abb-s4c+irb 940 m2000 electrical maintenance training manual

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

IRB 940 Tricept™

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ABB Automation Technology Products ABRoboticsS-721 68 VÄSTERÅSSWEDENTelephone: +46 (0) 21 344000Telefax: +46 (0) 21 132592

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Installation and Commissioning ManualIRB 940 Tricept™

3HAC 16638-1-

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

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

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

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

©Copyright 2002 ABB All rights reserved.

ABB Automation Technology Products ABRobotics

SE-721 68 VästeråsSweden


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Table of Contents

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Overview 1Product Documentation, IRB 940 Tricept™ 3

Chapter 1: Safety, service 5

Introduction 5Safety, service - General 6

Section A: References 7Limitation of Liability 7Applicable Safety Standards 7Related information 8

Section B: Safety risks 9Safety risks related to end effector 9Safety risks related to tools/workpieces 9Safety risks related to pneumatic/hydraulic systems 9Safety risks during operational disturbances 10Safety risks during installation and service 10Risks associated with live electric parts 11

Section C: Safety actions 13Safety fence dimensions 13Fire extinguishing 13Emergency release of the manipulator's arm 14Brake testing 14Risk of disabling function "Reduced speed 250 mm/s" 15Safe use of the Teach Pendant Unit 15Work inside the manipulators working range 15

Chapter 2: Reference Information 17

Introduction 17Screw joints 18Weight specifications 20

Chapter 3: Manipulator 21

Introduction 21

Section A: Unpacking 22Pre-installation procedure 22Working range, IRB 940 Tricept 26Risk of tipping/Stability 27

Section B: On-site installation 28Lifting manipulator in a horizontal orientation 28

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Lifting manipulator in a vertical orientation, using a trolley 31Lifting manipulator in a vertical orientation, using a lifting jack 35Manually releasing the brakes 39Orienting and securing the manipulator 40Fitting equipment on manipulator 44Loads 46

Section C: Electrical connections 47Installation of cabling on board the manipulator 47Connecting the manipulator to the control cabinet, manipulator cabling 49Connectors on the distribution box 52

Chapter 4: Controller 53

Introduction 53

Section A: Unpacking 54Transporting and unpacking, S4Cplus 54

Section B: On-site Installation 56Lifting the controller cabinet 56Required installation space, control cabinet 57Bolt pattern, control cabinet 58Installation of external power transformer 59Installation of Distributed Drive Unit (DDU) 64

Section C: Electrical connections 68

C - 1: Signal/Power cables 68Connecting the manipulator to the control cabinet, S4Cplus cabling 68Connectors on control cabinet, S4Cplus 70Connectors on distributed drive unit, DDU 71Connection of mains power to control cabinet, S4Cplus 72

C - 2: Signal connections 74Signal Classes 74Selecting Cables 75Interference elimination 77Connection types 79Connections to screw terminals 80Connections to connectors 81

C - 3: Customer connections on controller 81The MOTORS ON/MOTORS OFF circuit 81External customer connections on panel X1 - X4 91Connection of external safety relay 94

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C - 4: Supplies 96External 24V supply 9624V I/O supply 98115/230 VAC supply 99

C - 5: Buses 99Connection of the CAN bus 99Interbus-S, slave DSQC 351 104Profibus-DP, slave DSQC 352 110

C - 6: I/O units 114Distributed I/O units 114Distributed I/O, digital sensors 115Distributed I/O, digital I/O DSQC 328 (option) 116AD Combi I/O, DSQC 327 (optional) 120Analog I/O, DSQC 355 (optional) 124Encoder interface unit, DSQC 354 (optional) 130Relay I/O, DSQC 332 (optional) 136Digital I/O (120 VAC), DSQC 320 (optional) 140

C - 7: Communication 144Communication concept, Allen-Bradley 144RIO, remote I/O for Allen-Bradley PLC DSQC 350 146Communication, serial links 149Communication, Ethernet 154External operator’s panel 157

Section D: Start-up 159Inspection before start-up 159Start-up 160

Section E: Installation of controller software 162Loading system software 162RobotWare CD-ROM 164Installing new Robot Controller Software with RobInstall 166Create a new Robot Controller System 168Update the Robot Controller image 173Transfer Robot Controller System using Ethernet connection 175Transfer Robot Controller System using floppy disks 180RobInstall preferences 182

Section F: Robot controller 184BootImage 184Start window 185Reboot Window 187Boot Disk Window 188

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Network Settings Window 189LAN Settings Window 190Service Settings Window 192System selection window 193How to perform a Restart 194How to Start in Query Mode 198

Section G: System directory structure 200Media pool in the PC 200System pool in the PC 201File structure in the robot controller mass storage memory 202Preparation of S4Cplus software to be installed 203Handling mass memory storage capacity 204

Chapter 5: Calibration 207

When to calibrate 207

Section A: General 208How to calibrate the robot system 208Calibration tool kit, contents 210

Section B: Preliminaries 211Correct orientation of axes 211Checking the calibration position 215Updating the revolution counter 216Fine calibration procedure on TPU 219

Section C: Calibration 222Directions for all axes 222Fine calibration, all axes 224

Section D: After calibration 231Post calibration procedure 231

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Overview

About This Manual

This information product is a manual containing instructions for installing the

complete robot system, mechanically as well as electrically.

Usage This manual should be used during installation, from lifting the manipulator to its

work site through installing application software in the robot controller, making

the robot ready for operation.

Who Should Read This Manual?

This manual is intended for:

• installation personnel on the installation site.

Prerequisites The reader should...

• have the required knowledge of mechanical as well as electrical installa-tion work.

Organization of Chapters

The manual is organized in the following chapters:

Chapter Contents

1. Safety, service

2. Reference Information

3. Manipulator

4. Controller

5. Calibration

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References

Revisions

Reference Document Id

Circuit diagram, Manipulator Included in 3HAC 16640-1, Repair Manual, part 2

Circuit diagram, Controller Included in 3HAC 16640-1, Repair Manual, part 2

Revision Description

- First edition

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Product Documentation, IRB 940 Tricept™

General The complete documentation of IRB 940 Tricept™ including controller consists

of several manuals listed below:

Overview, Installation and Commissioning Manual

The Installation and Commissioning Manual contains the following main chap-

ters:

• Safety, Service

• Reference Information

• Unpacking

• On-site Installation

• Electrical connections

• Start-up

• Robot controller

• Installation of controller software

• System directory structure

• Calibration

Overview, Repair Manual

The Repair Manual contains the following main chapters:

• Safety, Service


• Remove/Refitting instructions for all manipulator details considered spare parts

• Remove/Refitting instructions for all controller cabinet details considered spare parts

• Circuit Diagram for manipulator

• Circuit Diagram for controller cabinet

Overview, Maintenance Manual

The Maintenance Manual contains the following main chapters:

• Safety, Service



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• Maintenance schedules

• Maintenance activities

• Disposal

The chapters for the maintenance activities include instructions for all the main-

tenance activities specified in the maintenance schedule.


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Safety, service

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Chapter 1:Safety, service

Introduction

Definitions This chapter details safety information for service personnel i.e. personnel per-

forming installation, repair and maintenance work.

Sections The chapter “Safety, service” is divided into the following sections:

A. References contains lists of:

• Limitation of liability

• applicable safety standards

• referenced documents

B. Safety risks lists dangers relevant when servicing the robot system. The dangers are split into different categories:

• Safety risks related to end effector

• Safety risks related to tools/workpieces

• Safety risks related to pneumatic/hydraulic systems

• Safety risks during operational disturbances

• Safety risks during installation and service

• Risks associated with live electric parts

C. Safety actions details actions which may be taken to remedy or avoid dangers.

• Safety fence dimensions

• Fire extinguishing

• Emergency release of the manipulator´s arm

• Brake testing

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

• Safe use of the Teach Pendant Unit enabling device

• Work inside the manipulator´s working range


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Safety, service

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Safety, service - General

Validity and responsibility

The information does not cover how to design, install and operate a complete

system, nor does it cover all peripheral equipment, which can influence the safety

of the total system. To protect personnel, the complete system must be designed

and installed in accordance with the safety requirements set forth in the standards

and regulations of the country where the robot is installed.

The users of ABB industrial robots are responsible for ensuring that the applicable

safety laws and regulations in the country concerned are observed and that the

safety devices necessary to protect people working with the robot system have

been designed and installed correctly. Personnel working with robots must be

familiar with the operation and handling of the industrial robot, described in the

applicable documents, e.g. User’s Guide and Product Manual.

Connection of external safety devices

Apart from the built-in safety functions, the robot is also supplied with an inter-

face for the connection of external safety devices. Via this interface, an external

safety function can interact with other machines and peripheral equipment. This

means that control signals can act on safety signals received from the peripheral

equipment as well as from the robot.

In the Product Manual - Installation and Commissioning, instructions are pro-

vided for connecting safety devices between the robot and the peripheral equip-

ment.


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Safety, serviceReferences

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Section A: References

Limitation of Liability

General Any information given in this information product regarding safety, must not be

construed as a warranty by ABB Robotics that the industrial robot will not cause

injury or damage even if all safety instructions have been complied with.

Applicable Safety Standards

Standards The robot is designed in accordance with the requirements of:

• EN 292-1, Safety of macheniry, basic terminology

• EN 292-2, Safety of machinery, technical principles/specifications, emer-gency stop

• EN 418, Safety of machinery, emergency stop equipment

• EN 563, Safety of machinery, temperatures of surfaces

• EN 614-1, Safety of machinery, ergonomic design principles

• EN 775, Robot safety

• EN 60204-1, Electrical equipment for industrial machines

• EN 50081-2EMC, Generic emission standard. Part 2: Industrial environ-ment(EN 55011 Class ARadiated emission enclosure)(EN 55011 Class AConducted emission AC Mains)

• EN 61000-6-2EMC, Generic standards - Immunity for Industrial environ-ments(EN 61000-4-2Electrostatic discharge immunity test)(EN 61000-4-3Radiated, radio-frequency, electromagnetic field immunity test)(EN 61000-4-4Electrical fast transient/burst immunity test)(EN 61000-4-5Surge immunity test)(EN 61000-4-6Immunity to conducted disturbances, induced by radio-fre-quency fields)(EN 61000-4-11Voltage dips, short interruptions and voltage variations immunity test)


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Related information

General The list below specifies documents which contain useful information:

Documents

Type of information Detailed in document Section

Installation of safety devices Installation and Commis-sioning Manual

Changing robot modes User’s Guide Start-up


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Safety, serviceSafety risks

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Section B: Safety risks

Safety risks related to end effector

Make sure to prevent an end effector from dropping a workpiece, if such is used.

Safety risks related to tools/workpieces

Safe handling It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure

that guards remain closed until the cutters stop rotating.

It should be possible to release parts by manual operation (valves).

Safe design Grippers/end effectors must be designed so that they retain workpieces in the

event of a power failure or a disturbance of the controller.

Safety risks related to pneumatic/hydraulic systems

General Special safety regulations apply to pneumatic and hydraulic systems.

Residual energy • Residual energy may be present in these systems so, after shutdown, par-ticular care must be taken.

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

• Note that the interior of the robot may be pressurized.

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

• Dump valves should be used in case of emergency.

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


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Safety risks during operational disturbances

General • The industrial robot is a flexible tool which can be used in many different industrial applications.

• All work must be carried out professionally and in accordance with the applicable safety regulations.

• Care must be taken at all times.

Qualified personnel

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

Extraordinary risks

If the working process is interrupted, extra care must be taken due to risks other

than those associated with regular operation. Such an interruption may have to be

rectified manually.

Safety risks during installation and service

General risks dur-ing installation and service

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

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

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

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

Nation/region specific regula-tions

To prevent injuries and damage during the installation, lifting and transport of the

robot system, the regulations applicable in the country concerned and the instruc-

tions of ABB Robotics must be complied with.


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Non-voltage related risks

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

• Turntables or the like should be used to keep the operator out of the robot's working space.

• The axes are affected by the force of gravity when the brakes are released or when the motors or other components are removed.

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

• Be aware of stored heat energy in the controller.

• Never use the robot as a ladder, i.e. do not climb on the robot motors or other parts during service work. There is a serious risk of slipping because of the high temperature of the motors or oil spills that can occur on the robot.

To be observed by the supplier of the complete sys-tem

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

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

Risks associated with live electric parts

Voltage related risks, general

• Although troubleshooting may, on occasion, have to be carried out while the power supply is turned on, the robot must be turned off (by setting the mains switch to OFF) when repairing faults, disconnecting electric leads and disconnecting or connecting units.

• The mains supply to the robot must be connected in such a way that it can be turned off outside the robot’s working space.


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Voltage related risks, controller, S4Cplus

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

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

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

• The mains supply/mains switch

• The power unit

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

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

• The drive unit (700 VDC)

• The service outlets (115/230 VAC)

• The power supply unit for tools, or special power supply units for the machining process

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

• Additional connections

Voltage related risks, manipula-tor, IRB 940 Tri-cept™

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

• The distribution box for the manipulator (up to 430 VDC)

• The power supply for the motors (up to 430 VDC)

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

Voltage related risks, tools, mate-rial handling devices, etc.

Tools, material handling devices, etc., may be live even if the robot system is in

the OFF position. Power supply cables which are in motion during the working

process may be damaged.


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Safety, serviceSafety actions

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Section C: Safety actions

Safety fence dimensions

General Install a safety cell around the robot to ensure safe robot installation and operation.

Dimensioning the fence or enclo-sure

Design the safety cell such that it will:

• - withstand any impact from a tool failure. Due to the high kinetic energy associated with HSM (High Speed Machining), a tool failure poses a seri-ous risk as any debris can cause serious personal injury. Both walls and ceilings must be designed and dimensioned so that they can withstand any projectiles that they may be subjected to. Windows must be made of suit-able safety glass. Study the planned process to determine the forces involved and appropriate materials.

• - insulate against sound pollution from the machining process. Typically the safety cell should be able to reduce sound from the machining process down to 75dBA, though individual installations may stipulate other values. Study the planned process to determine the allowable noise pollution lev-els and appropriate sound insulation.

• - isolate gases and mist generated by the machining process and spray mist lubrication. Study the planned process to determine the fumes involved and appropriate ventilation/filtering system.

Fire extinguishing

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


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Emergency release of the manipulator’s arm

Description In an emergency situation, any of the manipulator’s axes may be released manu-

ally by pushing the brake release buttons on the distribution box for the manipu-

lator. How to release the brakes is detailed in section "Manually releasing the

brakes" in the Installation Manual.

The manipulator arms may be moved manually when the brakes has been

released.

Increased injury Before releasing the brakes, make sure that the weight of the arms does not

increase the pressure on the trapped person, further increasing any injury!

Brake testing

When to test During operation the holding brakes of each axis motor wear normally. A test may

be performed to determine whether the brake can still perform its function.

How to test The function of each axis’ motor holding brakes may be checked as detailed

below:

1. Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized (max. static load).

2. Switch the motor to the MOTORS OFF position with the Operating mode selector on the controller.

3. Check that the axis maintains its position.

If the manipulator does not change position as the motors are switched off, then the brake function is adequate.


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

Do not change "Transm gear ratio" or other kinematic parameters from the Teach Pendant Unit or a PC. This will affect the safety function Reduced speed 250 mm/s.

Safe use of the Teach Pendant Unit

The enabling device is a push button located on the side of the Teach Pendant Unit (TPU) which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device is released or pushed all the way in, the robot is taken to the MOTORS OFF state. To ensure safe use of the Teach Pendant Unit, the following must be implemented: The enabling device must never be rendered inoperative in any way.

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

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

Work inside the manipulators working range

If work must be carried out within the robot’s work envelope, the following points must be observed: The operating mode selector on the controller must be in the manual mode position to render the enabling device operative and to block operation from a computer link or remote control panel.

The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in position < 250 mm/s. This should be the normal position when entering the working space. The position 100% “full speed” may only be used by trained per-sonnel who are aware of the risks that this entails. Also be aware of any danger that may be caused by rotating tools or other devices mounted on the manipulator or inside the cell.


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16 - 3HAC 16638-1

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Reference Information

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Chapter 2:Reference Information

Introduction

General This chapter presents generic pieces of information, complementing the more spe-

cific information in the following chapters.


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Screw joints

General This section details how to tighten the various types of screw joints in the manip-

ulator as well as the controller.

The instructions and torque values are valid for screw joints comprising metallic

materials and do not apply to soft or brittle materials.

Any instructions given in the repair, maintenance or installation procedure

description override any value or procedure given here, i.e. these instruction are

only valid for standard type screw joints.

Tightening torque The tightening torque values for different types of screw joint are specified in the

tables below:

Screws with slotted or cross recess head

Screws with hexagon socket head

Dimension Tightening torque (Nm) Class 4.8 "dry"

M2.5 0.25

M3 0.5

M4 1.2

M5 2.5

M6 5.0


Tightening torque (Nm) Class 10.9


M5 6 - -

M6 10 - 17

M8 24 28 40

M10 47 55 70

M12 82 95 120


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M16 200 235 300





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Weight specifications

Definition In all repair and maintenance instructions, weights of the components handled are

sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in

this way.

ABB recommends handling all components with a weight exceeding 22 kg using

lifting equipment to avoid inflicting injury.

Example Below is an example of how a weight specification is presented:

The actuator with motor weighs 40 kg! All lifting equipment used must be dimen-sioned accordingly!


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Manipulator

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Chapter 3:Manipulator

Introduction

Definitions This chapter contains necessary information for installing the manipulator to the

working site.


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ManipulatorUnpacking

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Section A: Unpacking

Pre-installation procedure

General This instruction is primarily intended for use when unpacking and installing the

manipulator (mechanical robot) for the first time. It also contains information use-

ful during later re-installation of the manipulator.

Checking the pre-requisites for installation

The checklist below details what must be observed before proceeding with the

actual installation of the manipulator:

1. Make sure only qualified installation personnel, conforming to all national and local codes, are allowed to perform the installation.

2. Make sure the manipulator has not been damaged, by visually inspect-ing the manipulator and control cabinet exterior.

3. Make sure the lifting device to be used is dimensioned to handle the weight of the manipulator as stated in Weight, manipulator.

4. If the manipulator is not to be installed directly, it must be stored as in Storage conditions, manipulator.

5. Make sure the appointed operating environment of the manipulator conforms to the specifications as in Operating conditions, manipulator.

6. Before taking the manipulator to its installation site, make sure the site conforms to Loads on flange, manipulator and Protection classes.

7. Before moving the manipulator, please observe Risk of tipping/Stability regarding risk of tipping!

8. When these prerequisites have been met, the manipulator may be taken to its installation site as in Lifting manipulator in a horizontal/ver-tical orientation.


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Weight, manipulator

The table below shows the weight of the manipulator:

Manipulator model Weight

IRB 940 Tricept 570 kg

Distribution box 31 kg


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Loads on flange, manipulator

The table below shows the maximum forces and torques working on the manipu-

lator during operation.

NOTE! These forces and torques are extreme values that are rarely encountered

during operation. The values also never reach their maximum simultaneously!

xx0200000362

Force Maximum stress transmitted to the mounting base

Force xy 51 kN

Force z 68 kN

Torque xy 14 kNm

Torque z 45 kNm

Tz


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Storage conditions, manipulator

The table below shows the allowed storage conditions for the manipulator and the

distribution box:

Operating conditions, manipulator

The table below shows the allowed operating conditions for the manipulator and

the distribution box:

Note! The robot must not be operated until the internal temperature of the robot is

stabilized within the prescribed operational temperature range!

Protection classes

The table below shows the protection class of the main parts of the robot system:

Parameter Value

Min. ambient temperature, storage -25°C

Max. ambient temperature, storage +55°C

Max. ambient temperature, storage (less than 24 hrs) +55°C

Max. ambient humidity, storage Max. 95% at constant temperature

Parameter Value

Min. ambient temperature, operation +5°C

Max. ambient temperature, operation, manipulator +45°C

Max. ambient humidity, operation Max. 95% at constant temperature

Equipment Protection class

Manipulator IP 66

Distribution box IP 67

Overpressure unit IP 67


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Working range, IRB 940 Tricept

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

xx0200000356

A Absolute Tolerance Area at the tool-coordinate system, TCP0

B Working range, centre of axis 5

(mm)

800 400 0 400 800 12001200

800

400

0

(mm)

800 400 0 400 800 12001200

800

400

0

A

B

A

B


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Risk of tipping/Stability

General The section below details how to make sure the manipulator does not tip over

before it has not been safely secured to the foundation.

Stability The figure below shows the robot in its shipping position which also is the most

stable.

The robot must be placed on a spacer, at least 100mm in height, in order to avoid

the risk of collision with the axis 2 servomotor.

xx0200000357

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

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

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

B Spacer, min. 100 mm in height

Axis Position Note

1, 2, 3 26 mm Shown in figure above!

4, 6 0°5 -90°

A

B


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ManipulatorOn-site installation

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Section B: On-site installation

Lifting manipulator in a horizontal orientation

General The section below details how to lift the manipulator in a horizontal orientation

from a transportation pallet to a stand.

Required equip-ment

Lifting in horizon-tal orientation

The section below details how to lift and move the manipulator from the transpor-

tation pallet, horizontally, using the lifting equipment specified above.

The IRB 940 manipulator weighs 570 kg! All lifting equipment used must be dimen-sioned accordingly!

No personnel must under any circumstances be present under the suspended load!

Failure to attach the straps correctly can cause the suspended load to tilt suddenly and cause both personal injury and severe damage to the load.

Equipment Note

Crane or hoist Lifting capacity: 1000 kg.

1 strap, length 2 m Lifting capacity: 1000 kg.

2 straps, length 1 m Lifting capacity: 1000 kg.

2 upper platform eyebolts M16

2 shackles The shackles must fit the eyebolts on the upper platform.


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Step Action Note

1. Run the overhead crane to a position above the manipulator.

2. Fit the 2 metre strap around the wrist unit, as shown in the adjacent fig-ure.

xx0200000317

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

xx0200000318

4. Unless already in posi-tion, fit the eyebolts to the upper platform.

Dimension specified above!


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

xx0200000319

• A: Strap, 1 m (2 pcs)

• B: Shackle (2 pcs)

• C: Eyebolt (2 pcs)

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

7. Lift the manipulator to the required location and dis-connect the lifting equip-ment.

Step Action Note

B

C

A


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Lifting manipulator in a vertical orientation, using a trolley

General The section below details how to lift the manipulator from a transportation pallet

to a stand, after turning it into a vertical orientation.

Notice that there are two different ways of turning the manipulator into a vertical

orientation. The section below details a method using a trolley or a machine skate,

that is used to wheel the front of the manipulator towards the centre of the lift as

the manipulator is hoisted.

Required equip-ment

Lifting in vertical orientation, using a trolley


tation pallet, vertically, using the lifting equipment specified above.



Equipment Note





Trolley (or machine skate) Capacity: 500 kg. Height: 400 mm.


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- Ensure that the area around the manipulator is clear as the machine can swing round as it leaves the pallet!

- Ensure that the trolley has free movement while lifting. If the trolley gets stuck, the manipulator is likely to fall off and can cause personal injury and damage to the manipulator!

Step Action Note




xx0200000320




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

B

C

A


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

xx0200000321


• B: Wrist unit

• C: Trolley

• D: 125 mm

• E: 400 mm

5. When the wrist is rest-ing squarely on the trol-ley it is safe to continue lifting it off the pallet, as shown in the adjacent figure. Note! Exercise extreme care when lowering the wrist unit on to the trol-ley. Dropping the manipulator onto the trolley can cause dam-age to the manipulator and/or affect the cali-bration of the tripod.

xx0200000322

Step Action Note

AB

C

DE


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

xx0200000323

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

xx0200000324

8. Lift the manipulator and move it to the required location.

Step Action Note


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Lifting manipulator in a vertical orientation, using a lifting jack

General The section below details how to lift the manipulator from a transportation pallet

to a stand, after turning it into a vertical orientation.

Notice that there are two different ways of turning the manipulator into a vertical

orientation. The section below details a method using a lifting jack.

Required equip-ment

Lifting in vertical orientation, using a lifting jack


tation pallet, vertically, using the lifting equipment specified above.




Equipment Note



1 strap, length 1 m Lifting capacity: 1000 kg.



Lifting jack Lifting capacity: 1000 kg.


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Step Action Note




xx0200000320




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

B

C

A


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

xx0200000317

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


xx0200000325

• A: Strap around wrist unit

• B: Crane

6. Lift the whole manipula-tor using the lift, or crane, away from the pallet and remove the pallet.

Step Action Note

A

B


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7. Lower the wrist end of the manipulator using the lifting jack.

When the wrist gets near the floor, raise the whole manipulator fur-ther, as shown in the adjacent figure.

Repeat until the manip-ulator hangs vertically.

xx0200000326

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

Step Action Note


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Manually releasing the brakes

General The section below details how to release the holding brakes of each axis’ motor.

