ABB-S4C+IRB 940 M2000 Electrical Maintenance Training Manual

Installation and Commissioning Manual
Industrial Robot IRB 940 Tricept

3HAC 16638-1 / M2000 / Rev. IRB 940 Tricept
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ABB Automation Technology Products AB Robotics S-721 68 VSTERS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592
Installation and Commissioning Manual IRB 940 Tricept

3HAC 16638-1
-
The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein. This manual and parts thereof must not be reproduced or copied without ABBs written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted. Additional copies of this manual may be obtained from ABB at its then current charge.
Copyright 2002 ABB All rights reserved. ABB Automation Technology Products AB Robotics SE-721 68 Vsters Sweden
Table of Contents
Overview Product Documentation, IRB 940 Tricept Chapter 1: Safety, service Introduction Safety, service - General
Section A: References
1 3 5 5 6
7
Limitation of Liability Applicable Safety Standards Related information

Section B: Safety risks
7 7 8
9
Safety risks related to end effector Safety risks related to tools/workpieces Safety risks related to pneumatic/hydraulic systems Safety risks during operational disturbances Safety risks during installation and service Risks associated with live electric parts
Section C: Safety actions
9 9 9 10 10 11
13
Safety fence dimensions Fire extinguishing Emergency release of the manipulator's arm Brake testing Risk of disabling function "Reduced speed 250 mm/s" Safe use of the Teach Pendant Unit Work inside the manipulators working range Chapter 2: Reference Information Introduction Screw joints Weight specifications Chapter 3: Manipulator Introduction
Section A: Unpacking
13 13 14 14 15 15 15 17 17 18 20 21 21
22
Pre-installation procedure Working range, IRB 940 Tricept Risk of tipping/Stability

Section B: On-site installation
22 26 27
28
Lifting manipulator in a horizontal orientation
28
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Table of Contents
Lifting manipulator in a vertical orientation, using a trolley Lifting manipulator in a vertical orientation, using a lifting jack Manually releasing the brakes Orienting and securing the manipulator Fitting equipment on manipulator Loads
Section C: Electrical connections
31 35 39 40 44 46
47
Installation of cabling on board the manipulator Connecting the manipulator to the control cabinet, manipulator cabling Connectors on the distribution box Chapter 4: Controller Introduction
Section A: Unpacking
47 49 52 53 53
54
Transporting and unpacking, S4Cplus

Section B: On-site Installation
54
56
Lifting the controller cabinet Required installation space, control cabinet Bolt pattern, control cabinet Installation of external power transformer Installation of Distributed Drive Unit (DDU)
Section C: Electrical connections
56 57 58 59 64
68
C - 1: Signal/Power cables Connecting the manipulator to the control cabinet, S4Cplus cabling Connectors on control cabinet, S4Cplus Connectors on distributed drive unit, DDU Connection of mains power to control cabinet, S4Cplus C - 2: Signal connections Signal Classes Selecting Cables Interference elimination Connection types Connections to screw terminals Connections to connectors C - 3: Customer connections on controller The MOTORS ON/MOTORS OFF circuit External customer connections on panel X1 - X4 Connection of external safety relay
68 68 70 71 72 74 74 75 77 79 80 81 81 81 91 94
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Table of Contents
C - 4: Supplies External 24V supply 24V I/O supply 115/230 VAC supply C - 5: Buses Connection of the CAN bus Interbus-S, slave DSQC 351 Profibus-DP, slave DSQC 352 C - 6: I/O units Distributed I/O units Distributed I/O, digital sensors Distributed I/O, digital I/O DSQC 328 (option) AD Combi I/O, DSQC 327 (optional) Analog I/O, DSQC 355 (optional) Encoder interface unit, DSQC 354 (optional) Relay I/O, DSQC 332 (optional) Digital I/O (120 VAC), DSQC 320 (optional) C - 7: Communication Communication concept, Allen-Bradley RIO, remote I/O for Allen-Bradley PLC DSQC 350 Communication, serial links Communication, Ethernet External operators panel
Section D: Start-up
96 96 98 99 99 99 104 110 114 114 115 116 120 124 130 136 140 144 144 146 149 154 157
159
Inspection before start-up Start-up

Section E: Installation of controller software
159 160
162
Loading system software RobotWare CD-ROM Installing new Robot Controller Software with RobInstall Create a new Robot Controller System Update the Robot Controller image Transfer Robot Controller System using Ethernet connection Transfer Robot Controller System using floppy disks RobInstall preferences
Section F: Robot controller
162 164 166 168 173 175 180 182

184
BootImage Start window Reboot Window Boot Disk Window
184 185 187 188
iii
Table of Contents
Network Settings Window LAN Settings Window Service Settings Window System selection window How to perform a Restart How to Start in Query Mode
Section G: System directory structure
189 190 192 193 194 198

200
Media pool in the PC System pool in the PC File structure in the robot controller mass storage memory Preparation of S4Cplus software to be installed Handling mass memory storage capacity Chapter 5: Calibration When to calibrate
Section A: General
200 201 202 203 204 207 207

208
How to calibrate the robot system Calibration tool kit, contents

Section B: Preliminaries
208 210
211
Correct orientation of axes Checking the calibration position Updating the revolution counter Fine calibration procedure on TPU
Section C: Calibration
211 215 216 219

222
Directions for all axes Fine calibration, all axes

Section D: After calibration
222 224
231
Post calibration procedure
231
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Overview
About This Manual
This information product is a manual containing instructions for installing the complete robot system, mechanically as well as electrically.
Usage
This manual should be used during installation, from lifting the manipulator to its work site through installing application software in the robot controller, making the robot ready for operation.
Who Should Read This Manual?
This manual is intended for:

installation personnel on the installation site.
Prerequisites
The reader should...

have the required knowledge of mechanical as well as electrical installation work.
Organization of Chapters
The manual is organized in the following chapters:
Chapter
1. 2. 3. 4. 5.
Contents
Safety, service Reference Information Manipulator Controller Calibration
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References Reference
Circuit diagram, Manipulator Circuit diagram, Controller
Document Id
Included in 3HAC 16640-1, Repair Manual, part 2 Included in 3HAC 16640-1, Repair Manual, part 2
Revisions Revision
-
Description
First edition
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Product Documentation, IRB 940 Tricept
General
The complete documentation of IRB 940 Tricept including controller consists of several manuals listed below:
Overview, Installation and Commissioning Manual
The Installation and Commissioning Manual contains the following main chapters:
Safety, Service Reference Information Unpacking On-site Installation Electrical connections Start-up Robot controller Installation of controller software System directory structure Calibration
Overview, Repair Manual
The Repair Manual contains the following main chapters:

Safety, Service Reference Information Remove/Refitting instructions for all manipulator details considered spare parts Remove/Refitting instructions for all controller cabinet details considered spare parts Circuit Diagram for manipulator Circuit Diagram for controller cabinet
Overview, Maintenance Manual
The Maintenance Manual contains the following main chapters:

Safety, Service Reference Information
Maintenance schedules Maintenance activities Disposal
The chapters for the maintenance activities include instructions for all the maintenance activities specified in the maintenance schedule.
Safety, service
Chapter 1:Safety, service

Introduction
Definitions
This chapter details safety information for service personnel i.e. personnel performing installation, repair and maintenance work.
Sections
The chapter Safety, service is divided into the following sections: A. References contains lists of:
Limitation of liability applicable safety standards referenced documents
B. Safety risks lists dangers relevant when servicing the robot system. The dangers are split into different categories:
C. Safety actions details actions which may be taken to remedy or avoid dangers.
Safety fence dimensions Fire extinguishing Emergency release of the manipulators arm Brake testing Risk of disabling function "Reduced speed 250 mm/s" Safe use of the Teach Pendant Unit enabling device Work inside the manipulators working range
Safety, service
Safety, service - General
Validity and responsibility
The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment, which can influence the safety of the total system. To protect personnel, the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed. The users of ABB industrial robots are responsible for ensuring that the applicable safety laws and regulations in the country concerned are observed and that the safety devices necessary to protect people working with the robot system have been designed and installed correctly. Personnel working with robots must be familiar with the operation and handling of the industrial robot, described in the applicable documents, e.g. Users Guide and Product Manual.
Connection of external safety devices
Apart from the built-in safety functions, the robot is also supplied with an interface for the connection of external safety devices. Via this interface, an external safety function can interact with other machines and peripheral equipment. This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot. In the Product Manual - Installation and Commissioning, instructions are provided for connecting safety devices between the robot and the peripheral equipment.
Safety, service
References
Section A: References Limitation of Liability
General
Any information given in this information product regarding safety, must not be construed as a warranty by ABB Robotics that the industrial robot will not cause injury or damage even if all safety instructions have been complied with.
Applicable Safety Standards
Standards
The robot is designed in accordance with the requirements of:

EN 292-1, Safety of macheniry, basic terminology EN 292-2, Safety of machinery, technical principles/specifications, emergency stop EN 418, Safety of machinery, emergency stop equipment EN 563, Safety of machinery, temperatures of surfaces EN 614-1, Safety of machinery, ergonomic design principles EN 775, Robot safety EN 60204-1, Electrical equipment for industrial machines EN 50081-2EMC, Generic emission standard. Part 2: Industrial environment (EN 55011 Class ARadiated emission enclosure) (EN 55011 Class AConducted emission AC Mains) EN 61000-6-2EMC, Generic standards - Immunity for Industrial environments (EN 61000-4-2Electrostatic discharge immunity test) (EN 61000-4-3Radiated, radio-frequency, electromagnetic field immunity test) (EN 61000-4-4Electrical fast transient/burst immunity test) (EN 61000-4-5Surge immunity test) (EN 61000-4-6Immunity to conducted disturbances, induced by radio-frequency fields) (EN 61000-4-11Voltage dips, short interruptions and voltage variations immunity test)
Safety, service
References
Related information
General
The list below specifies documents which contain useful information:
Documents Type of information

Installation of safety devices Changing robot modes
Detailed in document
Installation and Commissioning Manual User s Guide
Section
Start-up
Safety, service
Safety risks
Section B: Safety risks Safety risks related to end effector

Make sure to prevent an end effector from dropping a workpiece, if such is used.
Safety risks related to tools/workpieces
Safe handling
It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that guards remain closed until the cutters stop rotating. It should be possible to release parts by manual operation (valves).
Safe design
Grippers/end effectors must be designed so that they retain workpieces in the event of a power failure or a disturbance of the controller.
Safety risks related to pneumatic/hydraulic systems
General
Special safety regulations apply to pneumatic and hydraulic systems.
Residual energy
Residual energy may be present in these systems so, after shutdown, particular care must be taken. The pressure in pneumatic and hydraulic systems must be released before starting to repair them. Note that the interior of the robot may be pressurized.
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.
Safety, service
Safety risks
Safety risks during operational disturbances
General
The industrial robot is a flexible tool which can be used in many different industrial applications. All work must be carried out professionally and in accordance with the applicable safety regulations. Care must be taken at all times.
Qualified personnel
Remedial action must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts.
Extraordinary risks
If the working process is interrupted, extra care must be taken due to risks other than those associated with regular operation. Such an interruption may have to be rectified manually.
Safety risks during installation and service
General risks 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, lifting and transport of the robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with.
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Safety, service
Safety risks
Non-voltage related risks
Safety zones, which have to be crossed before admittance, must be set up in front of the robot's working space. Light beams or sensitive mats are suitable devices. Turntables or the like should be used to keep the operator out of the robot's working space. The axes are affected by the force of gravity when the brakes are released or when the motors or other components are removed. When dismantling/assembling mechanical units, watch out for falling objects. Be aware of stored heat energy in the controller. Never use the robot as a ladder, i.e. do not climb on the robot motors or other parts during service work. There is a serious risk of slipping because of the high temperature of the motors or oil spills that can occur on the robot.
To be observed by the supplier of the complete 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.
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 robots working space.
11
Safety, service
Safety risks
Voltage related risks, controller, S4Cplus
A danger of high voltage is associated with the following parts:

Be aware of stored electrical energy (DC link) in the controller. Units inside the controller, e.g. I/O modules, can be supplied with power from an external source. The mains supply/mains switch The power unit The power supply unit for the computer system (230 VAC) The rectifier unit (400-480 VAC and 700 VDC. N.B.: Capacitors!) The drive unit (700 VDC) The service outlets (115/230 VAC) The power supply unit for tools, or special power supply units for the machining process The external voltage connected to the control cabinet remains live even when the robot is disconnected from the mains. Additional connections
Voltage related risks, manipulator, IRB 940 Tricept
A danger of high voltage is associated with the manipulator in:

The distribution box for the manipulator (up to 430 VDC) The power supply for the motors (up to 430 VDC) The user connections for tools or other parts of the installation (max. 230V AC, see Product Manual - Installation and Commissioning)
Voltage related risks, tools, 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.
Safety, service
Safety actions
Section C: Safety actions Safety fence dimensions
General
Install a safety cell around the robot to ensure safe robot installation and operation.
Dimensioning the fence or enclosure
Design the safety cell such that it will:

- withstand any impact from a tool failure. Due to the high kinetic energy associated with HSM (High Speed Machining), a tool failure poses a serious risk as any debris can cause serious personal injury. Both walls and ceilings must be designed and dimensioned so that they can withstand any projectiles that they may be subjected to. Windows must be made of suitable safety glass. Study the planned process to determine the forces involved and appropriate materials. - insulate against sound pollution from the machining process. Typically the safety cell should be able to reduce sound from the machining process down to 75dBA, though individual installations may stipulate other values. Study the planned process to determine the allowable noise pollution levels and appropriate sound insulation. - isolate gases and mist generated by the machining process and spray mist lubrication. Study the planned process to determine the fumes involved and appropriate ventilation/filtering system.
Fire extinguishing
Use a CARBON DIOXIDE (CO 2 ) extinguisher in the event of a fire in the robot (manipulator or controller)!
13
Safety, service
Safety actions
Emergency release of the manipulators arm
Description
In an emergency situation, any of the manipulators axes may be released manually by pushing the brake release buttons on the distribution box for the manipulator. How to release the brakes is detailed in section "Manually releasing the brakes" in the Installation Manual. The manipulator arms may be moved manually when the brakes has been released.
Increased injury
Before releasing the brakes, make sure that the weight of the arms does not increase the pressure on the trapped person, further increasing any injury!
Brake testing
When to test
During operation the holding brakes of each axis motor wear normally. A test may be performed to determine whether the brake can still perform its function.
How to test
The function of each axis motor holding brakes may be checked as detailed below: 1. Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized (max. static load). 2. Switch the motor to the MOTORS OFF position with the Operating mode selector on the controller. 3. Check that the axis maintains its position.
If the manipulator does not change position as the motors are switched off, then the brake function is adequate.
Safety, service
Safety actions
Risk of disabling function "Reduced speed 250 mm/s"

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

The enabling device is a push button located on the side of the Teach Pendant Unit (TPU) which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device is released or pushed all the way in, the robot is taken to the MOTORS OFF state. To ensure safe use of the Teach Pendant Unit, the following must be implemented: The enabling device must never be rendered inoperative in any way. During programming and testing, the enabling device must be released as soon as there is no need for the robot to move. The programmer must always bring the Teach Pendant Unit with him/her, when entering the robots working space. This is to prevent anyone else taking control over the robot without the programmer knowing.
Work inside the manipulators working range

If work must be carried out within the robots 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 robots speed is limited to max. 250 mm/s when the operating mode selector is in position < 250 mm/s. This should be the normal position when entering the working space. The position 100% full speed may only be used by trained personnel who are aware of the risks that this entails. Also be aware of any danger that may be caused by rotating tools or other devices mounted on the manipulator or inside the cell.
15
Safety, service
Safety actions
Reference Information
Chapter 2:Reference Information

Introduction
General
This chapter presents generic pieces of information, complementing the more specific information in the following chapters.
17
Screw joints
General
This section details how to tighten the various types of screw joints in the manipulator as well as the controller. The instructions and torque values are valid for screw joints comprising metallic materials and do not apply to soft or brittle materials. Any instructions given in the repair, maintenance or installation procedure description override any value or procedure given here, i.e. these instruction are only valid for standard type screw joints.
Tightening torque
The tightening torque values for different types of screw joint are specified in the tables below:
Screws with slotted or cross recess head
Dimension
M2.5 M3 M4 M5 M6
Tightening torque (Nm) Class 4.8 "dry"

0.25 0.5 1.2 2.5 5.0
Screws with hexagon socket head
Dimension
M5 M6 M8 M10 M12

6 10 24 47 82
Tightening torque (Nm) Class 10.9

28 55 95

17 40 70 120
Dimension
M16

200

235

300
19
Weight specifications
Definition
In all repair and maintenance instructions, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way. ABB recommends handling all components with a weight exceeding 22 kg using lifting equipment to avoid inflicting injury.
Example
Below is an example of how a weight specification is presented:

The actuator with motor weighs 40 kg! All lifting equipment used must be dimensioned accordingly!
Manipulator
Chapter 3:Manipulator
Introduction
Definitions
This chapter contains necessary information for installing the manipulator to the working site.
21
Manipulator
Unpacking
Section A: Unpacking Pre-installation procedure
General
This instruction is primarily intended for use when unpacking and installing the manipulator (mechanical robot) for the first time. It also contains information useful during later re-installation of the manipulator.
Checking the prerequisites for installation
The checklist below details what must be observed before proceeding with the actual installation of the manipulator: 1. Make sure only qualified installation personnel, conforming to all national and local codes, are allowed to perform the installation. 2. Make sure the manipulator has not been damaged, by visually inspecting the manipulator and control cabinet exterior. 3. Make sure the lifting device to be used is dimensioned to handle the weight of the manipulator as stated in Weight, manipulator. 4. If the manipulator is not to be installed directly, it must be stored as in Storage conditions, manipulator. 5. Make sure the appointed operating environment of the manipulator conforms to the specifications as in Operating conditions, manipulator. 6. Before taking the manipulator to its installation site, make sure the site conforms to Loads on flange, manipulator and Protection classes. 7. Before moving the manipulator, please observe Risk of tipping/Stability regarding risk of tipping! 8. When these prerequisites have been met, the manipulator may be taken to its installation site as in Lifting manipulator in a horizontal/vertical orientation.
Manipulator
Unpacking
Weight, manipulator
The table below shows the weight of the manipulator:
Manipulator model
IRB 940 Tricept Distribution box
Weight
570 kg 31 kg
23
Manipulator
Unpacking
Loads on flange, manipulator
The table below shows the maximum forces and torques working on the manipulator during operation. NOTE! These forces and torques are extreme values that are rarely encountered during operation. The values also never reach their maximum simultaneously!
Tz
xx0200000362
Force
Force xy Force z Torque xy Torque z
Maximum stress transmitted to the mounting base

51 kN 68 kN 14 kNm 45 kNm
Manipulator
Unpacking
Storage conditions, manipulator
The table below shows the allowed storage conditions for the manipulator and the distribution box:
Parameter
Min. ambient temperature, storage Max. ambient temperature, storage Max. ambient temperature, storage (less than 24 hrs) Max. ambient humidity, storage
Value
-25C +55C +55C Max. 95% at constant temperature
Operating conditions, manipulator
The table below shows the allowed operating conditions for the manipulator and the distribution box:
Parameter
Min. ambient temperature, operation Max. ambient temperature, operation, manipulator Max. ambient humidity, operation
Value
+5C +45C Max. 95% at constant temperature
Note! The robot must not be operated until the internal temperature of the robot is stabilized within the prescribed operational temperature range!
Protection classes
The table below shows the protection class of the main parts of the robot system:
Equipment
Manipulator Distribution box Overpressure unit
Protection class
IP 66 IP 67 IP 67
25
Manipulator
Unpacking
Working range, IRB 940 Tricept
Illustration
The illustration below shows the unrestricted working range of IRB 940 Tricept:
0 400 800 1200 800 400 0 400
B A
0 400 800 800 1200 (mm) 1200 800 400 0 400
B A
800
1200 (mm)
xx0200000356
A B
Absolute Tolerance Area at the tool-coordinate system, TCP0 Working range, centre of axis 5
Manipulator
Unpacking
Risk of tipping/Stability
General
The section below details how to make sure the manipulator does not tip over before it has not been safely secured to the foundation.
Stability
The figure below shows the robot in its shipping position which also is the most stable. The robot must be placed on a spacer, at least 100mm in height, in order to avoid the risk of collision with the axis 2 servomotor.
B
xx0200000357
A B
26 mm (most stable position of axes 1, 2 and 3) Spacer, min. 100 mm in height
The table below specifies the most stable position of each axis of the manipulator. Axis
1, 2, 3 4, 6 5
Position
26 mm 0 -90
Note
Shown in figure above!
1. DO NOT change the manipulator position before securing it to its foundation. The shipping position is the most stable.
27
Manipulator
On-site installation
Section B: On-site installation Lifting manipulator in a horizontal orientation
General
The section below details how to lift the manipulator in a horizontal orientation from a transportation pallet to a stand.
Required equipment Equipment

Crane or hoist 1 strap, length 2 m 2 straps, length 1 m 2 upper platform eyebolts 2 shackles
Note
Lifting capacity: 1000 kg. Lifting capacity: 1000 kg. Lifting capacity: 1000 kg. M16 The shackles must fit the eyebolts on the upper platform.
Lifting in horizontal orientation
The section below details how to lift and move the manipulator from the transportation pallet, horizontally, using the lifting equipment specified above.
The IRB 940 manipulator weighs 570 kg! All lifting equipment used must be dimensioned accordingly!
No personnel must under any circumstances be present under the suspended load!
Failure to attach the straps correctly can cause the suspended load to tilt suddenly and cause both personal injury and severe damage to the load.
Manipulator
Step Action
1. Run the overhead crane to a position above the manipulator. Fit the 2 metre strap around the wrist unit, as shown in the adjacent figure.
Note
2.
xx0200000317
3.
Hook the strap to the lift, or crane, as shown in the adjacent figure.
xx0200000318
4.
Unless already in posiDimension specified above! tion, fit the eyebolts to the upper platform.
29
Manipulator
Step Action
5. Attach the 1 metre straps to the eyebolts using the shackles.
Note
A
C
xx0200000319
6. Attach the straps to the lift, or crane, as shown in figure above! Lift the manipulator to the required location and disconnect the lifting equipment.
A: Strap, 1 m (2 pcs) B: Shackle (2 pcs) C: Eyebolt (2 pcs)
7.
Manipulator
Lifting manipulator in a vertical orientation, using a trolley
General
The section below details how to lift the manipulator from a transportation pallet to a stand, after turning it into a vertical orientation. Notice that there are two different ways of turning the manipulator into a vertical orientation. The section below details a method using a trolley or a machine skate, that is used to wheel the front of the manipulator towards the centre of the lift as the manipulator is hoisted.

Crane or hoist 2 straps, length 2 m 2 upper platform eyebolts 2 shackles Trolley (or machine skate)
Note
Lifting capacity: 1000 kg. Lifting capacity: 1000 kg. M16 The shackles must fit the eyebolts on the upper platform. Capacity: 500 kg. Height: 400 mm.
Lifting in vertical orientation, using a trolley
The section below details how to lift and move the manipulator from the transportation pallet, vertically, using the lifting equipment specified above.
31
Manipulator
- Ensure that the area around the manipulator is clear as the machine can swing round as it leaves the pallet! - Ensure that the trolley has free movement while lifting. If the trolley gets stuck, the manipulator is likely to fall off and can cause personal injury and damage to the manipulator!
Step Action
1. Unless already in position, fit the eyebolts to the upper platform. Attach the 2 metre straps to the eyebolts using the shackles.
Note
Dimension specified above!
2.
C
xx0200000320
3. Attach the straps to the lift, or crane, as shown in figure above!
Manipulator
Step Action
4. Place the trolley under the wrist unit and guide it into the correct position as the manipulator is lifted, as shown in the adjacent figure.
Note
A B
C E
xx0200000321
D
A: Strap, 2 m (2 pcs) B: Wrist unit C: Trolley D: 125 mm E: 400 mm
5.
When the wrist is resting squarely on the trolley it is safe to continue lifting it off the pallet, as shown in the adjacent figure. Note! Exercise extreme care when lowering the wrist unit on to the trolley. Dropping the manipulator onto the trolley can cause damage to the manipulator and/or affect the calibration of the tripod.
xx0200000322
33
Manipulator
Step Action
6. As the manipulator is lifted off the pallet, carefully remove the pallet to allow free movement of the trolley towards the centre of the lift, as shown in the adjacent figure.
Note
xx0200000323
7.
Continue lifting the manipulator until it leaves the trolley and is hanging vertically, as shown in the adjacent figure.
xx0200000324
8.
Lift the manipulator and move it to the required location.
Manipulator
Lifting manipulator in a vertical orientation, using a lifting jack
General
The section below details how to lift the manipulator from a transportation pallet to a stand, after turning it into a vertical orientation. Notice that there are two different ways of turning the manipulator into a vertical orientation. The section below details a method using a lifting jack.

