ABB IRB 1400 User manual

Product manual

Articulated robot

IRB 1400

M2004

Product manual

3HAC021111-001

Revision: B

Articulated robot

IRB 1400

M2000

M2004

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, fit-

ness 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 per-

mission, and contents thereof must not be imparted to a third party nor be used for any unau-

thorized purpose. Contravention will be prosecuted.

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

ABB AB

Robotics Products

SE-721 68 Västerås

Sweden

Table of Contents

3

0.0.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

0.0.2 Product documentation, M2000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

0.0.3 Product documentation, M2004. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

1: Safety, service 13

1.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.1: General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.1.1 Safety, service - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.1.2 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.1.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.2: Safety risks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.2.1 Safety risks related to gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.2.2 Safety risks related to tools/workpieces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

1.2.3 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.2.4 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.2.5 Safety risks during installation and service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.2.6 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

1.3: Safety actions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.3.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.3.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.3.3 Emergency release of the manipulator's arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.3.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.3.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.3.6 Safe use of the Teach Pendant Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

1.3.7 Work inside the manipulator's working range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.3.8 Signal lamp (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2: Installation and commissioning 31

2.0.1 Transporting and Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.0.2 Stability / Risk of Tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.0.3 System CD ROM and Diskette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

2.0.4 Transport Locking Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2.1: On-site installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.1.1 Lifting the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.1.2 Turning the Manipulator (Inverted Suspension Application) . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.1.3 Assembling the robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2.1.4 Suspended Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.1.5 Stress Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

2.1.6 Amount of Space required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.1.7 Manually engaging the brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

2.1.8 Restricting the Working Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2.1.9 Mounting Holes for Equipment on the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2.1.10 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2.2: Customer connections on manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

2.2.1 Air supply and signals for extra equipment to upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

2.2.2 Connection of Extra Equipment to the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3: Maintenance 51

3.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

3.0.2 Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

3.1: Instructions for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

3.1.1 Oil in gears 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

3.1.2 Greasing axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

3.1.3 Lubricating spring brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

3.1.4 Changing the battery in the measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3.1.5 Checking the mechanical stop, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Table of Contents

4

4: Repair 59

4.1: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4.1.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4.1.2 Instructions for reading the following sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

4.1.3 Caution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

4.1.4 Fitting new Bearings and Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

4.1.5 Instructions for tightening Screw Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

4.1.6 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

4.1.7 Checking for play in gearboxes and wrist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

4.2: Axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

4.2.1 Changing the motor of axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

4.2.2 Changing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

4.2.3 Position indicator in axis 1 (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

4.2.4 Replacing the mechanical stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

4.3: Axis 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

4.3.1 Changing the motor of axis 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

4.3.2 Changing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

4.3.3 Dismantling the lower arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

4.3.4 Changing the bearings in the upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

4.3.5 Dismantling the balancing springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

4.4: Axis 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

4.4.1 Changing the motor of axis 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

4.4.2 Changing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

4.4.3 Dismantling the parallel arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

4.4.4 Changing the tie rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

4.4.5 Dismantling the complete upper arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

4.5: Axis 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

4.5.1 Changing the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

4.5.2 Changing the intermediate gear including sealing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

4.5.3 Dismantling the drive gear on the tubular shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

4.5.4 Dismantling the tubular shaft and changing bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

4.6: Cabling and serial measuring board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

