
r6_a
nd
_bra
ke 5
Wb
rake
5
910
AW
G22
blu
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5
Wm
oto
r5
R2.
SMB3
-6
Ï-R
T5-Y
5M 3
UV
W PE
+ -
CE
CE
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=M1/
7, A
xis
5
141
Circuit Diagram, IRB 940 Tricept™ - =M1/8, Axis 6
3HAC 16640-1 -
en02
0000
0417
-R1M
PB9
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Circuit Diagram, S4Cplus
wwwThe
Chapter 6:Circuit Diagram, S4Cplus
Introduction
DefinitionsThis chapter contains the circuit diagram for the controller S4Cplus. The chapter is divid-ed into the separate systems..
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Index
wwwThe
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Index
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Maintenance ManualIndustrial Robot IRB 940 Tricept™3HAC 16639-1 / M2000 / Rev. -
IRB 940 Tricept™
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ABB Automation Technology Products ABRoboticsS-721 68 VÄSTERÅSSWEDENTelephone: +46 (0) 21 344000Telefax: +46 (0) 21 132592
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Maintenance Manual, IRB 940 Tricept™ 3HAC 16639-1
-
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The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no re-sponsibility for any errors that may appear in this manual.
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 permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
©Copyright 2002 ABB All rights reserved.
ABB Automation Technology Products ABRobotics
SE-721 68 VästeråsSweden
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Table of Contents
wwwThe
Overview 1Product Documentation, IRB 940 Tricept ™ 3
Chapter 1: Safety, service 5
Introduction 5Safety, service - General 6
Section A: References 7Limitation of Liability 7Applicable Safety Standards 7Related information 8
Section B: Safety risks 9Safety risks related to end effector 9Safety risks related to tools/workpieces 9Safety risks related to pneumatic/hydraulic systems 9Safety risks during operational disturbances 10Safety risks during installation and service 10Risks associated with live electric parts 11
Section C: Safety actions 13Safety fence dimensions 13Fire extinguishing 13Emergency release of the manipulator's arm 14Brake testing 14Risk of disabling function "Reduced speed 250 mm/s" 15Safe use of the Teach Pendant Unit 15Work inside the manipulators working range 15
Chapter 2: Reference Information 17
Introduction 17Screw joints 18Weight specifications 20
Chapter 3: Maintenance activities, manipulator 21
Introduction 21
Section A: Maintenance intervals 22Specification of maintenance intervals 22Maintenance schedule, IRB 940 Tricept™ 23
Section B: Daily maintenance 24Daily maintenance, complete robot 24
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Table of Contents
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Section C: Lubrication activities 25Lubrication, linear bearings 25Lubrication, actuators 27
Section D: Replacement activities 29Replacement of filter element, OP-unit 29Adjusting the overpressure unit 31
Chapter 4: Maintenance activities, controller 33
Introduction 33
Section A: Maintenance intervals 34Specification of maintenance intervals 34Maintenance schedule, controller S4CPlus 35
Section B: Inspection activities 36Inspection of controller cabinet, S4Cplus 36
Section C: Replacement activities 37Replacement of air filter, controller 37Replacement of battery unit, controller 40Replacement of system fan unit 44
Section D: Cleaning activities 47Cleaning of controller cabinet 47Cleaning of air filter 49
Chapter 5: Disposal 51
Disposal 51
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wwwThe
Overview
About This Manual
This information product is a manual containing instructions for maintenance of
the complete robot system, mechanically as well as electrically.
Usage This manual should be used during maintenance work.
Who Should Read This Manual?
This manual is intended for:
• maintenance personnel in the user's organization.
• maintenance personnel in other organizations.
Prerequisites The reader should...
• be a trained maintenance craftsman
• have the required knowledge of mechanical maintenance work OR
• have the required knowledge of electrical maintenance work.