Crane or hoist 2 straps, length 2 m 1 strap, length 1 m 2 upper platform eyebolts 2 shackles Lifting jack
Note
Lifting capacity: 1000 kg. Lifting capacity: 1000 kg. Lifting capacity: 1000 kg. M16 The shackles must fit the eyebolts on the upper platform. Lifting capacity: 1000 kg.
Lifting in vertical orientation, using a lifting jack
The section below details how to lift and move the manipulator from the transportation pallet, vertically, using the lifting equipment specified above.
35
Manipulator
Step Action
1.
Note
Unless already in posi- Dimension specified above! tion, fit the eyebolts to the upper platform. Attach the 2 metre straps to the eyebolts using the shackles.
2.
C
xx0200000320
3. Attach the straps to the lift, or crane, as shown in figure above.
Manipulator
Step Action
4. Attach the 1 metre strap to the wrist as shown in the adjacent figure.
Note
xx0200000317
5.
Connect one end of the Dimension specified above! lifting jack to the strap around the wrist and B the other to the lift, or crane. Adjust the length so that the lifting jack is tightened, as shown in the adjacent figure. A
xx0200000325
6. Lift the whole manipulator using the lift, or crane, away from the pallet and remove the pallet.
A: Strap around wrist unit B: Crane
37
Manipulator
Step Action
7. Lower the wrist end of the manipulator using the lifting jack. When the wrist gets near the floor, raise the whole manipulator further, as shown in the adjacent figure. Repeat until the manipulator hangs vertically.
Note
xx0200000326
8.
Remove the lifting jack and lift the manipulator to the required location.
Manipulator
Manually releasing the brakes
General
The section below details how to release the holding brakes of each axis motor. This may be done by:
using push-buttons on the distribution box (internal brake release unit). This requires either that the controller is connected to the power supply or that the R1.MP connector (at the distribution box) is supplied with +24 V on R1.MP.B16 and 0 V on B14 or B15.
Supplying power on the wrong pin may cause all brakes on the manipulator to be released!
Internal brake release unit
This section details how to release the holding brakes using the internal brake release unit.
When releasing the holding brakes, the manipulator axes may move very quickly and sometimes in unexpected ways! Make sure no personnel is near the manipulator arm!
Step Action
1.
Info/Illustration
The push-button unit is equipped with six but- The push-button unit is tons for controlling the axis brakes. The but- located on the outside of tons are numbered with the axes numbers. the distribution box. Release the holding brake on a particular manipulator axis by pressing the appropriate button on the internal brake release panel. The brake will function again as soon as the button is released.
2.
39
Manipulator
Orienting and securing the manipulator
General
This section details how to orient and secure the manipulator at the stand in order to run the robot safely. The cable harness should be installed in the stand before the manipulator is mounted to it. Installation of the cabling is described in chapter "Electrical connections".
Attachment screws
The table below specifies the type of securing screws and washers to be used for securing the manipulator to the foundation. Securing screws are included in the delivery of the manipulator.
Suitable screws, lightly lubricated Quality Suitable washer Tightening torque
MC6S, M16 x 55 Quality 8.8 Thickness: 4 mm 200 Nm
A locating pin may be used in the mounting flange, when necessary. The dimension for the attachment hole is detailed in part "Hole configuration, mounting flange".
Manipulator
Illustration, securing manipulator at stand
The figure below shows how to mount the manipulator to a stand. The figure shows prepared cabling in the stand.
xx0200000348
A B C
Manipulator attachment bolts Centering ring Mounting flange
41
Manipulator
Securing the manipulator
This section details how to secure the manipulator to the stand in a vertical position, after fitting the stand to the foundation.
Step
1.
Action
Info/Illustration
Lift and turn the manipulator to vertical orien- Detailed in "Lifting the tation. manipulator in a vertical orientation, using a trolley/lifting jack". Move the manipulator to the vicinity of its installation location. Pull the cabling through the stand and through the centering ring. Fit the ring to the stand. Guide the manipulator gently while lowering it into its mounting position. Make sure the manipulator mounting flange is correctly fitted onto the centering ring! If necessary, use a locating pin in the flange. Fit the 8 bolts and washers in the mounting flange attachment holes. Shown in figure above!
2. 3.
4.
Shown in figure above! Location of the attachment hole for the pin is shown in part "Hole configuration, mounting flange". Specified in "Attachment screws". Shown in figure above! Note! Lightly lubricate the bolts before assembly!
5.
6.
Tighten the bolts in a criss-cross pattern to ensure that the flange is not distorted.
Manipulator
Hole configuration, mounting flange
The illustration below shows the hole configuration used when securing the manipulator. Note that the holes are not equally spaced on the flange.
A-A (400) 350 53 86.5 C C-C
18 Through 8x)
C 10 H8 Through 87.5 xx0200000358
3 6
43
Manipulator
Fitting equipment on manipulator
General
The manipulator features mounting holes for additional equipment.
Illustration, fitting of extra equipment on upper platform
The illustration below shows the mounting holes available for fitting extra equipment on the upper platform.
309.5
x M8x12 Deep
xx0200000360
Manipulator
Illustration, fitting on mounting flange
The illustration below shows the mounting holes available for fitting equipment on the mounting flange.
xx0200000359
Fastener quality
When fitting tools on the mounting flange (see the figure above), use only screws with quality 12.9. When fitting other equipment, standard screws with quality 8.8 can be used. A guiding pin may be used when fitting equipment on to the tool flange. Attach the pin to the extra equipment using a press fit, in order to make sure that the pin remains in the equipment when removing it from the flange.
45
Manipulator
Loads
General
Any loads mounted on the manipulator must be defined correctly and carefully (with regard to the position of centre of gravity and inertia factor) in order to avoid jolting movements and overloading the motors. If this is not done correctly operational stops may result.
References
Load diagrams, permitted extra loads (equipment) and their positions are specified in the Product Specification. The loads must also be defined in the software as detailed in the Users Guide.
Brake performance
Manipulator motor brake performance depends on any loads attached. For further information about brake performance, please contact ABB Robotics.
Manipulator
Electrical connections
Section C: Electrical connections Installation of cabling on board the manipulator
General
The manipulator is connected to the control cabinet via a distribution box, after mounting it on the stand. The section below describes how to install the cabling on board the manipulator. All the necessary cabling is included in the delivery of the robot but must be connected both to the manipulator and to the distribution box. All cabling is specified in the part "Connecting the manipulator to the control cabinet, manipulator (/controller) cabling" The figure below shows how the cabling is installed to the manipulator.
xx0200000349
Cabling in one of the two grooves in the upper platform
47
Manipulator
Installation of cabling on board the manipulator
Step
1.
Action
Attach the cables, axes 1-2-3, with straps in the cable grooves on the upper platform, as shown in the figure above. The cabling is marked with a red ring at the correct attachment point. The ring is then located behind the straps. When installing the cabling in the robot it is very important to adjust its looseness correctly.
Note/Illustration
2.
Connect the cables, axes 1-2-3, Connection points detailed in "Conto the motors of axes 1-2-3. Fit the necting the manipulator to the concables to the brackets mounted trol cabinet, manipulator cabling". nearby the motors and secure with straps. Fit the cables, axis 4-5-6, inside the cable chain. Connect the cables on top of the housing, at the upper end of the center unit. Fasten the cable chain with attachment screws in the cable bracket at axis 2 and at top of the housing. Connection points detailed in "Connecting the manipulator to the control cabinet, manipulator cabling".
3. 4.
5.
4x
4x
xx0200000428
Manipulator
Connecting the manipulator to the control cabinet, manipulator cabling
General
The manipulator is to be connected to the control cabinet via a distribution box, after mounted to the stand. This section specifies the cabling to be used and their connection points. How to install the manipulator cables on board the manipulator is detailed in the part "Installation of cabling on board the manipulator".
Main cable categories Cable category

Manipulator cables
Description
The cables between the distribution box and the manipulator motors are specially manufactured with extra strong screening. The cabling for each motor consists of two separate cables, one power cable and one signal cable. The cabling contains conductors for: The power cable contains conductors for: Motor phases Earth connection Motor brake Motor temperature sensors
The signal cable contains conductors for: Resolvers Distribution box cables Handles power supply to and control of the manipulator's motors as well as feedback from the serial measurement board.
49
Manipulator
Manipulator cables
The manipulator cables are included in the standard delivery. They are completely pre-manufactured and ready to plug in. The cabling transfers drive power and resolver data for drive and control of the six axes.
Cable sub-category
Manipulator cable, power, axis 1 Manipulator cable, signal, axis 1 Manipulator cable, power, axis 2 Manipulator cable, signal, axis 2 Manipulator cable, power, axis 3 Manipulator cable, signal, axis 3 Manipulator cable, power, axis 4 Manipulator cable, signal, axis 4 Manipulator cable, power, axis 5 Manipulator cable, signal, axis 5 Manipulator cable, power, axis 6 Manipulator cable, signal, axis 6
Connection point, Connection point, distribution box manipulator

XM1 XR1 XM2 XR2 XM3 XR3 XM4 XR4 XM5 XR5 XM6 XR6 XM1.1 XR1.1 XM2.1 XR2.1 XM3.1 XR3.1 XM4.1 XR4.1 XM5.1 XR5.1 XM6.1 XR6.1
Distribution box cables
These cables are included in the standard delivery. They are completely pre-manufactured and ready to plug in.
Cable subcategory
Distribution box cable, power
Description
Transfers drive power from the drive units in the control cabinet to the manipulators distribution box.
Connection Connection point, point, cabinet distribution box

XS1 R1.MP
Manipulator
Cable subcategory
Distribution box cable, signals
Description
Connection Connection point, point, cabinet distribution box

R1.SMB
Transfers resolver XS2 data from the serial measurement board and power supply to the SMB in the distribution box.
Distribution box cable, power Cable

Distribution box cable, power, 7 m Distribution box cable, power, 15 m Distribution box cable, power, 30 m
Article number
3HAC 11818-1 3HAC 11818-2 3HAC 11818-4
Distribution box cable, signals Cable

Distribution box cable, signal, shielded, 7 m Distribution box cable, signal, shielded, 15 m Distribution box cable, signal, shielded, 30 m
Article number
3HAC 7998-1 3HAC 7998-2 3HAC 7998-4
51
Manipulator
Connectors on the distribution box
General
Section "Connecting the distribution box to the control cabinet" specifies which cables to use in order to connect the manipulators distribution box to the controller.
Connectors on the distribution box
All distribution box connectors are shown in the figure below.
R1.MP
R1.SMB
XM4 XM1 XM5 XM2 XM6 XM3 XR1 XR2 XR3 XR4 XR5 XR6
xx0200000430
The connectors on the controller cabinet are located as detailed in part "Connectors on the controller cabinet, S4CPlus".
Controller
Chapter 4:Controller
Introduction
Definitions
This chapter contains necessary information for installing the controller to the working site.
53
Controller
Unpacking
Section A: Unpacking Transporting and unpacking, S4Cplus
General
Before starting to unpack and install the robot system, read the safety regulations and other instructions very carefully. These are found in separate sections in the User s Guide and Product manual. The installation must be done by qualified installation personnel and should conform to all national and local codes. When you have unpacked the cabinet, check that it has not been damaged during transport or while unpacking.
Weight, controller cabinet
The table below shows the weights for the controller cabinet:
Controller
S4Cplus controller cabinet Distributed Drive Unit (option)
Weight
240 kg 30 kg
Storage conditions, controller cabinet
The table below shows the allowed storage conditions for the controller:
Parameter
Min. ambient temperature Max. ambient temperature Max. ambient humidity
Value
-25C +55C Max. 95% at constant temperature
Max. ambient temperature (less than 24 h) +70C
Controller
Unpacking
The table below shows the allowed operating conditions for the controller: Operating conditions, controller cabinet
Parameter
Min. ambient temperature Max. ambient temperature Max. ambient humidity
Value
+5C +45C Max. 95% at constant temperature
Protection class, controller
The table below shows the protection class of the controller:
Equipment
Control cabinet Programming unit Distributed Drive Unit (option)
Protection class
IP 54 IP 54 IP 54
55
Controller
On-site Installation
Section B: On-site Installation Lifting the controller cabinet
Lifting device
Use the four lifting devices on the cabinet or a fork lift when lifting the controller cabinet S4Cplus as shown below. The figure below shows the minimum angle between the lifting straps and the cabinet when lifting the controller.
B
xx0100000153
A B
Min. 60when lifting with straps Fork lift
Cabinet delivered without top cover
If the controller is delivered without its top cover, a fork lift must be used. Do not use lifting devices!
Controller
Required installation space, control cabinet
Dimensions
The figure below shows the required installation space for the S4CPlus control cabinet:
A
200
200
800
800
820
950 980*
500 70 620
xx0100000156
A B *
Air distance to wall Cabinet extension (Option 124) Castor wheels (Option 126)
57
Controller
Bolt pattern, control cabinet
Dimensions
The figure below shows the bolt pattern for the S4CPlus control cabinet:
720
400
xx0100000157
Controller
Installation of external power transformer
Location of external power transformer
The external power transformer (option) is located outside the controller as shown in the figure below:
B A
xx0100000154
A B
Cable glands for input and output cables (large gland; input cable, small gland; output cable) Locking screws/lifting lugs
Required equipment Equipment, etc.

External power transformer unit Input cables Output cables
Spare part no. Art. no.

3HAC 11668-1
Note
Rec. 16 mm 2 Rec. 6 mm 2
59
Controller
Equipment, etc.
Fuse and holder
Note
Mains voltage 200 VAC: 63 A Mains voltage 600 VAC: 25 A Dimensioned for the expected currents
Circuit breaker
Standard toolkit
3HAC 15571-1
The contents are defined in section "Standard toolkit"! These procedures include references to the tools required.
Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Circuit Diagram, controller Circuit Diagram, external power transformer 3HAC 5582-2 3HAC 11668-11
Connections
The procedure below details how to connect the external power transformer unit.
Please observe the following before commencing any repair work on the controller: Turn off all electric power supply to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Step
1. 2.
Action
Connect the shop mains power supply Connect the external power transformer input.
Note/Illustration
Detailed in "Shop mains power supply" below! Detailed in "Transformer input" below!
Controller
Step
3. 4.
Action
Note/Illustration
Connect the external power transformer out- Detailed in "Transformer put. output" below! Connect the controller input. Detailed in "Controller input" below!
Shop mains power supply
The procedure below details how to connect the Shop mains power supply.
Step
1.
Action
Note/Illustration
Make sure the shop supply is fitted with suit- Fuse size specified in the able circuit breakers and fuses. table above!
Transformer input
The procedure below details how to connect the Transformer input.

Step
1.
Action
Run a cable from the shop supply outlet through the input cable inlet on the transformer unit.
Note/Illustration
Shown in the figure above!
61
Controller
Step
2. 3. 4.
Action
Open the transformer unit by removing the lock screws on top of the unit. Connect the input cable earth conductor to the earth terminal.
Note/Illustration
Connect the three input phases to the long Terminal: X1 terminal. Make sure the cables are connected to the terminals marked with the voltage value corresponding to the voltage supplied. Make sure all terminals are tightened to ensure good electric contact. Tightening torque: approx. 2 Nm
5.
Transformer output
The procedure below details how to connect the Transformer output.
Step
1. 2. 3.
Action
Note/Illustration
Run a cable from the transformer unit through Shown in the figure the output cable outlet to the robot controller. above! Connect the output cable earth conductor to the transformer unit earth terminal. Connect the three output phases to the output terminals. The terminals are marked with "475" for the output voltage. Make sure all terminals are tightened to ensure good electric contact. Terminals: X1.1, X1:2 and X1:3
4.
Tightening torque: approx. 2 Nm
Controller
Controller input
The procedure below details how to connect the Controller input.

Step
1.
Action
Remove the left cover plate under the robot controller top lid. Route the transformer output cable through the gland located on the left cabinet wall. Connect the cable inside the robot controller (not dependent on phase sequence): Phase 1 to L1 Phase 2 to L2 Phase 3 to L3 0 to XT26.N Earth to the cabinet earth connection (C in the figure). The earth connection is marked with a "PE" sticker.
Note/Illustration
2.
3.
A B C D
xx0100000155
A: Terminal X26 B: Connectors C: Earth connection (PE) D: Cable glands
4.
Make sure all terminals are Tightening torque: approx. 2 Nm tightened to ensure good electric contact.
63
Controller
Installation of Distributed Drive Unit (DDU)
Required installation space, DDU
The external DDU (option) is located outside the control cabinet. The figure below shows the required installation space for the DDU.
300
xx0200000340
50 mm, required free area for the exhaust air
Controller
Bolt pattern, DDU
The DDU is to be suspended nearby the control cabinet, using the bolt pattern shown in the figure below.
260
xx0200000374
Connection to earth
If the difference of potential between the control system and the DDU is too large or there are suspicions of shorter drops in voltage, the DDU must be connected to earth. This is done at the connection point GND (see the part "Connectors on the DDU").
Fan cooling
The main power from the control cabinet also feeds two fans in the DDU via an internal transformer with three input taps. The transformer wires are connected as
0 - 400V for nominal mains input 400V 0 - 440V for nominal mains input 440V 0 - 480V for nominal mains input 480V
65
Controller
Overheating
Overheating of the DDU may be caused by the following:

A line voltage lower than 480V is used, while the fans are connected as 480V. This causes a reduced fan cooling. See Changing the connection of the transformer below. The fuse, located at the screw terminal, has caused the fans to stop. Insufficient airflow. See Increasing the airflow below. Too heavy drive at too high ambient temperature. See the manual External axes.
Changing the connection of the transformer
The default connection of the transformer is the nominal mains input 480V. The cooling is, however, reduced, when a lower line voltage is used and there may be a risk that the drive unit is triggered at a high surrounding temperature. Therefore, if the line voltage differs from 480V, it is recommended to switch over the default connection to 440V or 400V instead. To change the voltage, remove the lid of the DDU and switch the connections on the screw terminals (see the part "Connections to screw terminals").
Controller
Increasing the airflow
If there appears to be an overheating of the DDU, without suspicion of reduced fan cooling, the airflow may be increased by replacing the two covering plates with vents, see figure below. This gives four openings instead of the normal two.
B A
xx0200000373
A B
Vent Covering plate
Cabling
Section "Connecting the manipulator to the control cabinet" specifies which cables to use and to which connectors these are to be connected, in order to connect the DDU to either the controller, the manipulator or to the external axis.
67
Controller
Section C: Electrical connections C - 1: Signal/Power cables Connecting the manipulator to the control cabinet, S4Cplus cabling
General
Connect the manipulator and control cabinet to each other after securing them to the foundation. The lists below specify which customer cables to be used. Manipulator cabling is specified in chapter Manipulator, section Electrical connections.
Customer cables
These cables are not included in the standard delivery, but are included in the delivery of each specific option. The cables are not ready to plug in, but require connection to terminals inside the control cabinet as well as keying. These activities are detailed in Customer Connection Kit. Connection Connection point, point, cabinet manipulator
XT/XP5.1 XT/XP6 XS6 XT/XP5.1 XT/XP6 XS6 XT/XP5.1 XT/XP6 XS6 XT/XP5.1 XT/XP6 DP/M XT/XP5.1 XT/XP6 DP/M R1.CP/CS
Cable
Fieldbus cable, CAN, 7 m
Art. no.
3HAC 13173-1
3HAC 13173-2
R1.CP/CS
3HAC 13173-4
R1.CP/CS
Fieldbus cable, Profibus, 7 m
3HAC 13174-1
R1.CP/CS
Fieldbus cable, Profibus, 15 m 3HAC 13174-2
R1.CP/CS
Controller
Cable
Art. no.
Connection Connection point, point, cabinet manipulator

XT/XP5.1 XT/XP6 DP/M XT/XP5.1 XT/XP5.2 XT/XP6.1 XS13 XT/XP5.1 XT/XP5.2 XT/XP6.1 XS13 XT/XP5.1 XT/XP5.2 XT/XP6.1 XS13 XT/XP5.1 XT/XP5.2 XT/XP6.1 XS13 XT/XP5.1 XT/XP5.2 XT/XP6.1 XS13 XT/XP5.1 XT/XP5.2 XT/XP6.1 XS13 R1.CP/CS
Fieldbus cable, Profibus, 30 m 3HAC 13174-4
Harness CP/CS, CAN, 7 m
3HAC 14890-4
R1.CP/CS
3HAC 14890-1
R1.CP/CS
3HAC 14890-6
R1.CP/CS
Harness CP/CS, Interbus, 7 m 3HAC 15644-4
R1.CP/CS
Harness CP/CS, Interbus, 15 m
3HAC 15644-1
R1.CP/CS
Harness CP/CS, Interbus, 30 m
3HAC 15644-5
R1.CP/CS
69
Controller
Connectors on control cabinet, S4Cplus
General
Section "Connecting the manipulator to the control cabinet" specifies which cables to use and to which connectors these are to be connected, in order to connect the controller to the manipulator.
Connections to the cabinet
All control cabinet connectors are shown in the figure below.
xx0100000247
* **
For 6400S/640 and Can Bus Option for 66X0 and 7600
Controller
Connectors on distributed drive unit, DDU
General
The section "Connecting the manipulator to the control cabinet" specifies which cables to use and to which connectors these are to be connected, in order to connect the DDU (distributed drive unit) to either the controller, the manipulator or to the external axis.
Connections to the DDU
All DDU connectors are shown in the figure below.
S77
XS78 GND
XP40
XP49
xx0200000372
The connections on the manipulator are located on the rear of the robot base.
71
Controller
Connection of mains power to control cabinet, S4Cplus
General
Connect the power supply either inside the cabinet, or to a optional socket on the left-hand side of the cabinet or the lower section of the front. The cable connector is supplied but not the cable. Dimension the mains supply cables and fuses in accordance with the rated power and line voltage, see rating plate on the controller.
Connections to the mains switch
Also see the Circuit Diagram. The instruction below details how to make all the required connections to the mains switch:
C D
xx0100000248
A B C D
XT 26 Protective Earth connection Cable gland Connector
Step
1.
Action
Remove the left cover plate under the top lid.
Info/Illustration
Controller
Step
2.
Action
Pull the mains cable (outer diam. 10.2 mm) through the gland located on the left cabinet wall. Release the connector from the knob by pushing the release buttons located on the side of the connector. Connect phase: 1 to L1 (Not dependent on phase sequence) 2 to L2 3 to L3 0 to XT26.N (line neutral is needed only for option 432) and protective earth to the protective earth connection.
Info/Illustration
3.
4.
Shown in the figure above! NOTE! Max. conductor size is 6 mm2 (AWG 10). Tighten to a torque of 2.3-2.5 Nm. Retighten after approx. 1 week.
5.
Snap the breaker on to the knob again and check that it is fixed properly in the correct position. Tighten the cable gland. Fasten the cover plate.
6. 7.
Connection through a power socket
It is possible to connect the mains supply via an industrial Harting connector (DIN 41 640). See the figure below: Cable connectors are supplied (option 132 - 134).
A
xx0100000162
DIN connector
73
Controller
C - 2: Signal connections Signal Classes
Overview
Different rules apply to the different classes when selecting and laying cable. Signals from different classes must not be mixed.
Signals
Power Signals: Supplies external motors and brakes. Control signals: Digital operating and data signals (digital I/O, safety stops, etc.). Measuring signals: Analog measuring and control signals (resolver and analog I/O). Data communication signals: Gateway (Field bus) connection, computer link.
Controller
Selecting Cables
Controller cables:
All cables laid in the controller must be capable of withstanding +70C.
Power Signal:
Shielded cable with an area of at least 0.75mm 2 or AWG 18.