This may be done by:

• using push-buttons on the distribution box (internal brake release unit). This requires either that the controller is connected to the power supply or that the R1.MP connector (at the distribution box) is supplied with +24 V on R1.MP.B16 and 0 V on B14 or B15.

Supplying power on the wrong pin may cause all brakes on the manipulator to be released!

Internal brake release unit

This section details how to release the holding brakes using the internal brake

release unit.

When releasing the holding brakes, the manipulator axes may move very quickly and sometimes in unexpected ways! Make sure no personnel is near the manipu-lator arm!

Step Action Info/Illustration

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

The push-button unit is located on the outside of the distribution box.

2. Release the holding brake on a particular manipulator axis by pressing the appropriate button on the internal brake release panel. The brake will function again as soon as the button is released.


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Orienting and securing the manipulator

General This section details how to orient and secure the manipulator at the stand in order

to run the robot safely.

The cable harness should be installed in the stand before the manipulator is

mounted to it. Installation of the cabling is described in chapter "Electrical con-

nections".

Attachment screws

The table below specifies the type of securing screws and washers to be used for

securing the manipulator to the foundation. Securing screws are included in the

delivery of the manipulator.

A locating pin may be used in the mounting flange, when necessary. The dimen-

sion for the attachment hole is detailed in part "Hole configuration, mounting

flange".

Suitable screws, lightly lubricated MC6S, M16 x 55

Quality Quality 8.8

Suitable washer Thickness: 4 mm

Tightening torque 200 Nm


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Illustration, securing manipu-lator at stand

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

shows prepared cabling in the stand.

xx0200000348

A Manipulator attachment bolts

B Centering ring

C Mounting flange

AB

C


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Securing the manipulator

This section details how to secure the manipulator to the stand in a vertical posi-

tion, after fitting the stand to the foundation.


1. Lift and turn the manipulator to vertical orien-tation.

Detailed in "Lifting the manipulator in a vertical orientation, using a trol-ley/lifting jack".

2. Move the manipulator to the vicinity of its installation location.

3. Pull the cabling through the stand and through the centering ring. Fit the ring to the stand.

Shown in figure above!

4. Guide the manipulator gently while lowering it into its mounting position. Make sure the manipulator mounting flange is correctly fitted onto the centering ring!If necessary, use a locating pin in the flange.


Location of the attach-ment hole for the pin is shown in part "Hole con-figuration, mounting flange".

5. Fit the 8 bolts and washers in the mounting flange attachment holes.

Specified in "Attachment screws". Shown in figure above!

Note! Lightly lubricate the bolts before assembly!

6. Tighten the bolts in a criss-cross pattern to ensure that the flange is not distorted.


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Hole configura-tion, mounting flange

The illustration below shows the hole configuration used when securing the

manipulator. Note that the holes are not equally spaced on the flange.

xx0200000358

A-A

C-C

(Ø400)

Ø350

53

86.5

18 Through ˜8x)

Ø10 H8 Through

87.5

C

C

3

6

A

A


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Fitting equipment on manipulator

General The manipulator features mounting holes for additional equipment.

Illustration, fitting of extra equip-ment on upper platform

The illustration below shows the mounting holes available for fitting extra equip-

ment on the upper platform.

xx0200000360

309.5 4

x M8x12 Deep


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Illustration, fitting on mounting flange

The illustration below shows the mounting holes available for fitting equipment

on the mounting flange.

xx0200000359

Fastener quality When fitting tools on the mounting flange (see the figure above), use only screws

with quality 12.9. When fitting other equipment, standard screws with quality 8.8

can be used.

A guiding pin may be used when fitting equipment on to the tool flange. Attach

the pin to the extra equipment using a press fit, in order to make sure that the pin

remains in the equipment when removing it from the flange.


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Loads

General Any loads mounted on the manipulator must be defined correctly and carefully

(with regard to the position of centre of gravity and inertia factor) in order to avoid

jolting movements and overloading the motors. If this is not done correctly oper-

ational stops may result.

References Load diagrams, permitted extra loads (equipment) and their positions are speci-

fied in the Product Specification. The loads must also be defined in the software

as detailed in the User’s Guide.

Brake perfor-mance

Manipulator motor brake performance depends on any loads attached. For further

information about brake performance, please contact ABB Robotics.


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Section C: Electrical connections

Installation of cabling on board the manipulator

General The manipulator is connected to the control cabinet via a distribution box, after

mounting it on the stand.

The section below describes how to install the cabling on board the manipulator.

All the necessary cabling is included in the delivery of the robot but must be con-

nected both to the manipulator and to the distribution box.

All cabling is specified in the part "Connecting the manipulator to the control

cabinet, manipulator (/controller) cabling"

The figure below shows how the cabling is installed to the manipulator.

xx0200000349

A Cabling in one of the two grooves in the upper platform

A


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Installation of cabling on board the manipulator Step Action Note/Illustration

1. Attach the cables, axes 1-2-3, with straps in the cable grooves on the upper platform, as shown in the figure above. The cabling is marked with a red ring at the correct attachment point. The ring is then located behind the straps.

When installing the cabling in the robot it is very important to adjust its looseness correctly.

2. Connect the cables, axes 1-2-3, to the motors of axes 1-2-3. Fit the cables to the brackets mounted nearby the motors and secure with straps.

Connection points detailed in "Con-necting the manipulator to the con-trol cabinet, manipulator cabling".

3. Fit the cables, axis 4-5-6, inside the cable chain.

4. Connect the cables on top of the housing, at the upper end of the center unit.

Connection points detailed in "Con-necting the manipulator to the con-trol cabinet, manipulator cabling".

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

xx0200000428

4x4x


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Connecting the manipulator to the control cabinet, manipulator cabling

General The manipulator is to be connected to the control cabinet via a distribution box,

after mounted to the stand. This section specifies the cabling to be used and their

connection points.

How to install the manipulator cables on board the manipulator is detailed in the

part "Installation of cabling on board the manipulator".

Main cable cate-gories

Cable category Description

Manipulator cables The cables between the distribution box and the manip-ulator motors are specially manufactured with extra strong screening. The cabling for each motor consists of two separate cables, one power cable and one signal cable. The cabling contains conductors for:

The power cable contains conductors for: • Motor phases

• Earth connection

• Motor brake

• Motor temperature sensors

The signal cable contains conductors for: • Resolvers

Distribution box cables Handles power supply to and control of the manipula-tor's motors as well as feedback from the serial mea-surement board.


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Manipulator cables

The manipulator cables are included in the standard delivery. They are completely

pre-manufactured and ready to plug in.

The cabling transfers drive power and resolver data for drive and control of the six

axes.

Distribution box cables

These cables are included in the standard delivery. They are completely pre-man-

ufactured and ready to plug in.

Cable sub-category Connection point, distribution box

Connection point, manipulator

Manipulator cable, power, axis 1 XM1 XM1.1

Manipulator cable, signal, axis 1 XR1 XR1.1











Cable sub-category

Description Connection point, cabinet

Connection point, distribution box

Distribution box cable, power

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

XS1 R1.MP


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Distribution box cable, power

Distribution box cable, signals

Distribution box cable, signals

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

XS2 R1.SMB

Cable sub-category

Description Connection point, cabinet

Connection point, distribution box

Cable Article number

Distribution box cable, power, 7 m 3HAC 11818-1



Cable Article number

Distribution box cable, signal, shielded, 7 m 3HAC 7998-1




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Connectors on the distribution box

General Section "Connecting the distribution box to the control cabinet" specifies which

cables to use in order to connect the manipulators distribution box to the control-

ler.

Connectors on the distribution box

All distribution box connectors are shown in the figure below.

xx0200000430

The connectors on the controller cabinet are located as detailed in part "Connec-

tors on the controller cabinet, S4CPlus".

XM1

XM2

XM3

XM4

XM5

XM6

XR1XR2XR3

XR4XR5XR6

R1.SMBR1.MP


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Chapter 4:Controller

Introduction

Definitions This chapter contains necessary information for installing the controller to the

working site.


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Section A: Unpacking

Transporting and unpacking, S4Cplus

General Before starting to unpack and install the robot system, read the safety regulations

and other instructions very carefully. These are found in separate sections in the

User’s Guide and Product manual.

The installation must be done by qualified installation personnel and should con-

form to all national and local codes.

When you have unpacked the cabinet, check that it has not been damaged during

transport or while unpacking.

Weight, controller cabinet

The table below shows the weights for the controller cabinet:

Storage conditions, controller cabinet

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

Controller Weight

S4Cplus controller cabinet 240 kg

Distributed Drive Unit (option) 30 kg

Parameter Value

Min. ambient temperature -25°C

Max. ambient temperature +55°C

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

Max. ambient humidity Max. 95% at constant temperature


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Operating condi-tions, controller cabinet

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

Protection class, controller

The table below shows the protection class of the controller:

Parameter Value

Min. ambient temperature +5°C

Max. ambient temperature +45°C

Max. ambient humidity Max. 95% at constant temperature

Equipment Protection class

Control cabinet IP 54

Programming unit IP 54

Distributed Drive Unit (option) IP 54


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Section B: On-site Installation

Lifting the controller cabinet

Lifting device Use the four lifting devices on the cabinet or a fork lift when lifting the controller

cabinet S4Cplus as shown below.

The figure below shows the minimum angle between the lifting straps and the

cabinet when lifting the controller.

xx0100000153

Cabinet delivered without top cover

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

use lifting devices!

A Min. 60°when lifting with straps

B Fork lift

B

A


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Required installation space, control cabinet

Dimensions The figure below shows the required installation space for the S4CPlus control

cabinet:

xx0100000156

A Air distance to wall

B Cabinet extension (Option 124)

* Castor wheels (Option 126)

500

70

620

820

950980*

800

800

200200

A

B


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Bolt pattern, control cabinet

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

xx0100000157

400

720


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Installation of external power transformer

Location of exter-nal power trans-former

The external power transformer (option) is located outside the controller as shown

in the figure below:

xx0100000154

Required equip-ment

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

B Locking screws/lifting lugs

A

B

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

External power trans-former unit

3HAC 11668-1

Input cables Rec. 16 mm 2

Output cables Rec. 6 mm 2


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Connections The procedure below details how to connect the external power transformer unit.

Please observe the following before commencing any repair work on the controller:

Turn off all electric power supply to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!

Fuse and holder Mains voltage 200 VAC: 63 A Mains voltage 600 VAC: 25 A

Circuit breaker Dimensioned for the expected cur-rents

Standard toolkit 3HAC 15571-1 The contents are defined in section "Standard toolkit"!

Other tools and proce-dures may be required. See references to these procedures in the step-by-step instruc-tions below.

These procedures include references to the tools required.

Circuit Diagram, con-troller

3HAC 5582-2

Circuit Diagram, exter-nal power transformer

3HAC 11668-11


Step Action Note/Illustration

1. Connect the shop mains power supply Detailed in "Shop mains power supply" below!

2. Connect the external power transformer input.

Detailed in "Transformer input" below!


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Shop mains power supply

The procedure below details how to connect the Shop mains power supply.

Please observe the following before commencing any repair work on the controller: Turn off all electric power supply to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!

Transformer input The procedure below details how to connect the Transformer input.


3. Connect the external power transformer out-put.

Detailed in "Transformer output" below!

4. Connect the controller input. Detailed in "Controller input" below!



1. Make sure the shop supply is fitted with suit-able circuit breakers and fuses.

Fuse size specified in the table above!


1. Run a cable from the shop supply outlet through the input cable inlet on the trans-former unit.

Shown in the figure above!


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Transformer output

The procedure below details how to connect the Transformer output.


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. Make sure the cables are connected to the terminals marked with the voltage value cor-responding to the voltage supplied.

Terminal: X1

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

Tightening torque: approx. 2 Nm



1. Run a cable from the transformer unit through the output cable outlet to the robot controller.


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

3. Connect the three output phases to the out-put terminals. The terminals are marked with "475" for the output voltage.

Terminals: X1.1, X1:2 and X1:3

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



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Controller input The procedure below details how to connect the Controller input.


Turn off all electric power supply to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!


1. Remove the left cover plate under the robot controller top lid.

2. Route the transformer output cable through the gland located on the left cabinet wall.

3. Connect the cable inside the robot controller (not depen-dent on phase sequence):

• Phase 1 to L1

• Phase 2 to L2

• Phase 3 to L3

• 0 to XT26.N

• Earth to the cabinet earth connection (C in the figure). The earth connection is marked with a "PE" sticker.

xx0100000155

• A: Terminal X26

• B: Connectors

• C: Earth connection (PE)

• D: Cable glands

4. Make sure all terminals are tightened to ensure good elec-tric contact.


A

C

B

D


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Installation of Distributed Drive Unit (DDU)

Required installa-tion space, DDU

The external DDU (option) is located outside the control cabinet. The figure

below shows the required installation space for the DDU.

xx0200000340

A 50 mm, required free area for the exhaust air

A300

A A


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Bolt pattern, DDU The DDU is to be suspended nearby the control cabinet, using the bolt pattern

shown in the figure below.

xx0200000374

Connection to earth

If the difference of potential between the control system and the DDU is too large

or there are suspicions of shorter drops in voltage, the DDU must be connected to

earth. This is done at the connection point GND (see the part "Connectors on the

DDU").

Fan cooling The main power from the control cabinet also feeds two fans in the DDU via an

internal transformer with three input taps.

The transformer wires are connected as

• 0 - 400V for nominal mains input 400V



260


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Overheating Overheating of the DDU may be caused by the following:

• A line voltage lower than 480V is used, while the fans are connected as 480V. This causes a reduced fan cooling. See “Changing the connection of the transformer” below.

• The fuse, located at the screw terminal, has caused the fans to stop.

• Insufficient airflow. See “Increasing the airflow” below.

• Too heavy drive at too high ambient temperature. See the manual “Exter-nal axes”.

Changing the connection of the transformer

The default connection of the transformer is the nominal mains input 480V. The

cooling is, however, reduced, when a lower line voltage is used and there may be

a risk that the drive unit is triggered at a high surrounding temperature. Therefore,

if the line voltage differs from 480V, it is recommended to switch over the default

connection to 440V or 400V instead.

To change the voltage, remove the lid of the DDU and switch the connections on

the screw terminals (see the part "Connections to screw terminals").


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Increasing the airflow

If there appears to be an overheating of the DDU, without suspicion of reduced

fan cooling, the airflow may be increased by replacing the two covering plates

with vents, see figure below. This gives four openings instead of the normal two.

xx0200000373

Cabling Section "Connecting the manipulator to the control cabinet" specifies which

cables to use and to which connectors these are to be connected, in order to con-

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

A Vent

B Covering plate

A

A

B


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Section C: Electrical connections

C - 1: Signal/Power cables

Connecting the manipulator to the control cabinet, S4Cplus cabling

General Connect the manipulator and control cabinet to each other after securing them to

the foundation. The lists below specify which customer cables to be used.

Manipulator cabling is specified in chapter “Manipulator”, section “Electrical

connections”.

Customer cables These cables are not included in the standard delivery, but are included in the

delivery of each specific option. The cables are not ready to plug in, but require

connection to terminals inside the control cabinet as well as keying. These activ-

ities are detailed in Customer Connection Kit.

Cable Art. no.Connection point, cabinet


Fieldbus cable, CAN, 7 m 3HAC 13173-1 XT/XP5.1 XT/XP6 XS6

R1.CP/CS

Fieldbus cable, CAN, 15 m 3HAC 13173-2 XT/XP5.1XT/XP6 XS6

R1.CP/CS

Fieldbus cable, CAN, 30 m 3HAC 13173-4 XT/XP5.1

XT/XP6 XS6

R1.CP/CS

Fieldbus cable, Profibus, 7 m 3HAC 13174-1 XT/XP5.1 XT/XP6

DP/M

R1.CP/CS

Fieldbus cable, Profibus, 15 m 3HAC 13174-2 XT/XP5.1 XT/XP6 DP/M

R1.CP/CS


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Fieldbus cable, Profibus, 30 m 3HAC 13174-4 XT/XP5.1 XT/XP6

DP/M

R1.CP/CS

Harness CP/CS, CAN, 7 m 3HAC 14890-4 XT/XP5.1 - XT/XP5.2 - XT/XP6.1 XS13

R1.CP/CS

Harness CP/CS, CAN, 15 m 3HAC 14890-1 XT/XP5.1 - XT/XP5.2 - XT/XP6.1 XS13

R1.CP/CS

Harness CP/CS, CAN, 30 m 3HAC 14890-6 XT/XP5.1 - XT/XP5.2 - XT/XP6.1

XS13

R1.CP/CS

Harness CP/CS, Interbus, 7 m 3HAC 15644-4 XT/XP5.1 - XT/XP5.2 - XT/XP6.1 XS13

R1.CP/CS

Harness CP/CS, Interbus, 15 m

3HAC 15644-1 XT/XP5.1 - XT/XP5.2 - XT/XP6.1 XS13

R1.CP/CS

Harness CP/CS, Interbus, 30 m

3HAC 15644-5 XT/XP5.1 - XT/XP5.2 - XT/XP6.1

XS13

R1.CP/CS

Cable Art. no.Connection point, cabinet



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Connectors on control cabinet, S4Cplus

General Section "Connecting the manipulator to the control cabinet" specifies which


nect the controller to the manipulator.

Connections to the cabinet

All control cabinet connectors are shown in the figure below.

xx0100000247

* For 6400S/640 and Can Bus

** Option for 66X0 and 7600


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Connectors on distributed drive unit, DDU

General The section "Connecting the manipulator to the control cabinet" specifies which


nect the DDU (distributed drive unit) to either the controller, the manipulator or

to the external axis.

Connections to the DDU

All DDU connectors are shown in the figure below.

xx0200000372

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

S77 XS78 XP40

GND

XP49


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Connection of mains power to control cabinet, S4Cplus

General Connect the power supply either inside the cabinet, or to a optional socket on the

left-hand side of the cabinet or the lower section of the front. The cable connector

is supplied but not the cable.

Dimension the mains supply cables and fuses in accordance with the rated power

and line voltage, see rating plate on the controller.

Connections to the mains switch

Also see the Circuit Diagram.

The instruction below details how to make all the required connections to the

mains switch:

xx0100000248

A XT 26

B Protective Earth connection

C Cable gland

D Connector


1. Remove the left cover plate under the top lid.

A

B

C

D


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Connection through a power socket

It is possible to connect the mains supply via an industrial Harting connector (DIN

41 640). See the figure below:

Cable connectors are supplied (option 132 - 134).

xx0100000162

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


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.


NOTE! Max. conductor size is 6 mm2 (AWG 10). Tighten to a torque of 2.3-2.5 Nm. Retighten after approx. 1 week.

5. Snap the breaker on to the knob again and check that it is fixed properly in the correct position.

6. Tighten the cable gland.

7. Fasten the cover plate.


A DIN connector

A


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C - 2: Signal connections

Signal Classes

Overview Different rules apply to the different classes when selecting and laying cable. Sig-

nals from different classes must not be mixed.

Signals • Power Signals: Supplies external motors and brakes.

• Control signals: Digital operating and data signals (digital I/O, safety stops, etc.).

• Measuring signals: Analog measuring and control signals (resolver and analog I/O).

• Data communication signals: Gateway (Field bus) connection, computer link.


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Selecting Cables

Controller cables: All cables laid in the controller must be capable of withstanding +70°C.

Power Signal: Shielded cable with an area of at least 0.75mm 2 or AWG 18.

Note that any local standards and regulations concerning insulation and area must always be complied with.

Control signals: Shielded cables.

Measuring signals:

Shielded cable with twisted pair conductors.

Data communica-tion signals:

Shielded cable with twisted pair conductors.

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

CAN bus with DeviceNet for dis-tributing I/O units:

A thin cable according to DeviceNet specification release 1.2, must be used, e.g.

ABB article no. 3HAB 8277-1. The cable is shielded and has four conductors, two

for electronic supply and two for signal transmission.

Note that a separate cable for suppling I/O loads is required.


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Allen-Bradley Remote I/O:

Cables according to Allen-Bradley specification, e.g. "Blue hose", should be used

for connections between DSQC 350 and the Allen-Bradley PLC bus.

Interbus-S: Cables according to Phoenix specification, e.g. "Green type", should be used for

connections between the DSQC 351 and external Interbus-S bus.

Profibus DP: Cables according to Profibus DP specification should be used for connections

between the I/O unit DSQC 352 and the external Profibus DP bus.

Ethernet: Shielded twisted pair conductors (10 Base T STP).


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Interference elimination

External units External relay coils, solenoids, and other units that will be connected to the con-

troller must be neutralized. The figure below illustrates how this can be done.

The turn-off time for DC relays increases after neutralization, especially if a diode is connected across the coil. Varistors give shorter turn-off times. Neutralizing the coils lengthens the life of the switches that control them.

Clamping with a diode

The diode should be dimensioned for the same current as the relay coil, and a

voltage of twice the supply voltage.

xx0100000163

Clamping with a varistor

The varistor should be dimensioned for the same current as the relay coil, and a

voltage of twice the supply voltage.

xx0100000164

+24V 0V

+24V 0V


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Clamping with an RC circuit

R 100 ohm, 1W C 0.1 - 1 mF.

>500V max. voltage, 125V nominal voltage.

xx0100000165

+24V DC,or AC voltage 0VR C


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Connection types

General I/O, external emergency stops, safety stops, etc. can be supplied on screw connec-

tions or as industrial connectors.

Connections

Designation Connection type

X(T) Screw terminal

XP Pin (male)

XS Sockets (female)


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Connections to screw terminals

Overview This section describes how to connect conductors to screw terminals. Detailed

information about connection location and functions will be found in the circuit

diagram (Service Manual).

Installation The installation should comply with the IP54 (NEMA 12) protective standard.

1. Bend unused conductors backwards and attach them to the cable using a clasp, or similar.

To prevent interference, ensure that unused conductors are not connected at the other end of the cable (antenna effect). In environments with much interference, disconnected conductors should be grounded (0V) at both ends.


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Connections to connectors

Location of con-nectors

If ordered, industrial connectors can be found on the left-hand side or front of the

control cabinet (depending on the customer order). Also see the figure in section

"Connectors on control cabinet"!

The manipulator arm (not IRB 940 Tricept) is equipped with round Burndy/Fram-

atome connectors (customer connector not included).

Connectors, description

Each industrial connector has accommodation for four rows of 16 conductors with

a maximum conductor area of 1.5 mm 2. The pull-relief clamp must be used when

connecting the shield to the case.

Making the con-nection

The section below details how to crimp cable connections to pins:

1. Using a special crimp tool, crimp a pin or socket on to each non-insu-lated conductor.

When two conductors are be connected to the same pin or socket, both of them must be crimped into the same pin or socket. A maximum of two conductors may be crimped into the same pin or socket.

2. Snap the pin into the connector housing.

3. Push the pin into the connector until it locks.

4. A special extractor tool must be used when removing pins or sockets from industrial connectors.

C - 3: Customer connections on controller

The MOTORS ON/MOTORS OFF circuit

Outline diagram The MOTORS ON/MOTORS OFF circuit is made up of two identical chains of

switches.

The diagram shows the available customer connections, AS, GS and ES.


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xx0100000174

A ES (emergency stop)

B LS (Limit switch)

C Solid state switches

D Contactor

E Mains

F Drive unit

G Second chain interlock

H GS (general mode safeguarded space stop)

J AS (Automatic mode safeguarded space stop)

K ED (TPU enabling device)

L Manual mode

M Motor

N Automatic mode

P Operating mode selector

R RUN

S EN1

G

CD

E

A

F

T

LN

P

M

H

J

K

B

R S


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Function of the MOTORS ON/MOTORS OFF cir-cuit

The circuit monitors all safety related equipment and switches. If any of the

switches is opened, the MOTORS ON/MOTORS OFF circuit switches the power

to the motors off.

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

OFF mode.

Connection of safety chains

The diagram below shows the two-channel safety chain.

The supply from internal 24V (X3/X4:12) and 0 V (X3/X4:7) is displayed. For an

external supply of GS and AS, X3/X4:10,11 is connected to 24V and X3/X4:8,9

is connected to external 0V. Connection tables for X1-X4 are given in "External

customer connections on panel X1 - X4".

T EN2


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xx0100000166

Technical data per chain

Limit switch Load: 300 mV

Max. voltage drop: 1 V

External connectors Load: 10 mA Max. voltage drop: 4 V

GS/AS load at 24 V 25 mA

GS/AS closed "1" >18 V

GS/AS open "0" < 5 V

External supply of GS/AS Max. + 35 VDC Min. - 35 VDC

24VX3:12X4:12

24VExt LIM1

X1:11 12

X3:10

8

11

9

Optoisol.

Optoisol.

Optoisol.

Optoisol.

