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ABB Robotics
Product manualFlexGun
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Product manual
FlexGun
Document ID: 3HAW050009061
Revision: F
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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 responsibility for any errors that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB’s written permission.
Additional copies of this manual may be obtained from ABB.
© Copyright 2013 ABB All rights reserved.
ABB Engineering (Shanghai) LtdN°5, Lane 369, Chuangye Rd,
Kangqiao Town, Nanhui District,Shanghai 201319; P.R. China
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0.0.1 Overview of this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70.0.2 Product documentation, M2004. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.0.3 How to read the product manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Safety 13
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141.2.1 Safety in the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Safety risks related to the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151.3.1 Safety risks during installation and service work on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151.3.2 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171.3.3 Safety risks related to pneumatic/hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181.3.4 Safety risks during operational disturbances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191.3.5 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.4 Safety actions related to the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211.4.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211.4.2 Fire extinguishing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221.4.3 Emergency release of the robots/manipulators axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231.4.4 Brake testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241.4.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251.4.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261.4.7 Work inside the manipulator's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271.4.8 Translate the information on safety and information labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.5 Safety stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291.5.1 What is an emergency stop? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.6 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311.6.1 Safety signals in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311.6.2 Safety risks related to spot welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331.6.3 Personnel safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2 Product description 35
2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352.2 Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.3 Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382.3.1 Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382.3.2 Detailed views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3 Standard and customized offers 43
3.1 Offers overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.2 Standard offer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443.2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443.2.2 X-gun standard offer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453.2.3 C-gun standard offer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473.2.4 Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503.2.5 Robot interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.3 Customized offer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523.3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523.3.2 Maximum force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533.3.3 Copper arm interface design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543.3.4 Arm holder design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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4 Technical details and requirements 57
4.1 Servo motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574.1.1 Servo motor type 9C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574.1.2 Servo motor type T. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.2 Centre of gravity and moment of inertia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604.2.1 Gun body with AC transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604.2.2 Gun body with MFDC transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.3 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624.4 Water cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 654.5 Temperature and hygrometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.6 Robot and robot controller requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 684.6.1 Gun used on a robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 684.6.2 Stationary gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714.6.3 Software requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5 Unpacking and handling 73
5.1 Pre-requisites for reception . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735.2 Unpacking and acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745.3 Lifting weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 755.4 Handling/lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6 Installation and commissioning 78
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.2 Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 796.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 796.2.2 Attachement - FlexGun side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806.2.3 Attachement - robot side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.3 Connection to the dresspack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 886.3.1 Principle and pre-requisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 886.3.2 Orientation of the DressPack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 896.3.3 MC plug details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906.3.4 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
6.4 Controllers settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 926.4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 926.4.2 Motion Control file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 936.4.3 System file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 976.4.4 Loading the files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
6.5 Position calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1016.6 Force calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6.7 Communication between the controller and the Bosch Timer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1056.7.1 Download the IRC5 I/O settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1056.7.2 Bosch Timer Unit settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1066.7.3 Install the BOS6000 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1066.7.4 Connect to the Spot welding cabinet through Serial Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1076.7.5 Check signals from IRC5 to timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1086.7.6 Quick start to welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
7 Maintenance 113
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1137.2 Maintenance planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
7.3 Maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1157.3.1 General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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7.3.2 Timing belt (tension check, adjustment and replacement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1167.3.3 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1197.3.4 Manual jogging of the mobile carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
7.4 Trouble shooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
8 Repair activities 123
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
8.2 Dismounting of the arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1248.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1248.2.2 Removal of the fixed arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1258.2.3 Re-assembly of the fixed arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1268.2.4 Removal of the mobile arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1278.2.5 Re-assembly of the mobile arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
8.3 Replacement of the pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1298.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1298.3.2 Pulley replacement procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
8.4 Replacement of the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1328.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1328.4.2 Motor replacement procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
8.5 Replacement of the transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1348.5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1348.5.2 Transformer replacement procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
8.6 Replacement of the roller screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1378.6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1378.6.2 Roller screw replacement procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
9 Decommissioning 143
9.1 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
10 Reference information 145
10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14510.2 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14610.3 Bolt, screws, tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14710.4 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14910.5 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
11 Spare parts 151
11.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15111.2 Motor and linear guiding material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15211.3 Welding power, conductive parts, and harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
11.4 Arms spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15811.4.1 Copper arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15811.4.2 Aluminium arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15911.4.3 Standard tips, electrode clamps and O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
11.5 Robot attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16111.6 Water cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16211.7 Casing and lubrication ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
12 Appendix 167
12.1 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
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0.0.1. Overview of this manual
About this manual
This manual contains instructions for:
• the characteristics of the FlexGun
• mechanical and electrical installation instructions for the FlexGun
• maintenance instructions for the FlexGun
• spare parts
Usage
This manual should be used when working during:
• installation, from lifting the robot to its work site and securing it to the foundation, to
making it ready for operation
• maintenance work
• repair work.
Who should read this manual?
This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
A maintenance /repair/ installation craftsman working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and electrical
installation/repair/maintenance work.
Organization of chapters
The manual is organized in the following chapters:
Chapter Content
Safety Safety information that must be read through before performing any installation or service work on the FlexGun. Contains general safety aspects as well as more specific information about how to avoid personal injuries and damage to the product.
Description and technical details
Specifications and characteristics of the FlexGun.
Unpacking, acceptance and handling
Information relative to the steps following the reception of the FlexGun, until its installation.
Maintenance Step-by-step procedures that describe how to perform maintenance of the FlexGun. Based on a maintenance schedule that may be used in the work of planning periodical maintenance.
Spare parts List of the spare parts available for the FlexGun.
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References
Revisions
Reference (ABB manuals) Document ID
Product manual - IRC5 Robot Controller 3HAC021313-001
Product manual - IRB6640 3HAC026876-001
Product manual - IRB7600 3HAC022033-001
Product manual - DressPack/SpotPack 3HAC025058-001
Service Information System - IRC5 3HAC025709-001
Application manual - Additional axes and stand alone controller 3HAC021395-001
Application manual - Servo-Gun tuning 3HAC026820-001
Application manual - Spot options 3HAC024762-001
Application manual - Mechanical Unit Manager 3HAC028797-001
Operating manual - IRC5 with FlexPendant 3HAC16590-1
System Parameters 3HAC17076-1
Operating manual - Calibration Pendulum 3HAC16578-1
Technical reference manual - RAPID Instructions, Functions, Data types
3HAC16581-1
Reference (Other manuals) Document ID
Timer and I/O Level - Technical Information Bosch Rexroth 1070 087 003-101
PST 6000.XXX Thyristor Power Unit with integrated control function - Technical Information
Bosch Rexroth 1070 080 058-101
Rexroth PSI 6xxx Medium-Frequency Inverter -Technical Information
Bosch Rexroth 1070080059
Rexroth BOS 6000 - User manual Bosch Rexroth 1070087074
PSI 6000 Medium-Frequency Inverters with integrated control function - Technical Information
Bosch Rexroth 1070 080 059-101
PST 6101.321 / PSI 6101.321- Technical Information Bosch Rexroth 1070 080 056-101
Revision Description
E First major revision
F • FlexGun offer for LeanID DressPack including new spare parts
• Arm holders detailed configurations
• Robot attachment detailed configurations
• New wiring diagrams in appendix
• Spare parts addition: water manifold type 1-1 and inverted mobile arm buss bar
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0.0.2. Product documentation, M2004
Categories for manipulator documentation
The manipulator documentation is divided into a number of categories. This listing is based
on the type of information in the documents, regardless of whether the products are standard
or optional.
All documents listed can be ordered from ABB on a DVD. The documents listed are valid for
M2004 manipulator systems.
Product manuals
All hardware, manipulators and controllers will be delivered with a Product manual that
contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation, electrical
connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals).
• Repair (descriptions of all recommended repair procedures including spare parts).
• Additional procedures, if any (calibration, decommissioning).
• Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards).
• Parts list.
• Foldouts or exploded views.
• Circuit diagrams (or references to circuit diagrams).
Technical reference manuals
The technical reference manuals describe the manipulator software in general and contain
relevant reference information.
• RAPID Overview: An overview of the RAPID programming language.
• RAPID Instructions, Functions and Data types: Description and syntax for all
RAPID instructions, functions, and data types.
• RAPID Kernel: A formal description of the RAPID programming language.
• System parameters: Description of system parameters and configuration workflows.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
• What is included (for example cables, I/O boards, RAPID instructions, system
parameters, CD with PC software).
• How to use the application.
• Examples of how to use the application.
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Operating manuals
The operating manuals describe hands-on handling of the products. The manuals are aimed
at those having first-hand operational contact with the product, that is production cell
operators, programmers, and trouble shooters.
The group of manuals includes:
• Emergency safety information
• General safety information
• Getting started, IRC5 and RobotStudio
• IRC5 with FlexPendant
• RobotStudio
• Introduction to RAPID
• Trouble shooting, for the controller and manipulator.
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0.0.3. How to read the product manual
Reading the procedures
The procedures contain references to figures, tools, material etc. The references are read as
described below.
References to figures
The procedures often include references to components or attachment points located on the
robot/controller. The components or attachment points are marked with italic text in the
procedures and completed with a reference to the figure where the current component or
attachment point is shown.
The denomination in the procedure for the component or attachment point corresponds to the
denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a procedure.
Reference to required equipment
The procedures often include references to equipment (spare parts, tools etc.) required for the
different actions in the procedure. The equipment is marked with italic text in the procedures
and completed with a reference to the section where the equipment is listed with further
information, i.e. article number, dimension.
The denomination in the procedure for the component or attachment point corresponds to the
denomination in the referenced list.
The table below shows an example of a reference to a list of required equipment, from a step
in a procedure.
Safety information
The manual includes a separate safety chapter that must be read through before proceeding
with any service or installation procedures. All procedures also include specific safety
information when dangerous steps are to be performed.
Read more in Safety on page 13.
Action Note/Illustration
8. Remove the rear attachment screws, gearbox.
Shown in the figure Location of gearbox on page xx.
Action Note/Illustration
3. Fit a new sealing, axis 2 to the gearbox. Art. no. is specified in Required equipment on page xx.
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1 Safety
1.1. Introduction
Overview
The safety information in this manual is divided in two categories:
• general safety aspects, important to attend to before performing any service work on
the robot. These are applicable for all service work and are found in General safety
information on page 14.
• specific safety information, pointed out in the procedure at the moment of the danger.
How to avoid and eliminate the danger is either detailed directly in the procedure, or
further detailed in separate instructions, found in Safety related instructions on page
31.
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1 Safety
1.2.1. Safety in the robot system
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1.2 General safety information
1.2.1. Safety in the robot system
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 are designed and installed correctly.
Personnel working with robots must be familiar with the operation and handling of the
industrial robot, described in the applicable documents, e.g. User's Guide and Product
Manual.
Connection of external safety devices
Apart from the built-in safety functions, the robot is also supplied with an interface for the
connection of external safety devices. Via this interface, an external safety function can
interact with other machines and peripheral equipment. This means that control signals can
act on safety signals received from the peripheral equipment as well as from the robot.
Limitation of liability
Any information given in this manual regarding safety, must not be construed as a warranty
by ABB that the industrial robot will not cause injury or damage even if all safety instructions
are complied with.
Related information
Type of information Detailed in document Section
Installation of safety devices Product manual for the robot Installation and commissioning
Changing robot modes Operators manual (RobotWare 5.0)
Operating modes
Restricting the working space Product manual for the robot Installation and commissioning
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1.3.1. Safety risks during installation and service work on robot©
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1.3 Safety risks related to the robot
1.3.1. Safety risks during installation and service work on robot
Overview
This section includes information of general safety risks to be considered when performing
installation and service work on the robot.
General risks during 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 regulations
To prevent injuries and damage during the installation of the robot system, the regulations
applicable in the country concerned and the instructions of ABB Robotics must be complied
with.
Non-voltage related risks
• Safety zones, which have to be crossed before admittance, must be set up in front of
the robot's working space. Light beams or sensitive mats are suitable devices.
• Turntables or the like should be used to keep the operator out of the robot's working
space.
• The axes are affected by the force of gravity when the brakes are released. In addition
to the risk of being hit by moving robot parts, you run the risk of being crushed by the
parallel arm.
• Energy, stored in the robot for the purpose of counterbalancing certain axes, may be
released if the robot, or parts thereof, are dismantled.
• When dismantling/assembling mechanical units, watch out for falling objects.
• Be aware of stored heat energy in the controller.
• Never use the robot as a ladder, i.e. do not climb on the robot motors or other part
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 system
• The supplier of the complete system must ensure that all circuits used in the safety
function are interlocked in accordance with the applicable standards for that function.
• The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance with the
applicable standards for the emergency stop function.
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Complete robot
Cabling
Gearboxes and motors
Safety risk Description
Hot components!
Removed parts may result in collapse of robot!
Caution signal
Caution!
Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!
Warning signal
Warning!
Take any necessary measures to ensure that the robot does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Safety risk Description
Cable packs are sensitive to mechanical damage!
Caution signal
Caution!
The cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them!
Safety risk Description
Gears may be damaged if excessive force is used!
Caution signal
Caution!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used!
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1.3.2. Safety risks related to tools/workpieces
Safe handling
It must be possible to safely turn off tools, such as milling cutters, etc. 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.
CAUTION!
Ensure that a gripper is prevented from dropping a workpiece, if such is used.
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1.3.3. Safety risks related to pneumatic/hydraulic systems
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1.3.3. Safety risks related to pneumatic/hydraulic systems
General
Special safety regulations apply to pneumatic and hydraulic systems.
Residual energy
• Residual energy may be present in these systems. After shutdown, particular care must
be taken.
• The pressure in pneumatic and hydraulic systems must be released before starting to
repair them.
Safe design
• Gravity may cause any parts or objects held by these systems to drop.
• Dump valves should be used in case of emergency.
• Shot bolts should be used to prevent tools, etc., from falling due to gravity.
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1.3.4. Safety risks during operational disturbances
General
• The industrial robot is a flexible tool which can be used in many different industrial
applications.
• All work must be carried out professionally and in accordance with the applicable
safety regulations.
• Care must be taken at all times.
Qualified personnel
• Corrective maintenance 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.
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1.3.5. Risks associated with live electric parts
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1.3.5. Risks associated with live electric parts
Voltage related risks, general
• Although troubleshooting may, on occasion, have to be carried out while the power
supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
• The mains supply to the robot must be connected in such a way that it can be turned
off outside the robot's working space.
Voltage related risks, controller IRC5
A danger of high voltage is associated with the following parts:
• Be aware of stored electrical energy (DC link, Ultra Cap unit) 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 transformers
• The power unit
• The control power supply (230 VAC)
• The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
• The drive unit (700 VDC)
• The drive system power supply (230 VAC)
• The service outlets (115/230 VAC)
• The customer power supply (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, robot
A danger of high voltage is associated with the robot in:
• The power supply for the motors (up to 800 VDC).
• The user connections for tools or other parts of the installation (max. 230 VAC, see
chapter Installation and commissioning in the Product manual).
Voltage related risks, tools, material handling devices, etc.
Tools, material handling devices, etc., may be live even if the robot system is in the OFF
position. Power supply cables which are in motion during the working process may be
damaged.
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1.4 Safety actions related to the robot
1.4.1. Safety fence dimensions
General
Install a safety cell around the robot to ensure safe robot installation and operation.
Dimensioning
Dimension the fence or enclosure to enable it to withstand the force created if the load being
handled by the robot is dropped or released at maximum speed. Determine the maximum
speed from the maximum velocities of the robot axes and from the position at which the robot
is working in the work cell (see Product Specification - Description, Robot Motion).
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating
tool or other device fitted to the manipulator.
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1.4.2. Fire extinguishing
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1.4.2. Fire extinguishing
NOTE!
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot (manipulator
or controller)!
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1.4.3. Emergency release of the robots/manipulators axes
Description
In an emergency situation, any of the robot's/manipulators axes may be released manually by
pushing the brake release buttons on the robot.
How to release the brakes is detailed in the robot product manual.
• The robot arm may be moved manually on smaller robot models, but larger models
may require using an overhead crane or similar.
Increased injury
Before releasing the brakes, make sure that the weight of the arms does not increase the
pressure on the trapped person, further increasing any injury!
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1.4.4. Brake testing
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1.4.4. Brake testing
When to test
During operation the holding brakes of each axis motor wear normally. A test may be per-
formed to determine whether the brake can still perform its function.
How to test
The function of each axis' motor holding brakes may be checked as detailed below:
1. Run each manipulator axis to a position where the combined weight of the
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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1.4.5. Risk of disabling function "Reduced speed 250 mm/s"©
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1.4.5. Risk of disabling function "Reduced speed 250 mm/s"
NOTE!
Do not change Transm. gear ratio or other kinematic parameters from the Teach Pendant Unit
or a PC. This will affect the safety function Reduced speed 250 mm/s.
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1.4.6. Safe use of the Teach Pendant Unit
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1.4.6. Safe use of the Teach Pendant Unit
NOTE!
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 of the
robot without the programmer knowing.
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1.4.7. Work inside the manipulator's working range
WARNING!
If work must be carried out within the robot's work envelope, the following points must be
observed:
• The operating mode selector on the controller must be in the manual mode position to
render the enabling device operative and to block operation from a computer link or
remote control panel.
• The robot's speed is limited to max. 250 mm/s when the operating mode selector is in
position < 250 mm/s. This should be the normal position when entering the working
space. The position 100% "full speed" may only be used by trained personnel who are
aware of the risks that this entails.
• Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in
order not to get entangled with hair or clothing. Also be aware of any danger that may
be caused by rotating tools or other devices mounted on the manipulator or inside the
cell.
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1.4.8. Translate the information on safety and information labels
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1.4.8. Translate the information on safety and information labels
Labels on the product
Both the manipulator and the controller are marked with several safety and information
labels, containing important information about the product. The information is useful for all
personnel handling the robot system, e.g. during installation, service or operation.
Translation possibilities
The labels fitted to the product contain space for adding a fourth language underneath the
three standard languages (English, German and French).
Add a local language to the label by:
• using a transparent sticker over the standard label with text added in a fourth language.
Drawings detailing the design (text, figure, dimensions) of the standard labels can be
ordered from ABB. Notice that each label is identified according to the article number
located in the lower corner of the label.
Example of transparent sticker
The figure below shows the location of the free space on one of the labels on the robot, where
the fourth language can be added. The figure also shows a transparent sticker, containing the
text in Swedish.
xx0500002517
A Free space for adding a fourth language
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1.5.1. What is an emergency stop?©
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1.5 Safety stops
1.5.1. What is an emergency stop?
Definition of emergency stop
An emergency stop is a state that overrides any other manipulator control, disconnects drivepower from the manipulator motors, stops all moving parts, and disconnects power from any
potentially dangerous functions controlled by the manipulator system.
An emergency stop state means that all power is disconnected from the manipulator except
for the manual brake release circuits. You must perform a recovery procedure, i.e, resetting
the emergency stop button and pressing the Motors On button, in order to return to normal
operation.
The manipulator system can be configured so that the emergency stop results in either:
• An uncontrolled stop, immediately stopping the manipulator actions by disconnecting
power from the motors.
• A controlled stop, stopping the manipulator actions with power available to the motors
so that the manipulator path can be maintained. When completed, power is
disconnected.
The default setting is uncontrolled stop. However, controlled stops are preferred since they
minimize extra, unnecessary wear on the manipulator and the actions needed to return the
manipulator system back to production. Please consult your plant or cell documentation to
see how your manipulator system is configured.
NOTE!
The emergency stop function may only be used for the purpose and under the conditions for
which it is intended.
NOTE!
The emergency stop function is intended for immediately stopping equipment in the event of
an emergency.
NOTE!
Emergency stop should not be used for normal program stops as this causes extra,
unnecessary wear on the manipulator.
Classification of stops
The safety standards that regulates automation and manipulator equipment defines categories
in which each type of stop applies:
If the stop is... ... then it is classified as...
uncontrolled category 0 (zero)
controlled category 1
293HAW050009061 Revision: F
1 Safety
1.5.1. What is an emergency stop?
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Emergency stop devices
In a manipulator system there are several emergency stop devices that can be operated in
order to achieve an emergency stop. There are emergency stop buttons available on the Flex-
Pendant and on the controller cabinet (on the Control Module on a Dual Cabinet
Controller).There can also be other types of emergency stops on your manipulator, consult
your plant or cell documentation to see how your manipulator system is configured.
3HAW050009061 Revision: F 30
1 Safety
1.6.1. Safety signals in the manual©
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1.6 Safety related instructions
1.6.1. Safety signals in the manual
Introduction to safety signals
This section specifies all dangers that may arise from performing the work detailed in themanual. Each danger is detailed in its own section consisting of:
• A caption specifying the danger level (DANGER, WARNING or CAUTION) and the
type of danger.
• A brief description of what will happen if the operator/service personnel do not
eliminate the danger.
• An instruction of how to eliminate the danger to facilitate performing the activity at
hand.
Danger levels
The table below defines the captions specifying the danger levels used throughout this
manual.
Symbol Designation Signification
danger
DANGER Warns that an accident will occur if the instructions are not followed, resulting in a serious or fatal injury and/or severe damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height etc.
warning
WARNING Warns that an accident may occur if the instructions are not followed, that can lead to serious injury, possibly fatal, and/or great damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height etc.