Note that any local standards and regulations concerning insulation and area must always be complied with.
Control signals:
Shielded cables.
Measuring signals:
Shielded cable with twisted pair conductors.
Data communication signals:
Shielded cable with twisted pair conductors.
A specific cable should be used for Gateway (Field bus) connections.
CAN bus with DeviceNet for distributing I/O units:
A thin cable according to DeviceNet specification release 1.2, must be used, e.g. ABB article no. 3HAB 8277-1. The cable is shielded and has four conductors, two for electronic supply and two for signal transmission.
Note that a separate cable for suppling I/O loads is required.
75
Controller
Allen-Bradley Remote I/O:
Cables according to Allen-Bradley specification, e.g. "Blue hose", should be used for connections between DSQC 350 and the Allen-Bradley PLC bus.
Interbus-S:
Cables according to Phoenix specification, e.g. "Green type", should be used for connections between the DSQC 351 and external Interbus-S bus.
Profibus DP:
Cables according to Profibus DP specification should be used for connections between the I/O unit DSQC 352 and the external Profibus DP bus.
Ethernet:
Shielded twisted pair conductors (10 Base T STP).
Controller
Interference elimination
External units
External relay coils, solenoids, and other units that will be connected to the controller must be neutralized. The figure below illustrates how this can be done.
The turn-off time for DC relays increases after neutralization, especially if a diode is connected across the coil. Varistors give shorter turn-off times. Neutralizing the coils lengthens the life of the switches that control them.
Clamping with a diode
The diode should be dimensioned for the same current as the relay coil, and a voltage of twice the supply voltage.
+24V 0V
xx0100000163
Clamping with a varistor
The varistor should be dimensioned for the same current as the relay coil, and a voltage of twice the supply voltage.
+24V 0V
xx0100000164
77
Controller
Clamping with an RC circuit
R 100 ohm, 1W C 0.1 - 1 mF. >500V max. voltage, 125V nominal voltage.
+24V DC, or AC voltage R C 0V
xx0100000165
Controller
Connection types
General
I/O, external emergency stops, safety stops, etc. can be supplied on screw connections or as industrial connectors.
Connections Designation
X(T) XP XS
Connection type
Screw terminal Pin (male) Sockets (female)
79
Controller
Connections to screw terminals
Overview
This section describes how to connect conductors to screw terminals. Detailed information about connection location and functions will be found in the circuit diagram (Service Manual).
Installation
The installation should comply with the IP54 (NEMA 12) protective standard. 1. Bend unused conductors backwards and attach them to the cable using a clasp, or similar.
To prevent interference, ensure that unused conductors are not connected at the other end of the cable (antenna effect). In environments with much interference, disconnected conductors should be grounded (0V) at both ends.
Controller
Connections to connectors
Location of connectors
If ordered, industrial connectors can be found on the left-hand side or front of the control cabinet (depending on the customer order). Also see the figure in section "Connectors on control cabinet"! The manipulator arm (not IRB 940 Tricept) is equipped with round Burndy/Framatome connectors (customer connector not included).
Connectors, description
Each industrial connector has accommodation for four rows of 16 conductors with a maximum conductor area of 1.5 mm 2. The pull-relief clamp must be used when connecting the shield to the case.
Making the connection
The section below details how to crimp cable connections to pins: 1. Using a special crimp tool, crimp a pin or socket on to each non-insulated conductor.
When two conductors are be connected to the same pin or socket, both of them must be crimped into the same pin or socket. A maximum of two conductors may be crimped into the same pin or socket.
2. Snap the pin into the connector housing. 3. Push the pin into the connector until it locks. 4. A special extractor tool must be used when removing pins or sockets from industrial connectors.
C - 3: Customer connections on controller The MOTORS ON/MOTORS OFF circuit
Outline diagram
The MOTORS ON/MOTORS OFF circuit is made up of two identical chains of switches. The diagram shows the available customer connections, AS, GS and ES.
81
Controller
A E C B D
G H J R K S T
L
xx0100000174
N P
A B C D E F G H J K L M N P R S
ES (emergency stop) LS (Limit switch) Solid state switches Contactor Mains Drive unit Second chain interlock GS (general mode safeguarded space stop) AS (Automatic mode safeguarded space stop) ED (TPU enabling device) Manual mode Motor Automatic mode Operating mode selector RUN EN1
Controller
EN2
Function of the MOTORS ON/ MOTORS OFF circuit
The circuit monitors all safety related equipment and switches. If any of the switches is opened, the MOTORS ON/MOTORS OFF circuit switches the power to the motors off. As long as the two chains are not identical, the robot will remain in MOTORS OFF mode.
Connection of safety chains
The diagram below shows the two-channel safety chain. The supply from internal 24V (X3/X4:12) and 0 V (X3/X4:7) is displayed. For an external supply of GS and AS, X3/X4:10,11 is connected to 24V and X3/X4:8,9 is connected to external 0V. Connection tables for X1-X4 are given in "External customer connections on panel X1 - X4".
83
Controller
24V X3:12 X4:12
Ext LIM1 24V X1:11 12 ES1 Opto GS1 isol. TPU En1 Opto AS1 isol. Auto1 External contactors 0V 24 V 0V X3:3 X4:3 4 4 CONT1 CONT2 Man1
K1 0V
X3:10 8 11 9
&
EN Run Intern locking
K1 K2
Ext LIM2 X2:11 12
K2
24 V
X4:10 8 11 9 Opto AS2 isol.
ES2 Opto GS2 isol. TPU En2
Drive Unit
&
Man2
Auto2
xx0100000166
Technical data per chain

Limit switch External connectors GS/AS load at 24 V GS/AS closed "1" GS/AS open "0" External supply of GS/AS Load: 300 mV Max. voltage drop: 1 V Load: 10 mA Max. voltage drop: 4 V 25 mA >18 V <5V Max. + 35 VDC Min. - 35 VDC
Controller
Technical data per chain

Max. potential in relation to the cabinet earthing and other signal groups Signal class 300 V Control signals
85
Controller
Connection of ES1/ES2 on panel unit
The diagram below shows the terminals for the emergency circuits. The supply from internal 24V (X1/X2:10) and 0V (X1/X2:10) is displayed. For an ext. supply, X1/X2:3 is connected to ext. 24V and X1/X2:8 is connected to ext. 0V (dotted lines).
A 24V 0V B 1:4 X1:10 X1:3 X1:7 X1:9 X1:8 X1:1 X1:2 24V C D
X1:6 E 24V
G 24V 0V B 2:4 C D X2:7 X2:8 X2:1 X2:2 24V
X2:6 H 24V X2:4 X2:5 J

xx0100000191
Controller
A B C D E F G H J
Internal Ext shop TPU Cabinet ES1 internal Run chain 1 top Internal ES2 internal Run chain 2 top
Technical data
ES1 and ES2 max output voltage ES1 and ES2 max output current 120 VAC or 48 VDC 120 VAC: 4 A 48 VDC L/R: 50 mA 24 VDC L/R: 2 A 24 VDC R load: 8 A Min. 22 V between terminals X1:9, 8 and X2:9, 8 respectively 40 mA 300 V Control signals
External supply of ES relay Rated current per chain Max. potential in relation to the cabinet earthing and other signal groups Signal class
87
Controller
Connection to MOTORS ON/ MOTORS OFF contactor
The diagram below shows the connection of terminals for customer use.
A B
X3:2 1 X4:2 1
xx0100000193
A B
K1 (Motor on/off 1) K1 (Motor on/off 2)
Technical data
Max. voltage Max. current Max. potential in relation to the cabinet earthing and other signal groups Signal class 48 VDC 4A 300 V Control signals
Controller
Connection to operating mode selector
S1.1.x1 8 A 7 6 B D 5 S1.1.x1 4 3 2 E
xx0100000197
A B C D E F
Auto 1 MAN1 100% (Option) Auto 2 MAN2 100% (Option)
Technical data
89
Controller
Connection to brake contactor
A
X4:5 6
xx0100000199
K3 (Brake)
Technical data
Controller
External customer connections on panel X1 - X4
Outline diagram
The diagram shows the customer connections X1 - X4 located on the panel unit.
WARNING
REMOVE JUMPERS BEFORE CONNECTING ANY EXTERNAL EQUIPMENT
xx0100000205
grey field
Jumper
Connection of X1: 12-pole type Phoenix COMBICON connector
The table below shows the signal descriptions for X1. The signal names refer to the Circuit Diagram.
Signal
ES1 out: A ES1 out: B ES1 top 24 V panel Run ch1 top ES1 internal Sep. ES1: A Sep. ES1: B
Terminal no. Comment

1 2 3 4 5 6 7 8 Emergency stop out chain 1 Emergency stop out chain 1 Top of emergency stop chain 1 + 24 V emergency stop chain 1 and run chain 1 Top of run chain 1 Internal signal from emergency stop relay chain 1 Separated emergency stop chain 1 Separated emergency stop chain 1
91
Controller
Signal
ES1 bottom 0V Ext. LIM1: A Ext. LIM1: B

9 10 11 12 Bottom of emergency stop chain 1 0 V emergency stop chain 1 External limit switch chain 1 External limit switch chain 1
Signal
ES2 out: A ES2 out: B ES2 top 0V Run ch2 top ES2 internal Sep. ES2: A Sep. ES2: B ES2 bottom 24 V panel Ext. LIM2: A Ext. LIM2: B

1 2 3 4 5 6 7 8 9 10 11 12 Emergency stop out chain 2 Emergency stop out chain 2 Top of emergency stop chain 2 0 V emergency stop chain 2 Top of run chain 2 Internal signal from emergency stop relay chain 2 Separated emergency stop chain 2 Separated emergency stop chain 2 Bottom of emergency stop chain 2 + 24 V emergency stop chain 1 and run chain 2 External limit switch chain 2 External limit switch chain 2
Signal

Motor contactor 1 Motor contactor 1
Ext. MON 1: A 1 Ext. MON 1: B 2
Controller
Signal
0V CONT1

3 4 5 6 External contactor 1 0 V External contactor 1 No connection No connection 0 V to auto stop (AS) and general stop (GS) General stop minus chain 1 Auto stop minus chain 1 General stop plus chain 1 Auto stop plus chain 1 24 V to auto stop and general stop
0V GS1AS1GS1+ AS1+ 24 V panel
7 8 9 10 11 12
Signal

Motor contactor 2 Motor contactor 2 External contactor 2 24 V External contactor 2 Contactor for external brake Contactor for external brake 0 V to auto stop (AS) and general stop (GS) General stop minus chain 2 Auto stop minus chain 2 General stop plus chain 2 Auto stop plus chain 2 24 V to auto stop and general stop
Ext. MON 2: A 1 Ext. MON 2: B 2 24 V panel CONT2 3 4
Ext. BRAKE A 5 Ext. BRAKE B 6 0V GS2AS2GS2+ AS2+ 24 V panel 7 8 9 10 11 12
93
Controller
Connection of external safety relay
Description
The motor contactors K1 and K2 in the controller can operate with external equipment if external relays are used. The figure below shows two examples of how to connect the external safety relays:
Controller
Connection examples
X4:4 CONT 2 24 V X4:3 E xt MON 2 X4:2 K2 X4:1 X3:2 K1 E xt MON 1 X3:1 0 V X3:3 CONT 1 X3:4
0V
24 V
E AS F E K H J
xx0100000246
GS F
AS
GS G
Panel unit
95
Controller
B C D E F G H J K
Relays with positive action Robot 1 Robot 2 External supply ES (emergency stop) out Safety relay To other equipment Safety gate Cell ES (emergency stop)
C - 4: Supplies External 24V supply
When is an external supply recommended?
An external supply is recommended to make use of the advantages offered by the galvanic insulation on the I/O units or on the panel unit. An external supply must be used in the following cases:
When the internal supply is insufficient When the emergency stop circuits must be independent of whether or not the robot has power on, for example. When there is a risk that major interference can be carried over into the internal 24V supply.
How to connect the external supply
The external supply neutral wire must be connected to the chassis such that the maximum permitted potential difference in the chassis earth is not exceeded. For example, a neutral wire can be connected to the chassis earth of the controller, or some other common earthing point.
Technical data
Potential difference to chassis earth Max. 60 V continuously Max. 500 V during 1 minute
Controller
Permitted supply voltage
I/O units 19 VDC - 35 VDC incl. ripple Panel unit 20.6 VDC - 30 VDC incl. ripple
97
Controller
24V I/O supply
General
The 24V I/O is not galvanically separated from the rest of the controller voltages.
24 VDC supply for internal and external use
Voltage Ripple Permitted customer load Current limit
24.0 - 26.4V Max. 0.2V Max. 7A 13,5 ~0A.
24 VDC supply available at XT 31
24V I/O available for customer connections at XT 31 is shown in the figure in "Connections to screw terminals".
XT.31.2 XT.31.1 XT.31.4
24 V (through a 2 A fuse) for own fuses 0 V (connected to cabinet structure)
Controller
115/230 VAC supply
General
This voltage is used in the robot for supplying optional service outlets. The AC supply is not galvanically separated from the rest of the controller voltages.
115/230 VAC supply for internal and external use
Voltage Permitted customer load Fuse size, 115 V Fuse size, 230 V
115 VAC or 230 VAC Max. 500 VA 6.3 A 3.15 A
115/230 VAC supply available at XT 21
115 VAC/230 VAC available for customer connections at XT 21 is shown in the figure in "Connection to screw terminals".
XT.21.1-5 XT.21.6-8 XT.21.9-13
230 VAC 115 VAC N (connected to cabinet structure)
C - 5: Buses Connection of the CAN bus
Illustration
The illustration below shows an example of how to connect the CAN bus:
99
Controller
C
A
D
X15 CAN1.1 (Internal I/O)
X6 CAN1.2 X7 CAN1.3
G D D
D E
X15, X6, X7
1. 2. 3. 4. 5.
0V_CAN CAN_L drain CAN_H 24V_I/O
1. 2. 3. 4. 5.
xx0100000241
A B
Base connector unit CAN bus
Controller
C D E F G
Control cabinet I/O Termination of last unit 120 ohm, 1%, 0.25 W metal film resistor See figure in section "CAN 2" below!
CAN 1.1
Used for internal I/O unit mounted inside the cabinet. No terminating resistor is fitted on CAN 1.1 regardless of whether any I/O units are used or not. CAN 1.1 is connected to socket X15 on the Base connector unit (see Connection of the CAN bus).
CAN 1.2
If CAN 1.2 is not used, a terminating resistor must be connected to the X6 socket (exceptional case see below!). If CAN 1.2 is used, the terminating resistor should be moved to the last I/O unit on the CAN 1.2 chain.
If CAN 1.2, for example, is not connected at the end of any CAN chain but somewhere between the end points of the chain, then no terminating resistor should be mounted in CAN 1.3. This is in accordance with the basic rule, i.e. the CAN chain should be terminated in both end points.
CAN 1.3
If CAN 1.3 is unused, a terminating resistor must be connected to the X7 socket. If CAN 1.3 is used, the terminating resistor should be moved to the last I/O unit on the CAN 1.3 chain.
If CAN 1.2, for example, is not connected at the end of any CAN chain but somewhere between the end points of the chain, then no terminating resistor should be mounted in CAN 1.3. This is in accordance with the basic rule, i.e. the CAN chain should be terminated in both end points.
101
Controller
Termination resistors in CAN bus
The CAN chain must be terminated with terminating resistors at each end! If CAN 1.2, for example, is not connected at the end of any CAN chain but somewhere between the end points of the chain, then no terminating resistor should be mounted in CAN 1.3.
CAN 2
The illustration below shows an example of how to connect the CAN 2 bus:
A B X8 CAN 2 D D D C
X8
1. 0V_CAN 2. CAN_L 3. drain 4. CAN_H 5. 24V_I/O
1. 0V_CAN 2. CAN_L 3. drain 4. CAN_H 5. 24V_I/O
1. 2. 3. 4. 5.
xx0100000242
A B C D E F
Controller Base connector unit See figure in section "Illustration" above! I/O Termination of last unit 120 ohm, 1%, 0.25 W metal film resistor
Controller
The illustration below shows CAN connections on base connector unit:
A B C D
xx0100000243
A B C D
X6 CAN 1.2 (external I/O) X7 CAN 1.3 (external I/O) X8 CAN 2 (external I/O) X15 CAN 1.1 (internal I/O)
103
Controller
Interbus-S, slave DSQC 351
General
The unit can be operated as a slave for an Interbus-S system.
Supply
The Interbus-S slave must be fed externally to avoid shutting down the InterbusS net if a robot cell is switched off. The 24V power supply must be fed from outside the control cabinet and be connected to pin 2 on the Phoenix connector located on the Interbus-S cards front panel marked 24V.
Technical data
Also see the Interbus-S specification.
Further information
For setup parameters, see Users Guide - System Parameters, Topic: Controller. Also see the Circuit Diagram.
Unit ID
The unit ID to be entered in the Interbus-S master is 3. The length code depends on the selected data. Width between 1 and 4.
Layout, DSQC 351
The figure below shows the layout of the DSQC 351 board:
Controller
X20
X21
X5
X3
xx0100000225
X3 X5 X20 X21
Power connector DeviceNet connector Interbus-S, input Interbus-S, output
Communication concept
The Interbus-S system is able to communicate with a number of external devices, depending on the number of process words occupied by each unit. The robot may be equipped with one or two DSQC 351. The Interbus-S inputs and outputs are accessible in the robot as general inputs and outputs. For application data, refer to Interbus-S, International Standard, DIN 19258. An outline diagram of the communication concept is shown below:
105
Controller
E A
In
F C D
Out *1 In Out
B
Out *1 In
xx0100000224
A B C D E F *1
Master PLC Robot 1, word 1:3 Robot 1, word 4:7 Robot 2, word 8:11 128 inputs/128 outputs 64 inputs/64 outputs xx
Termination link
A link is connected between pins 5 and 9 in the plug on the interconnection cable connected to the OUT connector of each unit. The link informs the Interbus-S unit that more units are connected further out in the chain. (The last unit in the chain does not have a cable connected and therefore no link).
Connections, X5 DeviceNet connectors
See DeviceNet Connectors.
Controller
Connections, connector X20, Interbus-S IN
The figure below shows the pin configuration of the connector:
6 9
xx0100000220
The table below shows the connections to connector X20, Interbus-S IN:
Signal name
TPDO1 TPDI1 GND NC NC TPDO1-N TPDI1-N NC NC
X20 pin
1 2 3 4 5 6 7 8 9
Function
Communication line TPDO1 Communication line TPDI1 Ground connection Not connected Not connected Communication line TPDO1-N Communication line TPDI1-N Not connected Not connected
Connections, connector X21, Interbus-S OUT
6 9
xx0100000220
The table below shows the connections to connector X21, Interbus-S OUT:
107
Controller
Signal name
TPDO2 TPDI2 GND NC +5V TPDO2-N TPDI2-N NC RBST
X21 pin
1 2 3 4 5 6 7 8 9
Function
Communication line TPDO2 Communication line TPDI2 Ground connection Not connected + 5 VDC Communication line TPDO2-N Communication line TPDI2-N Not connected Synchronization
Connections, connector X3
5
xx0100000221
The table below shows the connections to connector X3:
Signal name
0 VDC NC GND NC + 24 VDC
X3 pin
1 2 3 4 5
Function
External supply of Interbus-S Not connected Ground connection Not connected + 24 VDC
Bus status LEDs
The designations refer to LEDs shown in the figure in section "Layout, DSQC 352" above.
Controller
The figure and table below show the location and significance of the LEDs on the board.
Designation
POWER-24 VDC NS/MS CAN Tx/CAN Rx POWER- 5 VDC RBDA
Color
Green Green/red Green/red Green Red
Description
Indicates that a supply voltage is present, and has a level above 12 VDC. See section "CAN bus status LED description". See section "CAN bus status LED description". Lit when both 5 VDC supplies are within limits, and no reset is active. Lit when this Interbus-S station is last in the Interbus-S network. If it is not (which is required), check parameter setup. Lit when Interbus-S is active. If there is no light, check network, nodes and connections. Lit when Interbus-S communication runs without errors.
BA
Green
RC
Green
109
Controller
Profibus-DP, slave DSQC 352
General
The unit can be operated as a slave for a Profibus-DP system.
Supply
The Profibus does not need any external power supply. All the robot cells are connected to the trunk cable through a special D-sub connector which works as a very short drop cable. Because of this the profibus will work correctly even if a robot cell is turned off.
Technical data
Also see the Profibus-DP specification, International Standard DIN E 19245, part 3.
Further information
For setup parameters, see Users Guide - System Parameters, Topic: I/O Signals. Also see the Circuit diagram.
Layout, DSQC 352
Controller
X20
X5
X3
xx0100000223
X3 X5 X20
Power connector DeviceNet connector Profibus connection
Communication concept
The Profibus-DP system is able to communicate with a number of external devices, depending on the number of process words occupied by each unit. The robot may be equipped with one or two DSQC 352. The Profibus-DP inputs and outputs are accessible in the robot as general inputs and outputs. An outline diagram of the communication concept is shown below:
E A B C
F D
xx0100000222
111
Controller
A B C D E F
Master PLC Robot 1, word 1:8 Robot 1, word 9:16 Robot 2, word 17:24 256 inputs/256 outputs 128 inputs/128 outputs
Termination
The Profibus cable must be terminated in both ends.
Connections, X5 DeviceNet connectors
See "Device Net Connectors".
Connections, connector X20, Profibus-DP
6 9
xx0100000220
The table below shows the connections to connector X20, Interbus-S IN:
Signal name
Shield NC RxD/TxD-P Control-P GND +5 VDC
X20 pin
1 2 3 4 5 6
Function
Cable screen Not connected Receive/Transmit data P Ground
Controller
Signal name
NC RxD/TxD-N NC
X20 pin
7 8 9
Function
Not connected Receive/Transmit data N Not connected
5
xx0100000221
Signal name
0 VDC NC GND NC + 24 VDC
X3 pin
1 2 3 4 5
Function
External supply of Profibus-DP Not connected Ground connection Not connected External supply of Profibus-DP
Bus status LEDs
The figure and table below show the location and significance of the LEDs on the board. The designations refer to LEDs shown in the figure in section "Layout, DSQC 352" above.
Designation
Profibus active
Color
Green
Description
Lit when the node is communicating with the master. If there is no light, check system messages in robot and in Profibus net.
113
Controller
Designation
NS/MS CAN Tx/CAN Rx
Color
Green/red Green/red
Description
See section "CAN bus status LED description". See section "CAN bus status LED description". Indicates that a supply voltage is present, and has a level above 12 VDC. If there is no light, check that voltage is present in the power unit and in the power connector. If not, check cables and connectors. If power is applied to the unit but it does not work, replace the unit.
POWER, 24 VDC Green
C - 6: I/O units Distributed I/O units
General
Up to 20 units can be connected to the same controller but only four of these can be installed inside the controller. Normally a distributed I/O unit is placed outside the controller.
Connection
The maximum total length of the distributed I/O cable is 100 m (from one end of the chain to the other end). The controller can be one of the end points or be placed somewhere in the middle of the chain.
Parameter setup
For setup parameters, see Users Guide, section System Parameters, Topic: I/O Signals.
Controller
Distributed I/O, digital sensors
General
Digital sensors are connected to one optional digital unit.
Technical data
See Product Specification for Controller S4Cplus.
Allowed types of digital sensors
The table below shows the allowed types of digital sensors to be used, and their signal levels respectively:
Sensor type Digital one bit sensor Digital two bit sensor
Signal level High, "1" Low, "0" High, "01" No signal, "00" Low, "10" Error status, "11" (stop program running)
115
Controller
Distributed I/O, digital I/O DSQC 328 (option)
General
The digital I/O unit handles digital communication between the robot system and any external systems.
Technical data
No. of inputs No. of outputs Supply voltage Supply source 16 (divided into two groups of 8, galvanically isolated from each other) 16 (divided into two groups of 8, galvanically isolated from each other) 24 VDC 24 V I/O or separate external supply
Also see Product Specification for controller S4Cplus.
Further information
Layout, DSQC 328
The figure below show the layout of the DSQC328 board:

A
OUT IN X1 1 10 X2 1 X4 1 10 10 MS NS OUT
9 10 11 12 13 14 15 16
IN
X3
10
12
1 X5
xx0100000240
Status LEDs
Controller
If supervision of the supply voltage is required, a bridge connection can be made to an optional digital input. The supervision instruction must be written in the RAPID program. This is described in the Users Guide. The table below shows the connections to connector X1:
Unit function
Optically isolated output Optically isolated output Optically isolated output Optically isolated output Optically isolated output Optically isolated output Optically isolated output Optically isolated output Optically isolated output Optically isolated output
Signal name
Out ch 1 Out ch 2 Out ch 3 Out ch 4 Out ch 5 Out ch 6 Out ch 7 Out ch 8 0 V for outputs 1-8 24 V for outputs 1-8
X1 pin
1 2 3 4 5 6 7 8 9 10
Unit function
Optically isolated output Optically isolated output Optically isolated output Optically isolated output Optically isolated output Optically isolated output Optically isolated output
Signal name
Out ch 9 Out ch 10 Out ch 11 Out ch 12 Out ch 13 Out ch 14 Out ch 15
X2 pin
1 2 3 4 5 6 7
117
Controller
Unit function
Optically isolated output Optically isolated output Optically isolated output
Signal name
Out ch 16 0 V for outputs 9-16 24 V for outputs 9-16
X2 pin
8 9 10
Unit function
Optically isolated input Optically isolated input Optically isolated input Optically isolated input Optically isolated input Optically isolated input Optically isolated input Optically isolated input Optically isolated input Optically isolated input
Signal name
In ch 1 In ch 2 In ch 3 In ch 4 In ch 5 In ch 6 In ch 7 In ch 8 0 V for inputs 1-8 Not used
X3 pin
1 2 3 4 5 6 7 8 9 10
The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected to ground, to prevent disturbances, causes a short rush of current when setting the input. When connecting outputs, sensitive to pre-oscillation current, a series resistor (100 W) may be used.
Unit function
Optically isolated input Optically isolated input
Signal name
In ch 9 In ch 10
X4 pin
1 2
Controller
Unit function
Optically isolated input Optically isolated input Optically isolated input Optically isolated input Optically isolated input Optically isolated input Optically isolated input Optically isolated input
Signal name
In ch 11 In ch 12 In ch 13 In ch 14 In ch 15 In ch 16 0 V for inputs 9-16 Not used
X4 pin
3 4 5 6 7 8 9 10
119
Controller
AD Combi I/O, DSQC 327 (optional)
General
The digital I/O unit handles digital and analog communication between the robot system and any external systems.
Technical data
No. of digital inputs No. of digital outputs No. of analog outputs Supply voltage Supply source, digital I/O 16 (divided into two groups of 8, galvanically isolated from each other) 16 (divided into two groups of 8, galvanically isolated from each other) 2 (galvanically isolated from the controller electronics) 24 VDC 24 V I/O or separate external supply
Supply source, analog I/O 24 V_CAN (with galvanically isolated DC/AC converter)
Further information
For setup parameters, see User s Guide - System Parameters, Topic: Controller. Also see the Circuit Diagram.
Layout, DSQC 327
The figure below shows the layout of the DSQC327 board:
Controller
OUT IN
MS NS X2
10
11
12
13
14
15
16
OUT IN
X1 1 10
X6 1 10 1 6
X3
X4 1 10
10
12
1 X5
xx0100000239
Status LEDs
Connector X5 is a CAN connector further described in section "Connection and address keying of the CAN bus".
Unit function
Signal name
X1 pin
1 2 3 4 5 6 7 8 9 10
121
Controller
Unit function
Signal name
X2 pin
1 2 3 4 5 6 7 8 9 10
Unit function
Signal name
X3 pin
1 2 3 4 5 6 7 8 9 10
Controller
Unit function
Signal name
X4 pin
1 2 3 4 5 6 7 8 9 10
Connections, connectors X6
The table below shows the connections to connectors X6:
Signal name:
AN_ICH1 AN_ICH2 0V 0 VA AN_OCH1 AN_OCH2
X6 pin:
1 2 3 4 5 6
Explanation:
For test purposes only For test purposes only 0 V for In channels 1-2 0 V for Out channels 1-2 Out channels 1 Out channels 2
123
Controller
Analog I/O, DSQC 355 (optional)
General
The analog I/O unit handles communication between the robot system and any external systems through analog sensors.
Technical data
No. of analog inputs No. of analog outputs No. of analog outputs Supply voltage 4 (-10 V/+10 V) 3 (-10 V/+10 V) 1 (4-20 mA)) 2 (galvanically isolated from the controller electronics) 24 VDC
Further information
Layout, DSQC 355
Controller
X8
X7
Bus s tatus
X8 S2S3 X2 X5 X3
X7
DS QC 355
Analog I/O
AB B F lexible Automation
X5
xx0100000238
X3
X3 X5 X7 X8
Not used DeviceNet input and ID connector Analog outputs Analog inputs
Connections, connectors X7 analog output
13
12
xx0100000236
24
125
Controller
Signal name: X7 pin:

ANOUT_ ANOUT_ ANOUT_ ANOUT_ Not used Not used Not used Not used Not used Not used Not used Not used Not used Not used Not used Not used Not used Not used GND GND GND GND GND GND 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Explanation:
Analog output 1, -10 V/+10 V Analog output 2, -10 V/+10 V Analog output 3, -10 V/+10 V Analog output 4, 4-20 mA
Analog output 1, 0 V Analog output 2, 0 V Analog output 3, 0 V Analog output 4, 0 V
The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected to ground, to prevent disturbances, causes a short rush of current when setting the input. Connect a resistor (100 W) in series when connecting outputs, sensitive to preoscillation current.
Controller
Connections, connectors X8 analog input
17
16
xx0100000237
32

ANIN_1 ANIN_2 ANIN_3 ANIN_4 Not used Not used Not used Not used Not used Not used Not used Not used Not used Not used Not used Not used +24 V out 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Explanation:
Analog input 1, -10 V/+10 V Analog input 2, -10 V/+10 V Analog input 3, -10 V/+10 V Analog input 4, -10 V/+10 V
+24 VDC supply
127
Controller

+24 V out +24 V out +24 V out +24 V out +24 V out +24 V out +24 V out GND GND GND GND GND GND GND GND 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Explanation:
+24 VDC supply +24 VDC supply +24 VDC supply +24 VDC supply +24 VDC supply +24 VDC supply +24 VDC supply Analog input 1, 0 V Analog input 2, 0 V Analog input 3, 0 V Analog input 4, 0 V
The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected to ground, to prevent disturbances, causes a short rush of current when setting the input. Connect a resistor (100 W) in series when connecting outputs, sensitive to preoscillation current.
Bus status LEDs
Designation
NS/MS RS232 Rx
Color
Green/ red Green
Description
See section 4.1. Indicates the state of the RS232 Rx line. LED is active when receiving data. If there is no light, check communication line and connections.
Controller
Designation
RS232 Tx
Color
Green
Description
Indicates the state of the RS232 Tx line. LED is active when transceiving data. If there is no light when transmission is expected, check error messages and check also system boards in rack. Indicates that supply voltage is present and at correct level. If there is no light, check that voltage is present on power unit and that power is present in power connector. If not, check cables and connectors. If power is applied to the unit but it does not work, replace the unit.
+5VDC / +12VDC / -12VDC Green
129
Controller
Encoder interface unit, DSQC 354 (optional)
General
The encoder interface unit handles communication with an external conveyor:

One encoder input (synchronization of conveyor position with robot movements). The encoder is supplied with 24 V and 0 V, and sends position information on two channels. This information is computed by the on-board computer using quadrature decoding (QDEC) to determine position and direction. One digital input (external start signal/conveyor synchronization point)
Technical data
No. of encoder inputs No. of digital inputs Supply voltage Supply source 1 1 (24 VDC) 24 VDC 24 V I/O or external supply
Further information
User reference Description Conveyor Tracking. For setup parameters, see Users Guide - System Parameters, Topic: Controller. Also see the Circuit Diagram.
Controller
Layout, DSQC 354
X20
X5
X3
xx0100000233
X3 X5 X20
Not used DeviceNet input and ID connector Conveyor connection
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Controller
Encoder connections
The figure below shows the encoder connections:

AF AA AB 24 VDC 0V AC A B 24 VDC AD 0V
AE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Opto Opto
Opto
Opto Opto
Opto
AG
xx0100000234
AA AB AC AD AE AF AG
24 V I/O or external supply 0 V I/O or external supply Encoder Sync switch 10-16 not used Encoder unit Galvanic isolation
Controller
Connections, connectors X20 encoder and digital input connections

24 VDC 0V ENC ENC ENC_A ENC_B DIGIN DIGIN DIGIN Not used Not used Not used Not used Not used Not used Not used 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Explanation:
24 VDC supply 0V Encoder 24 VDC Encoder 0 VDC Encoder phase A Encoder phase B Synchronization switch 24 VDC 0V Synchronization switch digital input
The figure below shows the layout of the pins in connector X20:
16
xx0100000235
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Controller
Bus status LEDs
Designation
Color
Description
Indicates that a supply voltage is present, and has a level above 12 VDC. If there is no light, check that voltage is present on power unit and in connector X20. If not, check cables and connectors. If power is applied to the unit but it does not work, replace the unit. See section "CAN bus status LED description". See section "CAN bus status LED description". Indicates phase 1 and 2 from encoder. Flashes at each Encoder pulse. At frequencies higher than a few Hz, flashing can no longer be observed (light will appear weaker). If there is no light, there is an error due to one or more of the following reasons: Faulty power supply for input circuit (internal or external). Defective input circuit on board. Short circuit or broken wire in external wiring or connectors. Internal error in unit.
POWER, 24 VDC Green
NS/MS ENC 1A/1B
Green/red Green
CAN Tx/CAN Rx Green/red
Constant light indicates constant high level on input and vice versa. No light on one LED indicates fault in one encoder phase.
Controller
Designation
DIGIN1
Color
Green
Description
Digital input. Lit when digital input is active. The input is used for external start signal/conveyor synchronization point. If there is no light, there is an error due to one or more of the following reasons: Faulty power supply for input circuit (internal or external). Faulty limit switch, photocell etc. Short circuit or broken wire in external wiring or connectors. Defective input circuit on board.
135
Controller
Relay I/O, DSQC 332 (optional)
General
The unit handles communication between the robot system and any external systems through relay outputs and digital inputs.
Technical data
No. of digital inputs No. of relay outputs Supply voltage Supply source 16 (divided into two groups of 8, galvanically isolated from each other) 16 (a single normally open contact, isolated from each other) 24 VDC 24 V I/O or separate external supply
Further information
Layout, DSQC 332
A
OUT IN X1 1 X3 1 16 1 16 16 1 16 X4 MS NS OUT
9 10 11 12 13 14 15 16
IN X2
12
1 X5
xx0100000232
Status LEDs
Controller
X1 X2 X3 X4 X5
See below for connection tables! See below for connection tables! See below for connection tables! See below for connection tables! CAN connection detailed in section "Connection of CAN bus"!
Signal name
Out ch 1a Out ch 1b Out ch 2a Out ch 2b Out ch 3a Out ch 3b Out ch 4a Out ch 4b Out ch 5a Out ch 5b Out ch 6a Out ch 6b Out ch 7a Out ch 7b Out ch 8a Out ch 8b
X1 pin
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Function
Contact, relay 1 Contact, relay 1 Contact, relay 2 Contact, relay 2 Contact, relay 3 Contact, relay 3 Contact, relay 4 Contact, relay 4 Contact, relay 5 Contact, relay 5 Contact, relay 6 Contact, relay 6 Contact, relay 7 Contact, relay 7 Contact, relay 8 Contact, relay 8
Signal name
Out ch 9a
X2 pin
1
Function
Contact, relay 9
137
Controller
Signal name
Out ch 9b Out ch 10a Out ch 10b Out ch 11a Out ch 11b Out ch 12a Out ch 12b Out ch 13a Out ch 13b Out ch 14a Out ch 14b Out ch 15a Out ch 15b Out ch 16a Out ch 16b
X2 pin
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Function
Contact, relay 9 Contact, relay 10 Contact, relay 10 Contact, relay 11 Contact, relay 11 Contact, relay 12 Contact, relay 12 Contact, relay 13 Contact, relay 13 Contact, relay 14 Contact, relay 14 Contact, relay 15 Contact, relay 15 Contact, relay 16 Contact, relay 16
Signal name
In ch 1 In ch 2 In ch 3 In ch 4 In ch 5 In ch 6 In ch 7 In ch 8 0 v for In ch 1-8 Not used Not used
X3 pin
1 2 3 4 5 6 7 8 9 10 11
Controller
Signal name
Not used Not used Not used Not used Not used
X3 pin
12 13 14 15 16
Signal name
In ch 9 In ch 10 In ch 11 In ch 12 In ch 13 In ch 14 In ch 15 In ch 16 0 v for In ch 9-16 Not used Not used Not used Not used Not used Not used Not used
X4 pin
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
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Controller
Digital I/O (120 VAC), DSQC 320 (optional)
General
The unit handles communication between the robot system and any external systems through galvanically isolated outputs and inputs.
Technical data
No. of inputs No. of outputs Supply voltage 16 (galvanically isolated from each other) 16 (galvanically isolated from each other) 120 VAC
Further information
Layout, DSQC 320
A
OUT IN X1 1 X3 1 16 1 16 16 1 16 X4 MS NS OUT
9 10 11 12 13 14 15 16
IN X2
12
1 X5
xx0100000231
A X1 X2
Status LEDs See below for connection tables! See below for connection tables!
Controller
X3 X4 X5
See below for connection tables! See below for connection tables! CAN connection detailed in section "Connection of CAN bus"!
Signal name X1 pin

Out ch 1a Out ch 1b Out ch 2a Out ch 2b Out ch 3a Out ch 3b Out ch 4a Out ch 4b Out ch 5a Out ch 5b Out ch 6a Out ch 6b Out ch 7a Out ch 7b Out ch 8a Out ch 8b 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Function
AC voltage to switch 1/AC output signal from switch 1 AC voltage to switch 1/AC output signal from switch 1 AC voltage to switch 2/AC output signal from switch 2 AC voltage to switch 2/AC output signal from switch 2 AC voltage to switch 3/AC output signal from switch 3 AC voltage to switch 3/AC output signal from switch 3 AC voltage to switch 4/AC output signal from switch 4 AC voltage to switch 4/AC output signal from switch 4 AC voltage to switch 5/AC output signal from switch 5 AC voltage to switch 5/AC output signal from switch 5 AC voltage to switch 6/AC output signal from switch 6 AC voltage to switch 6/AC output signal from switch 6 AC voltage to switch 7/AC output signal from switch 7 AC voltage to switch 7/AC output signal from switch 7 AC voltage to switch 8/AC output signal from switch 8 AC voltage to switch 8/AC output signal from switch 8
Signal name
Out ch 9a Out ch 9b
X2 pin
1 2
Function
AC voltage to switch 9/AC output signal from switch 9 AC voltage to switch 9/AC output signal from switch 9
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Controller
Signal name
Out ch 10a Out ch 10b Out ch 11a Out ch 11b Out ch 12a Out ch 12b Out ch 13a Out ch 13b Out ch 14a Out ch 14b Out ch 15a Out ch 15b Out ch 16a Out ch 16b
X2 pin
3 4 5 6 7 8 9 10 11 12 13 14 15 16
Function
AC voltage to switch 10/AC output signal from switch 10 AC voltage to switch 10/AC output signal from switch 10 AC voltage to switch 11/AC output signal from switch 11 AC voltage to switch 11/AC output signal from switch 11 AC voltage to switch 12/AC output signal from switch 12 AC voltage to switch 12/AC output signal from switch 12 AC voltage to switch 13/AC output signal from switch 13 AC voltage to switch 13/AC output signal from switch 13 AC voltage to switch 14/AC output signal from switch 14 AC voltage to switch 14/AC output signal from switch 14 AC voltage to switch 15/AC output signal from switch 15 AC voltage to switch 15/AC output signal from switch 15 AC voltage to switch 16/AC output signal from switch 16 AC voltage to switch 16/AC output signal from switch 16
Signal name
In ch 1a In ch 1b In ch 2a In ch 2b In ch 3a In ch 3b In ch 4a In ch 4b In ch 5a In ch 5b
X3 pin
1 2 3 4 5 6 7 8 9 10
Function
AC input signal from switch 1/Neutral voltage to switch 1 AC input signal from switch 1/Neutral voltage to switch 1 AC input signal from switch 2/Neutral voltage to switch 2 AC input signal from switch 2/Neutral voltage to switch 2 AC input signal from switch 3/Neutral voltage to switch 3 AC input signal from switch 3/Neutral voltage to switch 3 AC input signal from switch 4/Neutral voltage to switch 4 AC input signal from switch 4/Neutral voltage to switch 4 AC input signal from switch 5/Neutral voltage to switch 5 AC input signal from switch 5/Neutral voltage to switch 5
Controller
Signal name
In ch 6a In ch 6b In ch 7a In ch 7b In ch 8a In ch 8b
X3 pin
11 12 13 14 15 16
Function
AC input signal from switch 6/Neutral voltage to switch 6 AC input signal from switch 6/Neutral voltage to switch 6 AC input signal from switch 7/Neutral voltage to switch 7 AC input signal from switch 7/Neutral voltage to switch 7 AC input signal from switch 8/Neutral voltage to switch 8 AC input signal from switch 8/Neutral voltage to switch 8
Signal name
In ch 9a In ch 9b In ch 10a In ch 10b In ch 11a In ch 11b In ch 12a In ch 12b In ch 13a In ch 13b In ch 14a In ch 14b In ch 15a In ch 15b In ch 16a In ch 16b
X4 pin
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Function
AC input signal from switch 1/Neutral voltage to switch 1 AC input signal from switch 1/Neutral voltage to switch 1 AC input signal from switch 2/Neutral voltage to switch 2 AC input signal from switch 2/Neutral voltage to switch 2 AC input signal from switch 3/Neutral voltage to switch 3 AC input signal from switch 3/Neutral voltage to switch 3 AC input signal from switch 4/Neutral voltage to switch 4 AC input signal from switch 4/Neutral voltage to switch 4 AC input signal from switch 5/Neutral voltage to switch 5 AC input signal from switch 5/Neutral voltage to switch 5 AC input signal from switch 6/Neutral voltage to switch 6 AC input signal from switch 6/Neutral voltage to switch 6 AC input signal from switch 7/Neutral voltage to switch 7 AC input signal from switch 7/Neutral voltage to switch 7 AC input signal from switch 8/Neutral voltage to switch 8 AC input signal from switch 8/Neutral voltage to switch 8
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Controller
C - 7: Communication Communication concept, Allen-Bradley
General
The robot may communicate with the Allen Bradley system only, or be used in combination with the I/O system in the robot. For example, the inputs to the robot may come from the Allen Bradley system while the outputs from the robot control external equipment go via general I/O addresses and the Allen Bradley system only reads the outputs as status signals.
Definitions
The Allen Bradley system can communicate with up to 64 external systems. Each of these systems is called a Rack and is given a Rack Address 0-63. Basically, each robot connected to the Allen Bradley system will occupy one rack. Each rack is divided into four sections called Quarters. Each quarter provides 32 inputs and 32 outputs and a rack will subsequently provide 128 inputs and 128 outputs. A rack may also be shared by 2, 3, or 4 robots. Each of these robots will then have the same rack address, but different starting quarters must be specified.
Controller
Illustration
The illustration below shows a block diagram of the Allen-Bradley system, where Robot 1 uses a full rack while robot 2 and robot 3 share one rack. The rack address, starting quarter, and other required parameters such as baud rate, LED status etc. are entered in the configuration parameters.
Allen Bradley control system
Robot 1 - 128 in / 128 out Quarter 1 Quarter 2 Quarter 3 Quarter 4 Rack ID 12 (example) Rack size 4 Starting quarter 1 128 in / 128 out
Robot 2 - 64 in / 64 out Quarter 1 Quarter 2 Rack ID 13 (example) Rack size 2 Starting quarter 1 Robot 3 - 64 in / 64 out Quarter 3 Quarter 4 Rack ID 13 (example) Rack size 2 Starting quarter 3 64 in / 64 out 64 in / 64 out
Other systems Quarter 1 Quarter 2 Quarter 3 Quarter 4
en0100000255
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Controller
RIO, remote I/O for Allen-Bradley PLC DSQC 350
General
The unit handles communication between the robot system and the Allen Bradley system.
Technical data
No. of digital inputs No. of digital outputs Unit is programmable for 32, 64, 96 or 128 digital inputs Unit is programmable for 32, 64, 96 or 128 digital outputs
Also see the Allen-Bradley RIO specification.
Further information
For setup parameters, see Users Guide - System Parameters, Topic: I/O Signals. Also see Circuit Diagram.
Connection
The RIO-unit should be connected to an Allen-Bradley PLC using a screened, two conductor cable.
Layout, DSQC 350
X5 X9
X3
X8 DS QC 350
AB B F lexible Automation
xx0100000226
Controller
X3 X5 X8 X9
Not used DeviceNet and ID connector RIO in RION out
5
xx0100000221
Signal name
LINE1 (blue) LINE2 (clear) Shield Cabinet ground
X8 pin
1 2 3 4
Function
Remote I/O in Remote I/O in Remote I/O in Remote I/O in
5
xx0100000221
Signal name
Blue Clear Shield Cabinet ground
X9 pin
1 2 3 4
Function
Remote I/O out Remote I/O out Remote I/O out Remote I/O out
147
Controller
Termination
When the robot is last in a RIO loop, the loop must be terminated with a termination resistor according to Allen-Bradleys specification.
Warranty
This product incorporates a communications link which is licensed under patents and proprietary technology of the Allen-Bradley Company, Inc. The Allen-Bradley Company, Inc. does not warrant or support this product. All warranty and support services for this product are the responsibility of and provided by ABB Flexible Automation.
Bus status LEDs
The figure and table below show the location and significance of the LEDs on the board. The designations refer to LEDs shown in the figure in section "Layout, DSQC 350" above.
Designation
Color
Description
Indicates that a supply voltage is present, and has a level above 12 VDC. If there is no light, check that voltage is present on power unit and in power connector. If not, check cables and connectors. If power is applied to the unit but it does not work, replace the unit. See section "CAN bus status LED description". Steady green indicates RIO link in operation. If there is no light, check network, cables and connections. Also check that PLC is operational. Flashing green indicates that communication is established, but the INIT_COMPLETE bit is not set in NA chip, or configuration, rack size etc. does not match configuration set in PLC. If LED keeps flashing continuously, check setup
POWER-24 VDC Green
NS/MS CAN Tx/CAN Rx NAC STATUS
Green/red See section "CAN bus status LED description". Yellow Green
Controller
Communication, serial links
General
The robot has three serial channels, which can be used by the customer to communicate with printers, terminals, computers, and other equipment (see the figure in "Connections" below).
COM1 (computer system) - RS 232 115 kbps. This was formerly referred to as Com2. COM2 - RS 232 with RTS-CTS-control and support for XON/XOFF, transmission speed 300 - 38 400 bps. This was formerly referred to as SIO1. COM3 - RS 422 full duplex TXD4, TXD4-N, RXD4, RXD4-N, transmission speed 300 - 38 400 bps. This was formerly referred to as SIO2. For temporary use: MC/CONSOLE - RS 232 115 kbps. This was formerly referred to as Com1.
Further information
For setup parameters, see User's Guide - System Parameters, Topic: I/O Signals. Circuit Diagram. Location in the cabinet (see figure in section "Connection to screw terminals").
Technical data
See Product Specification for controller S4Cplus. Separate documentation is included when the option RAP Serial link is ordered.
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Controller
Connections
The figure below shows the connection of serial channels:
xx0100000219
External computer
Customer terminals, on base connector board: X10 (COM2) and X9 (COM3), see section "Connection to screw terminals".
Connections on DSQC 504, COM1
Standard RS232 port. The figure below shows the pin configuration of the connector:
5
6 9
xx0100000220
The table below shows the signals from the COM1 (RS232):
Signal
DCD RX TX
Pin
1 2 3
Description
Data carrier Detect Receive Data Transmit Data
Controller
Signal
DTR GND DSR RTS CTS RI NC
Pin
4 5 6 7 8 9 10
Description
Data Terminal Ready Signal Ground Data Set Ready Request To Send Clear To Send Ring Indicator Not Connected
Connections on DSQC 504, D-sub connector X10, COM2

5
6 9
xx0100000220
COM2 Signal name

RxD (Receive Data) TxD (Transmit Data) DTR (Data Terminal Ready) 0V DSR (Data Ready Set) RTS N (Request To Send N) CTS (Clear To Send)
X10 pin
1 2 3 4 5 6 7 8 9
151
Controller
Connections on DSQC 504, D-sub connector X9, COM3

5
6 9
xx0100000220
COM3 Signal name

TxD (Transmit Data) TxD N (Transmit Data N) RxD (Receive Data) RxD N (Receive data N) 0V DATA (Data Signals in Half Duplex Mode) DATA N (Data Signals in Half Duplex Mode N) DCLK (Data Transmission Clock) DCLK N (Data Transmission Clock N)
X9 socket
1 2 3 4 5 6 7 8 9
Connections to MC/CONSOLE
The figure below shows the MC/CONSOLE connection behind the service hatch:
xx0100000218
Controller
External computer
Standard RS232 port intended for temporary use, e.g. connection of laptop/PC. The table below shows the signals on the MC/CONSOLE (RS232):
Signal
RX TX GND
Pin
2 3 5
Description
Receive Data Transmit Data Signal Ground
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Controller
Communication, Ethernet
General
The robot has two Ethernet channels available:

LAN (connected to the Main computer) Service (connected to the I/O computer)
Connection of LAN (Main computer)
The figure below shows an outline diagram of the Ethernet TCP/IP:
E thernet hub
xx0100000217
A B C
External computer Controller Robot 1 Controller Robot 2
Used for connection of shielded twisted-pair Ethernet (TPE), or as defined in IEEE 802.3: 10/100 BASE-T. Maximum node-to-node distance 100 meter. The main computer board has no termination for a cable shield. The cable shield must be grounded at the cabinet wall with a cable gland. 10BASE-T is a point-to-point net, connected via a HUB, see the figure above.
Signal
TX+
X1 Pin
1
Description
Transmit data line +
Controller
Signal
TXRX+ NC NC RXNC NC
X1 Pin
2 3 4 5 6 7 8
Description
Transmit data line Receive data line + Not Connected Not Connected Receive data line Not Connected Not Connected
The figure below shows the main computer board front:

1
X1
LAN
PWR
HDD
STATUS
X2
xx0100000216
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Controller
Connection of Service (I/O Computer)
Used for connection of a laptop to the service outlet on the front of the controller cabinet (behind service hatch). The figure below shows how to connect a laptop to the service outlet:
E thernet
xx0100000215
For setup parameters, see Users Guide - System Parameters, Topic: I/O Signals. Also see the Circuit Diagram. Separate documentation is included when the option Ethernet services is ordered.
Controller
External operators panel
General
All necessary components are supplied, except for the external enclosure.
Dimensions for installation
Install the assembled panel in a housing which satisfies protection class, IP 54, in accordance with IEC 144 and IEC 529! The figure below shows the main dimensions of the external operators panel:
B M8 (x4) 62 A M4 (x4)
C 45 70 140 184 200
E 90 5 (x2) F G
155
xx0100000214
A B
Holes for operators panel Holes for flange
157
Controller
C D E F G
Required depth: 200 mm External panel enclosure (option) Holes for teach pendant unit (TPU) holder Teach pendant unit (TPU) connector Connection to the controller
Controller
Start-up
Section D: Start-up Inspection before start-up
General
Perform the following checks before starting up the robot system:
Check that:
1. the controller mains section is protected with fuses. 2. the electrical connections are correct and correspond to the identification plate on the controller. 3. the teach pendant and peripheral equipment are properly connected. 4. any limiting devices that establish the restricted space (when utilized) are installed. 5. the physical environment is as specified. 6. the operating mode selector on the operators panel is in the Manual mode position. 7. when external safety devices are used, check that these have been connected or that the following circuits in either XS3 (connector on the outside left cabinet wall) or X1-X4 (screw terminals on the panel unit) are strapped:
Device External limit switches External emergency stop External emergency stop internal 24 V General stop + General stop Auto stop + Auto stop Motor off clamping
XS3 A5-A6, B5-B6 A3-A4, B3-B4 A1-A2, B1-B2 A11-A12, B11-B12 A13-A14, B13-B14 A7-A8, B7-B8 A9-A10, B9-10 A15-A16, B15-16
Panel unit X1.3-4, X2.3-4 X1.9-10, X2.9-10 X1.7-8, X2.7-8 X3.10-12, X4.10-12 X3.7-8, X4.7-8 X3.11-12, X4.11-12 X3.7-9, X4.7-9 X1.5-6, X2.5-6
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Start-up
Start-up
General
1. Switch on the mains switch on the cabinet. 1. The robot performs its self-test on both the hardware and software, which takes approximately 1 minute. 2. If the robot is not supplied with the software already installed, install the software as described in chapter "Robot Controller".
A welcome message is shown on the Teach Pendant Unit display.
3. To switch from MOTORS OFF to MOTORS ON, press the enabling device on the teach pendant. 4. Update the revolution counters as described in the Calibration chapter, section "Updating the revolution counters". 5. IRB 940: Check the position of the spiral cable in the centre tube sleeve. Correct position is described in the Calibration chapter, section "Correct orientation of axes". 6. Check the calibration position as described in the Calibration chapter, section "Checking the calibration position". 7. When the controller, with the manipulator electrically connected, is powered up for the first time, ensure that the power supply is connected for at least 36 hours continuously, in order to fully charge the batteries for the serial measurement board. It takes approx. 4 hours to fully charge a computer system battery. 8. After having checked the above, verify that:
the start, stop and mode selection (including the key lock switches) control devices work as intended. each axis moves and is restricted (if possible) as intended. emergency stop and safety stop (where included) circuits and devices are functional. it is possible to disconnect and isolate the external power sources. the teach and playback facilities work correctly. the safeguarding is in place.
Controller
Start-up
at reduced speed, the robot operates properly and has the capability to handle the product or workpiece. in automatic (normal) operation, the robot operates properly and has the capability to perform the intended task at the rated speed and load.
9. The robot is now ready for operation.
Operating the robot
Starting and operating the robot is described in the Users Guide. Before start-up, make sure that the robot cannot collide with any other objects in the working space.
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Controller
Installation of controller software
Section E: Installation of controller software Loading system software
General
The robot system may be delivered with or without system software. When the system is not delivered with software, this must be downloaded in one of a number of ways.
Software installed on delivery
If the robot controller is ordered with the software installed on delivery, the controller software and settings are already stored in the storage memory and the system is ready to use.
Software not installed on delivery
If the robot controller is ordered and delivered without software or if you want to reconfigure your system, the RobInstall tool must be used to install the controller software. The RobInstall tool is included on the RobotWare CD-ROM (see section "RobotWare CD-ROM"). The RobInstall tool can be used both for creation of the controller software and for downloading it to the controller system.
Types of software loading
A B C E
xx0100000192
Controller
A B C D E
RobotWare CD-ROM to install RobInstall and System Pack on PC Floppy Disks IOC Ethernet (service) with delivered boot cable UTP-X Connected to IOC MC Ethernet (LAN) network in workshop
When downloading, the controller software can be transferred to the controller storage memory in three ways as shown in the figure above.
using floppy disks, using Ethernet connected direct to the IO computer (IOC) service outlet on the front of the controller cubicle, using Ethernet connected via a local area network (LAN) to the main computer (MC).
Boot Image
The transfer and installation of the controller software to the controller storage memory via Ethernet or floppy disks is executed by a basic program named Boot Image. This basic program must always be in the storage memory. When starting the controller, with no controller software installed, Boot Image will start and ask the operator for controller software installation instructions. If the controller software is already installed and a warm start is performed, Boot Image is not used. The installed controller software can be deleted by a cold start and then the Boot Image will be reactivated.
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Controller
RobotWare CD-ROM
The CD contains all the System software and should therefore be treated and stored carefully.
RobotWare CDROM contents
The RobotWare CD-ROM contains the following:
Contents
1. RobInstall
Description
A PC tool used to create and install the controller operating system in the robot control system. On-line documentation for the RobInstall application and the Controller Operating System Package. Controller Operating System Package for S4Cplus. This package includes all the software needed to create the controller operating system with any ordered options. Please note that it is possible to install different releases with different versions of the same system package (see section "Media Pool in the PC"). A tool (created in LabView) for viewing MotionTest Signals (oscilloscope function) and also for logging these signals. On the CD is also included a so called FTP client named Voyager. Please note that this is not an ABB product but a shareware program, which means that it can be installed and used for a limited time, but that it has to be registered for permanent use. Registering means that a certain fee must be paid to the vendor. The FTP client is used to transport files manually between the PC and the robot controller storage memory. These actions are carried out in the same way as in a file manager or in Windows Explorer.
2.
Documentation
3.
Controller OS Package
4.
Test Signal Viewer
5.
FTP Client
Controller
Installation of the RobotWare on the PC (except FTP Client)
This section describes how to install the software delivered on the RobotWare CD-ROM onto a PC hard drive, to be transferred to the robot system. 1. Insert the CD in your reader. 1. The Install Shield will automatically start and guide you through the install process (if it does not start, double-click the CD icon on your PC). When the setup type window is displayed, it is recommended to select the Custom button. Then Next button will open the Select Components window, where normally all the four options, RobInstall, Documentation, Controller OS Package and Test Signal Viewer should be marked as selected.
Installation of the FTP Client on the PC
This section describes how to install the FTP Client onto a PC hard drive. 1. In the Explorer, select and open the directory "ftp" on the CD. 2. Double-click the file ftpvsetup.exe.
The Install Shield for the FTP client will start and guide you through the installation. Please read the "Readme" file for information about license regulations.
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Controller
Installing new Robot Controller Software with RobInstall
General
Since most systems have the operating system installed already on delivery, the RobotWare CD-ROM is normally not needed. However it should be used when:
creating a new controller operating system, changing the current operating system configuration, e.g. concerning included options.
Nomenclature
In the text dealing with RobInstall, the following nomenclature is used:
Concept:
System pack
Means:
This is the RobotWare Controller Operating System Package for S4Cplus, including all options, even if they are not ordered and activated. This is a text string, or a special file with the text string, which is used to define and open both the BaseWare and all ordered RobotWare options. This is a complete controller software, i.e. controller operating system, based on the system pack and the key. It can also include any user files to be added to the home directory on the controller storage memory.
Key
System
How to use RobInstall
Robinstall is used to create and install the controller software in the S4Cplus robot controller. With RobInstall, you can:
create a new system, update an existing system, download a system to the controller using the Ethernet connection, create Boot Disks to transfer the system to the Controller.
Controller
Step
1.
Action
Make sure RobInstall is installed. If not, install it according to the instructions in section "Installation of the RobotWare on the PC". Click the start button on your PC and select programs/ABB Robotics/RobInstall/RobInstall. The RobInstall start window will open.
Illustration/Info
2.
3.
xx0100000185
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Controller
Create a new Robot Controller System
Setting up the system Step

1.
Action
Start RobInstall as described in section "How to use Robinstall". Choose New to create a new Robot Controller system as shown in the figure.
Illustration/Info
2.
xx0100000179
3.
Enter a name for the new controller system. Select a saving location or use the default directory, normally "Program Files\ABB Robotics\system" (see the figure below, position 1).
xx0100000180
4.
Enter the RobotWare key or add from file. If added from a file, files with the extension .kxt should be used (see the figure above, position 2).
Controller
Step
5.
Action
Press OK. The configured system will be displayed in the next window (see the figure below).
Illustration/Info
xx0100000181
6.
If no external options or parameters are to be added or changed, press Finish to create the new controller system. Otherwise press Next to continue to "Additional Keys" (see section "Add or remove external options").
Add or remove external options Step

1.
Action
To add or remove external options, press Next in the screen shown in the last figure in section "Setting up the system" or click on "Additional Keys" in the menu to the left.
Illustration/Info
xx0100000182
169
Controller
Step
2.
Action
Enter the key string for the selected option and press Add Key to list, or pressAdd key from file to select a key string file. To remove additional keys, select the key in the Included Additional Keys list and press Remove Key. Press Finish to create the controller system or press Next to continue to "Parameter Data" (see section "Add or remove additional system parameters).
Illustration/Info
3.
4.
Add or remove additional system parameters
Step
1.
Action
To add or remove additional parameters, press Next in the screen shown in the last figure in section "Add or remove external options" or click on "Parameter Data" in the menu to the left.
Illustration/Info
xx0100000183
2.
Press Add to load manipulator calibration data (see the figure above, position 1). This is the calib.cfg file delivered on the Manipulator Parameter disk (see section "The manipulator parameter disk").
Controller
Step
3.
Action
To remove manipulator calibration data, press Remove. Press Add to load additional system parameters, see pos. 2. All system parameter files added here will be automatically loaded together with the system, when the controller is restarted with the new system. To remove additional parameters, select the parameter in the "Loaded Additional Parameters" list and press Remove. Press Finish to create the controller system or press Next to continue to "Options" (see section "Change options or system pack revision").
Illustration/Info
4.
5.
6.
Change options or system pack revision
Step
1.
Action
To change the option configuration, press Next in the screen shown in the figure below or click on "Options" in the menu to the left.
Illustration/Info
xx0100000184
171
Controller
Step
2.
Action
To change the Teach Pendant Unit language, robot type, or software options, press Options (see the figure above, position 1). Normally the latest release or revision of all system packages and option packages stored in the media pool (see section "Media Pool in the PC") will be used. If an earlier revision should be used, uncheck the check mark and press Rev. Select (see the figure above, position 2). In the new window select the system package to use and press OK. If you want the system to start up in query mode, put a mark in the query mode selection square. For further details of the query mode, see section "Start in Query Mode". Press Finish to create the controller system or press Next to view the current configuration.
Illustration/Info
3.
4.
5.
Controller
Update the Robot Controller image
Actions Step
1.
Action
To update an existing controller system, press Update, see the figure below.
Illustration/Info
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2.
Select a system in the system list and press OK, see the figure above. Please note that a pop up menu can be shown by clicking right mouse button. With this menu Copy, Rename or Delete can be selected for the marked system.
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173
Controller
Step
3.
Action
The window displaying the current configuration of the system will be shown. Follow the instructions in sections "Add or remove external options", "Add or remove additional system parameters" or "Change options or system pack revision" to modify the system.
Illustration/Info
Controller
Transfer Robot Controller System using Ethernet connection
Selecting type of set-up
Before a system can be downloaded to a robot controller using the RobInstall tool some preparations and set up must be done. This may be done in one of two ways:
If you are using:
...then see instructions in section:
...and continue in section:
a direct connection between "If using a direct connection "Download Robot PC and IOC service outlet between PC and IOC service Controller System" on controller outlet on controller" below! below! Network Intranet connection "If using Network Intranet with fixed IP addresses connection with fixed IP addresses " below! Network Intranet connection "If using Network Intranet with DHCP (Dynamic Host connection with DHCP " Configuration Protocol) below! "Download Robot Controller System" below! "Download Robot Controller System" below!
If using a direct connection between PC and IOC service outlet on controller
Step
1.
Action
Connect a patch-cable between the Ethernet connection on the front of the controller and the corresponding connection on the PC/Laptop. Make sure that the Network protocol is set for TCP/IP properties.
Illustration/Info
2.
175
Controller
Step
3.
Action
Change the TCP/IP Properties in accordance with the following table and figure:
Illustration/Info
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If using Network Intranet connection with fixed IP addresses
Step
1. 2.
Action
Make sure that the Network protocol is set for TCP/ IP properties. Change the TCP/IP Properties in accordance with the values to be used for IP address, Subnet mask and Gateway. Perform a X-START (see section "x-START") or CSTART (see section "C-start") on the S4Cplus controller. Configure the IP address to be used for the robot controller from the TPU.
Illustration/Info
3.
4.
Controller
If using Network Intranet connection with DHCP
Step
1.
Action
Read Ethernet MAC-id on the Teach Pendant Unit (see section "LAN settings").
Illustration/Info
Download Robot Controller System

Before downloading, check the following: Make sure there is at least 25 Mb free disk space on the controller mass storage memory. For information on how to perform a manual storage capacity check, see section "Check Storage Capacity". Make sure that the robot controller displays the Start Window on the Teach Pendant Unit (see section "Start window").
Step
1.
Action
To download a controller system, press Download as in the figure below:
Illustration/Info
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177
Controller
Step
2.
Action
Illustration/Info
Select a target system as in If a direct connection is used with the patch the figure, position 1. cable between the PC and the controller front, then just select the default IP address (192.168.125.1) and "Direct" option. In other cases, write the correct IP address for the robot controller and select "Hostname or IP-address". RobInstall will store already used IP addresses, which can later be selected with the down arrow. Type your username and password if required by the robot controller as in the figure below, position 2.
3.
xx0100000177
4.
Test the connection by pressing Test Connection and press OK if a connection is established. Select a system in the list on the left and press OK as in the figure below. Please note that it is possible to select another system pool than the shown one (in such case be sure to select the system pool directory, not the system itself on the lower level).
5.
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Controller
Step
6.
Action
Illustration/Info
RobInstall will now create a After downloading it is possible to restart system file and download it the controller with the new downloaded to the controller. controller system. Otherwise, the controller may be restarted from the Teach Pendant Unit as detailed in section "Reboot".
179
Controller
Transfer Robot Controller System using floppy disks

Before downloading, make sure: there is at least 25 Mb free disk space on the controller mass storage memory. For information on how to perform a manual storage capacity check, see section "Check Storage Capacity". that the robot controller displays the Start Window on the Teach Pendant Unit (see section "Start Window"). an optional floppy disk drive is installed in the robot controller.
Create Boot Diskettes from RobInstall
Step
1.
Action
Press Create Boot Disk as in the figure below.
Illustration/Info
xx0100000173
Controller
Step
2.
Action
Select a system in the list on the left and press OK as in the figure below. RobInstall will now create an image file and estimate the number of disks needed.
Illustration/Info
xx0100000175
xx0100000188
3. 4.
Insert a formatted 1.44 Mb diskette into the disk drive. Press Continue to start copy the Robot Controller System image to the disks. Use the finished floppy disks to boot your system as described in section "Boot Disks".
5.
181
Controller
RobInstall preferences
Customizing RobInstall
RobInstall may be customized to suit particular requirements.
Step
1.
Action
To customize RobInstall for new programs and optional products, press Preferences as shown in the figure. See also chapter "System Directory Structure".
Illustration/Info
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2.
To select another media pool (see section "Media Pool in the PC"), press Select Media Pool as shown in the figure, position 1.
xx0100000187
Controller
Step
3.
Action
To add a new system package or option package to the media pool, press Import Program as shown in the figure, position 2. Also see chapter "System Directory Structure".
Illustration/Info
183
Controller
Robot controller
Section F: Robot controller BootImage
General
The BootImage is a basic program which is used to start up the system from "scratch".
Purpose of the program
This program is already installed in the controller at delivery and is used to:
restart the system load the system from boot disks or network connections set or check network settings choose a system from the mass storage memory.
Controller
Robot controller
Start window
When is it shown?
xx0100000168
The start window displays the start menu and will appear in the following cases:
When no controller operating system is installed at power on. After X-START (see the part "How to perform a Restart"). After C-START (see the part "How to perform a Restart").
Possible actions
From this window you can choose to do one of the following:
Restart the system, Reboot
The BootImage will be re-executed, used to apply changes in the system settings (see the part "Reboot Window").
Load a system from diskettes, Boot Disks
(See the part "Boot Disk Window".)
Set the network settings, Network Settings
Set network settings for the Main Computer or check how to configure your PC (see the part "Network Settings Window").
185
Controller
Robot controller
Choose a system from the mass storage memory, Select System
If there is one or more systems in the mass storage memory, you can choose to activate one of them (see the part "System selection window").
Controller
Robot controller
Reboot Window
When is it shown?
The Reboot window will be displayed if any of the system settings are changed or when Reboot is pressed in the Start window as shown in the figure below:.
xx0100000169
Button YES NO
Function Restarts the system Returns to the start window
187
Controller
Robot controller
Boot Disk Window
When is it shown?
The Boot Disk window will be displayed when Boot Disks is pressed in the Start window as shown in the figure in section "Start window".
How to create boot disks
Information on how to create boot disks from RobInstall can be found in section "Create Boot Diskettes from Robinstall".
Load the system Step

1.
Action
Insert the correct diskette in the floppy disk drive and press OK. If the diskette is alright, the system will be loaded. CANCEL removes all previously loaded data and returns to the Start window as shown in the figure in section "Start window".
Illustration/Info
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Controller
Robot controller
Network Settings Window
When is it shown?
The Network Settings window will be displayed when Network Settings is pressed in the Start window as shown below.
xx0200000209
LAN Settings Service Settings CANCEL
Press to configure the Main Computer for communication with a PC on a Local Area Network (LAN). Also see "LAN settings"! Press to view the required settings for the PC to communicate with the I/O Computer. Also see "Service settings"! Press to return to the Start window as shown in figure "Start window".
189
Controller
Robot controller
LAN Settings Window
When is it shown?
The LAN Settings window will be displayed when LAN Settings is pressed in the Network Settings window as shown in the figure in section "Network Settings".
en0100000256.gif
NONE CANCEL
will, after the system is rebooted, remove the IP settings. returns to the Start window, as shown in the figure in section "Start Window", without changing any settings.
Node identification Parameter

MAC ID Current IP
Type
Node identification Node identification
Description
The Main Computers ethernet address. The Main Computers current IP address. This row is blank if the LAN Settings have not been defined. Space for typing in a new IP address, for the Main Computer or the DHCP server. See Configure for fixed IP network and Configure for DHCP distributed IP network below.
IP
Network setting
Controller
Robot controller
Parameter
Type
Description
Shows the subnet mask of the network. Only visible when configured for fixed IP. Shows the gateway IP for the network. Only visible when configured for fixed IP.
(Subnet mask) Network setting (Gateway) Network setting
Configure for fixed IP network
1. Press FIX IP. 2. Fill in the assigned IP address for the Main Computer, and the Subnet Mask and Gateway for the Network and press OK.
You will be asked to reboot the system.
3. Press YES to make the new setting take effect.
Configure for DHCP distributed IP network
1. Press DHCP. 1. The value for IP will change to DHCP. 2. Press OK.
You will be asked to reboot the system.
3. Press YES to make the new setting take effect.
191
Controller
Robot controller
Service Settings Window
When is it shown?
The Service Settings window will be displayed when Service Settings is pressed in the Network Settings window as shown in the figure in section "Network Settings".
en0100000257
OK
returns to the Start window as shown in the figure in section "Start Window".
Service Setting Parameter

IP Subnet mask Gateway
Description
Required to configure your PCs network settings for communication between RobInstall and the I/O Computer. Required to configure your PCs network settings for communication between RobInstall and the I/O Computer. Required to configure your PCs network settings for communication between RobInstall and the I/O Computer.
IP (service setting) The IP Address for the I/O Computer
Controller
Robot controller
System selection window
When is it shown?
The Select System window will be displayed when Select System is pressed in the Start window, as shown in the figure in section "Start Window".
xx0100000171
CANCEL
returns to the Start window as shown in the figure in section "Start Window".
How to select system
The window shows all systems installed on the controller mass storage memory.
Step
1.
Action
Select by moving the X to a desired system and press OK. The system will reboot with the new system and then display the Welcome window as shown in the figure.
Illustration/Info
xx0100000172
193
Controller
Robot controller
How to perform a Restart
General
Performing a restart may be done in a number of ways. These are detailed below:
Reboot (Warm start), apply changed settings
When executing a Warm start, the system reboots with the current system, e.g. to make new or changed settings take effect.
Step
1.
Action
Press the button Miscellaneous and select Service window or System Parameter window
Illustration/Info
Miscellaneous button:
xx0100000194
2.
Select Restart from the File menu and press OK. The system reboots and returns to the Welcome window as shown in the second figure in section "Select System".
P-START, reinstallation of RAPID
A P-Start will warm start the current system, with a reinstallation of the RAPID language and all auto-loaded modules. This means that all RAPID program and system modules currently loaded in the working memory will be closed, and thus have to be reloaded again after the P-Start, with the exception of such modules that are automatically loaded, due to settings in the System Parameters/Controller/ Task Modules.
Step
1.
Action
Press the button Miscellaneous and select Service window.
Illustration/info
xx0100000194
2.
Select Restart from the File menu.
Controller
Robot controller
Step
3. 4.
Action
Enter the numbers: 2_5_8 (the fifth function key changes to P-START) Press P-START. The system will reboot, reinstall RAPID and its auto-loaded modules, and return to the Welcome window as shown in the second figure in section "Select System".
Illustration/info
X-START, change active controller system
An X-start will exit the running system, store system data on the mass storage memory, and then execute the BootImage to display the Start window. Any system stored in the mass storage memory may then be selected as described in section "Select System". When performing an X-Start all stored system data will be restored (similar to performing a warm start).
Step
1.
Action
Press the button Miscellaneous and select Service window.
Illustration/Info
xx0100000194
2. 3. 4.
Select Restart from the File menu. Enter the numbers: 1_5_9 (the fifth function key changes to X-START) Press X-START. The system will reboot and return to the Start window as shown in the figure in section "Start Window".
I-START, start in Query mode
An I-start can be done if "Use Query Mode at System Boot" was selected when creating the running system in RobInstall (see section "Change options or system pack revision"). An I-Start will restart the current system and give the opportunity
195
Controller
Robot controller
to set some values at start-up, e.g. language, IRB type (within the same model) or options (see section "Start in Query Mode").
Step
1.
Action
Press the button Miscellaneous and selectService window.
Illustration/Info
xx0100000194
2. 3. 4.
Select Restart from the File menu. Enter the numbers: 1_4_7 (the fifth function key changes to I-START). Press I-START. The system will start to reboot, then pause to ask for Silent, Easy, or Query mode. For more information on the different modes, continue to section "Start in Query Mode".
C-START (Cold start), delete the active system
When executing a C-Start, the system exits the running system and deletes it from the mass storage memory. The BootImage is then executed and the Start window as shown in the figure in section "Start Window" is displayed.
Use C-start with caution. Since it deletes the current system, it should not be used to just switch between installed systems. For this purpose, use X-Start (see section "X-start"). It will take quite some time to implement a Cold start. Just wait until the robot shows the Start window. When the Start window is shown, a new system can be selected if available in the mass storage memory (see section "Select System) or a new system can be downloaded and started (see section "Transfer Robot Controller System using Ethernet connection" or "Transfer Robot Controller System using floppy disks"). Do not touch any key, joystick, enable device, or emergency stop during the cold start until the Start window is shown as in the figure in section "Start Window".
Controller
Robot controller
Step
1.
Action
Press the button Miscellaneous and selectService window.
Illustration/Info
xx0100000194
2. 3. 4.
Select Restart from the File menu. Enter the numbers: 1_3_4_6_7_9 (the fifth function key changes to C-START) Press C-START.
197
Controller
Robot controller
How to Start in Query Mode
Pre-conditions for selecting Query Mode start
If "Use Query Mode at System Boot" was selected when creating the system in RobInstall (see section "Change options or system pack revision"), it is possible to set some values, e.g. language, IRB type (within the same model) or options, at the first start-up of the system, using a C-Start (see section "C-start"), or later on when performing an I-Start (see section "I-start").
Types of Query Mode
The first question from the system is which Query Mode to start. Depending on your needs, you should select one of the following three:
Silent Mode, pushbutton Silent. If Silent Mode is selected, the operating system will be installed with the system configured as defined in RobInstall. Easy Query Mode, pushbutton Easy Query. In Easy Query Mode you can change language, remove selected options and select service or standard mode (see section "Easy Query Mode"). Query Mode, pushbutton Query. In Query Mode you can, as well as the things in Easy Query, select DC-link, change Robot type (within the same family) and for IRB 7600, select balancing unit (see section "Query Mode").
Easy Query Mode
If Easy Query was chosen as start-up query mode, the following steps will be required to start the system:
Step
1.
Action
Select Service/Standard motion param. Choose between standard or service motion parameters (pushbutton Stand / pushbutton Service). Choose TP Language. If there was another language than English selected in RobInstall (see section "Change options or system pack revision"), it will be possible to choose the language (pushbutton English /pushbutton "Other").
Illustration/Info
2.
Controller
Robot controller
Step
3.
Action
Install xxx? For every option that was selected in RobInstall (see section "Change options or system pack revision") it is now possible to select Yes to keep the option, or No to remove it from the system.
Illustration/Info
Query Mode
If Query Mode was chosen as start-up query mode, the following steps will be required to start the system:
Step
1. 2. 3.
Action
Select Service/Standard motion param. See section "Easy Query Mode", step 1. Choose TP Language. See section "Easy Query Mode", step 2. Select external axes config. You can find the article number of the DC-link used on the unit inside the controller, then use the table below to find out the configuration ID for that DC-link.
Illustration/info
4.
Select xxxx model. Choose Robot model type within in the same family, e.g. 1400, 6400 etc. If there are more than three options, press pushbutton SCAN to view them. Install xxx. See section "Easy Query Mode", step 3.
5.
199
Controller
System directory structure
Section G: System directory structure Media pool in the PC
Directory
All RobotWare System Packages and Option Packages are stored in a media pool directory (folder) as shown in the table below. Two revisions of the same system package may exist in the pool. By default, after having installed RobInstall, a directory "MediaPool" will be found in the directory Program Files\ABB Robotics\, and will also be the current one. However any directory in the structure can be set up as the current media pool in the Preference window (see section "Robinstall Preferences").
xx0100000259
Art. no./folder name