GS1

AS1

ES1

TPU En1

Internlocking

EN

Run

Auto1 Man1

Man2

&

&

External contactors

0 V24 V

X3:3X4:3

44

CONT1CONT2

Ext LIM20 V X2:11 12

K1

K2

K10 V

K224 V

Drive Unit

M

X4:10

8

11

9AS2

GS2

TPU En2

Auto2

ES2


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Max. potential in relation to the cabinet earthing and other signal groups

300 V

Signal class Control signals

Technical data per chain


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Connection of ES1/ES2 on panel unit

The diagram below shows the terminals for the emergency circuits.

The supply from internal 24V (X1/X2:10) and 0V (X1/X2:10) is displayed. For

an ext. supply, X1/X2:3 is connected to ext. 24V and X1/X2:8 is connected to ext.

0V (dotted lines).

xx0100000191

24V

24V

0V

0V

1:4

X1:10

X1:3

X1:9

X1:7

X1:8

X1:1

X1:2 24V

A

B C D

D

X1:6

E24V

X2:7

X2:8

X2:1

X2:224V

X2:6

FB

24VX2:4X2:5

C

2:4

G

H

J


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A Internal

B Ext shop

C TPU

D Cabinet

E ES1 internal

F Run chain 1 top

G Internal

H ES2 internal

J Run chain 2 top

Technical data

ES1 and ES2 max output voltage 120 VAC or 48 VDC

ES1 and ES2 max output current 120 VAC: 4 A

48 VDC L/R: 50 mA 24 VDC L/R: 2 A 24 VDC R load: 8 A

External supply of ES relay Min. 22 V between terminals X1:9, 8 and X2:9, 8 respectively

Rated current per chain 40 mA


300 V



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Connection to MOTORS ON/MOTORS OFF contactor

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

xx0100000193

A K1 (Motor on/off 1)

B K1 (Motor on/off 2)

Technical data

Max. voltage 48 VDC

Max. current 4 A


300 V


A

B

X3:2

X4:21

1


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Connection to operating mode selector


xx0100000197

A Auto 1

B MAN1

C 100% (Option)

D Auto 2

E MAN2

F 100% (Option)

Technical data

Max. voltage 48 VDC

Max. current 4 A


300 V


A

B C

D

E F1

2

3

4

5

6

7

8S1.1.x1

S1.1.x1


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Connection to brake contactor


xx0100000199

A K3 (Brake)

Technical data

Max. voltage 48 VDC

Max. current 4 A


300 V


X4:56

A


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External customer connections on panel X1 - X4

Outline diagram The diagram shows the customer connections X1 - X4 located on the panel unit.

xx0100000205

Connection of X1: 12-pole type Phoenix COM-BICON connector

The table below shows the signal descriptions for X1.

The signal names refer to the Circuit Diagram.

grey field Jumper

WARNINGREMOVE JUMPERS BEFORE CONNECTINGANY EXTERNAL EQUIPMENT

Signal Terminal no. Comment

ES1 out: A 1 Emergency stop out chain 1

ES1 out: B 2 Emergency stop out chain 1

ES1 top 3 Top of emergency stop chain 1

24 V panel 4 + 24 V emergency stop chain 1 and run chain 1

Run ch1 top 5 Top of run chain 1

ES1 internal 6 Internal signal from emergency stop relay chain 1

Sep. ES1: A 7 Separated emergency stop chain 1

Sep. ES1: B 8 Separated emergency stop chain 1


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ES1 bottom 9 Bottom of emergency stop chain 1

0 V 10 0 V emergency stop chain 1

Ext. LIM1: A 11 External limit switch chain 1

Ext. LIM1: B 12 External limit switch chain 1



ES2 out: A 1 Emergency stop out chain 2

ES2 out: B 2 Emergency stop out chain 2

ES2 top 3 Top of emergency stop chain 2

0 V 4 0 V emergency stop chain 2

Run ch2 top 5 Top of run chain 2

ES2 internal 6 Internal signal from emergency stop relay chain 2

Sep. ES2: A 7 Separated emergency stop chain 2

Sep. ES2: B 8 Separated emergency stop chain 2

ES2 bottom 9 Bottom of emergency stop chain 2

24 V panel 10 + 24 V emergency stop chain 1 and run chain 2

Ext. LIM2: A 11 External limit switch chain 2

Ext. LIM2: B 12 External limit switch chain 2


Ext. MON 1: A 1 Motor contactor 1

Ext. MON 1: B 2 Motor contactor 1


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0 V 3 External contactor 1 0 V

CONT1 4 External contactor 1

5 No connection

6 No connection

0 V 7 0 V to auto stop (AS) and general stop (GS)

GS1- 8 General stop minus chain 1

AS1- 9 Auto stop minus chain 1

GS1+ 10 General stop plus chain 1

AS1+ 11 Auto stop plus chain 1

24 V panel 12 24 V to auto stop and general stop



Ext. MON 2: A 1 Motor contactor 2

Ext. MON 2: B 2 Motor contactor 2

24 V panel 3 External contactor 2 24 V

CONT2 4 External contactor 2

Ext. BRAKE A 5 Contactor for external brake

Ext. BRAKE B 6 Contactor for external brake

0 V 7 0 V to auto stop (AS) and general stop (GS)

GS2- 8 General stop minus chain 2

AS2- 9 Auto stop minus chain 2

GS2+ 10 General stop plus chain 2

AS2+ 11 Auto stop plus chain 2

24 V panel 12 24 V to auto stop and general stop


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Connection of external safety relay

Description The motor contactors K1 and K2 in the controller can operate with external equip-

ment if external relays are used.

The figure below shows two examples of how to connect the external safety

relays:


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Connection examples

xx0100000246

A Panel unit

K2

K1

X3:4X3:3

X3:1

X3:2

X4:1

X4:2

X4:3X4:4

0 VCONT 1

Ext MON 1

Ext MON 224 V

CONT 2

24 V

0 V

A B

AS GSAS GS

E

E

F F

G

H

K

J

C D


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C - 4: Supplies

External 24V supply

When is an exter-nal supply recom-mended?

An external supply is recommended to make use of the advantages offered by the

galvanic insulation on the I/O units or on the panel unit.

An external supply must be used in the following cases:

• When the internal supply is insufficient

• When the emergency stop circuits must be independent of whether or not the robot has power on, for example.

• When there is a risk that major interference can be carried over into the internal 24V supply.

How to connect the external sup-ply

The external supply neutral wire must be connected to the chassis such that the

maximum permitted potential difference in the chassis earth is not exceeded. For

example, a neutral wire can be connected to the chassis earth of the controller, or

some other common earthing point.

Technical data

B Relays with positive action

C Robot 1

D Robot 2

E External supply

F ES (emergency stop) out

G Safety relay

H To other equipment

J Safety gate

K Cell ES (emergency stop)

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


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Permitted supply voltage I/O units 19 VDC - 35 VDC incl. ripple

Panel unit 20.6 VDC - 30 VDC incl. ripple


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24V I/O supply

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

24 VDC supply for internal and external use

24 VDC supply available at XT 31

24V I/O available for customer connections at XT 31 is shown in the figure in

"Connections to screw terminals".

Voltage 24.0 - 26.4V

Ripple Max. 0.2V

Permitted customer load Max. 7A

Current limit 13,5 ~0A.

XT.31.2 24 V (through a 2 A fuse)

XT.31.1 for own fuses

XT.31.4 0 V (connected to cabinet structure)


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115/230 VAC supply

General This voltage is used in the robot for supplying optional service outlets. The AC

supply is not galvanically separated from the rest of the controller voltages.

115/230 VAC sup-ply for internal and external use

115/230 VAC sup-ply available at XT 21

115 VAC/230 VAC available for customer connections at XT 21 is shown in the

figure in "Connection to screw terminals".

C - 5: Buses

Connection of the CAN bus

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

Voltage 115 VAC or 230 VAC

Permitted customer load Max. 500 VA

Fuse size, 115 V 6.3 A

Fuse size, 230 V 3.15 A

XT.21.1-5 230 VAC

XT.21.6-8 115 VAC

XT.21.9-13 N (connected to cabinet structure)


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xx0100000241

A Base connector unit

B CAN bus

X15 CAN1.1 (Internal I/O)

X7 CAN1.3

X6 CAN1.2

A

B

C

D

D

G

D

D D

D D

E

F

D D

1. 0V_CAN2. CAN_L3. drain4. CAN_H5. 24V_I/O

X15, X6, X7 1.2.3.4.5.


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CAN 1.1 Used for internal I/O unit mounted inside the cabinet. No terminating resistor is

fitted on CAN 1.1 regardless of whether any I/O units are used or not. CAN 1.1 is

connected to socket X15 on the Base connector unit (see Connection of the CAN

bus).

CAN 1.2 If CAN 1.2 is not used, a terminating resistor must be connected to the X6 socket

(exceptional case see below!).

If CAN 1.2 is used, the terminating resistor should be moved to the last I/O unit

on the CAN 1.2 chain.

If CAN 1.2, for example, is not connected at the end of any CAN chain but some-where between the end points of the chain, then no terminating resistor should be mounted in CAN 1.3. This is in accordance with the basic rule, i.e. the CAN chain should be terminated in both end points.

CAN 1.3 If CAN 1.3 is unused, a terminating resistor must be connected to the X7 socket.

If CAN 1.3 is used, the terminating resistor should be moved to the last I/O unit

on the CAN 1.3 chain.

If CAN 1.2, for example, is not connected at the end of any CAN chain but some-where between the end points of the chain, then no terminating resistor should be mounted in CAN 1.3. This is in accordance with the basic rule, i.e. the CAN chain should be terminated in both end points.

C Control cabinet

D I/O

E Termination of last unit

F 120 ohm, 1%, 0.25 W metal film resistor

G See figure in section "CAN 2" below!


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Termination resistors in CAN bus

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

If CAN 1.2, for example, is not connected at the end of any CAN chain but some-

where between the end points of the chain, then no terminating resistor should be

mounted in CAN 1.3.

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

xx0100000242

A Controller

B Base connector unit

C See figure in section "Illustration" above!

D I/O

E Termination of last unit

F 120 ohm, 1%, 0.25 W metal film resistor

D D

B

1. 0V_CAN2. CAN_L3. drain4. CAN_H5. 24V_I/O

X8 1. 0V_CAN2. CAN_L3. drain4. CAN_H5. 24V_I/O

1.2.3.4.5.

A

X8 CAN 2

C

E

F

D


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The illustration below shows CAN connections on base connector unit:

xx0100000243

A X6 CAN 1.2 (external I/O)

B X7 CAN 1.3 (external I/O)

C X8 CAN 2 (external I/O)

D X15 CAN 1.1 (internal I/O)

A

B

C

D


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Interbus-S, slave DSQC 351

General The unit can be operated as a slave for an Interbus-S system.

Supply The Interbus-S slave must be fed externally to avoid shutting down the Interbus-

S net if a robot cell is switched off. The 24V power supply must be fed from

outside the control cabinet and be connected to pin 2 on the Phoenix connector

located on the Interbus-S card’s front panel marked 24V.

Technical data Also see the Interbus-S specification.

Further informa-tion

For setup parameters, see User’s Guide - System Parameters, Topic: Controller.


Unit ID The unit ID to be entered in the Interbus-S master is 3. The length code depends

on the selected data. Width between 1 and 4.

Layout, DSQC 351

The figure below shows the layout of the DSQC 351 board:


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xx0100000225

Communication concept

The Interbus-S system is able to communicate with a number of external devices,

depending on the number of process words occupied by each unit. The robot may

be equipped with one or two DSQC 351. The Interbus-S inputs and outputs are

accessible in the robot as general inputs and outputs.

For application data, refer to Interbus-S, International Standard, DIN 19258.

An outline diagram of the communication concept is shown below:

X3 Power connector

X5 DeviceNet connector

X20 Interbus-S, input

X21 Interbus-S, output

X20

X5 X3

X21


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xx0100000224

Termination link A link is connected between pins 5 and 9 in the plug on the interconnection cable

connected to the OUT connector of each unit. The link informs the Interbus-S unit

that more units are connected further out in the chain. (The last unit in the chain

does not have a cable connected and therefore no link).

Connections, X5 DeviceNet con-nectors

See DeviceNet Connectors.

A Master PLC

B Robot 1, word 1:3

C Robot 1, word 4:7

D Robot 2, word 8:11

E 128 inputs/128 outputs

F 64 inputs/64 outputs

*1 xx

A B DC

E F

In Out In Out In Out

*1 *1


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Connections, connector X20, Interbus-S IN

The figure below shows the pin configuration of the connector:

xx0100000220

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

Connections, connector X21, Interbus-S OUT


xx0100000220

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

Signal name X20 pin Function

TPDO1 1 Communication line TPDO1

TPDI1 2 Communication line TPDI1

GND 3 Ground connection

NC 4 Not connected

NC 5 Not connected

TPDO1-N 6 Communication line TPDO1-N

TPDI1-N 7 Communication line TPDI1-N

NC 8 Not connected

NC 9 Not connected

5

1 9

6

5

1 9

6


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Connections, connector X3


xx0100000221

The table below shows the connections to connector X3:

Bus status LEDs The designations refer to LEDs shown in the figure in section "Layout, DSQC

352" above.


TPDO2 1 Communication line TPDO2

TPDI2 2 Communication line TPDI2


NC 4 Not connected

+ 5 V 5 + 5 VDC

TPDO2-N 6 Communication line TPDO2-N

TPDI2-N 7 Communication line TPDI2-N

NC 8 Not connected

RBST 9 Synchronization


0 VDC 1 External supply of Interbus-S

NC 2 Not connected


NC 4 Not connected

+ 24 VDC 5 + 24 VDC

15


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The figure and table below show the location and significance of the LEDs on the

board.

Designation Color Description

POWER-24 VDC Green Indicates that a supply voltage is present, and has a level above 12 VDC.

NS/MS Green/red See section "CAN bus status LED descrip-tion".

CAN Tx/CAN Rx Green/red See section "CAN bus status LED descrip-tion".

POWER- 5 VDC Green Lit when both 5 VDC supplies are within lim-its, and no reset is active.

RBDA Red Lit when this Interbus-S station is last in the Interbus-S network.

If it is not (which is required), check parame-ter setup.

BA Green Lit when Interbus-S is active.

If there is no light, check network, nodes and connections.

RC Green Lit when Interbus-S communication runs without errors.


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Profibus-DP, slave DSQC 352

General The unit can be operated as a slave for a Profibus-DP system.

Supply The Profibus does not need any external power supply. All the robot cells are

connected to the trunk cable through a special D-sub connector which works as a

very short drop cable. Because of this the profibus will work correctly even if a

robot cell is turned off.

Technical data Also see the Profibus-DP specification, International Standard DIN E 19245, part

3.


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

Also see the Circuit diagram.

Layout, DSQC 352



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xx0100000223

Communication concept

The Profibus-DP system is able to communicate with a number of external

devices, depending on the number of process words occupied by each unit. The

robot may be equipped with one or two DSQC 352. The Profibus-DP inputs and

outputs are accessible in the robot as general inputs and outputs.

An outline diagram of the communication concept is shown below:

xx0100000222

X3 Power connector

X5 DeviceNet connector

X20 Profibus connection

X20

X5 X3

A B

E F

C D


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Termination The Profibus cable must be terminated in both ends.

Connections, X5 DeviceNet con-nectors

See "Device Net Connectors".

Connections, connector X20, Profibus-DP


xx0100000220

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

A Master PLC

B Robot 1, word 1:8

C Robot 1, word 9:16

D Robot 2, word 17:24

E 256 inputs/256 outputs

F 128 inputs/128 outputs


Shield 1 Cable screen

NC 2 Not connected

RxD/TxD-P 3 Receive/Transmit data P

Control-P 4

GND 5 Ground

+5 VDC 6

5

1 9

6


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xx0100000221


Bus status LEDs The figure and table below show the location and significance of the LEDs on the

board.

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

352" above.

NC 7 Not connected

RxD/TxD-N 8 Receive/Transmit data N

NC 9 Not connected



0 VDC 1 External supply of Profibus-DP

NC 2 Not connected


NC 4 Not connected

+ 24 VDC 5 External supply of Profibus-DP

15


Profibus active Green Lit when the node is communicating with the master.

If there is no light, check system messages in robot and in Profibus net.


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C - 6: I/O units

Distributed I/O units

General Up to 20 units can be connected to the same controller but only four of these can

be installed inside the controller. Normally a distributed I/O unit is placed outside

the controller.

Connection The maximum total length of the distributed I/O cable is 100 m (from one end of

the chain to the other end).

The controller can be one of the end points or be placed somewhere in the middle

of the chain.

Parameter setup For setup parameters, see User’s Guide, section System Parameters, Topic: I/O

Signals.

NS/MS Green/red See section "CAN bus status LED descrip-tion".

CAN Tx/CAN Rx Green/red See section "CAN bus status LED descrip-tion".

POWER, 24 VDC Green Indicates that a supply voltage is present, and has a level above 12 VDC. If there is no light, check that voltage is present in the power unit and in the power connector. If not, check cables and connec-tors.

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



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Distributed I/O, digital sensors

General Digital sensors are connected to one optional digital unit.

Technical data See Product Specification for Controller S4Cplus.

Allowed types of digital sensors

The table below shows the allowed types of digital sensors to be used, and their

signal levels respectively:

Sensor type Signal level

Digital one bit sensor High, "1"

Low, "0"

Digital two bit sensor High, "01" No signal, "00" Low, "10"

Error status, "11" (stop program running)


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

General The digital I/O unit handles digital communication between the robot system and

any external systems.

Technical data

Also see Product Specification for controller S4Cplus.


For setup parameters, see Users Guide - System Parameters, Topic: Controller.


Layout, DSQC 328

The figure below show the layout of the DSQC328 board:

xx0100000240

No. of inputs 16 (divided into two groups of 8, galvanically isolated from each other)

No. of outputs 16 (divided into two groups of 8, galvanically isolated from each other)

Supply voltage 24 VDC

Supply source 24 V I/O or separate external supply

A Status LEDs

OUT

INNS

MS16151413121110987654321

OUT

IN

X1

X3

X2

X4

101101

101 101

X5

112

A


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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.







Unit function Signal name X1 pin

Optically isolated output Out ch 1 1








Optically isolated output 0 V for outputs 1-8 9











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The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected

to ground, to prevent disturbances, causes a short rush of current when setting the

input.

When connecting outputs, sensitive to pre-oscillation current, a series resistor

(100 W) may be used.








Optically isolated input In ch 1 1








Optically isolated input 0 V for inputs 1-8 9

Optically isolated input Not used 10





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input.













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AD Combi I/O, DSQC 327 (optional)

General The digital I/O unit handles digital and analog communication between the robot

system and any external systems.

Technical data





Layout, DSQC 327

The figure below shows the layout of the DSQC327 board:

No. of digital inputs 16 (divided into two groups of 8, galvanically isolated from each other)

No. of digital outputs 16 (divided into two groups of 8, galvanically isolated from each other)

No. of analog outputs 2 (galvanically isolated from the controller electron-ics)


Supply source, digital I/O 24 V I/O or separate external supply

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


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xx0100000239

Connector X5 is a CAN connector further described in section "Connection and

address keying of the CAN bus".






A Status LEDs

OUT

INNS

MS16151413121110987654321

OUT

IN

X1

X3

X2

X4

X6

1 10 101

1 6101 101

X5

112

A













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Connections, connectors X6

The table below shows the connections to connectors X6:



input.














Signal name: X6 pin: Explanation:

AN_ICH1 1 For test purposes only

AN_ICH2 2 For test purposes only

0 V 3 0 V for In channels 1-2

0 VA 4 0 V for Out channels 1-2

AN_OCH1 5 Out channels 1

AN_OCH2 6 Out channels 2


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Analog I/O, DSQC 355 (optional)

General The analog I/O unit handles communication between the robot system and any

external systems through analog sensors.

Technical data





Layout, DSQC 355


No. of analog inputs 4 (-10 V/+10 V)

No. of analog outputs 3 (-10 V/+10 V) 1 (4-20 mA))

No. of analog outputs 2 (galvanically isolated from the controller electronics)



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xx0100000238

Connections, connectors X7 analog output


xx0100000236

X3 Not used

X5 DeviceNet input and ID connector

X7 Analog outputs

X8 Analog inputs

DS QC 355 AB B F lexible Automation

Bus s tatus

Analog I/O

X8

X8

S 3S 2

X3

X3

X5

X5

X2

X7

X7

1

12

13

24


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input.

Connect a resistor (100 W) in series when connecting outputs, sensitive to pre-

oscillation current.


ANOUT_ 1 Analog output 1, -10 V/+10 V



ANOUT_ 4 Analog output 4, 4-20 mA

Not used 5

Not used 6

Not used 7

Not used 8

Not used 9

Not used 10

Not used 11

Not used 12

Not used 13

Not used 14

Not used 15

Not used 16

Not used 17

Not used 18

GND 19 Analog output 1, 0 V




GND 23

GND 24


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Connections, connectors X8 analog input


xx0100000237



ANIN_1 1 Analog input 1, -10 V/+10 V




Not used 5

Not used 6

Not used 7

Not used 8

Not used 9

Not used 10

Not used 11

Not used 12

Not used 13

Not used 14

Not used 15

Not used 16

+24 V out 17 +24 VDC supply

1 17

3216


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input.

Connect a resistor (100 W) in series when connecting outputs, sensitive to pre-

oscillation current.


board.








GND 25 Analog input 1, 0 V




GND 29

GND 30

GND 31

GND 32



NS/MS Green/red

See section 4.1.

RS232 Rx Green Indicates the state of the RS232 Rx line. LED is active when receiving data. If there is no light, check communication line and connections.


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RS232 Tx Green Indicates the state of the RS232 Tx line. LED is active when transceiving data. If there is no light when transmission is expected, check error messages and check also system boards in rack.

+5VDC / +12VDC /

-12VDC Green Indicates that supply voltage is present and at correct level. If there is no light, check that voltage is present on power unit and that power is present in power connector. If not, check cables and connectors. If power is applied to the unit but it does not work, replace the unit.



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Encoder interface unit, DSQC 354 (optional)

General The encoder interface unit handles communication with an external conveyor:

• One encoder input (synchronization of conveyor position with robot move-ments). The encoder is supplied with 24 V and 0 V, and sends position information on two channels. This information is computed by the on-board computer using quadrature decoding (QDEC) to determine position and direction.

• One digital input (external start signal/conveyor synchronization point)

Technical data



User reference Description Conveyor Tracking. For setup parameters, see User’s

Guide - System Parameters, Topic: Controller. Also see the Circuit Diagram.

No. of encoder inputs 1

No. of digital inputs 1 (24 VDC)


Supply source 24 V I/O or external supply


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Layout, DSQC 354


xx0100000233

X3 Not used

X5 DeviceNet input and ID connector

X20 Conveyor connection

X20

X5 X3


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Encoder connec-tions

The figure below shows the encoder connections:

xx0100000234

AA 24 V I/O or external supply

AB 0 V I/O or external supply

AC Encoder

AD Sync switch

AE 10-16 not used

AF Encoder unit

AG Galvanic isolation

12345678910111213141516

OptoOpto

Opto

OptoOpto

Opto

B

A

24 VDC

24 VDC

0V

0V

AA

AB

AC

AD

AE

AF

AG


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Connections, connectors X20 encoder and digi-tal input connec-tions


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

xx0100000235


24 VDC 1 24 VDC supply

0 V 2 0 V

ENC 3 Encoder 24 VDC

ENC 4 Encoder 0 VDC

ENC_A 5 Encoder phase A

ENC_B 6 Encoder phase B

DIGIN 7 Synchronization switch 24 VDC

DIGIN 8 0 V

DIGIN 9 Synchronization switch digital input

Not used 10

Not used 11

Not used 12

Not used 13

Not used 14

Not used 15

Not used 16

116


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board.


POWER, 24 VDC Green Indicates that a supply voltage is present, and has a level above 12 VDC.

If there is no light, check that voltage is present on power unit and in connector X20. If not, check cables and connectors. If power is applied to the unit but it does not work, replace the unit.

NS/MS Green/red See section "CAN bus status LED description".

CAN Tx/CAN Rx Green/red See section "CAN bus status LED description".

ENC 1A/1B Green Indicates phase 1 and 2 from encoder. Flashes at each Encoder pulse. At frequencies higher than a few Hz, flashing can no longer be observed (light will appear weaker).

If there is no light, there is an error due to one or more of the following reasons:

• Faulty power supply for input circuit (internal or external).

• Defective input circuit on board.

• Short circuit or broken wire in external wiring or connectors.

• Internal error in unit.

Constant light indicates constant high level on input and vice versa. No light on one LED indicates fault in one encoder phase.


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DIGIN1 Green Digital input. Lit when digital input is active. The input is used for external start signal/conveyor synchronization point.

If there is no light, there is an error due to one or more of the following reasons:

• Faulty power supply for input circuit (internal or external).

• Faulty limit switch, photocell etc.

• Short circuit or broken wire in external wiring or connectors.

• Defective input circuit on board.