Electrical shock
ELECTRICAL SHOCK
The electrocution or electrical shock symbol indicates electrical hazards which could result in severe personal injury or death.
caution
CAUTION Warns that an accident may occur if the instructions are not followed, that can result in injury and/or damage to the product. It also applies to warnings of risks that include burns, eye injury, skin injury, hearing damage, crushing or slipping, tripping, impact, fall from height etc. Furthermore, it applies to warnings that include function requirements when fitting and removing equipment, where there is a risk of damaging the product or causing a breakdown.
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1.6.1. Safety signals in the manual
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Electrostatic discharge (ESD)
ELECTROSTATIC DISCHARGE (ESD)
The electrostatic discharge (ESD) symbol indicates electrostatic hazards which could result in severe damage to the product.
Magnetic fields
MAGNETIC FIELDS
An intense and/or variable magnetic field can affect or damage certain electrical devices like cardiac pacemakers.
Protection of eyes
EYES DANGER Wear safety goggles.
Protection of hands
HANDS DANGER Use safety gloves.
Protection of ears
EARS DANGER Use hearing protection devices.
Note
NOTE Note symbols alert you to important facts and conditions.
Tip
TIP Tip symbols direct you to specific instructions, where to find additional information or how to perform a certain operation in an easier way.
Symbol Designation Signification
3HAW050009061 Revision: F 32
1 Safety
1.6.2. Safety risks related to spot welding©
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1.6.2. Safety risks related to spot welding
Environment
CAUTION!
The FlexGun is intended to be used in normal indoor industrial environments; it is not
intended for use in extremely dusty, humid or explosive environments.
WARNING!
Spot welding generates fumes. The FlexGun must be used in a ventilated environment.
WARNING!
The FlexGun must be used in a safety cell. Access to the cell must be monitored according to
local safety legislation.
Work pieces
WARNING!
The work pieces for welding should be free of oils and other residues that may cause fire,
poisonous fumes or other inconveniences.
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1 Safety
1.6.3. Personnel safety
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1.6.3. Personnel safety
General
CAUTION!
The FlexGun is intended to be used by specifically appointed and qualified staff.
Unauthorized staff should not handle it.
Personal Protection Equipment
Personnel working with the FlexGun must use the following equipment:
Protection of eyes
Safety goggles should be worn within cell during welding operations. Sparks from the welding may injure the eyes.
Protection of hands
Work pieces may be hot after welding. Always use safety gloves during manual handling of work pieces.
Always let the FlexGun cool down before any mechanical intervention.
Protection of ears
Always use hearing protection devices during work in and around the work cell, as handling of the material as well as surrounding processes may give rise to elevated sound levels.
The sound pressure level excluding the welding process is less than 70 dBA.
During welding process with the FlexGun, the sound pressure level can sporadically reach 75-80 dBA.
3HAW050009061 Revision: F 34
2 Product description
2.1. Overview©
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2 Product description
2.1. Overview
Overview
The FlexGun is a spot welding gun. Available with MFDC or AC welding transformer, it has
a modular design consisting of one standard gun body that receives various X and J/C gun
arm types.
High performance
The FlexGun is servo controlled. It is integrated into the ABB robot as a 7th axis, offering
improved welding quality and cycle time performance.
The FlexGun is able to produce high forces at the electrode tips for welding of high strength
steels.
Complete protection
Stainless steel covers on the FlexGun protect the internal mechanics of the gun from weld
splatter and eliminates the need for expensive welding gun bags.
Easy installation
The FlexGun is designed to suit the ABB welding robots. This includes the interface plugs
and connections to the standard ABB DressPack. The FlexGun comes with the motor tuned
and the Equalization parameters already prepared.
Modularity
The gun body is standardized. This makes it possible to keep a single range of spare parts for
a complete library of different guns, and results in a saving on spare parts.
353HAW050009061 Revision: F
2 Product description
2.2. Terminology
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2.2. Terminology
You'll find in the table hereunder some explanations regarding the terms used in this manual:
Designation Definition
Arm A conductive component, made of copper or aluminium, which mates to the arm holder and holds the electrode holder or the electrode. The term arm is sometimes used to refer to the complete arm assembly (arm, electrode holder, electrode adapter, electrode and weld cap).
Arm holder A bracket which mates to the gun body and holds the arm.
Beam The mounting frame of the gun.
Body The standard mechanical unit of the servo-gun including: chassis, linear unit, motor. The arms are not considered as being part of the gun body.
Buss bar A copper component which conducts current from a transformer to a leaf shunt or from a leaf shunt to an arm.
Electrode adapter An electrode which mates to the weld cap and is held by an electrode holder or the arm.
Electrode clamp A clamp which secures the electrode holder to the arm.
Electrode holder A conductive part which mates to the arm and holds the electrode adapter.
Equalization The process which compensates for the bending of the fixed arm during the application of the welding force.
Fixture/Hardtool Parts to be welded are held in fixtures or hardtools.
Linear unit The linear unit is the mechanical assembly that transforms rotational movement from the motor into linear movement. It includes the roller screw, the bearings and spacers, and linear guiding material.
Manipulator The 6 axis mechanical unit of the robot.
MFDC Medium Frequency Direct Current
Mobile carriage The mobile part of the gun body on which the mobile arm holder is attached.
Pedestal gun assembly
Weld gun is mounted to a stand or pedestal, and the metals are supplied by a robot.
Proximity sensor Device which detects whether or not a target is in a predetermined zone.
Robot The manipulator and the controller
Robot mount Surface on the weld gun to which the robot is mounted.
Robotic system The robot controller, the robot manipulator and the servo-gun.
Roller screw A roller screw transforms rotational movement into linear movement. A roller screw uses grooved rollers as the anti-friction device between the nut along the outside of the screw and the screw itself, thus offering much higher efficiency than ball screws.
Servo Motor A motor used for motion control in robots. A servomotor is paired with an encoder to provide position/speed feedback.
Software Equalization
A robot function which uses the robot to move the gun body and fixed arm during the application of the welding force to compensate for the bending of the fixed arm such that the fixed electrode tip remains stationary despite the bending of the arm.
Shunt (leaf shunt) Layered copper sheets used to conduct weld current to moving components on the weld gun
Stroke/window The distance between the caps when the gun is fully opened.
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2.2. Terminology©
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Throat depth The distance in a welding machine from the centerline of the electrodes to the nearest point of interference.
Throat gap The distance between the fixed arm and mobile arm when the gun is closed.
Tip alignment The proximity of the two cap axis.
Tip dresser Tooling used to re-shape the electrode welding caps after use.
Tip force The actual force applied to the metal to be welded.
Transformer primary
The terminal on the transformer, where power is supplied.
Transformer secondary
This terminal connects to resistance welding circuit.
Water pressure differential
Difference in water pressure between the in and out ports of a water circuit.
Weld cap The consumable electrode which makes contact with the sheet metal.
Welding current The current flowing through the secondary circuit during the resistance weld.
Designation Definition
373HAW050009061 Revision: F
2 Product description
2.3.1. Principle
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2.3 Concept
2.3.1. Principle
Modular design
The FlexGun is a modular unit built around a standard body (chassis).
Its constitutive elements can be categorized as below:
• Linear transmission unit including servomotor, gearbox, roller screw and moving
carriage
• Welding power including transformer
• Gun interface to robot
• Fluid and electrical connections
• Arm holders, arms, shunts, electrode holders and caps
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2 Product description
2.3.2. Detailed views©
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2.3.2. Detailed views
Overview
Overview
1 Servo-motor and gear box
2 Welding transformer
3 Primary connection of the transformer
4 Harting connector for OrangeLine DressPack robot connection
5 Manifold for water cooling
6 Gun back plate / Robot mount
7 Mobile carriage
8 Mobile arm
9 Fixed arm
10 Electrode adapter
11 Weld cap (consumable)
12 Laminated leaf shunt
13 Cooling circuit
14 Arm holder
15 Electrode holder
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2.3.2. Detailed views
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Servo-motor
Servo-motor
Transmission
Transmission
1 4 screws for motor holder fastening
2 Servo-motor
3 Motor holder
4 4 screws for servo-motor fastening
1 4 screws for motor holder fastening
2 2 screws to adjust the belt tension
3 2 nuts to lock the adjustment screws
4 Toothed belt. Power transmission from the servo-motor to the linear unit
5 Primary pinion mounted on the servo-motor shaft
6 Secondary pinion mounted on the roller screw of the linear unit
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2 Product description
2.3.2. Detailed views©
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Arm and electrode on X-Gun
Arm & tip on X-gun
Arm and electrode on C-Gun
Arm & tip on C-gun
1 Weld cap (consumable)
2 Electrode adapter
3 Threaded electrode adapter
4 Electrode holder
5 Clamp
6 Arm
7 Electrode cooling tube (water inlet)
8 Outlet / water return
9 O-ring joint
10 Copper gasket
1 Weld cap (consumable)
2 Electrode adapter
3 Clamp
4 Arm
5 Electrode cooling tube (water inlet)
6 Outlet / water return
7 O-ring joint
413HAW050009061 Revision: F
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2.3.2. Detailed views
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3HAW050009061 Revision: F 42
3 Standard and customized offers
3.1. Offers overview©
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3 Standard and customized offers
3.1. Offers overview
Overview
The FlexGun offers can be categorized as below:
• The FlexGun standard offer: it consists in a complete servo-gun including the standard
gun body, a transformer, and the arm assemblies. The transformer is chosen between
AC or MFDC. The arms are chosen in the library of standard X or C/J arms.
• The FlexGun standard body with customized arms: it consists in a complete servo-gun
including the standard gun body, a transformer, and the arm assemblies. The
transformer is chosen between AC or MFDC. The arms are manufactured and tested
by ABB but designed by the customer or by an ABB expert according to the
requirements and specifications given by the customer.
• The FlexGun standard body: it consists in the standard gun body. An AC or MFDC
transformer can be supplied. if the standard arms holders and/or arms are not supplied,
they must be designed and manufactured according to the recommendations given in
the following chapters.
433HAW050009061 Revision: F
3 Standard and customized offers
3.2.1. Overview
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3.2 Standard offer
3.2.1. Overview
Modular design
The Standard FlexGun is available in X and C types, which only differ by their arms and a
very limited number of parts:
Standard X-gun
Standard C-gun
3HAW050009061 Revision: F 44
3 Standard and customized offers
3.2.2. X-gun standard offer©
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3.2.2. X-gun standard offer
Depth and maximum tip force
Standard X-gun depth
On a X-gun, the depth depends on the length of the arm.
The maximum tip force depends on the design (length, diameter, etc.) of the arms, electrode
holder and tips.
The maximal gun opening is 255 mm.
The following table shows the maximum force in function of the standard depths, for an
electrode holder which length is 40mm:
The following table shows the maximum force in function of the standard depths, for an
electrode holder which length is 80mm:
D Gun Depth (mm)
Gun Depth (mm) 222 272 322 372 422 472 572 672 772 872 972
Max Force available (daN)
630 630 630 630 630 630 503 410 346 300 264
Gun Depth (mm) 262 312 362 412 462 512 612 712 812 912 1012
Max Force available (daN)
535 535 535 535 535 535 461 382 326 284 252
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3.2.2. X-gun standard offer
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Standard X-gun arm attachments
Arms Type Attachement type
References Illustration
Copper Standard
Complete set3HAW061005100-001
Fixed holder set
3HAW061005100-001-F
Mobile holder set
3HAW061005100-001-M
CopperInverted mobile arm holder
Complete set3HAW061005100-002
Fixed holder set
3HAW061005100-001-F
Mobile holder set
3HAW061005100-002-M
Aluminium Standard
Complete set3HAW061005100-003
Fixed holder set
3HAW061005100-003-F
Mobile holder set
3HAW061005100-003-M
3HAW050009061 Revision: F 46
3 Standard and customized offers
3.2.3. C-gun standard offer©
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3.2.3. C-gun standard offer
Depth and maximum tip force
Standard C-gun depth
On the standard C-gun, the depth is 220mm and the maximum opening is 255mm.
The maximum force allowed is 1000 daN but this forces also depends on the design of the
tips.
The actual parameters are indicated on the machine plate.
There are other available designs for the C-gun. Please contact ABB.
D Gun depth (mm)
473HAW050009061 Revision: F
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3.2.3. C-gun standard offer
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Standard C-gun arm attachments
Arms Type Attachement type
Reference Illustration
CopperStraight fixed arm holder
Complete set3HAW061005600-001
Fixed holder set
3HAW061005600-001-F
Mobile holder set
3HAW061005600-001-M
Copper15° fixed arm holder
Complete set3HAW061005600-002
Fixed holder set
3HAW061005600-002-F
Mobile holder set
3HAW061005600-001-M
Copper30° fixed arm holder
Complete set3HAW061005600-003
Fixed holder set
3HAW061005600-003-F
Mobile holder set
3HAW061005600-001-M
Copper45° fixed arm holder
Complete set3HAW061005600-004
Fixed holder set
3HAW061005600-004-F
Mobile holder set
3HAW061005600-001-M
Copper60° fixed arm holder
Complete set3HAW061005600-005
Fixed holder set
3HAW061005600-005-F
Mobile holder set
3HAW061005600-001-M
Aluminium fixed arm
Copper mobile arm
Straight fixed arm holder
Complete set3HAW061005600-006
Fixed holder set
3HAW061005600-006-F
Mobile holder set
3HAW061005600-001-M
3HAW050009061 Revision: F 48
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3.2.3. C-gun standard offer©
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Aluminium fixed arm
Copper mobile arm
15° fixed arm holder
Complete set3HAW061005600-007
Fixed holder set
3HAW061005600-007-F
Mobile holder set
3HAW061005600-001-M
Aluminium fixed arm
Copper mobile arm
30° fixed arm holder
Complete set3HAW061005600-008
Fixed holder set
3HAW061005600-008-F
Mobile holder set
3HAW061005600-001-M
Aluminium fixed arm
Copper mobile arm
45° fixed arm holder
Complete set3HAW061005600-009
Fixed holder set
3HAW061005600-009-F
Mobile holder set
3HAW061005600-001-M
Aluminium fixed arm
Copper mobile arm
60° fixed arm holder
Complete set3HAW061005600-010
Fixed holder set
3HAW061005600-010-F
Mobile holder set
3HAW061005600-001-M
Aluminium fixed arm
Copper mobile arm
90° fixed arm holder
Complete set3HAW061005600-011
Fixed holder set
3HAW061005600-011-F
Mobile holder set
3HAW061005600-001-M
493HAW050009061 Revision: F
3 Standard and customized offers
3.2.4. Transformer
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3.2.4. Transformer
Characteristics
The FlexGun is available with AC or MFDC transformer:
Other transformers can be offered. Please contact ABB.
Transformer type MFDC_10V AC_10V
Secondary voltage 10V 10V
Primary voltage 500V 400V
Primary frequency 1000 Hz 50 Hz
Power (S50) 91 kV.A 88 kV.A
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3.2.5. Robot interface©
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3.2.5. Robot interface
List of robot interface configurations
Positioning Interface Reference Illustration
In line
Basic 3HAW061005250
Standard interface IRB6600 3HAW061005251
Standard interface IRB7600 3HAW061005252
Manual tool changer ABB IRB6600 3HAW061005253
Manual tool changer ABB IRB7600 3HAW061005254
Automatic tool changer RSP 350 3HAW061005255
Automatic tool changer Sigma3 3HAW061005256
40°(8 orientations
are possible
using the
same
material)
Basic 3HAW061005260
Standard interface IRB6600 3HAW061005261
Standard interface IRB7600 3HAW061005262
Manual tool changer ABB IRB6600 3HAW061005263
Manual tool changer ABB IRB7600 3HAW061005264
Automatic tool changer RSP 350 3HAW061005265
Automatic tool changer Sigma3 3HAW061005266
90°connector side Transformer MFDC
Basic 3HAW061005270
Standard interface IRB6600 3HAW061005271
Standard interface IRB7600 3HAW061005272
Manual tool changer ABB IRB6600 3HAW061005273
Manual tool changer ABB IRB7600 3HAW061005274
Automatic tool changer RSP 350 3HAW061005275
Automatic tool changer Sigma3 3HAW061005276
90°connector side Transformer AC_10V
Basic 3HAW061005280
Standard interface IRB6600 3HAW061005281
Standard interface IRB7600 3HAW061005282
Manual tool changer ABB IRB6600 3HAW061005283
Manual tool changer ABB IRB7600 3HAW061005284
Automatic tool changer RSP 350 3HAW061005285
Automatic tool changer Sigma3 3HAW061005286
90° motor side
Basic 3HAW061005290
Standard interface IRB6600 3HAW061005291
Standard interface IRB7600 3HAW061005292
Manual tool changer ABB IRB6600 3HAW061005293
Manual tool changer ABB IRB7600 3HAW061005294
Automatic tool changer RSP 350 3HAW061005295
Automatic tool changer Sigma3 3HAW061005296
90° left / right side
Basic 3HAW061005300
Standard interface IRB6600 3HAW061005301
Standard interface IRB7600 3HAW061005302
Manual tool changer ABB IRB6600 3HAW061005303
Manual tool changer ABB IRB7600 3HAW061005304
Automatic tool changer RSP 350 3HAW061005305
Automatic tool changer Sigma3 3HAW061005306
513HAW050009061 Revision: F
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3.3.1. Overview
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3.3 Customized offer
3.3.1. Overview
Overview
The FlexGun arm holders, arms and electrodes can be designed and manufactured according
to the customers specific requirements and specifications. The following chapters contain the
rules for the design of such a customized FlexGun.
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3.3.2. Maximum force©
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3.3.2. Maximum force
Depth and maximum tip force
The level of force at the tips depends on the type and length of the arms and tips.
The curve below shows the tip force in relation with the depth:
The maximal gun opening depends on the tips used. It can not exceed 255 mm.
D Gun Depth, in mm (Distance between tips and the mobile carriage).
F Tip Force, in DaN
L1 Mechanical unit limit, in DaN
L2 User defined tip and arm limit, in DaN
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3.3.3. Copper arm interface design
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3.3.3. Copper arm interface design
Drawing
When ABB arm holders are used, the end of the arm (interface) must be designed as shown
below (for copper arms):
arm shaft
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3.3.4. Arm holder design©
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3.3.4. Arm holder design
Mobile arm holder mounting
If the ABB mobile arm holder is not used, it is recommended to design the interface of the
holder in accordance with the mounting surface of the carrier shown below:
Mobile arm holder mount surface
Mobile arm holder interface
Mobile arm carriage maximum loads
The following gives the maximum loads applicable to the mobile arm carriage:
Maximum loads
Torque Maximum value Force Maximum value
To.x 3580 N.m Fx (not relevant)
To.y 6070 N.m Fy (not relevant)
To.z 580 N.m Fz 100% duty cycle: 7600 N
50% duty cycle: 11000 N
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3.3.4. Arm holder design
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Fixed arm holder mounting
If the ABB fixed arm holder is not used, it is recommended to design the interface of the
holder in accordance with the beam mounting surface shown below:
Fixed arm holder mount
Fixed arm holder interface
3HAW050009061 Revision: F 56
4 Technical details and requirements
4.1.1. Servo motor type 9C4©
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4 Technical details and requirements
4.1 Servo motor
4.1.1. Servo motor type 9C4
Overview
The servo motor type 9C4 was used on the FlexGun until 2012.
The standard version of this motor is not equipped with a brake. Below are its main
characteristics:
Resolver
The resolver is of the type “speed one” There is only one pair pole. It fulfills the ABB robot
requirements. It is connected to a 17 pins male industrial connector.
17 pins resolver connector
# Attribute Symbol Value Unit
1 Continuous torque at zero speed M07.5 Nm
2 Peak torque MMAX22.5 Nm
3 Torque constant KT1.232 Nm/A
4 Rated speed NN4000 rpm
5 Resistance between phases RU-V1.81 Ω
6 Self between phases (U-V) LU-V11.9 mH
7 Number of pair poles PP5 /
Pin Signal Detail
1 S1 Cos +
2 S2 Sin+
3 S3 Cos-
4 S4 Sin-
5 Not used
6 Not used
7 R1 Reference +
8 R2/R3 Reference -
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4 Technical details and requirements
4.1.1. Servo motor type 9C4
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Power
A temperature sensor (PTC) is implemented inside the phases winding.
8 pins motor connector
Pin Signal Detail
1 V Motor phase V
2 GND To be connected to earth protection
3 U Motor phase U
4 W Motor phase W
A B+ Brake + (optional)
B B- Brake - (optional)
C PTC Temperature sensor
D PTC Temperature sensor
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4 Technical details and requirements
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4.1.2. Servo motor type T
Overview
This servo motor was introduced on the FlexGun in 2012. Its characteristics and
performances are similar to those of the motor type 9C4, with the notable exception that the
motor type T is equipped with a brake.
Below are its main characteristics:
1) Torque produced on motor shaft at speed n>=10 rpm for an infinite period of time.2) Same as T0 but at the speed nN
3) Same as T0 but at the speed n=nRMS
Brake
Below are the main characteristics of the motor brake:
# Attribute Symbol Value Unit
1 Low speed rotor torque1)T0
10 Nm
2 Rated torque2)TN
6 Nm
3 RMS torque3)TRMS
8.3 Nm
4 Maximum motor shaft torque at zero speed T0MAX18 Nm
5 Rated speed nN4780 rpm
6 Speed at RMS torque nRMS2265 rpm
7 Nominal winding resistance per phase at 20 °C R202.25 Ω
8 Nominal winding inductance per phase at zero current
L011.9 mH
9 Number of poles Poles 8 /
# Attribute Value Unit
1 Static min torque 10.5 Nm
2 Dynamic max torque 16.8 Nm
3 Min dynamic torque Nm at speed (~ 0.8*nN) 3830 rpm 9.5 Nm
4 Maximum motor shaft torque at zero speed 18 Nm
5 Power consumption 31.6 W
6 Inertia 2.79 kg.cm²
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4 Technical details and requirements
4.2.1. Gun body with AC transformer
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4.2 Centre of gravity and moment of inertia
4.2.1. Gun body with AC transformer
Overview
The following details are given for a standard Flexgun body without arms and with a
transformer AC.