4.6.1 Changing serial measuring boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

4.6.2 Changing the cabling in axes 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

4.6.3 Changing the cabling in axes 4, 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

4.7: The wrist and axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

4.7.1 Dismantling the wrist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

4.7.2 Dismantling the complete drive mechanism of axes 5 and 6. . . . . . . . . . . . . . . . . . . . . . . . . .95

4.7.3 Changing the motor or driving belt of axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

4.7.4 Measuring play in axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

4.8: Motor units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

4.8.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

5: Calibration, M2000 99

5.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

5.1: Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

5.1.1 How to calibrate the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

5.1.2 Calibration, prerequisites. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

5.2: Reference information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

5.2.1 Calibration scales and correct axis position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

5.2.2 Directions for all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

5.2.3 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

Table of Contents

5

5.2.4 Positions and directions of sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

5.2.5 Initialization of Levelmeter 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

5.3: Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

5.3.1 Calibration axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

5.3.2 Calibration, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

5.3.3 Calibration, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

5.3.4 Calibration, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

5.3.5 Calibration, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

5.3.6 Calibration, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

5.3.7 Fine calibration procedure on TPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

5.3.8 Resetting of Levelmeter 2000 and sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

5.3.9 Updating the revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

5.4: After calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

5.4.1 Post calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

6: Calibration information 131

6.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

6.0.2 Calibration methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

6.0.3 Calibration scales and correct axis position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

6.0.4 Calibration movement directions for all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

6.0.5 Updating revolution counters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

6.0.6 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

7: Alternative calibration 141

7.0.1 Alternative calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

7.0.2 Alternative calibrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

7.0.3 New calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

7.0.4 New calibration offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

7.0.5 Retrieving offset values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

8: Reference information, IRB 1400 147

8.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

8.0.2 Applicable Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

8.0.3 Unit conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

8.0.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

8.0.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

8.0.6 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

8.0.7 Standard toolkit, IRB 1400. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

8.0.8 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

8.0.9 Lifting equipment and lifting instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

9: Spare part list 159

9.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

9.0.2 Manipulator complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

9.0.3 Arm housing, complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

9.0.4 Drive unit, axes 5-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

9.0.5 Serial measurement unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

10: Foldouts 167

10.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

11: Circuit diagram 169

11.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

11.0.2 Sheet 101 List of contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

11.0.3 Sheet 102 Connection point location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

11.0.4 Sheet 103 Serial measurement board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Table of Contents

6

11.0.5 Sheet 104 Motor axes 1 - 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

11.0.6 Sheet 105 Feedback axes 1 - 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

11.0.7 Sheet 106 Motor axes 4 - 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

11.0.8 Sheet 107 Feedback axes 4 - 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

11.0.9 Sheet 108 Customer connection (Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

11.0.10 Sheet 109 Integrated wirefeed cabling (Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

11.0.11 Sheet 110 Position indicator axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

11.0.12 Sheet 111 External connections (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181

0.0.1 Overview

3HAC021111-001 Revision: B 7

0.0.1 Overview

About this

manual

This manual contains instructions for

• mechanical and electrical installation of the manipulator

• maintenance of the manipulator

• mechanical and electrical repair of the manipulator.

Usage This manual should be used during

• installation, from lifting the manipulator to its work site and securing it to the foundation

to making it ready for operation

• maintenance work

• repair work and calibration.

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:

References

Chapter Contents

Safety, service Safety information

Installation and commissioning Information about installation of the manipulator.

Maintenance Information about maintenance work, including mainte-

nance schedules.

Repair Information about repair work.

Calibration Information about calibration of the manipulator.

Decommissioning Environmental information about the manipulator.

Reference Document Id

0.0.1 Overview

8 3HAC021111-001 Revision: B

Revisions

Revision Description

- First edition.

Replaces previous product manual 3HAC 7617-1

Changes made in the material from the previous manuals:

• Model M2004 implemented.

A Yaskawa motors included.

B Changes made in:

• Prerequisites in section Owerview

• Oil change in section Maintenance

0.0.2 Product documentation, M2000

3HAC021111-001 Revision: B 9

0.0.2 Product documentation, M2000

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

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

Hardware

manuals

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

that is divided into two parts:

Product manual, procedures

• Safety information

• Installation and commissioning (descriptions of mechanical installation, electrical con-

nections and loading system software)

• Maintenance (descriptions of all required preventive maintenance procedures includ-

ing periodicity)

• 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 refered to in Product man-

ual, 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 oper-

ation.

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

Hardware option

manual

Each hardware option 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.