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Relay I/O, DSQC 332 (optional)

General The unit handles communication between the robot system and any external sys-

tems through relay outputs and digital inputs.

Technical data





Layout, DSQC 332


xx0100000232

No. of digital inputs 16 (divided into two groups of 8, galvanically isolated from each other)

No. of relay outputs 16 (a single normally open contact, isolated from each other)


Supply source 24 V I/O or separate external supply

A Status LEDs

OUT

INNS

MS16151413121110987654321

OUT

IN

X1

X3

161

X2

X4

161

161 161

A

X5

112


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X1 See below for connection tables!




X5 CAN connection detailed in section "Connection of CAN bus"!


Out ch 1a 1 Contact, relay 1

Out ch 1b 2 Contact, relay 1


















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Signal name X3 pin

In ch 1 1

In ch 2 2

In ch 3 3

In ch 4 4

In ch 5 5

In ch 6 6

In ch 7 7

In ch 8 8

0 v for In ch 1-8 9

Not used 10

Not used 11


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Not used 12

Not used 13

Not used 14

Not used 15

Not used 16

Signal name X3 pin

Signal name X4 pin

In ch 9 1

In ch 10 2

In ch 11 3

In ch 12 4

In ch 13 5

In ch 14 6

In ch 15 7

In ch 16 8

0 v for In ch 9-16 9

Not used 10

Not used 11

Not used 12

Not used 13

Not used 14

Not used 15

Not used 16


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

General The unit handles communication between the robot system and any external sys-

tems through galvanically isolated outputs and inputs.

Technical data





Layout, DSQC 320


xx0100000231

No. of inputs 16 (galvanically isolated from each other)

No. of outputs 16 (galvanically isolated from each other)

Supply voltage 120 VAC

A Status LEDs



OUT

INNS

MS16151413121110987654321

OUT

IN

X1

X3

161

X2

X4

161

161 161

A

X5

112


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X5 CAN connection detailed in section "Connection of CAN bus"!


Out ch 1a 1 AC voltage to switch 1/AC output signal from switch 1

Out ch 1b 2 AC voltage to switch 1/AC output signal from switch 1















Signal name

X2 pin Function




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Signal name

X2 pin Function

Signal name

X3 pin Function

In ch 1a 1 AC input signal from switch 1/Neutral voltage to switch 1

In ch 1b 2 AC input signal from switch 1/Neutral voltage to switch 1










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Signal name

X3 pin Function

Signal name

X4 pin Function


















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C - 7: Communication

Communication concept, Allen-Bradley

General The robot may communicate with the Allen Bradley system only, or be used in

combination with the I/O system in the robot. For example, the inputs to the robot

may come from the Allen Bradley system while the outputs from the robot control

external equipment go via general I/O addresses and the Allen Bradley system

only reads the outputs as status signals.

Definitions The Allen Bradley system can communicate with up to 64 external systems. Each

of these systems is called a Rack and is given a Rack Address 0-63. Basically, each

robot connected to the Allen Bradley system will occupy one rack.

Each rack is divided into four sections called Quarters. Each quarter provides 32

inputs and 32 outputs and a rack will subsequently provide 128 inputs and 128

outputs. A rack may also be shared by 2, 3, or 4 robots. Each of these robots will

then have the same rack address, but different starting quarters must be specified.


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Illustration The illustration below shows a block diagram of the Allen-Bradley system, where

Robot 1 uses a full rack while robot 2 and robot 3 share one rack. The rack address,

starting quarter, and other required parameters such as baud rate, LED status etc.

are entered in the configuration parameters.

en0100000255

Allen Bradleycontrol system

Robot 1 - 128 in / 128 out Robot 2 - 64 in / 64 out

128 in / 128 out

64 in / 64 out

Quarter 2

Quarter 3

Quarter 4

Quarter 1

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

Quarter 2

Quarter 1


Robot 3 - 64 in / 64 out

64 in / 64 out

Quarter 4

Quarter 3


Quarter 2

Quarter 3

Quarter 4

Quarter 1

Other systems


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

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

system.

Technical data

Also see the Allen-Bradley RIO specification.



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


xx0100000226

No. of digital inputs Unit is programmable for 32, 64, 96 or 128 digital inputs

No. of digital outputs Unit is programmable for 32, 64, 96 or 128 digital outputs

DS QC 350 ABB F lexible Automation

X8

X9X5

X3


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xx0100000221




xx0100000221


X3 Not used

X5 DeviceNet and ID connector

X8 RIO in

X9 RION out


LINE1 (blue) 1 Remote I/O in

LINE2 (clear) 2 Remote I/O in

Shield 3 Remote I/O in

Cabinet ground 4 Remote I/O in

15


Blue 1 Remote I/O out

Clear 2 Remote I/O out

Shield 3 Remote I/O out

Cabinet ground 4 Remote I/O out

15


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Termination When the robot is last in a RIO loop, the loop must be terminated with a termina-

tion resistor according to Allen-Bradley’s specification.

Warranty This product incorporates a communications link which is licensed under patents

and proprietary technology of the Allen-Bradley Company, Inc. The Allen-Brad-

ley Company, Inc. does not warrant or support this product. All warranty and sup-

port services for this product are the responsibility of and provided by ABB

Flexible Automation.


board.

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

350" above.


POWER-24 VDC Green Indicates that a supply voltage is present, and has a level above 12 VDC. If there is no light, check that voltage is present on power unit and in power connector. If not, check cables and connectors. If power is applied to the unit but it does not work, replace the unit.

NS/MS Green/red See section "CAN bus status LED description".

CAN Tx/CAN Rx Yellow See section "CAN bus status LED description".

NAC STATUS Green Steady green indicates RIO link in operation. If there is no light, check network, cables and connections. Also check that PLC is operational. Flashing green indicates that communication is established, but the INIT_COMPLETE bit is not set in NA chip, or configuration, rack size etc. does not match configuration set in PLC. If LED keeps flashing continuously, check setup


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Communication, serial links

General The robot has three serial channels, which can be used by the customer to com-

municate with printers, terminals, computers, and other equipment (see the figure

in "Connections" below).

• COM1 (computer system) - RS 232 115 kbps. This was formerly referred to as Com2.

• COM2 - RS 232 with RTS-CTS-control and support for XON/XOFF, trans-mission speed 300 - 38 400 bps. This was formerly referred to as SIO1.

• COM3 - RS 422 full duplex TXD4, TXD4-N, RXD4, RXD4-N, transmission speed 300 - 38 400 bps. This was formerly referred to as SIO2.

• For temporary use: MC/CONSOLE - RS 232 115 kbps. This was formerly referred to as Com1.


• For setup parameters, see User's Guide - System Parameters, Topic: I/O Signals.

• Circuit Diagram.

• Location in the cabinet (see figure in section "Connection to screw termi-nals").

Technical data See Product Specification for controller S4Cplus. Separate documentation is

included when the option RAP Serial link is ordered.


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Connections The figure below shows the connection of serial channels:

xx0100000219

Customer terminals, on base connector board: X10 (COM2) and X9 (COM3), see

section "Connection to screw terminals".

Connections on DSQC 504, COM1

Standard RS232 port.


xx0100000220

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

A External computer

A

Signal Pin Description

DCD 1 Data carrier Detect

RX 2 Receive Data

TX 3 Transmit Data

5

1 9

6


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


xx0100000220


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


COM2 Signal name X10 pin

1

RxD (Receive Data) 2

TxD (Transmit Data) 3

DTR (Data Terminal Ready) 4

0 V 5

DSR (Data Ready Set) 6

RTS N (Request To Send N) 7

CTS (Clear To Send) 8

9

5

1 9

6


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


xx0100000220


Connections to MC/CONSOLE

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

xx0100000218

COM3 Signal name X9 socket

TxD (Transmit Data) 1

TxD N (Transmit Data N) 2

RxD (Receive Data) 3

RxD N (Receive data N) 4

0 V 5

DATA (Data Signals in Half Duplex Mode) 6

DATA N (Data Signals in Half Duplex Mode N) 7

DCLK (Data Transmission Clock) 8

DCLK N (Data Transmission Clock N) 9

5

1 9

6

A


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Standard RS232 port intended for temporary use, e.g. connection of laptop/PC.

The table below shows the signals on the MC/CONSOLE (RS232):

A External computer


RX 2 Receive Data

TX 3 Transmit Data

GND 5 Signal Ground


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Communication, Ethernet

General The robot has two Ethernet channels available:

• LAN (connected to the Main computer)

• Service (connected to the I/O computer)

Connection of LAN (Main com-puter)

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

xx0100000217

Used for connection of shielded twisted-pair Ethernet (TPE), or as defined in

IEEE 802.3: 10/100 BASE-T. Maximum node-to-node distance 100 meter. The

main computer board has no termination for a cable shield. The cable shield must

be grounded at the cabinet wall with a cable gland. 10BASE-T is a point-to-point

net, connected via a HUB, see the figure above.

A External computer

B Controller Robot 1

C Controller Robot 2

Signal X1 Pin Description

TX+ 1 Transmit data line +

E thernet hub

A B C


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The figure below shows the main computer board front:

xx0100000216

TX- 2 Transmit data line -

RX+ 3 Receive data line +

NC 4 Not Connected

NC 5 Not Connected

RX- 6 Receive data line -

NC 7 Not Connected

NC 8 Not Connected

Signal X1 Pin Description

X1LAN

PWR

HDD

STATUS

X2

1

8


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Connection of Service (I/O Com-puter)

Used for connection of a laptop to the service outlet on the front of the controller

cabinet (behind service hatch).

The figure below shows how to connect a laptop to the service outlet:

xx0100000215


Also see the Circuit Diagram. Separate documentation is included when the

option Ethernet services is ordered.

E thernet


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External operator’s panel

General All necessary components are supplied, except for the external enclosure.

Dimensions for installation

Install the assembled panel in a housing which satisfies protection class, IP 54, in

accordance with IEC 144 and IEC 529!

The figure below shows the main dimensions of the external operator’s panel:

xx0100000214

A Holes for operator’s panel

B Holes for flange

184200

70

45°

62

D

E

90

155

C

A

M4 (x4)

ø5 (x2)

F

G

B

140

M8 (x4)


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C Required depth: 200 mm

D External panel enclosure (option)

E Holes for teach pendant unit (TPU) holder

F Teach pendant unit (TPU) connector

G Connection to the controller


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Section D: Start-up

Inspection before start-up

General Perform the following checks before starting up the robot system:

Check that: 1. the controller mains section is protected with fuses.

2. the electrical connections are correct and correspond to the identifica-tion plate on the controller.

3. the teach pendant and peripheral equipment are properly connected.

4. any limiting devices that establish the restricted space (when utilized) are installed.

5. the physical environment is as specified.

6. the operating mode selector on the operator’s panel is in the Manual mode position.

7. when external safety devices are used, check that these have been connected or that the following circuits in either XS3 (connector on the outside left cabinet wall) or X1-X4 (screw terminals on the panel unit) are strapped:

Device XS3 Panel unit

External limit switches A5-A6, B5-B6 X1.3-4, X2.3-4

External emergency stop A3-A4, B3-B4 X1.9-10, X2.9-10

External emergency stop internal 24 V

A1-A2, B1-B2 X1.7-8, X2.7-8

General stop + A11-A12, B11-B12 X3.10-12, X4.10-12

General stop - A13-A14, B13-B14 X3.7-8, X4.7-8

Auto stop + A7-A8, B7-B8 X3.11-12, X4.11-12

Auto stop - A9-A10, B9-10 X3.7-9, X4.7-9

Motor off clamping A15-A16, B15-16 X1.5-6, X2.5-6


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Start-up

General 1. Switch on the mains switch on the cabinet.

1. The robot performs its self-test on both the hardware and software, which takes approximately 1 minute.

2. If the robot is not supplied with the software already installed, install the software as described in chapter "Robot Controller".

A welcome message is shown on the Teach Pendant Unit display.

3. To switch from MOTORS OFF to MOTORS ON, press the enabling device on the teach pendant.

4. Update the revolution counters as described in the Calibration chapter, section "Updating the revolution counters".

5. IRB 940: Check the position of the spiral cable in the centre tube sleeve. Correct position is described in the Calibration chapter, section "Correct orientation of axes".

6. Check the calibration position as described in the Calibration chapter, section "Checking the calibration position".

7. When the controller, with the manipulator electrically connected, is powered up for the first time, ensure that the power supply is connected for at least 36 hours continuously, in order to fully charge the batteries for the serial measurement board. It takes approx. 4 hours to fully charge a computer system battery.

8. After having checked the above, verify that:

• the start, stop and mode selection (including the key lock switches) control devices work as intended.

• each axis moves and is restricted (if possible) as intended.

• emergency stop and safety stop (where included) circuits and devices are functional.

• it is possible to disconnect and isolate the external power sources.

• the teach and playback facilities work correctly.

• the safeguarding is in place.


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ControllerStart-up

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• at reduced speed, the robot operates properly and has the capability to handle the product or workpiece.

• in automatic (normal) operation, the robot operates properly and has the capability to perform the intended task at the rated speed and load.

9. The robot is now ready for operation.

Operating the robot

Starting and operating the robot is described in the User’s Guide. Before start-up,

make sure that the robot cannot collide with any other objects in the working

space.


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ControllerInstallation of controller software

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Section E: Installation of controller software

Loading system software

General The robot system may be delivered with or without system software. When the

system is not delivered with software, this must be downloaded in one of a number

of ways.

Software installed on delivery

If the robot controller is ordered with the software installed on delivery, the con-

troller software and settings are already stored in the storage memory and the

system is ready to use.

Software not installed on deliv-ery

If the robot controller is ordered and delivered without software or if you want to

reconfigure your system, the RobInstall tool must be used to install the controller

software. The RobInstall tool is included on the RobotWare CD-ROM (see section

"RobotWare CD-ROM"). The RobInstall tool can be used both for creation of the

controller software and for downloading it to the controller system.

Types of software loading

xx0100000192

AB

C

DE


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When downloading, the controller software can be transferred to the controller

storage memory in three ways as shown in the figure above.

• using floppy disks,

• using Ethernet connected direct to the IO computer (IOC) service outlet on the front of the controller cubicle,

• using Ethernet connected via a local area network (LAN) to the main com-puter (MC).

Boot Image The transfer and installation of the controller software to the controller storage

memory via Ethernet or floppy disks is executed by a basic program named Boot

Image.

This basic program must always be in the storage memory. When starting the

controller, with no controller software installed, Boot Image will start and ask the

operator for controller software installation instructions. If the controller software

is already installed and a warm start is performed, Boot Image is not used. The

installed controller software can be deleted by a cold start and then the Boot Image

will be reactivated.

A RobotWare CD-ROM to install RobInstall and System Pack on PC

B Floppy Disks

C IOC Ethernet (service) with delivered boot cable UTP-X

D Connected to IOC

E MC Ethernet (LAN) network in workshop


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RobotWare CD-ROM

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

RobotWare CD-ROM contents

The RobotWare CD-ROM contains the following:

Contents Description

1. RobInstall A PC tool used to create and install the control-ler operating system in the robot control sys-tem.

2. Documentation On-line documentation for the RobInstall appli-cation and the Controller Operating System Package.

3. Controller OS Package Controller Operating System Package for S4Cplus. This package includes all the soft-ware needed to create the controller operating system with any ordered options. Please note that it is possible to install different releases with different versions of the same system package (see section "Media Pool in the PC").

4. Test Signal Viewer A tool (created in LabView) for viewing Motion-Test Signals (oscilloscope function) and also for logging these signals.

5. FTP Client On the CD is also included a so called FTP cli-ent named Voyager. Please note that this is not an ABB product but a shareware program, which means that it can be installed and used for a limited time, but that it has to be regis-tered for permanent use. Registering means that a certain fee must be paid to the vendor.

The FTP client is used to transport files manu-ally between the PC and the robot controller storage memory. These actions are carried out in the same way as in a file manager or in Win-dows Explorer.


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Installation of the RobotWare on the PC (except FTP Client)

This section describes how to install the software delivered on the RobotWare

CD-ROM onto a PC hard drive, to be transferred to the robot system.

1. Insert the CD in your reader.

1. The Install Shield will automatically start and guide you through the install process (if it does not start, double-click the CD icon on your PC). When the setup type window is displayed, it is recommended to select the Custom button. Then Next button will open the Select Components window, where normally all the four options, RobInstall, Documenta-tion, Controller OS Package and Test Signal Viewer should be marked as selected.

Installation of the FTP Client on the PC

This section describes how to install the FTP Client onto a PC hard drive.

1. In the Explorer, select and open the directory "ftp" on the CD.

2. Double-click the file ftpvsetup.exe.

The Install Shield for the FTP client will start and guide you through the instal-lation. Please read the "Readme" file for information about license regulations.


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Installing new Robot Controller Software with RobInstall

General Since most systems have the operating system installed already on delivery, the

RobotWare CD-ROM is normally not needed. However it should be used when:

• creating a new controller operating system,

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

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

How to use Rob-Install

Robinstall is used to create and install the controller software in the S4Cplus robot

controller. With RobInstall, you can:

• create a new system,

• update an existing system,

• download a system to the controller using the Ethernet connection,

• create Boot Disks to transfer the system to the Controller.

Concept: Means:

System pack This is the RobotWare Controller Operating System Package for S4Cplus, including all options, even if they are not ordered and activated.

Key This is a text string, or a special file with the text string, which is used to define and open both the BaseWare and all ordered RobotWare options.

System This is a complete controller software, i.e. controller operating system, based on the system pack and the key. It can also include any user files to be added to the home directory on the controller storage memory.


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Step Action Illustration/Info

1. Make sure RobInstall is installed. If not, install it according to the instruc-tions in section "Installa-tion of the RobotWare on the PC".

2. Click the start button on your PC and select pro-grams/ABB Robotics/Rob-Install/RobInstall.

3. The RobInstall start win-dow will open.

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Create a new Robot Controller System

Setting up the system


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

2. Choose New to create a new Robot Controller sys-tem as shown in the fig-ure.

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3. Enter a name for the new controller system. Select a saving location or use the default directory, nor-mally "Program Files\ABB Robotics\sys-tem" (see the figure below, position 1).

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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).


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Add or remove external options

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

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6. If no external options or parameters are to be added or changed, press Finish to create the new controller system. Other-wise press Next to con-tinue to "Additional Keys" (see section "Add or remove external options").



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

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Add or remove additional system parameters

2. Enter the key string for the selected option and press Add Key to list, or pressAdd key from file to select a key string file.

3. To remove additional keys, select the key in the Included Additional Keys list and press Remove Key.

4. Press Finish to create the controller system or press Next to continue to "Parame-ter Data" (see section "Add or remove additional system parameters).



1. To add or remove addi-tional parameters, press Next in the screen shown in the last figure in section "Add or remove external options" or click on "Parameter Data" in the menu to the left.

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


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Change options or system pack revision

3. To remove manipulator calibration data, press Remove.

4. Press Add to load addi-tional system parameters, see pos. 2. All system parameter files added here will be automatically loaded together with the system, when the control-ler is restarted with the new system.

5. To remove additional parameters, select the parameter in the "Loaded Additional Parameters" list and press Remove.

6. Press Finish to create the controller system or press Next to continue to "Options" (see section "Change options or sys-tem pack revision").



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

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2. To change the Teach Pen-dant Unit language, robot type, or software options, press Options (see the fig-ure above, position 1).

3. Normally the latest release or revision of all system packages and option packages stored in the media pool (see sec-tion "Media Pool in the PC") will be used. If an earlier revision should be used, uncheck the check mark and press Rev. Select (see the figure above, position 2). In the new window select the system package to use and press OK.

4. If you want the system to start up in query mode, put a mark in the query mode selection square. For fur-ther details of the query mode, see section "Start in Query Mode".

5. Press Finish to create the controller system or press Next to view the current configuration.



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Update the Robot Controller image

Actions


1. To update an existing con-troller system, press Update, see the figure below.

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2. Select a system in the sys-tem list and press OK, see the figure above. Please note that a pop up menu can be shown by clicking right mouse button. With this menu Copy, Rename or Delete can be selected for the marked system.

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3. The window displaying the current configuration of the system will be shown. Fol-low the instructions in sec-tions "Add or remove external options", "Add or remove additional system parameters" or "Change options or system pack revi-sion" to modify the system.



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Transfer Robot Controller System using Ethernet connection

Selecting type of set-up

Before a system can be downloaded to a robot controller using the RobInstall tool

some preparations and set up must be done. This may be done in one of two ways:

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

If you are using: ...then see instructions in section:

...and continue in section:

a direct connection between PC and IOC service outlet on controller

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

"Download Robot Controller System" below!

Network Intranet connection with fixed IP addresses

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


Network Intranet connection with DHCP (Dynamic Host Configuration Protocol)

"If using Network Intranet connection with DHCP " below!



1. Connect a patch-cable between the Ethernet con-nection on the front of the controller and the corre-sponding connection on the PC/Laptop.

2. Make sure that the Net-work protocol is set for TCP/IP properties.


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If using Network Intranet connec-tion with fixed IP addresses

3. Change the TCP/IP Prop-erties in accordance with the following table and fig-ure:

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

2. Change the TCP/IP Properties in accordance with the values to be used for IP address, Subnet mask and Gateway.

3. Perform a X-START (see section "x-START") or C-START (see section "C-start") on the S4Cplus con-troller.

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


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If using Network Intranet connec-tion with DHCP

Download Robot Controller Sys-tem

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


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


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

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2. Select a target system as in the figure, position 1.

If a direct connection is used with the patch cable between the PC and the controller front, then just select the default IP address (192.168.125.1) and "Direct" option. In other cases, write the correct IP address for the robot controller and select "Host-name or IP-address". RobInstall will store already used IP addresses, which can later be selected with the down arrow.

3. Type your username and password if required by the robot controller as in the fig-ure below, position 2.

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4. Test the connection by pressing Test Connection and press OK if a connec-tion is established.

5. Select a system in the list on the left and press OK as in the figure below. Please note that it is possible to select another system pool than the shown one (in such case be sure to select the system pool directory, not the system itself on the lower level).

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6. RobInstall will now create a system file and download it to the controller.

After downloading it is possible to restart the controller with the new downloaded controller system. Otherwise, the controller may be restarted from the Teach Pendant Unit as detailed in section "Reboot".



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Transfer Robot Controller System using floppy disks

Before downloading, make sure: there is at least 25 Mb free disk space on the controller mass storage memory. For information on how to perform a manual storage capacity check, see section "Check Storage Capacity".

that the robot controller displays the Start Window on the Teach Pendant Unit (see section "Start Window").

an optional floppy disk drive is installed in the robot controller.

Create Boot Dis-kettes from Rob-Install Step Action Illustration/Info

1. Press Create Boot Disk as in the figure below.

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2. Select a system in the list on the left and press OK as in the figure below.

RobInstall will now create an image file and estimate the number of disks needed.

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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".



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RobInstall preferences

Customizing Rob-Install

RobInstall may be customized to suit particular requirements.


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

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

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



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ControllerRobot controller

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Section F: Robot controller

BootImage

General The BootImage is a basic program which is used to start up the system from

"scratch".

Purpose of the program

This program is already installed in the controller at delivery and is used to:

• restart the system

• load the system from boot disks or network connections

• set or check network settings

• choose a system from the mass storage memory.


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Start window

When is it shown?

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The start window displays the start menu and will appear in the following cases:

• When no controller operating system is installed at power on.

• After X-START (see the part "How to perform a Restart").

• After C-START (see the part "How to perform a Restart").

Possible actions From this window you can choose to do one of the following:

Restart the sys-tem, Reboot

The BootImage will be re-executed, used to apply changes in the system settings

(see the part "Reboot Window").

Load a system from diskettes, Boot Disks

(See the part "Boot Disk Window".)

Set the network settings, Network Settings

Set network settings for the Main Computer or check how to configure your PC

(see the part "Network Settings Window").


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Choose a system from the mass storage memory, Select System

If there is one or more systems in the mass storage memory, you can choose to

activate one of them (see the part "System selection window").


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Reboot Window

When is it shown?

The Reboot window will be displayed if any of the system settings are changed or

when Reboot is pressed in the Start window as shown in the figure below:.

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Button Function

YES Restarts the system

NO Returns to the start window


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Boot Disk Window

When is it shown?

The Boot Disk window will be displayed when Boot Disks is pressed in the Start

window as shown in the figure in section "Start window".

How to create boot disks

Information on how to create boot disks from RobInstall can be found in section

"Create Boot Diskettes from Robinstall".

Load the system


1. Insert the correct diskette in the floppy disk drive and press OK. If the diskette is alright, the system will be loaded. CANCEL removes all previ-ously loaded data and returns to the Start window as shown in the figure in section "Start window".

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Network Settings Window

When is it shown?

The Network Settings window will be displayed when Network Settings is

pressed in the Start window as shown below.

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LAN Settings Press to configure the Main Computer for communication with a PC on a Local Area Network (LAN). Also see "LAN settings"!