Data
Centre of gravity
Mass
Total mass: 110.54 kg
Inertia matrix/G
IoxG: 1.075 kg.m² IoyG: 5.097 kg.m² IozG: 5.036 kg.m²
IxyG: -0.088 kg.m² IxzG: -0.081 kg.m² IyzG: -0.005 kg.m²
Principal Moments/G
M1: 1.071 kg.m² M2: 5.037 kg.m² M3: 5.099 kg.m²
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4 Technical details and requirements
4.2.2. Gun body with MFDC transformer©
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4.2.2. Gun body with MFDC transformer
Overview
The following details are given for a standard Flexgun body without arms and with a
transformer type MFCD.
Data
Centre of gravity
Mass
Total mass: 93.8 kg
Inertia matrix/G
IoxG: 0.933 kg.m² IoyG: 4.196 kg.m² IozG: 4.138 kg.m²
IxyG: -0.077 kg.m² IxzG: -0.043 kg.m² IyzG: -0.005 kg.m²
Principal Moments/G
M1: 0.991 kg.m² M2: 4.138 kg.m² M3: 4.199 kg.m²
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4 Technical details and requirements
4.3. Electrical connections
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4.3. Electrical connections
Principle
The electrical signals from the welding gun transformer, motor and resolver are transferred
through a harting socket (for OrangeLine DressPack) or 3 circular sockets (for LeanID
DresspPack).
The power is transferred through the MC Plug.
Electrical plugs for OrangeLine DressPack
A Harting socket.
B MC Plug. For 3 phase power.
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Connectors for OrangeLine DressPack
A socket is prepared for direct connection to the harting plug on the Orange Line DressPack.
Harting plug
Plug details
For details, see Wiring diagrams on page 167.
Connectors for LeanID DressPack
There are 3 circular sockets prepared for direct connection to the LeanID DressPack.
FlexGun connectors for LeanID DressPack
For details, see Wiring diagrams on page 167.
A Harting modular connector from IRB robot
B Resolver: Sin, Cos, Ref. Temperature sensor
Motor: U, V, W phases. Brake (motor type T only)
C Transformer. Current sensor. Temperature sensor
A R3.CPS: Transformer. Current sensor. Temperature sensor
B R4.FB: Resolver Sin, Cos, Ref. Temperature sensor
C R3.SP: Motor: U, V, W phases. Brake
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4 Technical details and requirements
4.3. Electrical connections
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MC Plug
The FlexGun comes with an MC female plug 25mm² (LeanID DressPack) or 35mm²
(OrangeLine DressPack) for connection of the welding power to the guns transformer.
The plug is shown below:
MC plug
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4 Technical details and requirements
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4.4. Water cooling
Overview
Resistance welding equipment develops very high secondary currents. The heat is generated
primarily at the electrode tips where the resistance is greatest and internally inside the
transformer. Inadequate water cooling can cause failure to welding equipment, reduce the
durability of components and produce poor welds. Therefore the water flow should be
monitored regularly.
Diagram
Cooling circuit
Connections
Water manifold
A Water inlet to transformer (DN12)
Connect PROC2 on ABB Orange Line DressPack
B Water outlet from mobile arm (DN12)
Connect PROC3 on ABB Orange Line DressPack
C Water outlet from fixed arm (DN12)
Connect PROC4 on ABB Orange Line DressPack
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4 Technical details and requirements
4.4. Water cooling
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Network requirementsThe input and output water circuits should be equipped with manual valves.To avoid water leaks, it is recommended to install a bleeder system in order to release the pressure in the cooling circuit before maintenance operation.
The following shows the requirements for FlexGun water coolant network:
(1) Cooling water must be free of contaminants. The flow passages in the weld gun can become blocked by contaminants causing restricted water flow and overheating. Use only neutral water without chlorides, sulfates,...
Parameter Value Unit
Minimal differential pressure between inlet and outlet 1.5 bars
Maximal pressure 10 bars
Maximal temperature at inlet 30 °C
Minimal temperature at inlet 10 °C
Minimal water flow at transformer level 8 L/min
Minimal water flow at arm level 4 L/min
Minimal filtration (1) 0.2 mm
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4.5. Temperature and hygrometry
RequirementsThe following table shows the requirements for FlexGun operation and storage:
Category Value Unit
Ambient temperature
Operating 10 to 50 °C
Storage 10 to 70 °C
Ambient hygrometry
Max ambient humidity at constant temperature (for operating and storage condition)
80 %
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4 Technical details and requirements
4.6.1. Gun used on a robot
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4.6 Robot and robot controller requirements
4.6.1. Gun used on a robot
Overview
When the FlexGun is associated with an IRB 6640 or 7600 robot, it is controlled like an
external axis. However, the robot controller must satisfy some requirements to get an
optimum integration. The FlexGun has been designed for ABB IRC5 controller, for
compatibility with other control systems please contact ABB.
Orange Line DressPack (left) and LeanID DressPack (right)
NOTE!
The servo gun uses the robot serial measurement board. The servo gun dresspack connects
the gun resolver to the robot serial measurement board. Thus there is no additional signal
cable from the robot base to the IRC5.
If a stationery gun is however used, an additional signal cable is required. This runs from the
robot base to the gun and is called a “Process cable”.
NOTE!
The FlexGun can be used with orange line, silver line, and integrated LeanID DressPacks.
Robot cabling
A servo gun requires at least three cables between the IRC5 and the robot:
• Spot welding power cable - 3 phases 35mm²/25mm² welding cable
• Servo Gun Motor Power cable - 3 phases power to the gun motor
• CP/CS - Signals from the welding gun: temperature, etc.
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4 Technical details and requirements
4.6.1. Gun used on a robot©
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Requirements for the robot and controller - with Orange Line DressPackThe robot and controller equipment must fulfill the following requirements to integrate a FlexGun:
Option number
Type Description
16-1 Connection to cabinet
Floor cables and connections inside the I/O section for the DressPack are chosen. The length and configuration of the floor harness is specified under the options below.
Option 94-1,-2,-3,-4 and 455-1 for parallel communication
Option 90-2,-3,-4,-5 and 455-4 for parallel communication and field bus communication with Can/DeviceNet.
Option 92-2,-3,-4,-5 and 455-4 for parallel communication and field bus communication with Profibus.
Option 859-1,-2,-3,-4 and 455-8 for parallel communication and field bus communication with Ethernet.
455-1 Parallel communication
Offers the signal cables needed for parallel communication in lower and upper arm DressPack.
Note: The FlexGun only requires parallel communication for the dresspack and floor cables. This is for signals from the transformer and gun motor
455-4 Parallel and Bus communication
Offers the signal cables needed for the combination of parallel and bus communication in lower and upper arm DressPack.
455-8 Parallel and Ethernet communication
Offers the signal cables needed for the combination of parallel and Ethernet communication in lower and upper arm DressPack.
635-3
or -5
Spot software Spot Servo or Spot Servo Equalizing
907-1 Single drive unit
Drive unit for 7th axis with corresponding cables assembled inside Drive cabinet.
778-2 Robot gun Spot welding
785-1 Robot gun This option includes: Cables within manipulator for servo power signals (servo gun/axis 7).
798-2 and
780-2
Or
781-2
Base to axis 2 and axis 2 to axis 6
Or
Base to axis 6
864-1 Resolver connection, axis7
630-1 OptionServo tool changer
Can be added if servo gun tool changer is required.
608-1 Option World Zones
610-1 Option Independent axis
613-1 Option Collision Detection
626-1 Option Advanced RAPID
629-1 Option Servo Tool Control
793-1 OptionSecond water return
Used to safeguard against overheating of the gun arms and transformer. One water return for each arm.
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4 Technical details and requirements
4.6.1. Gun used on a robot
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Requirements for the robot and controller - with integrated LeanID DressPackThe robot and controller equipment must fulfill the following requirements to integrate a FlexGun:
Option number
Type Description
16-1 Connection to cabinet
Floor cables and connections inside the I/O section for the DressPack are chosen. The length and configuration of the floor harness is specified under the options below.
Option 94-1,-2,-3,-4 and 455-1 for parallel communication
Option 90-2,-3,-4,-5 and 455-4 for parallel communication and field bus communication with Can/DeviceNet.
Option 92-2,-3,-4,-5 and 455-4 for parallel communication and field bus communication with Profibus.
Option 859-1,-2,-3,-4 and 455-8 for parallel communication and field bus communication with Ethernet.
455-1 Parallel communication
Offers the signal cables needed for parallel communication in lower and upper arm DressPack.
Note: The FlexGun only requires parallel communication for the dresspack and floor cables. This is for signals from the transformer and gun motor
455-4 Parallel and Bus communication
Offers the signal cables needed for the combination of parallel and bus communication in lower and upper arm DressPack.
455-8 Parallel and Ethernet communication
Offers the signal cables needed for the combination of parallel and Ethernet communication in lower and upper arm DressPack.
635-3
or -5
Spot software Spot Servo or Spot Servo Equalizing
907-1 Single drive unit
Drive unit for 7th axis with corresponding cables assembled inside Drive cabinet.
778-2 Robot gun Spot welding
785-1 Robot gun This option includes: Cables within manipulator for servo power signals (servo gun/axis 7).
798-3 and
780-4
Base to axis 3
Int. Axis 3 to 6
864-1 Resolver connection, axis7
630-1 OptionServo tool changer
Can be added if servo gun tool changer is required.
608-1 Option World Zones
610-1 Option Independent axis
613-1 Option Collision Detection
626-1 Option Advanced RAPID
629-1 Option Servo Tool Control
793-1 OptionSecond water return
Used to safeguard against overheating of the gun arms and transformer. One water return for each arm.
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4 Technical details and requirements
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4.6.2. Stationary gun
Stationary gun
The FlexGun can be mounted on a stationary frame/pedestal.
Please contact ABB to define the controller configuration.
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4 Technical details and requirements
4.6.3. Software requirements
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4.6.3. Software requirements
Requirements
Use Robware version 5.12 or later.
A corresponding version of Robot Studio should also be installed.
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5 Unpacking and handling
5.1. Pre-requisites for reception©
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5 Unpacking and handling
5.1. Pre-requisites for reception
Pre-requisites
The check-list below details what must be observed before proceeding with the unpacking
and/or installation of the FlexGun:
Action Note
1. Make sure that only qualified installation personnel conforming to all national and local codes are allowed to perform the installation.
Specified in Personnel safety on page 34.
2. Make sure that the FlexGun has not been damaged, by visual inspection.
Specified in Unpacking and acceptance on page 74.
3. Make sure that the lifting device to be used is dimensioned to handle the weight of the FlexGun.
Specified in Lifting weight on page 75.
4. If the FlexGun is not to be installed directly, it must be stored.
Read Temperature and hygrometry on page 67.
5. Make sure the appointed operating environment of the FlexGun conforms to the specifications.
Specified in Safety risks related to spot welding on page 33.
6. When these prerequisites have been met, the FlexGun may be taken to its storage or installation site.
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5 Unpacking and handling
5.2. Unpacking and acceptance
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5.2. Unpacking and acceptance
TIP!
Before unpacking the unit, quickly check that the package is not damaged, and that the goods
are as ordered.
Contents
The content of the delivery package should be detailed on the delivery note.
A standard delivery package generally contains (not including options):
• The FlexGun
• The robot attachment
Inspection
The FlexGun is wrapped in a protective bag. Unpack it and check for any visible transport
damage. If the FlexGun is damaged, stop unpacking and contact ABB.
Make sure that all parts of the packing list have been delivered.
It is recommended to photograph the unit immediately after unpacking to document the
conditions of delivery.
Cleaning
If the unit seems to have been contaminated by impurities during the transport, clean them
with a clean lint-free cloth.
Identification plate
To identify the delivery, read the identification plate and compare it to the delivery note.
The identification plate is located on the side of the gun body (see fig. below) and indicates
in particular the FlexGun type, serial number and weight:
ID Plate location
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5 Unpacking and handling
5.3. Lifting weight©
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5.3. Lifting weight
Weight
The actual weight of the FlexGun depends on the configuration.
The weight of a FlexGun body with transformer but without arms is approximately 90 kg.
The weight of a FlexGun with arms is usually between 110 and 140 kg, depending on the arms
type. The actual weight is indicated on the machine plate.
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5 Unpacking and handling
5.4. Handling/lifting
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5.4. Handling/lifting
Before lifting
CAUTION!
Before lifting the FlexGun, read through the safety instructions carefully.
If the Gun is mounted on the robot or pedestal, disconnect and secure the power supply and
water coolant circuit.
Handling equipment for FlexGun
CAUTION!
Only use straps for lifting the FlexGun. Chains could damage the FlexGun.
Recommended equipment
4 Eye-bolts with a M10 thread
4 U-shackles
2 lifting straps rated for a minimum of 200kg
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5 Unpacking and handling
5.4. Handling/lifting©
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Lifting the FlexGun
There are 4 M10 threaded holes on the gun body (2 on each side):
Eye bolt holes
At least two eye-bolts must be tightened to the FlexGun body, one on each side.
Make sure that the strap is not in position to damage any leaf shunt, tube or any other piece
of equipment.
Lift slowly and carefully.
Lifting with straps
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6 Installation and commissioning
6.1. Introduction
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6 Installation and commissioning
6.1. Introduction
Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed! There are general safety aspects that must be read through, as well as more
specific safety information that describe danger and safety risks when performing the
procedures. Read Safety on page 13 before performing any service work.
Pre-requisites for installation
The check-list specified in Pre-requisites for reception on page 73 must be observed before
proceeding with the actual installation of the FlexGun.
Required equipment
Bolts and screws and tightening torques
Specified in Bolt, screws, tightening torques on page 147.
Equipment Note
Handling equipment Specified in Handling/lifting on page 76.
Standard toolkit Specified in Standard toolkit on page 149.
Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.
Specified in Special tools on page 150.
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6.2 Mechanical installation
6.2.1. Introduction
Overview
The FlexGun can be mounted on a robot or on a pedestal. It can be connected to the robot via
a manual or automatic tool changer.
The gun can be mounted on a robot with different orientations. This is done through different
robot-to-gun interface attachments (see Robot interface on page 51).
Handling of the FlexGun
The FlexGun must be handled and positioned such as this operation is safe and comfortable.
Use proper handling equipment as described in Handling/lifting on page 76 and make sure
that the weight of the unit does not rest on fragile equipment such as connectors.
Mounting of the FlexGun onto the robot - general principles
Actions Info/Illustration
1 Either jog the robot down to marry the back plate with the gun on the floor or use the handling equipment to lift the gun to the robot role-face.
The body back plate or interface bracket should be attached to the robot 6th axis flange.
Use the dowel pin location to correctly orientate the gun.
See the details of the robot role-faces in the robot product manuals.
See the details of the assembly on the ABB assembly drawings provided with the FlexGun and in: Attachement - FlexGun side on page 80, and
Attachement - robot side on page 83
Robot roleface
Use screws as recommended in the robot product manual.
For fastening of tool-flange to robot-flange, every other one of the bolt holes for 6 bolts class 12.9 shall be used.
Attached FlexGun
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6 Installation and commissioning
6.2.2. Attachement - FlexGun side
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6.2.2. Attachement - FlexGun side
In-line positioning back side 3HAW06100525x
40° positioning 3HAW06100526x
It is possible to orientate the bracket in 8 positions:
8 possible orientations of the 40° positioning bracket
Actions Info/Illustration
1 Fix the standard gun interface or the manual tool changer to the interface plate of the gun.
See the details of the assembly on the ABB assembly drawings provided with the FlexGun or in:
Attachement - robot side on page 83
Standard attachement (left) and attachement with manual changer (right)
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90° positioning connector side 3HAW06100527x (MFDC) - 3HAW06100528x (AC)
Actions Info/Illustration
1 Gun plate interface and bracket:
• Install the M6 screw for mistake-proofing at the chosen location (A), and lock it. Once all the parts are assembled, the head of the screw will be in the hole (D)
• Install the two dowel pins (E)
• Install the bracket on the plate interface of the gun, and fix it
End bracket side:
• Install the locator W060005262 and fix it with the M6 screw
• Install the dowel pin (B) and the screw (C) at the chosen location
40° Positioning
Actions Info/Illustration
1 (3HAW061005270: used with MFDC transformer
3HAW061005280: used with AC 10V transformer)
• Install the holder (A or B), and fix it on the gun with the 2 screws (C)
• Install the 2 dowel pins (D)
• Install the bracket (3HAW060005263) on the plate interface of the gun, and fix it with the 2 screws (F) and the 5 screws (G)
• Install the locator 3HAW060005262 and fix it with the M6 screw
90° Positioning - connector side - MFDC transfomer
90° Positioning - connector side - AC transfomer
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6 Installation and commissioning
6.2.2. Attachement - FlexGun side
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90° positioning motor side 3HAW06100529x (X-Gun only)
90° positioning left/right side 3HAW06100530x
Actions Info/Illustration
1 • Install the holder (A), and fix it on the gun with the 2 screws (B).
• Install the 2 dowel pins (C)
• Install the bracket (D) on the plate interface of the gun, and fix it with the 2 screws (E) and the 5 screws (F)
• Install the locator 3HAW060005262 and fix it with the M6 screw
90° Positioning - motor side
Actions Info/Illustration
1 (The bracket may be oriented on the right or left of the FlexGun)
• Install the two dowel pins (B)
• Install the bracket 3HAW0600052623 on the interface plate of the gun, and fix it with the 2 screws (C) and the 7 screws (D)
• Install the locator 3HAW060005262 and fix it with the M6 screw
90° Positioning - right side
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6.2.3. Attachement - robot side
Standard interface for IRB6640 - procedure
Actions Info/Illustration
1 Robot side:
• Install the locator 3HAW060005262 and fix it with the M6 screw
• Install the dowel pin (A)
• Fix the plate 3HAW060005274 on the robot with the 11x M12x25 screws (F)
Gun side:
• Install the dowel pin (B) and the mistake-proofing screw (C) at the chosen location
• Install the dowel pin (D)
• Install the gun plate 3HAW060005273 on the gun bracket or the gun back plate.
• Fix it with the 10x M10 screws
Robot and gun assembly:
• Move the robot and/or the gun to have contact between the gun plate and the robot axis 6 plate
• Fix the two plates with the 11x M10 screws (E)
See the assembly drawing W060005275 on next page
standard IRB6640 interface
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6.2.3. Attachement - robot side
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Standard interface for IRB6640 - drawing (from ABB drawing n°W060005275)
Interface IRB6640
Mark Quantity Description Standard or ABB number
1 1 Interface plate 3HAW060005274
2 1 Interface plate 3HAW060005273
3 2 Locating 3HAW060005262
4 11 Socket Head Cap Screw
Washer
ISO 4762 M12x25
DIN 6798 - A 12
5 1 Dowel DIN EN ISO 8736-A-12x32
6 2 Hex Screw
Washer
ISO 4017 - M6x16
DIN 433 - 6x12.2
7 1 Dowel DIN EN ISO 8736-A-12x24
8 1 Dowel DIN EN ISO 8736-A-12x32
9 10 Socket Head Cap Screw
Washer
ISO 4762 M10x30
DIN 6798-A 10
10 10 Socket Head Cap Screw
Washer
ISO 4762 M10x25
DIN 6798-A 10
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Standard interface for IRB7600 - procedure
Actions Info/Illustration
1 Robot side:
• Install the locator 3HAW060005289 and fix it with the M6 screw
• Install the dowel pin (A)
• Fix the plate 3HAW060005287 on the robot with the 12x M16 screws (F)
Gun side:
• Install the dowel pin (B) and the mistake-proofing screw (C) at the chosen location
• Install the dowel pin (D)
• Install the gun plate 3HAW060005288 on the gun bracket or the gun back plate.
• Fix it with the 10x M10 screws
Robot and gun assembly:
• Move the robot and/or the gun to have contact between the gun plate and the robot axis 6 plate
• Fix the two plates with the 12x M10 screws (E)
See the assembly drawing W061005252 on next page
standard IRB7600 interface
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Standard interface for IRB7600 - drawing (from ABB drawing n°W061005252)
Interface IRB7600
Mark Quantity Description Standard or ABB number
1 / FlexGun back plate Included with the gun body
2 1 Dowel DIN EN ISO 8736-A-12x32
3 1 Interface Plate 7600, tool side 3HAW060005288
4 22 Washer DIN 6798-A 10.5
5 10 Socket Head Cap Screw ISO 4762 M10x25
6 2 Locating 3HAW060005289
7 2 Washer DIN 433 - 6.4
8 2 Hex Screw ISO 4017 - M6x16
9 12 Socket Head Cap Screw ISO 4762 M16x30
10 12 Washer DIN 6798-A 17
11 1 Interface Plate 7600, robot side 3HAW060005287
12 12 Socket Head Cap Screw ISO 4762 M10x30
13 / IRB7600 Axis 6 /
14 1 Dowel DIN EN ISO 8736-A-12x26
15 1 Dowel DIN EN ISO 8736-A-12x40
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Manual tool changer IRB6640
Automatic tool changers
Actions Info/Illustration
1 Gun bracketside:
• Install the locator 3HAW060005262 and fix it
• Select one of the 2 locating holes (A)
• Install the dowel pin (B)
• Install a screw (C) in the unused locating hole
• Install the gun plate 3HAW060005252 on the gun bracket or plate
• Fix it with the 10 M10 screws (D)
Robot and gun assembly:
• Move the robot and/or the gun to have contact between the gun plate and the robot axis 6 plate
• Install the 2 half brackets 3HAW060005253
• Tighten the 2 screws (E)
Manual tool changer IRB6640
Actions Info/Illustration
1 RSP TA350-SWS:
• The automatic tool changer RSP is fixed directly on the bracket attachment
Applied Sigma 3.1:
• The automatic tool changer Applied Sigma 3.1 needs an interface plate to be fixed on all gun attachments.
