ABB-S4C+IRB 940 M2000 Electrical Maintenance Training Manual

Installation and Commissioning Manual Industrial Robot IRB 940 Tricept™ 3HAC 16638-1 / M2000 / Rev. IRB 940 Tricept™

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ABB Automation Technology Products AB Robotics S-721 68 VÄSTERÅS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592


Installation and Commissioning Manual IRB 940 Tricept™ 3HAC 16638-1 -


The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. 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 AB Robotics SE-721 68 Västerås Sweden


Table of Contents

Overview Product Documentation, IRB 940 Tricept™ Chapter 1: Safety, service Introduction Safety, service - General Section A: References

Limitation of Liability Applicable Safety Standards Related information Section B: Safety risks

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 Section C: Safety actions

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 Work inside the manipulators working range Chapter 2: Reference Information Introduction Screw joints Weight specifications Chapter 3: Manipulator Introduction Section A: Unpacking

Pre-installation procedure Working range, IRB 940 Tricept Risk of tipping/Stability Section B: On-site installation

Lifting manipulator in a horizontal orientation

1 3 5 5 6 7

7 7 8 9

9 9 9 10 10 11 13

13 13 14 14 15 15 15 17 17 18 20 21 21 22

22 26 27 28

28

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i

Table of Contents

Lifting manipulator in a vertical orientation, using a trolley Lifting manipulator in a vertical orientation, using a lifting jack Manually releasing the brakes Orienting and securing the manipulator Fitting equipment on manipulator Loads Section C: Electrical connections

Installation of cabling on board the manipulator Connecting the manipulator to the control cabinet, manipulator cabling Connectors on the distribution box Chapter 4: Controller Introduction Section A: Unpacking

Transporting and unpacking, S4Cplus Section B: On-site Installation

Lifting the controller cabinet Required installation space, control cabinet Bolt pattern, control cabinet Installation of external power transformer Installation of Distributed Drive Unit (DDU) Section C: Electrical connections

C - 1: Signal/Power cables Connecting the manipulator to the control cabinet, S4Cplus cabling Connectors on control cabinet, S4Cplus Connectors on distributed drive unit, DDU Connection of mains power to control cabinet, S4Cplus C - 2: Signal connections Signal Classes Selecting Cables Interference elimination Connection types Connections to screw terminals Connections to connectors C - 3: Customer connections on controller The MOTORS ON/MOTORS OFF circuit External customer connections on panel X1 - X4 Connection of external safety relay

31 35 39 40 44 46 47

47 49 52 53 53 54

54 56

56 57 58 59 64 68

68 68 70 71 72 74 74 75 77 79 80 81 81 81 91 94

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Table of Contents

C - 4: Supplies External 24V supply 24V I/O supply 115/230 VAC supply C - 5: Buses Connection of the CAN bus Interbus-S, slave DSQC 351 Profibus-DP, slave DSQC 352 C - 6: I/O units Distributed I/O units Distributed I/O, digital sensors Distributed I/O, digital I/O DSQC 328 (option) AD Combi I/O, DSQC 327 (optional) Analog I/O, DSQC 355 (optional) Encoder interface unit, DSQC 354 (optional) Relay I/O, DSQC 332 (optional) Digital I/O (120 VAC), DSQC 320 (optional) C - 7: Communication Communication concept, Allen-Bradley RIO, remote I/O for Allen-Bradley PLC DSQC 350 Communication, serial links Communication, Ethernet External operator’s panel Section D: Start-up

Inspection before start-up Start-up Section E: Installation of controller software

Loading system software RobotWare CD-ROM Installing new Robot Controller Software with RobInstall Create a new Robot Controller System Update the Robot Controller image Transfer Robot Controller System using Ethernet connection Transfer Robot Controller System using floppy disks RobInstall preferences Section F: Robot controller

BootImage Start window Reboot Window Boot Disk Window

96 96 98 99 99 99 104 110 114 114 115 116 120 124 130 136 140 144 144 146 149 154 157 159

159 160 162

162 164 166 168 173 175 180 182 184

184 185 187 188


iii

Table of Contents

Network Settings Window LAN Settings Window Service Settings Window System selection window How to perform a Restart How to Start in Query Mode

189 190 192 193 194 198

Section G: System directory structure

200

Media pool in the PC System pool in the PC File structure in the robot controller mass storage memory Preparation of S4Cplus software to be installed Handling mass memory storage capacity Chapter 5: Calibration When to calibrate Section A: General

How to calibrate the robot system Calibration tool kit, contents Section B: Preliminaries

Correct orientation of axes Checking the calibration position Updating the revolution counter Fine calibration procedure on TPU Section C: Calibration

Directions for all axes Fine calibration, all axes Section D: After calibration

Post calibration procedure

200 201 202 203 204 207 207 208

208 210 211

211 215 216 219 222

222 224 231

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:

Prerequisites

The reader should...

•

•

Organization of Chapters

installation personnel on the installation site.

have the required knowledge of mechanical as well as electrical installation work.

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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1

References 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

Revisions 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 chapters:

Overview, Repair Manual

Overview, Maintenance Manual

•

Safety, Service

•


•

Unpacking

•

On-site Installation

•

Electrical connections

•

Start-up

•

Robot controller

•

Installation of controller software

•

System directory structure

•

Calibration

The Repair Manual contains the following main chapters: •

Safety, Service

•


•

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

The Maintenance Manual contains the following main chapters: •

Safety, Service

•



3

•

Maintenance schedules

•

Maintenance activities

•

Disposal

The chapters for the maintenance activities include instructions for all the maintenance activities specified in the maintenance schedule.


Safety, service

Chapter 1:Safety, service Introduction

Definitions

This chapter details safety information for service personnel i.e. personnel performing 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


5

Safety, service

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 interface for the connection of external safety devices. Via this interface, an external safety function can interact with other machines and peripheral equipment. This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot. In the Product Manual - Installation and Commissioning, instructions are provided for connecting safety devices between the robot and the peripheral equipment.


Safety, service References

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, emergency 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 environment (EN 55011 Class ARadiated emission enclosure) (EN 55011 Class AConducted emission AC Mains)

•

EN 61000-6-2EMC, Generic standards - Immunity for Industrial environments (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-frequency fields) (EN 61000-4-11Voltage dips, short interruptions and voltage variations immunity test)


7


Related information

General

The list below specifies documents which contain useful information:

Documents Type of information

Detailed in document

Installation of safety devices

Installation and Commissioning Manual

Changing robot modes

User’s Guide

Section

Start-up


Safety, service Safety risks

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

Residual energy

Safe design

Special safety regulations apply to pneumatic and hydraulic systems.

•

Residual energy may be present in these systems so, after shutdown, particular care must be taken.

•

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

•

Note that the interior of the robot may be pressurized.

•

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.


9


Safety risks during operational disturbances

General

Qualified personnel

Extraordinary risks

•

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.

•

Remedial action must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts.

If the working process is interrupted, extra care must be taken due to risks other than those associated with regular operation. Such an interruption may have to be rectified manually.

Safety risks during installation and service

General risks during installation and service

Nation/region specific regulations

•

The instructions in the Product Manual - Installation and Commissioning must always be followed.

•

Emergency stop buttons must be positioned in easily accessible places so that the robot can be stopped quickly.

•

Those in charge of operations must make sure that safety instructions are available for the installation in question.

•

Those who install the robot must have the appropriate training for the robot system in question and in any safety matters associated with it.

To prevent injuries and damage during the installation, lifting and transport of the robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with.

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Non-voltage related risks

To be observed by the supplier of the complete system

•

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.

•

The supplier of the complete system must ensure that all circuits used in the safety function are interlocked in accordance with the applicable standards for that function.

•

The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner, in accordance with the applicable standards for the emergency stop function.

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.


11


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, manipulator, IRB 940 Tricept™

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

Voltage related risks, tools, material handling devices, etc.

Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged.

•

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)


Safety, service Safety actions

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 enclosure

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 serious 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 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 levels 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)!


13


Emergency release of the manipulator’s arm

Description

In an emergency situation, any of the manipulator’s axes may be released manually by pushing the brake release buttons on the distribution box for the manipulator. 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.



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 personnel 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.


15




Chapter 2:Reference Information Introduction

General

This chapter presents generic pieces of information, complementing the more specific information in the following chapters.


17


Screw joints

General

This section details how to tighten the various types of screw joints in the manipulator as well as the controller. The instructions and torque values are valid for screw joints comprising metallic materials and do not apply to soft or brittle materials. Any instructions given in the repair, maintenance or installation procedure description override any value or procedure given here, i.e. these instruction are only valid for standard type screw joints.

Tightening torque

Screws with slotted or cross recess head

Screws with hexagon socket head

The tightening torque values for different types of screw joint are specified in the tables below:

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 10.9


M5

6

-

-

M6

10

-

17

M8

24

28

40

M10

47

55

70

M12

82

95

120



Dimension




M16

200

235

300


19


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 dimensioned accordingly!


Manipulator

Chapter 3:Manipulator Introduction

Definitions

This chapter contains necessary information for installing the manipulator to the working site.


21

Manipulator Unpacking

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 useful during later re-installation of the manipulator.

Checking the prerequisites 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 inspecting the manipulator and control cabinet exterior. 3. Make sure the lifting device to be used is dimensioned to handle the weight of the manipulator as 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/vertical orientation.



Weight, manipulator

The table below shows the weight of the manipulator:

Manipulator model

Weight

IRB 940 Tricept

570 kg

Distribution box

31 kg


23


Loads on flange, manipulator

The table below shows the maximum forces and torques working on the manipulator during operation. NOTE! These forces and torques are extreme values that are rarely encountered during operation. The values also never reach their maximum simultaneously!

Tz

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



Storage conditions, manipulator

Operating conditions, manipulator

The table below shows the allowed storage conditions for the manipulator and the distribution box:

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

The table below shows the allowed operating conditions for the manipulator and the distribution box:

Parameter

Value

Min. ambient temperature, operation

+5°C

Max. ambient temperature, operation, manipulator

+45°C

Max. ambient humidity, operation


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:

Equipment

Protection class

Manipulator

IP 66

Distribution box

IP 67

Overpressure unit

IP 67


25


Working range, IRB 940 Tricept

Illustration

The illustration below shows the unrestricted working range of IRB 940 Tricept:

0

B

400

0 400

A

A

800

800 1200

B

800

400

0

400

800

1200

1200

800

400

0

400

(mm)

800

1200 (mm)

xx0200000356

A

Absolute Tolerance Area at the tool-coordinate system, TCP0

B

Working range, centre of axis 5



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.

A

B xx0200000357

A

26 mm (most stable position of axes 1, 2 and 3)

B

Spacer, min. 100 mm in height

The table below specifies the most stable position of each axis of the manipulator. Axis

Position

Note

1, 2, 3

26 mm

Shown in figure above!

4, 6

0°

5

-90°

1. DO NOT change the manipulator position before securing it to its foundation. The shipping position is the most stable.


27

Manipulator On-site installation

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 equipment

Lifting in horizontal orientation

Equipment

Note

Crane or hoist

Lifting capacity: 1000 kg.

1 strap, length 2 m


2 straps, length 1 m


2 upper platform eyebolts

M16

2 shackles

The shackles must fit the eyebolts on the upper platform.

The section below details how to lift and move the manipulator from the transportation pallet, horizontally, using the lifting equipment specified above. The IRB 940 manipulator weighs 570 kg! All lifting equipment used must be dimensioned 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.



Step Action 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 figure.

Note

xx0200000317

3.

Hook the strap to the lift, or crane, as shown in the adjacent figure.

4.

Unless already in posiDimension specified above! tion, fit the eyebolts to the upper platform.

xx0200000318


29


Step Action 5.

Note

Attach the 1 metre straps to the eyebolts using the shackles.

A

B

C xx0200000319

6.

Attach the straps to the lift, or crane, as shown in figure above!

7.

Lift the manipulator to the required location and disconnect the lifting equipment.

•

A: Strap, 1 m (2 pcs)

•

B: Shackle (2 pcs)

•

C: Eyebolt (2 pcs)



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 equipment

Lifting in vertical orientation, using a trolley

Equipment

Note

Crane or hoist





M16

2 shackles


Trolley (or machine skate)

Capacity: 500 kg. Height: 400 mm.

The section below details how to lift and move the manipulator from the transportation pallet, vertically, using the lifting equipment specified above.

The IRB 940 manipulator weighs 570 kg! All lifting equipment used must be dimensioned accordingly!



31



- 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 1.

Unless already in position, fit the eyebolts to the upper platform.

2.


Note Dimension specified above!

A

B

C xx0200000320

3.

•


•

B: Shackle (2 pcs)

•

C: Eyebolt (2 pcs)

Attach the straps to the lift, or crane, as shown in figure above!



Step Action 4.

Note

Place the trolley under the wrist unit and guide it into the correct position as the manipulator is lifted, as shown in the adjacent figure.

A B

C E

D

xx0200000321

5.

When the wrist is resting squarely on the trolley 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 trolley. Dropping the manipulator onto the trolley can cause damage to the manipulator and/or affect the calibration of the tripod.

•


•

B: Wrist unit

•

C: Trolley

•

D: 125 mm

•

E: 400 mm

xx0200000322


33


Step Action 6.

As the manipulator is lifted off the pallet, carefully remove the pallet to allow free movement of the trolley towards the centre of the lift, as shown in the adjacent figure.

7.

Continue lifting the manipulator until it leaves the trolley and is hanging vertically, as shown in the adjacent figure.

8.

Lift the manipulator and move it to the required location.

Note

xx0200000323

xx0200000324



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 equipment

Lifting in vertical orientation, using a lifting jack

Equipment

Note

Crane or hoist




1 strap, length 1 m



M16

2 shackles


Lifting jack


The section below details how to lift and move the manipulator from the transportation pallet, vertically, using the lifting equipment specified above.

The IRB 940 manipulator weighs 570 kg! All lifting equipment used must be dimensioned accordingly!




35


Step Action

Note

1.

Unless already in posi- Dimension specified above! tion, fit the eyebolts to the upper platform.

2.


A

B

C xx0200000320

3.

•


•

B: Shackle (2 pcs)

•

C: Eyebolt (2 pcs)

Attach the straps to the lift, or crane, as shown in figure above.



Step Action 4.

Note

Attach the 1 metre strap to the wrist as shown in the adjacent figure.

xx0200000317

5.

Connect one end of the Dimension specified above! lifting jack to the strap around the wrist and B the other to the lift, or crane. Adjust the length so that the lifting jack is tightened, as shown in the adjacent figure. A

xx0200000325

6.

•

A: Strap around wrist unit

•

B: Crane

Lift the whole manipulator using the lift, or crane, away from the pallet and remove the pallet.


37


Step Action 7.

Note

Lower the wrist end of the manipulator using the lifting jack. When the wrist gets near the floor, raise the whole manipulator further, as shown in the adjacent figure. Repeat until the manipulator hangs vertically.

xx0200000326

8.

Remove the lifting jack and lift the manipulator to the required location.



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 manipulator arm!

Step Action

Info/Illustration

1.

The push-button unit is equipped with six but- The push-button unit is tons for controlling the axis brakes. The but- located on the outside of tons are numbered with the axes numbers. 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.


39


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 connections".

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.

Suitable screws, lightly lubricated

MC6S, M16 x 55

Quality

Quality 8.8

Suitable washer

Thickness: 4 mm

Tightening torque

200 Nm

A locating pin may be used in the mounting flange, when necessary. The dimension for the attachment hole is detailed in part "Hole configuration, mounting flange".



Illustration, securing manipulator at stand

The figure below shows how to mount the manipulator to a stand. The figure shows prepared cabling in the stand.

B

A

C

xx0200000348

A

Manipulator attachment bolts

B

Centering ring

C

Mounting flange


41


Securing the manipulator

This section details how to secure the manipulator to the stand in a vertical position, after fitting the stand to the foundation.

Step

Action

Info/Illustration

1.

Lift and turn the manipulator to vertical orien- Detailed in "Lifting the tation. manipulator in a vertical orientation, using a trolley/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 attachment hole for the pin is shown in part "Hole configuration, 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.



Hole configuration, 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.

A

A

A-A (Ø400) Ø350 53 86.5

C-C

C

18 Through ˜ 8x)

C

3 Ø10 H8 Through

6

87.5 xx0200000358


43


Fitting equipment on manipulator

General

The manipulator features mounting holes for additional equipment.

Illustration, fitting of extra equipment on upper platform

The illustration below shows the mounting holes available for fitting extra equipment on the upper platform.

309.5

4

x M8x12 Deep

xx0200000360



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.


45


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 operational stops may result.

References

Load diagrams, permitted extra loads (equipment) and their positions are specified in the Product Specification. The loads must also be defined in the software as detailed in the User’s Guide.

Brake performance

Manipulator motor brake performance depends on any loads attached. For further information about brake performance, please contact ABB Robotics.


Manipulator Electrical connections

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 connected 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.