Service Settings Press to view the required settings for the PC to communicate with the I/O Computer. Also see "Service settings"!

CANCEL Press to return to the Start window as shown in figure "Start window".


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LAN Settings Window

When is it shown?

The LAN Settings window will be displayed when LAN Settings is pressed in the

Network Settings window as shown in the figure in section "Network Settings".

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Node identifica-tion

NONE will, after the system is rebooted, remove the IP settings.

CANCEL returns to the Start window, as shown in the figure in section "Start Window", without changing any settings.

Parameter Type Description

MAC ID Node identification The Main Computer’s ethernet address.

Current IP Node identification The Main Computer’s current IP address. This row is blank if the LAN Settings have not been defined.

IP Network setting Space for typing in a new IP address, for the Main Computer or the DHCP server. See Configure for fixed IP network and Configure for DHCP distributed IP network below.


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Configure for fixed IP network

1. Press FIX IP.

2. Fill in the assigned IP address for the Main Computer, and the Subnet Mask and Gateway for the Network and press OK.

You will be asked to reboot the system.

3. Press YES to make the new setting take effect.

Configure for DHCP distributed IP network

1. Press DHCP.

1. The value for IP will change to DHCP.

2. Press OK.

You will be asked to reboot the system.

3. Press YES to make the new setting take effect.

(Subnet mask) Network setting Shows the subnet mask of the network. Only visible when configured for fixed IP.

(Gateway) Network setting Shows the gateway IP for the network.

Only visible when configured for fixed IP.

Parameter Type Description


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Service Settings Window

When is it shown?

The Service Settings window will be displayed when Service Settings is pressed

in the Network Settings window as shown in the figure in section "Network Set-

tings".

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Service Setting

OK returns to the Start window as shown in the figure in section "Start Win-dow".

Parameter Description

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

IP Required to configure your PC’s network settings for com-munication between RobInstall and the I/O Computer.

Subnet mask Required to configure your PC’s network settings for com-munication between RobInstall and the I/O Computer.

Gateway Required to configure your PC’s network settings for com-munication between RobInstall and the I/O Computer.


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System selection window

When is it shown?

The Select System window will be displayed when Select System is pressed in the

Start window, as shown in the figure in section "Start Window".

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How to select system

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

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


1. Select by moving the X to a desired system and press OK. The system will reboot with the new system and then display the Welcome window as shown in the figure.

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How to perform a Restart

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

Reboot (Warm start), apply changed settings

When executing a Warm start, the system reboots with the current system, e.g. to

make new or changed settings take effect.

P-START, reinstal-lation of RAPID

A P-Start will warm start the current system, with a reinstallation of the RAPID

language and all auto-loaded modules. This means that all RAPID program and

system modules currently loaded in the working memory will be closed, and thus

have to be reloaded again after the P-Start, with the exception of such modules that

are automatically loaded, due to settings in the System Parameters/Controller/

Task Modules.


1. Press the button Miscellaneous and select Service window or System Parameter win-dow

Miscellaneous button:

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

Step Action Illustration/info

1. Press the button Miscellaneous and select Service window.


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2. Select Restart from the File menu.


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X-START, change active controller system

An X-start will exit the running system, store system data on the mass storage

memory, and then execute the BootImage to display the Start window. Any system

stored in the mass storage memory may then be selected as described in section

"Select System".

When performing an X-Start all stored system data will be restored (similar to

performing a warm start).

I-START, start in Query mode

An I-start can be done if "Use Query Mode at System Boot" was selected when

creating the running system in RobInstall (see section "Change options or system

pack revision"). An I-Start will restart the current system and give the opportunity

3. Enter the numbers: 2_5_8 (the fifth function key changes to P-START)

4. Press P-START. The system will reboot, reinstall RAPID and its auto-loaded modules, and return to the Welcome window as shown in the second fig-ure in section "Select System".



1. Press the button Miscellaneous and select Service window.


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3. Enter the numbers: 1_5_9 (the fifth function key changes to X-START)

4. Press X-START. The system will reboot and return to the Start window as shown in the figure in section "Start Window".


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to set some values at start-up, e.g. language, IRB type (within the same model) or

options (see section "Start in Query Mode").

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

When executing a C-Start, the system exits the running system and deletes it from

the mass storage memory. The BootImage is then executed and the Start window

as shown in the figure in section "Start Window" is displayed.

Use C-start with caution. Since it deletes the current system, it should not be used to just switch between installed systems. For this purpose, use X-Start (see section "X-start").

It will take quite some time to implement a Cold start. Just wait until the robot shows the Start window. When the Start window is shown, a new system can be selected if available in the mass storage memory (see section "Select System) or a new system can be downloaded and started (see section "Transfer Robot Controller System using Ethernet connection" or "Transfer Robot Controller System using floppy disks"). Do not touch any key, joystick, enable device, or emergency stop during the cold start until the Start window is shown as in the figure in section "Start Window".


1. Press the button Miscellaneous and select-Service window.


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3. Enter the numbers: 1_4_7 (the fifth function key changes to I-START).

4. Press I-START.

The system will start to reboot, then pause to ask for Silent, Easy, or Query mode. For more information on the different modes, continue to section "Start in Query Mode".


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1. Press the button Miscellaneous and select-Service window.


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

4. Press C-START.


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How to Start in Query Mode

Pre-conditions for selecting Query Mode start

If "Use Query Mode at System Boot" was selected when creating the system in

RobInstall (see section "Change options or system pack revision"), it is possible

to set some values, e.g. language, IRB type (within the same model) or options, at

the first start-up of the system, using a C-Start (see section "C-start"), or later on

when performing an I-Start (see section "I-start").

Types of Query Mode

The first question from the system is which Query Mode to start. Depending on

your needs, you should select one of the following three:

• Silent Mode, pushbutton Silent. If Silent Mode is selected, the operating system will be installed with the system configured as defined in RobIn-stall.

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

• Query Mode, pushbutton Query. In Query Mode you can, as well as the things in Easy Query, select DC-link, change Robot type (within the same family) and for IRB 7600, select balancing unit (see section "Query Mode").

Easy Query Mode If Easy Query was chosen as start-up query mode, the following steps will be

required to start the system:


1. Select Service/Standard motion param. Choose between standard or service motion parameters (pushbutton Stand / pushbutton Service).

2. Choose TP Language. If there was another language than English selected in RobInstall (see section "Change options or system pack revision"), it will be possible to choose the language (pushbutton English /pushbutton "Other").


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

required to start the system:

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



1. Select Service/Standard motion param. See section "Easy Query Mode", step 1.

2. Choose TP Language. See section "Easy Query Mode", step 2.

3. Select external axes config.

You can find the article number of the DC-link used on the unit inside the controller, then use the table below to find out the configura-tion ID for that DC-link.

4. Select xxxx model. Choose Robot model type within in the same family, e.g. 1400, 6400 etc. If there are more than three options, press pushbutton SCAN to view them.

5. Install xxx. See section "Easy Query Mode", step 3.


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ControllerSystem directory structure

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Section G: System directory structure

Media pool in the PC

Directory All RobotWare System Packages and Option Packages are stored in a media pool

directory (folder) as shown in the table below.

Two revisions of the same system package may exist in the pool. By default, after

having installed RobInstall, a directory "MediaPool" will be found in the directory

Program Files\ABB Robotics\, and will also be the current one. However any

directory in the structure can be set up as the current media pool in the Preference

window (see section "Robinstall Preferences").

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Naming conven-tions

Each package is stored in a directory, the name of which is an article number

ending with the sub-number and with the revision number as shown in the table

above. All the system packs and option packs in one media pool must have the

correct revision numbers in their directory names. Thus a later revision can be

loaded into the program pool, to be added to the old one, without changing the

article number.

Art. no./folder name Description

3HAXaaaa-1.00 RobotWare System Pack 3HAXaaaa-1, rev 00

3HAXbbbb-1.02 RobotWare System Pack 3HAXbbbb-1, rev 02

3HAXcccc-1.01 ABB Robotics external option program 3HAXcccc-1, rev 01

3HYZdddd-1.00 OEM customer external option program 3XYZdddd-1, rev 00


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System pool in the PC

Directory All systems created with the RobInstall will be stored in a system pool. The

default name of such a system pool is "system" as shown below. Each system

stored in the system pool is a directory with the name of the system as shown in

the table below.

By default, after installing RobInstall, a directory "system" will be found in Pro-

gram Files\ABB Robotics\ and will also be the current one. However any direc-

tory in the structure can be set up as the current system directory in the Create New

System window or Select System window.

File system requirements

The system directory must hold these files and directories to allow software instal-

lation:

• key.id (encrypted key file for the actual controller)

• program.id (file with paths to selected programs in the media pool)

• A syspar directory containing .cfg files to be included in the software instal-lation procedure. All system parameter files, included when creating a sys-tem with RobInstall, are stored in this syspar directory as shown in the table in section "System Pool Directory".

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

Directory view Folder "System 1"

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File structure in the robot controller mass storage memory

Files in root direc-tory, hd0a

The root directory of the mass storage memory is called hd0a. This includes sev-

eral components:

Directories and subdirectories

Each system directory holds a number of subdirectories, defining for instance lan-

guage, options, robots, etc.

"Home" directory The system directory is the "home" directory for the system. When using the

address "home:" in the RAPID program, this directory will be addressed.

"Bin" subdirec-tory

The subdirectory bin, containing the storage area for all system data, e.g. at power

break. This means that at warm start, in addition to restoring the operating system

from the control system package, all system data is restored from this directory

and reloaded into the working memory.

Never change these directories!

Never delete or change the \bin or BootRom.sys directories in the root directory.

If this is done, the controller cannot be restarted and it will be impossible to use

the mass storage memory.

File name Description

E.g. 3HAC6811-1.00 Control system package, named as an article number

bin BootImage code

BootRom.sys System configuration and description file for the mass storage memory

MC.cfg Network configuration for the main computer

ctrl.bin Holds e.g. revolution counter values

system.dir Holds information on the current system

system directories Different systems stored in the mass storage memory


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Preparation of S4Cplus software to be installed

Illustration

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Files to be pre-pared

The list details what happens during preparation:

• RobInstall creates a file named Key.id from the key strings specifying the options to be installed from the System Pack and the external option pro-grams to be installed.

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

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

Media pool S ystem pool

S ystem Pack in/3haxbbbb-1.nn*.* signature no

Ext Option in/3haxcccc-1.nn*.* relkey.txt

Created fileskey.idprogram.id

My system/system_nkey.idprogram.idkeystr.txt/syspar

*.cfg

Inserted key stringsare saved in keystr.txt

S ystem Pack fromRobotWare CD-ROM

External option fromdisk or CD-ROM

RobotWare keystrings define the optionsto be included from the S ystem Packthey belong to and Ext opt keystrings defineadded external option packages.All keys must have the same serial number.


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Handling mass memory storage capacity

General In some cases it is very important that there is enough free space in the mass

storage memory, before attempting to download new system software. How to

check its capacity, and if required increase it, is detailed below.

A manual check on the free space can be done in one of the following ways:

Checking storage capacity from the Teach Pendant Unit

1. Press the button Miscellaneous to select Service window.

2. Select Storage Capacity from the System Info menu. The Mass Storage Memory is called hd0a.

Checking storage capacity through connection to the MC/CONSOLE port

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

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

Increasing stor-age capacity

If the capacity of the mass storage memory is less than 25 Mb when a new con-

troller system is to be downloaded, storage memory must be released by removing

old systems from the mass storage memory. This can be done in one of the follow-

ing ways:

1. Boot up on the system you would like to remove and then make a C-START (see section "C-start").

2. Use the FileManager in the Teach Pendant Unit, see User’s Guide - File Manager, for more information on how to use the FileManager.

3. Use a third-party "ftp" client (like FTPVoyager supplied on the Robot-Ware CD).


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Removing systems using the FileManager or FTP-client may be hazardous since the \bin and BootRom.sys directories must be kept intact. Proceed with the utmost care to avoid accidentally removing such files or directo-ries!


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206 - 3HAC 16638-1

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Calibration

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Chapter 5:Calibration

When to calibrate

Types of calibra-tion procedures

Calibrate the measurement system carefully if any of the resolver values has been

changed. This may occur when parts affecting the calibration position have been

replaced on the robot.

Calibrate the system roughly as detailed in section "Updating the revolution

counter" if the contents of the revolution counter memory are lost. This may occur

when:

• the battery is discharged

• a resolver error occurs

• the signal between a resolver and measurement board is interrupted

• a robot axis has been moved with the control system disconnected


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CalibrationGeneral

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Section A: General

How to calibrate the robot system

General This section provides an overview of the procedure required when calibrating the

robot system. Many of the steps in the procedure are detailed in other sections to

which references are given.

Procedure


1. Check that all required hardware is available for calibrating the robot.

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

2. Check the correct orientation of axis 4. Incorrect orientation of the axis may cause damage on cabling!

Detailed in "Correct orientation of axes".

3. Manually, run the robot axes to a posi-tion close to the correct calibration position.

Use the calibration scales or dis-tances to locate this position, detailed in "Correct orientation of axes".

4. Start the calibration procedure on the TPU.

Detailed in "Fine calibration pro-cedure on TPU".

5. Calibrate each axis. Detailed in "Fine calibration, all axes".

6. Verify that the calibration was suc-cessfully carried out.

Detailed in "Post calibration pro-cedure".


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CalibrationGeneral

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Additional information

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

tion related actions may be performed:

Action Detailed in section:

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

Updating the revolution counter

How to manually check the current calibration position.

Checking the calibration position


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Calibration tool kit, contents

Calibration tool kit, 3HAC xxxxx-x

The calibration tool kit, 3HAC xxxxx-x, can be ordered from ABB Automation

Technologies AB, Robotics.

The kit contains:

• Digital indicator

• Magnetic stand

• Calibration tool for actuator

• Calibration tool for wrist

• Tool case


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Section B: Preliminaries

Correct orientation of axes

General This section details the correct orientation of all axes.

The orientation of axis 4 must be especially checked and corrected if necessary

before performing any calibration!


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Index marks The figure below shows the index marks of axes 4-5-6 and the correct position of

the spiral cable. It also shows the calibration distance on axes 1-2-3.

xx0200000341

A Axis 4 (center tube) E Index marks for axis 5

B Spiral cable inspection cover F Index marks for axis 6

C Correct orientation of the spiral cable (and axis 4)

G Calibration distance for axes 1-2-3: 26 mm on each axis

D Index marks for axis 4

B

A

C

D

E F

G


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Correct position of axes 1-2-3

The axes 1-2-3 should be positioned with an approximate distance of 26 mm

between the actuator and the calibration spacer above the lower joint, shown in

figure above. This distance is set exactly during the fine calibration procedure.

Correct orienta-tion of axis 4

The procedure below details how to check and eventually correct the orientation

of axis 4.

Axis 4 has no mechanical limitation! Cabling inside the manipulator may be dam-aged if axis 4 is oriented incorrectly when performing calibration of the robot!

If work must be carried out within the robot’s work envelope, the following points must be observed: The operating mode selector on the controller must be in the manual mode position to render the enabling device operative and to block operation from a computer link or remote control panel. The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in position < 250 mm/s. This should be the normal position when entering the working space. The position 100%”full speed” may only be used by trained person-nel who are aware of the risks that this entails.

Step Action Note

1. Remove the spiral cable inspection cover on the center tube sleeve by removing its 4 attachment screws.


2. Make a visual check of the numbers, marked on the spiral cable.

The numbers 4-3-2-1 must be positioned in a straight line, as shown in figure above!

In case the index marks are not present: make sure that the normal vector of the face of the gearbox, axis 5, is pointing in approxi-mate (+ / - a couple of degrees) +Y direction!

Directions detailed in part “Directions for all axes”.

3. In case correction is necessary, turn axis 4 with the TPU into the approximate calibration position by positioning the numbers into a straight line!


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Correct orienta-tion of axes 5-6

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

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

Step Action Note


1. Make sure that the index marks of axis 5 are roughly aligned.

In case the index marks are not present: make sure that the normal vector of the face of the tool flange is pointing approximately (+ / - a couple of degrees) in the +Z direction (positive)!

Location shown in figure above!

Directions detailed in part “Directions for all axes”.

2. Make sure that the index marks of axis 6 are roughly aligned.In case the index marks are not present: make sure that the hole for the guide pin in the tool flange is pointing approximately (+ / - a couple of degrees) in the -X direction (neg-ative)!

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


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Checking the calibration position

General Check the calibration position before beginning any programming of the robot

system. This may be done as detailed below.

Using the Jog-ging window on the teach pendant Step Action Note/Illustration

1. Open the Jogging window.

xx0100000195

2. Choose running axis-by-axis.

xx0100000196

3. Check that the positions of axes 1-2-3 are reached and that the calibration marks on axes 4-5-6 are aligned correctly. If they are not, update the revolution counters as detailed in "Update the revolution counter".

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


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Updating the revolution counter

Manually running the manipulator to the sync posi-tion

This section details the first step when updating the revolution counter; manually

running the manipulator to the synchronization position.

Axis 4 has no mechanical limitation! Cabling inside manipulator may be damaged

if axis 4 is oriented incorrectly when performing calibration of the robot!the

Storing the revo-lution counter setting

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

the revolution counter settings.

If a revolution counter is incorrectly updated, it will cause incorrect robot position-ing, which in turn may cause damage or injury!

Step Action Illustration

1. Select axis-by-axis motion mode

2. Press the enabling device on the teach pen-dant and, using the joystick, move the robot manually so that the calibration marks or dis-tances lie within the tolerance zone.

Calibration marks shown in section "Correct orien-tation of axes".

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

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


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1. Press the button "Miscella-neous".

xx0100000194

2. Select the Service window by pressing ENTER.

xx0100000200

3. Select Calibration from the View menu.

The Calibration window appears.

xx0100000201

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

The Revolution Counter Update window appears.

xx0100000202

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


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

CANCEL returns to the Cali-bration window.

7. Press OK again to confirm and start the update.CANCEL returns to the Rev-olution Counter Update win-dow.

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

Not required.

9. Recheck the calibration posi-tion as described in "Check-ing the calibration position".



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Fine calibration procedure on TPU

General The section below details how to use the Teach Pendant Unit (TPU) when per-

forming a fine-calibration of the robot.

Procedure


1. Press the button "Miscella-neous".

xx0100000194

2. Select the Service window by pressing ENTER.

xx0100000200


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

xx0100000201

Explanation of status: • Synchronized: all axes are cali-

brated and their positions are known. The unit is ready for use.

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

• Not calibrated: one (or more) of the axis is NOT fine-calibrated. This axis, or these axes, must therefore be fine-calibrated as described in "Fine calibration".

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

xx0100000203



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5. Move the manipulator to its calibration position and press OK. The Fine Cali-brate window appears.

Calibration positions for the manipulator detailed in "Checking the calibration posi-tion".

xx0100000204

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

7. Press OK when all axes that are to be updated are marked with an x.CANCEL returns to the Cali-bration window.

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

CANCEL returns to the Fine Calibration window.

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



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Section C: Calibration

Directions for all axes

Calibration move-ment directions

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

xx0200000355

1

2

3

4

5

6

+

- +

++

+

+

-

-

---


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Jogging directions

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

xx0200000378

+Y +X

+Z +Z


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Fine calibration, all axes

Introduction This section details how to calibrate the complete robot, using calibration tools.

The section is divided into the following parts:

• Before calibration

• Required equipment

• Calibration order

• Calibration, axes 1, 2 and 3

• Calibration, axis 5



Before calibration Before calibrating the robot, make sure that the requirements in the previous sec-

tions "General" and "Preliminaries" are met!

Required equip-ment

Calibration order The order of calibration of the axes 1, 2 and 3 is of no importance, but the remain-

ing axes must be calibrated in the following sequence: 5 - 6 - 4.

Equipment, etc. Art. no. Note

Calibration tool kit - Contains tools for calibration of complete robot. May be ordered from ABB Automa-tion Technologies AB, Robotics.


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Calibration axis 1, 2 and 3

The procedure below details how to calibrate axis 1, but it is the same for axes 2

and 3. Calibrate one axis at a time and then repeat the procedure for the remaining

axes.


1. Turn the operating mode selector to MAN-UAL MODE AT REDUCED SPEED.

2. Operate current axis (axis 1, 2 or 3) in man-ual mode with the joystick until only 40-50 mm of the movable part of the actuator is visible.

3. Insert the gauge block between the plat-form and the actuator cover (see adjacent figure) and then gently contract the actua-tor until the gauge block fits exactly but is not jammed.Note! All three actuators should have approximately the same length when one of them is calibrated.

xx0200000351

• A: 26 mm

4. Update only the current axis (axis 1, 2 or 3) as detailed in "Fine calibration procedure on TPU".

5. Remove the calibration tools.

A


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Calibration, axis 5 The procedure below details how to calibrate axis 5.


1. Put a dial gauge (mounted on a sup-port positioned on a flat surface external to the robot) against the edge of the tool flange as shown in the adjacent figure. The purpose of this procedure is to adjust axis 5 so that it is possible to rotate axis 4 without reading any off-set on the indicator.

xx0200000352


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2. Lock all other axes when jogging axis 4.

• Rotate axis 4 in joint +180 degrees.

• Rotate axis 5 to compensate for half the value read on the indicator (i.e. the indicator shows 0.58 mm, move axis 5 gently until the indicator shows 0.29).

• Rotate axis 4 -180 degrees (=back to the starting posi-tion, 0 degrees).

• Repeat until it is possible to rotate axis 4 180 degrees without reading any error on the gauge. Normally, it requires 2-4 attempts.

3. Update only axis 5, as detailed in "Fine calibration procedure on TPU".




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Calibration axis 6 The procedure below details how to calibrate axis 6.


1. Run the following axis to the specified position:

• Axis 5: -90 degrees.

2. Fit the wrist calibration tool at the tool flange and put a dial gauge (mounted on as support positioned on a flat sur-face external to the robot) against the edge of the tool, see the adjacent fig-ure.

xx0200000353

3. Lock all other linear directions except for Z.

Directions shown in “Directions for all axes”.


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Calibration, axis 4 The procedure below details how to calibrate axis 4.

4. Move the robot in +/-Z (in base) and adjust axis 6 until the indicator shows minimum change (usually a few hun-dredths of a millimeter) while travel-ling from the middle of the tool to one end (i.e. if the indicator shows 0.46 mm while travelling from the center of the tool to one end of the tool, rotate axis 6 by 0.46 mm).






1. Run the following axes to the specified positions:

• Axis 5: -90 degrees.

• Axis 6: +90 degrees.

• Axis 4: 0 degrees.

2. Put a dial gauge (mounted on a support positioned on a flat surface external to the robot) against the ground face of the tool, see the adja-cent figure.

xx0200000354


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3. Lock all other linear direc-tions except for Y.


4. Move the robot in +/-Y (in base) and adjust axis 4 until the indicator shows mini-mum change (usually a few hundredths of a millimeter) while travelling from the mid-dle of the tool to one end (i.e. if the indicator shows 0.52 mm while travelling from the center of the tool to one end of the tool, rotate axis 4 by 0.52 mm).






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CalibrationAfter calibration

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Section D: After calibration

Post calibration procedure

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

cedure is intended to verify that all calibration positions are correct.

Procedure


1. Run the calibration home position program twice.

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

Detailed in "Checking the calibration position".

2. Check all calibration positions. Detailed in "Checking the calibration position".

3. Repeat the check as above.

4. Adjust the calibration marks when the calibra-tion is done.

Shown in section "Cor-rect orientation of axes".