RSP TA350-SWS
Applied Sigma 3.1
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6.3.1. Principle and pre-requisites
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6.3 Connection to the dresspack
6.3.1. Principle and pre-requisites
General
The FlexGun is connected to the drive unit of the robot controller, to the measurement board
of the robot or to an external one, and to a welding cabinet.
When the FlexGun is mounted onto an ABB robot, all electrical connections including the
welding signal and the servo motor power and signal, but not the welding power, are made
through a modular Harting connector, The ABB electrical drawing number is W060005802
(see Wiring diagrams on page 167).
The welding power is transferred through the MC Plug (see Electrical connections on page
62).
This chapter describes the connection of the FlexGun to an ABB IRB robot equipped with
welding dresspack. For other type of connection, contact ABB.
CAUTION!
Before connecting the FlexGun, make sure that all power supplies are secured and that the
water-cooling circuit is out of pressure.
DANGER!
Only authorized staff may carry out electrical operations!
Appropriate tools must be used!
Safety procedure must be respected!
Earth grounding must be done properly!
Required equipment
The standard toolkit is described in Standard toolkit on page 149.
Electrical tools are also necessary to connect the dresspack to the MC plug of the FlexGun,
see Special tools on page 150.
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6.3.2. Orientation of the DressPack
Orientation of the dresspack support plate
It is possible to orientate the support plate of the DressPack on the left or the right of the
FlexGun:
DressPack orientation
The orientation chosen depends on the required movement of the gun, as there can be an
interference issue if the gun is required to move at a very tight angle on axis 5 of the robot.
If this is the case, mount the dresspack on the opposite side.
Note that once the MC plug is crimped to the welding power, the orientation can not be
changed without ordering new crimping pins from MC.
NOTE!
The recommended orientation of the DressPack bracket is shown in option A.
It is the safest way to keep the cables and hoses away from the moving leaf shunt of the gun
mobile arm.
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6.3.3. MC plug details
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6.3.3. MC plug details
MC Plug
The flexGun comes with an MC plug for connection of the welding power from the robot
dresspack to the guns transformer. The assembled plug is shown below:
MC plug
Details
The dresspack has 2 phases plus an earth core that need to be connected to the MC plug. The
dresspack cables should be labelled V & U, with the earth being a green/yellow color.
The cores should be connected as shown in the picture below:
Multi-contact plug details
A Earth
B V terminal
C U terminal
D PG36 cable gland
Can be connected on either the left or right side.
E Welding lug: 35mm² for Orange Line DressPack and 25mm² for Lean ID DressPack
F Welding swivel joint: 35mm² for Orange Line DressPack and 25mm² for Lean ID DressPack
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6.3.4. Procedure
Procedure
The steps below describe the necessary actions required for connecting the ABB DressPack
the MC plug used for the gun.
Action Info/Illustration
1. The FlexGun must be first mechanically attached to the robot as described in Mechanical installation on page 79.
2. Position the DressPack supporting plate on either the left or right side of the gun as described in Orientation of the DressPack on page 89.
3. Check that the gun can open and close completely without interference of its components with the cables or any other equipment.
This is a critical step as the gun leaf shunt and water tubes move into the vicinity of the electrical cables, and water hoses.
4. Cut the cables to the appropriate length.
NOTE!
The MC plug allows for the cable to enter from either the left side or the right. The pins inside the plug can be rotated for either direction. However note that once crimped, it is impossible to change the entry location of the cable.
5. If it is assembled on the Gun, remove the MC plug and open it.
Feed the cable into the MC plug before crimping. This cannot be done afterward.
6. Choose the correct phase and pin connection.
For MFDC transformer, there are two phases plus the earth.
See MC plug details on page 90.
NOTE!
When used with MFDC transformer, the mobile arm is live while the stationary arm is neutral. The current flows from the mobile arm to the stationary arm.
7. Crimp the 25 or 35mm² cores and reassemble the MC plug. Reattach the MC plug back onto the gun.
Follow the Multi-Contact Assembly Instructions manual MA228
8. Cut the water dresspack water hoses and connect them to the FlexGun.
See Water cooling on page 65.
All the necessary fittings are supplied with the FlexGun.
9. Plug the connector to the FlexGun Harness (Harting connector or circular connectors)
See Electrical connections on page 62.
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6.4.1. Overview
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6.4 Controllers settings
6.4.1. Overview
Overview
The gun is controlled as a 7th axis of the robot. In order for the robot to identify that the gun
exists and to control it, configuration files must be loaded into the IRC5 system.
Two files need to be set to add the Servo gun and have it controlled by the system:
• The Motion Control file: MOC.cfg
• The System file: SYS.cfg
The robot controller has existing MOC.cfg and SYS.cfg files with specific settings related to
the robot and robot system. The servo gun settings simply need to be added to these files.
The Motion control file is provided with the FlexGun.
The system file depends on the robot to which the gun will be attached.
The system file should be set depending on your existing system.
NOTE!
Up to 4 FlexGuns can be added to one system.
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6.4.2. Motion Control file
Motion control file
The motion control settings file (MOC.cfg) contains information that is specific to the
particular gun. The specific parameters for the gun will be supplied.
The following settings are provided in the motion control setting file with the FlexGun:
• ARM:
• ACC_DATA:
• TRANSMISSION:
• BRAKE:
• BRAKE_TYPE:
• SUPERVISION_TYPE:
• SG_PROCESS:
• FORCE_MASTER:
• FORCE_MASTER_CONTROL:
• AXC_FILTER:
• MOTOR_TYPE:
• MOTOR_CALIB:
• STRESS_DUTY_CYCLE:
• UCCM0:
• LCM0:
The gun will be provided with tuned position and force settings. These settings should not be
changed.
Settings for the drive unit and measurement channel used to control the guns motor may need
to be changed depending on the robot system’s hardware configuration.
The easiest way to do this is to use the ABB software called “Mechanical unit manager”. This
software is specifically designed for the modification of the configuration files for Servo
Guns and Tracks. “Mechanical unit manager” can be found on the Robot Studio DVD under
“Tools\Mechanical Unit Manager” or can be downloaded from the ABB internal software
website at the following address:
http://solutionsbank.us.abb.com
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Below is the process for importing and modifying the standard FlexGun configuration file, and exporting the file ready to be loaded into the robot controller.:
Action
1. Open the mechanical Unit Manager:
Open the software
2. Open the project “FlexGun*.data” downloaded from the ABB library:
Open the file
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3. Choose to export the file:
Export the file
4. Select the version of the FlexGun. This depends on the shipment date of the gun as described in the file information overview.
Choose the version
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The following file is also required: “FlexGun_Mechanical_Unit_Manager.data”
This file is available on the FlexGun page of http://inside.abb.com
For more information about this package, see the application manual IRC5 Unit Manager -
3HAC028797-001.
The following settings are specific for every gun depending on the arm shape, and as a result
the parameters under these subjects are gun specific and supplied with each gun.
• ARM:
• SG_PROCESS:
• FORCE_MASTER:
• FORCE_MASTER_CONTROL:
5. If necessary, adjust the following parameters according to the physical layout and connection of the FlexGun to the robot
Adjust the parameters
6. Save the new CFG and import this into the robot.
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6.4.3. System file
System file
In order for the robot controller to be able to control the gun, the gun needs to be assigned to
a “task”.
In a standard system without multi-move, the gun is automatically part of the robot task.
However when the gun is being used on a multi-move system, it must be added to the robot
“Mechanical Unit Group”.
This can be done in the SYS.CFG file.
Procedure for modifying the system file
The existing SYS.CFG can be downloaded from the controller and modified on any
computer.
Using Robot Studio, connect to the IRC5 and follow the procedure below:
MECHANICAL_UNIT_GROUP:
-Name “Rob1”-Robot “ROB_1”-MechanicalUnit_1 “SERVOGUN”
-UseMotionPlanner "motion_planner_1"
Action Info/Illustration
1. Open Robot Studio and Connect Online to the Robot Controller. Then click Save Parameters.
Robot Studio menu
2. Select Controller and click on Save...
Save system parameters
3. Save the file on your local system in an appropriate location.
Modify the file using a text editor such as Notepad, then load the SYS.cfg file back onto the IRC5. See instruction below on how to load CFG files onto the IRC5.
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6.4.4. Loading the files
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6.4.4. Loading the files
Procedure for loading the files into the controller
To load the files back into the controller, there are two methods: you can either use a USB
stick and load them directly into the IRC5, or use Robot Studio Online.
The procedure below describes the first method:
Action Info/Illustration
1. Start the IRC5 and tap on the ABB logo of the TeachPendant.
NOTE!
Create a backup of the existing system before bringing any modification!
2. In the menu, tap on Control Panel.
3. Tap on Configuration.
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4. Tap on File.
5. Tap on Load parameters.
6. Tap on Load parameters and replace duplicates.
7. Browse for the appropriate *.CFG files to add, and tap OK.
Do not restart the controller yet.
8. Repeat Steps 2-8 for all *.CFG files that need to be loaded, and then warm restart the controller.
Action Info/Illustration
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6.4.4. Loading the files
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Jogging
Now the system has the basic set of parameters needed to carefully jog the servo gun.
WARNING!
At this stage, the system limitation of force, motor torque and working range is incomplete.
It is therefore possible to move beyond the software limits and damage the gun. If moving the
gun, make sure that the carriage remains within the mechanical limits.
9. Once both the Motion Control and the System CFG files have been loaded on the IRC5, it should be possible to see the mechanical unit in the Jogging Window, as well as to jog the Gun.
Besides, the gun will now be controllable using the Spot Robware instructions.
If the IRC5 reboots without error, then the *.CFG files have been loaded correctly. If an error occurs, record the error message and number and send the back up of the original system, the system layout and the error information to the After-sales support to get help.
If the system enters “System failure state”, it is necessary to perform a cold start. This will restore the system to default settings with no mechanical units or programs. Then restore the original backup taken before loading the CFG files. Retry loading the CFG files.
Action Info/Illustration
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6.5. Position calibration
Pre-requisite
NOTE!
The position calibration must be done with unused tips. Make sure that they are new and
replace them if it is necessary.
Fine calibration
Close the gun until the tips are in contact without force. the robot power and execute a fine
calibrate.
Follow the calibration procedure in the manual 3HAC026820-001 - Servo Gun Tuning -
section Fine Calibration.
The position limits are now available.
Check that the gun can move up to the upper limit, without damage to any components such
as cable, fitting, tube,...
Position calibration
In manual mode execute the service routine ManServiceCalib.
Follow the calibration procedure in the manual 3HAC026820-001 - Servo Gun Tuning -
section Position control
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6.5. Position calibration
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Test jogging the servo-gun
TIP!
If it is impossible to jog the gun, and instead you get a joint collision error, verify that:
• the gun is not physically stuck
• the motor phases are connected correctly
• the resolver is connected correctly
• that commutation is OK
Action Info/Illustration
1. Start the IRC5 and tap on the ABB logo of the TeachPendant.
2. Choose Mechanical unit and select SERVOGUN.
Tap OK.
3. Try jogging the SERVOGUN slowly back and forth. Make sure that the jogging is carried out away from the end limits as the gun position is not yet calibrated.
WARNING!
When the gun revolution counter is not updated, it is possible to move beyond the software limit and damage the gun. When moving the gun, make sure that the carriage remains within the mechanical limits.
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6.6. Force calibration
Required equipment
The standard toolkit is described in Standard toolkit on page 149.
A Vernier caliper and a spot welding gun calibration kit are also required to perform force
calibration:
TIP!
You can order the Miyachi calibration kit to ABB under the reference number
3HAW05000904. See Special tools on page 150
Qty Tool Product
1 A welding gun calibration kit with electronic force sensor (range 0-10kN) and an electronic kilo Ammeter, able to measure the secondary voltage (range 0-20V) and secondary current (range 3-40kA).
The calibration tool sensor thickness must not exceed 40mm.
Kistler type 9831C
or
Miyachi MM380 with MA771 Sensor
Miyachi welding gun calibration kit
1 Caliper
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Force calibration procedure
Action Info/Illustration
1. Use the caliper to measure the thickness of the force sensor.
Be sure to take into account the indent of the force sensor as shown on the picture.
D: Distance between electrode tips when clamping on force sensor
2. If the Gun is mechanically attached to a robot, the gun must be first positioned such as the gravity does not affect the force calibration: The axis of the electrodes must be horizontal (parallel to the plan of the floor).
A gravity compensation software is available from ABB. Please contact ABB.
3. Follow the calibration procedure in the manual 3HAC026820-001 - Servo Gun Tuning - section Force Calibration and execute the service routine ManForceCalib.
NOTE!
When measuring the force, it is important to take the actual force value, and not an average value.
The reason is that the average force includes the ramp up and ramp down of the force. This results in the average force being slightly lower than the constant applied force.
If the average value is used, it will result in a poor calibration, where the applied force is greater that the desired force.
Use the following parameters to set up force calibration data:Number of Force: 5
Force max: 90% of the maximum force allowed for this gun (Unit: N)
Thickness: the actual thickness of the force sensor (Unit: mm)
Time: 1or 2 (Unit: s)
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6.7 Communication between the controller and the Bosch Timer
6.7.1. Download the IRC5 I/O settings
Instructions
In order for the Bosch timer to communicate with the IRC5, the device needs to be defined in
the IRC5 I/O settings.
The following tasks must be performed:
1.)The possible EIO unit types should be added to the EIO.cfg.
2.)The Bosch Timer Unit should be defined with a DeviceNet Address.
3.)The IO signals should be assigned to the Bosch Timer Unit.
4.)Communication should be tested between the Bosch Timer and the IRC5.
The EIO settings can be altered by first downloading the existing EIO.CFG. The file can then
be modified and uploaded again. Using Robot Studio, connect to the IRC5:
Action Info/Illustration
1. Open Robot Studio and Connect Online to the Robot Controller. Then click Save Parameters.
Robot Studio menu
2. Select I/O and click on Save...
Save I/O parameters
3. Save the file on your local system in an appropriate location.
Modify the file using a text editor such as Notepad, as shown in the following procedures.
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6.7.2. Bosch Timer Unit settings
EIO Unit TypesThe following settings are the standard EIO Unit Type for the standard MFDC and the AC Bosch Timers:
Bosch timer unit
The Bosch timer is typically connected on the “DeviceNet1” with the DeviceNet address 21.
This should be checked with the Bosch Timer Manual.
The baud rate is typically set to 500kbs.
Once these settings have been made to the EIO.cfg, load the file back in to the IRC5 and
perform a warm restart. The communication can then be checked.
After the restart, ensure that no error appears on the teach pendent related to the DeviceNet.
Then check the Bosch timer DeviceNet signal is without error.
6.7.3. Install the BOS6000 Software
General
The BOS6000 Software is used to interface with the Bosch Timer.
This software can be acquired from your local Bosch supplier.
EIO_UNIT_TYPE:
For MFDC timer:
-Name “PSX6100_630” -BusType “DNET” -VendorName “Robert BOSCH Gmbh”\
-ProductName “PSI6100.630L2” -DN_VendorId 255 -DN_ProductCode 9\
-DN_DeviceType 12 -DN_MajorRev 2 -DN_MinorRev 2 -DN_C1Type “COS”\
-DN_C1OutputSize 9 -DN_C1InputSize 9
For AC timer:
-Name “PST6100_630” -BusType “DNET” -VendorName “Robert BOSCH Gmbh”\
-ProductName “PST6100.630L1” -DN_VendorId 255 -DN_ProductCode 9\
-DN_DeviceType 12 -DN_MajorRev 2 -DN_MinorRev 2 -DN_ExplicitMsgEnabled \
-DN_C1Type “COS” -DN_C1OutputSize 9 -DN_C1InputSize 9
EIO_BUS:
-Name “DeviceNet1” -BusType “DNET” -ConnectorID “PCI1”\
-ConnectorLabel “First DeviceNet”
EIO_UNIT:
For PSX6100_630
-Name “SWTimer1_PC1” -UnitType “PSX6100_630” -Bus “DeviceNet1”\
-UnitLabel “SWTimer1_PC1” -DN_Address 21
For PST6100_630
-Name “SWTimer1_PC1” -UnitType “PST6100_630” -Bus “DeviceNet1”\
-UnitLabel “SWTimer1_PC1” -DN_Address 21
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6.7.4. Connect to the Spot welding cabinet through Serial Link
Cabling
To connect the Bosch Timer, a Serial cable or a USB to Serial Adaptor cable is required:
Qty Tool Info
1 USB to Serial Adaptor
USB to serial adapter
Or:
1 Female to Female Serial Cable
Female to Female Serial Cable
Note that here are different types of female to female serial cable connectors. The Spot welding cabinet only works with the following internal wiring:
Female to Female Serial Cable wiring
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6.7.5. Check signals from IRC5 to timer
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6.7.5. Check signals from IRC5 to timer
Diagnosis
The Bosch Timer interface has a function to view the signals into and out of the timer. The
user can use this view to check that signals to the IRC5 are being received by the Bosch Timer
and to see what signals are being sent by the Bosch Timer:
Diagnosis
Background Information on Bosch IO signals
Note that the parity bit is used to invert the parity of the program number. The default is to
have this bit set. One of the outcomes of this is that the Program number will be high on the
Bosch timer, when the Program1 bit is low on the IRC5.
Input E00 “Program number / Spot name select”
If the serial input E06 = 1; The timer regards the input bits 32... 51 and the input bits 57 to 68
as a program number selection. When the entered number is above 255, the timer stops with
the error message: “Program number out of range”.
If the serial input E06 = 0; The timer regards the input bits 32... 51 and the input bits 57 to 68
as a spot number selection. When the entered spot number is below 256, the timer stops with
the error message: “Spot number out of range”.
Output bit 6: “Program number / Spot name selection confirmation” confirms the mode of
selection:
Serial input bit 06 = 1 => Serial output bit 06 =1;
Serial input bit 06 = 0 => Serial output bit 06 =0;
Electrode tip and tip dresser maintenance:
For 4 tips and 4 dresser knifes, by separate signals.
Tip 1 = Knife 1, Tip 2 = Knife 2 etc.
Admissible electrode number: 1....4
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6.7.6. Quick start to welding
Instructions
Reference the Bosch Software manual BOS6000 User Manual (1070087074 ed 1) for more
information on how to use the BOS6000 Software.
Below are the setting for a simple MFDC spot that can be used to verify that the spot welding gun is working correctly:
Action
1. Start the BOS6000 software. The standard password is bos6000 (note that this is case sensitive).
Login
2. Add a new Timer, and choose the correct COM port for the serial connection to the Bosch Timer:
Add Timer
Note: The COM port of the serial cable can be checked in the computer device manager. Check what the required port number is under Ports (COM & LPT):
Device manager
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3. Click OK followed by Continue to proceed to the next screen.
If communication cannot be established, the Status will be RED:
Red status
In this case, check the following:
• Serial Cable connection to the Bosch Timer is correctly connected.
• The Correct COM port has been selected for the this serial connection
• The correct type of serial cable is being used
If communication is established, the Status will be YELLOW:
Yellow status
The software will also prompt the user to select the synchronization direction.
If the timer has later settings which are to be kept, then choose Timer -> DB
If the PC has later settings, then choose DB -> Timer
4. Once synchronization has been completed, the following window will automatically open:
Sequence tab
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6.7.6. Quick start to welding©
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5. Before completing any welding, the transformer settings should be set.
Choose the Electrode tab, and under Transformer and Diodes fields input the following:
For MFDC:
MFDC Settings
For AC:
AC settings
1113HAW050009061 Revision: F
6 Installation and commissioning
6.7.6. Quick start to welding
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7 Maintenance
7.1. Introduction©
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7 Maintenance
7.1. Introduction
General
This chapter details all maintenance activities recommended for the FlexGun.
It is based on the maintenance schedule, located in the beginning of the chapter. The schedule
contains information about required maintenance activities including intervals and refers to
procedures for the activities. Each procedure contains all information required to perform the
activity, e.g. required tools and materials. The procedures are gathered in different sections,
divided according to the maintenance activity.
Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed! There are general safety aspects that must be read through, as well as more
specific safety information that describe danger and safety risks when performing the
procedures. Read Safety on page 13 before performing any service work.
Precautions
The precautions below should be observed before proceeding with the maintenance of the
FlexGun:
CAUTION!
• Welding arms and cooling systems are hot after welding. Let them cool down before
any intervention.
• All power supplies to the FlexGun as well as to other machines within the danger zone
must be turned off.
• If required, the main switch should be locked.
• Make sure that the cooling system is not pressurized.
• Use only original ABB spare parts. The use of unauthorized parts or others than
original parts will void the warranty.
Required equipment
Bolts and screws and tightening torques
Specified in Bolt, screws, tightening torques on page 147.