A

xx0200000349

A

Cabling in one of the two grooves in the upper platform


47


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, Connection points detailed in "Conto the motors of axes 1-2-3. Fit the necting the manipulator to the concables to the brackets mounted trol cabinet, manipulator cabling". nearby the motors and secure with straps.

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.

5.

Fasten the cable chain with attachment screws in the cable bracket at axis 2 and at top of the housing.

Connection points detailed in "Connecting the manipulator to the control cabinet, manipulator cabling".

4x

4x

xx0200000428



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 categories Cable category

Description

Manipulator cables

The cables between the distribution box and the manipulator 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 manipulator's motors as well as feedback from the serial measurement board.


49


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

Cable sub-category

Connection point, Connection point, distribution box manipulator

Manipulator cable, power, axis 1

XM1

XM1.1

Manipulator cable, signal, axis 1

XR1

XR1.1


XM2

XM2.1


XR2

XR2.1


XM3

XM3.1


XR3

XR3.1


XM4

XM4.1


XR4

XR4.1


XM5

XM5.1


XR5

XR5.1


XM6

XM6.1


XR6

XR6.1

These cables are included in the standard delivery. They are completely pre-manufactured and ready to plug in.

Cable subcategory Distribution box cable, power

Description Transfers drive power from the drive units in the control cabinet to the manipulators distribution box.

Connection Connection point, point, cabinet distribution box XS1

R1.MP



Cable subcategory Distribution box cable, signals

Description

Connection Connection point, point, cabinet distribution box

Transfers resolver XS2 data from the serial measurement board and power supply to the SMB in the distribution box.

R1.SMB

Distribution box cable, power Cable

Article number

Distribution box cable, power, 7 m

3HAC 11818-1


3HAC 11818-2


3HAC 11818-4

Cable

Article number

Distribution box cable, signal, shielded, 7 m

3HAC 7998-1


3HAC 7998-2


3HAC 7998-4

Distribution box cable, signals


51


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 controller.

Connectors on the distribution box

All distribution box connectors are shown in the figure below.

R1.MP

R1.SMB

XM4 XM1 XM5 XM2 XM6 XM3 XR1 XR2 XR3

XR4 XR5 XR6

xx0200000430

The connectors on the controller cabinet are located as detailed in part "Connectors on the controller cabinet, S4CPlus".


Controller

Chapter 4:Controller Introduction

Definitions

This chapter contains necessary information for installing the controller to the working site.


53

Controller Unpacking

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 conform 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

Storage conditions, controller cabinet

The table below shows the weights for the controller cabinet:

Controller

Weight

S4Cplus controller cabinet

240 kg

Distributed Drive Unit (option)

30 kg

The table below shows the allowed storage conditions for the controller:

Parameter

Value

Min. ambient temperature

-25°C

Max. ambient temperature

+55°C

Max. ambient temperature (less than 24 h) +70°C Max. ambient humidity



Controller Unpacking

The table below shows the allowed operating conditions for the controller: Operating conditions, controller cabinet

Protection class, controller

Parameter

Value

Min. ambient temperature

+5°C

Max. ambient temperature

+45°C

Max. ambient humidity


The table below shows the protection class of the controller:

Equipment

Protection class

Control cabinet

IP 54

Programming unit

IP 54

Distributed Drive Unit (option)

IP 54


55

Controller On-site Installation

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.

A

B xx0100000153

Cabinet delivered without top cover

A

Min. 60°when lifting with straps

B

Fork lift

If the controller is delivered without its top cover, a fork lift must be used. Do not use lifting devices!



Required installation space, control cabinet

Dimensions

The figure below shows the required installation space for the S4CPlus control cabinet: A

200

200

800

800

B

820

950 980*

500 70 620

xx0100000156

A

Air distance to wall

B

Cabinet extension (Option 124)

*

Castor wheels (Option 126)


57


Bolt pattern, control cabinet

Dimensions

The figure below shows the bolt pattern for the S4CPlus control cabinet:

720

400

xx0100000157



Installation of external power transformer

Location of external power transformer

The external power transformer (option) is located outside the controller as shown in the figure below:

B A

xx0100000154

A

Cable glands for input and output cables (large gland; input cable, small gland; output cable)

B

Locking screws/lifting lugs

Required equipment Equipment, etc. External power transformer unit

Spare part no. Art. no.

Note

3HAC 11668-1

Input cables

Rec. 16 mm 2

Output cables

Rec. 6 mm 2


59


Equipment, etc.


Note

Fuse and holder

Mains voltage 200 VAC: 63 A Mains voltage 600 VAC: 25 A

Circuit breaker

Dimensioned for the expected currents

Standard toolkit

3HAC 15571-1

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

Connections

The contents are defined in section "Standard toolkit"! These procedures include references to the tools required.

Circuit Diagram, controller

3HAC 5582-2

Circuit Diagram, external power transformer

3HAC 11668-11

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 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!

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!



Step

Shop mains power supply

Action

Note/Illustration

3.

Connect the external power transformer out- Detailed in "Transformer put. output" below!

4.

Connect the controller input.

Detailed in "Controller input" below!

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 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!

Step 1.

Transformer input

Action

Note/Illustration

Make sure the shop supply is fitted with suit- Fuse size specified in the able circuit breakers and fuses. table above!

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 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!

Step 1.

Action

Note/Illustration

Run a cable from the shop supply outlet through the input cable inlet on the transformer unit.

Shown in the figure above!


61


Step

Transformer output

Action

Note/Illustration

2.

Open the transformer unit by removing the lock screws on top of the unit.


3.

Connect the input cable earth conductor to the earth terminal.

4.

Connect the three input phases to the long Terminal: X1 terminal. Make sure the cables are connected to the terminals marked with the voltage value corresponding to the voltage supplied.

5.

Make sure all terminals are tightened to ensure good electric contact.

Tightening torque: approx. 2 Nm

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 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!

Step

Action

Note/Illustration

1.

Run a cable from the transformer unit through Shown in the figure the output cable outlet to the robot controller. above!

2.

Connect the output cable earth conductor to the transformer unit earth terminal.

3.

Connect the three output phases to the output 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



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 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!

Step

Action

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 dependent on phase sequence): • Phase 1 to L1

4.

•

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.

Note/Illustration

A B C D

xx0100000155

•

A: Terminal X26

•

B: Connectors

•

C: Earth connection (PE)

•

D: Cable glands

Make sure all terminals are Tightening torque: approx. 2 Nm tightened to ensure good electric contact.


63


Installation of Distributed Drive Unit (DDU)

Required installation space, DDU

The external DDU (option) is located outside the control cabinet. The figure below shows the required installation space for the DDU.

A

300

A

A

xx0200000340

A

50 mm, required free area for the exhaust air



Bolt pattern, DDU

The DDU is to be suspended nearby the control cabinet, using the bolt pattern shown in the figure below.

260 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

•


•



65


Overheating

Changing the connection of the transformer

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 “External axes”.

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").



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.

A

B A

xx0200000373

Cabling

A

Vent

B

Covering plate

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 connect the DDU to either the controller, the manipulator or to the external axis.


67

Controller Electrical connections

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 activities are detailed in Customer Connection Kit. Connection Connection point, point, cabinet manipulator

Cable

Art. no.

Fieldbus cable, CAN, 7 m

3HAC 13173-1

XT/XP5.1 XT/XP6 XS6

R1.CP/CS


3HAC 13173-2

XT/XP5.1 XT/XP6 XS6

R1.CP/CS


3HAC 13173-4

XT/XP5.1 XT/XP6 XS6

R1.CP/CS

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


R1.CP/CS



Cable

Art. no.

Connection Connection point, point, cabinet manipulator

Fieldbus cable, Profibus, 30 m 3HAC 13174-4


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


3HAC 14890-1


R1.CP/CS


3HAC 14890-6


R1.CP/CS

Harness CP/CS, Interbus, 7 m 3HAC 15644-4


R1.CP/CS

Harness CP/CS, Interbus, 15 m

3HAC 15644-1


R1.CP/CS

Harness CP/CS, Interbus, 30 m

3HAC 15644-5


R1.CP/CS


69


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 connect 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



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 connect 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.

S77

XS78

XP40

GND

XP49

xx0200000372

The connections on the manipulator are located on the rear of the robot base.


71


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:

A

B

C D xx0100000248

A

XT 26

B

Protective Earth connection

C

Cable gland

D

Connector

Step 1.

Action

Info/Illustration

Remove the left cover plate under the top lid.



Step

Connection through a power socket

Action

Info/Illustration

2.

Pull the mains cable (outer diam. 10.2 mm) through the gland located on the left cabinet wall.


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.

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.

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.

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).

A xx0100000162

A

DIN connector


73


C - 2: Signal connections Signal Classes

Overview

Signals

Different rules apply to the different classes when selecting and laying cable. Signals from different classes must not be mixed.

•

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.



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 communication signals:

Shielded cable with twisted pair conductors.

A specific cable should be used for Gateway (Field bus) connections.

CAN bus with DeviceNet for distributing 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.


75


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).



Interference elimination

External units

External relay coils, solenoids, and other units that will be connected to the controller must be neutralized. The figure below illustrates how this can be done. The turn-off time for DC relays increases after 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. +24V

0V

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. +24V

0V

xx0100000164


77


Clamping with an RC circuit

R 100 ohm, 1W C 0.1 - 1 mF. >500V max. voltage, 125V nominal voltage. +24V DC, or AC voltage

R

C

0V

xx0100000165



Connection types

General

I/O, external emergency stops, safety stops, etc. can be supplied on screw connections or as industrial connectors.

Connections Designation

Connection type

X(T)

Screw terminal

XP

Pin (male)

XS

Sockets (female)


79


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.



Connections to connectors

Location of connectors

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/Framatome 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 connection

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-insulated 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.


81


A E C D

B

G

F

H J R

S

T

M

K

L

N P

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



T

EN2

Function of the MOTORS ON/ MOTORS OFF circuit

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.

Connection of safety chains

The diagram below shows the two-channel safety chain.

As long as the two chains are not identical, the robot will remain in MOTORS OFF mode.

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".


83


24V X3:12 X4:12

Ext LIM1 24V

K1 0V

X1:11 12 ES1

X3:10

Opto GS1 isol. TPU En1

8 11

&

Opto AS1 isol.

9

Auto1

K1

EN Run

Intern locking

K2

Man1

External contactors 0V 24 V 0V

X3:3 X4:3

4 4

CONT1 CONT2

Ext LIM2 X2:11 12

K2

8

Opto GS2 isol. TPU En2

11 9

Drive Unit

ES2

X4:10

24 V

&

M

Opto AS2 isol. Auto2

Man2

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"

<5V

External supply of GS/AS

Max. + 35 VDC Min. - 35 VDC



Technical data per chain Max. potential in relation to the cabinet earthing and other signal groups

300 V

Signal class

Control signals


85


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). A 24V 0V B

C

D

X1:3

1:4

X1:7 X1:10

X1:9

X1:8 X1:1 X1:2

24V

X1:6 E 24V

G 24V 0V

F B

D

C

2:4

X2:7 X2:8 X2:1 X2:2

24V

X2:6 H 24V X2:4 X2:5 J xx0100000191



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


87


Connection to MOTORS ON/ MOTORS OFF contactor

The diagram below shows the connection of terminals for customer use. A B

X3:2 1 X4:2 1 xx0100000193

A

K1 (Motor on/off 1)

B

K1 (Motor on/off 2)

Technical data Max. voltage

48 VDC

Max. current

4A


300 V

Signal class

Control signals



Connection to operating mode selector

The diagram below shows the connection of terminals for customer use.

S1.1.x1 8 A

7 6 5

B

S1.1.x1 4 D

C

3 2 1

E

F

xx0100000197

A

Auto 1

B

MAN1

C

100% (Option)

D

Auto 2

E

MAN2

F

100% (Option)


48 VDC

Max. current

4A


300 V

Signal class

Control signals


89


Connection to brake contactor

The diagram below shows the connection of terminals for customer use. A

X4:5 6

xx0100000199

A

K3 (Brake)


48 VDC

Max. current

4A


300 V

Signal class

Control signals



External customer connections on panel X1 - X4

Outline diagram

The diagram shows the customer connections X1 - X4 located on the panel unit. WARNING REMOVE JUMPERS BEFORE CONNECTING ANY EXTERNAL EQUIPMENT

xx0100000205

grey field

Connection of X1: 12-pole type Phoenix COMBICON connector

Jumper

The table below shows the signal descriptions for X1. The signal names refer to the Circuit Diagram.

Signal

Terminal no. Comment

ES1 out: A

1

Emergency stop out chain 1

ES1 out: B

2


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



91




Signal


ES1 bottom

9

Bottom of emergency stop chain 1

0V

10

0 V emergency stop chain 1

Ext. LIM1: A

11

External limit switch chain 1

Ext. LIM1: B

12



Signal


ES2 out: A

1


ES2 out: B

2


ES2 top

3

Top of emergency stop chain 2

0V

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


Sep. ES2: B

8


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


Ext. LIM2: B

12



Signal


Ext. MON 1: A 1

Motor contactor 1

Ext. MON 1: B 2

Motor contactor 1




Signal


0V

3

External contactor 1 0 V

CONT1

4

External contactor 1

5

No connection

6

No connection

0V

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


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

0V

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


93


Connection of external safety relay

Description

The motor contactors K1 and K2 in the controller can operate with external equipment if external relays are used. The figure below shows two examples of how to connect the external safety relays:



Connection examples

A

B

X4:4 CONT 2 24 V X4:3 E xt MON 2 X4:2

0V

K2 X4:1 X3:2 K1 E xt MON 1

X3:1

24 V

0 V X3:3 CONT 1 X3:4

C

D

E AS F

AS

GS

GS

F G

E K H J xx0100000246

A

Panel unit


95


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)

C - 4: Supplies External 24V supply

When is an external supply recommended?

How to connect the external supply

An external supply is recommended to make use of the advantages offered by the galvanic insulation on the I/O units or on the panel unit. An external supply must be used in the following cases: •

When the 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.

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 Potential difference to chassis earth Max. 60 V continuously Max. 500 V during 1 minute



Permitted supply voltage

I/O units 19 VDC - 35 VDC incl. ripple Panel unit 20.6 VDC - 30 VDC incl. ripple


97


24V I/O supply

General

24 VDC supply for internal and external use

24 VDC supply available at XT 31

The 24V I/O is not galvanically separated from the rest of the controller voltages.

Voltage

24.0 - 26.4V

Ripple

Max. 0.2V

Permitted customer load

Max. 7A

Current limit

13,5 ~0A.

24V I/O available for customer connections at XT 31 is shown in the figure in "Connections to screw terminals".

XT.31.2

24 V (through a 2 A fuse)

XT.31.1

for own fuses

XT.31.4

0 V (connected to cabinet structure)



115/230 VAC supply

General

115/230 VAC supply for internal and external use

115/230 VAC supply available at XT 21

This voltage is used in the robot for supplying optional service outlets. The AC supply is not galvanically separated from the rest of the controller voltages.

Voltage

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

115 VAC/230 VAC available for customer connections at XT 21 is shown in the figure in "Connection to screw terminals".

XT.21.1-5

230 VAC

XT.21.6-8

115 VAC

XT.21.9-13

N (connected to cabinet structure)

C - 5: Buses Connection of the CAN bus

Illustration

The illustration below shows an example of how to connect the CAN bus:


99


C A

D

D

D

X15 CAN1.1 (Internal I/O)

B

X6 CAN1.2 X7 CAN1.3

G D

D

D

D

D

D E

X15, X6, X7

1. 2. 3. 4. 5.

0V_CAN CAN_L drain CAN_H 24V_I/O

1. 2. 3. 4. 5.

F

xx0100000241

A

Base connector unit

B

CAN bus



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!

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 somewhere between the end points of the chain, then no terminating resistor should be mounted in CAN 1.3. This is in accordance with the basic rule, i.e. the CAN chain should be terminated in both end points.

CAN 1.3

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 somewhere between the end points of the chain, then no terminating resistor should be mounted in CAN 1.3. This is in accordance with the basic rule, i.e. the CAN chain should be terminated in both end points.


101


Termination resistors in CAN bus

The CAN chain must be terminated with terminating resistors at each end!

CAN 2

The illustration below shows an example of how to connect the CAN 2 bus:

If CAN 1.2, for example, is not connected at the end of any CAN chain but somewhere between the end points of the chain, then no terminating resistor should be mounted in CAN 1.3.

A

C

B D

X8 CAN 2

D

D

E

1. 0V_CAN 2. CAN_L 3. drain 4. CAN_H 5. 24V_I/O

X8

1. 0V_CAN 2. CAN_L 3. drain 4. CAN_H 5. 24V_I/O

1. 2. 3. 4. 5.