3HAXaaaa-1.00 3HAXbbbb-1.02 3HAXcccc-1.01 3HYZdddd-1.00
Description
RobotWare System Pack 3HAXaaaa-1, rev 00 RobotWare System Pack 3HAXbbbb-1, rev 02 ABB Robotics external option program 3HAXcccc-1, rev 01 OEM customer external option program 3XYZdddd-1, rev 00
Naming conventions
Each package is stored in a directory, the name of which is an article number ending with the sub-number and with the revision number as shown in the table above. All the system packs and option packs in one media pool must have the correct revision numbers in their directory names. Thus a later revision can be loaded into the program pool, to be added to the old one, without changing the article number.
Controller
System pool in the PC
Directory
All systems created with the RobInstall will be stored in a system pool. The default name of such a system pool is "system" as shown below. Each system stored in the system pool is a directory with the name of the system as shown in the table below. By default, after installing RobInstall, a directory "system" will be found in Program Files\ABB Robotics\ and will also be the current one. However any directory in the structure can be set up as the current system directory in the Create New System window or Select System window.
Directory view
Folder "System 1"
xx0100000260
xx0100000261
File system requirements
The system directory must hold these files and directories to allow software installation:
key.id (encrypted key file for the actual controller) program.id (file with paths to selected programs in the media pool) A syspar directory containing .cfg files to be included in the software installation procedure. All system parameter files, included when creating a system with RobInstall, are stored in this syspar directory as shown in the table in section "System Pool Directory". A directory called Home. In this home directory the user can include any file or files, which should be downloaded to the controller together with the operating system. Such files will then be placed in the home directory of the system in the controller.
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Controller
File structure in the robot controller mass storage memory
Files in root directory, hd0a
The root directory of the mass storage memory is called hd0a. This includes several components:
File name
bin BootRom.sys MC.cfg ctrl.bin system.dir system directories
Description
BootImage code System configuration and description file for the mass storage memory Network configuration for the main computer Holds e.g. revolution counter values Holds information on the current system Different systems stored in the mass storage memory
E.g. 3HAC6811-1.00 Control system package, named as an article number
Directories and subdirectories
Each system directory holds a number of subdirectories, defining for instance language, options, robots, etc.
"Home" directory
The system directory is the "home" directory for the system. When using the address "home:" in the RAPID program, this directory will be addressed.
"Bin" subdirectory
The subdirectory bin, containing the storage area for all system data, e.g. at power break. This means that at warm start, in addition to restoring the operating system from the control system package, all system data is restored from this directory and reloaded into the working memory.
Never change these directories!
Never delete or change the \bin or BootRom.sys directories in the root directory. If this is done, the controller cannot be restarted and it will be impossible to use the mass storage memory.
Controller
Preparation of S4Cplus software to be installed
Illustration
Media pool S ystem Pack in /3haxbbbb-1.nn *.* si gnature no S ystem pool
E xt Option in /3haxcccc1.nn *.* relkey.txt
Created files key.id program.id
E xternal option from disk or CD-R OM
My syst em /syst em_n key.id program.id keystr.txt /syspar *.cfg
S ystem Pack from R obotWare CD-R OM
Inserted key strings are saved in keystr.txt R obotWare keystrings define the options to be included from the S ystem Pack they belong to and E xt opt keystrings define added external option packa ges. All keys must have the same serial number.
xx0100000262
Files to be prepared
The list details what happens during preparation:

RobInstall creates a file named Key.id from the key strings specifying the options to be installed from the System Pack and the external option programs to be installed. Unless deselected in RobInstall, the latest revision of the System Pack and External Option Programs is selected as default (see section "Change options or system pack revisions"). These are copied from the media pool and concatenated into one target file that also holds the key.id and the syspar directory. This may then be downloaded to the controller via Ethernet or a set of diskettes. The target file is temporarily stored in the system directory before downloading or creating diskettes.
203
Controller
Handling mass memory storage capacity
General
In some cases it is very important that there is enough free space in the mass storage memory, before attempting to download new system software. How to check its capacity, and if required increase it, is detailed below. A manual check on the free space can be done in one of the following ways:
Checking storage capacity from the Teach Pendant Unit
1. Press the button Miscellaneous to select Service window. 2. Select Storage Capacity from the System Info menu. The Mass Storage Memory is called hd0a.
Checking storage capacity through connection to the MC/CONSOLE port
1. Connect a console to the MC/CONSOLE outlet on the controller and execute the command dosFsShow.
There should always be at least 25 Mb free disk space on the controller mass storage memory before attempting to download a new system. For information on how to increase storage capacity, see below!
Increasing storage capacity
If the capacity of the mass storage memory is less than 25 Mb when a new controller system is to be downloaded, storage memory must be released by removing old systems from the mass storage memory. This can be done in one of the following ways: 1. Boot up on the system you would like to remove and then make a CSTART (see section "C-start"). 2. Use the FileManager in the Teach Pendant Unit, see Users Guide - File Manager, for more information on how to use the FileManager. 3. Use a third-party "ftp" client (like FTPVoyager supplied on the RobotWare CD).
Controller
Removing systems using the FileManager or FTP-client may be hazardous since the \bin and BootRom.sys directories must be kept intact. Proceed with the utmost care to avoid accidentally removing such files or directories!
205
Controller
Calibration
Chapter 5:Calibration
When to calibrate
Types of calibration procedures
Calibrate the measurement system carefully if any of the resolver values has been changed. This may occur when parts affecting the calibration position have been replaced on the robot. Calibrate the system roughly as detailed in section "Updating the revolution counter" if the contents of the revolution counter memory are lost. This may occur when:
the battery is discharged a resolver error occurs the signal between a resolver and measurement board is interrupted a robot axis has been moved with the control system disconnected
207
Calibration
General
Section A: General How to calibrate the robot system
General
This section provides an overview of the procedure required when calibrating the robot system. Many of the steps in the procedure are detailed in other sections to which references are given.
Procedure Step
1.
Action
Check that all required hardware is available for calibrating the robot.
Note/Illustration
Required hardware is specified in the calibrating procedures for each axis.
2.
Check the correct orientation of axis 4. Detailed in "Correct orientation Incorrect orientation of the axis may of axes". cause damage on cabling! Manually, run the robot axes to a posi- Use the calibration scales or distion close to the correct calibration tances to locate this position, position. detailed in "Correct orientation of axes". Start the calibration procedure on the TPU. Calibrate each axis. Verify that the calibration was successfully carried out. Detailed in "Fine calibration procedure on TPU". Detailed in "Fine calibration, all axes". Detailed in "Post calibration procedure".
3.
4. 5. 6.
Calibration
General
Additional information
In addition to the basic calibration procedure detailed above, a number of calibration related actions may be performed:
Action
How to update the robot revolution counter without performing a complete calibration.
Detailed in section:
Updating the revolution counter
How to manually check the current calibration Checking the calibration position position.
209
Calibration
General
Calibration tool kit, contents
Calibration tool kit, 3HAC xxxxx-x
The calibration tool kit, 3HAC xxxxx-x, can be ordered from ABB Automation Technologies AB, Robotics. The kit contains:
Digital indicator Magnetic stand Calibration tool for actuator Calibration tool for wrist Tool case
Calibration
Preliminaries
Section B: Preliminaries Correct orientation of axes
General
This section details the correct orientation of all axes. The orientation of axis 4 must be especially checked and corrected if necessary before performing any calibration!
211
Calibration
Preliminaries
Index marks
The figure below shows the index marks of axes 4-5-6 and the correct position of the spiral cable. It also shows the calibration distance on axes 1-2-3.
C B G D
E
xx0200000341
F
E F G Index marks for axis 5 Index marks for axis 6 Calibration distance for axes 12-3: 26 mm on each axis
A B C D
Axis 4 (center tube) Spiral cable inspection cover Correct orientation of the spiral cable (and axis 4) Index marks for axis 4
Calibration
Preliminaries
Correct position of axes 1-2-3
The axes 1-2-3 should be positioned with an approximate distance of 26 mm between the actuator and the calibration spacer above the lower joint, shown in figure above. This distance is set exactly during the fine calibration procedure.
Correct orientation of axis 4
The procedure below details how to check and eventually correct the orientation of axis 4.
Axis 4 has no mechanical limitation! Cabling inside the manipulator may be damaged if axis 4 is oriented incorrectly when performing calibration of the robot!
If work must be carried out within the robots 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 robots speed is limited to max. 250 mm/s when the operating mode selector is in position < 250 mm/s. This should be the normal position when entering the working space. The position 100%full speed may only be used by trained personnel who are aware of the risks that this entails.
Step Action
Note
1. Remove the spiral cable inspection cover on Shown in figure above! the center tube sleeve by removing its 4 attachment screws. 2. Make a visual check of the numbers, marked Directions detailed in part on the spiral cable. Directions for all axes. The numbers 4-3-2-1 must be positioned in a straight line, as shown in figure above! In case the index marks are not present: make sure that the normal vector of the face of the gearbox, axis 5, is pointing in approximate (+ / - a couple of degrees) +Y direction! 3. In case correction is necessary, turn axis 4 with the TPU into the approximate calibration position by positioning the numbers into a straight line!
213
Calibration
Preliminaries
Step Action
4. Refit the spiral cable inspection cover with the 4 attachment screws!
Note
Correct orientation of axes 5-6
The procedure below details the correct orientation of axes 5-6.
Step
1.
Action
Make sure that the index marks of axis 5 are roughly aligned. In case the index marks are not present: make sure that the normal vector of the face of the tool flange is pointing approximately (+ / - a couple of degrees) in the +Z direction (positive)! Make sure that the index marks of axis 6 are roughly aligned. In case the index marks are not present: make sure that the hole for the guide pin in the tool flange is pointing approximately (+ / a couple of degrees) in the -X direction (negative)!
Note/Illustration
Location shown in figure above! Directions detailed in part Directions for all axes.
2.
Location shown in figure above! Directions detailed in part Directions for all axes.
Calibration
Preliminaries
Checking the calibration position
General
Check the calibration position before beginning any programming of the robot system. This may be done as detailed below.
Using the Jogging window on the teach pendant
Step
1.
Action
Open the Jogging window.
Note/Illustration
xx0100000195
2.
Choose running axis-by-axis.
xx0100000196
3.
Check that the positions of axes 1-2-3 are reached and that the calibration marks on axes 4-5-6 are aligned correctly. If they are not, update the revolution counters as detailed in "Update the revolution counter".
Calibration positions and marks for each axis are shown in section "Correct orientation of axes".
215
Calibration
Preliminaries
Updating the revolution counter
Manually running the manipulator to the sync position
This section details the first step when updating the revolution counter; manually running the manipulator to the synchronization position.
Axis 4 has no mechanical limitation! Cabling inside manipulator may be damaged if axis 4 is oriented incorrectly when performing calibration of the robot!
the
Step
1. 2.
Action
Select axis-by-axis motion mode
Illustration
Press the enabling device on the teach pen- Calibration marks shown dant and, using the joystick, move the robot in section "Correct orienmanually so that the calibration marks or dis- tation of axes". tances lie within the tolerance zone. Note that axis 6 does not have any mechanical stop and can thus be calibrated at the wrong faceplate revolution. Do not operate axis 6 manually before the robot has been calibrated. When all axes have been positioned as above, store the revolution counter settings using the Teach Pendant Unit as detailed below:
3.
4.
Storing the revolution counter setting
This section details the second step when updating the revolution counter; storing the revolution counter settings.
If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, which in turn may cause damage or injury!
Calibration
Preliminaries
Step
1.
Action
Press the button "Miscellaneous".
Illustration
xx0100000194
2.
Select the Service window by pressing ENTER.
xx0100000200
3.
Select Calibration from the View menu. The Calibration window appears.
xx0100000201
4.
Select the desired unit and choose Rev Counter Update from the Calib menu. The Revolution Counter Update window appears.
xx0100000202
5.
Select the desired axis and press Incl to include it (it will be marked with an x) or press All to select all axes.
217
Calibration
Preliminaries
Step
6.
Action
Press OK when all axes that are to be updated are marked with an x. CANCEL returns to the Calibration window. Press OK again to confirm and start the update. CANCEL returns to the Revolution Counter Update window. At this point, it is recommended that the revolution counter values are saved to a diskette. Recheck the calibration position as described in "Checking the calibration position".
Illustration
7.
8.
Not required.
9.
Calibration
Preliminaries
Fine calibration procedure on TPU
General
The section below details how to use the Teach Pendant Unit (TPU) when performing a fine-calibration of the robot.
Procedure Step
1.
Action
Press the button "Miscellaneous".
Note/Illustration
xx0100000194
2.
Select the Service window by pressing ENTER.
xx0100000200
219
Calibration
Preliminaries
Step
3.
Action
Choose Calibration from the View menu. The Calibration window appears.
Note/Illustration
xx0100000201
Explanation of status: Synchronized: all axes are calibrated and their positions are known. The unit is ready for use. Revolution Counter not updated: all axes are fine-calibrated but one (or more) of the axes has a counter that is NOT updated. This axis, or these axes, must therefore be updated as described in "Updating the revolution counter". Not calibrated: one (or more) of the axis is NOT fine-calibrated. This axis, or these axes, must therefore be fine-calibrated as described in "Fine calibration".
4.
Select the desired unit and choose Fine Calibrate from the Calib menu. A Warning window appears.
xx0100000203
Calibration
Preliminaries
Step
5.
Action
Move the manipulator to its calibration position and press OK. The Fine Calibrate window appears.
Note/Illustration
Calibration positions for the manipulator detailed in "Checking the calibration position".
xx0100000204
6.
Select the desired axis and press Incl to include it (it will be marked with an x) or press All to select all axes. Press OK when all axes that are to be updated are marked with an x. CANCEL returns to the Calibration window. Press OK again to confirm and start the update. CANCEL returns to the Fine Calibration window. An alert box is displayed during calibration. The Status window appears when the fine calibration is complete. The revolution counters are always updated at the same time as the calibration is performed.
7.
8.
221
Calibration
Calibration
Section C: Calibration Directions for all axes
Calibration movement directions
The figure below shows the positive and negative directions for each axis.
+
4
+ + + +
5
+ 6
xx0200000355
Calibration
Calibration
Jogging directions
The figure below shows the linear directions when jogging the robot.
+Y
+X
+Z
+Z
xx0200000378
223
Calibration
Calibration
Fine calibration, all axes
Introduction
This section details how to calibrate the complete robot, using calibration tools. The section is divided into the following parts:
Before calibration Required equipment Calibration order Calibration, axes 1, 2 and 3 Calibration, axis 5 Calibration, axis 6 Calibration, axis 4
Before calibration
Before calibrating the robot, make sure that the requirements in the previous sections "General" and "Preliminaries" are met!

Calibration tool kit
Art. no.
-
Note
Contains tools for calibration of complete robot. May be ordered from ABB Automation Technologies AB, Robotics.
Calibration order
The order of calibration of the axes 1, 2 and 3 is of no importance, but the remaining axes must be calibrated in the following sequence: 5 - 6 - 4.
Calibration
Calibration
Calibration axis 1, 2 and 3
The procedure below details how to calibrate axis 1, but it is the same for axes 2 and 3. Calibrate one axis at a time and then repeat the procedure for the remaining axes.
Step
1. 2.
Action
Turn the operating mode selector to MANUAL MODE AT REDUCED SPEED. Operate current axis (axis 1, 2 or 3) in manual mode with the joystick until only 40-50 mm of the movable part of the actuator is visible. Insert the gauge block between the platform and the actuator cover (see adjacent figure) and then gently contract the actuator until the gauge block fits exactly but is not jammed. Note! All three actuators should have approximately the same length when one of them is calibrated.
Note/Illustration
3.
xx0200000351
4. Update only the current axis (axis 1, 2 or 3) as detailed in "Fine calibration procedure on TPU". Remove the calibration tools.
A: 26 mm
5.
225
Calibration
Calibration
Calibration, axis 5
The procedure below details how to calibrate axis 5.
Step
1.
Action
Put a dial gauge (mounted on a support positioned on a flat surface external to the robot) against the edge of the tool flange as shown in the adjacent figure. The purpose of this procedure is to adjust axis 5 so that it is possible to rotate axis 4 without reading any offset on the indicator.
Note/Illustration
xx0200000352
Calibration
Calibration
Step
2.
Action
Lock all other axes when jogging axis 4. Rotate axis 4 in joint +180 degrees. Rotate axis 5 to compensate for half the value read on the indicator (i.e. the indicator shows 0.58 mm, move axis 5 gently until the indicator shows 0.29). Rotate axis 4 -180 degrees (=back to the starting position, 0 degrees). Repeat until it is possible to rotate axis 4 180 degrees without reading any error on the gauge. Normally, it requires 2-4 attempts.
Note/Illustration
3. 4.
Update only axis 5, as detailed in "Fine calibration procedure on TPU". Remove the calibration tools.
227
Calibration
Calibration
Calibration axis 6
Step
1.
Action
Run the following axis to the specified position: Axis 5: -90 degrees. Fit the wrist calibration tool at the tool flange and put a dial gauge (mounted on as support positioned on a flat surface external to the robot) against the edge of the tool, see the adjacent figure.
Note/Illustration
2.
xx0200000353
3.
Lock all other linear directions except Directions shown in Directions for Z. for all axes.
Calibration
Calibration
Step
4.
Action
Note/Illustration
Move the robot in +/-Z (in base) and Directions shown in Directions adjust axis 6 until the indicator shows for all axes. minimum change (usually a few hundredths of a millimeter) while travelling from the middle of the tool to one end (i.e. if the indicator shows 0.46 mm while travelling from the center of the tool to one end of the tool, rotate axis 6 by 0.46 mm). Update only axis 6, as detailed in "Fine calibration procedure on TPU". Remove the calibration tools.
5. 6.
Calibration, axis 4
Step
1.
Action
Run the following axes to the specified positions: Axis 5: -90 degrees. Axis 6: +90 degrees. Axis 4: 0 degrees.
Note/Illustration
2.
Put a dial gauge (mounted on a support positioned on a flat surface external to the robot) against the ground face of the tool, see the adjacent figure.
xx0200000354
229
Calibration
Calibration
Step
3. 4.
Action
Lock all other linear directions except for Y.
Note/Illustration
Directions shown in Directions for all axes.
Move the robot in +/-Y (in Directions shown in Directions for all base) and adjust axis 4 until axes. the indicator shows minimum change (usually a few hundredths of a millimeter) while travelling from the middle of the tool to one end (i.e. if the indicator shows 0.52 mm while travelling from the center of the tool to one end of the tool, rotate axis 4 by 0.52 mm). Update only axis 4, as detailed in "Fine calibration procedure on TPU". Remove the calibration tools.
5.
6.
Calibration
After calibration
Section D: After calibration Post calibration procedure
General
Perform the following procedure after calibrating any manipulator axes. The procedure is intended to verify that all calibration positions are correct.
Procedure Step
1.
Action
Illustration
Run the calibration home position program Detailed in "Checking the twice. calibration position". Do not change the position of the manipulator axes after running the program! Check all calibration positions. Repeat the check as above. Adjust the calibration marks when the calibra- Shown in section "Cortion is done. rect orientation of axes". The system parameters will be saved to the storage memory at power off. Remove any calibration equipment from the manipulator. Detailed in "Checking the calibration position".
2. 3. 4. 5. 6.
231
Calibration
After calibration
Index
233
Index
Repair Manual
Repair Manual, IRB 940 Tricept

3HAC 16640-1
-
Table of Contents
1 3 5 5 6
7

7 7 8
9
9 9 9 10 10 11
13
Safety fence dimensions Fire extinguishing Emergency release of the manipulator's arm Brake testing Risk of disabling function "Reduced speed 250 mm/s" Safe use of the Teach Pendant Unit Work inside the manipulators working range Chapter 2: Reference Information Introduction Screw joints Weight specifications Chapter 3: Manipulator Introduction
Section A: Manipulator repairs
13 13 14 14 15 15 15 17 17 18 20 21 21
22
Removal of actuator, including motor Refitting of actuator, including motor Removal of servomotor, axes 1-3 Refitting of servomotor, axes 1-3 Removal of servomotor, axis 4
22 27 34 38 43
Table of Contents
Refitting of servomotor, axis 4 Removal of lower joint Refitting of lower joint Removal of wrist Refitting of wrist Removal of center unit Refitting of center unit Removal of spiral cable Refitting of spiral cable
Section B: Distribution box repairs
49 55 58 62 67 72 77 82 85
89
Replacement of battery, distribution box Replacement of serial measurement card, distribution box Replacement of brake release card, distribution box Chapter 4: Controller Introduction Putting the computer unit in the service position Replacement of air filter, controller Replacement of battery unit, controller Replacement of I/O and gateway units Replacement of bleeder resistor Replacement of mass storage memory Replacement of internal cooling fan Replacement of drive units and rectifier Replacement of system fan unit Replacement of power supply unit Chapter 5: Circuit Diagram, IRB 940 Tricept Introduction =M1/2, Potentials from control =M1/3, Axis 1 =M1/4, Axis 2 =M1/5, Axis 3 =M1/6, Axis 4 =M1/7, Axis 5 =M1/8, Axis 6 =M1/9, Serial Measure board, Earth connections =M/10, Brake release unit
89 92 95 99 99 100 103 106 109 113 116 120 125 129 132 135 135 136 137 138 139 140 141 142 143 144 144
Table of Contents
Chapter 6: Circuit Diagram, S4Cplus Introduction

System 1: General information
145 145
146
Sheet 1-1. Block Diagram Sheet 1-2. View of Control Cabinet Sheet 1-3. View of Control Cabinet Sheet 1-4. Designation Sheet 1-5. Designation
System 2: Mains Connection and Power Supply
146 147 148 149 150

151
Sheet 2-1. Mains Connection Sheet 2-2. Transformer Unit Sheet 2-3. Power Supply Sheet 2-4. Power Supply Sheet 2-5. External transformer unit 200-500V IRB6600/7600 Sheet 2-6. Transformer unit 400-475V IRB 6600/7600
System 3: Computer Unit and Connector Unit
151 152 153 154 155 156

157
Sheet 3-1. Block Diagram/Computer Unit Sheet 3-2. Cabling in Computer Unit Sheet 3-3. Main Computer and Hard Disk / Flash Disk Drive Sheet 3-4. Compute Cooling Sheet 3-5. Base Connector Board and I/O Computer Sheet 3-6. Connector Board and I/O Computer Sheet 3-7. Connector Board and Axis Computer Sheet 3-8. Base Connector Unit Sheet 3-9. Connector Plate on Controller Panel
System 4: Emergency Stops and Run Chain
157 158 159 160 161 162 163 164 165

166
Sheet 4-1. Emergency Stop Sheet 4-2. Run Chain Sheet 4-3. Run Chain Sheet 4-4. Power Unit Servo Disconnector
System 5: Drive System and Robot Cable
166 167 168 169