Equipment Note
Handling equipment Specified in Handling/lifting on page 76.
Standard toolkit Specified in Standard toolkit on page 149.
Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.
Specified in Special tools on page 150.
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7.2. Maintenance planning
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7.2. Maintenance planning
Even though the FlexGun is designed to require few maintenance operations, it is important
to check the points mentioned hereafter and follow the maintenance time intervals and
instructions.
Time interval Item Maintenance More info.
Every 250,000 weld strokes and once a year
Welding splatters
Clean the unit from welding splatters.
Use a metallic brush.
Cables and harness
Look for premature wearing. General Inspection on page 115.
Water cooling circuit
Look for water leakage or premature hose wearing
General Inspection on page 115.
Laminated leaf shunts
• Re-tighten the bolted joints.
• Remove broken leaves.
• Replace the leaf shunt if 10% of the leaves are damaged.
General Inspection on page 115.
Bolt, screws, tightening torques on page 147.
Every 500,000 weld strokes
Robot attachment
Re-tighten the bolted joints Bolt, screws, tightening torques on page 147.
Mechanical installation on page 79.
Arms Inspect the condition of the arms
Re-tighten the bolted joints Bolt, screws, tightening torques on page 147.
Every 2,500,000 weld strokes
General condition
Covers removed, inspect the condition of the unit and clean it thoroughly.
Timing belt • Look for premature wearing.
• Measure the belt tension and adjust it if necessary.
• Replace the belt in case of apparent damage.
Timing belt (tension check, adjustment and replacement) on page 116.
Linear unit Lubrication of the roller screw, Lubrication on page 119.Lubrication of the carriage
guideways and ball bearing blocks
Every 10,000,000 weld strokes
Major overhaul Inspection and testing of the FlexGun by an ABB expert.
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7.3.1. General Inspection©
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7.3 Maintenance instructions
7.3.1. General Inspection
General
A general inspection of the FlexGun should be done every 250,000 cycles and once a year.
The welding gun should be taken off the robot. Read the necessary precautions in this chapter
Introduction on page 113.
Clean the gun from welding splatters with a metallic brush.
Leaf shunts
Inspect the condition of the laminated leaf shunts and the fasteners. Verify that no abnormal
wear, cracks or deformation have occurred.
If required, retighten the fasteners. See Bolt, screws, tightening torques on page 147
Remove the damaged leaves. If more than 10% of the leaves are damaged, the shunt should
be replaced.
See Welding power, conductive parts, and harness on page 155
WARNING!
Damaged shunts or shunts with less than 90% of their initial leaves may cause severe over-
heating, and ultimately, the destruction of the gun!
Water cooling
Inspect the condition of the hoses, connectors fittings and make sure that there is no coolant
leaking.
If required, retighten the connectors or fitting with a thread sealant for conical fittings such
as Loctite 577. See Bolt, screws, tightening torques on page 147
If necessary, replace the damaged hoses or fittings. See Water cooling on page 162
WARNING!
Malfunction of the water cooling circuit may cause severe over-heating, and ultimately, the
destruction of the gun!
Electrical harness and connectors
Verify that cables and connectors are intact, properly fastened and protected, and that there is
no risk of them getting caught or being damaged in any way.
Verify that all the communication signals function properly.
Verify that the earthing is properly done. The FlexGun must not be connected or used if this
is not the case.
See Connection to the dresspack on page 88
DANGER!
Only authorized staff may carry out electrical operations!
Appropriate tools must be used!
Safety procedure must be respected!
Earth grounding must be done properly!
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7 Maintenance
7.3.2. Timing belt (tension check, adjustment and replacement)
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7.3.2. Timing belt (tension check, adjustment and replacement)
Inspection
The belt is located under the fixed arm of the gun, protected by a cover. Remove the cover
and inspect the condition of the belt. Wearing of the belt is normal and the presence of a
reasonable quantity of black dust should not be alarming. If however the belt shows signs of
advanced wearing, it should be replaced (see Motor and linear guiding material on page
152).
Location of the timing belt
In any case, you must measure the tension of the belt and, if necessary, adjust it.
1 Motor mounting screws and washers (4x socket head cap screws CHC M8x25)
2 Tension adjustment locknuts (2x hex nut H8)
3 Tension adjustment screws (2x socket head cap screws CHC M8x40)
4 Timing belt
5 Motor shaft pulley
6 Roller screw shaft pulley
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7.3.2. Timing belt (tension check, adjustment and replacement)©
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Tension of the belt
The easiest and most reliable method to measure the belt tension is to use a tension gauge with
an optical resonance frequency meter, such as the Continental CONTITECH VSM-1.
You can also measure the belt tension by measuring the rib/strand deflection distance of the
belt when applying a force.
Below are the correct values for the belt tension:
TIP!
You can order a tension gauge (Continental CONTITECH VSM-1) to ABB under the
reference number 3HAW050009048. See Special tools on page 150
Tension gauge method Deflection method
New belt 189 ± 5 Hz F = 25 to 27 N
d = 1.95 mm
Used belt 160 ± 5 Hz F= 20 to 21 N
d = 1.95 mm
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7.3.2. Timing belt (tension check, adjustment and replacement)
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Adjustment or replacement of the belt
Steps Actions Info/Illustration
1. • For the replacement of the belt, the fixed arm and its holder must be removed first.
• For a tuning, simply remove the cover.
2. • For a replacement, loosen the 4 motor mounting screws but do not remove them. Loosen the locknuts and the adjustment screws until you can lift the motor mounting such as the belt is loose enough to be removed. Replace the belt. Make sure that the replaced belt is perfectly vertical.
• For a tuning, simply slightly loosen the 4 motor mounting screws. The engine mounting must be kept flat against the beam surface but now able to move up and down for the belt tensioning.
NOTE!
When planning to remove and re-install used belts, measure and record the tension before removing. If the belt is functioning correctly and its resonance frequency is within the ranges indicated on the previous page (i.e. not less than 155 Hz), re-install at the recorded tension.
Loosen the screws
For a replacement, pull up the motor mounting
3. Measure the tension of the belt, preferably with a tension gauge.
Loosen the locknuts and screw/unscrew the 2 adjustment screws to respectively increase/decrease the tension.
Do it bit by bit: try to balance the adjustment on both sides of the motor mounting.
Measure the tension
Adjust the tension
4. When the tension is correct, lock the two nuts, tighten the screws of the motor mounting, and measure the tension again to make sure it has not changed. Put the cover back.
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7.3.3. Lubrication©
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7.3.3. Lubrication
Lubrication
Lubrication should be performed every 2,500,000 cycles.
Make sure that the gun is fully open to make the lubrication nipples match the ports.
There are 6 lubrication ports on the FlexGun:
Grease fittings
The mobile arm carriage must be in its upper position (end of stroke, transformer side) to
carry out the lubrication of the carriage linear ball bearing blocks.
Inject 2 cm3 of grease into each port.
NOTE!
To remove old grease or grease in excess, use a spatula and/or a clean lint-free cloth. Do not
use a brush, which hair could contaminate the unit.
WARNING!
Use only lithium base grease, with a mineral oil base, and the following characteristics:
• NLGI consistency 2
• Base oil viscosity ISO VG68 to ISO VG 100
• Doped with EP additives.
Recommended product:
1 5 plugs to be removed to clear access to the lubrication nipples
2 Port for the lubrication of the roller nut
3 Port for the lubrication of the carriage linear ball runner blocks
4 Port for the lubrication of the ball bearings
Equipment Note
Lubricant TOTAL LICAL EP 2
1193HAW050009061 Revision: F
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7.3.4. Manual jogging of the mobile carriage
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7.3.4. Manual jogging of the mobile carriage
Principle
The FlexGuns with motor type 9C4 without brake can be manually jogged easily using the
ABB tool 3HAW060005711 and 2 long M6 screws, applied on the roller screw or motor
pulley (see Special tools on page 150).
Manual jogging with 3HAW060005711
On the FlexGuns with motor type T, the brake needs to released by applying 24V power
between the pins 13 and 15 of the Harting socket of the gun, or the pins 2and 5 of the motor
power connector (see Wiring diagrams on page 167).
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7 Maintenance
7.4. Trouble shooting©
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7.4. Trouble shooting
Only skilled and authorized staff should perform trouble-shooting. Read the necessary
precautions in this chapter Introduction on page 113.
Trouble Possible cause Action More info.
Motor is not running
Brake is not released (only for motors with brake)
Verify the brake circuit Servo motor type 9C4 on page 57.
A wire is cut Verify the motor and resolver wiring
Change cable
Electrical connections on page 62.
Drive unit failure Replace the drive unit Robot and robot controller requirements on page 68.
Shunt or transformer over temperature
Screws are loosen Verify that shunts and contacts are not damaged. Replace the part if it is necessary and/or tighten the screws with torque wrench
General Inspection on page 115.
Water cooling flow rate too low
Verify the cooling circuit Water cooling on page 65.
Secondary current overload
Verify that the actual permanent current is lower than the rated current expected
Welding current too low (1)
Primary voltage too low
Verify the voltage of the welding power supply
No or bad feedback from current sensor
Verify its resistance is about 30 Ohm
Verify the wiring
Electrical connections on page 62.
Some screws are loosen
Tighten the screws with torque wrench
General Inspection on page 115.
Welding current too high (2)
No or bad feedback from current sensor
Verify its resistance is about 30 Ohm
Verify the wiring
Electrical connections on page 62.
Tips abnormal wear or weld spot bent
Electrode are not perpendicular to the sheets
Verify/modify the robot target
Electrode misalignment
Perform a correct alignment of the electrode
Stuck spot weld Worn tips Dress/change the tips
Sheets are dirty Clean the sheets
Welding current too low
See above (1)
Welding force too high Perform a force calibration Force calibration on page 103.
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7.4. Trouble shooting
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Large splatter during welding
Abnormal tips wear Check the cooling circuit
Dress/change the tips
Water cooling on page 65.
Sheets are dirty Clean the sheets
Welding current too low
See above (2)
Welding force too low Check the programmed force Perform a force calibration
Force calibration on page 103.
Tips are dirty Clean/dress the tips
Stuck tips Insufficient cooling of the tips
Check the cooling circuit
Dress/change the tips
Water cooling on page 65.
Secondary current overload
Verify that the actual permanent current is lower than the expected rated current
Welding force too low Check the programmed force Perform a force calibration
Force calibration on page 103.
Shock/noise when gun closing
Wrong value of the sheet programmed thickness
Check/change the programmed thickness
Sheet geometrical issue
Check/Fix the issue
Unstable force at tips level
Bad gun parameters Check them, reload if it is necessary
Do a gun parameter tuning
Controllers settings on page 92.
Abnormal friction and/or clearance on mechanical unit
Check the belt, the motor fasteners, the linear unit
Timing belt (tension check, adjustment and replacement) on page 116.
Trouble Possible cause Action More info.
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8 Repair activities
8.1. Introduction©
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8 Repair activities
8.1. Introduction
General
This chapter details some common activities that may be required for a thorough inspection
of the unit or in case of failure of the FlexGun. Each procedure contains all information
required to perform the activity, e.g. required tools and materials.
Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed! There are general safety aspects that must be read through, as well as more
specific safety information that describe danger and safety risks when performing the
procedures. Read Safety on page 13 before performing any service work.
Precautions
The precautions below should be observed before proceeding with the maintenance of the
FlexGun:
CAUTION!
• Welding arms and cooling systems are hot after welding. Let them cool down before
any intervention.
• All power supplies to the FlexGun as well as to other machines within the danger zone
must be turned off.
• If required, the main switch should be locked.
• Make sure that the cooling system is not pressurized.
• Use only original ABB spare parts. The use of unauthorized parts or others than
original parts will void the warranty.
Required equipment
Bolts and screws and tightening torques
Specified in Bolt, screws, tightening torques on page 147.
Equipment Note
Handling equipment Specified in Handling/lifting on page 76.
Standard toolkit Specified in Standard toolkit on page 149.
Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.
Specified in Special tools on page 150.
1233HAW050009061 Revision: F
8 Repair activities
8.2.1. Introduction
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8.2 Dismounting of the arms
8.2.1. Introduction
General
The following instructions are based on the procedures required to dismount the arms of a
standard X-Gun. The principle is however applicable for operations on most types of
FlexGuns.
The required equipment is the standard toolkit, and in particular:
Besides, it is recommended to use strong braided thread to fix the position of the leaf shunt.
Toolkit, illustration.
1. Spanner 17, 19
2. Hex keys (Allen keys) 5, 6, 8
3. Hex keys (Allen key) 8 with short neck (no longer than 30mm)
4. Dowel pin remover + long M5 screw
5. Plastic mallet
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8.2.2. Removal of the fixed arm©
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8.2.2. Removal of the fixed arm
Procedure
Steps Actions Info/Illustration
1. Disconnect the water cooling pipes from the buss bar with the spanner 19.Be careful as there might be residual water in the pipes and shunt.
fixed arm removal, step1
2. Remove the 4 screws to disconnect the leaf shunt from the buss bar with the hex key 5.
fixed arm removal, step 2
3. Remove the 5 screws that attach the arm to the main beam with the hex key 8. Use the short hex key 8 for the screw located under the buss bar.
fixed arm removal, step 3
4. Use the spanner 17 to remove the screw that is located under the arm.
fixed arm removal, step 4
5. Remove the 2 dowel pins. It is not necessary to extract them completely from the arm holder. Be careful because the dowel pins are now the only attachment of the holder to the beam.
The arm can now be taken off from the Flexgun body.
fixed arm removal, step 5
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8.2.3. Re-assembly of the fixed arm
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8.2.3. Re-assembly of the fixed arm
Procedure
Steps Actions Info/Illustration
1. If the pins are still in the arm holder, leave them. If they are not, insert them completely. Position the arm holder on the gun body and use the mallet to insert the pins in the gun body, but not completely yet. It is preferable to start tightening the screws first.
fixed arm re-assembly, step1
2. Use the hex key 8 to tighten all the screws but do not tighten them completely yet. Use the short hex key to tighten the screw located under the buss bar.Finish inserting the dowel pins with the mallet and then torque-tighten all screws (use the spanner 17 for the one located under the arm).
3. Attach the leaf shunt to the buss bar. If present, don’t forget the aluminium and copper plates, located between the screws and the leaf shunt, and between the leaf shunt and the buss bar.
Reconnect the water cooling pipes to the buss bar with the spanner 19.
Copper and aluminium plate, example
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8.2.4. Removal of the mobile arm©
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8.2.4. Removal of the mobile arm
Procedure
Steps Actions Info/Illustration
1. Disconnect the water cooling pipes from the buss bar with the spanner 19.Be careful as there might be residual water in the pipes and shunt.
mobile arm removal, step1
2. Remove the 4 screws to disconnect the leaf shunt from the buss bar with the hex key 5.
TIP!
To prevent the leaf shunt from being damaged during following maintenance operations, use the braided wire to keep it bent and attached to the transformer buss bar. mobile arm removal, step 2
3. Remove the 8 screws that attach the arm to the mobile carriage with the hex key 8.
mobile arm removal, step 3
4. Remove the 2 dowel pins. It is not necessary to extract them completely from the holder. Be careful because the dowel pins are now the only attachment of the bracket to the carriage.
The arm can now be removed from the carriage.
mobile arm removal, step 4
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8.2.5. Re-assembly of the mobile arm
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8.2.5. Re-assembly of the mobile arm
Procedure
Steps Actions Info/Illustration
1. Position the arm bracket on the carriage.Insert the pins with the mallet, but not completely yet. It is preferable to start tightening the screws first.
mobile arm re-assembly, step1
2. Use the hex key 8 to tighten all the screws but do not tighten them completely yet.Finish inserting the dowel pins with the mallet and then torque-tighten all screws.
3. Attach the leaf shunt to the buss bar. Don’t forget the intermediate aluminium and copper plates, located between the screws and the leaf shunt, and between the leaf shunt and the buss bar.
Reconnect the water cooling pipes to the buss bar with the spanner 19.
Copper and aluminium plates, example
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8.3.1. Introduction©
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8.3 Replacement of the pulleys
8.3.1. Introduction
General
To replace either one of the pulleys, it is necessary to first dismount the fixed arm and the belt.
See Pulley replacement procedure on page 130 and Timing belt (tension check, adjustment
and replacement) on page 116.
The required equipment is the addition of the tool 3HAW060005711 (see Special tools on
page 150) and the standard toolkit, and in particular:
Toolkit, illustration.
1. Spanner 19
2. Hex keys (Allen keys) 3, 5 and 6 (6 for ball screw pulley only)
3. Lock wrench
4. The following screws:
• 2x CHc M6x25 or 2x CHc M6x30 (to be associated with 3HAW060005711)
• 1x H M12x45 or 1x H M12x50 (removal of the pulley)
• 1x CHc M8x50 (reassembly of the pulley on the roller screw shaft)
• 1x CHc M8x35 (reassembly of the pulley on the roller screw shaft)
• 1x CHc M6x50 (reassembly of the pulley on the motor shaft)
• 1x CHc M6x35 (reassembly of the pulley on the motor shaft)
• 1x plain washer inner diameter 6.2
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8 Repair activities
8.3.2. Pulley replacement procedure
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8.3.2. Pulley replacement procedure
Procedure
Steps Actions Info/Illustration
1. Unscrew the lock screw (type hpc M6x6) with the hex key 3.
pulley replacement, step1
2. Use the 2 screws M6x25 or M6x30 to attach the tool 3HAW060005711 to the pulley. Then start screwing the M12 screw in the central hole.
pulley replacement, step 2
3. Use the spanner 19 to screw the M12 screw while you hold the tool 3HAW060005711 with the other hand. This will pull the pulley away from the motor or ball screw shaft.If the M12 screw is not long enough, you can finish the extraction by gently tapping behind the pulley with a soft mallet.
pulley replacement, step 3-1
pulley replacement, step 3-2
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8.3.2. Pulley replacement procedure©
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4. If necessary, use the lock wrench to extract the key from the shaft.
pulley replacement, step 4
5. If you need to replace the pulley, detach the tool 3HAW060005711 from the current one and use the 2 screws M6x25 or M6x30 to attach it to the new one.
pulley replacement, step 5
6. Position the pulley onto the shaft and use the hex key (5 for the motor shaft or 6 for the ball screw shaft) to start screwing the M6x50 or M8x50 screw with the washer on. This will push the pulley onto the shaft.
When you reach the maximum you can screw with the 50mm screw, replace it with the 35mm screw and keep screwing until the pulley is back into the position it originally was. Make sure that the pulley doesn’t come in contact with the gun body surface.The 2 pulleys must be perfectly aligned on a vertical plan.
pulley replacement, step 6
7. Finally, re-tighten the lock screw (type hpc M6x6) with the hex key 3.
Steps Actions Info/Illustration
1313HAW050009061 Revision: F
8 Repair activities
8.4.1. Introduction
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8.4 Replacement of the motor
8.4.1. Introduction
General
To dismount the motor, it is necessary to first dismount the fixed arm and the belt. See Pulley
replacement procedure on page 130 and Timing belt (tension check, adjustment and
replacement) on page 116.
For a replacement of the motor, you need to transfer the pulley from the old motor shaft to the
new one. See Pulley replacement procedure on page 130
The required equipment is the standard toolkit, and in particular:
8.4.2. Motor replacement procedure
Procedure
1. Spanners 10 and 13
2. Hex key (Allen key) 6
Steps Actions Info/Illustration
1. Position the gun on the worktable such as the motor cables can be easily disconnected and the motor easily extracted.
motor replacement, step1
2. Disconnect the motor cables. See Electrical connections on page 62.
motor replacement, step 2
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3. If the belt is present, remove it as explained inTiming belt (tension check, adjustment and replacement) on page 116. For a replacement of the motor, you need to transfer the pulley from the old motor shaft to the new one. See Pulley replacement procedure on page 130.
NOTE!
When planning to remove and re-install used belts, measure and record the tension before removing. If the belt is functioning correctly and its resonance frequency is within the indicated ranges (i.e. not less than 155 Hz), re-install at the recorded tension.
4. Use the Allen key 6 to remove the motor mounting screws. Be sure to hold the motor mounting with your other hand as these screws are its last attachment to the gun body.
You can now extract the motor and its mounting out of the gun body.
motor replacement, step 4
5. Remove the 4 screws with the Allen key 6 to separate the motor from its mounting.
fixed arm removal, step 5
6. To re-assemble, proceed in the opposite order. Torque-tighten all screws and perform a tuning of the belt tension!
Steps Actions Info/Illustration
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8.5.1. Introduction
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8.5 Replacement of the transformer
8.5.1. Introduction
General
To replace the transformer, it is necessary to first dismount the FlexGun back plate. It is
recommended to dismount the arms as well.
Before proceeding, the gun carriage should be in “open” position to clear the access to the
buss bar fasteners.
The required equipment is the standard toolkit, and in particular:
Toolkit, illustration.