F

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



The illustration below shows CAN connections on base connector unit:

A B C D

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)


103


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 InterbusS 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 information

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:



X20

X21

X5

X3

xx0100000225

Communication concept

X3

Power connector

X5

DeviceNet connector

X20

Interbus-S, input

X21

Interbus-S, output

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:


105


E A

F

B In

C Out

In *1

D Out

In

Out

*1

xx0100000224

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


*1

xx

Termination link

A link is connected between pins 5 and 9 in the plug on the interconnection cable connected to the OUT connector of each unit. The link informs the Interbus-S unit that more units are connected further out in the chain. (The last unit in the chain does not have a cable connected and therefore no link).

Connections, X5 DeviceNet connectors

See DeviceNet Connectors.



Connections, connector X20, Interbus-S IN

The figure below shows the pin configuration of the connector:

5

1

6 9

xx0100000220

The table below shows the connections to connector X20, Interbus-S IN:

Connections, 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

6 9

xx0100000220

The table below shows the connections to connector X21, Interbus-S OUT:


107


Connections, connector X3

Signal name

X21 pin

Function

TPDO2

1

Communication line TPDO2

TPDI2

2

Communication line TPDI2

GND

3

Ground connection

NC

4

Not connected

+5V

5

+ 5 VDC

TPDO2-N

6

Communication line TPDO2-N

TPDI2-N

7

Communication line TPDI2-N

NC

8

Not connected

RBST

9

Synchronization


5

1

xx0100000221

The table below shows the connections to connector X3:

Bus status LEDs

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

The designations refer to LEDs shown in the figure in section "Layout, DSQC 352" above.



The figure and table below show the location and significance of the 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 description".

CAN Tx/CAN Rx

Green/red


POWER- 5 VDC

Green

Lit when both 5 VDC supplies are within limits, 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 parameter 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.


109


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 information

For setup parameters, see User’s Guide - System Parameters, Topic: I/O Signals. Also see the Circuit diagram.

Layout, DSQC 352




X20

X5

X3

xx0100000223

Communication concept

X3

Power connector

X5

DeviceNet connector

X20

Profibus connection

The Profibus-DP system is able to communicate with a number of external devices, depending on the number of process words occupied by each unit. The robot may be equipped with one or two DSQC 352. The Profibus-DP inputs and outputs are accessible in the robot as general inputs and outputs. An outline diagram of the communication concept is shown below:

E A

B

F C

D

xx0100000222


111


A

Master PLC

B

Robot 1, word 1:8

C

Robot 1, word 9:16

D

Robot 2, word 17:24

E


F


Termination

The Profibus cable must be terminated in both ends.

Connections, X5 DeviceNet connectors

See "Device Net Connectors".

Connections, connector X20, Profibus-DP


5

1

6 9

xx0100000220

The table below shows the connections to connector X20, Interbus-S IN:

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

+5 VDC

6

Ground




Signal name

X20 pin

Function

NC

7

Not connected

RxD/TxD-N

8

Receive/Transmit data N

NC

9

Not connected


5

1

xx0100000221


Bus status LEDs

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

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.

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.


113


Designation

Color

Description

NS/MS

Green/red


CAN Tx/CAN Rx

Green/red


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 connectors. If power is applied to the unit but it does not work, replace the unit.

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.



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)


115


Distributed I/O, digital I/O DSQC 328 (option)

General

The digital I/O unit handles digital communication between the robot system and any external systems.

Technical data No. of inputs

16 (divided into two groups of 8, galvanically isolated from each other)

No. of outputs


Supply voltage

24 VDC

Supply source

24 V I/O or separate external supply

Also see Product Specification for controller S4Cplus.

Further information

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: A

1

2

3

4

5

6

7

8

OUT

MS

IN

NS

X1

X3

OUT 9

10

11

12

13

14

15

16

IN

X2 1

1

10

1

12

10

X4 1

10

10

1 X5

xx0100000240

A

Status LEDs




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:


Unit function

Signal name

X1 pin

Optically isolated output

Out ch 1

1


Out ch 2

2


Out ch 3

3


Out ch 4

4


Out ch 5

5


Out ch 6

6


Out ch 7

7


Out ch 8

8


0 V for outputs 1-8

9


24 V for outputs 1-8

10


Unit function

Signal name

X2 pin


Out ch 9

1


Out ch 10

2


Out ch 11

3


Out ch 12

4


Out ch 13

5


Out ch 14

6


Out ch 15

7


117



Unit function

Signal name

X2 pin


Out ch 16

8



9



10


Unit function

Signal name

X3 pin

Optically isolated input

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 inputs 1-8

9


Not used

10

The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected to ground, to prevent disturbances, causes a short rush of current when setting the input. When connecting outputs, sensitive to pre-oscillation current, a series resistor (100 W) may be used.



Unit function

Signal name

X4 pin


In ch 9

1


In ch 10

2



Unit function

Signal name

X4 pin


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 inputs 9-16

9


Not used

10



119


AD Combi I/O, DSQC 327 (optional)

General

The digital I/O unit handles digital and analog communication between the robot system and any external systems.

Technical data No. of digital inputs


No. of digital outputs


No. of analog outputs

2 (galvanically isolated from the controller electronics)

Supply voltage

24 VDC

Supply source, digital I/O


Supply source, analog I/O 24 V_CAN (with galvanically isolated DC/AC converter)


Further information


Layout, DSQC 327

The figure below shows the layout of the DSQC327 board:



A

1

2

3

4

5

6

7

8

OUT

MS

IN

NS

X1

X3

9

10

11

12

13

14

15

IN

X2 1

1

12

X6 1

10

10

1

X4

10

OUT

16

1

6

10

1 X5

xx0100000239

A

Status LEDs

Connector X5 is a CAN connector further described in section "Connection and address keying of the CAN bus".



Unit function

Signal name

X1 pin


Out ch 1

1


Out ch 2

2


Out ch 3

3


Out ch 4

4


Out ch 5

5


Out ch 6

6


Out ch 7

7


Out ch 8

8


0 V for outputs 1-8

9



10


121





Unit function

Signal name

X2 pin


Out ch 9

1


Out ch 10

2


Out ch 11

3


Out ch 12

4


Out ch 13

5


Out ch 14

6


Out ch 15

7


Out ch 16

8



9



10


Unit 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 inputs 1-8

9


Not used

10




Connections, connectors X6


Unit function

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 inputs 9-16

9


Not used

10

The table below shows the connections to connectors X6:

Signal name:

X6 pin:

Explanation:

AN_ICH1

1

For test purposes only

AN_ICH2

2

For test purposes only

0V

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



123


Analog I/O, DSQC 355 (optional)

General

The analog I/O unit handles communication between the robot system and any external systems through analog sensors.

Technical data No. of analog inputs

4 (-10 V/+10 V)


3 (-10 V/+10 V) 1 (4-20 mA))


2 (galvanically isolated from the controller electronics)

Supply voltage

24 VDC


Further information


Layout, DSQC 355




X7

X8

X8

Bus s tatus

X7

S2S3 X2 X5 X3 Analog I/O

DS QC 355

X5

AB B F lexible Automation

X3

xx0100000238

Connections, connectors X7 analog output

X3

Not used

X5

DeviceNet input and ID connector

X7

Analog outputs

X8

Analog inputs


1

13

12

24

xx0100000236


125



Signal name: X7 pin:

Explanation:

ANOUT_

1

Analog output 1, -10 V/+10 V

ANOUT_

2


ANOUT_

3


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


GND

21


GND

22


GND

23

GND

24

The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected to ground, to prevent disturbances, causes a short rush of current when setting the input. Connect a resistor (100 W) in series when connecting outputs, sensitive to preoscillation current.



Connections, connectors X8 analog input


1

17

16

32

xx0100000237



Explanation:

ANIN_1

1

Analog input 1, -10 V/+10 V

ANIN_2

2


ANIN_3

3


ANIN_4

4


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


127



Explanation:

+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

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 preoscillation current.

Bus status LEDs


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.



Designation

Color

Description

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.

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.

+5VDC / +12VDC / -12VDC


129


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 movements). 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 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


Further information

User reference Description Conveyor Tracking. For setup parameters, see User’s Guide - System Parameters, Topic: Controller. Also see the Circuit Diagram.



Layout, DSQC 354


X20

X5

X3

xx0100000233

X3

Not used

X5

DeviceNet input and ID connector

X20

Conveyor connection


131


Encoder connections

The figure below shows the encoder connections: AF AA AB 24 VDC 0V AC

A B 24 VDC

AD

0V

AE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Opto Opto

Opto

Opto Opto

Opto

AG

xx0100000234

AA


AB


AC

Encoder

AD

Sync switch

AE

10-16 not used

AF

Encoder unit

AG

Galvanic isolation



Connections, connectors X20 encoder and digital input connections



Explanation:

24 VDC

1

24 VDC supply

0V

2

0V

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

0V

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

The figure below shows the layout of the pins in connector X20:

16

1

xx0100000235


133


Bus status LEDs


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


CAN Tx/CAN Rx Green/red


ENC 1A/1B

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).

Green

•

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.



Designation

Color

Description

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.


135


Relay I/O, DSQC 332 (optional)

General

The unit handles communication between the robot system and any external systems through relay outputs and digital inputs.



No. of relay outputs

16 (a single normally open contact, isolated from each other)

Supply voltage

24 VDC

Supply source



Further information


Layout, DSQC 332

The figure below shows the layout of the DSQC 332 board: A

1

2

3

4

5

6

7

8

OUT

MS

IN

NS

OUT 9

10

11

12

13

14

15

16

IN

X1

X2 16

1

16

1

X3

X4 16

1

12

1

16

1 X5

xx0100000232

A

Status LEDs





X1

See below for connection tables!

X2


X3


X4


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


137



Signal name

X2 pin

Function

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

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




Signal name

X3 pin

Not used

12

Not used

13

Not used

14

Not used

15

Not used

16


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


139


Digital I/O (120 VAC), DSQC 320 (optional)

General

The unit handles communication between the robot system and any external systems through galvanically isolated outputs and inputs.

Technical data No. of inputs

16 (galvanically isolated from each other)

No. of outputs

16 (galvanically isolated from each other)

Supply voltage

120 VAC


Further information


Layout, DSQC 320

The figure below shows the layout of the DSQC 320 board: A

1

2

3

4

5

6

7

8

OUT

MS

IN

NS

OUT 9

10

11

12

13

14

15

16

IN

X1

X2 16

1

16

1

X3

X4 16

1

12

1

16

1 X5

xx0100000231

A

Status LEDs

X1


X2






X3


X4


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


Out ch 2a

3


Out ch 2b

4


Out ch 3a

5


Out ch 3b

6


Out ch 4a

7


Out ch 4b

8


Out ch 5a

9


Out ch 5b

10


Out ch 6a

11


Out ch 6b

12


Out ch 7a

13


Out ch 7b

14


Out ch 8a

15


Out ch 8b

16



Signal name

X2 pin

Function

Out ch 9a

1


Out ch 9b

2



141



Signal name

X2 pin

Function

Out ch 10a

3


Out ch 10b

4


Out ch 11a

5


Out ch 11b

6


Out ch 12a

7


Out ch 12b

8


Out ch 13a

9


Out ch 13b

10


Out ch 14a

11


Out ch 14b

12


Out ch 15a

13


Out ch 15b

14


Out ch 16a

15


Out ch 16b

16



Signal name

X3 pin

Function

In ch 1a

1

AC input signal from switch 1/Neutral voltage to switch 1

In ch 1b

2


In ch 2a

3


In ch 2b

4


In ch 3a

5


In ch 3b

6


In ch 4a

7


In ch 4b

8


In ch 5a

9


In ch 5b

10





Signal name

X3 pin

Function

In ch 6a

11


In ch 6b

12


In ch 7a

13


In ch 7b

14


In ch 8a

15


In ch 8b

16



Signal name

X4 pin

Function

In ch 9a

1


In ch 9b

2


In ch 10a

3


In ch 10b

4


In ch 11a

5


In ch 11b

6


In ch 12a

7


In ch 12b

8


In ch 13a

9


In ch 13b

10


In ch 14a

11


In ch 14b

12


In ch 15a

13


In ch 15b

14


In ch 16a

15


In ch 16b

16



143


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.



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. Allen Bradley control system

Robot 1 - 128 in / 128 out Quarter 1 Quarter 2

Robot 2 - 64 in / 64 out Quarter 1

128 in / 128 out

Quarter 3 Quarter 4 Rack ID 12 (example) Rack size 4 Starting quarter 1

64 in / 64 out

Other systems Quarter 1 Quarter 2

Quarter 2 Rack ID 13 (example) Rack size 2 Starting quarter 1

Quarter 3 Quarter 4

Robot 3 - 64 in / 64 out Quarter 3

64 in / 64 out

Quarter 4 Rack ID 13 (example) Rack size 2 Starting quarter 3 en0100000255


145


RIO, remote I/O for Allen-Bradley PLC DSQC 350

General

The unit handles communication between the robot system and the Allen Bradley system.


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

Also see the Allen-Bradley RIO specification.

Further information

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


X5 X9

X3

X8 DS QC 350

AB B F lexible Automation

xx0100000226




X3

Not used

X5

DeviceNet and ID connector

X8

RIO in

X9

RION out


5

1

xx0100000221



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


5

1

xx0100000221


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


147


Termination

When the robot is last in a RIO loop, the loop must be terminated with a termination 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-Bradley Company, Inc. does not warrant or support this product. All warranty and support services for this product are the responsibility of and provided by ABB Flexible Automation.

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

POWER-24 VDC Green

Description 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


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



Communication, serial links

General

Further information

Technical data

The robot has three serial channels, which can be used by the customer to communicate with printers, terminals, computers, and other equipment (see the figure in "Connections" below). •

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, transmission 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.

•

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 terminals").

See Product Specification for controller S4Cplus. Separate documentation is included when the option RAP Serial link is ordered.


149


Connections

The figure below shows the connection of serial channels:

A

xx0100000219

A

External computer

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: 5

1

6 9

xx0100000220

The table below shows the signals from the COM1 (RS232):

Signal

Pin

Description

DCD

1

Data carrier Detect

RX

2

Receive Data

TX

3

Transmit Data



Connections on DSQC 504, D-sub connector X10, COM2

Signal

Pin

Description

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

The figure below shows the pin configuration of the connector: 5

1

6 9

xx0100000220


COM2 Signal name

X10 pin 1

RxD (Receive Data)

2

TxD (Transmit Data)

3

DTR (Data Terminal Ready)

4

0V

5

DSR (Data Ready Set)

6

RTS N (Request To Send N)

7

CTS (Clear To Send)

8 9


151


Connections on DSQC 504, D-sub connector X9, COM3

The figure below shows the pin configuration of the connector: 5

1

6 9

xx0100000220


Connections to MC/CONSOLE

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

0V

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

The figure below shows the MC/CONSOLE connection behind the service hatch:

A

xx0100000218



A

External computer

Standard RS232 port intended for temporary use, e.g. connection of laptop/PC. The table below shows the signals on the MC/CONSOLE (RS232):

Signal

Pin

Description

RX

2

Receive Data

TX

3

Transmit Data

GND

5

Signal Ground


153


Communication, Ethernet

General

Connection of LAN (Main computer)

The robot has two Ethernet channels available: •

LAN (connected to the Main computer)

•

Service (connected to the I/O computer)

The figure below shows an outline diagram of the Ethernet TCP/IP:

A

B

C

E thernet hub xx0100000217

A

External computer

B

Controller Robot 1

C

Controller Robot 2

Used for connection of shielded twisted-pair Ethernet (TPE), or as defined in IEEE 802.3: 10/100 BASE-T. Maximum node-to-node distance 100 meter. The main computer board has no termination for a cable shield. The cable shield must be grounded at the cabinet wall with a cable gland. 10BASE-T is a point-to-point net, connected via a HUB, see the figure above.

Signal

X1 Pin

Description

TX+

1

Transmit data line +



Signal

X1 Pin

Description

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

The figure below shows the main computer board front: 1

8

X1 LAN

PWR

HDD

STATUS

X2 xx0100000216


155


Connection of Service (I/O Computer)

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:

E thernet

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.



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: A

B M8 (x4)

M4 (x4)

62

C 45° 70 140 184 200

D

E 90 ø5 (x2)

155

F G

xx0100000214

A

Holes for operator’s panel

B

Holes for flange


157


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


Controller Start-up

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 identification 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


159

Controller Start-up

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.


Controller Start-up

• 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.


161

Controller Installation of controller software

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 controller software and settings are already stored in the storage memory and the system is ready to use.

Software not installed on delivery

If the robot controller is ordered and delivered without software or if you want to reconfigure your system, the RobInstall tool must be used to install the controller software. The RobInstall tool is included on the RobotWare CD-ROM (see section "RobotWare CD-ROM"). The RobInstall tool can be used both for creation of the controller software and for downloading it to the controller system.

Types of software loading

A B C E

D

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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

When downloading, the controller software can be transferred to the controller storage memory in three ways as shown in the figure above.

Boot Image

•

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 computer (MC).

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.


163


RobotWare CD-ROM The CD contains all the System software and should therefore be treated and stored carefully.

RobotWare CDROM contents

The RobotWare CD-ROM contains the following:

Contents

Description

1.