0.0.2 Product documentation, M2000

10 3HAC021111-001 Revision: B

0.0.3 Product documentation, M2004

3HAC021111-001 Revision: B 11

0.0.3 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 one delivery of robot products will not contain

all documents listed, but only some of them.

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

M2004 robot systems.

Hardware

manuals

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

that is divided into two parts:

Product manual, procedures

• Safety information

• Installation and commissioning (descriptions of mechanical installation, electrical con-

nections and loading system software)

• Maintenance (descriptions of all required preventive maintenance procedures includ-

ing periodicity)

• 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 refered to in Product man-

ual, 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 reference informa-

tion about it:

• 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 parame-

ters and configuration workflows.

Application

manuals

Specific applications (e.g. software or hardware options) are described in Application man-

uals . An application manual can describe one or several applications.

An application manual generally contains information about:

• The purpose of the application (what does it do and when is it useful)

• What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)

• How to use the application

• Examples of how to use the application

0.0.3 Product documentation, M2004

12 3HAC021111-001 Revision: B

Operating

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, and include:

• Operating Manual - IRC5 with FlexPendant

• Operating Manual - RobotStudioOnline

• Trouble shooting Manual for the controller and manipulator

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)

1 Safety, service

1.0.1 Introduction

3HAC021111-001 Revision: B 13

1: Safety, service

1.0.1 Introduction

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

lation, repair and maintenance work.

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

1. General information contains lists of:

• Safety, service -general

• Limitation of liability

• Referenced documents

2. Safety risks lists dangers relevant when servicing the robot system. The dangers

are split into different categories:

• Safety risks related to gripper/end effector

• Safety risks related to tools/workpieces

• Safety risks related to pneumatic/hydraulic systems

• Safety risks during operational disturbances

• Safety risks during installation and service

• Risks associated with live electric parts

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

• Safety fence dimensions

• Fire extinguishing

• Emergency release of the manipulator´s arm

• Brake testing

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

• Safe use of the Teach Pendant Unit enabling device

• Work inside the manipulator´s working range

• Signal lamp (optional)

1 Safety, service

1.1.1 Safety, service - General

14 3HAC021111-001 Revision: B

1.1: General information

1.1.1 Safety, service - General

Validity and

responsibility

The information does not cover how to design, install and operate a complete system, nor

does it cover all peripheral equipment, which can influence the safety of the total system. To

protect personnel, the complete system must be designed and installed in accordance with the

safety requirements set forth in the standards and regulations of the country where the robot

is installed.

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

and regulations in the country concerned are observed and that the safety devices necessary

to protect people working with the robot system have been designed and installed correctly.

Personnel working with robots must be familiar with the operation and handling of the indus-

trial 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 inter-

act with other machines and peripheral equipment. This means that control signals can act on

safety signals received from the peripheral equipment as well as from the robot.

In the Product Manual - Installation and Commissioning, instructions are provided for con-

necting safety devices between the robot and the peripheral equipment.

1 Safety, service

1.1.2 Limitation of Liability

3HAC021111-001 Revision: B 15

1.1.2 Limitation of Liability

General Any information given in this information product 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 have been complied with.

1 Safety, service

1.1.3 Related information

16 3HAC021111-001 Revision: B

1.1.3 Related information

General The list below specifies documents which contain useful information:

Documents

Type of information Detailed in document Section

Installation of safety devices Product manual for the manipulator Installation and com-

missioning

Changing robot modes User’s Guide Start-up

Restricting the working space Product manual for the manipulator Installation and com-

missioning

1 Safety, service

1.2.1 Safety risks related to gripper

3HAC021111-001 Revision: B 17

1.2: Safety risks

1.2.1 Safety risks related to gripper

CAUTION!

Ensure that a gripper is prevented from dropping a workpiece, if such is used.

1 Safety, service

1.2.2 Safety risks related to tools/workpieces

18 3HAC021111-001 Revision: B

1.2.2 Safety risks related to tools/workpieces

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

remain closed until the cutters stop rotating.

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

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

failure or a disturbance of the controller.

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ABB IRB 1400 User manual

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