1. Spanner 8 and 10 (socket wrenches recommended)
2. Hex keys (Allen keys) 6 and 8
3. Dowel pin remover + long M5 screw (for the removal of the back plate)
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8.5.2. Transformer replacement procedure©
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8.5.2. Transformer replacement procedure
Procedure
Steps Actions Info/Illustration
1. Use the spanners 8 and 10 to remove the 4 screws of the top cover. Remove the cover by sliding it out.
transformer replacement, step 1
2. Use the hex key 6 to detach the manifold from the gun beam.
transformer replacement, step 2
3. From the top of the gun, use the hex key 6 to remove the 6 screws that attach the buss bars to the transformer.
transformer replacement, step 3
4. Use the spanner 8 to remove the 4 screws of the screen plate and remove the plate.
transformer replacement, step 4
5. Disconnect the quick connect fittings of the water cooling circuit (you can pull the “WATER IN” fitting from outside of the beam).
transformer replacement, step 5
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8 Repair activities
8.5.2. Transformer replacement procedure
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6. Use the hex key 6 to remove the 8 screws (4 on each side) that hold the transformer.
transformer replacement, step 6
7. Extract the transformer from the bottom of the Flexgun. It is preferable to use the help of another person as the transformer is very heavy and can be difficult to extract.
transformer replacement, step 7
8. To re-assemble, proceed in the opposite order.If necessary, use a mallet to push the transformer back in.Torque-tighten all screws!
transformer replacement, step 7
Steps Actions Info/Illustration
3HAW050009061 Revision: F 136
8 Repair activities
8.6.1. Introduction©
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8.6 Replacement of the roller screw
8.6.1. Introduction
General
The roller screw is an essential high-technology component of the FlexGun linear unit. It is
designed to sustain very high loads and, if lubrication is performed according to the related
instructions of the maintenance section, it should last for the whole lifetime of the FlexGun.
In case of failure of the linear drive unit, make sure that you first identify and, when required,
fix all the possible root causes other than a failure of the roller screw.
Unless there is a confirmed need to dismount the roller screw, do not do it. The roller nut
(locked in the mobile carriage) is precisely synchronised to the screw and removing it implies
a risk of problematic re-assembly and/or damage.
To dismount the roller screw, it is necessary to first dismount the mobile and fixed arms, and
the timing belt. See Dismounting of the arms on page 124 and Timing belt (tension check,
adjustment and replacement) on page 116.
The required equipment is the addition of the tools 3HAW060005708, 3HAW060005711 (see
Special tools on page 150) and the standard toolkit (in particular, the tools required in
Dismounting of the arms on page 124, Timing belt (tension check, adjustment and
replacement) on page 116 and Pulley replacement procedure on page 130).
It is also recommended to use ball bearing blocks plastic protections (shaped like the rails) to
prevent the balls from falling off the block when sliding them off the rails.
Toolkit, illustration.
1373HAW050009061 Revision: F
8 Repair activities
8.6.2. Roller screw replacement procedure
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8.6.2. Roller screw replacement procedure
Procedure
Steps Actions Info/Illustration
1. Use the spanners 8 and 10 to remove the 4 screws of the top cover. Remove the cover by sliding it out.
roller screw replacement, step 1
2. Use the hex key 6 to remove the 3 screws on the end cover (connector side). Use the wrench 8 to remove the screws on each side cover.Remove the end cover.
roller screw replacement, step 2
3. If necessary, manually jog the carriage with the tool 3HAW060005711 as shown in Manual jogging of the mobile carriage on page 120 to move the carrier until you can see the hard stop bumper attached to the beam.
Use the hex key 6 to remove the 2 screws of the bumper and take it off the beam.
roller screw replacement, step 3
The reason of doing this is that the roller screw cannot be extracted from the body as long as the roller nut (locked in the carriage) does not reach the un-threaded part of the screw. To achieve so, the carriage must be manually jogged beyond its normal mechanical limit.
3HAW050009061 Revision: F 138
8 Repair activities
8.6.2. Roller screw replacement procedure©
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4. Manually jog the carriage with the tool 3HAW060005711 as shown in Manual jogging of the mobile carriage on page 120 to move the carrier to the connector side, until you reach the position shown on the picture.
CAUTION!
Be careful as there is a risk of losing ball bearings from the runner block. Use the plastic protection (shaped like the rails) if possible
roller screw replacement, step 4-1
roller screw replacement, step 4-2
5. Remove the roller screw shaft pulley as shown in Pulley replacement procedure on page 130.
6. Use the (socket) wrench 10 to remove the locknut.
Then use the Allen key 3 to remove the screw.
roller screw replacement, step 6-1
roller screw replacement, step 6-2
7. Remove the sealing threaded ring using the tool 3HAW060005708. The ring is torque-wrenched (43 N.m) so you might need a long wrench.
roller screw replacement, step 7
Steps Actions Info/Illustration
1393HAW050009061 Revision: F
8 Repair activities
8.6.2. Roller screw replacement procedure
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8. Extract the roller screw.
If the roller nut (located in the mobile carriage) is still on the threaded part of the screw, you need to rotate the shaft counter-clock wise until it can be extracted.
The spacer 3HAW060005311 should come with the roller screw.
roller screw replacement, step 8
9. For a replacement of the roller screw, the roller nut contained in the carriage must be replaced as well (screw and nut are strictly paired).
To do so, take the carriage off the rails (with the necessary precautions explained above) and
remove the lock screw and threaded ring using the tool 3HAW060005708. the roller nut can now be replaced.Re-tighten the threaded ring with the ABB tool 3HAW060005708 and the torque wrench set at 43 N.m with a drop of thread-locker. roller screw replacement, step 9
10. To reassemble, gently tap the ball screw with the mallet to insert the set of bearings deep in the beam slot and use your hand to manually start screwing it in the carriage roller nut.
Leave the ball bearing protections in position until the runner blocks are back onto the rails.
NOTE!
The screw should be perfectly clean of any impurity, and covered with a clean film of oil. See the requirements in Lubrication on page 119.
11. Insert the spacer 3HAW060005311. Pay attention to the spacer orientation, the notches must appear outside.
You can use a couple of screws to fully push the spacer in its slot.
roller screw replacement, step 8
Steps Actions Info/Illustration
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8.6.2. Roller screw replacement procedure©
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12. Re-tighten the threaded ring with the ABB tool 3HAW060005708 and the torque wrench set at 43 N.m with a drop of thread-locker.
Use the Allen key 3 to lock the ring by screwing the M6X12 screw with Delrin tip. Tighten it with a low torque (6-7 N.m max.).
Tighten the locknut on it with the socket wrench 10.
roller screw replacement, step 12
13. Re-assemble the pulley as shown in Pulley replacement procedure on page 130.
Manually jog the carriage back and forth to make sure that the carriage movement is smooth and fiction-free.
Re-assemble the hard stop bumper onto the beam.
14. Re-assemble the timing belt as shown in Timing belt (tension check, adjustment and replacement) on page 116.
Put all the covers back
Steps Actions Info/Illustration
1413HAW050009061 Revision: F
8 Repair activities
8.6.2. Roller screw replacement procedure
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3HAW050009061 Revision: F 142
9 Decommissioning
9.1. Decommissioning©
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9 Decommissioning
9.1. Decommissioning
Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed! There are general safety aspects that must be read through, as well as more
specific safety information that describe danger and safety risks when performing the
procedures. Read Safety on page 13 before performing any service work.
Precautions
The precautions below should be observed before proceeding with the decommissioning of
the FlexGun:
CAUTION!
• Welding arms and cooling systems are hot after welding. Let them cool down before
any intervention.
• All power supplies to the FlexGun as well as to other machines within the danger zone
must be turned off.
• If required, the main switch should be locked.
• Make sure that the cooling system is not pressurized.
Required equipment
Hazardous materialThe table specifies some of the materials in the track motion and their respective use throughout the product. Dispose of the components properly to prevent health or environmen-tal hazards.
Equipment Note
Handling equipment Specified in Handling/lifting on page 76.
Standard toolkit Specified in Standard toolkit on page 149.
Material Example application
Copper alloy Cable, motor, transformer, arm, tip, shunt, etc.
Steel Gears, screws, nuts, etc.
Stainless steel Cover, screws for primary connection of transformer, etc.
Plastic / Rubber (PVC) Cables, connectors, belt, etc.
Aluminium Beam, mobile carriage, motor holder, arm holders, etc.
1433HAW050009061 Revision: F
9 Decommissioning
9.1. Decommissioning
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Oil and grease
Where possible, arrange for the oil and grease to be recycled. Dispose of oil and grease via
an authorized person/contractor in accordance with local regulations. Do not dispose of oil
and grease near lakes, ponds, ditches, down drains or onto soil. Incineration must be carried
out under controlled conditions in accordance with local regulations.
Also note that:
• Spills may form a film on water surfaces causing damage to organisms. Oxygen
transfer could also be impaired.
• Spillage may penetrate the soil causing ground water contamination.
3HAW050009061 Revision: F 144
10 Reference information
10.1. Introduction©
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10 Reference information
10.1. Introduction
General
This chapter includes general information, complementing the more specific information in
the different procedures in the manual.
1453HAW050009061 Revision: F
10 Reference information
10.2. Unit conversion
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10.2. Unit conversion
Converter table
Use the following table to convert units used in this manual.
Quantity Unit
Length 1 m 3.28 ft 39.37 in
Weight 1 kg 2.21 lb
Pressure 1 bar 100 kPa 14.5 psi
Force 1 N 0.738 lbf
Moment 1 N.m 0.738 lbf-tn
Volume 1 L 0.264 US gal
3HAW050009061 Revision: F 146
10 Reference information
10.3. Bolt, screws, tightening torques©
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10.3. Bolt, screws, tightening torques
Bolt and screws
Before tightening any screw, observe the following:
• Determine whether a standard tightening torque or special torque is to be applied.
The standard torques are specified in the following tables. Any special torques are
specified in the repair, maintenance or installation procedure descriptions. Any
special torque specified overrides the standard torque!
• Use the correct tightening torque for each type of screw joint.
• Only use correctly calibrated torque keys.
• Always tighten the joint by hand, and never use pneumatic tools.
• Use the correct tightening technique, tighten the screw in a slow, flowing motion.
• Maximum allowed total deviation from the specified value is 10%!
NOTE!
The bolts used on (or provided with) the FlexGun are of 3 different classes: 8.8, 10.9, and
12.9. Unless indicated otherwise, the screws are by default of class 8.8.
NOTE!
Unless indicated otherwise, all bolts must be clean of oil or grease and tightened with a mild
thread-locker such as Loctite 243.
Standard tightening torques
The following table specifies the recommended standard tightening torques for hex screws
and socket head cap screws:
The following table specifies the recommended standard tightening torque for water and air
connectors when one or both connectors are made of bras:
Screw thread size M5 M6 M8 M10 M12
Tightening torque
CLASS 8.8
5.5 N.m 9.5 N.m 23 N.m 46 N.m 79 N.m
Tightening torque
CLASS 10.9
8.1 N.m 14 N.m 34 N.m 67 N.m 116 N.m
Tightening torque
CLASS 12.9
9.5 N.m 16.4 N.m 40 N.m 79 N.m 136 N.m
Dimension Tightening torque Nm - Nominal
Tightening torque Nm - Minimal
Tightening torque Nm - Maximum
1/8 12 N.m 8 N.m 15 N.m
1/4 15 N.m 10 N.m 20 N.m
3/8 20 N.m 15 N.m 25 N.m
1/2 40 N.m 30 N.m 50 N.m
3/4 70 N.m 55 N.m 90 N.m
1473HAW050009061 Revision: F
10 Reference information
10.3. Bolt, screws, tightening torques
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Notable tightening torques
The following table specifies the tightening torques for notable parts of the unit, which
fastener are not standard class 8.8 screws:
Parts Fasteners Tightening torque
Standard electrode holder clamping
Clamping
4x
socket head cap screws M6x25
CLASS 12.9
16.4 N.m
Threaded rings that hold the ball bearings on the beam, and the roller nut in the carriage
Threaded rings
To be tightened with ABB tool 3HAW060005708 + torque wrench.
43 N.m
Fastening of the carriage onto the ball bearing blocks
Carriage and runner blocks
4x
4x
socket head cap screws M6x16
CLASS 10.9
14 N.m
Fastening of the guideways onto the beam
Guideways fastening
2x
10x
socket head cap screws M6x20
CLASS 12.9
16.4 N.m
Transformer primary pins
Transformer primary pins
/ 6 N.m
3HAW050009061 Revision: F 148
10 Reference information
10.4. Standard toolkit©
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10.4. Standard toolkit
General
All service (repairs, maintenance and installation) procedures contain lists of tools required
to perform the specified activity.
All special tools required are listed directly in the procedures while all the tools that are
considered standard are gathered in the standard toolkit and defined in the table below.
This way, the tools required are the sum of the standard toolkit and any tools listed in the
instruction.
Contents, standard toolkit
Qty Tool
1 Set of spanners 8-22 mm
1 Hex keys (Allen key) 3, 4, 5, 6, 8 and 10 mm
1 Torque wrench 10-140 Nm
1 Ratchet head for torque wrench 1/2
1 Socket head cap 5mm, 6mm, 8mm, 10mm socket 1/2" bit L 20 MM
(for socket head cap screws - ISO 4762 - sometimes referred to as “CHC screws”)
1 Hex head cap 8mm, 10mm, 13mm, 19mm socket 1/2" bit L 20 MM
(for hex screws - ISO 4017 - sometimes referred to as "H screws")
1 Plastic mallet
1 Dowel Pin remover
1 Mild thread-locker (Recommended: Loctite 243)
1493HAW050009061 Revision: F
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10.5. Special tools
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10.5. Special tools
General
All service instructions contain lists of tools required to perform the specified activity. The
required tools are a sum of standard tools, defined in the section Standard toolkit on page 149,
and of special tools, listed directly in the instructions and also gathered in this section.
Special tools
The following table specifies the special tools required during several of the service
procedures. The tools are also specified directly in concerned instructions in the Product
manual.
Special tools available from ABB
The following table specifies the special tools required during several of the service
procedures. The tools may be ordered separately and are also specified directly in concerned
instructions in the Product manual.
For operations on water cooling circuit connectors:
Qty Tool Product
1 Thread sealant for conical fittings Loctite 577
For operations on conductive parts:
Qty Tool Product
1 Conductive grease Molydal Thermolub SP
1 Insulation meter
For operations on electrical parts:
Qty Tool Product
1 Crimping pliers for 35mm² lug and insertsORCrimping pliers for 25mm² lug and inserts
The type of needed pliers depends on the type of DressPack: 35mm² lugs for the Orange Line 25mm² for the Integrated DressPack IRB 6640 LeanID
- Multi Contact (MC):
Crimping pliers 18.3710 - M-PZ-T2600 with
35mm² cores 18.3712 - TB9-13
or
25mm² cores 18.3704 - MES-PZ-TB11/25
A: Crimping pliers, B: Inserts
1 Wire stripper
1 Cable cutter
Qty Tool ABB Article no.
1 ABB wrench tool for pulley 3HAW060005711
1 ABB wrench tool for threaded rings 3HAW060005708
1 Welding Gun force and current calibration kit 3HAW050009047
1 Tension gauge 3HAW050009048
3HAW050009061 Revision: F 150
11 Spare parts
11.1. Introduction©
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11 Spare parts
11.1. Introduction
General
This chapter specifies all spare parts and replacement articles of the FlexGun.
Unless indicated otherwise, the listed parts are suitable for all standard X-type and C-type
FlexGuns.
The parts specific to one type are marked as such.
The list of the spare parts specific to your FlexGun(s) (typically, the constitutive parts of the
arms and robot attachment) should be provided with the delivery.
1513HAW050009061 Revision: F
11 Spare parts
11.2. Motor and linear guiding material
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11.2. Motor and linear guiding material
Motor and motor mounting
The following parts depend on the version of the motor used.
All FlexGuns assembled before 2012 use a motor type 9C (without brake).
If you do not know which version you have, contact ABB.
Motor and motor mounting
Item Quantity ABB part reference no. Note
A 1 3HAWL000101 Servomotor type 9C
3HAWL000325 Servomotor type T
B 1 3HAW060005003 Motor holder for motor type 9C
3HAW060005143 Motor holder for motor type T
3HAW050009061 Revision: F 152
11 Spare parts
11.2. Motor and linear guiding material©
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Linear guiding and roller screw
Linear guiding and roller screw
NOTE!
Contact ABB if you do not know whether your FlexGun requires Bosch Rexroth or SBC linear
guiding material.
Item Quantity ABB part reference no. Description
A 4 3HAWL000103 Ball bearing block (Bosch Rexroth)
3HAWL000178 Ball bearing block (SBC)
B 2 3HAW060005033 Guideway (Bosch Rexroth)
3HAWL000177 Guideway (SBC)
C 1 3HAWD06000001 Roller screw kit (including bearings)
D 1 3HAW060005026 Toothed pulley 36 - 5M25
(Order in addition the tool 3HAW060005711. See Special tools on page 150.)
- 1 3HAWL000132 Key 6x6x35 (for roller screw shaft)
You can also obtain it from a standard components supplier.
Example: Misumi, ref. KESH6-35
E 1 3HAWL000138 Timing belt
F 1 3HAW060005025 Toothed pulley 28 - 5M25
(Order in addition the tool 3HAW060005711. See Special tools on page 150.)
- 1 3HAWL000320 Key 6x6x30 (for motor shaft)
You can also obtain it from a standard components supplier.
Example: Misumi, ref. KESH6-30
- 1 3HAW060005012 Hard stop for mobile arm carriage
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11.2. Motor and linear guiding material
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Threaded rings for roller screw nut and bearings
Threaded rings
Item Quantity ABB part reference no. Description
A 1 3HAW060005308 Threaded ring for beam - holds the roller screw bearings.
(Order in addition the tool 3HAW060005708. See Special tools on page 150.)
B 1 3HAWL000111 Sealing for threaded ring
C 1 3HAWL000104 Threaded ring for carriage - holds the roller nut.
(Order in addition the tool 3HAW060005708. See Special tools on page 150.)
D 1 - Screw with Delrin tip M6x16
+ flat M6 nut
You can obtain it from a standard components supplier.
Example: Misumi, ref. SBPP6-16
E 1 - Screw with Delrin tip M6x12
You can obtain it from a standard components supplier.
Example: Misumi, ref. SBPP6-12
3HAW050009061 Revision: F 154
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11.3. Welding power, conductive parts, and harness©
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11.3. Welding power, conductive parts, and harness
Transformers
Buss bars and insulation, standard gun body
Buss bars and insulation, standard gun body
ABB part reference no. Description
3HAWL000102 DC Transformer (Elesa type)10V, 500V, 1000Hz, 91kVA
3HAWL000170 AC Transformer (Elesa type)10V, 400V, 50Hz, 88kVA
3HAWL000317 DC Transformer (Roman type)10.8 V, 500V, 1000Hz, 91kVA
Item Quantity ABB part reference no. Description
A 2 3HAW060005017 Nylon shunt holder
B 1 3HAW060005015 Insulating plate between beam and buss bars
C 1 3HAW060005016 Insulating plate between buss bars
D 2 3HAW060005410 Nylon dowel pin
E 1 3HAW060005055 Transformer buss bar - fixed arm side
F 1 3HAW060005082 Transformer buss bar - mobile arm side
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11.3. Welding power, conductive parts, and harness
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Buss bars and leaf shunts, standard X- and C-types
The following picture shows the assembly of a standard X-Gun with copper arms.
The table below also provides their equivalent for standard guns with copper or aluminium
arms, X- and C types.
Buss bars and leaf shunts, Standard X- and C-types
Item Quantity ABB part no. Description
A 1 3HAW060005057 Mobile arm leaf shunt (all types of gun)
B 1 3HAW060005058 X-Gun fixed arm leaf shunt
3HAW050023065 C-Gun 0° fixed arm leaf shunt
3HAW050023064 C-Gun 15° fixed arm leaf shunt
3HAW050023066 C-Gun 30° fixed arm leaf shunt
3HAW060005079 C-Gun 45° fixed arm leaf shunt
3HAW060005040 C-Gun 60° fixed arm leaf shunt
C 1 3HAW060005059 X-Gun mobile copper arm buss bar
3HAW060005062 X-Gun mobile copper arm buss bar - inverted
3HAW050009018 X-Gun mobile aluminium arm buss bar
3HAW060005077 C-Gun mobile copper or aluminium arm buss bar
D 1 3HAW060005060 X-Gun fixed copper arm buss bar
3HAW050009019 X-Gun fixed aluminium arm buss bar
3HAW060005078 C-Gun fixed copper arm buss bar
3HAW060005027 C-Gun fixed aluminium arm buss bar
E 4 3HAW060005411 Aluminium plate for leaf shunts fixation
F 2 3HAWL000133 O Ring 2.1X1.6 for buss bar
3HAW050009061 Revision: F 156
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11.3. Welding power, conductive parts, and harness©
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Adapter plate and female plug
Adapter plate and female plug
Gun Harness
Item Quantity ABB part reference no. Description
A 1 3HAWL000140 Adapter Plate
B 13HAWL000141 Female plug 35mm²
3HAWL000381 Female plug 25mm²
Quantity ABB part no. Description
1 3HAW050008639 Electrical harness (for guns with motor type 9C) - OrangeLine DressPack
1 3HAW050008653 Electrical harness (for guns with motor type T) - OrangeLine DressPack
1 3HAW050008658 Electrical harness (for guns with motor type T) - LeanID DressPack
1573HAW050009061 Revision: F
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11.4.1. Copper arms
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11.4 Arms spare parts
11.4.1. Copper arms
Copper arm holders, X-Gun
Arm holders - X-type
Copper arm holders, C-Gun
Arm holders - C-type
Copper arm insulation
Insulating sleeve and washer
Item Quantity ABB part reference no. Description
A 1 3HAW060005005 X-Gun mobile arm holder
B 1 3HAW060005004 X-Gun fixed arm holder
Item Quantity ABB part reference no. Description
A 1 3HAW060005269 C-Gun mobile arm holder
B 1 3HAW061017002 C-Gun 0° fixed arm holder
3HAW061017012 C-Gun 15° fixed arm holder
3HAW061017022 C-Gun 30° fixed arm holder
3HAW060005270 C-Gun 45° fixed arm holder
Item Quantity ABB part reference no. Description
A 2 3HAW060005605 Insulating sleeve
B 2 3HAW060005606 Insulating washer
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11.4.2. Aluminium arms©
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11.4.2. Aluminium arms
Aluminium arm holders, X-Gun
Aluminium arm holders, C-Gun
Aluminium arms insulation
Quantity ABB part reference no. Description
1 3HAW060005023 Arm holder for X-type fixed aluminium arm
1 3HAW060005022 Arm holder for X-type mobile aluminium arm
Quantity ABB part reference no. Description
1 3HAW060005030 Arm holder for C-type 0° fixed aluminium arm
1 3HAW060005028 Arm holder for C-type 15° fixed aluminium arm
1 3HAW060005029 Arm holder for C-type 30° fixed aluminium arm
1 3HAW060005024 Arm holder for C-type 45° fixed aluminium arm
1 3HAW060005038 Arm holder for C-type 60° fixed aluminium arm
1 3HAW060005039 Arm holder for C-type 90° fixed aluminium arm
1 3HAW060005269 Arm holder for C-type mobile aluminium arm
Quantity ABB part reference no. Description
4 3HAW050008766 Insulation Plate 1-1/1-3, for X-type alu. arms gun
2 3HAW050008769 Insulation Plate 1-2 for, X-type alu. arms gun
2 3HAW050008771 Insulation Plate 1-4, for X-type alu. arms gun
2 3HAW050008767 Insulation Plate 2, for X-type alu. arms gun
2 3HAW050008768 Side Plate, for X-type alu. arms gun
2 3HAW060005605 Insulating sleeve, for C-type aluminium arm
2 3HAW060005606 Insulating plate, for C-type aluminium arm
1593HAW050009061 Revision: F
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11.4.3. Standard tips, electrode clamps and O-rings
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hts
rese
rved
.