Organization of Chapters
The information product is organized in the following chapters:
Chapter Contents
1. Safety, service
2. Reference information
3. Maintenance activities, manipulator
4. Maintenance activities, controller
5. Disposal
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References
Revisions
Reference Document Id
Circuit diagram, Manipulator 3HAC 16640-1, Repair Manual part 2
Circuit diagram, Controller 3HAC 16640-1, Repair Manual part 2
Revision Description
- First edition
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Product Documentation, IRB 940 Tricept ™
General The complete documentation of IRB 940 Tricept™ including controller consists
of several manuals listed below:
Overview, Installation and Commissioning Manual
The Installation and Commissioning Manual contains the following main chap-
ters:
• Safety, Service
• Reference Information
• Unpacking
• On-site Installation
• Electrical connections
• Start-up
• Robot controller
• Installation of controller software
• System directory structure
• Calibration
Overview, Repair Manual
The Repair Manual contains the following main chapters:
• Safety, Service
• Reference Information
• Remove/Refitting instructions for all manipulator details considered spare parts
• Remove/Refitting instructions for all controller cabinet details considered spare parts
• Circuit Diagram for manipulator
• Circuit Diagram for controller cabinet
Overview, Maintenance Manual
The Maintenance Manual contains the following main chapters:
• Safety, Service
• Reference Information
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• Maintenance schedules
• Maintenance activities
• Disposal
The chapters for the maintenance activities include instructions for all the main-
tenance activities specified in the maintenance schedule.
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Safety, service
wwwThe
Chapter 1:Safety, service
Introduction
Definitions This chapter details safety information for service personnel i.e. personnel per-
forming installation, repair and maintenance work.
Sections The chapter "Safety, service" is divided into the following sections:
A. References contains lists of:
• Limitation of liability
• applicable safety standards
• referenced documents
B. Safety risks lists dangers relevant when servicing the robot system. The dangers are split into different categories:
• Safety risks related to 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
C. 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
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Safety, service
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Safety, service - General
Validity and responsibility
The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment, which can influence the safety
of the total system. To protect personnel, the complete system must be designed
and installed in accordance with the safety requirements set forth in the standards
and regulations of the country where the robot is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable
safety laws and regulations in the country concerned are observed and that the
safety devices necessary to protect people working with the robot system have
been designed and installed correctly. Personnel working with robots must be
familiar with the operation and handling of the industrial robot, described in the
applicable documents, e.g. 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 inter-
face for the connection of external safety devices. Via this interface, an external
safety function can interact with other machines and peripheral equipment. This
means that control signals can act on safety signals received from the peripheral
equipment as well as from the robot.
In the Product Manual - Installation and Commissioning, instructions are pro-
vided for connecting safety devices between the robot and the peripheral equip-
ment.
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Safety, serviceReferences
wwwThe
Section A: References
Limitation of Liability
General Any information given in this information product regarding safety, must not be
construed as a warranty by ABB Robotics that the industrial robot will not cause
injury or damage even if all safety instructions have been complied with.
Applicable Safety Standards
Standards The robot is designed in accordance with the requirements of:
• EN 292-1, Safety of macheniry, basic terminology
• EN 292-2, Safety of machinery, technical principles/specifications, emer-gency stop
• EN 418, Safety of machinery, emergency stop equipment
• EN 563, Safety of machinery, temperatures of surfaces
• EN 614-1, Safety of machinery, ergonomic design principles
• EN 775, Robot safety
• EN 60204-1, Electrical equipment for industrial machines
• EN 50081-2EMC, Generic emission standard. Part 2: Industrial environ-ment(EN 55011 Class ARadiated emission enclosure)(EN 55011 Class AConducted emission AC Mains)
• EN 61000-6-2EMC, Generic standards - Immunity for Industrial environ-ments(EN 61000-4-2Electrostatic discharge immunity test)(EN 61000-4-3Radiated, radio-frequency, electromagnetic field immunity test)(EN 61000-4-4Electrical fast transient/burst immunity test)(EN 61000-4-5Surge immunity test)(EN 61000-4-6Immunity to conducted disturbances, induced by radio-fre-quency fields)(EN 61000-4-11Voltage dips, short interruptions and voltage variations immunity test)
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Safety, serviceReferences
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Related information
General The list below specifies documents which contain useful information:
Documents
Type of information Detailed in document Section
Installation of safety devices Installation and Commis-sioning Manual
Changing robot modes User’s Guide Start-up
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Safety, serviceSafety risks
wwwThe
Section B: Safety risks
Safety risks related to end effector
Make sure to prevent an end effector from dropping a workpiece, if such is used.
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.
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, par-ticular care must be taken.
