ABB M2004 Reference guide



Product manual (part 2 of 2), reference information

Articulated robot

IRB 140

M2000, M2000A, M2004

Product manual (part 2 of 2), reference information

IRB 140

M2000

M2000A

M2004

Document ID: 3HAC023297-001

Revision: A

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, and contents thereof must not be imparted to

a third party nor be used for any unauthorized purpose. Contravention

will be prosecuted.

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

current charge.

ABB Automation Technologies AB

Robotics

SE-721 68 Västerås

Sweden

Table of Contents

33HAC023297-001 Revision: A

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1 Reference information 11

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.2 Applicable Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.6 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.7 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.8 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.9 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.10 Mounting instructions for bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.11 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2 Spare part / part list 27

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.2 Spare part / part list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3 Foldouts 33

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4 Circuit diagram 35

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Table of Contents

3HAC023297-001 Revision: A4

Overview

53HAC023297-001 Revision: A

Overview

About this manual

This manual contains reference information for all procedures in part 1: Product manual,

procedures.

Usage

This manual should be used during:

• installation

• 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 Contents

Reference information Useful information when performing installation, maintenance

or repair works. Includes lists of necessary tools, additional

documents, safety standards, etc.

Spare part / Part list Complete spare part lists and complete lists of robot

components, shown in the foldouts.

Foldouts Detailed illustrations of the robot with reference numbers to the

part list.

Circuit diagram Circuit diagram for the robot.

Overview

3HAC023297-001 Revision: A6

Revisions

Revision Description

- First edition

Replaces previous manuals:

• Installation and commissioning manual

• Maintenance manual

• Repair manual, part 1

• Repair manual, part 2

Changes made in the material from the previous manuals:

• Model M2004 implemented.

•Section Document references added to the chapter Reference

information.

• Information about the controller removed from the manual.

• Additional spare part numbers for the motors.

A Changes made in:

• Prerequisites in section O

verview

• Oil change in section Maintenance

Product documentation, M2000/M2000A

73HAC023297-001 Revision: A

Product documentation, M2000/M2000A

General

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

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

Hardware manuals

All hardware, robots and controller cabinets, will be delivered with a Product manual which

is divided into two parts:

Product manual, procedures

• Safety information

• Installation and commissioning (descriptions of mechanical installation, electrical

connections and loading system software)

• 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)

Product manual, reference information

• Reference information (article numbers for documentation referred to in Product

manual, procedures, lists of tools, safety standards)

•Part list

• Foldouts or exploded views

• Circuit diagrams

Software manuals

The software documentation consists of a wide range of manuals, ranging from manuals for

basic understanding of the operating system to manuals for entering parameters during

operation.

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

Controller hardware option manual

Each hardware option for the controller is supplied with its own documentation. Each

document set contains the types of information specified below:

• Installation information

• Repair information

• Maintenance information

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

Product documentation, M2004

3HAC023297-001 Revision: A8

Product documentation, M2004

General

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

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

are standard or optional. This means that any given delivery of robot products will not contain

all documents listed, only the ones pertaining to the equipment delivered.

However, all documents listed may be ordered from ABB. The documents listed are valid for

M2004 robot systems.

Hardware manuals

All hardware, robots and controller cabinets, will be delivered with a Product manual which

is divided into two parts:

Product manual, procedures

• Safety information

• Installation and commissioning (descriptions of mechanical installation, electrical

connections and loading system software)

• 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)

Product manual, reference information

• Reference information (article numbers for documentation referred to in Product

manual, procedures, lists of tools, safety standards)

•Part list

• Foldouts or exploded views

• Circuit diagrams

RobotWare manuals

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

information:

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

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

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

• Technical reference manual - System parameters: Description of system

parameters and configuration workflows.

Application manuals

Specific applications (e.g. 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 (e.g. cables, I/O boards, RAPID instructions, system parameters)

Product documentation, M2004

93HAC023297-001 Revision: A

• How to use the application

• Examples of how to use the application

Operator’s manuals

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

i.e. production cell operators, programmers and trouble shooters. The group of manuals

include:

• Operator’s manual - IRC5 with FlexPendant

• Operator’s manual - RobotStudioOnline

• Trouble shooting Manual for the controller and robot

Miscellaneous

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

include:

• Robot fundamentals (describing the fundamental aspects, functions, concept and

similar, of a robot system to provide a basic understanding of the robot system)

Product documentation, M2004

3HAC023297-001 Revision: A10

1 Reference information

1.1. Introduction

113HAC023297-001 Revision: A

1 Reference information

1.1. Introduction

General

This chapter includes general information, complementing the more specific information in

the Product manual (part 1 of 2), procedures.

1 Reference information

1.2. Applicable Safety Standards

3HAC023297-001 Revision: A12

1.2. Applicable Safety Standards

Standards, general

The robot is designed in accordance with the requirements of:

• EN ISO10218-1 : 2005, Robots for industrial environments - Safety requirements -

Part 1 Robot

• ANSI/RIA 15.06-1999

• ISO/DIS 11161, Industrial automation systems - safety of integrated manufacturing

systems - Basic requirements

• DIN 19258 - Interbus-S, International Standard

Standards, safety fence

The following standards are applicable to the safety fence surrounding the robot cell:

• ISO/DIS 11161, Industrial automation systems -safety of integrated manufacturing

systems - Basic requirements

• prEN 999:1995

Standards, robot cell

The following standards are applicable when the robot is part of a robot cell:

• IEN 294, Safety of machinery - Safety distance to prevent danger zones being reached

by the upper limbs.

• EN 349, Safety of machinery - Minimum gaps to avoid crushing of parts of the human

body.

• EN 811 Safety of machinery - Safety distance to prevent danger zones being reached

by the lower limbs.