11.4.3. Standard tips, electrode clamps and O-rings
List of tips, clamps and o-rings
Caps B
ABB part reference no. Description
3HAW060005910 Copper electrode cap B D13 (see drawing below)
3HAW060005911 Copper electrode cap B D16 (see drawing below)
3HAW060005912 Copper electrode cap B D20 (see drawing below)
3HAW060005085 Electrode clamp D20
3HAW060005086 Electrode clamp D25
3HAW060005974 Electrode clamp D31.5
3HAWL000356 O-ring D10×1.8
3HAWL000354 O-ring D10×2.65
3HAWL000364 O-ring D12x1
3HAWL000355 O-ring D20x1.8
3HAWL000360 O-ring D20x2
3HAWL000358 O-ring D22×1.9
3HAWL000133 O-ring D22.1X1.6
3HAWL000361 O-ring D24x2
3HAWL000174 O-ring D25x2.4
3HAWL000351 O-ring D25×2.65
3HAWL000362 O-ring D28x2
3HAWL000357 O-ring D28×2.4
3HAWL000363 O-ring D30x2.5
3HAWL000134 O-ring D31.47x1.78
3HAWL000359 O-ring D31.5×1.8
3HAWL000353 O-ring D31.5×2.65
3HAWL000350 O-ring D32x2
3HAWL000175 O-ring D35x2
3HAWL000352 O-ring D35.5×2.65
3HAW050009061 Revision: F 160
11 Spare parts
11.5. Robot attachment©
Cop
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013
AB
B. A
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ight
s re
serv
ed.
11.5. Robot attachment
Robot attachment parts
See Attachement - FlexGun side on page 80 and Attachement - robot side on page 83, or the
assembly drawing delivered with your FlexGun for the parts details and needed quantities.
ABB part reference no. Description
3HAW060005268 FlexGun back plate
3HAW060005262 Locating ring
3HAW060005261 Holder for 40° positioning - connector side
3HAW060005263 Holder for 90° positioning - connector side
3HAW060005273 Interface plate IRB6640 - gun side
3HAW060005274 Interface plate IRB6640 - robot side
3HAW060005288 Interface plate IRB7600 - gun side
3HAW060005287 Interface plate IRB7600 - robot side
3HAW060005289 Locating ring for IRB7600
1613HAW050009061 Revision: F
11 Spare parts
11.6. Water cooling
© C
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11.6. Water cooling
Water manifold
Water manifold 1 input - 2 outputs
Hose: Transformer buss bar to mobile arm
Hose: transformer buss bar to mobile arm
Hose: Transformer buss bar to fixed arm
Hose: transformer buss bar to fixed arm
Item Qty ABB part reference no. Note
- 1 3HAW060005054 Water manifold1 input - 2 outputs
- 1 3HAW050009020 Water manifold1 input - 1output
3HAW050009061 Revision: F 162
11 Spare parts
11.6. Water cooling©
Cop
yrig
ht 2
013
AB
B. A
ll r
ight
s re
serv
ed.
Hose: Fixed arm to output, X-gun
Hose: from fixed arm to output (X-gun)
Hose: Fixed arm to output, C-gun
Hose: from fixed arm to output (C-gun)
Hose: Mobile arm to output, X-gun
Hose: from mobile arm to output (X-gun)
Hose: Mobile arm to output, C-gun
Hose: from mobile arm to output (C-gun)
Connector and closing plug used on buss bars
Buss bar connector and closing plug
1633HAW050009061 Revision: F
11 Spare parts
11.6. Water cooling
© C
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201
3 A
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. All
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.
List of the water connectors
You can find below the details of the FlexGun water connectors and hoses, and their reference
number from the original supplier (Parker-Legris or Festo).
ABB ref. no.Qty Xgun
Qty Cgun
Description Supplier ref. no.
3HAWC101125 5 5 Plug BSP G1/8
Legris 0205 10 00
3HAWL000116 7 7 EO Male stud connector with seal G1/4-M16X1.5
Parker GE10LREDOMDMS
3HAWL000117 1 1 Swivel connector with seal G1/2-M22X1.5
Parker EVGE-15LREDMS
3HAWL000118 2 2 Union male with seal G1/2-M22X1.5
Parker F4UCOB16 1/2
3HAWL000119 1 1 Male elbow R1/4-M16X1.5
Parker C4UCOB10 1/4
3HAWL000120 2 2 Female swivel M22x1.5 DN12
Parker 3C382-15-8B
3HAWL000121 1 1 Male straight M22x1.5 DN12
Parker 3D082-15-8B
3HAWL000122 5 4 Female swivel M16x1.5 DN10
Parker 3C382-10-6B
3HAWL000123 1 2 Female swivel elbow45 M16x1.5 DN10
Parker 39B82-10-6BK
3HAWL000124 2 2 Female swivel elbow90 M16x1.5 DN10
Parker 3C582-10-6B
3HAWL000125 2m 2m Push-lock hose DN10 (green)
Parker 837PU-6-GRN-RL
Connectors and hose used for the cooling of the transformer:
3HAWL000114 1 1 Equal elbow male taper R1/4
Legris 0152 13 13
3HAWL000126 3 3 Push-in fitting straight male R1/4-D10
Festo 153073 QSL-10
3HAWL000127 1 1 Equal elbow D10 D10
Festo 153073 QSL-10
3HAWL000128 1 1 Push-in fitting straight female G1/4-D10
Festo 153028 QSF-1/4-10-B
3HAWL000130 4 4 Push-in fitting with tailpieceD10
Festo 153059
3HAWL000131 1 1 Distributor G1/4 D10 D10
Festo 153217
3HAWL000129 1m 1m Anti spark tube D10
Festo 160552
3HAW050009061 Revision: F 164
11 Spare parts
11.7. Casing and lubrication ports©
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013
AB
B. A
ll r
ight
s re
serv
ed.
11.7. Casing and lubrication ports
Casing
Casing pieces
Lubrication ports and nipples
Item Quantity ABB part reference no. Description
A 1 3HAW060005018 X-Type motor cover
3HAW060005021 C-Type motor cover
B 1 3HAW060005306 Left side cover
C 1 3HAW060005305 Right side cover
D 1 3HAW060005009 Upper cover
E 1 3HAW060005307 End cover (transformer side)
F 1 3HAW060005013 Cover support
Quantity ABB part reference no. Description
1 3HAW060005020 Grease nipple(Located on the side of the body, used for the lubrication of the roller screw bearings)
5 3HAWL000113 Plug to lubrication ports on end cover
1653HAW050009061 Revision: F
11 Spare parts
11.7. Casing and lubrication ports
© C
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.
3HAW050009061 Revision: F 166
12 Appendix
12.1. Wiring diagrams©
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ht 2
013
AB
B. A
ll r
ight
s re
serv
ed.
12 Appendix
12.1. Wiring diagrams
List
This chapter contains the following wiring diagrams:
• 3HAW060008639: Electrical harness, motor type 9C4, OrangeLine DressPack
• 3HAW050008653: Electrical harness, motor type T, OrangeLine DressPack
• 3HAW050008658: Electrical harness, motor type T, LeanID DressPack
1673HAW050009061 Revision: F
12 Appendix
12.1. Wiring diagrams
© C
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3HAW050009061 Revision: F 168
Page
Total Page
FlexGun Harness For ABB MotorHousing With 2xM25 Cable Gland
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Date Replaced by
Title page / cover sheet
1
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0 76
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8 93
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4
0
2
=
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serv
eal
lrig
hts
inth
isdo
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ent
and
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form
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Repr
oduc
tion,
use
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toth
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sw
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tex
pres
sau
thor
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sric
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Copy
right
ABB
3HAW050008639
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2011/10/10N,Cao 2013/6/7 004
2011/10/10
Respsonsible Department: RS / BIW
F26_ABB_Cover
Document Number
Number of pages
FlexGun Harness For ABB MotorHousing With 2xM25 Cable Gland
16
Project Discription
3HAW050008639Revision 004
Page
Total Page
FlexGun Harness For ABB MotorHousing With 2xM25 Cable Gland
1
+
Date Replaced by
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1
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8 93
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4
2
2
=
Approve by,
5W
ere
serv
eal
lrig
hts
inth
isdo
cum
ent
and
inth
ein
form
atio
nco
ntai
ned
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Repr
oduc
tion,
use
ordi
sclo
sure
toth
irdpa
rtie
sw
ithou
tex
pres
sau
thor
ityis
sric
tlyfo
rbid
den.
Copy
right
ABB
3HAW050008639
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2011/10/10N,Cao 2013/6/7 004
2011/10/10
Respsonsible Department: RS / BIW
ac
4
8
73
26
51
1725
1687
1524236
145
132221
1243
112019
1021
918
ac
7
21
8
93
104
5 11
126
3.7
7.60.8
0.8
W2
W3
W4
W5
13.5W1
MP
1
2
3
4
1
2
3
4
MR
X2:1 X2:2
1.7M
1.5M
1.1M 1.1M 0.2M
X1S X1P
4
1 3PE
A
B C
D
12
3
4
5 6 7
8
9
1011
17
12
13
14 15
16
2
3HAW050008639
4 X Harting:09 14 000 99084 Guide Pin Inastalled on connector
Page
Total Page
FlexGun Harness For ABB MotorHousing With 2xM25 Cable Gland
2.a
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Connection
1
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8 93
16
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4
3
2
=
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5W
ere
serv
eal
lrig
hts
inth
isdo
cum
ent
and
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ein
form
atio
nco
ntai
ned
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Repr
oduc
tion,
use
ordi
sclo
sure
toth
irdpa
rtie
sw
ithou
tex
pres
sau
thor
ityis
sric
tlyfo
rbid
den.
Copy
right
ABB
3HAW050008639
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2011/10/10N,Cao 2013/6/7 004
2011/10/10
Respsonsible Department: RS / BIW
FlexGunConnector
Motor PowerConnector
Motor ResolverConnector
WeldingTransformer(Supply By ABB)
VoltageMeasurement
FixArm
MoveArm
TransformerTS maybe 2 or 3
GUNFlex Gun
Connector
-b
11 1213 1415 24 25 16 17
PE
-c
123 4
PE PE
-MPFlexGun
Motor PowerConnector
43 1 2
PE
CA B D
-MRFlexGun
Motor ResolverConnector
PE-TSFR
CTCurrent
Meter
CT+
M
CT-
M
TS1Temperature
Sensor
TS2Temperature
Sensor
TS+
T1
TS-
T1
TS+
T2
TS-
T2
-X2 1 2 3 4
-X2 1 2
-W2 SH1-WH1-BN 2-YE2-GN 3-PK3-GY -W6
11
-W4 BK
BNWH BUBU BKBKX2 5
TS3Temperature
Sensor
6YEYE
TS+
T3
TS-
T3
-W5 BKBUBN BKWH
-a
1 23 4
1 23 4
-X1S
-X1P
-W3 WH BKBN BU
-W1 SH2-V1-U Y/G3-W 65 87
1 3 24 78
18 19 2120 23 22
Page
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FlexGun Harness For ABB MotorHousing With 2xM25 Cable Gland
3
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Cable diagram =+-W1
1
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0 76
Replacement of
8 93
16
5
4
4
2
=
Approve by,
5W
ere
serv
eal
lrig
hts
inth
isdo
cum
ent
and
inth
ein
form
atio
nco
ntai
ned
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Repr
oduc
tion,
use
ordi
sclo
sure
toth
irdpa
rtie
sw
ithou
tex
pres
sau
thor
ityis
sric
tlyfo
rbid
den.
Copy
right
ABB
3HAW050008639
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2011/10/10N,Cao 2013/6/7 004
2011/10/10
Respsonsible Department: RS / BIW
F09_002_ABBCable diagram
Page / columnTarget designation from conductor Target designation to Connectionpoint
cable type
no. of conductorsfunction text
function text
cross-section Length
Page / columnfunction text
Cable name
Connectionpoint
=+-W1
24G1.5+2x(2x0.75)
Igus:CF210.UL.15.07.02.02
3 3 U1-U-GUN-cU -MP /3.1/3.1
2 1 V2-V-GUN-cV -MP /3.1/3.1
1 4 W3-W-GUN-cW -MP /3.1/3.1
13 A 24V BK5-GUN-b24V BK -MP /3.2/3.2
15 B 0V BK6-GUN-b0V BK -MP /3.2/3.2
11 C PTC7-GUN-bPTC -MP /3.2/3.2
12 D 0V PTC8-GUN-b0V PTC -MP /3.3/3.3
PE SH-GUN /3.3/3.3 PE-MP
PE Y/G-GUN /3.1/3.1 2 PE-MP
Page
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FlexGun Harness For ABB MotorHousing With 2xM25 Cable Gland
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Cable diagram =+-W2
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0 76
Replacement of
8 93
16
6
4
5
2
=
Approve by,
5W
ere
serv
eal
lrig
hts
inth
isdo
cum
ent
and
inth
ein
form
atio
nco
ntai
ned
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ein
Repr
oduc
tion,
use
ordi
sclo
sure
toth
irdpa
rtie
sw
ithou
tex
pres
sau
thor
ityis
sric
tlyfo
rbid
den.
Copy
right
ABB
3HAW050008639
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2011/10/10N,Cao 2013/6/7 004
2011/10/10
Respsonsible Department: RS / BIW
F09_002_ABBCable diagram
Page / columnTarget designation from conductor Target designation to Connectionpoint
cable type
no. of conductorsfunction text
function text
cross-section Length
Page / columnfunction text
Cable name
Connectionpoint
=+-W2
1.63x2x0.25mm
Igus:CF211.02.03.02
1-BN18 1 S1-GUN-bX (S1,Cos+) -MR /3.4/3.4
1-WH19 3 S3-GUN-b0V-X(S3,Cos-) -MR /3.4/3.4
2-GN20 4 S4-GUN-bY(S4,Sin+) -MR /3.4/3.4
2-YE21 2 S2-GUN-b0V-Y(S2,Sin-) -MR /3.4/3.4
3-GY23 8 R1-GUN-bEXC(R1,24V) -MR /3.4/3.4
3-PK22 7 R2-GUN-b0V-EXC(R2,0V) -MR /3.4/3.4
PE 11SH-GUN -MR /3.5/3.5 PE
Page
Total Page
FlexGun Harness For ABB MotorHousing With 2xM25 Cable Gland
5
+
Date Replaced by
Cable diagram =+-W3
1
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0 76
Replacement of
8 93
16
7
4
6
2
=
Approve by,
5W
ere
serv
eal
lrig
hts
inth
isdo
cum
ent
and
inth
ein
form
atio
nco
ntai
ned
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ein
Repr
oduc
tion,
use
ordi
sclo
sure
toth
irdpa
rtie
sw
ithou
tex
pres
sau
thor
ityis
sric
tlyfo
rbid
den.
Copy
right
ABB
3HAW050008639
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2011/10/10N,Cao 2013/6/7 004
2011/10/10
Respsonsible Department: RS / BIW
F09_002_ABBCable diagram
Page / columnTarget designation from conductor Target designation to Connectionpoint
cable type
no. of conductorsfunction text
function text
cross-section Length
Page / columnfunction text
Cable name
Connectionpoint
=+-W3
0.25 0.44
IFM:EVC150
14 4BK-GUN-bTMP OK -X1S /3.6/3.6
24 1BN-GUN-bKSR -X1S /3.6/3.6
25 3BU-GUN-b= -X1S /3.6/3.6
4 2WH-GUN-c24V+ -X1S /3.6/3.1
Page
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FlexGun Harness For ABB MotorHousing With 2xM25 Cable Gland
6
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Cable diagram =+-W4
1
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0 76
Replacement of
8 93
16
8
4
7
2
=
Approve by,
5W
ere
serv
eal
lrig
hts
inth
isdo
cum
ent
and
inth
ein
form
atio
nco
ntai
ned
ther
ein
Repr
oduc
tion,
use
ordi
sclo
sure
toth
irdpa
rtie
sw
ithou
tex
pres
sau
thor
ityis
sric
tlyfo
rbid
den.
Copy
right
ABB
3HAW050008639
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2011/10/10N,Cao 2013/6/7 004
2011/10/10
Respsonsible Department: RS / BIW
F09_002_ABBCable diagram
Page / columnTarget designation from conductor Target designation to Connectionpoint
cable type
no. of conductorsfunction text
function text
cross-section Length
Page / columnfunction text
Cable name
Connectionpoint
=+-W4
0.5mm 1.21
Lappkabel:4550114
16 1BK-GUN-bV Reg+ -X2 /3.8/3.8
Page
Total Page
FlexGun Harness For ABB MotorHousing With 2xM25 Cable Gland
7
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Date Replaced by
Cable diagram =+-W5
1
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0 76
Replacement of
8 93
16
9
4
8
2
=
Approve by,
5W
ere
serv
eal
lrig
hts
inth
isdo
cum
ent
and
inth
ein
form
atio
nco
ntai
ned
ther
ein
Repr
oduc
tion,
use
ordi
sclo
sure
toth
irdpa
rtie
sw
ithou
tex
pres
sau
thor
ityis
sric
tlyfo
rbid
den.
Copy
right
ABB
3HAW050008639
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2011/10/10N,Cao 2013/6/7 004
2011/10/10
Respsonsible Department: RS / BIW
F09_002_ABBCable diagram
Page / columnTarget designation from conductor Target designation to Connectionpoint
cable type
no. of conductorsfunction text
function text
cross-section Length
Page / columnfunction text
Cable name
Connectionpoint
=+-W5
0.5mm 1.21
Lappkabel:4550114
17 2BK-GUN-bV Reg- -X2 /3.8/3.8
Page
Total Page
FlexGun Harness For ABB MotorHousing With 2xM25 Cable Gland
8
+
Date Replaced by
Cable diagram =+-W6
1
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0 76
Replacement of
8 93
16
10
4
9
2
=
Approve by,
5W
ere
serv
eal
lrig
hts
inth
isdo
cum
ent
and
inth
ein
form
atio
nco
ntai
ned
ther
ein
Repr
oduc
tion,
use
ordi
sclo
sure
toth
irdpa
rtie
sw
ithou
tex
pres
sau
thor
ityis
sric
tlyfo
rbid
den.