170
Sheet 5-1. Block Diagram Sheet 5-2. Rectifier, Fans and Bleeder Sheet 5-3. Drive System Signal Connection 2 Drive Units Sheet 5-4. Drive System Signal Connection 3 Drive Units Sheet 5-5. Servo Drive Units / IRB 140 Sheet 5-6. Servo Drive Units / IRB 340 Sheet 5-7. Servo Drive Units / IRB 640, 840 Sheet 5-8. Servo Drive Units / IRB 1400, 2400
170 171 172 173 174 175 176 177
iii
Table of Contents
Sheet 5-9. Servo Drive Units / IRB 4400, 6400S/PE Sheet 5-10. Servo Drive Units / IRB 6400R Sheet 5-11. Control Cable IRB 140 Sheet 5-12. Control Cable IRB 340, 1400 and 2400 Sheet 5-13. Control Cable IRB 640, 840, 4400 and 6400S/PE Sheet 5-14. Control Cable IRB 6400R Sheet 5-15. Rectifier, fans and bleeder Sheet 5-16. Servo Drive System Sheet 5-17. Control cable
System 6: External axes
178 179 180 181 182 183 184 185 186

187
Sheet 6-1. External axes Sheet 6-2. Axes Computer 2 and Connector Board Sheet 6-3. Expansion Board Axis Connector Board Sheet 6-4. Drive System Signal Connection External Axes Sheet 6-5. External axes no. 7th - 9th Control Signal Connection Sheet 6-6. Axis Computer 2 and Axis Connector Unit if External Axis Cabinet Sheet 6-7. Connection to External Axis Cabinet Sheet 6-8. Servogun-SMB power/signals cable
System 7: I/O Units and Field Bus Modules
187 188 189 190 191 192 193 194

195
Sheet 7-1. I/O Unit Position Sheet 7-2. Digital Part of Combi I/O and Digital I/O Unit Input Part Sheet 7-3. Digital I/O Unit Output Part Sheet 7-4. Combi I/O Unit Digital and Analogue Output Part Sheet 7-5. Digital Input Part of 120V AC I/O Unit Sheet 7-6. Digital Output Part of 120V AC I/O Unit Sheet 7-7. Relay I/O Unit Input 1-16 Sheet 7-8. Digital with Relays I/O Output 1-8 Sheet 7-9. Digital with Relays I/O Output 9-16 Sheet 7-10. Analogue I/O Unit Sheet 7-11. Remote I/O Unit For Allen Bradley PLC Sheet 7-12. Interbus-S Master/Slave - Interbus-S Master Sheet 7-13. Profibus DP SLave Sheet 7-14. Encoder Unit Sheet 7-15. Profibus DP Master/Slave Sheet 7-16. Interbus master/slave optical fibre and copper wire
System 8: Other options
195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210
211
Sheet 8-1. Floppy Disk Sheet 8-2. Service Equipment Supply Sheet 8-3. External Connections System Signals Sheet 8-4. Position Switches on Manipulator
211 212 213 214
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Table of Contents
Sheet 8-5. Customer Signals Sheet 8-6. Sustomer Power/SIgnal IRB 2400, 4400, 6400S/PE Sheet 8-7. Customer Cable Power/Signal/CAN IRB 6400R Sheet 8-8. External Control Panel Sheet 8-9. Extension Cable Teach Pendant Sheet 8-10. Time Relay Sheet 8-11. Customer Precess / Power / Signal / Profibus DP M/S Sheet 8-12. Optional customer power/signal Profibus IRB 6400R Sheet 8-13. LAN Ethernet connection Sheet 8-14. Customer power/CAN-BUS IRB 640/6400S Sheet 8-15. Customer cable power/signal CAN-BUS IRB 6600/7600 Sheet 8-16. Customer cable power/signal Profibus IRB 6600/7600 Sheet 8-17. Optional customer power/signal Profibus IRB 6400R
System 9: External Axis Cabinet
215 216 217 218 219 220 221 222 223 224 225 226 227
228
Sheet 9-1. Block Diagram Sheet 9-2. View of External Axis Cabinet Sheet 9-3. Designation Sheet 9-4. Mains Connection Sheet 9-5. Transformer Unit Sheet 9-6. Power Supply, I/O Supply Sheet 9-7. Power Unit Sheet 9-8. Rectifier, Fans and Bleeder Sheet 9-9. Drive Unit Signal Connection 1 External Drive Unit Sheet 9-10. Drive Unit Signal Connection 2 External Drive Units Sheet 9-11. Drive Unit Signal Connection 3 External Drive Units Sheet 9-12. Drive Unit and Control Cable Drive Unit GT Sheet 9-13. Drive Unit and Control Cable Drive Unit GT+CCB Sheet 9-14. Drive Unit and Control Cable Sheet 9-15. Service Equipment Supply
228 229 230 231 232 233 234 235 236 237 238 239 240 241 242
Table of Contents
www.cadfamily.com EMail:cadserv21@hotmail.com vi document is for study only,if tort to your rights,please inform us,we will 3HAC 16640-1 The delete
Overview
About This Manual
This information product is a manual containing instructions for repairing the complete robot system, mechanically as well as electrically.
Usage
This manual should be used during repair work.

repair personnel in the users organization. repair personnel in other organizations.
Prerequisites

be a trained repair craftsman have the required knowledge of mechanical repair work OR have the required knowledge of electrical repair work.
The manual is organized in the following chapters:
Chapter
1. 2. 3. 4.
Contents
Safety Reference information Manipulator Controller
Circuit diagrams, Manipulator
Document Id
Included in Repair Manual, 3HAC 16640-1
Reference
Circuit diagrams, Controller
Document Id
Included in Repair Manual, 3HAC 16640-1
Revisions Revision
-
Description
First edition
General


Safety, service

Introduction
Definitions
Sections
The chapter "Safety, service" is divided into the following sections: A. References contains lists of:
Safety, service
Safety, service
References
General
Standards

Safety, service
References
Related information
General

Section
Start-up
Safety, service
Safety risks

Safe handling
Safe design
General
Residual energy
Safe design
Safety, service
Safety risks
General
Qualified personnel
Extraordinary risks
Safety, service
Safety risks
11
Safety, service
Safety risks


Safety, service
Safety actions
General

- withstand any impact from a tool failure. Due to the high kinetic energy associated with HSM (High Speed Machining), a tool failure poses a serious risk as any debris can cause serious personal injury. Both walls and ceilings must be designed and dimensioned so that they can withstand any projectiles that they may be subjected to. Windows must be made from suitable safety glass. Study the planned process to determine the forces involved and appropriate materials. - insulate against sound pollution from the machining process. Typically the safety cell should be able to reduce sound from the machining process down to 75dBA, though individual installations may stipulate other values. Study the planned process to determine the allowable noise pollution levels and appropriate sound insulation. - isolate gases and mist generated by the machining process and spray mist lubrication. Study the planned process to determine the fumes involved and appropriate ventilation/filtering system.
Fire extinguishing
13
Safety, service
Safety actions
Description
Increased injury
Brake testing
When to test
How to test
Safety, service
Safety actions



15
Safety, service
Safety actions

Introduction
General
17
Screw joints
General
This section details how to tighten the various types of screw joints in the manipulator as well as the controller. The instructions and torque values are valid for screw joints comprising metallic materials and does not apply to soft or brittle materials. Any instructions given in the repair, maintenance or installation procedure description override any value or procedure given here, i.e. these instruction are only valid for standard type screw joints.
Tightening torque
Dimension
M2.5 M3 M4 M5 M6

0.25 0.5 1.2 2.5 5.0
Dimension
M5 M6 M8 M10 M12

6 10 24 47 82

28 55 95

17 40 70 120
Dimension
M16

200

235

300
19
Definition
Within all repair and maintenance instructions, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are highlighted in this way. ABB recommends handling all components with a weight exceeding 22 kg using lifting equipment to avoid inflicting injury.
Example

Manipulator
Chapter 3:Manipulator
Introduction
Definitions
This chapter details all repair activities recommended for the manipulator, including the manipulators distribution box. It is made up of separate units, each detailing a specific repair activity, e.g. Removal or Refitting of a certain component on the manipulator. Each unit contains all information required to perform the activity, e.g. spare parts numbers, required special tools and materials. The chapter is divided into:
Removal/refitting instructions for all the spare parts on the manipulator Replacement instructions for all the spare parts in the manipulators distribution box
21
Manipulator
Manipulator repairs
Section A: Manipulator repairs Removal of actuator, including motor
Location
The three actuators are located on the manipulator as shown in the figure below.
D A
C
xx0200000296
Manipulator
Manipulator repairs
A B C D E F
Actuator Actuator servomotor Lower joint Actuator fork Center tube Wrist

Hook wrench
Note
3 mm pin, shown in figure the below!
xx0200000350
Hook wrench with 3 mm pin
Safety
Please read the following notations before the removal.

Please observe the following before commencing any repair work on the manipulator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them! - Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot!
23
Manipulator
Manipulator repairs
- When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures. - Before removing, clean the work area and the components to be removed. - Place the removed components in a clean container.
Preparatory work
Follow the instructions below for preparatory work, before commencing to remove an actuator.
Step
1.
Action
Run the actuators to half way in length, and ensure all the actuators are of equal length. This is done in order to allow the actuator to retract when the lower joint is unscrewed. Switch off the power supply.
Note/Illustration
2. 3.
The weight of an actuator is around 40kg (88lb). Shown in the figure Before removal, the actuator must therefore be above! secured using straps, as the center unit will tend to move away from the corner with the removed actuator. If the manipulator is vertically orientated, it is important to anchor the center tube to the surrounding equipment in order to prevent this. For other orientations, try to anticipate the movement and secure accordingly.
Manipulator
Manipulator repairs
Removal of actuator
The procedure below details how to remove an actuator, including the motor. The procedure is the same for all actuators. Make sure the preparatory work above is done before removing an actuator!
Step
1.
Action
Remove the eletric cabling from the servomotor located on the actuator to be removed. Move and secure the cabling so it can not get damaged during removal of the actuator. Secure the actuator from above using straps from a hoist or from the forks of a fork lift. Use a heating gun to loosen the threadlocking substance, before unscrewing the lower joint from the lower platform.
Note/Illustration
2.
3.
4.
To release the bottom end of the actuator Shown in the figure above! from the lower platform, unscrew the lower Specified above! joint using thehook wrench. Make sure the center tube and wrist are anchored as detailed in the preparatory work above! Unscrew the four attachment screws hold- Shown in the figure above! ing the actuator to the actuator fork. Gently remove the actuator and lift it safely to a flat surface. Inspect the actuator fork and the thread in the lower platform for damage. If only the actuator is to be replaced, remove the servomotor as detailed below.
5. 6. 7. 8.
25
Manipulator
Manipulator repairs
Removal of motor
The procedure below details how to remove the motor from a dismounted actuator.
Step
1.
Action
Unscrew the four fixing screws that hold the servomotor to the actuator housing.
Note/Illustration
A B D C
xx0200000302
2. 3. Remove the servomotor from the actuator. If the toothed wheel ring stays with the backlash-free coupling attached to the actuator (shown in the figure above), detach it and fit it to the coupling on the servomotor. Remove the coupling from the actuator shaft.
A: Servomotor B: Fixing screws (4 pcs) C: Toothed wheel ring D: Backlash-free coupling
4.
Manipulator
Manipulator repairs
Refitting of actuator, including motor
Location
The actuators are located as shown in the figure below.
D A
C
xx0200000296
A B
Actuator Actuator servomotor
27
Manipulator
Manipulator repairs
C D E F
Lower joint Actuator fork Center tube Wrist

Actuator with motor Thread-locking substance

3HAC 17151-1
Note
e.g. Loctite 242. Used when securing the lower joint to the lower platform. 3 mm pin
Hook wrench
xx0200000350
Safety
Please read the following notations before refitting.

Please observe the following before commencing any repair work on the manipulator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them!
Manipulator
Manipulator repairs
- Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! - When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures. Please observe the following when refitting components: - Carefully clean the mating surfaces. - Ensure that there are no damaged surfaces or other parts that need rectifying or replacing. - Replace all gaskets. The actuator with motor weighs 40 kg! All lifting equipment used must be dimensioned accordingly!
Refitting of motor
In case the servomotor has been removed from the actuator, refit it as detailed in procedure below.
Step
1.
Action
Fit the backlash-free coupling onto the new actuator. Make sure the shaft lies flush with the coupling surface, as shown in figure to the right.
Note/Illustration
xx0200000303
A: Actuator shaft B: 0mm
29
Manipulator
Manipulator repairs
Step
2.
Action
Note/Illustration
Assemble the servomotor, back- 4 pcs; tightening torque: 24 Nm. lash-free coupling and the actuator. Tighten the fixing screws of the motor.
A B D C
xx0200000302
A: Servomotor B: Fixing screws (4 pcs) C: Toothed wheel ring D: Backlash-free coupling
Refitting of actuator
The procedure below details how to refit the actuator, including the motor. The procedure is the same for all actuators.
Step
1. 2.
Action
Refit the motor, in case it has been removed, as detailed above. Place the actuator in the actuator fork by lifting it with a hoist.
Note/Illustration
Manipulator
Manipulator repairs
Step
3.
Action
Push the actuator to the left so that it is flush with the left hand side of the fork, as shown with the arrow in figure to the right. The direction is the same for all three actuators.
Note/Illustration
A B
xx0200000304
4. Adjust the circlip so that the actuator remains tight against the left hand side.
A: Clamp B: Circlip
5.
Fit the clamps and tighten the four 4 pcs; tightening torque: 10 Nm. hexagonal screws that hold the clamps. Fit the sealing caps onto either side of the actuator fork as shown in figure to the right.
6.
xx0200000305
A: Sealing cap
31
Manipulator
Manipulator repairs
Step
7.
Action
Note/Illustration
Refit the actuator by screwing the Shown in the figure above! lower joint to the lower platform. Use normal thread-locking fluid. Note that, as each turn of the lower joint will alter the length of the actuator by 10 mm, the actuator will be extended around 150 mm as the universal joint is screwed in. Attach the supplied labels to the actuator and motor; the warning label close to the actuator fork and the appropriate axis label on the housing of the actuator. Reconnect the cables to the servomotor.
8.
9.
Commissioning
Follow the instructions below before commissioning after refitting an actuator.
Step
1.
Action
Check the manipulator and its surrounding equipment to ensure that all screws, nuts and bolts are tightened and that no foreign objects remain within the workspace. Recalibrate the robot. Failure to calibrate the robot will seriously affect the performance and can, in the worst case, cause damage to equipment. When the spare part replacements have been completed, ensure that the machine data folder is updated, specifying all details such as what has been replaced and when, part serial numbers and other related component data.
Note/Illustration
2.
Detailed in Installation Manual.
3.
When performing the first test run after a service activity (repair, installation or maintenance), it is vital that: - all normal safety equipment is installed properly, e.g. TPU enabling device.
Manipulator
Manipulator repairs
- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind any safety fences, etc. - special attention is paid to the function of the part previously serviced.
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Manipulator
Manipulator repairs
Removal of servomotor, axes 1-3
Location
The servomotors of axes 1, 2 and 3 are located on top of the actuators, as shown in the figure below.
xx0200000297
Servomotors, axes 1-3
Manipulator
Manipulator repairs
Required equipment Equipment, etc. Spare part no. Art. no.

Circuit Diagram 3HAC 16640-1
Note
Repair Manual, part 2
Safety

Please observe the following before commencing any repair work on the manipulator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them! - Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! - When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures. - Before removing, clean the work area and the components to be removed. - Place the removed components in a clean container.
Preparatory work
Follow the instructions below for preparatory work, before commencing the removal of a motor.
Step
1.
Action
Support the wrist before disconnecting the servomotor from the actuator, in order to keep the lower platform stable and reduce the risk of injury and/or damage. Switch off the power supply. The weight of an actuator servomotor is around 14kg (31lb). The actuator may therefore need to be secured using straps before being removed.
Note/Illustration
2. 3.
35
Manipulator
Manipulator repairs
Step
4.
Action
The actuator is free to turn when the servomotor is removed. If not correctly supported, the center unit will tend to move away from the corner with the removed actuator servomotor. In a vertically orientated manipulator, it is important to anchor the center tube to the surrounding equipment in order to prevent this. For manipulators in other orientations, try to anticipate the movement and secure accordingly.
Note/Illustration
Removal
The procedure below details how to remove the servomotor, axes 1, 2 and 3.
Step
1.
Action
Remove the eletric cabling from the servomotor. Move and secure the cabling so that it can not get damaged during the removal of the actuator. Unscrew the four fixing screws that hold the servomotor to the actuator housing, as shown in the figure below. Lift the servomotor straight up from the actuator.
Note/Illustration
2.
3.
Manipulator
Manipulator repairs
Step
4.
Action
If the toothed wheel ring stays with the backlash-free coupling attached to the servomotor, detach it and fit it to the coupling on the actuator.
Note/Illustration
A B D C
xx0200000302
5. Remove the coupling from the servomotor shaft.
A: Servomotor B: Fixing screws (4 pcs) C: Toothed wheel ring D: Backlash-free coupling on servomotor shaft
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Manipulator
Manipulator repairs
Refitting of servomotor, axes 1-3
Location
The servomotors of axes 1, 2 and 3 are located on top of the actuators, as shown in the figure below.
xx0200000297
Servomotors, axes 1-3
Manipulator
Manipulator repairs

Servomotor, axes 1-3 Circuit Diagram 3HAC 17152-1 3HAC 16640-1 Repair Manual, part 2
Note
Safety
Please read the following notations before the refitting.

Please observe the following before commencing any repair work on the manipulator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them! - Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! - When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures. Please observe the following when refitting components: - Carefully clean the mating surfaces. - Ensure that there are no damaged surfaces or other parts that need rectifying or replacing. - Replace all gaskets.
Refitting
The procedure below details how to refit the servomotor, axes 1-3.
39
Manipulator
Manipulator repairs
Step
1.
Action
Note/Illustration
Fit the backlash-free coupling Spare part no. specified above! onto the new servomotor, ensuring that the shaft enters the coupling to a depth of 10 mm, as shown in figure to the right.
A
xx0200000308
A: 10 0.5 mm
Manipulator
Manipulator repairs
Step
2.
Action
Note/Illustration
Assemble the servomotor, 4 pcs; tightening torque: 24Nm. backlash-free coupling and the actuator. Tighten the fixing screws. Note! The brake performance is reduced if the servomotor shaft is pushed in too far into the actuator. Make sure there B is a lash. Measure the distance between the coupling D C and the contact surface, according to the figure to the xx0200000302 right. A: Servomotor B: Fixing screws (4 pcs) C: Toothed wheel ring
D: Backlash-free coupling on the servomotor shaft

A B
79
xx0200000447
51
A: Coupling on actuator shaft B: Coupling on servomotor shaft 79 mm, required distance between coupling and contact surface on actuator. 51 mm, required distance between coupling and contact surface on servomotor.
3.
Reconnect the cables to the servomotor.
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Manipulator
Manipulator repairs
Commissioning
Follow the instructions below before commissioning after refitting motor on axes 1, 2 and 3.
Step
1.
Action
Note/Illustration
2.
3.
When performing the first test run after a service activity (repair, installation or maintenance), it is vital that: - all normal safety equipment is installed properly, e.g. TPU enabling device. - all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind any safety fences, etc. - special attention is paid to the function of the part previously serviced.
Manipulator
Manipulator repairs
Removal of servomotor, axis 4
Location
The motor unit of axis 4 is located inside the center tube sleeve, at the lower part of the center unit, as shown in the figure below.
B C
A
xx0200000299
A B C D E
Axis 4 motor unit (located beneath center tube sleeve) Center tube sleeve Spiral cable inspection cover Gimbal Lower platform
43
Manipulator
Manipulator repairs

Lifting bracket String Attach to the cabling to be able to feed it through the center tube while lifting. 3HAC 16640-1 Repair Manual, part 2
Note
Circuit Diagram
Safety

The center unit is very heavy and in a vertically orientated robot, there is a risk of pinching between the center tube and the axis 4 motor.
Manipulator
Manipulator repairs
Preparatory work
Follow the instructions below for preparatory work, before commencing the removal of the motor unit on axis 4.
Step
1.
Action
Run the actuators so that they are extended to around 500 mm in length. All actuators should have equal length. This is done in order to allow enough space between the center tube sleeve and the center tube. Position axes 4, 5 and 6 at 0respectively. Switch off the power supply.
Note/Illustration
2. 3.
Removal
The procedure below details how to remove the motor unit on axis 4. Make sure the preparatory work above is done before removing the actuator!
Step
1.
Action
Cut the straps and disconnect the cabling to axes 4, 5 and 6, at the top of the center tube. Also remove the cable guide for the cabling. Remove the top plate of the center tube. The cabling underneath the lid is still attached! Remove the lid carefully! Note the position of each connector and remove the cable connector holders from the lid. Attach a string to the cabling in order not to drop it into the center tube when lifting.
Note/Illustration
2.
See the figure below!
3.
45
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Manipulator repairs
Step
4.
Action
Remove the housing and the lower plate, exercising care with the cables inside the housing. See figure to the right for layout.
Note/Illustration
A B C D
xx0200000306
5. Fit the lifting tool to the center tube, ensuring that the cables can pass through the loop freely and not get caught. Remove the spiral cable cover on the back of center tube sleeve. Remove also the spiral cable inspection cover.
A: Top plate of center tube B: Cable connector holder C: Housing D: Lower plate E: Center tube
6.
Manipulator
Manipulator repairs
Step
7.
Action
Unscrew the 18 screws that hold the center tube to the axis 4 motor and remove the locating pin, center tube.
Note/Illustration
A B
D
xx0200000363
A: 6 pcs: M8. B: 12 pcs: M6. C: Locating pin, center tube D: Locating pin, center tube sleeve
On reassembly the same locating pin is refitted! 8. Lift the center tube, using a hoist or lift, Shown in the figure above! until the bottom of the center tube almost reaches the gimbal. When lifting the center tube, be very careful not to stretch or squash the cables inside. Eliminate the risk of stretching the cabling by feeding it through at the top at the same rate as the center tube is lifted, with the help of a string. Remove the cable clamp that holds the spiral cable in place.
9.
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Manipulator
Manipulator repairs
Step
10.
Action
Note/Illustration
Remove the 12 screws that hold the Shown in the figure above! center tube sleeve to the lower platOn reassembly the same locatform interface. ing pin is refitted! Remove the locating pin that positions the center tube sleeve. Lift the center tube sleeve, tilting the wrist slightly for increased accessibility.
11.
A B C
xx0200000307
12. 13. 14. Make a note of the position of the motor unit. Remove the spacer from the axis 4 motor unit. Unscrew the 8 screws that attach the motor unit to the center shaft and remove the motor unit. Check all surfaces to make sure they are free from damage and contamination before proceeding with the assembly routine.
A: center tube sleeve B: Spacer C: Axis 4 motor unit
15.
Manipulator
Manipulator repairs
Refitting of servomotor, axis 4
Location
The motor unit of axis 4 is located inside the center tube sleeve, at the lower part of the center unit, as shown in the figure below.
B C
A
xx0200000299
A B C D E
Axis 4 motor unit (located inside the center tube sleeve) Center tube sleeve Spiral cable inspection cover Gimbal Lower platform
49
Manipulator
Manipulator repairs

Servomotor, axis 4 Lifting bracket Circuit Diagram 3HAC 16640-1 Repair Manual, part 2 3HAC 17153-1
Note
Safety