• The pressure in pneumatic and hydraulic systems must be released before starting to repair them.
• Note that the interior of the robot may be pressurized.
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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Safety, serviceSafety risks
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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 personnel
• 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.
Safety risks during installation and service
General risks dur-ing installation 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, lifting and transport of the
robot system, the regulations applicable in the country concerned and the instruc-
tions of ABB Robotics must be complied with.
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Safety, serviceSafety risks
wwwThe
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 or when the motors or other components are removed.
• 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 temperature of the motors or oil spills that can occur on the robot.
To be observed by the supplier of the complete sys-tem
• The supplier of the complete system must ensure that all circuits used in the safety function are interlocked in accordance with the applicable stan-dards for that function.
• The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner, in accor-dance with the applicable standards for the emergency stop function.
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.
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Voltage related risks, controller, S4Cplus
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 external 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. N.B.: 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 process
• The external voltage connected to the control cabinet remains live even when the robot is disconnected from the mains.
• Additional connections
Voltage related risks, manipula-tor, IRB 940 Tri-cept™
A danger of high voltage is associated with the manipulator in:
• The distribution box for the manipulator (up to 430 VDC)
• The power supply for the motors (up to 430 VDC)
• The user connections for tools or other parts of the installation (max. 230V AC, see Product Manual - Installation and Commissioning)
Voltage related risks, tools, mate-rial handling devices, etc.
Tools, material handling devices, etc., may be live even if the robot system is in
the OFF position. Power supply cables which are in motion during the working
process may be damaged.
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Section C: Safety actions
Safety fence dimensions
General Install a safety cell around the robot to ensure safe robot installation and operation.
Dimensioning the fence or enclo-sure
Design the safety cell such that it will:
• - withstand any impact from a tool failure. Due to the high kinetic energy associated with HSM (High Speed Machining), a tool failure poses a seri-ous risk as any debris can cause serious personal injury. Both walls and ceilings must be designed and dimensioned so that they can withstand any projectiles that they may be subjected to. Windows must be made from suitable safety glass. Study the planned process to determine the forces involved and appropriate materials.
• - insulate against sound pollution from the machining process. Typically the safety cell should be able to reduce sound from the machining process down to 75dBA, though individual installations may stipulate other values. Study the planned process to determine the allowable noise pollution lev-els and appropriate sound insulation.
• - isolate gases and mist generated by the machining process and spray mist lubrication. Study the planned process to determine the fumes involved and appropriate ventilation/filtering system.
Fire extinguishing
Use a CARBON DIOXIDE (CO 2 ) extinguisher in the event of a fire in the robot (manipulator or controller)!
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Emergency release of the manipulator’s arm
Description In an emergency situation, any of the manipulator’s axes may be released manu-
ally by pushing the brake release buttons on the distribution box for the manipu-
lator. How to release the brakes is detailed in section "Manually releasing the
brakes" in the Installation Manual.
The manipulator arms may be moved manually when the brakes has been
released.
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!
Brake testing
When to test During operation the holding brakes of each axis motor wear normally. A test may
be performed to determine whether the brake can still perform its function.
How to test The function of each axis’ motor holding brakes may be checked as detailed
below:
1. Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized (max. static load).
2. Switch the motor to the MOTORS OFF position with the Operating mode selector on the controller.
3. Check that the axis maintains its position.
If the manipulator does not change position as the motors are switched off, then the brake function is adequate.
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Risk of disabling function "Reduced speed 250 mm/s"
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.
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.
Work inside the manipulators working range
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 per-sonnel who are aware of the risks that this entails. Also be aware of any danger that may be caused by rotating tools or other devices mounted on the manipulator or inside the cell.
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Chapter 2:Reference Information
Introduction
General This chapter presents generic pieces of information, complementing the more spe-
cific information in the following chapters.
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Screw joints
General This section details how to tighten the various types of screw joints in the manip-
ulator as well as the controller.
The instructions and torque values are valid for screw joints comprising metallic
materials and does not apply to soft or brittle materials.
Any instructions given in the repair, maintenance or installation procedure
description override any value or procedure given here, i.e. these instruction are
only valid for standard type screw joints.