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

6. Remove any calibration equipment from the manipulator.


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232 - 3HAC 16638-1

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Index

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3HAC 16638-1 233
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Index

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234 3HAC 16638-1

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

IRB 940 Tricept™


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

-


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Table of Contents

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Overview 1 Product Documentation, IRB 940 Tricept™ 3








Chapter 3: Manipulator 21

Introduction 21

Section A: Manipulator repairs 22Removal of actuator, including motor 22Refitting of actuator, including motor 27Removal of servomotor, axes 1-3 34Refitting of servomotor, axes 1-3 38Removal of servomotor, axis 4 43


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Refitting of servomotor, axis 4 49Removal of lower joint 55Refitting of lower joint 58Removal of wrist 62Refitting of wrist 67Removal of center unit 72Refitting of center unit 77Removal of spiral cable 82Refitting of spiral cable 85

Section B: Distribution box repairs 89Replacement of battery, distribution box 89Replacement of serial measurement card, distribution box 92Replacement of brake release card, distribution box 95

Chapter 4: Controller 99

Introduction 99Putting the computer unit in the service position 100Replacement of air filter, controller 103Replacement of battery unit, controller 106Replacement of I/O and gateway units 109Replacement of bleeder resistor 113Replacement of mass storage memory 116Replacement of internal cooling fan 120Replacement of drive units and rectifier 125Replacement of system fan unit 129Replacement of power supply unit 132

Chapter 5: Circuit Diagram, IRB 940 Tricept™ 135

Introduction 135=M1/2, Potentials from control 136=M1/3, Axis 1 137=M1/4, Axis 2 138=M1/5, Axis 3 139=M1/6, Axis 4 140=M1/7, Axis 5 141=M1/8, Axis 6 142=M1/9, Serial Measure board, Earth connections 143=M/10, Brake release unit 144

144


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Chapter 6: Circuit Diagram, S4Cplus 145

Introduction 145

System 1: General information 146Sheet 1-1. Block Diagram 146Sheet 1-2. View of Control Cabinet 147Sheet 1-3. View of Control Cabinet 148Sheet 1-4. Designation 149Sheet 1-5. Designation 150

System 2: Mains Connection and Power Supply 151Sheet 2-1. Mains Connection 151Sheet 2-2. Transformer Unit 152Sheet 2-3. Power Supply 153Sheet 2-4. Power Supply 154Sheet 2-5. External transformer unit 200-500V IRB6600/7600 155Sheet 2-6. Transformer unit 400-475V IRB 6600/7600 156

System 3: Computer Unit and Connector Unit 157Sheet 3-1. Block Diagram/Computer Unit 157Sheet 3-2. Cabling in Computer Unit 158Sheet 3-3. Main Computer and Hard Disk / Flash Disk Drive 159Sheet 3-4. Compute Cooling 160Sheet 3-5. Base Connector Board and I/O Computer 161Sheet 3-6. Connector Board and I/O Computer 162Sheet 3-7. Connector Board and Axis Computer 163Sheet 3-8. Base Connector Unit 164Sheet 3-9. Connector Plate on Controller Panel 165

System 4: Emergency Stops and Run Chain 166Sheet 4-1. Emergency Stop 166Sheet 4-2. Run Chain 167Sheet 4-3. Run Chain 168Sheet 4-4. Power Unit Servo Disconnector 169

System 5: Drive System and Robot Cable 170Sheet 5-1. Block Diagram 170Sheet 5-2. Rectifier, Fans and Bleeder 171Sheet 5-3. Drive System Signal Connection 2 Drive Units 172Sheet 5-4. Drive System Signal Connection 3 Drive Units 173Sheet 5-5. Servo Drive Units / IRB 140 174Sheet 5-6. Servo Drive Units / IRB 340 175Sheet 5-7. Servo Drive Units / IRB 640, 840 176Sheet 5-8. Servo Drive Units / IRB 1400, 2400 177

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Sheet 5-9. Servo Drive Units / IRB 4400, 6400S/PE 178Sheet 5-10. Servo Drive Units / IRB 6400R 179Sheet 5-11. Control Cable IRB 140 180Sheet 5-12. Control Cable IRB 340, 1400 and 2400 181Sheet 5-13. Control Cable IRB 640, 840, 4400 and 6400S/PE 182Sheet 5-14. Control Cable IRB 6400R 183Sheet 5-15. Rectifier, fans and bleeder 184Sheet 5-16. Servo Drive System 185Sheet 5-17. Control cable 186

System 6: External axes 187Sheet 6-1. External axes 187Sheet 6-2. Axes Computer 2 and Connector Board 188Sheet 6-3. Expansion Board Axis Connector Board 189Sheet 6-4. Drive System Signal Connection External Axes 190Sheet 6-5. External axes no. 7th - 9th Control Signal Connection 191Sheet 6-6. Axis Computer 2 and Axis Connector Unit if External Axis Cabinet 192Sheet 6-7. Connection to External Axis Cabinet 193Sheet 6-8. Servogun-SMB power/signals cable 194

System 7: I/O Units and Field Bus Modules 195Sheet 7-1. I/O Unit Position 195Sheet 7-2. Digital Part of Combi I/O and Digital I/O Unit Input Part 196Sheet 7-3. Digital I/O Unit Output Part 197Sheet 7-4. Combi I/O Unit Digital and Analogue Output Part 198Sheet 7-5. Digital Input Part of 120V AC I/O Unit 199Sheet 7-6. Digital Output Part of 120V AC I/O Unit 200Sheet 7-7. Relay I/O Unit Input 1-16 201Sheet 7-8. Digital with Relays I/O Output 1-8 202Sheet 7-9. Digital with Relays I/O Output 9-16 203Sheet 7-10. Analogue I/O Unit 204Sheet 7-11. Remote I/O Unit For Allen Bradley PLC 205Sheet 7-12. Interbus-S Master/Slave - Interbus-S Master 206Sheet 7-13. Profibus DP SLave 207Sheet 7-14. Encoder Unit 208Sheet 7-15. Profibus DP Master/Slave 209Sheet 7-16. Interbus master/slave optical fibre and copper wire 210

System 8: Other options 211Sheet 8-1. Floppy Disk 211Sheet 8-2. Service Equipment Supply 212Sheet 8-3. External Connections System Signals 213Sheet 8-4. Position Switches on Manipulator 214

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Sheet 8-5. Customer Signals 215Sheet 8-6. Sustomer Power/SIgnal IRB 2400, 4400, 6400S/PE 216Sheet 8-7. Customer Cable Power/Signal/CAN IRB 6400R 217Sheet 8-8. External Control Panel 218Sheet 8-9. Extension Cable Teach Pendant 219Sheet 8-10. Time Relay 220Sheet 8-11. Customer Precess / Power / Signal / Profibus DP M/S 221Sheet 8-12. Optional customer power/signal Profibus IRB 6400R 222Sheet 8-13. LAN Ethernet connection 223Sheet 8-14. Customer power/CAN-BUS IRB 640/6400S 224Sheet 8-15. Customer cable power/signal CAN-BUS IRB 6600/7600 225Sheet 8-16. Customer cable power/signal Profibus IRB 6600/7600 226Sheet 8-17. Optional customer power/signal Profibus IRB 6400R 227

System 9: External Axis Cabinet 228Sheet 9-1. Block Diagram 228Sheet 9-2. View of External Axis Cabinet 229Sheet 9-3. Designation 230Sheet 9-4. Mains Connection 231Sheet 9-5. Transformer Unit 232Sheet 9-6. Power Supply, I/O Supply 233Sheet 9-7. Power Unit 234Sheet 9-8. Rectifier, Fans and Bleeder 235Sheet 9-9. Drive Unit Signal Connection 1 External Drive Unit 236Sheet 9-10. Drive Unit Signal Connection 2 External Drive Units 237Sheet 9-11. Drive Unit Signal Connection 3 External Drive Units 238Sheet 9-12. Drive Unit and Control Cable Drive Unit GT 239Sheet 9-13. Drive Unit and Control Cable Drive Unit GT+CCB 240Sheet 9-14. Drive Unit and Control Cable 241Sheet 9-15. Service Equipment Supply 242

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vi 3HAC 16640-1

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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.



• repair personnel in the user´s organization.

• repair personnel in other organizations.


• 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:

References

Chapter Contents

1. Safety

2. Reference information

3. Manipulator

4. Controller


Circuit diagrams, Manipulator Included in Repair Manual, 3HAC 16640-1


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Revisions

Circuit diagrams, Controller Included in Repair Manual, 3HAC 16640-1



- First edition


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Product Documentation, IRB 940 Tricept™





ters:

• Safety, Service


• Unpacking



• Start-up




• Calibration



• Safety, Service








• Safety, Service



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• Disposal




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Introduction



Sections The chapter "Safety, service" is divided into the following sections:
















• Brake testing





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ment.


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Related information


Documents





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Qualified personnel


Extraordinary risks



rectified manually.












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• The power unit


















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• - withstand any impact from a tool failure. Due to the high kinetic energy associated with HSM (High Speed Machining), a tool failure poses a seri-ous risk as any debris can cause serious personal injury. Both walls and ceilings must be designed and dimensioned so that they can withstand any projectiles that they may be subjected to. Windows must be made from suitable safety glass. Study the planned process to determine the forces involved and appropriate materials.



Fire extinguishing



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released.



Brake testing




below:






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16 - 3HAC 16640-1

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Introduction




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Screw joints




materials and does not apply to soft or brittle materials.





tables below:




M2.5 0.25

M3 0.5

M4 1.2

M5 2.5

M6 5.0




M5 6 - -

M6 10 - 17

M8 24 28 40

M10 47 55 70

M12 82 95 120


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M16 200 235 300





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Definition Within all repair and maintenance instructions, weights of the components han-

dled are sometimes specified. All components exceeding 22 kg (50 lbs) are high-

lighted in this way.






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Manipulator

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Chapter 3:Manipulator

Introduction

Definitions This chapter details all repair activities recommended for the manipulator, includ-

ing the manipulator´s distribution box.

It is made up of separate units, each detailing a specific repair activity, e.g.

Removal or Refitting of a certain component on the manipulator. Each unit con-

tains all information required to perform the activity, e.g. spare parts numbers,

required special tools and materials.

The chapter is divided into:

• Removal/refitting instructions for all the spare parts on the manipulator

• Replacement instructions for all the spare parts in the manipulators distri-bution box


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Section A: Manipulator repairs

Removal of actuator, including motor

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

xx0200000296

A

B

C

D

E

F


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Required equip-ment

xx0200000350

Safety Please read the following notations before the removal.

Please observe the following before commencing any repair work on the manipu-lator:

- Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them!

- Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot!

A Actuator

B Actuator servomotor

C Lower joint

D Actuator fork

E Center tube

F Wrist


Hook wrench 3 mm pin, shown in figure the below!

- Hook wrench with 3 mm pin


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- When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures.

- Before removing, clean the work area and the components to be removed. - Place the removed components in a clean container.


Preparatory work Follow the instructions below for preparatory work, before commencing to

remove an actuator.


1. Run the actuators to half way in length, and ensure all the actuators are of equal length. This is done in order to allow the actuator to retract when the lower joint is unscrewed.

2. Switch off the power supply.

3. The weight of an actuator is around 40kg (88lb). Before removal, the actuator must therefore be secured using straps, as the center unit will tend to move away from the corner with the removed actuator.

If the manipulator is vertically orientated, it is important to anchor the center tube to the sur-rounding equipment in order to prevent this. For other orientations, try to anticipate the movement and secure accordingly.



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Removal of actua-tor

The procedure below details how to remove an actuator, including the motor. The

procedure is the same for all actuators. Make sure the preparatory work above is

done before removing an actuator!


1. Remove the eletric cabling from the servo-motor located on the actuator to be removed. Move and secure the cabling so it can not get damaged during removal of the actua-tor.

2. Secure the actuator from above using straps from a hoist or from the forks of a fork lift.

3. Use a heating gun to loosen the thread-locking substance, before unscrewing the lower joint from the lower platform.

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


Specified above!

5. Unscrew the four attachment screws hold-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.


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Removal of motor The procedure below details how to remove the motor from a dismounted actua-

tor.


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

xx0200000302

• A: Servomotor

• B: Fixing screws (4 pcs)

• C: Toothed wheel ring

• D: Backlash-free coupling

2. Remove the servomotor from the actuator.

3. If the toothed wheel ring stays with the backlash-free coupling attached to the actuator (shown in the figure above), detach it and fit it to the coupling on the servomotor.

4. Remove the coupling from the actuator shaft.

A

B

CD


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Refitting of actuator, including motor

Location The actuators are located as shown in the figure below.

xx0200000296

A Actuator

B Actuator servomotor

A

B

C

D

E

F


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Required equip-ment

xx0200000350

Safety Please read the following notations before refitting.

Please observe the following before commencing any repair work on the manipu-lator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them!

C Lower joint

D Actuator fork

E Center tube

F Wrist


Actuator with motor 3HAC 17151-1

Thread-locking sub-stance

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

Hook wrench 3 mm pin



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- Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! - When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures.

Please observe the following when refitting components: - Carefully clean the mating surfaces.

- Ensure that there are no damaged surfaces or other parts that need rectifying or replacing.

- Replace all gaskets.


Refitting of motor In case the servomotor has been removed from the actuator, refit it as detailed in

procedure below.


1. Fit the backlash-free coupling onto the new actuator. Make sure the shaft lies flush with the coupling surface, as shown in figure to the right.

xx0200000303

• A: Actuator shaft

• B: 0mm

B

A


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Refitting of actua-tor

The procedure below details how to refit the actuator, including the motor. The

procedure is the same for all actuators.

2. Assemble the servomotor, back-lash-free coupling and the actu-ator. Tighten the fixing screws of the motor.

4 pcs; tightening torque: 24 Nm.

xx0200000302

• A: Servomotor



• D: Backlash-free coupling


A

B

CD


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.



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3. Push the actuator to the left so that it is flush with the left hand side of the fork, as shown with the arrow in figure to the right. The direction is the same for all three actuators.

xx0200000304

• A: Clamp

• B: Circlip

4. Adjust the circlip so that the actua-tor remains tight against the left hand side.

5. Fit the clamps and tighten the four hexagonal screws that hold the clamps.


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

xx0200000305

• A: Sealing cap


A

B

A


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Commissioning Follow the instructions below before commissioning after refitting an actuator.

When performing the first test run after a service activity (repair, installation or maintenance), it is vital that:

- all normal safety equipment is installed properly, e.g. TPU enabling device.

7. Refit the actuator by screwing the lower joint to the lower platform. Use normal thread-locking fluid.

Note that, as each turn of the lower joint will alter the length of the actuator by 10 mm, the actuator will be extended around 150 mm as the universal joint is screwed in.


8. Attach the supplied labels to the actuator and motor; the warning label close to the actuator fork and the appropriate axis label on the housing of the actuator.

9. Reconnect the cables to the servo-motor.



1. Check the manipulator and its surrounding equipment to ensure that all screws, nuts and bolts are tightened and that no foreign objects remain within the workspace.

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

Detailed in Installation Manual.

3. When the spare part replacements have been completed, ensure that the machine data folder is updated, specifying all details such as what has been replaced and when, part serial numbers and other related component data.


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- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind any safety fences, etc. - special attention is paid to the function of the part previously serviced.


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Removal of servomotor, axes 1-3

Location The servomotors of axes 1, 2 and 3 are located on top of the actuators, as shown

in the figure below.

xx0200000297

A Servomotors, axes 1-3

A A


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Required equip-ment


Please observe the following before commencing any repair work on the manipu-lator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them!- Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! - When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures.


Preparatory work Follow the instructions below for preparatory work, before commencing the

removal of a motor.


Circuit Diagram 3HAC 16640-1 Repair Manual, part 2


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


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


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

4. The actuator is free to turn when the servomotor is removed. If not correctly supported, the center unit will tend to move away from the corner with the removed actuator servomotor. In a vertically orien-tated manipulator, it is important to anchor the cen-ter tube to the surrounding equipment in order to prevent this. For manipulators in other orientations, try to antic-ipate the movement and secure accordingly.



1. Remove the eletric cabling from the servomotor. Move and secure the cabling so that it can not get damaged dur-ing the removal of the actuator.

2. Unscrew the four fixing screws that hold the servomotor to the actuator housing, as shown in the figure below.

3. Lift the servomotor straight up from the actuator.


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4. If the toothed wheel ring stays with the backlash-free coupling attached to the servomotor, detach it and fit it to the coupling on the actuator.

xx0200000302

• A: Servomotor



• D: Backlash-free coupling on servomotor shaft

5. Remove the coupling from the servomotor shaft.


A

B

CD


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Refitting of servomotor, axes 1-3

Location The servomotors of axes 1, 2 and 3 are located on top of the actuators, as shown


xx0200000297

A Servomotors, axes 1-3

A A


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Required equip-ment

Safety Please read the following notations before the refitting.





Please observe the following 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.


Servomotor, axes 1-3

3HAC 17152-1



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1. Fit the backlash-free coupling onto the new servomotor, ensuring that the shaft enters the coupling to a depth of 10 mm, as shown in figure to the right.

Spare part no. specified above!

xx0200000308

• A: 10 ±0.5 mm

A


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2. Assemble the servomotor, backlash-free coupling and the actuator. Tighten the fixing screws. Note! The brake performance is reduced if the servomotor shaft is pushed in too far into the actuator. Make sure there is a lash. Measure the dis-tance between the coupling and the contact surface, according to the figure to the right.

4 pcs; tightening torque: 24Nm.

xx0200000302

• A: Servomotor



• D: Backlash-free coupling on the servomotor shaft

xx0200000447

• A: Coupling on actuator shaft

• B: Coupling on servomotor shaft

• 79 mm, required distance between coupling and contact surface on actuator.

• 51 mm, required distance between coupling and contact surface on servomotor.

3. Reconnect the cables to the servomotor.


A

B

CD

79 51

A B


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Commissioning Follow the instructions below before commissioning after refitting motor on axes

1, 2 and 3.


- 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.







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Removal of servomotor, axis 4

Location The motor unit of axis 4 is located inside the center tube sleeve, at the lower part

of the center unit, as shown in the figure below.

xx0200000299

A Axis 4 motor unit (located beneath center tube sleeve)

B Center tube sleeve

C Spiral cable inspection cover

D Gimbal

E Lower platform

B

D

C

E

A


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Required equip-ment




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.


Lifting bracket

String Attach to the cabling to be able to feed it through the center tube while lifting.



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removal of the motor unit on axis 4.

Removal The procedure below details how to remove the motor unit on axis 4. Make sure

the preparatory work above is done before removing the actuator!


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.



1. Cut the straps and disconnect the cabling to axes 4, 5 and 6, at the top of the center tube. Also remove the cable guide for the cabling.

2. Remove the top plate of the center tube. The cabling underneath the lid is still attached! Remove the lid carefully!

See the figure below!

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


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

xx0200000306

• A: Top plate of center tube

• B: Cable connector holder

• C: Housing

• D: Lower plate

• E: Center tube

5. Fit the lifting tool to the center tube, ensuring that the cables can pass through the loop freely and not get caught.

6. Remove the spiral cable cover on the back of center tube sleeve. Remove also the spiral cable inspection cover.


ABC

D

E


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

xx0200000363

• A: 6 pcs: M8.

• B: 12 pcs: M6.

• C: Locating pin, center tube

• D: Locating pin, center tube sleeve

On reassembly the same locat-ing pin is refitted!

8. Lift the center tube, using a hoist or lift, until the bottom of the center tube almost reaches the gimbal. When lifting the center tube, be very careful not to stretch or squash the cables inside. Eliminate the risk of stretching the cabling by feeding it through at the top at the same rate as the center tube is lifted, with the help of a string.


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


C

D

A

B


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10. Remove the 12 screws that hold the center tube sleeve to the lower plat-form interface.

Remove the locating pin that positions the center tube sleeve.

Shown in the figure above! On reassembly the same locat-ing pin is refitted!

11. Lift the center tube sleeve, tilting the wrist slightly for increased accessibil-ity.

xx0200000307

• A: center tube sleeve

• B: Spacer

• C: Axis 4 motor unit

12. Make a note of the position of the motor unit.

13. Remove the spacer from the axis 4 motor unit.

14. Unscrew the 8 screws that attach the motor unit to the center shaft and remove the motor unit.

15. Check all surfaces to make sure they are free from damage and contamina-tion before proceeding with the assembly routine.


AB

C


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Refitting of servomotor, axis 4

Location The motor unit of axis 4 is located inside the center tube sleeve, at the lower part

of the center unit, as shown in the figure below.

xx0200000299

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

B Center tube sleeve


D Gimbal

E Lower platform

B

D

C

E

A


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Required equip-ment






Refitting The procedure below details how to refit the motor unit, axis 4.


Servomotor, axis 4 3HAC 17153-1

Lifting bracket



1. Fit the axis 4 motor unit to the center shaft and tighten the screws. Ensure it has the same orientation as the old one

8 pcs: tightening torque: 33 Nm.


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

xx0200000307

• A: Center tube sleeve

• B: Spacer

• C: Axis 4 motor unit

3. Refit the center tube sleeve, ensuring that the locating pin, center tube sleeve, has the correct orientation. Tighten the 12 screws that hold the sleeve.

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

4. Refit the cable clamp for the spiral cable. Ensure that the spiral cable runs freely 360°in either direction by manually turning the wrist and watching the cable through the inspection hole in the side of the center tube.

5. Align the fixing holes in the axis 4 motor unit to the holes in the center tube sleeve by turning the wrist.

6. Feed the cabling through the center tube (with the help of the string) and lower the center tube carefully in order not to squash the cables.


AB

C


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7. Locate the center tube using the loca-tion pin, center tube, as reference and fit the 18 screws.

xx0200000363

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

• B: 12 pcs: M6; tighten-ing torque: 17 Nm.

• C: Locating pin, center tube

• D: Locating pin, center tube sleeve

Make sure to refit the correct locating pin!

8. Refit the spiral cable inspection cover and the spiral cable cover, including their sealings.


9. Remove the lifting tool from the center tube.


C

D

A

B


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

xx0200000306

• A: Top plate

• B: Cable connector holder

• C: Housing

• D: Lower plate

• E: Center tube

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

12. Fit the top plate to the housing. Shown in the figure above!

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


ABC

D

E


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Commissioning Follow the instructions below before commissioning after refitting the motor, axis

4.









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Removal of lower joint

Location The lower joint is located between the actuator and the lower platform, as shown


xx0200000298

A Lower joint (beneath the cover)

B Lower platform

C Actuator

D Calibration spacer

A

B

A

C

D


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Required equip-ment

xx0200000350



- Before removing, clean the work area and the components to be removed.

- Place the removed components in a clean container.





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removal of the lower joint.

Removal The procedure below details how to remove a lower joint. The procedure is the

same for all actuators. Make sure the preparatory work above is done before sep-

arating the parts!


1. Run actuators to half way in length. All the actua-tors should also have an equal length.

This is done in order to allow the actuator to retract when the lower joint is unscrewed.


3. In a vertically orientated manipulator the center unit will tend to move away from the corner with the removed lower joint. It is therefor important to anchor the center tube to the surrounding equip-ment in order to avoid this. For manipulators in other orientations, try to anticipate the movement and secure accordingly.


1. Use a heating gun to loosen the thread-lock-ing substance, before removing the lower joint.

2. Loosen the actuator piston from the lower joint with the hook wrenches. The actuator is top heavy and will tend to swing, once disconnected at the bottom. Ensure that the actuator is well anchored.

Shown in the figure above! Specified above!

3. Loosen the lower joint from the lower platform using a hook wrench, 3 mm pin.


Specified above!

4. Remove the lower joint and the cover.

5. Remove the calibration spacer from the lower joint, in order to refit it onto the new joint!


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Refitting of lower joint

Location The lower joint is located between the actuator and the lower platform, as shown


xx0200000298

A Lower joint (beneath the cover)

B Lower platform

C Actuator

D Calibration spacer

A

B

A

C

D


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Required equip-ment

xx0200000350




Lower joint 3HAC 17154-1


e.g. Loctite 242. Used when secur-ing the lower joint to the lower platform.




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Refitting The procedure below details how to refit the lower joint. The procedure is the

same for all actuators.

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


1. Fit the calibration spacer and the cover 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 uni-versal joint is screwed in.



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



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3. When the spare part replacements have been completed, ensure that the machine data folder is updated, specifying all details such as what has been replaced and when, part serial num-bers and other related component data.



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Removal of wrist

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

xx0200000300

A Wrist

B Center tube


D Gimbal

E Center tube sleeve

F Lower platform

A

C

B

F

D

E

A


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Required equip-ment







The wrist weighs 36 kg! All lifting equipment used must be dimensioned accord-ingly!


Lifting bracket

Punch tool Used for the crossed roller bearing.

Lifting jack Stroke of at least 100 mm.


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removal of the wrist unit.


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.




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Removal The procedure below details how to remove the wrist. Make sure the preparatory

work above is done before removing the wrist!


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

xx0200000363

• A: Attachment screws, axis 4 motor to centre tube: 6 pcs, M8 x 60.

• B: Attachment screws

• C: Locating pin, centre tube

• D: Locating pin, centre tube sleeve

2. Remove the spiral cable cover on the back of centre tube sleeve and the spi-ral cable inspection cover on the same sleeve.


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

C

D

A

B


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4. Unscrew 10 of the 12 screws in the wrist flange that hold the wrist to the lower platform. Turn the wrist to access all the screws.Leave one screw at the front and one at the rear of the wrist, but ensure that they are both accessible for removal without having to turn the wrist.


5. Position the lifting jack underneath the wrist housing, in its extended position, so that it can lower the wrist at least 100 mm without being repositioned.

6. Remove the final two screws.

7. Lower the wrist gently until the screws that attach the centre shaft to the wrist are accessible. If the wrist appears to be stuck, it needs to be pressed out. Use two of the fixing holes for the wrist/lower plat-form joint, that are threaded M8 and lie 180°in relation to each other. Note! Turn the wrist so that these holes are not aligned with the M6 holes in the lower platform, as this will damage the threads and hamper assembly at a later stage. If possible, insert a metal shim to protect the sur-face of the lower platform flange.Insert two M8 bolts, with at least 40 mm of thread, into the holes, and pull the wrist off the lower platform.

xx0200000364

8. Remove the screws and lower the wrist while disconnecting the cabling.

Note! When removing the wrist: make sure it is lowered carefully, following the same orientation when mounted. If tilted, the interface of the wrist and the lower platform may be damaged!