Copy
right
ABB
3HAW050008639
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2011/10/10N,Cao 2013/6/7 004
2011/10/10
Respsonsible Department: RS / BIW
F09_002_ABBCable diagram
Page / columnTarget designation from conductor Target designation to Connectionpoint
cable type
no. of conductorsfunction text
function text
cross-section Length
Page / columnfunction text
Cable name
Connectionpoint
=+-W6
0.54x0.25mm
IFM:E11190
4 4BK-X1P -X2 /3.6/3.6
1 1BN-X1P -X2 /3.6/3.6
3 2BU-X1P -X2 /3.6/3.6
2 3WH-X1P -X2 /3.6/3.6
Page
Total Page
FlexGun Harness For Tamagawa MotorHousing With 2xM25 Cable Gland
+
Date Replaced by
Title page / cover sheet
1
Prepare by,
0 76
Replacement of
8 93
16
1
4
0
2
=
Approve by,
5W
e re
serv
e al
l rig
hts
in t
his
docu
men
t an
d in
the
info
rmat
ion
cont
aine
d th
erei
nRe
prod
uctio
n, u
se o
r di
sclo
sure
to
third
par
ties
with
out
expr
ess
auth
ority
is s
rictly
for
bidd
en. C
opyr
ight
ABB
3HAW050008653
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2012-2-23N,Cao 2012-3-14 002
2012-2-23
Respsonsible Department: RS/BIW
F26_ABB_Cover
Document Number
Number of pages
FlexGun Harness For Tamagawa MotorHousing With 2xM25 Cable Gland
16
Project Discription
3HAW050008653Revision 002
Page
Total Page
FlexGun Harness For Tamagawa MotorHousing With 2xM25 Cable Gland
1
+
Date Replaced by
Layout
1
Prepare by,
0 76
Replacement of
8 93
16
2.a
4
2
2
=
Approve by,
5W
e re
serv
e al
l rig
hts
in t
his
docu
men
t an
d in
the
info
rmat
ion
cont
aine
d th
erei
nRe
prod
uctio
n, u
se o
r di
sclo
sure
to
third
par
ties
with
out
expr
ess
auth
ority
is s
rictly
for
bidd
en. C
opyr
ight
ABB
3HAW050008653
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2012-2-23N,Cao 2012-3-14 002
2012-2-23
Respsonsible Department: RS/BIW
Technical Provisions
Supplementary Document Doc Type Document DescriptionTP 3HAB8053-1 Barcodes
Technical Provisions TP 3HAB8053-1 Manufact Moving Cable
ac
4
8
73
26
51
1725
1687
1524236
145
132221
1243
112019
1021
918
ac
7
2
1
8
93
104
5 11
126
3.7∅
7.6∅0.8∅
0.8∅
W2
W3
W4
W5
14.5∅
W1
MP 3HAW050008653
1
2
34
1
2
3
4
MR
X2:1 X2:2
1.7M
1.5M
1.1M 1.1M
0.2M
X1S X1P
D-Sub 9 Pin Female
12
3
4
5
6
7
8
9
1011
12
DO NOT installsocket into connector
Heat Shrink L=30mm
Heat Shrink L=30mm
150 mm
100 mm 1500 mm
1700 mm
Need RemoveCover
Page
Total Page
FlexGun Harness For Tamagawa MotorHousing With 2xM25 Cable Gland
2.a
+
Date Replaced by
Connection
1
Prepare by,
0 76
Replacement of
8 93
16
4
4
3
2
=
Approve by,
5W
e re
serv
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opyr
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ABB
3HAW050008653
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2012-2-23N,Cao 2012-3-14 002
2012-2-23
Respsonsible Department: RS/BIW
FlexGunConnector
Motor PowerConnectorTamagawa Motor
Motor ResolverConnectorTamagawa Motor
WeldingTransformer(Supply By ABB)
VoltageMeasurement
FixArm
MoveArm
TransformerTS maybe 2 or 3
FlexGunMotor Power
GUNFlex Gun
Connector
-b
11 1213 1415 18 19 2120 23 22 24 25 16 17
PE
-c
123 4
PE PE
-MPFlexGun
Motor PowerConnector
71 3 9
PE
82 5 11 6 1 27 83
-TSFR
CTCurrent
Meter
CT+
M
CT-
M
TS1Temperature
Sensor
TS2Temperature
Sensor
TS+
T1
TS-
T1
TS+
T2
TS-
T2
-X2 1 2 3 4
-X2 1 2
-W1 SH2-V1-U Y/G3-W 65 87 -W2 SH1-WH1-BN 2-YE2-GN 3-PK3-GY -W6
-W4 BK
BNWH BUBU BKBKX2 5
TS3Temperature
Sensor
6YEYE
TS+
T3
TS-
T3
-W5 BKBUBN BKWH
-a
1 23 4
1 23 4
-X1S
-X1P
-W3 WH BKBN BU
-MRFlexGun
Motor ResolverConnector
Page
Total Page
FlexGun Harness For Tamagawa MotorHousing With 2xM25 Cable Gland
3
+
Date Replaced by
Cable diagram =+-W1
1
Prepare by,
0 76
Replacement of
8 93
16
5
4
4
2
=
Approve by,
5W
e re
serv
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l rig
hts
in t
his
docu
men
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cont
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en. C
opyr
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ABB
3HAW050008653
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2012-2-23N,Cao 2012-3-14 002
2012-2-23
Respsonsible Department: RS/BIW
F09_002_ABBCable diagram
Page / columnTarget designation from conductor Target designation to Connection point
cable type
no. of conductorsfunction text
function text
cross-section Length
Page / columnfunction text
Cable name
Connection point
=+-W1
24G1.5+2x(2x0.75)
Igus:CF210.UL.15.07.02.02
3 1 U1-U-GUN-cU -MP /3.1/3.1
2 3 V2-V-GUN-cV -MP /3.1/3.1
1 7 W3-W-GUN-cW -MP /3.1/3.1
13 2 24V BK5-GUN-b24V BK -MP /3.2/3.2
15 5 0V BK6-GUN-b0V BK -MP /3.2/3.2
11 8 PTC7-GUN-bPTC -MP /3.2/3.2
12 11 0V PTC8-GUN-b0V PTC -MP /3.3/3.3
PE SH-GUN /3.2/3.3
PE SH-GUN /3.3/3.3
PE SH-GUN /3.3/3.3
PE 9 PEY/G-GUN -MP /3.1/3.1
Page
Total Page
FlexGun Harness For Tamagawa MotorHousing With 2xM25 Cable Gland
4
+
Date Replaced by
Cable diagram =+-W2
1
Prepare by,
0 76
Replacement of
8 93
16
6
4
5
2
=
Approve by,
5W
e re
serv
e al
l rig
hts
in t
his
docu
men
t an
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the
info
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ion
cont
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to
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with
out
expr
ess
auth
ority
is s
rictly
for
bidd
en. C
opyr
ight
ABB
3HAW050008653
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2012-2-23N,Cao 2012-3-14 002
2012-2-23
Respsonsible Department: RS/BIW
F09_002_ABBCable diagram
Page / columnTarget designation from conductor Target designation to Connection point
cable type
no. of conductorsfunction text
function text
cross-section Length
Page / columnfunction text
Cable name
Connection point
=+-W2
1.73x2x0.25mm
Igus:CF211.02.03.02
18 6 Cos+1-BN-GUN-bCos+ -MR /3.4/3.4
19 1 Cos-1-WH-GUN-bCos- -MR /3.4/3.4
20 7 Sin+2-GN-GUN-bSin+ -MR /3.4/3.4
21 2 Sin-2-YE-GUN-bSin- -MR /3.4/3.4
23 3 24V+3-GY-GUN-b24V -MR /3.4/3.4
22 8 0V3-PK-GUN-b0V -MR /3.4/3.4
PESH -GUN /3.5/3.5
Page
Total Page
FlexGun Harness For Tamagawa MotorHousing With 2xM25 Cable Gland
5
+
Date Replaced by
Cable diagram =+-W3
1
Prepare by,
0 76
Replacement of
8 93
16
7
4
6
2
=
Approve by,
5W
e re
serv
e al
l rig
hts
in t
his
docu
men
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cont
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with
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expr
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auth
ority
is s
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bidd
en. C
opyr
ight
ABB
3HAW050008653
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2012-2-23N,Cao 2012-3-14 002
2012-2-23
Respsonsible Department: RS/BIW
F09_002_ABBCable diagram
Page / columnTarget designation from conductor Target designation to Connection point
cable type
no. of conductorsfunction text
function text
cross-section Length
Page / columnfunction text
Cable name
Connection point
=+-W3
0.25 0.44
IFM:EVC150
14 4BK-GUN-bTMP OK -X1S /3.6/3.6
24 1BN-GUN-bKSR -X1S /3.6/3.6
25 3BU-GUN-b= -X1S /3.6/3.6
4 2WH-GUN-c24V+ -X1S /3.6/3.1
Page
Total Page
FlexGun Harness For Tamagawa MotorHousing With 2xM25 Cable Gland
6
+
Date Replaced by
Cable diagram =+-W4
1
Prepare by,
0 76
Replacement of
8 93
16
8
4
7
2
=
Approve by,
5W
e re
serv
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l rig
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in t
his
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men
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cont
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auth
ority
is s
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en. C
opyr
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ABB
3HAW050008653
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2012-2-23N,Cao 2012-3-14 002
2012-2-23
Respsonsible Department: RS/BIW
F09_002_ABBCable diagram
Page / columnTarget designation from conductor Target designation to Connection point
cable type
no. of conductorsfunction text
function text
cross-section Length
Page / columnfunction text
Cable name
Connection point
=+-W4
0.5mm 1.21
Lappkabel:4550114
16 1BK-GUN-bV Reg+ -X2 /3.8/3.8
Page
Total Page
FlexGun Harness For Tamagawa MotorHousing With 2xM25 Cable Gland
7
+
Date Replaced by
Cable diagram =+-W5
1
Prepare by,
0 76
Replacement of
8 93
16
9
4
8
2
=
Approve by,
5W
e re
serv
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l rig
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in t
his
docu
men
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the
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ion
cont
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with
out
expr
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auth
ority
is s
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for
bidd
en. C
opyr
ight
ABB
3HAW050008653
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2012-2-23N,Cao 2012-3-14 002
2012-2-23
Respsonsible Department: RS/BIW
F09_002_ABBCable diagram
Page / columnTarget designation from conductor Target designation to Connection point
cable type
no. of conductorsfunction text
function text
cross-section Length
Page / columnfunction text
Cable name
Connection point
=+-W5
0.5mm 1.21
Lappkabel:4550114
17 2BK-GUN-bV Reg- -X2 /3.8/3.8
Page
Total Page
FlexGun Harness For Tamagawa MotorHousing With 2xM25 Cable Gland
8
+
Date Replaced by
Cable diagram =+-W6
1
Prepare by,
0 76
Replacement of
8 93
16
10
4
9
2
=
Approve by,
5W
e re
serv
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l rig
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in t
his
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men
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cont
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ority
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en. C
opyr
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ABB
3HAW050008653
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2012-2-23N,Cao 2012-3-14 002
2012-2-23
Respsonsible Department: RS/BIW
F09_002_ABBCable diagram
Page / columnTarget designation from conductor Target designation to Connection point
cable type
no. of conductorsfunction text
function text
cross-section Length
Page / columnfunction text
Cable name
Connection point
=+-W6
0.54x0.25mm
IFM:E11190
4 4BK-X1P -X2 /3.6/3.6
1 1BN-X1P -X2 /3.6/3.6
3 2BU-X1P -X2 /3.6/3.6
2 3WH-X1P -X2 /3.6/3.6
Page
Total Page
FlexGun Harness For Tamagawa Motor for IRB6640 Dresspack LeanID
+
Date Replaced by
Title page / cover sheet
1
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0 76
Replacement of
8 93
17
1
4
0
2
=
Approve by,
5
We
rese
rve
all r
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s in
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and
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Rep
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en. C
opyr
ight
ABB
3HAW050008658
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2012-11-10N,Cao 2012-11-29 004
2012-11-10
Respsonsible Department: RS/BIW
F26_ABB_Cover
Document Number
Number of pages
FlexGun Harness For Tamagawa Motor for IRB6640 Dresspack LeanID
17
Project Discription
3HAW050008658Revision 004
Page
Total Page
FlexGun Harness For Tamagawa Motor for IRB6640 Dresspack LeanID
1
+
Date Replaced by
Layout
1
Prepare by,
0 76
Replacement of
8 93
17
2.a
4
2
2
=
Approve by,
5
We
rese
rve
all r
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s in
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expr
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ority
is s
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for
bidd
en. C
opyr
ight
ABB
3HAW050008658
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2012-11-10N,Cao 2012-11-29 004
2012-11-10
Respsonsible Department: RS/BIW
Technical Provisions
Supplementary Document Doc Type Document DescriptionTP 3HAB8053-1 Barcodes
Technical Provisions TP 3HAB8053-1 Manufact Moving Cable
MP 3HAW050008658
1
2
3
41
2
3
4
MR
X2:1 X2:2
1.7M
1.5M
1.1M 1.1M
0.2M
X1S X1P
D-Sub 9 Pin Female
12
3
4
5
6
7
8
9
1011
12
Heat Shrink L=30mm
Heat Shrink L=30mm
RemoveCover
W060005144
150
100 W1=1700
AB
C
D
E
F
GHJ
K
L
M
N
P
RS
T
UV
W
X
Y
Z
4
1 3PE
A
B C
D
2
W2=1500
R4.FB
R3.SP
R3.CPS
12
3
4
5 6 7
8
9
1011
17
12
13
14 15
16
Page
Total Page
FlexGun Harness For Tamagawa Motor for IRB6640 Dresspack LeanID
2.b
+
Date Replaced by
Connection
1
Prepare by,
0 76
Replacement of
8 93
17
4
4
3
2
=
Approve by,
5
We
rese
rve
all r
ight
s in
thi
s do
cum
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and
in t
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form
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Rep
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with
out
expr
ess
auth
ority
is s
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for
bidd
en. C
opyr
ight
ABB
3HAW050008658
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2012-11-10N,Cao 2012-11-29 004
2012-11-10
Respsonsible Department: RS/BIW
Motor PowerConnectorTamagawa Motor
Motor ResolverConnectorTamagawa Motor
WeldingTransformer(Supply By ABB)
VoltageMeasurement
FixArm
MoveArm
TransformerTS maybe 2 or 3
FlexGunMotor Power
C DA AB 1 3 24 7 8 K L M N
PE
413 EPE
PE
-MPFlexGun
Motor PowerConnector
71 3 9
PE
82 5 11 6 1 27 83
-TSFR
CTCurrent
Meter
CT+
M
CT-
M
TS1Temperature
Sensor
TS2Temperature
Sensor
TS+
T1
TS-
T1
TS+
T2
TS-
T2
-X2 1 2 3 4 -X3 1 2
-W1 SH2-V1-U Y/G3-W 65 87 -W2 SH1-WH1-BN 2-YE2-GN 3-PK3-GY -W6
-W4 BK
BNWH BUBU BKBKX2 5
TS3Temperature
Sensor
6YEYE
TS+
T3
TS-
T3
-W5 BK
BUBN BKWH
1 23 4
1 23 4
-X1S
-X1P
-W3 WH BKBN BU
-MRFlexGun
Motor ResolverConnector
-W060005144
-R3_CPSCPCS Plug
-R4_FBSignal Plug
-R3_SPPower Plug
Page
Total Page
FlexGun Harness For Tamagawa Motor for IRB6640 Dresspack LeanID
3
+
Date Replaced by
Cable diagram =+-W1
1
Prepare by,
0 76
Replacement of
8 93
17
5
4
4
2
=
Approve by,
5
We
rese
rve
all r
ight
s in
thi
s do
cum
ent
and
in t
he in
form
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n co
ntai
ned
ther
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Rep
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ctio
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sclo
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to
third
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ties
with
out
expr
ess
auth
ority
is s
rictly
for
bidd
en. C
opyr
ight
ABB
3HAW050008658
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2012-11-10N,Cao 2012-11-29 004
2012-11-10
Respsonsible Department: RS/BIW
F09_002_ABBCable diagram
Page / columnTarget designation from conductor Target designation to Connection point
cable type
no. of conductorsfunction text
function text
cross-section Length
Page / columnfunction text
Cable name
Connection point
=+-W1
24G1.5+2x(2x0.75)
Igus:CF210.UL.15.07.02.02
1 3 U1-U-MPU -R3_SP /3.1/3.1
3 1 V2-V-MPV -R3_SP /3.1/3.1
7 4 W3-W-MPW -R3_SP /3.1/3.1
2 A 24V BK5-MP24V BK -R3_SP /3.2/3.2
5 B 0V BK6-MP0V BK -R3_SP /3.2/3.2
8 C PTC7-MPPTC -R3_SP /3.2/3.2
11 D 0V PTC8-MP0V PTC -R3_SP /3.2/3.2
PESH -R3_SP /3.2/3.2
PESH -R3_SP /3.2/3.2
PESH -R3_SP /3.2/3.2
9 PEY/G-MPPE -R3_SP /3.1/3.1
Page
Total Page
FlexGun Harness For Tamagawa Motor for IRB6640 Dresspack LeanID
4
+
Date Replaced by
Cable diagram =+-W2
1
Prepare by,
0 76
Replacement of
8 93
17
6
4
5
2
=
Approve by,
5
We
rese
rve
all r
ight
s in
thi
s do
cum
ent
and
in t
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form
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n co
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ned
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Rep
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ties
with
out
expr
ess
auth
ority
is s
rictly
for
bidd
en. C
opyr
ight
ABB
3HAW050008658
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2012-11-10N,Cao 2012-11-29 004
2012-11-10
Respsonsible Department: RS/BIW
F09_002_ABBCable diagram
Page / columnTarget designation from conductor Target designation to Connection point
cable type
no. of conductorsfunction text
function text
cross-section Length
Page / columnfunction text
Cable name
Connection point
=+-W2
1.73x2x0.25mm
Igus:CF211.02.03.02
6 1 X (S1,Cos+)1-BN-MRS1 -R4_FB /3.3/3.3
1 3 0V-X(S3,Cos-)1-WH-MRS3 -R4_FB /3.3/3.3
7 4 Y(S4,Sin+)2-GN-MRS4 -R4_FB /3.4/3.4
2 2 0V-Y(S2,Sin-)2-YE-MRS2 -R4_FB /3.4/3.4
3 7 EXC(R1,24V)3-GY-MRR1 -R4_FB /3.4/3.4
8 8 0V-EXC(R2,0V)3-PK-MRR2 -R4_FB /3.4/3.4
PESH -R4_FB /3.4/3.4
Page
Total Page
FlexGun Harness For Tamagawa Motor for IRB6640 Dresspack LeanID
5
+
Date Replaced by
Cable diagram =+-W3
1
Prepare by,
0 76
Replacement of
8 93
17
7
4
6
2
=
Approve by,
5
We
rese
rve
all r
ight
s in
thi
s do
cum
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and
in t
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form
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n co
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ned
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Rep
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ctio
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with
out
expr
ess
auth
ority
is s
rictly
for
bidd
en. C
opyr
ight
ABB
3HAW050008658
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2012-11-10N,Cao 2012-11-29 004
2012-11-10
Respsonsible Department: RS/BIW
F09_002_ABBCable diagram
Page / columnTarget designation from conductor Target designation to Connection point
cable type
no. of conductorsfunction text
function text
cross-section Length
Page / columnfunction text
Cable name
Connection point
=+-W3
0.25 0.44
IFM:EVC150
A 4BK-R3_CPSTMP OK -X1S /3.6/3.6
K 1BN-R3_CPSKSR -X1S /3.6/3.6
L 3BU-R3_CPS= -X1S /3.6/3.6
E 2WH-R3_CPS24V+ -X1S /3.6/3.6
Page
Total Page
FlexGun Harness For Tamagawa Motor for IRB6640 Dresspack LeanID
6
+
Date Replaced by
Cable diagram =+-W4
1
Prepare by,
0 76
Replacement of
8 93
17
8
4
7
2
=
Approve by,
5
We
rese
rve
all r
ight
s in
thi
s do
cum
ent
and
in t
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form
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n co
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ned
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Rep
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n, u
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to
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ties
with
out
expr
ess
auth
ority
is s
rictly
for
bidd
en. C
opyr
ight
ABB
3HAW050008658
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2012-11-10N,Cao 2012-11-29 004
2012-11-10
Respsonsible Department: RS/BIW
F09_002_ABBCable diagram
Page / columnTarget designation from conductor Target designation to Connection point
cable type
no. of conductorsfunction text
function text
cross-section Length
Page / columnfunction text
Cable name
Connection point
=+-W4
0.5mm 1.21
Lappkabel:4550114
M 1BK-R3_CPSV Reg+ -X3 /3.8/3.8
Page
Total Page
FlexGun Harness For Tamagawa Motor for IRB6640 Dresspack LeanID
7
+
Date Replaced by
Cable diagram =+-W5
1
Prepare by,
0 76
Replacement of
8 93
17
9
4
8
2
=
Approve by,
5
We
rese
rve
all r
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s in
thi
s do
cum
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and
in t
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n co
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Rep
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ABB
3HAW050008658
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2012-11-10N,Cao 2012-11-29 004
2012-11-10
Respsonsible Department: RS/BIW
F09_002_ABBCable diagram
Page / columnTarget designation from conductor Target designation to Connection point
cable type
no. of conductorsfunction text
function text
cross-section Length
Page / columnfunction text
Cable name
Connection point
=+-W5
0.5mm 1.21
Lappkabel:4550114
N 2BK-R3_CPSV Reg- -X3 /3.8/3.8
Page
Total Page
FlexGun Harness For Tamagawa Motor for IRB6640 Dresspack LeanID
8
+
Date Replaced by
Cable diagram =+-W6
1
Prepare by,
0 76
Replacement of
8 93
17
10
4
9
2
=
Approve by,
5
We
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and
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ties
with
out
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auth
ority
is s
rictly
for
bidd
en. C
opyr
ight
ABB
3HAW050008658
ApprovedStatus:
Document no. Rev.IndDate A,Stapelberg 2012-11-10N,Cao 2012-11-29 004
2012-11-10
Respsonsible Department: RS/BIW
F09_002_ABBCable diagram
Page / columnTarget designation from conductor Target designation to Connection point
cable type
no. of conductorsfunction text
function text
cross-section Length
Page / columnfunction text
Cable name
Connection point
=+-W6
0.54x0.25mm
IFM:E11190
4 4BK-X1P -X2 /3.6/3.6
1 1BN-X1P -X2 /3.6/3.6
3 2BU-X1P -X2 /3.6/3.6
2 3WH-X1P -X2 /3.6/3.6
3HA
W05
0009
061
Rev
F, e
n
Contact us
ABB Engineering (Shanghai) Ltd.FlexLean ProductsNo.5, Lane 369, Chuangye Road, Kangqiao Town, Nanhui District, Shanghai 201319 P.R.CHINATelephone +86 (0) 21 6105 6666
www.abb.com
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