Tightening torque The tightening torque values for different types of screw joint are specified in the
tables below:
Screws with slotted or cross recess head
Screws with hexagon socket head
Dimension Tightening torque (Nm) Class 4.8 "dry"
M2.5 0.25
M3 0.5
M4 1.2
M5 2.5
M6 5.0
Dimension Tightening torque (Nm) Class 8.8 "dry"
Tightening torque (Nm) Class 10.9
Tightening torque (Nm) Class 12.9
M5 6 - -
M6 10 - 17
M8 24 28 40
M10 47 55 70
M12 82 95 120
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M16 200 235 300
Dimension Tightening torque (Nm) Class 8.8 "dry"
Tightening torque (Nm) Class 10.9
Tightening torque (Nm) Class 12.9
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Weight specifications
Definition In all repair and maintenance instructions, weights of the components handled are
sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in
this way.
ABB recommends handling all components with a weight exceeding 22 kg using
lifting equipment to avoid inflicting injury.
Example Below is an example of how a weight specification is presented:
The actuator with motor weighs 40 kg! All lifting equipment used must be dimen-sioned accordingly!
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Chapter 3:Maintenance activities, manipulator
Introduction
Definitions This chapter details all maintenance activities recommended for the manipulator.
This chapter is made up of separate units, each detailing a specific maintenance
activity. Each unit contains all the information required to perform the activity,
e.g. spare parts numbers, required special tools and materials.
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Section A: Maintenance intervals
Specification of maintenance intervals
Description The intervals may be specified in different ways depending on the type of main-
tenance activity to be carried out and the working conditions of the robot.
• Calendar time: specified in months regardless of whether the robot system is run or not.
• Operating time: specified in operating hours. More frequent running of the robot means more frequent maintenance activities.
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Maintenance schedule, IRB 940 Tricept™
General The robot, consisting of manipulator and controller cabinet, must be maintained
regularly to ensure its function. The maintenance activities and their respective
intervals are specified in the table below.
Non-predictable situations also give rise to inspections of the robot. If damage is
discovered, attend to it immediately!
Activities and intervals
The section referred to in the table can be found in the different chapters for every
maintenance activity.
The table below specifies the required maintenance activities and intervals:
1) The interval is based on utilization under normal operating conditions. Opera-
tion under severe conditions such as increased ambient temperature or the pres-
ence of abrasive or grease absorbent dust will require a more regular maintenance
cycle.
Maintenance activity
Equipment Interval Detailed in section
Daily maintenance Complete robot Daily "Daily maintenance"
Lubrication Linear bearings 1000h 1 "Lubrication, linear bear-ings"
Lubrication Actuator 1000h 1 "Lubrication, actuators"
Changing Filter, overpres-sure unit
“Replacement of filter ele-ment, OP-unit”
Changing Battery, distribu-tion box
“Removal/Refitting of bat-tery, distribution box” in the Repair Manual.
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Section B: Daily maintenance
Daily maintenance, complete robot
General The IRB 940 Tricept™ requires regular maintenance. It is therefore important to
adhere to the following maintenance chart as well as applying the preventive
maintenance schedules set out in any auxiliary equipment chapters. When main-
taining the robot it is important to:
• Clean the robot and its surrounding environment daily.
• Not to use compressed air in sections of the machinery which may suffer from chips or dust being blown into sensitive areas.
• Only use soft cloths when cleaning so as not to cause abrasions on the machine surfaces.
• Not to use any solvents that may have an abrasive or corrosive effect on the machine surfaces.
Daily maintenance
The daily maintenance of the robot and its surrounding environment includes:
• Removing all chips and/or dust that result from the machining process.
• Performing checks on all safety related equipment such as safety switches and barriers.
• Checking for signs of damage or wear on all cables, hoses and other com-ponents that can lead to a safety risk or interrupted production in case of failure.
• Checking levels of all lubrication and cooling fluids on both the manipulator and auxiliary equipment.
• Checking that all media supplies, such as compressed air and water, main-tain the correct pressures and flows.
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Section C: Lubrication activities
Lubrication, linear bearings
Location The figure below shows the location of the grease lubrication nipple on the linear
guide bearing. The other linear bearing is located on the other side of the center
tube.
xx0200000293
Required equip-ment
A Grease lubrication nipple (one on either side of the center tube)
A
Equipment, etc. Spare part no. Art. no. Note
Lubricant Klüber Isoflex NBU 15 2 x 4 ml per lin-ear bearing.