RobInstall

A PC tool used to create and install the controller operating system in the robot control system.

2.

Documentation

On-line documentation for the RobInstall application and the Controller Operating System Package.

3.

Controller OS Package

Controller Operating System Package for S4Cplus. This package includes all the software 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 MotionTest Signals (oscilloscope function) and also for logging these signals.

5.

FTP Client

On the CD is also included a so called FTP client 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 registered for permanent use. Registering means that a certain fee must be paid to the vendor. The FTP client is used to transport files manually 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 Windows Explorer.



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, Documentation, Controller OS Package and Test Signal Viewer should be marked as selected.

Installation of the FTP Client on the PC

This section describes how to install the FTP Client onto a PC hard drive. 1. In the Explorer, select and open the directory "ftp" on the CD. 2. Double-click the file ftpvsetup.exe. The Install Shield for the FTP client will start and guide you through the installation. Please read the "Readme" file for information about license regulations.


165


Installing new Robot Controller Software with RobInstall

General

Nomenclature

How to use RobInstall

Since most systems have the operating system installed already on delivery, the RobotWare CD-ROM is normally not needed. However it should be used when: •

creating a new controller operating system,

•

changing the current operating system configuration, e.g. concerning included options.

In the text dealing with RobInstall, the following nomenclature is used:

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.

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.



Step

Action

1.

Make sure RobInstall is installed. If not, install it according to the instructions in section "Installation of the RobotWare on the PC".

2.

Click the start button on your PC and select programs/ABB Robotics/RobInstall/RobInstall.

3.

The RobInstall start window will open.

Illustration/Info

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167


Create a new Robot Controller System

Setting up the system Step

Action

1.

Start RobInstall as described in section "How to use Robinstall".

2.

Choose New to create a new Robot Controller system as shown in the figure.

Illustration/Info

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3.

Enter a name for the new controller system. Select a saving location or use the default directory, normally "Program Files\ABB Robotics\system" (see the figure below, position 1).

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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).



Step

Action

5.

Press OK. The configured system will be displayed in the next window (see the figure below).

6.

If no external options or parameters are to be added or changed, press Finish to create the new controller system. Otherwise press Next to continue to "Additional Keys" (see section "Add or remove external options").

Illustration/Info

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Add or remove external options Step 1.

Action

Illustration/Info

To add or remove external options, press Next in the screen shown in the last figure in section "Setting up the system" or click on "Additional Keys" in the menu to the left.

xx0100000182


169


Step

Add or remove additional system parameters

Action

Illustration/Info

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 "Parameter Data" (see section "Add or remove additional system parameters).

Step

Action

1.

To add or remove additional 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.

2.

Press Add to load manipulator calibration data (see the figure above, position 1). This is the calib.cfg file delivered on the Manipulator Parameter disk (see section "The manipulator parameter disk").

Illustration/Info

xx0100000183



Step

Change options or system pack revision

Action

3.

To remove manipulator calibration data, press Remove.

4.

Press Add to load additional system parameters, see pos. 2. All system parameter files added here will be automatically loaded together with the system, when the controller 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 system pack revision").

Step 1.

Action

Illustration/Info

Illustration/Info

To change the option configuration, press Next in the screen shown in the figure below or click on "Options" in the menu to the left.

xx0100000184


171


Step

Action

2.

To change the Teach Pendant Unit language, robot type, or software options, press Options (see the figure above, position 1).

3.

Normally the latest release or revision of all system packages and option packages stored in the media pool (see section "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 further 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.

Illustration/Info



Update the Robot Controller image

Actions Step 1.

Action

Illustration/Info

To update an existing controller system, press Update, see the figure below.

xx0100000189

2.

Select a system in the system 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


173


Step 3.

Action

Illustration/Info

The window displaying the current configuration of the system will be shown. Follow the instructions in sections "Add or remove external options", "Add or remove additional system parameters" or "Change options or system pack revision" to modify the system.



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 you are using:

...then see instructions in section:

...and continue in section:

a direct connection between "If using a direct connection "Download Robot PC and IOC service outlet between PC and IOC service Controller System" on controller outlet on controller" below! below!

If using a direct connection between PC and IOC service outlet on controller

Network Intranet connection "If using Network Intranet with fixed IP addresses connection with fixed IP addresses " below!

"Download Robot Controller System" below!

Network Intranet connection "If using Network Intranet with DHCP (Dynamic Host connection with DHCP " Configuration Protocol) below!

"Download Robot Controller System" below!

Step

Action

1.

Connect a patch-cable between the Ethernet connection on the front of the controller and the corresponding connection on the PC/Laptop.

2.

Make sure that the Network protocol is set for TCP/IP properties.

Illustration/Info


175


Step 3.

Action

Illustration/Info

Change the TCP/IP Properties in accordance with the following table and figure:

xx0100000178

If using Network Intranet connection with fixed IP addresses

Step

Action

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 CSTART (see section "C-start") on the S4Cplus controller.

4.

Configure the IP address to be used for the robot controller from the TPU.

Illustration/Info



If using Network Intranet connection with DHCP

Step 1.

Action

Illustration/Info

Read Ethernet MAC-id on the Teach Pendant Unit (see section "LAN settings").

Download Robot Controller System Before downloading, check the following: Make sure there is at least 25 Mb free disk space on the controller mass storage memory. For information on how to perform a manual storage capacity check, see section "Check Storage Capacity". Make sure that the robot controller displays the Start Window on the Teach Pendant Unit (see section "Start window").

Step 1.

Action

Illustration/Info

To download a controller system, press Download as in the figure below:

xx0100000176


177


Step

Action

Illustration/Info

2.

Select a target system as in If a direct connection is used with the patch the figure, position 1. cable between the PC and the controller front, then just select the default IP address (192.168.125.1) and "Direct" option. In other cases, write the correct IP address for the robot controller and select "Hostname or 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 figure below, position 2.

xx0100000177

4.

Test the connection by pressing Test Connection and press OK if a connection 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 6.

Action

Illustration/Info

RobInstall will now create a After downloading it is possible to restart system file and download it the controller with the new downloaded to the controller. controller system. Otherwise, the controller may be restarted from the Teach Pendant Unit as detailed in section "Reboot".


179


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 Diskettes from RobInstall

Step 1.

Action

Illustration/Info

Press Create Boot Disk as in the figure below.

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Step 2.

Action

Illustration/Info

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".


181


RobInstall preferences

Customizing RobInstall

RobInstall may be customized to suit particular requirements.

Step

Action

1.

To customize RobInstall for new programs and optional products, press Preferences as shown in the figure. See also chapter "System Directory Structure".

2.

To select another media pool (see section "Media Pool in the PC"), press Select Media Pool as shown in the figure, position 1.

Illustration/Info

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xx0100000187



Step 3.

Action

Illustration/Info

To add a new system package or option package to the media pool, press Import Program as shown in the figure, position 2. Also see chapter "System Directory Structure".


183

Controller Robot controller

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.



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 system, 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").


185


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").



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


187


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 1.

Action

Illustration/Info

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 previously loaded data and returns to the Start window as shown in the figure in section "Start window". xx0100000170



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".


189


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

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.

Node identification 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.



Parameter

Configure for fixed IP network

Type

Description

(Subnet mask) Network setting

Shows the subnet mask of the network. Only visible when configured for fixed IP.

(Gateway)

Shows the gateway IP for the network. Only visible when configured for fixed IP.

Network setting

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.


191


Service Settings Window

When is it shown?

The Service Settings window will be displayed when Service Settings is pressed in the Network Settings window as shown in the figure in section "Network Settings".

en0100000257

OK

returns to the Start window as shown in the figure in section "Start Window".

Service Setting Parameter

Description

IP (service setting) The IP Address for the I/O Computer IP

Required to configure your PC’s network settings for communication between RobInstall and the I/O Computer.

Subnet mask


Gateway




System selection window

When is it shown?

The Select System window will be displayed when Select System is pressed in the Start window, as shown in the figure in section "Start Window".

xx0100000171

CANCEL

How to select system

returns to the Start window as shown in the figure in section "Start Window".

The window shows all systems installed on the controller mass storage memory.

Step 1.

Action

Illustration/Info

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


193


How to perform a Restart

General

Performing a restart may be done in a number of ways. These are detailed below:

Reboot (Warm start), apply changed settings

When executing a Warm start, the system reboots with the current system, e.g. to make new or changed settings take effect.

Step 1.

Action

Illustration/Info

Press the button Miscellaneous and select Service window or System Parameter window

Miscellaneous button:

xx0100000194

2.

P-START, reinstallation of RAPID

Select Restart from the File menu and press OK. The system reboots and returns to the Welcome window as shown in the second figure in section "Select System".

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.


2.

Select Restart from the File menu.

xx0100000194



Step

X-START, change active controller system

Action

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 figure in section "Select System".

Illustration/info

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).

Step

Action

Illustration/Info

1.

Press the button Miscellaneous and select Service window.


2.


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".

xx0100000194

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


195


to set some values at start-up, e.g. language, IRB type (within the same model) or options (see section "Start in Query Mode").

Step

Action

Illustration/Info

1.

Press the button Miscellaneous and selectService window.


2.


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".

xx0100000194

C-START (Cold start), delete the active system

When executing a C-Start, the system exits the running system and deletes it from the mass storage memory. The BootImage is then executed and the Start window as shown in the figure in section "Start Window" is 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 1.

Action

Illustration/Info

Press the button Miscellaneous and selectService window.


xx0100000194

2.


3.

Enter the numbers: 1_3_4_6_7_9 (the fifth function key changes to C-START)

4.

Press C-START.


197


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:

Easy Query Mode

•

Silent Mode, pushbutton Silent. If Silent Mode is selected, the operating system will be installed with the system configured as defined in RobInstall.

•

Easy Query Mode, pushbutton Easy Query. In Easy Query Mode you can change language, remove selected options and select service or standard mode (see section "Easy Query Mode").

•

Query Mode, pushbutton Query. In Query Mode you can, 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").

If Easy Query was chosen as start-up query mode, the following steps will be required to start the system:

Step

Action

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").

Illustration/Info



Step 3.

Query Mode

Action

Illustration/Info

Install xxx? For every option that was selected in RobInstall (see section "Change options or system pack revision") it is now possible to select Yes to keep the option, or No to remove it from the system.

If Query Mode was chosen as start-up query mode, the following steps will be required to start the system:

Step

Action

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.

Illustration/info

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 configuration 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.


199

Controller System directory structure

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 conventions

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

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.



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 Program Files\ABB Robotics\ and will also be the current one. However any directory in the structure can be set up as the current system directory in the Create New System window or Select System window.

Directory view

Folder "System 1"

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xx0100000261

File system requirements

The system directory must hold these files and directories to allow software installation: •

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 installation procedure. All system parameter files, included when creating a system with RobInstall, are stored in this syspar directory as shown in the table in section "System Pool Directory".

•

A directory called Home. In this home directory the user can include any file or files, which should be downloaded to the controller together with the operating system. Such files will then be placed in the home directory of the system in the controller.


201


File structure in the robot controller mass storage memory

Files in root directory, hd0a

The root directory of the mass storage memory is called hd0a. This includes several components:

File name

Description

E.g. 3HAC6811-1.00 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

Directories and subdirectories

Each system directory holds a number of subdirectories, defining for instance language, options, robots, etc.

"Home" directory

The system directory is the "home" directory for the system. When using the address "home:" in the RAPID program, this directory will be addressed.

"Bin" subdirectory

The subdirectory bin, containing the storage area for all system data, e.g. at power break. This means that at warm start, in addition to restoring the operating system from the control system package, all system data is restored from this directory and reloaded into the working memory.

Never change these directories!

Never delete or change the \bin or BootRom.sys directories in the root directory. If this is done, the controller cannot be restarted and it will be impossible to use the mass storage memory.



Preparation of S4Cplus software to be installed

Illustration Media pool S ystem Pack in /3haxbbbb-1.nn *.* si gnature no

S ystem pool

E xt Option in /3haxcccc1.nn *.* relkey.txt

Created files key.id program.id

E xternal option from disk or CD-R OM

S ystem Pack from R obotWare CD-R OM

My syst em /syst em_n key.id program.id keystr.txt /syspar *.cfg

Inserted key strings are saved in keystr.txt R obotWare keystrings define the options to be included from the S ystem Pack they belong to and E xt opt keystrings define added external option packages. All keys must have the same serial number.

xx0100000262

Files to be prepared

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 programs to be installed.

•

Unless deselected in RobInstall, the latest revision of the System Pack and External Option Programs is selected as default (see section "Change options or system pack revisions").

•

These are copied from the media pool and concatenated into one target file that also holds the key.id and the syspar directory. This may then be downloaded to the controller via Ethernet or a set of diskettes. The target file is temporarily stored in the system directory before downloading or creating diskettes.


203


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

Checking storage capacity through connection to the MC/CONSOLE port

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.

1. Connect a console to the MC/CONSOLE outlet on the controller and execute the command dosFsShow.

There should always be at least 25 Mb free disk space on the controller mass storage memory before attempting to download a new system. For information on how to increase storage capacity, see below!

Increasing storage capacity

If the capacity of the mass storage memory is less than 25 Mb when a new controller system is to be downloaded, storage memory must be released by removing old systems from the mass storage memory. This can be done in one of the following ways: 1. Boot up on the system you would like to remove and then make a CSTART (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 RobotWare CD).



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 directories!


205



Calibration

Chapter 5:Calibration When to calibrate

Types of calibration 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


207

Calibration General

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. Detailed in "Correct orientation Incorrect orientation of the axis may of axes". cause damage on cabling!

3.

Manually, run the robot axes to a posi- Use the calibration scales or distion close to the correct calibration tances to locate this position, position. detailed in "Correct orientation of axes".

4.

Start the calibration procedure on the TPU.

Detailed in "Fine calibration procedure on TPU".

5.

Calibrate each axis.

Detailed in "Fine calibration, all axes".

6.

Verify that the calibration was successfully carried out.

Detailed in "Post calibration procedure".


Calibration General

Additional information

In addition to the basic calibration procedure detailed above, a number of calibration related actions may be performed:

Action

Detailed in section:

How to update the robot revolution counter without performing a complete calibration.

Updating the revolution counter

How to manually check the current calibration Checking the calibration position position.


209

Calibration General

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


Calibration Preliminaries

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!


211


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.

A

C B G D

E

F

xx0200000341

A

Axis 4 (center tube)

E

Index marks for axis 5

B

Spiral cable inspection cover

F


C

Correct orientation of the spiral cable (and axis 4)

G

Calibration distance for axes 12-3: 26 mm on each axis

D




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 orientation 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 damaged 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 personnel who are aware of the risks that this entails.

Step Action

Note

1. Remove the spiral cable inspection cover on Shown in figure above! the center tube sleeve by removing its 4 attachment screws. 2. Make a visual check of the numbers, marked Directions detailed in part on the spiral cable. “Directions for all axes”. 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 approximate (+ / - a couple of degrees) +Y direction! 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!


213


Step Action

Note

4. Refit the spiral cable inspection cover with the 4 attachment screws!

Correct orientation of axes 5-6

The procedure below details the correct orientation of axes 5-6.

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 (negative)!

Location shown in figure above! Directions detailed in part “Directions for all axes”.



Checking the calibration position

General

Using the Jogging window on the teach pendant

Check the calibration position before beginning any programming of the robot system. This may be done as detailed below.

Step 1.

Action

Note/Illustration

Open the Jogging window.

xx0100000195

2.

Choose running axis-by-axis.

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".

xx0100000196

Calibration positions and marks for each axis are shown in section "Correct orientation of axes".


215


Updating the revolution counter

Manually running the manipulator to the sync position

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

Step

Storing the revolution counter setting

Action

Illustration

1.

Select axis-by-axis motion mode

2.

Press the enabling device on the teach pen- Calibration marks shown dant and, using the joystick, move the robot in section "Correct orienmanually so that the calibration marks or dis- tation of axes". tances lie within the tolerance zone.

3.

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

4.

When all axes have been positioned as above, store the revolution counter settings using the Teach Pendant Unit as detailed below:

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 positioning, which in turn may cause damage or injury!



Step 1.

Action

Illustration

Press the button "Miscellaneous".

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.


217


Step

Action

6.

Press OK when all axes that are to be updated are marked with an x. CANCEL returns to the Calibration window.

7.

Press OK again to confirm and start the update. CANCEL returns to the Revolution Counter Update window.

8.

At this point, it is recommended that the revolution counter values are saved to a diskette.

9.

Recheck the calibration position as described in "Checking the calibration position".

Illustration

Not required.



Fine calibration procedure on TPU

General

The section below details how to use the Teach Pendant Unit (TPU) when performing a fine-calibration of the robot.

Procedure Step

Action

1.

Press the button "Miscellaneous".

2.

Select the Service window by pressing ENTER.

Note/Illustration

xx0100000194

xx0100000200


219


Step 3.

Action

Note/Illustration

Choose Calibration from the View menu. The Calibration window appears.

xx0100000201

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

4.