• Pr EN 999 Safety of machinery - The positioning of protective equipment in respect

of approach speeds of the human body.

• EN 1088 Safety of machinery - Interlocking device associated with guards principles

for design and selection.

1 Reference information

1.3. Unit conversion

133HAC023297-001 Revision: A

1.3. Unit conversion

Converter table

Use the table below to convert units used in this manual.

Quantity Units

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 Nm 0.738 lbf-tn

Volume 1 L 0.264 US gal

1 Reference information

1.4. Screw joints

3HAC023297-001 Revision: A14

1.4. Screw joints

General

This section details how to tighten the various types of screw joints on the robot and the

controller.

The instructions and torque values are valid for screw joints comprised of metallic materials

and do not apply to soft or brittle materials.

UNBRAKO screws

UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It

features special surface treatment (Gleitmo as described below), and is extremely resistant to

fatigue.

Whenever used, this is specified in the instructions, and in such cases, no other type of

replacement screw is allowed! Using other types of screws will void any warranty and may

potentially cause serious damage or injury!

Gleitmo treated screws

Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.

Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After

this the screw must be discarded and replaced with a new one.

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

be used.

Screws lubricated in other ways

Screws lubricated with Molycote 1000 should only be used when specified in the repair,

maintenance or installation procedure descriptions.

In such cases, proceed as follows:

1. Apply lubricant to the screw thread.

2. Apply lubricant between the plain washer and screw head.

3. Tighten to the torque specified in section Tightening torque below. Screw dimensions

of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or

smaller may be tightened without a torque wrench if this is done by trained and

qualified personnel.

Tightening torque

Before tightening any screw, note the following:

• Determine whether a standard tightening torque or special torque is to be applied. The

standard torques are specified in the tables below. Any special torques are specified in

the Repair, Maintenance or Installation procedure description. Any special torque

specified overrides the standard value.

•Use the correct tightening torque for each type of screw joint.

Lubricant Art. no.

Molycote 1000 (molybdenum disulphide grease) 1171 2016-618

1 Reference information

1.4. Screw joints

153HAC023297-001 Revision: A

• Only use correctly calibrated torque keys.

•Always tighten the joint by hand, and never use pneumatical tools.

•Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a slow,

flowing motion.

• Maximum allowed total deviation from the specified value is 10%!

The table below specifies the recommended standard tightening torque for oil-lubricated

screws with slotted or cross-recess head screws.

The table below specifies the recommended standard tightening torque for oil-lubricated

screws with Allen head screws.

The table below specifies the recommended standard tightening torque for Molycote-

lubricated screws with Allen head screws.

Dimension

Tightening torque (Nm)

Class 4.8, oil-lubricated

M2.5 0.25

M3 0.5

M4 1.2

M5 2.5

M6 5.0

Dimension

Tightening torque

(Nm)

Class 8.8, oil-

lubricated

Tightening torque

(Nm)

Class 10.9, oil-

lubricated

Tightening torque

(Nm)

Class 12.9, oil-

lubricated

M5 6 - -

M6 10 - -

M8 24 34 40

M10 47 67 80

M12 82 115 140

M16 200 290 340

Dimension

Tightening torque (Nm)

Class 10.9, Molycote-lubricated

Tightening torque (Nm)

Class 12.9, Molycote-lubricated

M8 28 34

M10 55 66

M12 96 115

M16 235 280

1 Reference information

1.4. Screw joints

3HAC023297-001 Revision: A16

The table below specifies the recommended standard tightening torque for water and air

connectors when one or both connectors are made of brass.

Dimension

Tightening torque

Nm - Nominal

Tightening torque

Nm - Min.

Tightening torque

Nm - Max.

1/8 12 8 15

1/4 15 10 20

3/8 20 15 25

1/2 40 30 50

3/4 70 55 90

1 Reference information

1.5. Weight specifications

173HAC023297-001 Revision: A

1.5. Weight specifications

Definition

In all repair and maintenance procedures, weights of the components handled are sometimes

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

To avoid injury, ABB recommends the use of lifting equipment when handling components

with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for

each manipulator model.

Example

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

CAUTION!

Caution!

The motor weighs 32 kg! All lifting equipment used must be sized accordingly!

1 Reference information

1.6. Document references

3HAC023297-001 Revision: A18

1.6. Document references

General

The contents of this manual may include references to additional documentation necessary to

perform certain procedures. This section specifies the article numbers for the referenced

documentation.

Product specification, robot

The product specification includes generic technical data. The specification listed below is

the English version.

Product manuals, controller

The product manuals include information about installation and service activities. The table

below specifies the article numbers of the product manuals for all controller models. The part

number -001 is the English version.

Operators manual

The operators manual contains instructions for daily operation of robot systems. The table

below specifies the article numbers of the operators manuals for different robot systems.

Calibration manuals

Document name Document ID

Product specification 3HAC 9041-1

Document name Document ID

Product manual, S4Cplus M2000 3HAC 021333-001

Product manual, S4Cplus M2000A 3HAC 021128-001

Product manual, IRC5 M2004 3HAC 021313-001

Document name Document ID Note

User’s guide (S4Cplus) 3HAC 7793-1 Contains instructions for daily operation

of S4Cplus based robot systems.

Operator’s manual (IRC5) 3HAC 16590-1

Document name Document ID Note

Calibration Pendulum

Instruction

3HAC 16578-1 Enclosed with the Calibration Pendulum

Toolkit.

Instructions for Levelmeter

calibration (alternative

method)

3HAC 022907-001 Enclosed with the Levelmeter 2000.

CalibWare 2.0 Users Guide 3HAC 16090-1 Calibration tool for Absolute Accuracy

calibration.

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