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Lubrication The procedure below details how to lubricate the linear bearings.
Please observe the following before commencing any repair work on the manipu-lator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them!- Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! - When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures.
- Before lubrication, always clean lubrication interfaces to prevent contamination entering the lubrication system.
- After lubrication, always clean any spillage around lubrication interfaces.
Step Action Note/Illustration
1. Clean the rails from old grease and dust.
2. Apply 4 ml lubricant through the nipple at the bottom end of the linear guide bearing.
Both sides must be lubricated! Note! The ends of the linear bearing are made from plastic and can crack if not suffi-cient care is taken when lubricating the bear-ings.
Shown in figure above! Lubricant specified above!
3. Run the robot back and forth in the Z-direc-tion several times.
4. Apply a further 4 ml lubricant through the same nipples at both side of the center tube.
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Lubrication, actuators
Location The three actuators require lubrication with grease. There are four separate grease
nipples for the lubrication on each actuator. The grease nipple that faces up is used
so that as the grease is applied it falls onto the lead screw inside the actuator hous-
ing.
The figure below shows the location of the grease lubrication nipples on the actu-
ator.
xx0200000294
Required equip-ment
A Grease lubrication nipples on the actuator
A
Equipment, etc. Spare part no. Art. no. Note
Lubricant Klüberplex BEM 34-132
2 x 4 ml per actuator.
For lubrication of the actuators.
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Lubrication The procedure below details how to lubricate the actuators.
Please observe the following before commencing any repair work on the manipu-lator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them!- Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! - When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures.
- Before lubrication, always clean lubrication interfaces to prevent contamination entering the lubrication system.
- After lubrication, always clean any spillage around lubrication interfaces.
Step Action Note/Illustration
1. Extend the actuators to their maximum allow-able length.
If a fixture or other work area restrictions affect the positioning of the robot, run it so that one of the actuators is extended, lubri-cate it and move on to the other two in turn.
2. Apply 4 ml of lubricant to each actuator through the topmost grease nipple.
Note! Ensure that the grease nipple that faces upwards is used, as any other orien-tated grease nipple will not ensure that the grease is applied to the lead screw correctly.
Lubricant specified above!
Shown in the figure above!
3. Run the actuators through their whole stroke several times.
Note! The actuators must be extended prior to lubrication in order to get the correct appli-cation onto the actuator screw. Lubricating a contracted actuator will not apply any grease on the screw threads.
4. Apply a further 4 ml through the same grease nipple.
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Section D: Replacement activities
Replacement of filter element, OP-unit
Location The filter element is located in the overpressure (OP) unit as shown in the figure
below.
xx0200000420
Required equip-ment
- Removal of the filter element
Equipment, etc. Spare part no. Art. no. Note
Filter 3HAC 17158-1
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Replacement of filter
The procedure below details how to replace the filter element in the overpressure
unit.
Step Action Note/Illustration
1. Exhaust the system and the unit.
2. Unscrew the filter bowl in an anti-clockwise direction.
3. Grasp a new filter element only at the lower end.
4. Refit the parts in the reverse order from dis-mantling.
5. Recommission the overpressure unit. Detailed in the section "Adjusting the overpres-sure unit".
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Adjusting the overpressure unit
Location The overpressure unit is installed as shown in figure below.
xx0200000421
A Regulator
B Pressure guard
C Pressure indicator light
D Air input
A
B
C
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Adjusting The procedure below details how to adjust the overpressure unit after installation
or after replacement of the filter element.
The output pressure must under no circumstances exceed 1 bar!
Step Action Note/Illustration
1. Slowly pressurize the complete system.
2. Pull the pressure setting button upwards (away from the housing).
3. Turn the pressure setting until the desired pres-sure (1 bar) is shown on the manometer. The input pressure must be at least 1 bar greater than the output pressure.
4. Press the pressure setting button downwards (towards the housing) to secure it against uninten-tional turning.
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Chapter 4:Maintenance activities, controller
Introduction
Definitions This chapter details all maintenance activities recommended for the control cabi-
net.
This chapter is made up of separate units, each detailing a specific maintenance
activity. Each unit contains all the information required to perform the activity,
e.g. spare parts numbers, required special tools and materials.