•

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".

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

xx0100000203



Step 5.

Action

Note/Illustration

Move the manipulator to its calibration position and press OK. The Fine Calibrate window appears.

Calibration positions for the manipulator detailed in "Checking the calibration position".

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 Calibration window.

8.

Press OK again to confirm and start the update. CANCEL returns to the Fine Calibration window. An alert box is displayed during 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 performed.


221

Calibration Calibration

Section C: Calibration Directions for all axes

Calibration movement directions

The figure below shows the positive and negative directions for each axis.

-

-

1

3

+

+

2

+ 4

6

+ +

5

-

+

xx0200000355



Jogging directions

The figure below shows the linear directions when jogging the robot.

+Y

+Z

+X

+Z

xx0200000378


223


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

•

Before calibration

•

Required equipment

•

Calibration order

•

Calibration, axes 1, 2 and 3

•

Calibration, axis 5

•

Calibration, axis 6

•

Calibration, axis 4

Before calibrating the robot, make sure that the requirements in the previous sections "General" and "Preliminaries" are met!

Required equipment

Calibration order

Equipment, etc.

Art. no.

Note

Calibration tool kit

-

Contains tools for calibration of complete robot. May be ordered from ABB Automation Technologies AB, Robotics.

The order of calibration of the axes 1, 2 and 3 is of no importance, but the remaining axes must be calibrated in the following sequence: 5 - 6 - 4.



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

1.

Turn the operating mode selector to MANUAL MODE AT REDUCED SPEED.

2.

Operate current axis (axis 1, 2 or 3) in manual 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 platform and the actuator cover (see adjacent figure) and then gently contract the actuator 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.

Note/Illustration

A

xx0200000351

• 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: 26 mm


225


Calibration, axis 5

The procedure below details how to calibrate axis 5.

Step 1.

Action

Note/Illustration

Put a dial gauge (mounted on a support 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 offset on the indicator.

xx0200000352



Step 2.

Action

Note/Illustration

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 position, 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.



227


Calibration axis 6


Step

Action

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 surface external to the robot) against the edge of the tool, see the adjacent figure.

Note/Illustration

xx0200000353

3.

Lock all other linear directions except Directions shown in “Directions for Z. for all axes”.



Step

Calibration, axis 4

Action

Note/Illustration

4.

Move the robot in +/-Z (in base) and Directions shown in “Directions adjust axis 6 until the indicator shows for all axes”. minimum change (usually a few hundredths of a millimeter) while travelling 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).

5.


6.



Step 1.

2.

Action

Note/Illustration

Run the following axes to the specified positions: • Axis 5: -90 degrees. •

Axis 6: +90 degrees.

•

Axis 4: 0 degrees.

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 adjacent figure.

xx0200000354


229


Step

Action

Note/Illustration

3.

Lock all other linear directions except for Y.

Directions shown in “Directions for all axes”.

4.

Move the robot in +/-Y (in Directions shown in “Directions for all base) and adjust axis 4 until axes”. the indicator shows minimum change (usually a few hundredths of a millimeter) while travelling from the middle 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).

5.


6.



Calibration After calibration

Section D: After calibration Post calibration procedure

General

Perform the following procedure after calibrating any manipulator axes. The procedure is intended to verify that all calibration positions are correct.

Procedure Step

Action

Illustration

1.

Run the calibration home position program Detailed in "Checking the twice. calibration position". Do not change the position of the manipulator axes after running the program!

2.

Check all calibration positions.

3.

Repeat the check as above.

4.

Adjust the calibration marks when the calibra- Shown in section "Cortion is done. 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.

Detailed in "Checking the calibration position".


231

Calibration After calibration


Index


233

Index


Repair Manual Industrial Robot IRB 940 Tricept™ 3HAC 16640-1 / M2000 / Rev. IRB 940 Tricept™




Repair Manual, IRB 940 Tricept™ 3HAC 16640-1 -





Table of Contents

Overview Product Documentation, IRB 940 Tricept™ Chapter 1: Safety, service Introduction Safety, service - General Section A: References



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 Work inside the manipulators working range Chapter 2: Reference Information Introduction Screw joints Weight specifications Chapter 3: Manipulator Introduction Section A: Manipulator repairs

Removal of actuator, including motor Refitting of actuator, including motor Removal of servomotor, axes 1-3 Refitting of servomotor, axes 1-3 Removal of servomotor, axis 4

1 3 5 5 6 7

7 7 8 9

9 9 9 10 10 11 13

13 13 14 14 15 15 15 17 17 18 20 21 21 22

22 27 34 38 43


i

Table of Contents

Refitting of servomotor, axis 4 Removal of lower joint Refitting of lower joint Removal of wrist Refitting of wrist Removal of center unit Refitting of center unit Removal of spiral cable Refitting of spiral cable

49 55 58 62 67 72 77 82 85

Section B: Distribution box repairs

89

Replacement of battery, distribution box Replacement of serial measurement card, distribution box Replacement of brake release card, distribution box Chapter 4: Controller Introduction Putting the computer unit in the service position Replacement of air filter, controller Replacement of battery unit, controller Replacement of I/O and gateway units Replacement of bleeder resistor Replacement of mass storage memory Replacement of internal cooling fan Replacement of drive units and rectifier Replacement of system fan unit Replacement of power supply unit Chapter 5: Circuit Diagram, IRB 940 Tricept™ Introduction =M1/2, Potentials from control =M1/3, Axis 1 =M1/4, Axis 2 =M1/5, Axis 3 =M1/6, Axis 4 =M1/7, Axis 5 =M1/8, Axis 6 =M1/9, Serial Measure board, Earth connections =M/10, Brake release unit

89 92 95 99 99 100 103 106 109 113 116 120 125 129 132 135 135 136 137 138 139 140 141 142 143 144 144


Table of Contents

Chapter 6: Circuit Diagram, S4Cplus Introduction System 1: General information

Sheet 1-1. Block Diagram Sheet 1-2. View of Control Cabinet Sheet 1-3. View of Control Cabinet Sheet 1-4. Designation Sheet 1-5. Designation System 2: Mains Connection and Power Supply

Sheet 2-1. Mains Connection Sheet 2-2. Transformer Unit Sheet 2-3. Power Supply Sheet 2-4. Power Supply Sheet 2-5. External transformer unit 200-500V IRB6600/7600 Sheet 2-6. Transformer unit 400-475V IRB 6600/7600 System 3: Computer Unit and Connector Unit

Sheet 3-1. Block Diagram/Computer Unit Sheet 3-2. Cabling in Computer Unit Sheet 3-3. Main Computer and Hard Disk / Flash Disk Drive Sheet 3-4. Compute Cooling Sheet 3-5. Base Connector Board and I/O Computer Sheet 3-6. Connector Board and I/O Computer Sheet 3-7. Connector Board and Axis Computer Sheet 3-8. Base Connector Unit Sheet 3-9. Connector Plate on Controller Panel System 4: Emergency Stops and Run Chain

Sheet 4-1. Emergency Stop Sheet 4-2. Run Chain Sheet 4-3. Run Chain Sheet 4-4. Power Unit Servo Disconnector System 5: Drive System and Robot Cable

Sheet 5-1. Block Diagram Sheet 5-2. Rectifier, Fans and Bleeder Sheet 5-3. Drive System Signal Connection 2 Drive Units Sheet 5-4. Drive System Signal Connection 3 Drive Units Sheet 5-5. Servo Drive Units / IRB 140 Sheet 5-6. Servo Drive Units / IRB 340 Sheet 5-7. Servo Drive Units / IRB 640, 840 Sheet 5-8. Servo Drive Units / IRB 1400, 2400

145 145 146

146 147 148 149 150 151

151 152 153 154 155 156 157

157 158 159 160 161 162 163 164 165 166

166 167 168 169 170

170 171 172 173 174 175 176 177


iii

Table of Contents

Sheet 5-9. Servo Drive Units / IRB 4400, 6400S/PE Sheet 5-10. Servo Drive Units / IRB 6400R Sheet 5-11. Control Cable IRB 140 Sheet 5-12. Control Cable IRB 340, 1400 and 2400 Sheet 5-13. Control Cable IRB 640, 840, 4400 and 6400S/PE Sheet 5-14. Control Cable IRB 6400R Sheet 5-15. Rectifier, fans and bleeder Sheet 5-16. Servo Drive System Sheet 5-17. Control cable System 6: External axes

Sheet 6-1. External axes Sheet 6-2. Axes Computer 2 and Connector Board Sheet 6-3. Expansion Board Axis Connector Board Sheet 6-4. Drive System Signal Connection External Axes Sheet 6-5. External axes no. 7th - 9th Control Signal Connection Sheet 6-6. Axis Computer 2 and Axis Connector Unit if External Axis Cabinet Sheet 6-7. Connection to External Axis Cabinet Sheet 6-8. Servogun-SMB power/signals cable System 7: I/O Units and Field Bus Modules

Sheet 7-1. I/O Unit Position Sheet 7-2. Digital Part of Combi I/O and Digital I/O Unit Input Part Sheet 7-3. Digital I/O Unit Output Part Sheet 7-4. Combi I/O Unit Digital and Analogue Output Part Sheet 7-5. Digital Input Part of 120V AC I/O Unit Sheet 7-6. Digital Output Part of 120V AC I/O Unit Sheet 7-7. Relay I/O Unit Input 1-16 Sheet 7-8. Digital with Relays I/O Output 1-8 Sheet 7-9. Digital with Relays I/O Output 9-16 Sheet 7-10. Analogue I/O Unit Sheet 7-11. Remote I/O Unit For Allen Bradley PLC Sheet 7-12. Interbus-S Master/Slave - Interbus-S Master Sheet 7-13. Profibus DP SLave Sheet 7-14. Encoder Unit Sheet 7-15. Profibus DP Master/Slave Sheet 7-16. Interbus master/slave optical fibre and copper wire System 8: Other options

Sheet 8-1. Floppy Disk Sheet 8-2. Service Equipment Supply Sheet 8-3. External Connections System Signals Sheet 8-4. Position Switches on Manipulator

178 179 180 181 182 183 184 185 186 187

187 188 189 190 191 192 193 194 195

195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211

211 212 213 214

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Table of Contents

Sheet 8-5. Customer Signals Sheet 8-6. Sustomer Power/SIgnal IRB 2400, 4400, 6400S/PE Sheet 8-7. Customer Cable Power/Signal/CAN IRB 6400R Sheet 8-8. External Control Panel Sheet 8-9. Extension Cable Teach Pendant Sheet 8-10. Time Relay Sheet 8-11. Customer Precess / Power / Signal / Profibus DP M/S Sheet 8-12. Optional customer power/signal Profibus IRB 6400R Sheet 8-13. LAN Ethernet connection Sheet 8-14. Customer power/CAN-BUS IRB 640/6400S Sheet 8-15. Customer cable power/signal CAN-BUS IRB 6600/7600 Sheet 8-16. Customer cable power/signal Profibus IRB 6600/7600 Sheet 8-17. Optional customer power/signal Profibus IRB 6400R System 9: External Axis Cabinet

Sheet 9-1. Block Diagram Sheet 9-2. View of External Axis Cabinet Sheet 9-3. Designation Sheet 9-4. Mains Connection Sheet 9-5. Transformer Unit Sheet 9-6. Power Supply, I/O Supply Sheet 9-7. Power Unit Sheet 9-8. Rectifier, Fans and Bleeder Sheet 9-9. Drive Unit Signal Connection 1 External Drive Unit Sheet 9-10. Drive Unit Signal Connection 2 External Drive Units Sheet 9-11. Drive Unit Signal Connection 3 External Drive Units Sheet 9-12. Drive Unit and Control Cable Drive Unit GT Sheet 9-13. Drive Unit and Control Cable Drive Unit GT+CCB Sheet 9-14. Drive Unit and Control Cable Sheet 9-15. Service Equipment Supply

215 216 217 218 219 220 221 222 223 224 225 226 227 228

228 229 230 231 232 233 234 235 236 237 238 239 240 241 242


v

Table of Contents

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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.



Prerequisites


•

repair personnel in the user´s organization.

•

repair personnel in other organizations.

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.

The manual is organized in the following chapters:

Chapter

Contents

1.

Safety

2.

Reference information

3.

Manipulator

4.

Controller


Document Id

Circuit diagrams, Manipulator

Included in Repair Manual, 3HAC 16640-1


1

Reference

Document Id

Circuit diagrams, Controller

Included in Repair Manual, 3HAC 16640-1

Revisions Revision

Description

-

First edition


Product Documentation, IRB 940 Tricept™

General






•

Safety, Service

•


•

Unpacking

•


•


•

Start-up

•

Robot controller

•


•


•

Calibration


Safety, Service

•


•


•


•


•



Safety, Service

•



3

•


•


•

Disposal



Safety, service


Definitions


Sections

The chapter "Safety, service" is divided into the following sections: A. References contains lists of: • Limitation of liability • applicable safety standards • referenced documents




5

Safety, service









General



Standards



•


•


•


•


•


•


•


•



7


Related information

General







User’s Guide

Section

Start-up





Safe handling


Safe design



General

Residual energy

Safe design


•


•


•


•


•


•



9



General

Qualified personnel

Extraordinary risks

•


•


•


•






•


•


•


•







•


•


•


•


•


•


•


•




•


•



11





•


•


•

The power unit

•


•


•


•


•


•


•






•


•


•





General




- withstand any impact from a tool failure. Due to the high kinetic energy associated with HSM (High Speed Machining), a tool failure poses a serious 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.

•


•




13



Description


Increased injury


Brake testing

When to test


How to test








15





General



17


Screw joints

General

This section details how to tighten the various types of screw joints in the manipulator 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




Dimension


M2.5

0.25

M3

0.5

M4

1.2

M5

2.5

M6

5.0

Dimension




M5

6

-

-

M6

10

-

17

M8

24

28

40

M10

47

55

70

M12

82

95

120



Dimension




M16

200

235

300


19



Definition

Within all repair and maintenance instructions, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are highlighted in this way. ABB recommends handling all components with a weight exceeding 22 kg using lifting equipment to avoid inflicting injury.

Example



Manipulator

Chapter 3:Manipulator Introduction

Definitions

This chapter details all repair activities recommended for the manipulator, including 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 contains 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 distribution box


21

Manipulator Manipulator repairs

Section A: Manipulator repairs Removal of actuator, including motor

Location

The three actuators are located on the manipulator as shown in the figure below.

E

B

D A

F

C xx0200000296



A

Actuator

B

Actuator servomotor

C

Lower joint

D

Actuator fork

E

Center tube

F

Wrist

Required equipment Equipment, etc.


Hook wrench

Note 3 mm pin, shown in figure the below!

xx0200000350

-

Safety

Hook wrench with 3 mm pin

Please read the following notations before the removal. Please observe the following before commencing any repair work on the manipulator: - 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!


23


- 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 dimensioned 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). Shown in the figure Before removal, the actuator must therefore be above! 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 surrounding equipment in order to prevent this. For other orientations, try to anticipate the movement and secure accordingly.



Removal of actuator

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 servomotor located on the actuator to be removed. Move and secure the cabling so it can not get damaged during removal of the actuator.

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 threadlocking substance, before unscrewing the lower joint from the lower platform.

4.

To release the bottom end of the actuator Shown in the figure above! from the lower platform, unscrew the lower Specified above! joint using thehook wrench. Make sure the center tube and wrist are anchored as detailed in the preparatory work above!

5.

Unscrew the four attachment screws hold- Shown in the figure above! ing the actuator to the actuator fork.

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.


25


Removal of motor

The procedure below details how to remove the motor from a dismounted actuator.

Step 1.

Action

Note/Illustration

Unscrew the four fixing screws that hold the servomotor to the actuator housing.

A B D C xx0200000302

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: Servomotor

•

B: Fixing screws (4 pcs)

•

C: Toothed wheel ring

•

D: Backlash-free coupling



Refitting of actuator, including motor

Location

The actuators are located as shown in the figure below.

E

B

D A

F

C xx0200000296

A

Actuator

B

Actuator servomotor


27


C

Lower joint

D

Actuator fork

E

Center tube

F

Wrist



Actuator with motor

3HAC 17151-1

Note

Thread-locking substance

e.g. Loctite 242. Used when securing the lower joint to the lower platform.

Hook wrench

3 mm pin

xx0200000350

-

Safety


Please read the following notations before refitting. Please observe the following before commencing any repair work on the manipulator: - 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 actuator with motor weighs 40 kg! All lifting equipment used must be dimensioned accordingly!

Refitting of motor

In case the servomotor has been removed from the actuator, refit it as detailed in procedure below.

Step 1.

Action

Note/Illustration

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.

B

A

xx0200000303

•

A: Actuator shaft

•

B: 0mm


29


Step 2.

Action

Note/Illustration

Assemble the servomotor, back- 4 pcs; tightening torque: 24 Nm. lash-free coupling and the actuator. Tighten the fixing screws of the motor.