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Refitting of wrist

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

xx0200000300

A Wrist

B Center tube


D Gimbal

E Center tube sleeve

F Lower platform

A

C

B

F

D

E

A


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Required equip-ment






The wrist weighs 36 kg! All lifting equipment used must be dimensioned accord-ingly!


Wrist 3HAC 17155-1

Punch tool Used for the crossed roller bearing.

Lifting jack Stroke of at least 100 mm.


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Refitting The procedure below details how to refit the wrist.


1. Replace the o-ring on the centre shaft with the new one that is included in the spare parts kit. Ensure that the o-ring is lubricated prior to fitment.

xx0200000367

2. Ensure that the jack is correctly posi-tioned underneath the lower platform, and that it is in its lowest position. Place the wrist on the jack.

3. Reconnect the cabling.

4. Elevate the wrist with the jack and guide it so that it fits onto the centre shaft. Ensure that the cabling is guided into the correct position and does not get jammed. Note! Make sure the wrist is elevated in the same direction that the centre tube is pointing, so that the interfaces are not damaged!

5. Attach the centre shaft to the wrist using the 12 screws.



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Commissioning Follow the instructions below before commissioning after refitting.

6. Lift the wrist with the jack until it is possi-ble to fasten the attachment screws through the wrist flange into the lower platform. Press the wrist to its topmost position by tightening two of the attach-ment screws, 180°in relation to each other. Check that the bearing runs smoothly by turning the wrist manually.

12 pcs; tightening torque: 10 Nm. Shown in the figure above!

7. Refit the spiral cable clamp and ensure that the spiral cable twists freely through-out the ±360°of the axis 4 rotation.

It must not catch or have any tendency to rub or over-tighten, as this will drastically shorten the life of the cable.

8. Align the holes in the centre tube sleeve with the holes in the axis 4 motor unit by turning the wrist.


9. Fit the six M8 screws. Tighten them as detailed to the right.

6 pcs: M8; tightening torque: 40 Nm.

10. Refit the spiral cable cover and the spiral cable inspection cover with their seal-ings.





2. Recalibrate the robot.

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



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Removal of center unit

Location The center unit includes the center tube, wrist, spiral cable, linear guide and axis

4 motor unit. It is located in the center of the manipulator, as shown in the figure

below. When removed, the housing and the gimble is left mounted on the center

unit, as shown in the figure below.

xx0200000301

A Center unit F Lower joint

B Wrist unit G Upper platform

C Center tube H Gimbal

D Axis 4 motor unit (inside center tube sleeve)

I Linear guide

E Lower platform

B

D

C

G

E

F

H

I

A


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Required equip-ment

xx0200000350





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





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removal of the center unit.

Removal The procedure below details how to remove the center unit. Make sure the prepa-

ratory work above is done before removal!


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.




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


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2. Secure the center unit with a strap attached to a hoist or lift. Fasten the strap around the body of the center tube just below the upper housing so that it hangs well balanced, in such a way that the center unit will be easy to handle. Note! The center unit weighs over 100 kg and must be secured properly when the gim-bal and actuator joints are dis-connected as the unit will tend to move suddenly as it is top heavy.

xx0200000365

3. Use a heating gun at the lower joint, to loosen the thread-lock-ing substance before removing the joint.

4. Remove the actuators from the lower platform by disconnect-ing the lower joints from the lower platform using the hook wrench. Note! The actuators are top heavy and will turn when released from the lower plat-form. Ensure that they are fas-tened before releasing them after removal.

Shown in the figure above! Specified above!



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5. Remove the center unit from the upper platform by removing the 4 attachment screws, located as shown in the figure to the right.Note! The gimbal weighs approximately 20 kg, be careful when removing the attachment screws!


xx0200000309

• A: Attachment screws that hold the gimbal to the upper plat-form (4 pcs)

6. Lower the gimbal to the bottom of the run of the linear guides so that it rests securely. Secure it to the center unit so that it does not turn or move suddenly when the center unit is released.


7. Lower the center unit with the hoist.


A A


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Refitting of center unit

Location The center unit includes the center tube, wrist and axis 4 motor unit. It is located

in the center of the manipulator, as shown in the figure below. When removed, the

housing and the gimble is left mounted on the center unit, as shown in the figure

below.

xx0200000301

A Center unit F Lower joint

B Wrist G Upper platform

C Center tube H Gimbal

D Axis 4 motor unit (inside center tube sleeve)

I Linear guide

E Lower platform

B

D

C

G

E

F

H

I

A


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Required equip-ment

xx0200000350




Center Unit 3HAC 17156-1


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



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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.


1. Lift the center unit in posi-tion with the hoist.

2. Insert the four screws that hold the gimbal to the upper platform, but do not tighten them. Just screw them in to the point where it is still pos-sible to move the gimbal in relation to the upper plat-form.



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3. Push the gimbal to the left (as seen when facing the front of the robot) so that the surfaces of the master lie flush, as shown in the figure to the right.

xx0200000310

• A: center unit

• B: Gimbal

• C: Upper platform

• D: Master

• E: Direction for pushing the gimbal

4. Tighten the 4 screws. 4 pcs; tightening torque: 40 Nm.

5. Refit the actuators by screwing the lower joint of each actuator to the lower platform, with the hook wrench and using normal thread-locking fluid.

Note that, as each turn of the lower joint will alter the length of the actuator by 10 mm, the actuator will be extended around 150 mm as the universal joint is screwed in.



AB

C

D

E


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

When performing the first test run after a service activity (repair, installation or maintenance), it is vital that: - all normal safety equipment is installed properly, e.g. TPU enabling device.

- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind any safety fences, etc.

- special attention is paid to the function of the part previously serviced.







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Removal of spiral cable

Location The spiral cable is located inside the center tube, running from the top of the

manipulator to the wrist unit.

xx0200000312

A Spiral cable

B Spiral cable inspection cover

C Wrist unit

B

C

A


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Required equip-ment










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removal of the spiral cable.

Removal The procedure below details how to remove the spiral cable. Make sure the pre-

paratory work above is done before removal!


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.



1. Remove the axis 4 motor unit. Detailed in Removal of ser-vomotor, axis 4.

2. Remove the wrist unit. Detailed in Removal of wrist unit.

3. Remove the cable clamp that holds the spiral cable to the center shaft and remove the spiral cable.


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Refitting of spiral cable

Location The spiral cable is located inside the center tube, running from the top of the

manipulator down to the wrist unit.

xx0200000312

A Spiral cable

B Spiral cable inspection cover

C Wrist unit

B

C

A


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Required equip-ment



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.



Spiral Cable 3HAC 17157-1




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Refitting The procedure below details how to refit the spiral cable.

Commissioning Follow the instructions below before commissioning after refitting the spiral cable

and wrist unit.


1. Fit the new spiral cable and refit the cable clamp that holds the spi-ral cable to the centre shaft.

Make sure that the spiral cable is properly attached so that it can not run up and down on the shaft. Press down the spiral cable so that the first bend is tightly secured against the upper surface of the shaft as shown in the figure to the right!


xx0200000366

2. Refit the wrist unit. Detailed in Refitting of wrist unit.

3. Refit the axis 4 motor unit. Detailed in Refitting of servomotor, axis 4.




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When performing the first test run after a service activity (repair, installation or maintenance), it is vital that: - all normal safety equipment is installed properly, e.g. TPU enabling device.

- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind any safety fences, etc.

- special attention is paid to the function of the part previously serviced.






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ManipulatorDistribution box repairs

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Section B: Distribution box repairs

Replacement of battery, distribution box

Location The battery is located in the distribution box as shown in the figure below.

xx0200000394

A Serial measurement card

B Battery

A B


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Required equip-ment

Safety Please read the following notations before the replacement.

Please observe the following before commencing any repair work on the controller or units connected to the controller: Turn off all electric power supply to the cabinet! Many components inside the cabinet or inside any external units are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!

Removal The procedure below details how to remove the battery from the distribution box.


Battery 4944026-4


1. Note the position of the battery and cable ties. Shown in the figure above!

2. Remove the battery connector connecting the battery to the serial measurement circuit board.

3. Cut the two cable ties and remove the battery. The battery must be disposed of through the appropriate recycling channels.


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Refitting The procedure below details how to refit the battery to the distribution box.


1. Place the new battery on top of the serial measurement card cover.

Part no. specified above!Shown in the figure above!

2. Use cable ties to fix the battery.

3. Connect the electrical connector.


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Replacement of serial measurement card, distribution box

Location The serial measurement card is located in the distribution box as shown in the

figure below.

xx0200000394

A Serial measurement card

B Battery

A B


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Required equip-ment



Removal The procedure below details how to remove the serial measurement card from the

distribution box.


Serial Measurement card 3HAC 14505-1


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.


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Refitting The procedure below details how to refit the serial measurement card to the dis-

tribution box.


1. Fit the battery to the new serial measurement card.

Part no. specified above!


2. Carefully fit the card and the battery in place.

3. Refit the three screws holding the serial mea-surement card and the battery to the enclosure.

4. Refit the four electrical connectors.


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Replacement of brake release card, distribution box

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

below.

xx0200000393

A Brake release card

B Brake release buttons

A B


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Required equip-ment



Removal The procedure below details how to remove the brake release card from the dis-

tribution box.


Brake Release card 3HAC 0017-1


1. Remove the three electrical connectors attached to the brake release card.

2. Remove the four screws holding the card to the enclosure.

3. Remove the brake release card. Shown in the figure above!


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Refitting The procedure below details how to refit the brake release card to the distribution

box.


1. Carefully fit the new brake release card in place.

Part no. specified above!Shown in the figure above!

2. Refit the four screws holding the brake release card to the enclosure.

3. Replace the three electrical connectors.

Note! It is very important that all screening is reconnected correctly in order to achieve maximum performance from the equipment.


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98 - 3HAC 16640-1

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Controller repair

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Chapter 4:Controller

Introduction

Definitions This chapter details all repair activities recommended for the controller.

It is made up of separate units, each detailing a specific repair activity, e.g.

Removal or Refitting of a certain component in the controller. Each unit contains

all information required to perform the activity, e.g. spare parts numbers, required

special tools and materials.

The chapter is divided into:

• Removal instructions for all components

• Refitting instructions for all components

• Remaining instructions


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Putting the computer unit in the service position

Location of com-puter unit

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

xx0200000105

Opening The procedure below details how to open the computer unit.

Please observe the following before commencing any repair work on the manipu-lator: - Motors and gears are HOT after running the robot! Burns may result from touch-

ing the motors or gears!- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! - Take any necessary measures to ensure that the manipulator does not collapse

as parts are removed, e.g. securing the lower arm with fixtures before removing motor, axis 2.

A Computer unit

A


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Controller repair

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1. Make sure the ESD-wrist band is worn and connected to ground.

2. Disconnect all connectors/cables and make sure they do not obstruct pulling the computer unit out.

3. Unscrew the transport locks in both corners of the com-puter unit. This is done by turning the screw two turns (see position 1 in the figure) and pushing the lock wash-ers towards the screw (see position 2). xx0200000016

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

xx0200000017

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

See the figure above!

12

1

2


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Closing The procedure below details how to close the computer unit.


- Motors and gears are HOT after running the robot! Burns may result from touch-ing the motors or gears!

- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! - Take any necessary measures to ensure that the manipulator does not collapse

as parts are removed, e.g. securing the lower arm with fixtures before removing motor, axis 2.

6. Pull the computer unit out of the cabinet until it locks in its end position. Then swing it to the left as shown in the figure.

xx0200000018

7. If work is to be performed on the computer unit while in the service position, it must be locked in this position. This is done by placing the puck (located on the lower left side) on the metal bar. Alternatively, the computer unit may be lifted straight up and placed on a work bench.



1. Swing the computer unit back into position and secure it.

See the figure above! Also see the procedure above!


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Controller repair

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Replacement of air filter, controller

Location of air fil-ter

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

xx0200000284

Required equip-ment

A Air filter magazine

A A


Air filter 3HAB 8028-1


These proce-dures include ref-erences to the tools required.


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Removal, air filter The procedure below details how to remove the air filter.

Refitting, air filter The procedure below details how to refit the air filter.


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

xx0200000001

2. Unlock the lower springs. Lower the magazine and remove.

3. Remove the old filter by releasing the lock shackle and lifting it.

Note! In cases of less contamina-tion, the air filter may be cleaned and refitted. The procedure for this is detailed in section "Clean-ing the air filter, controller" in the Maintenance Manual.

xx0200000003

1

2


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


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2. Fit the spring at the top of the air filter magazine into the cabinet door and push upwards inwards.

Push until the lower springs snap into the cabinet door.

xx0200000006



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Replacement of battery unit, controller

Location of bat-tery unit

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

xx0200000103

Required equip-ment

A Battery unit

A

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

Battery unit 3HAC 5393-2 To be replaced as a complete unit


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Controller repair

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Removal, battery unit

The procedure below details how to remove the battery unit.

Please observe the following before commencing any repair work on the controller: Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!





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

xx0200000004

2. Pull the battery unit out.

X3

X2

X1

X2 X2 X2

X1 X1 X1


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Refitting, battery unit

The procedure below details how to refit the battery unit.


3. Disconnect the three cables from the battery unit.

xx0200000005



1. Place the battery unit close to its position. Art. no. specified above! See illustration above!

2. Reconnect the cables and push the unit into position.

See illustration above!

3. Secure it with the attachment screws. See illustration above!


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Replacement of I/O and gateway units

Location of I/O and gateway units

The I/O and gateway units are located as shown in the figure below.

xx0200000009

A I/O and gateway units located beneath the top cover of the cabinet

B Four available slots for I/O and gateway units

A

B


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Required equip-ment

Removal The procedure below details how to remove an I/O or gateway board.


Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!


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


1. Disconnect any connec-tors from the unit. Note which connector goes where, to facilitate reas-sembly.

The actual number of connectors vary depending on type of unit.


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Controller repair

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Refitting The procedure below details how to refit an I/O or gateway board.


2. Lift the unit until the upper claw, that holds the unit to the rail, is released. Use:

• a screwdriver when replacing I/O units (posi-tion 2a in the fig-ure).

• by hand when replacing a gate-way unit (posi-tion 2b in the figure).

xx0200000010

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


1

1

2a 3a

3b2b


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


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Controller repair

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2. Reconnect all connectors disconnected during removal.



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Controller repair

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Replacement of bleeder resistor

Location of bleeder resistor

The bleeder resistor is located behind the drive units, as shown in the figure below.

xx0200000007

A Drive units

B Bleeder resistor unit

C System fan unit

D Rectifier (drive unit)

E Power supply unit


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Required equip-ment

Removal The procedure below details how to remove the bleeder resistor.

Please observe the following before commencing any repair work on the controller: Turn off all electric power supplies to the cabinet!

Many components inside the cabinet are sensitive to ESD (ElectroStatic Dis-charge) and will be destroyed if subjected to it!

Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!


Bleeder resistor 3HAC 4560-5


1. Swing the power supply unit out of the way.

Detailed in section "Replacement of power supply unit".

2. Remove the drive units. Detailed in section "Replacement of drive units and rectifier".

3. Disconnect the cable secured on top of the bleeder resistor unit (see position 1 in the fig-ure).

xx0200000015

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

2

1

0

2

1

0


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Refitting The procedure below details how to refit the bleeder resistor.




1. Fit the bleeder resistor into position and secure it with the spring.

Art. no. specified above! Also see the figure above!

2. Secure the cable disconnected during disas-sembly.

3. Refit the drive unit. Detailed in section "Replacement of drive units and rectifier".

4. Swing the power supply unit back into posi-tion.

Detailed in section "Replacement of power supply unit".


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Replacement of mass storage memory

Location of mass storage memory

The mass storage memory is located in the computer system, which is shown in

the figure below.

xx0200000105

Required equip-ment

A Computer system

A


Mass storage memory, 64 MB

3HAC 7519-2

Mass storage memory, 128 MB

3HAC 7519-3


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Controller repair

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Removal The procedure below details how to remove the mass storage memory.







1. Put the computer unit in the service position.

Detailed in section "Putting the com-puter in the service position".

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

xx0200000019

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

See figure above!

3

42

1


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Refitting The procedure below details how to refit the mass storage memory.


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

See figure above!



1. Fit the mass storage mem-ory in position and secure it with its M4 attachment screws (items 3 and 4 in the figure)

Art. no. is specified above!

xx0200000019

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


3

42

1


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Controller repair

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


4. Put the computer system back in its regular operation position.

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



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Replacement of internal cooling fan

Location of inter-nal cooling fan

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

figure below.

xx0200000105

Required equip-ment

A Computer system

A


Internal cooling fan 3HAC 6655-1 Two fans required




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Controller repair

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Removal The procedure below details how to remove the internal cooling fan.




1. Put the computer unit in the ser-vice position.

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


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Refitting The procedure below details how to refit the internal cooling fan.



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

xx0200000020

• A: Upper fan

• B: Lower fan

• C: Locking tabs

• D: Connector E5

• E: Connector E6

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



A

CD

E

B


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Controller repair

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1. Tip the internal cooling fan with its top towards the cabinet wall and fit it into the hole (see the figure).

Art. no. specified above!

xx0200000021

• A: Push direction

2. With the wall between the upper lock spring hooks, push the fan unit upward and inward until the locking tab snaps to the wall.


A

A


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3. Reconnect the connector E5 or E6 respec-tively, depending on which fan was replaced.

4. Put the computer unit back in the regular operation position.

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



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Replacement of drive units and rectifier

Location of drive units and rectifier

The drive units and rectifier are located as shown in the figure below.

xx0200000007

A Drive units


C System fan unit


E Power supply unit


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Required equip-ment

Removal The procedure below details how to remove the drive units.




Drive unit (rectifier) 3HAB 8101-17 DSQC 545A

Drive unit, axes 1-6 3HAB 8101-18 DSQC 546A




1. Swing the power supply unit out of the way.

Detailed in section "Replacement of power supply unit"


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Controller repair

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

xx0200000013

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

See figure above!

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

xx0200000014

5. Tip it out and remove it (see position 4 in the fig-ure).

See figure above!


1

1

2

3 4


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Refitting The procedure below details how to refit the drive units.




1. Fit the unit into position and secure it with the spring.

Also see figure above!

2. Refit the power bar in front of the unit.

3. Reconnect all connectors X1 and X2.

4. Swing the power supply unit back into position. Detailed in section "Replacement of power supply unit"


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Replacement of system fan unit

Location of sys-tem fan unit

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

xx0200000007

A Drive units


C System fan unit


E Power supply unit


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Required equip-ment

Removal The procedure below details how to remove the system fan unit.




System fan unit 3HAC 12924-2




1. Remove the bleeder resistor unit.

Detailed in "Replacement of bleeder resistor" in the Repair Manual.

2. Disconnect the cable (see position 1 in the figure).

xx0200000008

221

1


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Refitting The procedure below details how to refit the system fan unit.



3. Pull the back of the system fan unit upwards to free it and then tip it out of the enclosure (see posi-tion 2 in the figure).



1. Fit the system fan unit into position and 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.


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Replacement of power supply unit

Location of power supply unit

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

xx0200000011

Required equip-ment

A Power supply unit locking spring (view from front)

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

B

A


Power supply unit 3HAB 4297-1 DSQC 506




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Removal The procedure below details how to remove the power supply unit.




1. Push the power supply unit locking spring down to release the power sup-ply unit.


2. Swing the unit out of the cabinet.

Shown in figure above

3. Remove the cable straps on top of the power sup-ply unit (see position 1 in the figure).

xx0200000012

4. Disconnect the cables at the back of the unit (see position 2 in the figure).

5. Remove the screw (see position 3 in the figure).

2


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Refitting The procedure below details how to refit the power supply unit.


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



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).


2. Reconnect all connectors disconnected during removal (see position 2 in figure).

3. Secure the cables on top of the unit with new cable straps (see position 1 in figure).

4. Swing the unit back into the cabinet and secure it with the locking spring.


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Circuit Diagram, IRB 940 Tricept™

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Chapter 5:Circuit Diagram, IRB 940 Tricept™

Introduction

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

3HAC 16640-1 - 135


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

3HAC 16640-1 -

en02

0000

0410

+EC

1c

on

tac

tR

1 M

P

+EC

1c

on

tac

tR

1 SM

B


=M1/

2, P

ote

nti

als

fro

m c

on

tro

l

136

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

3HAC 16640-1 -

en02

0000

0411

-R1M

PA

1

-XM

1A

-XM

1.1

A

A2

B B

D6

A3

C C

A4

D D

D8

A5

E E

A6

F F

D10

PE

-XTP

EP

E G G

PE

PE H H

PE

PE

PE

PE

C3

J J

C1

K K

L L

M M

-XP

1-4

2

-XR

1A

-XR

1.1

A

14 B B

3 C C

15 D D

6 E E

18 F FG

4.3

+EC

14.

0

+M

1M

oto

r a

xis

1C

E

-SM

B9.

5Se

rial

me

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ring

bo

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Re

solv

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AW

G16

gre

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11

23

45

6

AW

G16

yel/

gr

AW

G16

yel/

gr

PE1

AW

G20

blu

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78

AW

G20

blu

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910

AW

G22

blu

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1

R2.

SMB1

-4

Ï-R

T1-Y

1M 3

UV

W PE

+ -

CE

CE


=M1/

3, A

xis

1

137

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3HAC 16640-1 -

en02

0000

0412-R

1MP

A7

-XM

2A

-XM

2.1

A

A8

B B

A9

C C

A10

D D

A11

E E

A12

F F

-XTP

EP

E G G

PE H H

C5

J J

C4

K K

L L

M M

-XP

1-4

4

-XR

2A

-XR

2.1

A

16 B B

5 C C

17 D D

7 E E

19 F FG

3.4

5.3

+EC

13.

0

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me

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solv

er 2

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G16

gre

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21

23

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6

PE1

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yel/

gr

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blu

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78

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910

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2M 3

UV

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+ -

CE

CE


=M1/

4, A

xis

2

138

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3HAC 16640-1 -

en02

0000

0414

-R1M

PA

13

-XM

3A

-XM

3.1

A

A14

B B

C13

A15

C C

A16

D D

C14

B1 E E

B2 F F

C15 -XTP

EP

E G G

PE H H

C7

J J

C6

K K

L L

M M

-XP

1-4

9

-XR

3A

-XR

3.1

A

21 B B

10 C C

22 D D

8 E E

20 F FG

4.3

6.3

+EC

13.

0

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-SM

B9.

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me

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bo

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solv

er 3

AW

G16

gre

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31

23

45

6

PE1

AW

G16

yel/

gr

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AW

G20

blu

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78

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blu

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910

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UV

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+ -

CE

CE


=M1/

5, A

xis

3

139

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3HAC 16640-1 -

en02

0000

0415

-R1M

PB3

-XM

4A

-XM

4.1

A

-XM

TR4

1

D11

B4 C C 2

D12

B5 E E 3

D13

-XTP

EP

E G G 4

C9

J J 8

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K K 9

L L 5

M M 6

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2

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12

14 B B 13

3 C C 15

15 D D 14

6 E E 11

18 F F 10

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13.

0

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6, A

xis

4

140

www.cadfamily.com


3HAC 16640-1 -

en02

0000

0416

-R1M

PB7

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5A

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5.1

A

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61

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621

16 B B 22

5 C C 24

17 D D 23

7 E E 20

19 F F 19

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0

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=M1/

7, A

xis

5

141

www.cadfamily.com


3HAC 16640-1 -

en02

0000

0417

-R1M

PB9

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6A

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6.1

A

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65

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C C 6

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10 C C 33

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8 E F 29

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=M1/

8, A

xis

6

142

www.cadfamily.com

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

3HAC 16640-1 -

en02

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0418

R1M

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1D

3

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=M1/

9, S

eria

l Mea

sure

bo

ard

, Ear

th c

on

nec

tio

ns

143

www.cadfamily.com

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

3HAC 16640-1 - 144

=M1/

10 B

rake

rel

ease

un

it

en02

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65

43

21

AW

G16

blu

e


www.cadfamily.com

Circuit Diagram, S4Cplus

wwwThe

Chapter 6:Circuit Diagram, S4Cplus

Introduction

DefinitionsThis chapter contains the circuit diagram for the controller S4Cplus. The chapter is divid-ed into the separate systems..

3HAC 16640-1 - 145


www.cadfamily.com

Circuit Diagram, S4Cplus - Sheet 1-1.

wTh

Sys

tem

1:

Gen

eral

info

rmat

ion

Sh

eet

1-1.

Blo

ck D

iag

ram

3HAC 16640-1 - 146ww.cadfamily.com EMail:[email protected] document is for study only,if tort to your rights,please inform us,we will delete

www.cadfamily.com


wTh

Sh

eet

1-2.