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Section A: Maintenance intervals
Specification of maintenance intervals
Description The intervals may be specified in different ways depending on the type of main-
tenance activity to be carried out and the working conditions of the robot.
• Calendar time: specified in months regardless of whether the robot system is run or not.
• Operating time: specified in operating hours. More frequent running of the robot means more frequent maintenance activities.
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Maintenance schedule, controller S4CPlus
General The robot controller must be maintained at regular intervals to ensure its function.
The maintenance activities and their respective intervals are specified in the table
below:
Intervals
1) Hours denotes operational time whereas months denotes actual calender time.
Maintenance activity
Equipment Interval Detailed in section
Inspection Controller cabinet 6 mths "Inspection, controller cabinet"
Cleaning Controller cabinet "Cleaning, controller cabinet"
Cleaning Air filter "Cleaning, air filter"
Replacement Air filter 4 000 h/24 mths 1
"Replacement, air filter"
Replacement Battery unit 12 000 h/36 mths 1
"Replacement, battery unit"
Replacement System fan unit 60 mths "Replacement, system fan unit".
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Section B: Inspection activities
Inspection of controller cabinet, S4Cplus
Inspection The procedure below details how to inspect the controller cabinet.
Please observe the following before commencing any repair work on the controller: Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it!
Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Step Action Note/Illustration
1. Inspect the cabinet interior to make sure there is no contamination. If any contamination is found, the cabinet interior must be cleaned and all gaskets and seals to the cabinet inspected.
Replace any faulty seals as required.
2. Inspect all sealing joints and cable glands to make sure they are airtight in order to prevent dust and dirt from being sucked into the cab-inet.
3. Inspect connectors and cabling to make sure they are securely fastened and cabling not damaged.
4. Inspect any air filters to make sure they are clean.
Clean any contaminated filters as detailed in "Cleaning, air filter".
5. Inspect any fans to make sure they function correctly.
Replace any malfunc-tioning fans as detailed in their sections respec-tively.
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Section C: Replacement activities
Replacement of air filter, controller
Location of air fil-ter
The air filter is located in the air filter magazine in the front hatch.
xx0200000284
Required equip-ment
A Air filter magazine
A A
Equipment, etc. Spare part no. Art. no. Note
Air filter 3HAB 8028-1
Other tools and proce-dures may be required. See references to these procedures in the step-by-step instruc-tions below.
These procedures include references to the tools required.
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Removal, air filter The procedure below details how to remove the air filter.
Step Action Note/Illustration
1. Open the bottom of the air filter magazine as shown in the figure.
xx0200000001
2. Unlock the lower springs. Lower the magazine and remove.
3. Remove the old filter by releasing the lock shackle and lifting it. Note! In cases of less contamina-tion, the air filter may be cleaned and refitted. The procedure for this is detailed in section "Clean-ing the air filter, controller" in the Maintenance Manual.
xx0200000003
1
2
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Refitting, air filter The procedure below details how to refit the air filter.
Step Action Note/Illustration
1. Fit the air filter in the magazine.
Art. no. is specified above!
2. Fit the spring at the top of the air filter magazine into the cabinet door and push upwards inwards.
Push until the lower springs snap into the cabinet door.
xx0200000006
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Replacement of battery unit, controller
Location of bat-tery unit
The battery unit is located at the bottom of the controller.
xx0200000103
A Battery unit
A
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Required equip-ment
Removal, battery unit
The procedure below details how to remove the battery unit.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Equipment, etc. Spare part no. Art no. Note
Battery unit 3HAC 5393-2 To be replaced as a complete unit
Other tools and proce-dures may be required. See references to these procedures in the step-by-step instruc-tions below.
These procedures include references to the tools required.
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Step Action Note/Illustration
1. Remove the battery unit by unscrewing its attachment screws (1).
xx0200000004
2. Pull the battery unit out (2).
3. Disconnect the three cables from the battery unit (3).
xx0200000005
X3
X2
X1
X2 X2 X2
X1 X1 X1
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Refitting, battery unit
The procedure below details how to refit the battery unit.
Please observe the following before commencing any repair work on the controller: Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Step Action Note/Illustration
1. Place the battery unit close to its position. Art. no. specified above! See illustration above!
2. Reconnect the cables (3) and push the unit into position.
See illustration above!