A B D C xx0200000302

Refitting of actuator

•

A: Servomotor

•


•


•

D: Backlash-free coupling

The procedure below details how to refit the actuator, including the motor. The procedure is the same for all actuators.

Step

Action

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.

Note/Illustration




Step 3.

Action

Note/Illustration

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.

A B xx0200000304

•

A: Clamp

•

B: Circlip

4.

Adjust the circlip so that the actuator remains tight against the left hand side.

5.

Fit the clamps and tighten the four 4 pcs; tightening torque: 10 Nm. hexagonal screws that hold the clamps.

6.

Fit the sealing caps onto either side of the actuator fork as shown in figure to the right.

A

xx0200000305

•

A: Sealing cap


31


Step

Commissioning

Action

Note/Illustration

7.

Refit the actuator by screwing the Shown in the figure above! 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.

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 servomotor.

Follow the instructions below before commissioning after refitting an actuator.

Step

Action

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.

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.

Note/Illustration

Detailed in Installation Manual.

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.


33


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.

A

A

xx0200000297

A

Servomotors, axes 1-3



Required equipment

Safety

Equipment, etc. Spare part no. Art. no.

Note

Circuit Diagram

Repair Manual, part 2

3HAC 16640-1

Please read the following notations before the removal. Please observe the following before commencing any repair work on the manipulator: - 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.

Step

Action

1.

Support the wrist before disconnecting the servomotor from the actuator, in order to keep the lower platform stable and reduce the risk of injury and/or damage.

2.


3.

The weight of an actuator servomotor is around 14kg (31lb). The actuator may therefore need to be secured using straps before being removed.

Note/Illustration


35


Step 4.

Removal

Action

Note/Illustration

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 orientated manipulator, it is important to anchor the center tube to the surrounding equipment in order to prevent this. For manipulators in other orientations, try to anticipate the movement and secure accordingly.

The procedure below details how to remove the servomotor, axes 1, 2 and 3.

Step

Action

1.

Remove the eletric cabling from the servomotor. Move and secure the cabling so that it can not get damaged during 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.

Note/Illustration



Step 4.

Action

Note/Illustration

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.

A B D C xx0200000302

5.

•

A: Servomotor

•


•


•

D: Backlash-free coupling on servomotor shaft

Remove the coupling from the servomotor shaft.


37


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.

A

A

xx0200000297

A

Servomotors, axes 1-3



Required equipment Equipment, etc. Spare part no. Art. no. Servomotor, axes 1-3 Circuit Diagram

Safety

Note

3HAC 17152-1 3HAC 16640-1


Please read the following notations before the refitting. Please observe the following before commencing any repair work on the manipulator: - 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.


39


Step 1.

Action

Note/Illustration

Fit the backlash-free coupling Spare part no. specified above! onto the new servomotor, ensuring that the shaft enters the coupling to a depth of 10 mm, as shown in figure to the right.

A xx0200000308

•

A: 10 ±0.5 mm



Step 2.

Action

Note/Illustration

Assemble the servomotor, 4 pcs; tightening torque: 24Nm. 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 B is a lash. Measure the distance between the coupling D C and the contact surface, according to the figure to the xx0200000302 right. • A: Servomotor

A

•


•


•

D: Backlash-free coupling on the servomotor shaft A

B

79

51

xx0200000447

3.

•

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.

Reconnect the cables to the servomotor.


41


Commissioning

Follow the instructions below before commissioning after refitting motor on axes 1, 2 and 3.

Step

Action

1.


2.


3.


Note/Illustration


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.



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.

D

B C

E

A xx0200000299

A

Axis 4 motor unit (located beneath center tube sleeve)

B

Center tube sleeve

C


D

Gimbal

E

Lower platform


43


Required equipment Equipment, etc. Spare part no. Art. no.

Note

Lifting bracket String

Circuit Diagram

Safety

Attach to the cabling to be able to feed it through the center tube while lifting. 3HAC 16640-1 Repair Manual, part 2


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.



Preparatory work

Follow the instructions below for preparatory work, before commencing the removal of the motor unit on axis 4.

Step

Removal

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.


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

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!

3.

Note the position of each connector and remove the cable connector holders from the lid. Attach a string to the cabling in order not to drop it into the center tube when lifting.

Note/Illustration

See the figure below!


45


Step 4.

Action

Note/Illustration

Remove the housing and the lower plate, exercising care with the cables inside the housing. See figure to the right for layout.

A B C D

E

xx0200000306

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.

•

A: Top plate of center tube

•

B: Cable connector holder

•

C: Housing

•

D: Lower plate

•

E: Center tube



Step 7.

Action

Note/Illustration

Unscrew the 18 screws that hold the center tube to the axis 4 motor and remove the locating pin, center tube.

A B

C

D xx0200000363

•

A: 6 pcs: M8.

•

B: 12 pcs: M6.

•

C: Locating pin, center tube

•

D: Locating pin, center tube sleeve

On reassembly the same locating pin is refitted! 8.

Lift the center tube, using a hoist or lift, Shown in the figure above! 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.

9.

Remove the cable clamp that holds the spiral cable in place.


47


Step

Action

Note/Illustration

10.

Remove the 12 screws that hold the Shown in the figure above! center tube sleeve to the lower platOn reassembly the same locatform interface. ing pin is refitted! Remove the locating pin that positions the center tube sleeve.

11.

Lift the center tube sleeve, tilting the wrist slightly for increased accessibility.

A B C

xx0200000307

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 contamination before proceeding with the assembly routine.

•

A: center tube sleeve

•

B: Spacer

•

C: Axis 4 motor unit



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.

D

B C

E

A xx0200000299

A

Axis 4 motor unit (located inside the center tube sleeve)

B

Center tube sleeve

C


D

Gimbal

E

Lower platform


49


Required equipment Equipment, etc. Spare part no. Art. no. Servomotor, axis 4

Note

3HAC 17153-1

Lifting bracket Circuit Diagram

Safety

3HAC 16640-1


Please read the following notations before refitting. Please observe the following before commencing any repair work on the manipulator: - 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.

Step 1.

Action

Note/Illustration

Fit the axis 4 motor unit to the center 8 pcs: tightening torque: 33 shaft and tighten the screws. Ensure it Nm. has the same orientation as the old one



Step 2.

Action

Note/Illustration

Fit and align the spacer to the axis 4 motor unit.

A B C

xx0200000307

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.

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.

•

A: Center tube sleeve

•

B: Spacer

•

C: Axis 4 motor unit

Shown in the figure above! 12 pcs; tightening torque: 17Nm. Make sure to refit the correct locating pin!


51


Step 7.

Action

Note/Illustration

Locate the center tube using the location pin, center tube, as reference and fit the 18 screws.

A B

C

D xx0200000363

•

A: 6 pcs: M8; tightening torque: 40 Nm.

•

B: 12 pcs: M6; tightening 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.

9.

Remove the lifting tool from the center tube.




Step 10.

Action

Note/Illustration

Refit the lower plate and the housing to the top of the center tube, taking extra care not to squash any cables, or subject them to any undue stress.

A B C D

E

xx0200000306

11.

Fit the cable connectors to the top plate, ensuring that the cables are orientated the same way as when they were removed.

12.

Fit the top plate to the housing.

13.

Refit the cable guide for the axes 4, 5 and 6 cabling and reconnect the cabling previously disconnected.

•

A: Top plate

•

B: Cable connector holder

•

C: Housing

•

D: Lower plate

•

E: Center tube



53


Commissioning

Follow the instructions below before commissioning after refitting the motor, axis 4.

Step

Action

1.


2.


3.


Note/Illustration





Removal of lower joint

Location

The lower joint is located between the actuator and the lower platform, as shown in the figure below.

B

C D A

A

xx0200000298

A

Lower joint (beneath the cover)

B

Lower platform

C

Actuator

D

Calibration spacer


55



Note

Hook wrench

3 mm pin

xx0200000350

-

Safety





Preparatory work

Follow the instructions below for preparatory work, before commencing the removal of the lower joint.

Step

Removal

Action

Note/Illustration

1.

Run actuators to half way in length. All the actuators should also have an equal length. This is done in order to allow the actuator to retract when the lower joint is unscrewed.

2.


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 equipment in order to avoid this. For manipulators in other orientations, try to anticipate the movement and secure accordingly.

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 separating the parts! Step

Action

Note/Illustration

1.

Use a heating gun to loosen the thread-locking 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.

3.

Loosen the lower joint from the lower platform Shown in figure above! using a hook wrench, 3 mm pin. 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!

Shown in the figure above! Specified above!


57


Refitting of lower joint

Location

The lower joint is located between the actuator and the lower platform, as shown in the figure below.

B

C D A

A

xx0200000298

A

Lower joint (beneath the cover)

B

Lower platform

C

Actuator

D

Calibration spacer





Lower joint

3HAC 17154-1

Note



Hook wrench

3 mm pin

xx0200000350

-

Safety


Please read the following notations before refitting. Please observe the following before commencing any repair work on the manipulator: - 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.


59


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.

Step

Commissioning

Action

Note/Illustration

1.

Fit the calibration spacer and the cover Spare part no. specified above! to the new lower joint.

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 universal joint is screwed in.

Follow the instructions below before commissioning after refitting the lower joint.

Step

Action

1.


2.

Recalibrate the robot. Failure to calibrate a robot will seriously affect the performance and can, in the worst-case, cause damage to equipment.

Note/Illustration




Step 3.

Action

Note/Illustration




61


Removal of wrist

Location

The wrist is located on the lower platform, as shown in the figure below.

B

D

E C

F A

A

xx0200000300

A

Wrist

B

Center tube

C


D

Gimbal

E

Center tube sleeve

F

Lower platform




Note

Lifting bracket

Safety

Punch tool

Used for the crossed roller bearing.

Lifting jack

Stroke of at least 100 mm.


The wrist weighs 36 kg! All lifting equipment used must be dimensioned accordingly!


63


Preparatory work

Follow the instructions below for preparatory work, before commencing the removal of the wrist unit.

Step

Action

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.


3.


Note/Illustration



Removal

The procedure below details how to remove the wrist. Make sure the preparatory work above is done before removing the wrist!

Step 1.

Action

Note/Illustration

Remove the 6 attachment screws that hold the axis 4 motor unit to the centre tube.

A B

C

D 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 Shown in the figure above! back of centre tube sleeve and the spiral cable inspection cover on the same sleeve.

3.

Remove the cable clamp that holds the spiral cable in place.


65


Step

Action

Note/Illustration

4.

Unscrew 10 of the 12 screws in the Shown in the figure above! 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.

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 platform 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 surface 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.

8.

xx0200000364

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!



Refitting of wrist

Location

The wrist is located on the lower platform, as shown in the figure below.

B

D

E C

F A

A

xx0200000300

A

Wrist

B

Center tube

C


D

Gimbal

E

Center tube sleeve

F

Lower platform


67


Required equipment

Safety

Equipment, etc.


Wrist

3HAC 17155-1

Note

Punch tool

Used for the crossed roller bearing.

Lifting jack

Stroke of at least 100 mm.

Please read the following notations before refitting. Please observe the following before commencing any repair work on the manipulator: - 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 accordingly!



Refitting

The procedure below details how to refit the wrist.

Step

Action

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.

2.

Ensure that the jack is correctly positioned 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.

Note/Illustration

xx0200000367

12 pcs; tightening torque: 17 Nm.


69


Step

Commissioning

Action

Note/Illustration

6.

Lift the wrist with the jack until it is possi- 12 pcs; tightening torque: 10 ble to fasten the attachment screws Nm. through the wrist flange into the lower Shown in the figure above! platform. Press the wrist to its topmost position by tightening two of the attachment screws, 180°in relation to each other. Check that the bearing runs smoothly by turning the wrist manually.

7.

Refit the spiral cable clamp and ensure that the spiral cable twists freely throughout 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.


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 Shown in the figure above! cable inspection cover with their sealings.

Follow the instructions below before commissioning after refitting.

Step

Action

1.


2.


Note/Illustration




Step 3.

Action

Note/Illustration




71


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. C I

H G

D

E B

A F 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





Hook wrench

Note 3 mm pin

xx0200000350

-

Safety



The center unit weighs over 100 kg! All lifting equipment must be dimensioned accordingly!


73


Preparatory work

Follow the instructions below for preparatory work, before commencing the removal of the center unit.

Step

Removal

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.


3.


The procedure below details how to remove the center unit. Make sure the preparatory work above is done before removal!

Step 1.

Action

Note/Illustration

Disconnect the cabling running into the center unit, at the top of the center unit.



Step 2.

Action

Note/Illustration

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 gimbal and actuator joints are disconnected 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-locking substance before removing the joint.

4.

Remove the actuators from the Shown in the figure above! lower platform by disconnect- Specified above! 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 platform. Ensure that they are fastened before releasing them after removal.


75


Step 5.

Action

Note/Illustration

Remove the center unit from Shown in the figure above! 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 A when removing the attachment screws!

A

xx0200000309

•

A: Attachment screws that hold the gimbal to the upper platform (4 pcs)

6.

Lower the gimbal to the bottom Shown in the figure above! 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.

7.

Lower the center unit with the hoist.



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.

C I

H G

D

E B

A F 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


77




Center Unit

3HAC 17156-1

Note



Hook wrench

3 mm pin

xx0200000350

Safety

Please read the following notations before refitting. Please observe the following before commencing any repair work on the manipulator: - 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 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 position with the hoist.

2.

Insert the four screws that Shown in the figure above! hold the gimbal to the upper platform, but do not tighten them. Just screw them in to the point where it is still possible to move the gimbal in relation to the upper platform.


79


Step 3.

Action

Note/Illustration

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.

A

B C

E

D

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 Shown in the figure above! 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.



Commissioning

Follow the instructions below before commissioning after refitting the center unit.

Step

Action

Note/Illustration

1.


2.

Recalibrate the robot. Detailed in Installation Failure to calibrate the robot will seriously affect Manual. the performance and can, in the worst case, cause damage to equipment.

3.




81


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.

B

C A xx0200000312

A

Spiral cable

B


C

Wrist unit






Safety

Note These procedures include references to the tools required.


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.


83


Preparatory work

Follow the instructions below for preparatory work, before commencing the removal of the spiral cable.

Step

Removal

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.


The procedure below details how to remove the spiral cable. Make sure the preparatory work above is done before removal!

Step

Action

Note/Illustration

1.

Remove the axis 4 motor unit.

Detailed in Removal of servomotor, 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.



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.

B

C A xx0200000312

A

Spiral cable

B


C

Wrist unit


85




Spiral Cable

3HAC 17157-1


Safety


Please read the following notations before refitting. Please observe the following before commencing any repair work on the manipulator: - 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.



Refitting

The procedure below details how to refit the spiral cable.

Step

Action

Note/Illustration

1.

Fit the new spiral cable and refit Spare part no. specified above! the cable clamp that holds the spiral 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!

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.

xx0200000366

Commissioning

Follow the instructions below before commissioning after refitting the spiral cable and wrist unit.

Step 1.

Action

Note/Illustration



87


Step

Action

Note/Illustration

2.

Recalibrate the robot. Detailed in Installation Failure to calibrate the robot will seriously affect Manual. the performance and can, in the worst case, cause damage to equipment.

3.




Manipulator Distribution box repairs

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.

A

B

xx0200000394

A

Serial measurement card

B

Battery


89


Required equipment Equipment, etc. Spare part no. Art. no. Battery

Safety

Note

4944026-4

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.

Step

Action

Note/Illustration

1.

Note the position of the battery and cable ties.


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.



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.


91


Replacement of serial measurement card, distribution box

Location

The serial measurement card is located in the distribution box as shown in the figure below.

A

B

xx0200000394

A

Serial measurement card

B

Battery





Serial Measurement card

Safety

Note

3HAC 14505-1


Removal

The procedure below details how to remove the serial measurement card from the distribution box.

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.


4.

Remove the battery from the card.

The battery is refitted on to the new card.


93


Refitting

The procedure below details how to refit the serial measurement card to the distribution box.

Step

Action

Note/Illustration

1.

Fit the battery to the new serial measurement card.


2.

Carefully fit the card and the battery in place.

3.

Refit the three screws holding the serial measurement card and the battery to the enclosure.

4.

Refit the four electrical connectors.



Replacement of brake release card, distribution box

Location

The brake release card is located in the distribution box as shown in the figure below.

A

B

xx0200000393

A

Brake release card

B

Brake release buttons


95


Required equipment Equipment, etc. Brake Release card

Safety


Note

3HAC 0017-1


Removal

The procedure below details how to remove the brake release card from the distribution box.

Step

Action

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.

Note/Illustration




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.


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.


97



Controller repair

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


99

Controller repair

Putting the computer unit in the service position

Location of computer unit

The computer unit is located as shown in the figure below.

A xx0200000105

A

Opening

Computer unit

The procedure below details how to open the computer unit. Please observe the following before commencing any repair work on the manipulator: - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! - Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. securing the lower arm with fixtures before removing motor, axis 2.


Controller repair

Step

Action

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 computer unit. This is done by turning the screw two turns (see position 1 in the figure) and pushing the lock washers towards the screw (see position 2).