Vie

w o

f C

on

tro

l Cab

inet


www.cadfamily.com


wTh

Sh

eet

1-3.

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www.cadfamily.com


wTh

Sh

eet

1-4.

Des

ign

atio

n


www.cadfamily.com


wTh

Sh

eet

1-5.

Des

ign

atio

n


www.cadfamily.com


wTh

Sys

tem

2:

Mai

ns

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nn

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on

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d P

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up

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Mai

ns

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on


www.cadfamily.com


wTh

Sh

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2-2.

Tra

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nit


www.cadfamily.com


wTh

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2-3.

Po

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ly


www.cadfamily.com


wTh

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2-4.

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www.cadfamily.com


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www.cadfamily.com


wTh

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www.cadfamily.com


wTh

Sys

tem

3:

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mp

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www.cadfamily.com


wTh

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www.cadfamily.com


wTh

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www.cadfamily.com


wTh

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mp

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www.cadfamily.com


wTh

Sh

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3-5.

Bas

e C

on

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www.cadfamily.com


wTh

Sh

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3-6.

Co

nn

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www.cadfamily.com


wTh

Sh

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www.cadfamily.com


wTh

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3-8.

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www.cadfamily.com


wTh

Sh

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3-9.

Co

nn

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www.cadfamily.com


wTh

Sys

tem

4:

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n C

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Sh

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Em

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www.cadfamily.com


wTh

Sh

eet

4-2.

Ru

n C

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www.cadfamily.com


wTh

Sh

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4-3.

Ru

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www.cadfamily.com


wTh

Sh

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4-4.

Po

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it S

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con

nec

tor


www.cadfamily.com


wTh

Sys

tem

5:

Dri

ve S

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m a

nd

Ro

bo

t C

able

Sh

eet

5-1.

Blo

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ram


www.cadfamily.com


wTh

Sh

eet

5-2.

Rec

tifi

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ans

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Ble

eder


www.cadfamily.com


wTh

Sh

eet

5-3.

Dri

ve S

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m S

ign

al C

on

nec

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n 2

Dri

ve U

nits


www.cadfamily.com


wTh

Sh

eet

5-4.

Dri

ve S

yste

m S

ign

al C

on

nec

tio

n 3

Dri

ve U

nits


www.cadfamily.com


wTh

Sh

eet

5-5.

Ser

vo D

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its /

IRB

140


www.cadfamily.com


wTh

Sh

eet

5-6.

Ser

vo D

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its /

IRB

340


www.cadfamily.com


wTh

Sh

eet

5-7.

Ser

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its /

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640

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www.cadfamily.com


wTh

Sh

eet

5-8.

Ser

vo D

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its /

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140

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400


www.cadfamily.com


wTh

Sh

eet

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440

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400S

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www.cadfamily.com


wTh

Sh

eet

5-10

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vo D

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its /

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640

0R


www.cadfamily.com


wTh

Sh

eet

5-11

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140


www.cadfamily.com


wTh

Sh

eet

5-12

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0 an

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www.cadfamily.com


wTh

Sh

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5-13

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www.cadfamily.com


wTh

Sh

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5-14

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www.cadfamily.com


wTh

Sh

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5-15

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www.cadfamily.com


wTh

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www.cadfamily.com


wTh

Sh

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5-17

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www.cadfamily.com


wTh

Sys

tem

6:

Ext

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al a

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Sh

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Ext

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www.cadfamily.com


wTh

Sh

eet

6-2.

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ter

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d C

on

nec

tor

Bo

ard


www.cadfamily.com


wTh

Sh

eet

6-3.

Exp

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on

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s C

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nec

tor

Bo

ard


www.cadfamily.com


wTh

Sh

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6-4.

Dri

ve S

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m S

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nec

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n E

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www.cadfamily.com


wTh

Sh

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6-5.

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on

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l Sig

nal

Co

nn

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on


www.cadfamily.com


wTh

Sh

eet

6-6.

Axi

s C

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pu

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Co

nn

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et


www.cadfamily.com


wTh

Sh

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6-7.

Co

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Ext

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www.cadfamily.com


wTh

Sh

eet

6-8.

Ser

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als

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le


www.cadfamily.com


wTh

Sys

tem

7:

I/O U

nits

an

d F

ield

Bu

s M

od

ule

s

Sh

eet

7-1.

I/O

Un

it P

osi

tio

n


www.cadfamily.com


wTh

Sh

eet

7-2.

Dig

ital P

art

of

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mb

i I/O

an

d D

igita

l I/O

Un

it In

pu

t P

art


www.cadfamily.com


wTh

Sh

eet

7-3.

Dig

ital I

/O U

nit

Ou

tpu

t P

art


www.cadfamily.com


wTh

Sh

eet

7-4.

Co

mb

i I/O

Un

it D

igita

l an

d A

nal

og

ue

Ou

tpu

t P

art


www.cadfamily.com


wTh

Sh

eet

7-5.

Dig

ital I

np

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Par

t o

f 12

0V A

C I/

O U

nit


www.cadfamily.com


wTh

Sh

eet

7-6.

Dig

ital O

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Par

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C I/

O U

nit


www.cadfamily.com


wTh

Sh

eet

7-7.

Rel

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www.cadfamily.com


wTh

Sh

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7-8.

Dig

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www.cadfamily.com


wTh

Sh

eet

7-9.

Dig

ital w

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Rel

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utp

ut

9-16


www.cadfamily.com


wTh

Sh

eet

7-10

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alo

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it


www.cadfamily.com


wTh

Sh

eet

7-11

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Un

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www.cadfamily.com


wTh

Sh

eet

7-12

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r


www.cadfamily.com


wTh

Sh

eet

7-13

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www.cadfamily.com


wTh

Sh

eet

7-14

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www.cadfamily.com


wTh

Sh

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7-15

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www.cadfamily.com


wTh

Sh

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www.cadfamily.com


wTh

Sys

tem

8:

Oth

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on

s

Sh

eet

8-1.

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y D

isk


www.cadfamily.com


wTh

Sh

eet

8-2.

Ser

vice

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t S

up

ply


www.cadfamily.com


wTh

Sh

eet

8-3.

Ext

ern

al C

on

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ns

Sys

tem

Sig

nal

s


www.cadfamily.com


wTh

Sh

eet

8-4.

Po

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www.cadfamily.com


wTh

Sh

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8-5.

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sto

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Sig

nal

s


www.cadfamily.com


wTh

Sh

eet

8-6.

Su

sto

mer

Po

wer

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nal

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240

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400,

640

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www.cadfamily.com


wTh

Sh

eet

8-7.

Cu

sto

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le P

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ign

al/C

AN

IRB

640

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www.cadfamily.com


wTh

Sh

eet

8-8.

Ext

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al C

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el


www.cadfamily.com


wTh

Sh

eet

8-9.

Ext

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Cab

le T

each

Pen

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t


www.cadfamily.com


wTh

Sh

eet

8-10

. Tim

e R

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www.cadfamily.com


wTh

Sh

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8-11

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sto

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Pre

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Sig

nal

/ P

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bu

s D

P M

/S


www.cadfamily.com


wTh

Sh

eet

8-12

. Op

tio

nal

cu

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mer

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nal

Pro

fib

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IRB

640

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www.cadfamily.com


wTh

Sh

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8-13

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www.cadfamily.com


wTh

Sh

eet

8-14

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sto

mer

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N-B

US

IRB

640

/640

0S


www.cadfamily.com


wTh

Sh

eet

8-15

. Cu

sto

mer

cab

le p

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al C

AN

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B 6

600/

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www.cadfamily.com


wTh

Sh

eet

8-16

. Cu

sto

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al P

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bu

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600/

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www.cadfamily.com


wTh

Sh

eet

8-17

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cu

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po

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nal

Pro

fib

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640

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www.cadfamily.com


wTh

Sys

tem

9:

Ext

ern

al A

xis

Cab

inet

Sh

eet

9-1.

Blo

ck D

iag

ram


www.cadfamily.com


wTh

Sh

eet

9-2.

Vie

w o

f E

xter

nal

Axi

s C

abin

et


www.cadfamily.com


wTh

Sh

eet

9-3.

Des

ign

atio

n


www.cadfamily.com


wTh

Sh

eet

9-4.

Mai

ns

Co

nn

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on


www.cadfamily.com


wTh

Sh

eet

9-5.

Tra

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er U

nit


www.cadfamily.com


wTh

Sh

eet

9-6.

Po

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Su

pp

ly, I

/O S

up

ply


www.cadfamily.com


wTh

Sh

eet

9-7.

Po

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it


www.cadfamily.com


wTh

Sh

eet

9-8.

Rec

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er, F

ans

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Ble

eder


www.cadfamily.com


wTh

Sh

eet

9-9.

Dri

ve U

nit

Sig

nal

Co

nn

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on

1 E

xter

nal

Dri

ve U

nit


www.cadfamily.com


wTh

Sh

eet

9-10

. Dri

ve U

nit

Sig

nal

Co

nn

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on

2 E

xter

nal

Dri

ve U

nits


www.cadfamily.com


wTh

Sh

eet

9-11

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ve U

nit

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nal

Co

nn

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on

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nal

Dri

ve U

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www.cadfamily.com


wTh

Sh

eet

9-12

. Dri

ve U

nit

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d C

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l Cab

le D

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Un

it G

T


www.cadfamily.com


wTh

Sh

eet

9-13

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3HAC 16640-1 243

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244 3HAC 16640-1

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

IRB 940 Tricept™


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

-


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Table of Contents

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Overview 1Product Documentation, IRB 940 Tricept ™ 3








Chapter 3: Maintenance activities, manipulator 21

Introduction 21

Section A: Maintenance intervals 22Specification of maintenance intervals 22Maintenance schedule, IRB 940 Tricept™ 23

Section B: Daily maintenance 24Daily maintenance, complete robot 24


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Section C: Lubrication activities 25Lubrication, linear bearings 25Lubrication, actuators 27

Section D: Replacement activities 29Replacement of filter element, OP-unit 29Adjusting the overpressure unit 31

Chapter 4: Maintenance activities, controller 33

Introduction 33

Section A: Maintenance intervals 34Specification of maintenance intervals 34Maintenance schedule, controller S4CPlus 35

Section B: Inspection activities 36Inspection of controller cabinet, S4Cplus 36

Section C: Replacement activities 37Replacement of air filter, controller 37Replacement of battery unit, controller 40Replacement of system fan unit 44

Section D: Cleaning activities 47Cleaning of controller cabinet 47Cleaning of air filter 49

Chapter 5: Disposal 51

Disposal 51


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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.



• maintenance personnel in the user's organization.

• maintenance personnel in other organizations.


• 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


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References

Revisions


Circuit diagram, Manipulator 3HAC 16640-1, Repair Manual part 2

Circuit diagram, Controller 3HAC 16640-1, Repair Manual part 2


- First edition


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Product Documentation, IRB 940 Tricept ™





ters:

• Safety, Service


• Unpacking



• Start-up




• Calibration



• Safety, Service








• Safety, Service



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• Disposal




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Safety, service

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Introduction



Sections The chapter "Safety, service" is divided into the following sections:
















• Brake testing





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Safety, service

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ment.


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Related information


Documents





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Qualified personnel


Extraordinary risks



rectified manually.












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• The power unit


















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• - withstand any impact from a tool failure. Due to the high kinetic energy associated with HSM (High Speed Machining), a tool failure poses a seri-ous risk as any debris can cause serious personal injury. Both walls and ceilings must be designed and dimensioned so that they can withstand any projectiles that they may be subjected to. Windows must be made from suitable safety glass. Study the planned process to determine the forces involved and appropriate materials.



Fire extinguishing



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released.



Brake testing




below:






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16 - 3HAC 16639-1

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Introduction




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Screw joints




materials and does not apply to soft or brittle materials.





tables below:




M2.5 0.25

M3 0.5

M4 1.2

M5 2.5

M6 5.0




M5 6 - -

M6 10 - 17

M8 24 28 40

M10 47 55 70

M12 82 95 120


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M16 200 235 300





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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.






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Maintenance activities, manipulator

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Chapter 3:Maintenance activities, manipulator

Introduction

Definitions This chapter details all maintenance activities recommended for the manipulator.

This chapter is made up of separate units, each detailing a specific maintenance

activity. Each unit contains all the information required to perform the activity,

e.g. spare parts numbers, required special tools and materials.


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Maintenance activities, manipulatorMaintenance intervals

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Section A: Maintenance intervals

Specification of maintenance intervals

Description The intervals may be specified in different ways depending on the type of main-

tenance activity to be carried out and the working conditions of the robot.

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

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


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Maintenance activities, manipulatorMaintenance intervals

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Maintenance schedule, IRB 940 Tricept™

General The robot, consisting of manipulator and controller cabinet, must be maintained

regularly to ensure its function. The maintenance activities and their respective

intervals are specified in the table below.

Non-predictable situations also give rise to inspections of the robot. If damage is

discovered, attend to it immediately!

Activities and intervals

The section referred to in the table can be found in the different chapters for every

maintenance activity.

The table below specifies the required maintenance activities and intervals:

1) The interval is based on utilization under normal operating conditions. Opera-

tion under severe conditions such as increased ambient temperature or the pres-

ence of abrasive or grease absorbent dust will require a more regular maintenance

cycle.

Maintenance activity

Equipment Interval Detailed in section

Daily maintenance Complete robot Daily "Daily maintenance"

Lubrication Linear bearings 1000h 1 "Lubrication, linear bear-ings"

Lubrication Actuator 1000h 1 "Lubrication, actuators"

Changing Filter, overpres-sure unit

“Replacement of filter ele-ment, OP-unit”

Changing Battery, distribu-tion box

“Removal/Refitting of bat-tery, distribution box” in the Repair Manual.


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Maintenance activities, manipulatorDaily maintenance

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Section B: Daily maintenance

Daily maintenance, complete robot

General The IRB 940 Tricept™ requires regular maintenance. It is therefore important to

adhere to the following maintenance chart as well as applying the preventive

maintenance schedules set out in any auxiliary equipment chapters. When main-

taining the robot it is important to:

• Clean the robot and its surrounding environment daily.

• Not to use compressed air in sections of the machinery which may suffer from chips or dust being blown into sensitive areas.

• Only use soft cloths when cleaning so as not to cause abrasions on the machine surfaces.

• Not to use any solvents that may have an abrasive or corrosive effect on the machine surfaces.

Daily maintenance

The daily maintenance of the robot and its surrounding environment includes:

• Removing all chips and/or dust that result from the machining process.

• Performing checks on all safety related equipment such as safety switches and barriers.

• Checking for signs of damage or wear on all cables, hoses and other com-ponents that can lead to a safety risk or interrupted production in case of failure.

• Checking levels of all lubrication and cooling fluids on both the manipulator and auxiliary equipment.

• Checking that all media supplies, such as compressed air and water, main-tain the correct pressures and flows.


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Maintenance activities, manipulatorLubrication activities

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Section C: Lubrication activities

Lubrication, linear bearings

Location The figure below shows the location of the grease lubrication nipple on the linear

guide bearing. The other linear bearing is located on the other side of the center

tube.

xx0200000293

Required equip-ment

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

A


Lubricant Klüber Isoflex NBU 15 2 x 4 ml per lin-ear bearing.


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Lubrication The procedure below details how to lubricate the linear bearings.


- Before lubrication, always clean lubrication interfaces to prevent contamination entering the lubrication system.

- After lubrication, always clean any spillage around lubrication interfaces.


1. Clean the rails from old grease and dust.

2. Apply 4 ml lubricant through the nipple at the bottom end of the linear guide bearing.

Both sides must be lubricated! Note! The ends of the linear bearing are made from plastic and can crack if not suffi-cient care is taken when lubricating the bear-ings.

Shown in figure above! Lubricant specified above!

3. Run the robot back and forth in the Z-direc-tion several times.

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


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Lubrication, actuators

Location The three actuators require lubrication with grease. There are four separate grease

nipples for the lubrication on each actuator. The grease nipple that faces up is used

so that as the grease is applied it falls onto the lead screw inside the actuator hous-

ing.

The figure below shows the location of the grease lubrication nipples on the actu-

ator.

xx0200000294

Required equip-ment

A Grease lubrication nipples on the actuator

A


Lubricant Klüberplex BEM 34-132

2 x 4 ml per actuator.

For lubrication of the actuators.


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Lubrication The procedure below details how to lubricate the actuators.


- Before lubrication, always clean lubrication interfaces to prevent contamination entering the lubrication system.

- After lubrication, always clean any spillage around lubrication interfaces.


1. Extend the actuators to their maximum allow-able length.

If a fixture or other work area restrictions affect the positioning of the robot, run it so that one of the actuators is extended, lubri-cate it and move on to the other two in turn.

2. Apply 4 ml of lubricant to each actuator through the topmost grease nipple.

Note! Ensure that the grease nipple that faces upwards is used, as any other orien-tated grease nipple will not ensure that the grease is applied to the lead screw correctly.

Lubricant specified above!


3. Run the actuators through their whole stroke several times.

Note! The actuators must be extended prior to lubrication in order to get the correct appli-cation onto the actuator screw. Lubricating a contracted actuator will not apply any grease on the screw threads.

4. Apply a further 4 ml through the same grease nipple.


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Maintenance activities, manipulatorReplacement activities

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Section D: Replacement activities

Replacement of filter element, OP-unit

Location The filter element is located in the overpressure (OP) unit as shown in the figure

below.

xx0200000420

Required equip-ment

- Removal of the filter element


Filter 3HAC 17158-1


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Replacement of filter

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

unit.


1. Exhaust the system and the unit.

2. Unscrew the filter bowl in an anti-clockwise direction.

3. Grasp a new filter element only at the lower end.

4. Refit the parts in the reverse order from dis-mantling.

5. Recommission the overpressure unit. Detailed in the section "Adjusting the overpres-sure unit".


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Adjusting the overpressure unit

Location The overpressure unit is installed as shown in figure below.

xx0200000421

A Regulator

B Pressure guard

C Pressure indicator light

D Air input

A

B

C


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Adjusting The procedure below details how to adjust the overpressure unit after installation

or after replacement of the filter element.

The output pressure must under no circumstances exceed 1 bar!


1. Slowly pressurize the complete system.

2. Pull the pressure setting button upwards (away from the housing).

3. Turn the pressure setting until the desired pres-sure (1 bar) is shown on the manometer. The input pressure must be at least 1 bar greater than the output pressure.

4. Press the pressure setting button downwards (towards the housing) to secure it against uninten-tional turning.


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Maintenance activities, controller

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Chapter 4:Maintenance activities, controller

Introduction

Definitions This chapter details all maintenance activities recommended for the control cabi-

net.

This chapter is made up of separate units, each detailing a specific maintenance

activity. Each unit contains all the information required to perform the activity,

e.g. spare parts numbers, required special tools and materials.


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Maintenance activities, controllerMaintenance intervals

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Section A: Maintenance intervals

Specification of maintenance intervals

Description The intervals may be specified in different ways depending on the type of main-

tenance activity to be carried out and the working conditions of the robot.

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

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


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Maintenance activities, controllerMaintenance intervals

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Maintenance schedule, controller S4CPlus

General The robot controller must be maintained at regular intervals to ensure its function.

The maintenance activities and their respective intervals are specified in the table

below:

Intervals

1) Hours denotes operational time whereas months denotes actual calender time.

Maintenance activity

Equipment Interval Detailed in section

Inspection Controller cabinet 6 mths "Inspection, controller cabinet"

Cleaning Controller cabinet "Cleaning, controller cabinet"

Cleaning Air filter "Cleaning, air filter"

Replacement Air filter 4 000 h/24 mths 1

"Replacement, air filter"

Replacement Battery unit 12 000 h/36 mths 1

"Replacement, battery unit"

Replacement System fan unit 60 mths "Replacement, system fan unit".


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Maintenance activities, controllerInspection activities

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Section B: Inspection activities

Inspection of controller cabinet, S4Cplus

Inspection The procedure below details how to inspect the controller cabinet.





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

Replace any faulty seals as required.

2. Inspect all sealing joints and cable glands to make sure they are airtight in order to prevent dust and dirt from being sucked into the cab-inet.

3. Inspect connectors and cabling to make sure they are securely fastened and cabling not damaged.

4. Inspect any air filters to make sure they are clean.

Clean any contaminated filters as detailed in "Cleaning, air filter".

5. Inspect any fans to make sure they function correctly.

Replace any malfunc-tioning fans as detailed in their sections respec-tively.


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Maintenance activities, controllerReplacement activities

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Section C: Replacement activities

Replacement of air filter, controller


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

xx0200000284

Required equip-ment

A Air filter magazine

A A


Air filter 3HAB 8028-1




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Removal, air filter The procedure below details how to remove the air filter.


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

xx0200000001

2. Unlock the lower springs. Lower the magazine and remove.

3. Remove the old filter by releasing the lock shackle and lifting it. Note! In cases of less contamina-tion, the air filter may be cleaned and refitted. The procedure for this is detailed in section "Clean-ing the air filter, controller" in the Maintenance Manual.

xx0200000003

1

2


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Refitting, air filter The procedure below details how to refit the air filter.


1. Fit the air filter in the magazine.

Art. no. is specified above!

2. Fit the spring at the top of the air filter magazine into the cabinet door and push upwards inwards.

Push until the lower springs snap into the cabinet door.

xx0200000006


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Replacement of battery unit, controller

Location of bat-tery unit

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

xx0200000103

A Battery unit

A


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Required equip-ment

Removal, battery unit

The procedure below details how to remove the battery unit.




Battery unit 3HAC 5393-2 To be replaced as a complete unit




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

xx0200000004

2. Pull the battery unit out (2).

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

xx0200000005

X3

X2

X1

X2 X2 X2

X1 X1 X1


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Refitting, battery unit

The procedure below details how to refit the battery unit.



1. Place the battery unit close to its position. Art. no. specified above! See illustration above!

2. Reconnect the cables (3) and push the unit into position.

See illustration above!

3. Secure it with the attachment screws (1). See illustration above!


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Replacement of system fan unit

Location of sys-tem fan unit

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

xx0200000007

A Drive units


C System fan unit


E Power supply unit

0

C

B

A

A A AD

E


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Required equip-ment

Removal The procedure below details how to remove the system fan unit.




System fan unit 3HAC 12924-2




1. Remove the bleeder resistor unit.

Detailed in "Replacement of bleeder resistor" in the Repair Manual.

2. Disconnect the cable (see position 1 in the figure).

xx0200000008

221

1


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Refitting The procedure below details how to refit the system fan unit.



3. Pull the back of the system fan unit upwards to free it and then tip it out of the enclosure (see position 2 in the figure).



1. Fit the system fan unit into position and 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.


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Maintenance activities, controllerCleaning activities

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Section D: Cleaning activities

Cleaning of controller cabinet

Required equip-ment

Cleaning of functional components

The procedure below details how to clean the functional components of the con-

troller cabinet.





Vacuum cleaner

Cleaning agent, exte-rior cleaning

Use rag with e.g. alco-hol, if necessary


1. Clean the cabinet interior with a vacuum cleaner if necessary.

2. If the cabinet is equipped with heat exchang-ers, it is of the utmost importance that these are cleaned.

Heat exchangers are normally found: • on the rear of power supplies

• on the rear of computer modules

• on drive units

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


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Do’s and don’ts! The section below specifies special considerations when cleaning the controller

cabinet.

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

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

Never! • Never remove any covers or other protective before cleaning the control-ler!

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

• Never spray with a high pressure cleaner!


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Cleaning of air filter


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

xx0200000002

Required equip-ment

A Air filter

B I/O and gateway units

C Power supply unit

D Drive system

E Computer system

A D E

B C


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

Compressed air


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Cleaning The procedure below details how to clean the air filter.

Please observe the following before commencing any repair work:

Turn off all electric power supplies to the robot! Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. securing the lower arm with fixtures before removing gear-box, axis 2.


1. Clean with the rough surface (on the clean-air side) turned inwards.

2. Clean the filter three or four times.

3. Allow the filter to dry in one of these ways:

• Lying flat on a flat surface

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

Do not wring the filter out!


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Disposal

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Chapter 5:Disposal

Disposal

General All used grease/oils and dead batteries must be disposed of in accordance with the

current legislation of the country in which the robot and the control unit have been

installed.

If the robot or the control unit is partially or completely disposed of, the various

parts must be grouped together according to their nature (e.g. all iron together and

all plastic together), and disposed of accordingly. These parts must also be dis-

posed of in accordance with the current legislation of the country in which the

robot and control unit have been installed.


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Disposal

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52 - 3HAC 16639-1

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3HAC 16639-1 53

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54 3HAC 16639-1

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abb-s4c+irb 940 m2000 electrical maintenance training manual

Documents

teach pendant unit

operating mode selector

5c 45c max

allowed operating conditions

twisted pair conductors

robots working space

required equipment equipmentcrane

serial measurement board