3. Secure it with the attachment screws (1). See illustration above!
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Replacement of system fan unit
Location of sys-tem fan unit
The system fan unit is located as shown in the figure below.
xx0200000007
A Drive units
B Bleeder resistor unit
C System fan unit
D Rectifier (drive unit)
E Power supply unit
0
C
B
A
A A AD
E
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Required equip-ment
Removal The procedure below details how to remove the system fan unit.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Equipment, etc. Spare part no. Art. no. Note
System fan unit 3HAC 12924-2
Other tools and proce-dures may be required. See references to these procedures in the step-by-step instruc-tions below.
These procedures include references to the tools required.
Step Action Note/Illustration
1. Remove the bleeder resistor unit.
Detailed in "Replacement of bleeder resistor" in the Repair Manual.
2. Disconnect the cable (see position 1 in the figure).
xx0200000008
221
1
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Refitting The procedure below details how to refit the system fan unit.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
3. Pull the back of the system fan unit upwards to free it and then tip it out of the enclosure (see position 2 in the figure).
Step Action Note/Illustration
Step Action Note/Illustration
1. Fit the system fan unit into position and secure it (see position 2 in the figure above).
Art. no. specified above!
2. Reconnect the cable disconnected during disassembly (see position 1 in the figure above).
3. Refit the bleeder resistor unit. Detailed in section "Replacement of bleeder resistor" in the Repairs Manual.
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Maintenance activities, controllerCleaning activities
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Section D: Cleaning activities
Cleaning of controller cabinet
Required equip-ment
Cleaning of functional components
The procedure below details how to clean the functional components of the con-
troller cabinet.
Please observe the following before commencing any repair work on the controller: Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it!
Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Equipment, etc. Spare part no. Art. no. Note
Vacuum cleaner
Cleaning agent, exte-rior cleaning
Use rag with e.g. alco-hol, if necessary
Step Action Note/Illustration
1. Clean the cabinet interior with a vacuum cleaner if necessary.
2. If the cabinet is equipped with heat exchang-ers, it is of the utmost importance that these are cleaned.
Heat exchangers are normally found: • on the rear of power supplies
• on the rear of computer modules
• on drive units
If required, remove any heat exchangers before cleaning as detailed in the "Repair Manual".
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Maintenance activities, controllerCleaning activities
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Do’s and don’ts! The section below specifies special considerations when cleaning the controller
cabinet.
Always! • Always use cleaning equipment as specified above! Any other cleaning equipment may shorten the life of paintwork, rust inhibitors, signs, or labels!
• Always check that all protective covers are fitted to the controller before cleaning!
Never! • Never remove any covers or other protective before cleaning the control-ler!
• Never use any cleaning agents, e.g. compressed air or solvents, other than those specified above!
• Never spray with a high pressure cleaner!
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Cleaning of air filter
Location of air fil-ter
The air filter is located as shown in the figure below:
xx0200000002
Required equip-ment
A Air filter
B I/O and gateway units
C Power supply unit
D Drive system
E Computer system
A D E
B C
Equipment, etc. Spare part no. Art. no. Note
Cleaning agent Water 30-40°C with washing-up liquid or detergent
Compressed air
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Cleaning The procedure below details how to clean the air filter.
Please observe the following before commencing any repair work:
Turn off all electric power supplies to the robot! Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. securing the lower arm with fixtures before removing gear-box, axis 2.
Step Action Note/Illustration
1. Clean with the rough surface (on the clean-air side) turned inwards.
2. Clean the filter three or four times.
3. Allow the filter to dry in one of these ways:
• Lying flat on a flat surface
• Blow dry with compressed air from the clean-air side.
Do not wring the filter out!
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Disposal
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Chapter 5:Disposal
Disposal
General All used grease/oils and dead batteries must be disposed of in accordance with the
current legislation of the country in which the robot and the control unit have been
installed.
If the robot or the control unit is partially or completely disposed of, the various
parts must be grouped together according to their nature (e.g. all iron together and
all plastic together), and disposed of accordingly. These parts must also be dis-
posed of in accordance with the current legislation of the country in which the
robot and control unit have been installed.
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Disposal
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Index
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Index
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