4.

Lift the two handles and push them together to release the computer unit (see position 1 in the figure).

Note/Illustration

2

1

xx0200000016

1

2

xx0200000017

5.

Push the locking device on See the figure above! the front of the computer unit to the right (see position 2 in the figure).


101

Controller repair

Step

Action

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.

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.

Note/Illustration

xx0200000018

Closing

The procedure below details how to close the computer unit. Please observe the following before commencing any repair work on the manipulator: - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! - Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. securing the lower arm with fixtures before removing motor, axis 2.

Step 1.

Action

Note/Illustration

Swing the computer unit back into position and secure it.

See the figure above! Also see the procedure above!


Controller repair

Replacement of air filter, controller

Location of air filter

The air filter is located in the air filter magazine in the front hatch.

A

A xx0200000284

A

Air filter magazine



Air filter

3HAB 8028-1




103

Controller repair

Removal, air filter

The procedure below details how to remove the air filter.

Step

Action

1.

Open the bottom of the air filter magazine as shown in the figure.

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 contamination, the air filter may be cleaned and refitted. The procedure for this is detailed in section "Cleaning the air filter, controller" in the Maintenance Manual.

Note/Illustration

xx0200000001

1

2

xx0200000003

Refitting, air filter

The procedure below details how to refit the air filter.

Step 1.

Action

Note/Illustration

Fit the air filter in the magazine. Art. no. is specified above!


Controller repair

Step 2.

Action

Note/Illustration

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


105

Controller repair

Replacement of battery unit, controller

Location of battery unit

The battery unit is located at the bottom of the controller.

A xx0200000103

A

Battery unit


Spare part no. Art no.

Note

Battery unit

3HAC 5393-2

To be replaced as a complete unit


Controller repair

Equipment, etc.


Note


Removal, battery unit

These procedures include references to the tools required.

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 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!

Step 1.

Action

Note/Illustration

Remove the battery unit by unscrewing its attachment screws (1). X1

X1

X1

X2

X2

X2

X1

X2

X3

xx0200000004

2.

Pull the battery unit out.


107

Controller repair

Step 3.

Action

Note/Illustration

Disconnect the three cables from the battery unit.

xx0200000005

Refitting, battery unit

The procedure below details how to refit the battery unit.


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.



Controller repair

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.

A

B

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


109

Controller repair


Removal


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

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 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!

Step 1.

Action

Note/Illustration

Disconnect any connec- The actual number of connectors vary tors from the unit. Note depending on type of unit. which connector goes where, to facilitate reassembly.


Controller repair

Step 2.

Action Lift the unit until the upper claw, that holds the unit to the rail, is released. Use: • a screwdriver when replacing I/O units (position 2a in the figure). •

by hand when replacing a gateway unit (position 2b in the figure).

Note/Illustration

1

2a

3a

1

2b

3b

xx0200000010

3.

Refitting

With the upper claw released, tip the unit away from the mounting rail and remove it (positions 3a and 3b in the figure).

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 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!

Step 1.

Action

Note/Illustration

Hook the unit back onto the mounting rail and snap it gently in position.


111

Controller repair

Step 2.

Action

Note/Illustration

Reconnect all connectors disconnected during removal.


Controller repair

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


113

Controller repair

Required equipment

Removal

Equipment, etc.


Bleeder resistor

3HAC 4560-5

Note

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 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!

Step

Action

Note/Illustration

1.

Swing the power supply Detailed in section "Replacement of power unit out of the way. 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 figure).

1 2

0

xx0200000015

4.

Remove the bleeder resistor unit from the enclosure (see position 2 in the figure).


Controller repair

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 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!

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 disassembly.

3.

Refit the drive unit.

Detailed in section "Replacement of drive units and rectifier".

4.

Swing the power supply unit back into position.

Detailed in section "Replacement of power supply unit".


115

Controller repair

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.

A xx0200000105

A

Computer system



Note

Mass storage memory, 3HAC 7519-2 64 MB Mass storage memory, 3HAC 7519-3 128 MB


Controller repair

Equipment, etc.


Note


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 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!

Step

Action

Note/Illustration

1.

Put the computer unit in the service position.

Detailed in section "Putting the computer in the service position".

2.

Remove the cover from the right side of the computer system by unscrewing the ten M5 screws (item 1 in the figure).

1

3

2

4

xx0200000019

3.

Disconnect the connectors X1 and X2 from the front of the mass storage memory (item 2 in the figure).

See figure above!


117

Controller repair

Step 4.

Refitting

Action

Note/Illustration

Remove the mass storage See figure above! memory by unscrewing its M4 attachment screws as shown in the figure (items 3 and 4 in the figure).

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 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!

Step 1.

Action

Note/Illustration

Fit the mass storage mem- Art. no. is specified above! ory in position and secure it 1 with its M4 attachment screws (items 3 and 4 in the figure) 3

2

4

xx0200000019

2.

Reconnect connectors X1 See the figure above! and X2 to the front of the computer unit (item 2 in the figure).


Controller repair

Step

Action

Note/Illustration

3.

Refit the cover on the right See the figure above! side of the computer unit and secure it with its ten M5 attachment screws (item 1 in the figure).

4.

Put the computer system Detailed in section "Putting the computer in back in its regular operation the service position". position.


119

Controller repair

Replacement of internal cooling fan

Location of internal cooling fan

The internal cooling fan is located in the computer system, which is shown in the figure below.

A xx0200000105

A

Computer system



Note

Internal cooling fan

3HAC 6655-1

Two fans required




Controller repair

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 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!

Step 1.

Action

Note/Illustration

Put the computer unit in the service position.

Detailed in "Putting the computer in the service position".


121

Controller repair

Step 2.

Action

Note/Illustration

Disconnect the connector E5 or E6 respectively, depending on which fan is to be replaced.

A

D

C

B

E xx0200000020

3.

Refitting

Remove the internal cooling fan inwards by gently pressing the locking tabs upwards.

•

A: Upper fan

•

B: Lower fan

•

C: Locking tabs

•

D: Connector E5

•

E: Connector E6

See the figure above!

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 Discharge) and will be destroyed if subjected to it!


Controller repair

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 1.

Action

Note/Illustration

Tip the internal cooling fan with its top towards Art. no. specified above! the cabinet wall and fit it into the hole (see the figure).

A

A

xx0200000021

• 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.

A: Push direction

See the figure above!


123

Controller repair

Step

Action

3.

Reconnect the connector E5 or E6 respectively, depending on which fan was replaced.

4.

Put the computer unit back in the regular operation position.

Note/Illustration

Detailed in "Putting the computer in the service position".


Controller repair

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


C

System fan unit

D


E

Power supply unit


125

Controller repair



Note

Drive unit (rectifier)

3HAB 8101-17

DSQC 545A

Drive unit, axes 1-6

3HAB 8101-18

DSQC 546A


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 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!

Step 1.

Action

Note/Illustration

Swing the power supply unit out of the way.

Detailed in section "Replacement of power supply unit"


Controller repair

Step 2.

Action

Note/Illustration

Disconnect connectors X1 and X2, four connectors each (see position 1 in the figure). 1

2

1

xx0200000013

3.

Remove the power supply See figure above! bar in front of the drive units (see position 2 in the figure).

4.

Lift the spring to release the drive unit and pull it slightly outwards (see position 3 in the figure).

3

4

xx0200000014

5.

Tip it out and remove it (see position 4 in the figure).

See figure above!


127

Controller repair

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 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!

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"


Controller repair

Replacement of system fan unit

Location of system fan unit

The system fan unit is located as shown in the figure below.

xx0200000007

A

Drive units

B


C

System fan unit

D


E

Power supply unit


129

Controller repair



System fan unit

3HAC 12924-2

Note


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 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!

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).

1

2

2

1

xx0200000008


Controller repair

Step 3.

Refitting

Action

Note/Illustration

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).

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 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!

Step

Action

Note/Illustration

1.

Fit the system fan unit into position and Art. no. specified above! secure it (see position 2 in the figure 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.


131

Controller repair

Replacement of power supply unit

Location of power supply unit

The power supply unit is located as shown in the figure below.

A

B

xx0200000011

A

Power supply unit locking spring (view from front)

B

Power supply unit folded out from the cabinet (view from above)



Note

Power supply unit

3HAB 4297-1

DSQC 506




Controller repair

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 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!

Step

Action

Note/Illustration

1.

Push the power supply Shown in figure above! unit locking spring down to release the power supply unit.

2.

Swing the unit out of the cabinet.

3.

Remove the cable straps on top of the power supply unit (see position 1 in the figure).

Shown in figure above

2

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).


133

Controller repair

Step 6.

Refitting

Action

Note/Illustration

Lift the unit straight up to release it from the hooks and remove it outwards (see position 4 in the figure).

The procedure below details how to refit the power supply unit. Please observe the following before commencing any repair work on the controller: Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. 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 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.


Circuit Diagram, IRB 940 Tricept™

Chapter 5:Circuit Diagram, IRB 940 Tricept™ Introduction Definitions

This chapter contains all the circuit diagrams for the IRB 940 Tricept™.

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135

contact R1 SMB contact R1 MP

en0200000410

=M1/2, Potentials from control

+EC1 +EC1

Circuit Diagram, IRB 940 Tricept™ - =M1/2, Potentials from control

www.cadfamily.com EMail:[email protected] 16640-1 The3HAC document is for study only,if tort to your rights,please inform us,we will delete

136

V

U

M 3

B

A

2

1

WM1

-XM1.1

B

A2

A

A1

-XM1

AWG16 grey

-R1MP

en0200000411

Motor axis 1

+M1

4.0

+EC1

PE

W

D6

C

3

C

A3

D

4

D

A4

D8

E

5

E

A5

F

6

F

A6

Ï

AWG16 yel/gr

-XTPE

AWG16 yel/gr

D10

G

G

PE

PE

H

H

PE

PE

PE

PE

PE

PE

4.3 PE1

-RT1

J

7

J

K

8

K

C1

-Y1

AWG20 blue

-

+

L

9

L

M

10

M

=M1/3, Axis 1

AWG20 blue

C3

CE

CE

-SMB 9.5 Serial measuring board

-XR1.1

WR1

-XR1

AWG22 blue

-XP1-4

A

A

2

B

B

14

C

C

3

R2.SMB1-4

D

D

15

E

E

6

F

F

18

Resolver 1

-B1

G

CE

Circuit Diagram, IRB 940 Tricept™ - =M1/3, Axis 1


137

V

U

3

M

B

A

2

1

WM2

-XM2.1

B

A8

A

A7

-XM2

AWG16 grey

-R1MP

en0200000412

Motor axis 2

+M2

3.0

+EC1

PE

W

C

3

C

A9

D

4

D

A10

E

5

E

F

6

F

A11 A12

Ï

AWG16 yel/gr

-XTPE PE

PE

G

G

H

H

5.3

PE1

3.4

PE1

J

7

J

K

8

K

C4

-Y2

AWG20 blue

-

+

L

9

L

M

10

M

=M1/4, Axis 2

-RT2

AWG20 blue

C5

CE

CE


-XR2.1

WR2

-XR2

AWG22 blue

-XP1-4

A

A

4

B

B

16

C

C

5

R2.SMB1-4

D

D

17

E

E

7

F

F

19

Resolver 2

-B2

G

CE



138

V

U

3

M

B

A

2

1

WM3

-XM3.1

B

A

PE

W

C

3

C

D

4

D

E

5

E

A13 A14 C13 A15 A16 C14 B1

-XM3

AWG16 grey

-R1MP

en0200000414

Motor axis 3

+M3

3.0

+EC1

F

6

F

B2

Ï

AWG16 yel/gr

-XTPE PE

PE

G

G

H

H

6.3

PE1

4.3

PE1

C15

-RT3

J

7

J

K

8

K

C6

-Y3

AWG20 blue

-

+

L

9

L

M

10

M

=M1/5, Axis 3

AWG20 blue

C7

CE

CE


-XR3.1

WR3

-XR3

AWG22 blue

-XP1-4

A

A

9

B

B

21

C

C

10

R2.SMB1-4

D

D

22

E

E

8

F

F

20

Resolver 3

-B3

G

CE



139

Wmotor4.1

-XMTR4

U

1

M

3

W

PE

2 3

E

C

A

-XM4.1

Wmotor4

5

3

E

B5

1

D12

WM4

B4

C

V

D11

A

B3

-XM4

AWG16 grey

-R1MP

en0200000415

Motor axis 4

+M4

3.0

+EC1 D13

Ï

AWG16 yel/gr

-XTPE PE

4

G

G

7.3

PE1

5.3

PE1

-RT4

8

J

7

J

9

K

8

K

C8

-Y4

AWG20 blue

-

+

5

L

9

L

6

M

10

M

=M1/6, Axis 4

AWG20 blue

C9

CE

CE


Wmotor4.1

-XMTR4

-XR4.1

WR4

-XR4

AWG22 blue

-XP3-6

12

A

A

2

13

B

B

14

15

C

C

3

R2.SMB3-6

14

D

D

15

11

E

E

6

10

F

F

18

Resolver 4

-B4

7

G

CE



140

Wmotor5 18x

-XMTR5-6

U

1

V

3

M

W

PE

A

-XM5.1

2

C

3

1

WM5

B6

C

en0200000416

Motor axis 5

D15

A

B7

-XM5

AWG16 grey

-R1MP

Wmotor_5-6 Spiral 28x

+M5

3.0

+EC1

D14

3

E

5

E

B8

D9

Ï

AWG16 yel/gr

-XTPE PE

12

G

G

8.3

PE1

6.3

PE1

-RT5

10

J

7

J

11

K

8

K

-Y5

-X5

AWG20 blue

-

+

1

9

L

9

L

2

CE

CE

-SMB

Wbrake5

-XR5.1

WR5

-XR5

AWG22 blue

-XP3-6

Wmotor5

-XMTR5-6

9.5 Serial measuring board

Wmotor6_and_brake 5

18

M

10

M

=M1/7, Axis 5

AWG20 blue

C11 C10

21

A

A

4

22

B

B

16

24

C

C

5

R2.SMB3-6

23

D

D

17

20

E

E

7

19

F

F

19

Resolver 5

-B5

25

G

CE



141

-XMTR5-6

+M6

en0200000417

Motor axis 6

U

5

V

3

M

W

PE

A

-XM6.1

Wmotor_5-6

3

1

WM6

6

C

C

B10

A

B9

-XM6

AWG16 grey

-R1MP

motor6_and_brake 5

3.0

+EC1

7

E

5

E

B11

Ï

AWG16 yel/gr

-XTPE

PE

16

G

G

9.1

PE1

7.3

PE1

14

J

7

J

15

K

8

K

C12

-Y6

AWG20 blue

-

+

27

L

9

L

36

M

10

M

=M1/8, Axis 6

-RT6

AWG20 blue

C2

CE

CE


-XR6.1

WR6

-XR6

AWG22 blue

-XP3-6

30

A

A

9

31

B

B

21

33

C

C

10

R2.SMB3-6

32

D

D

22

29

F

E

8

28

E

F

20

Resolver 6

-B6

34

G

CE



142

PE1

earth conn. (screw) distribution box chassie

AWG10 yel/gr

-XTPE

R1MP D1

AWG20 blue

=M1 +FO

earth conn. (screw) manip. foot

earth conn. (screw) distribution box outside

8.3/

en0200000418

3.0

EC1

D2

AWG10 5m yel/gr

PE

D3 D4

earth conn. (screw) cover

earth conn. (screw) mounting plate

PE


R2SMB 9

5

B

8

C

4

D

3

E

7

F

2

L

=M1/9, Serial Measure board, Earth connections

PE

WSMB canbus 8x

R1SMB A

6

K

J

M

CE

CE

-

+

R2G 2

blue

7,2VDC/4Ah Battery

-G

1

black

Circuit Diagram, IRB 940 Tricept™ - =M1/9, Serial Measure board, Earth connec-


143

10

-X9

11

3

-X8

4

en0200000419

-BU 3.0

+EC1

Brake release unit

AWG16 blue

-R1MP

B14 B15

6

8

9

5

4

5

4

-X10

5

6

3

3

=M1/10 Brake release unit

4

2

1

2

1

AWG16 blue

5

1

2

B16 B12 B13

Circuit Diagram, IRB 940 Tricept™ - =M1/10 Brake release unit


144

Circuit Diagram, S4Cplus

Chapter 6:Circuit Diagram, S4Cplus Introduction Definitions

This chapter contains the circuit diagram for the controller S4Cplus. The chapter is divided into the separate systems..

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145

Sheet 1-1. Block Diagram

System 1: General information

Circuit Diagram, S4Cplus - Sheet 1-1.

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146

Sheet 1-2. View of Control Cabinet



147

Sheet 1-3. View of Control Cabinet



148

Sheet 1-4. Designation



149




150

Sheet 2-1. Mains Connection

System 2: Mains Connection and Power Supply



151

Sheet 2-2. Transformer Unit



152

Sheet 2-3. Power Supply



153

Sheet 2-4. Power Supply



154

Sheet 2-5. External transformer unit 200-500V IRB6600/7600



155

Sheet 2-6. Transformer unit 400-475V IRB 6600/7600



156

Sheet 3-1. Block Diagram/Computer Unit

System 3: Computer Unit and Connector Unit



157

Sheet 3-2. Cabling in Computer Unit



158

Sheet 3-3. Main Computer and Hard Disk / Flash Disk Drive



159

Sheet 3-4. Compute Cooling



160

Sheet 3-5. Base Connector Board and I/O Computer



161

Sheet 3-6. Connector Board and I/O Computer



162

Sheet 3-7. Connector Board and Axis Computer



163

Sheet 3-8. Base Connector Unit



164

Sheet 3-9. Connector Plate on Controller Panel



165

Sheet 4-1. Emergency Stop

System 4: Emergency Stops and Run Chain



166

Sheet 4-2. Run Chain



167

Sheet 4-3. Run Chain



168

Sheet 4-4. Power Unit Servo Disconnector



169


System 5: Drive System and Robot Cable



170

Sheet 5-2. Rectifier, Fans and Bleeder



171

Sheet 5-3. Drive System Signal Connection 2 Drive Units



172

Sheet 5-4. Drive System Signal Connection 3 Drive Units



173

Sheet 5-5. Servo Drive Units / IRB 140



174

Sheet 5-6. Servo Drive Units / IRB 340



175

Sheet 5-7. Servo Drive Units / IRB 640, 840



176

Sheet 5-8. Servo Drive Units / IRB 1400, 2400



177

Sheet 5-9. Servo Drive Units / IRB 4400, 6400S/PE



178

Sheet 5-10. Servo Drive Units / IRB 6400R



179

Sheet 5-11. Control Cable IRB 140



180

Sheet 5-12. Control Cable IRB 340, 1400 and 2400



181

Sheet 5-13. Control Cable IRB 640, 840, 4400 and 6400S/PE



182

Sheet 5-14. Control Cable IRB 6400R



183

Sheet 5-15. Rectifier, fans and bleeder



184

Sheet 5-16. Servo Drive System



185

Sheet 5-17. Control cable



186

Sheet 6-1. External axes

System 6: External axes



187

Sheet 6-2. Axes Computer 2 and Connector Board



188

Sheet 6-3. Expansion Board Axis Connector Board



189

Sheet 6-4. Drive System Signal Connection External Axes



190

Sheet 6-5. External axes no. 7th - 9th Control Signal Connection



191

Sheet 6-6. Axis Computer 2 and Axis Connector Unit if External Axis Cabinet



192

Sheet 6-7. Connection to External Axis Cabinet



193

Sheet 6-8. Servogun-SMB power/signals cable



194

Sheet 7-1. I/O Unit Position

System 7: I/O Units and Field Bus Modules



195

Sheet 7-2. Digital Part of Combi I/O and Digital I/O Unit Input Part



196

Sheet 7-3. Digital I/O Unit Output Part



197

Sheet 7-4. Combi I/O Unit Digital and Analogue Output Part



198

Sheet 7-5. Digital Input Part of 120V AC I/O Unit



199

Sheet 7-6. Digital Output Part of 120V AC I/O Unit



200

Sheet 7-7. Relay I/O Unit Input 1-16



201

Sheet 7-8. Digital with Relays I/O Output 1-8



202

Sheet 7-9. Digital with Relays I/O Output 9-16



203

Sheet 7-10. Analogue I/O Unit



204

Sheet 7-11. Remote I/O Unit For Allen Bradley PLC



205

Sheet 7-12. Interbus-S Master/Slave - Interbus-S Master



206

Sheet 7-13. Profibus DP SLave



207

Sheet 7-14. Encoder Unit



208

Sheet 7-15. Profibus DP Master/Slave



209

Sheet 7-16. Interbus master/slave optical fibre and copper wire



210

Sheet 8-1. Floppy Disk

System 8: Other options



211

Sheet 8-2. Service Equipment Supply



212

Sheet 8-3. External Connections System Signals



213

Sheet 8-4. Position Switches on Manipulator



214

Sheet 8-5. Customer Signals



215

Sheet 8-6. Sustomer Power/SIgnal IRB 2400, 4400, 6400S/PE



216

Sheet 8-7. Customer Cable Power/Signal/CAN IRB 6400R



217

Sheet 8-8. External Control Panel



218

Sheet 8-9. Extension Cable Teach Pendant



219

Sheet 8-10. Time Relay



220

Sheet 8-11. Customer Precess / Power / Signal / Profibus DP M/S



221

Sheet 8-12. Optional customer power/signal Profibus IRB 6400R



222

Sheet 8-13. LAN Ethernet connection



223

Sheet 8-14. Customer power/CAN-BUS IRB 640/6400S



224

Sheet 8-15. Customer cable power/signal CAN-BUS IRB 6600/7600



225

Sheet 8-16. Customer cable power/signal Profibus IRB 6600/7600



226

Sheet 8-17. Optional customer power/signal Profibus IRB 6400R



227


System 9: External Axis Cabinet



228

Sheet 9-2. View of External Axis Cabinet



229




230

Sheet 9-4. Mains Connection



231

Sheet 9-5. Transformer Unit



232

Sheet 9-6. Power Supply, I/O Supply



233

Sheet 9-7. Power Unit



234

Sheet 9-8. Rectifier, Fans and Bleeder



235

Sheet 9-9. Drive Unit Signal Connection 1 External Drive Unit



236

Sheet 9-10. Drive Unit Signal Connection 2 External Drive Units



237

Sheet 9-11. Drive Unit Signal Connection 3 External Drive Units



238

Sheet 9-12. Drive Unit and Control Cable Drive Unit GT



239

Sheet 9-13. Drive Unit and Control Cable Drive Unit GT+CCB



240

Sheet 9-14. Drive Unit and Control Cable



241

Sheet 9-15. Service Equipment Supply



242

Index


243

Index


Maintenance Manual Industrial Robot IRB 940 Tricept™ 3HAC 16639-1 / M2000 / Rev. IRB 940 Tricept™




Maintenance Manual, IRB 940 Tricept™ 3HAC 16639-1 -





Table of Contents

Overview Product Documentation, IRB 940 Tricept ™ Chapter 1: Safety, service Introduction Safety, service - General Section A: References



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 Work inside the manipulators working range Chapter 2: Reference Information Introduction Screw joints Weight specifications Chapter 3: Maintenance activities, manipulator Introduction Section A: Maintenance intervals

Specification of maintenance intervals Maintenance schedule, IRB 940 Tricept™ Section B: Daily maintenance

Daily maintenance, complete robot

1 3 5 5 6 7

7 7 8 9

9 9 9 10 10 11 13

13 13 14 14 15 15 15 17 17 18 20 21 21 22

22 23 24

24


i

Table of Contents

Section C: Lubrication activities

25

Lubrication, linear bearings Lubrication, actuators

25 27

Section D: Replacement activities

Replacement of filter element, OP-unit Adjusting the overpressure unit Chapter 4: Maintenance activities, controller Introduction Section A: Maintenance intervals

Specification of maintenance intervals Maintenance schedule, controller S4CPlus Section B: Inspection activities

Inspection of controller cabinet, S4Cplus Section C: Replacement activities

Replacement of air filter, controller Replacement of battery unit, controller Replacement of system fan unit Section D: Cleaning activities

Cleaning of controller cabinet Cleaning of air filter Chapter 5: Disposal Disposal

29

29 31 33 33 34

34 35 36

36 37

37 40 44 47

47 49 51 51


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.



Prerequisites


•

maintenance personnel in the user's organization.

•

maintenance personnel in other organizations.

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.

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


1


Document Id

Circuit diagram, Manipulator

3HAC 16640-1, Repair Manual part 2

Circuit diagram, Controller

3HAC 16640-1, Repair Manual part 2

Revisions Revision

Description

-

First edition


Product Documentation, IRB 940 Tricept ™

General






•

Safety, Service

•


•

Unpacking

•


•


•

Start-up

•

Robot controller

•


•


•

Calibration


Safety, Service

•


•


•


•


•



Safety, Service

•



3

•


•


•

Disposal



Safety, service


Definitions


Sections

The chapter "Safety, service" is divided into the following sections: A. References contains lists of: • Limitation of liability • applicable safety standards • referenced documents




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Safety, service









General



Standards



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7


Related information

General







User’s Guide

Section

Start-up





Safe handling


Safe design



General

Residual energy

Safe design


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9



General

Qualified personnel

Extraordinary risks

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The power unit

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General




- withstand any impact from a tool failure. Due to the high kinetic energy associated with HSM (High Speed Machining), a tool failure poses a serious 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.

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13



Description


Increased injury


Brake testing

When to test


How to test








15





General



17


Screw joints

General

This section details how to tighten the various types of screw joints in the manipulator 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




Dimension


M2.5

0.25

M3

0.5

M4

1.2

M5

2.5

M6

5.0

Dimension




M5

6

-

-

M6

10

-

17

M8

24

28

40

M10

47

55

70

M12

82

95

120



Dimension




M16

200

235

300


19



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



Maintenance activities, manipulator

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.


21

Maintenance activities, manipulator Maintenance intervals

Section A: Maintenance intervals Specification of maintenance intervals

Description

The intervals may be specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the robot. •

Calendar time: specified in months regardless of whether the robot system is run or not.

•

Operating time: specified in operating hours. More frequent running of the robot means more frequent maintenance activities.


Maintenance activities, manipulator Maintenance intervals

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:

Maintenance activity

Equipment

Interval

Detailed in section

Daily maintenance

Complete robot

Daily

"Daily maintenance" 1

Lubrication

Linear bearings

1000h

"Lubrication, linear bearings"

Lubrication

Actuator

1000h 1

Changing

Filter, overpressure unit

“Replacement of filter element, OP-unit”

Changing

Battery, distribution box

“Removal/Refitting of battery, distribution box” in the Repair Manual.

"Lubrication, actuators"

1)

The interval is based on utilization under normal operating conditions. Operation under severe conditions such as increased ambient temperature or the presence of abrasive or grease absorbent dust will require a more regular maintenance cycle.


23

Maintenance activities, manipulator Daily maintenance

Section B: Daily maintenance Daily maintenance, complete robot

General

Daily maintenance

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 maintaining 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.

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 components 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, maintain the correct pressures and flows.


Maintenance activities, manipulator Lubrication activities

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.

A

xx0200000293

A

Grease lubrication nipple (one on either side of the center tube)

Required equipment Equipment, etc. Spare part no. Art. no. Lubricant

Note

Klüber Isoflex NBU 15 2 x 4 ml per linear bearing.


25


Lubrication

The procedure below details how to lubricate the linear bearings. Please observe the following before commencing any repair work on the manipulator: - 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 Shown in figure above! bottom end of the linear guide bearing. Lubricant specified Both sides must be lubricated! above! Note! The ends of the linear bearing are made from plastic and can crack if not sufficient care is taken when lubricating the bearings.

3.

Run the robot back and forth in the Z-direction several times.

4.

Apply a further 4 ml lubricant through the same nipples at both side of the center tube.



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 housing. The figure below shows the location of the grease lubrication nipples on the actuator.

A

xx0200000294

A

Grease lubrication nipples on the actuator


Note

Lubricant

2 x 4 ml per actuator. For lubrication of the actuators.

Klüberplex BEM 34-132


27


Lubrication

The procedure below details how to lubricate the actuators. Please observe the following before commencing any repair work on the manipulator: - 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

1.

Extend the actuators to their maximum allowable 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, lubricate 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 orientated grease nipple will not ensure that the grease is applied to the lead screw correctly.

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 application 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.

Note/Illustration

Lubricant specified above! Shown in the figure above!


Maintenance activities, manipulator Replacement activities

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

-

Removal of the filter element


Spare part no.

Filter

3HAC 17158-1

Art. no.

Note


29


Replacement of filter

The procedure below details how to replace the filter element in the overpressure unit.

Step

Action

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 dismantling.

5.

Recommission the overpressure unit.

Note/Illustration

Detailed in the section "Adjusting the overpressure unit".



Adjusting the overpressure unit

Location

The overpressure unit is installed as shown in figure below.

A

B

C xx0200000421

A

Regulator

B

Pressure guard

C

Pressure indicator light

D

Air input


31


Adjusting

The procedure below details how to adjust the overpressure unit after installation or after replacement of the filter element.

Step

Action

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 pressure (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 unintentional turning.

Note/Illustration

The output pressure must under no circumstances exceed 1 bar!


Maintenance activities, controller

Chapter 4:Maintenance activities, controller Introduction

Definitions

This chapter details all maintenance activities recommended for the control cabinet. 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.


33

Maintenance activities, controller Maintenance intervals

Section A: Maintenance intervals Specification of maintenance intervals

Description

The intervals may be specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the robot. •

Calendar time: specified in months regardless of whether the robot system is run or not.

•

Operating time: specified in operating hours. More frequent running of the robot means more frequent maintenance activities.


Maintenance activities, controller Maintenance intervals

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 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".

1)

Hours denotes operational time whereas months denotes actual calender time.


35

Maintenance activities, controller Inspection activities

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 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!

Step

Action

Note/Illustration

1.

Inspect the cabinet interior to make sure Replace any faulty seals there is no contamination. as required. If any contamination is found, the cabinet interior must be cleaned and all gaskets and seals to the cabinet inspected.

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 cabinet.

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 malfunctioning fans as detailed in their sections respectively.


Maintenance activities, controller Replacement activities

Section C: Replacement activities Replacement of air filter, controller


The air filter is located in the air filter magazine in the front hatch.

A

A xx0200000284

A

Air filter magazine



Air filter

3HAB 8028-1




37


Removal, air filter

The procedure below details how to remove the air filter.

Step 1.

Action

Note/Illustration

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 contamination, the air filter may be cleaned and refitted. The procedure for this is detailed in section "Cleaning the air filter, controller" in the Maintenance Manual.

1

2

xx0200000003



Refitting, air filter

The procedure below details how to refit the air filter.

Step

Action

Note/Illustration

1.

Fit the air filter in the Art. no. is specified above! magazine.

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 battery unit

The battery unit is located at the bottom of the controller.

A xx0200000103

A

Battery unit





Note

Battery unit

3HAC 5393-2

To be replaced as a complete unit


Removal, battery unit


The procedure below details how to remove the battery unit.



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Step 1.

Action

Note/Illustration

Remove the battery unit by unscrewing its attachment screws (1). X1

X1

X1

X2

X2

X2

X1

X2

X3

xx0200000004

2.

Pull the battery unit out (2).

3.

Disconnect the three cables from the battery unit (3).

xx0200000005



Refitting, battery unit

The procedure below details how to refit the battery unit.


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.


3.

Secure it with the attachment screws (1).



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Replacement of system fan unit

Location of system fan unit

The system fan unit is located as shown in the figure below.

E

A D

A

A

A B

0

C

xx0200000007

A

Drive units

B


C

System fan unit

D


E

Power supply unit





System fan unit

3HAC 12924-2

Note


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 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!

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). 1

2

2

1

xx0200000008


45


Step 3.

Refitting

Action

Note/Illustration

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).

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 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!

Step

Action

Note/Illustration

1.

Fit the system fan unit into position and Art. no. specified above! secure it (see position 2 in the figure 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.


Maintenance activities, controller Cleaning activities

Section D: Cleaning activities Cleaning of controller cabinet



Note

Vacuum cleaner Cleaning agent, exterior cleaning

Cleaning of functional components

Use rag with e.g. alcohol, if necessary

The procedure below details how to clean the functional components of the controller cabinet.


Step

Action

1.

Clean the cabinet interior with a vacuum cleaner if necessary.

2.

If the cabinet is equipped with heat exchangers, 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

Note/Illustration

If required, remove any heat exchangers before cleaning as detailed in the "Repair Manual".


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Do’s and don’ts!

Always!

Never!

The section below specifies special considerations when cleaning the controller cabinet.

•

Always use cleaning equipment as specified above! Any other cleaning equipment may shorten the life of paintwork, rust inhibitors, signs, or labels!

•

Always check that all protective covers are fitted to the controller before cleaning!

•

Never remove any covers or other protective before cleaning the controller!

•

Never use any cleaning agents, e.g. compressed air or solvents, other than those specified above!

•

Never spray with a high pressure cleaner!



Cleaning of air filter


The air filter is located as shown in the figure below: B

A

C

D

E

xx0200000002

A

Air filter

B

I/O and gateway units

C

Power supply unit

D

Drive system

E

Computer system

Required equipment Equipment, etc. Cleaning agent


Note Water 30-40°C with washing-up liquid or detergent

Compressed air


49


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 gearbox, axis 2.

Step

Action

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 •

Note/Illustration

Do not wring the filter out!

Blow dry with compressed air from the clean-air side.


Disposal

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 disposed 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


Index


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Index


ABB-S4C+IRB 940 M2000 Electrical Maintenance Training Manual

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