Please observe the following before commencing any repair work on the manipulator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them! - Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! - When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures. Please observe the following when refitting components: - Carefully clean the mating surfaces. - Ensure that there are no damaged surfaces or other parts that need rectifying or replacing. - Replace all gaskets.
Refitting
The procedure below details how to refit the motor unit, axis 4.
Step
1.
Action
Note/Illustration
Fit the axis 4 motor unit to the center 8 pcs: tightening torque: 33 shaft and tighten the screws. Ensure it Nm. has the same orientation as the old one
Manipulator
Manipulator repairs
Step
2.
Action
Fit and align the spacer to the axis 4 motor unit.
Note/Illustration
A B C
xx0200000307
3. Refit the center tube sleeve, ensuring that the locating pin, center tube sleeve, has the correct orientation. Tighten the 12 screws that hold the sleeve. Refit the cable clamp for the spiral cable. Ensure that the spiral cable runs freely 360in either direction by manually turning the wrist and watching the cable through the inspection hole in the side of the center tube. Align the fixing holes in the axis 4 motor unit to the holes in the center tube sleeve by turning the wrist. Feed the cabling through the center tube (with the help of the string) and lower the center tube carefully in order not to squash the cables.
A: Center tube sleeve B: Spacer C: Axis 4 motor unit
Shown in the figure above! 12 pcs; tightening torque: 17Nm. Make sure to refit the correct locating pin!
4.
5.
6.
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Manipulator
Manipulator repairs
Step
7.
Action
Locate the center tube using the location pin, center tube, as reference and fit the 18 screws.
Note/Illustration
A B
D
xx0200000363
A: 6 pcs: M8; tightening torque: 40 Nm. B: 12 pcs: M6; tightening torque: 17 Nm. C: Locating pin, center tube D: Locating pin, center tube sleeve
Make sure to refit the correct locating pin! 8. Refit the spiral cable inspection cover and the spiral cable cover, including their sealings. Remove the lifting tool from the center tube. Shown in the figure above!
9.
Manipulator
Manipulator repairs
Step
10.
Action
Refit the lower plate and the housing to the top of the center tube, taking extra care not to squash any cables, or subject them to any undue stress.
Note/Illustration
A B C D
xx0200000306
11. Fit the cable connectors to the top plate, ensuring that the cables are orientated the same way as when they were removed. Fit the top plate to the housing. Refit the cable guide for the axes 4, 5 and 6 cabling and reconnect the cabling previously disconnected.
A: Top plate B: Cable connector holder C: Housing D: Lower plate E: Center tube
12. 13.
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Manipulator
Manipulator repairs
Commissioning
Follow the instructions below before commissioning after refitting the motor, axis 4.
Step
1.
Action
Note/Illustration
2.
3.
Manipulator
Manipulator repairs
Removal of lower joint
Location
The lower joint is located between the actuator and the lower platform, as shown in the figure below.
C D A
xx0200000298
A B C D
Lower joint (beneath the cover) Lower platform Actuator Calibration spacer
55
Manipulator
Manipulator repairs

Hook wrench
Note
3 mm pin
xx0200000350
Safety

Manipulator
Manipulator repairs
Preparatory work
Follow the instructions below for preparatory work, before commencing the removal of the lower joint.
Step
1.
Action
Run actuators to half way in length. All the actuators should also have an equal length. This is done in order to allow the actuator to retract when the lower joint is unscrewed. Switch off the power supply. In a vertically orientated manipulator the center unit will tend to move away from the corner with the removed lower joint. It is therefor important to anchor the center tube to the surrounding equipment in order to avoid this. For manipulators in other orientations, try to anticipate the movement and secure accordingly.
Note/Illustration
2. 3.
Removal
The procedure below details how to remove a lower joint. The procedure is the same for all actuators. Make sure the preparatory work above is done before separating the parts! Step
1.
Action
Use a heating gun to loosen the thread-locking substance, before removing the lower joint. Loosen the actuator piston from the lower joint with the hook wrenches. The actuator is top heavy and will tend to swing, once disconnected at the bottom. Ensure that the actuator is well anchored.
Note/Illustration
2.
Shown in the figure above! Specified above!
3. 4. 5.
Loosen the lower joint from the lower platform Shown in figure above! using a hook wrench, 3 mm pin. Specified above! Remove the lower joint and the cover. Remove the calibration spacer from the lower joint, in order to refit it onto the new joint!
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Manipulator
Manipulator repairs
Refitting of lower joint
Location
The lower joint is located between the actuator and the lower platform, as shown in the figure below.
C D A
xx0200000298
A B C D
Lower joint (beneath the cover) Lower platform Actuator Calibration spacer
Manipulator
Manipulator repairs

Lower joint Thread-locking substance

3HAC 17154-1
Note
Hook wrench
xx0200000350
Safety

Please observe the following before commencing any repair work on the manipulator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them! - Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! - When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures.
59
Manipulator
Manipulator repairs
Please observe the following when refitting components: - Carefully clean the mating surfaces. - Ensure that there are no damaged surfaces or other parts that need rectifying or replacing. - Replace all gaskets.
Refitting
The procedure below details how to refit the lower joint. The procedure is the same for all actuators.
Step
1. 2. 3.
Action
Note/Illustration
Fit the calibration spacer and the cover Spare part no. specified above! to the new lower joint. Fit the lower joint to the actuator, using normal thread-locking fluid. Refit the actuator by screwing the lower joint into the lower platform. Note that, as each turn of the lower joint will alter the length of the actuator by 10 mm, the actuator will be extended around 150 mm as the universal joint is screwed in.
Commissioning
Follow the instructions below before commissioning after refitting the lower joint.
Step
1.
Action
Check the manipulator and its surrounding equipment to ensure that all screws, nuts and bolts are tightened and that no foreign objects remain within the workspace. Recalibrate the robot. Failure to calibrate a robot will seriously affect the performance and can, in the worst-case, cause damage to equipment.
Note/Illustration
2.
Manipulator
Manipulator repairs
Step
3.
Action
When the spare part replacements have been completed, ensure that the machine data folder is updated, specifying all details such as what has been replaced and when, part serial numbers and other related component data.
Note/Illustration
61
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Manipulator repairs
Removal of wrist
Location
The wrist is located on the lower platform, as shown in the figure below.
E C
F A
xx0200000300
A B C D E F
Wrist Center tube Spiral cable inspection cover Gimbal Center tube sleeve Lower platform
Manipulator
Manipulator repairs

Lifting bracket Punch tool Lifting jack Used for the crossed roller bearing. Stroke of at least 100 mm.
Note
Safety

The wrist weighs 36 kg! All lifting equipment used must be dimensioned accordingly!
63
Manipulator
Manipulator repairs
Preparatory work
Follow the instructions below for preparatory work, before commencing the removal of the wrist unit.
Step
1.
Action
Run the actuators so that they are extended to around 500 mm in length. All the actuators should have equal length. This is done in order to allow enough space between the centre tube sleeve and the centre tube. Position axes 4, 5 and 6 at 0respectively. Switch off the power supply.
Note/Illustration
2. 3.
Manipulator
Manipulator repairs
Removal
The procedure below details how to remove the wrist. Make sure the preparatory work above is done before removing the wrist!
Step
1.
Action
Remove the 6 attachment screws that hold the axis 4 motor unit to the centre tube.
Note/Illustration
A B
D
xx0200000363
A: Attachment screws, axis 4 motor to centre tube: 6 pcs, M8 x 60. B: Attachment screws C: Locating pin, centre tube D: Locating pin, centre tube sleeve
2.
Remove the spiral cable cover on the Shown in the figure above! back of centre tube sleeve and the spiral cable inspection cover on the same sleeve. Remove the cable clamp that holds the spiral cable in place.
3.
65
Manipulator
Manipulator repairs
Step
4.
Action
Note/Illustration
Unscrew 10 of the 12 screws in the Shown in the figure above! wrist flange that hold the wrist to the lower platform. Turn the wrist to access all the screws. Leave one screw at the front and one at the rear of the wrist, but ensure that they are both accessible for removal without having to turn the wrist. Position the lifting jack underneath the wrist housing, in its extended position, so that it can lower the wrist at least 100 mm without being repositioned. Remove the final two screws. Lower the wrist gently until the screws that attach the centre shaft to the wrist are accessible. If the wrist appears to be stuck, it needs to be pressed out. Use two of the fixing holes for the wrist/lower platform joint, that are threaded M8 and lie 180in relation to each other. Note! Turn the wrist so that these holes are not aligned with the M6 holes in the lower platform, as this will damage the threads and hamper assembly at a later stage. If possible, insert a metal shim to protect the surface of the lower platform flange. Insert two M8 bolts, with at least 40 mm of thread, into the holes, and pull the wrist off the lower platform. Remove the screws and lower the wrist while disconnecting the cabling. Note! When removing the wrist: make sure it is lowered carefully, following the same orientation when mounted. If tilted, the interface of the wrist and the lower platform may be damaged!
5.
6. 7.
xx0200000364
8.
Manipulator
Manipulator repairs
Refitting of wrist
Location
The wrist is located on the lower platform, as shown in the figure below.
E C
F A
xx0200000300
A B C D E F
Wrist Center tube Spiral cable inspection cover Gimbal Center tube sleeve Lower platform
67
Manipulator
Manipulator repairs

Wrist Punch tool

3HAC 17155-1
Note
Used for the crossed roller bearing. Stroke of at least 100 mm.
Lifting jack
Safety

Please observe the following before commencing any repair work on the manipulator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them! - Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! - When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures. Please observe the following when refitting components: - Carefully clean the mating surfaces. - Ensure that there are no damaged surfaces or other parts that need rectifying or replacing. - Replace all gaskets. The wrist weighs 36 kg! All lifting equipment used must be dimensioned accordingly!
Manipulator
Manipulator repairs
Refitting
The procedure below details how to refit the wrist.
Step
1.
Action
Replace the o-ring on the centre shaft with the new one that is included in the spare parts kit. Ensure that the o-ring is lubricated prior to fitment.
Note/Illustration
xx0200000367
2.
Ensure that the jack is correctly positioned underneath the lower platform, and that it is in its lowest position. Place the wrist on the jack. Reconnect the cabling. Elevate the wrist with the jack and guide it so that it fits onto the centre shaft. Ensure that the cabling is guided into the correct position and does not get jammed. Note! Make sure the wrist is elevated in the same direction that the centre tube is pointing, so that the interfaces are not damaged! Attach the centre shaft to the wrist using the 12 screws. 12 pcs; tightening torque: 17 Nm.
3. 4.
5.
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Manipulator repairs
Step
6.
Action
Note/Illustration
Lift the wrist with the jack until it is possi- 12 pcs; tightening torque: 10 ble to fasten the attachment screws Nm. through the wrist flange into the lower Shown in the figure above! platform. Press the wrist to its topmost position by tightening two of the attachment screws, 180in relation to each other. Check that the bearing runs smoothly by turning the wrist manually. Refit the spiral cable clamp and ensure that the spiral cable twists freely throughout the 360of the axis 4 rotation. It must not catch or have any tendency to rub or over-tighten, as this will drastically shorten the life of the cable. Align the holes in the centre tube sleeve with the holes in the axis 4 motor unit by turning the wrist. Fit the six M8 screws. Tighten them as detailed to the right. Shown in the figure above!
7.
8.
9. 10.
6 pcs: M8; tightening torque: 40 Nm.
Refit the spiral cable cover and the spiral Shown in the figure above! cable inspection cover with their sealings.
Commissioning
Follow the instructions below before commissioning after refitting.
Step
1.
Action
Check the manipulator and its surrounding equipment to ensure that all screws, nuts and bolts are tightened and that no foreign objects remain within the workspace. Recalibrate the robot. Failure to calibrate the robot will seriously affect the performance and can, in the worst case, cause damage to equipment.
Note/Illustration
2.
Manipulator
Manipulator repairs
Step
3.
Action
When the spare part replacements have been completed, ensure that the machine data folder is updated, specifying all details such as what has been replaced and when, part serial numbers and other related component data.
Note/Illustration
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Manipulator repairs
Removal of center unit
Location
The center unit includes the center tube, wrist, spiral cable, linear guide and axis 4 motor unit. It is located in the center of the manipulator, as shown in the figure below. When removed, the housing and the gimble is left mounted on the center unit, as shown in the figure below.
C I
H G
E A F
xx0200000301
A B C D E
Center unit Wrist unit Center tube Axis 4 motor unit (inside center tube sleeve) Lower platform
F G H I
Lower joint Upper platform Gimbal Linear guide
Manipulator
Manipulator repairs

Hook wrench
Note
3 mm pin
xx0200000350
Safety

The center unit weighs over 100 kg! All lifting equipment must be dimensioned accordingly!
73
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Manipulator repairs
Preparatory work
Follow the instructions below for preparatory work, before commencing the removal of the center unit.
Step
1.
Action
Run the actuators so that they are extended to around 300 mm in length. All the actuators should have equal length. This is done in order to allow enough space for the center unit to be removed. Position axes 4, 5 and 6 at 0respectively. Switch off the power supply.
Note/Illustration
2. 3.
Removal
The procedure below details how to remove the center unit. Make sure the preparatory work above is done before removal!
Step
1.
Action
Disconnect the cabling running into the center unit, at the top of the center unit.
Note/Illustration
Manipulator
Manipulator repairs
Step
2.
Action
Secure the center unit with a strap attached to a hoist or lift. Fasten the strap around the body of the center tube just below the upper housing so that it hangs well balanced, in such a way that the center unit will be easy to handle. Note! The center unit weighs over 100 kg and must be secured properly when the gimbal and actuator joints are disconnected as the unit will tend to move suddenly as it is top heavy.
Note/Illustration
xx0200000365
3.
Use a heating gun at the lower joint, to loosen the thread-locking substance before removing the joint. Remove the actuators from the Shown in the figure above! lower platform by disconnect- Specified above! ing the lower joints from the lower platform using the hook wrench. Note! The actuators are top heavy and will turn when released from the lower platform. Ensure that they are fastened before releasing them after removal.
4.
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Step
5.
Action
Note/Illustration
Remove the center unit from Shown in the figure above! the upper platform by removing the 4 attachment screws, located as shown in the figure to the right. Note! The gimbal weighs approximately 20 kg, be careful A when removing the attachment screws!
xx0200000309
A: Attachment screws that hold the gimbal to the upper platform (4 pcs)
6.
Lower the gimbal to the bottom Shown in the figure above! of the run of the linear guides so that it rests securely. Secure it to the center unit so that it does not turn or move suddenly when the center unit is released. Lower the center unit with the hoist.
7.
Manipulator
Manipulator repairs
Refitting of center unit
Location
The center unit includes the center tube, wrist and axis 4 motor unit. It is located in the center of the manipulator, as shown in the figure below. When removed, the housing and the gimble is left mounted on the center unit, as shown in the figure below.
C I
H G
E A F
xx0200000301
A B C D E
Center unit Wrist Center tube Axis 4 motor unit (inside center tube sleeve) Lower platform
F G H I
Lower joint Upper platform Gimbal Linear guide
77
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Manipulator repairs

Center Unit Thread-locking substance

3HAC 17156-1
Note
Hook wrench
xx0200000350
Safety

Please observe the following before commencing any repair work on the manipulator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them! - Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! - When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures.
Manipulator
Manipulator repairs
Please observe the following when refitting components: - Carefully clean the mating surfaces. - Ensure that there are no damaged surfaces or other parts that need rectifying or replacing. - Replace all gaskets. The center unit weighs over 100 kg! All lifting equipment must be dimensioned accordingly!
Refitting
The procedure below details how to refit the center unit.
Step
1. 2.
Action
Lift the center unit in position with the hoist.
Note/Illustration
Insert the four screws that Shown in the figure above! hold the gimbal to the upper platform, but do not tighten them. Just screw them in to the point where it is still possible to move the gimbal in relation to the upper platform.
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Step
3.
Action
Push the gimbal to the left (as seen when facing the front of the robot) so that the surfaces of the master lie flush, as shown in the figure to the right.
Note/Illustration
A B C
xx0200000310
4. 5. Tighten the 4 screws.
A: center unit B: Gimbal C: Upper platform D: Master E: Direction for pushing the gimbal
4 pcs; tightening torque: 40 Nm.
Refit the actuators by Shown in the figure above! screwing the lower joint of each actuator to the lower platform, with the hook wrench and using normal thread-locking fluid. Note that, as each turn of the lower joint will alter the length of the actuator by 10 mm, the actuator will be extended around 150 mm as the universal joint is screwed in.
Manipulator
Manipulator repairs
Commissioning
Follow the instructions below before commissioning after refitting the center unit.
Step
1.
Action
Check the manipulator and its surrounding equipment to ensure that all screws, nuts and bolts are tightened and that no foreign objects remain within the workspace.
Note/Illustration
2.
Recalibrate the robot. Detailed in Installation Failure to calibrate the robot will seriously affect Manual. the performance and can, in the worst case, cause damage to equipment. When the spare part replacements have been completed, ensure that the machine data folder is updated, specifying all details such as what has been replaced and when, part serial numbers and other related component data.
3.
81
Manipulator
Manipulator repairs
Removal of spiral cable
Location
The spiral cable is located inside the center tube, running from the top of the manipulator to the wrist unit.
C A
xx0200000312
A B C
Spiral cable Spiral cable inspection cover Wrist unit
Manipulator
Manipulator repairs

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

The center unit is very heavy and in a vertically orientated robot, there is a risk of pinching between the center tube and the axis 4 motor.
83
Manipulator
Manipulator repairs
Preparatory work
Follow the instructions below for preparatory work, before commencing the removal of the spiral cable.
Step
1.
Action
Run the actuators so that they are extended to around 500 mm in length. All the actuators should have equal length. This is done in order to allow enough space for the center tube to be removed. Position axes 4, 5 and 6 at 0 respectively. Switch off the power supply.
Note/Illustration
2. 3.
Removal
The procedure below details how to remove the spiral cable. Make sure the preparatory work above is done before removal!
Step
1. 2. 3.
Action
Remove the axis 4 motor unit. Remove the wrist unit. Remove the cable clamp that holds the spiral cable to the center shaft and remove the spiral cable.
Note/Illustration
Detailed in Removal of servomotor, axis 4. Detailed in Removal of wrist unit.
Manipulator
Manipulator repairs
Refitting of spiral cable
Location
The spiral cable is located inside the center tube, running from the top of the manipulator down to the wrist unit.
C A
xx0200000312
A B C
Spiral cable Spiral cable inspection cover Wrist unit
85
Manipulator
Manipulator repairs

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

3HAC 17157-1
Note
Safety

Please observe the following before commencing any repair work on the manipulator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them! - Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! - When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures. Please observe the following when refitting components: - Carefully clean the mating surfaces. - Ensure that there are no damaged surfaces or other parts that need rectifying or replacing. - Replace all gaskets. The center unit is very heavy and in a vertically orientated robot, there is a risk of pinching between the center tube and the axis 4 motor.
Manipulator
Manipulator repairs
Refitting
The procedure below details how to refit the spiral cable.
Step
1.
Action
Note/Illustration
Fit the new spiral cable and refit Spare part no. specified above! the cable clamp that holds the spiral cable to the centre shaft. Make sure that the spiral cable is properly attached so that it can not run up and down on the shaft. Press down the spiral cable so that the first bend is tightly secured against the upper surface of the shaft as shown in the figure to the right!
xx0200000366
2. 3.
Refit the wrist unit. Refit the axis 4 motor unit.
Detailed in Refitting of wrist unit. Detailed in Refitting of servomotor, axis 4.
Commissioning
Follow the instructions below before commissioning after refitting the spiral cable and wrist unit.
Step
1.
Action
Check the manipulator and its surrounding equipment to ensure that all screws, nuts and bolts are tightened and that no foreign objects remain within the workspace.
Note/Illustration
87
Manipulator
Manipulator repairs
Step
2.
Action
Note/Illustration
Recalibrate the robot. Detailed in Installation Failure to calibrate the robot will seriously affect Manual. the performance and can, in the worst case, cause damage to equipment. When the spare part replacements have been completed, ensure that the machine data folder is updated, specifying all details such as what has been replaced and when, part serial numbers and other related component data.
3.
Manipulator
Distribution box repairs
Section B: Distribution box repairs Replacement of battery, distribution box
Location
The battery is located in the distribution box as shown in the figure below.
xx0200000394
A B
Serial measurement card Battery
89
Manipulator

Battery 4944026-4
Note
Safety
Please read the following notations before the replacement.

Please observe the following before commencing any repair work on the controller or units connected to the controller: Turn off all electric power supply to the cabinet! Many components inside the cabinet or inside any external units are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Removal
The procedure below details how to remove the battery from the distribution box.
Step
1. 2. 3.
Action
Note the position of the battery and cable ties. Remove the battery connector connecting the battery to the serial measurement circuit board. Cut the two cable ties and remove the battery. The battery must be disposed of through the appropriate recycling channels.
Note/Illustration
Manipulator
Refitting
The procedure below details how to refit the battery to the distribution box.
Step
1.
Action
Place the new battery on top of the serial measurement card cover. Use cable ties to fix the battery. Connect the electrical connector.
Note/Illustration
Part no. specified above! Shown in the figure above!
2. 3.
91
Manipulator
Replacement of serial measurement card, distribution box
Location
The serial measurement card is located in the distribution box as shown in the figure below.
xx0200000394
A B
Serial measurement card Battery
Manipulator

Serial Measurement card

3HAC 14505-1
Note
Safety

Removal
The procedure below details how to remove the serial measurement card from the distribution box.
Step
1. 2. 3. 4.
Action
Remove the four electrical connectors attached to the serial measurement card. Remove the three screws holding the card and the battery to the enclosure. Remove the serial measurement card together with the battery. Remove the battery from the card.
Note/Illustration
Shown in the figure above! The battery is refitted on to the new card.
93
Manipulator
Refitting
The procedure below details how to refit the serial measurement card to the distribution box.
Step
1.
Action
Fit the battery to the new serial measurement card.
Note/Illustration
2. 3. 4.
Carefully fit the card and the battery in place. Refit the three screws holding the serial measurement card and the battery to the enclosure. Refit the four electrical connectors.
Manipulator
Replacement of brake release card, distribution box
Location
The brake release card is located in the distribution box as shown in the figure below.
xx0200000393
A B
Brake release card Brake release buttons
95
Manipulator

Brake Release card

3HAC 0017-1
Note
Safety

Removal
The procedure below details how to remove the brake release card from the distribution box.
Step
1. 2. 3.
Action
Remove the three electrical connectors attached to the brake release card. Remove the four screws holding the card to the enclosure. Remove the brake release card.
Note/Illustration
Manipulator
Refitting
The procedure below details how to refit the brake release card to the distribution box.
Step
1.
Action
Carefully fit the new brake release card in place. Refit the four screws holding the brake release card to the enclosure. Replace the three electrical connectors. Note! It is very important that all screening is reconnected correctly in order to achieve maximum performance from the equipment.
Note/Illustration
2. 3.
97
Manipulator
Controller repair
Chapter 4:Controller
Introduction
Definitions
This chapter details all repair activities recommended for the controller. It is made up of separate units, each detailing a specific repair activity, e.g. Removal or Refitting of a certain component in the controller. Each unit contains all information required to perform the activity, e.g. spare parts numbers, required special tools and materials. The chapter is divided into:
Removal instructions for all components Refitting instructions for all components Remaining instructions
99
Controller repair
Putting the computer unit in the service position
Location of computer unit
The computer unit is located as shown in the figure below.
A
xx0200000105
Computer unit
Opening
The procedure below details how to open the computer unit.

Please observe the following before commencing any repair work on the manipulator: - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! - Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. securing the lower arm with fixtures before removing motor, axis 2.
Controller repair
Step
1.
Action
Make sure the ESD-wrist band is worn and connected to ground. Disconnect all connectors/ cables and make sure they do not obstruct pulling the computer unit out. Unscrew the transport locks in both corners of the computer unit. This is done by turning the screw two turns (see position 1 in the figure) and pushing the lock washers towards the screw (see position 2). Lift the two handles and push them together to release the computer unit (see position 1 in the figure).
Note/Illustration
2.
3.
xx0200000016
4.
xx0200000017
5.
Push the locking device on See the figure above! the front of the computer unit to the right (see position 2 in the figure).
101
Controller repair
Step
6.
Action
Pull the computer unit out of the cabinet until it locks in its end position. Then swing it to the left as shown in the figure.
Note/Illustration
xx0200000018
7.
If work is to be performed on the computer unit while in the service position, it must be locked in this position. This is done by placing the puck (located on the lower left side) on the metal bar. Alternatively, the computer unit may be lifted straight up and placed on a work bench.
Closing
The procedure below details how to close the computer unit.

Please observe the following before commencing any repair work on the manipulator: - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! - Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. securing the lower arm with fixtures before removing motor, axis 2.
Step
1.
Action
Swing the computer unit back into position and secure it.
Note/Illustration
See the figure above! Also see the procedure above!
Controller repair
Replacement of air filter, controller
Location of air filter
The air filter is located in the air filter magazine in the front hatch.
A
xx0200000284
Air filter magazine

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

3HAB 8028-1
Note
103
Controller repair
Removal, air filter
The procedure below details how to remove the air filter.
Step
1.
Action
Open the bottom of the air filter magazine as shown in the figure.
Note/Illustration
xx0200000001
2. 3.
Unlock the lower springs. Lower the magazine and remove. Remove the old filter by releasing the lock shackle and lifting it. Note! In cases of less contamination, the air filter may be cleaned and refitted. The procedure for this is detailed in section "Cleaning the air filter, controller" in the Maintenance Manual.
xx0200000003
Refitting, air filter
The procedure below details how to refit the air filter.
Step
1.
Action
Note/Illustration
Fit the air filter in the magazine. Art. no. is specified above!
Controller repair
Step
2.
Action
Fit the spring at the top of the air filter magazine into the cabinet door and push upwards inwards. Push until the lower springs snap into the cabinet door.
Note/Illustration
xx0200000006
105
Controller repair
Replacement of battery unit, controller
Location of battery unit
The battery unit is located at the bottom of the controller.
A
xx0200000103
Battery unit

Battery unit
Spare part no. Art no.

3HAC 5393-2
Note
To be replaced as a complete unit
Controller repair
Equipment, etc.
Note
Removal, battery unit
The procedure below details how to remove the battery unit.
Please observe the following before commencing any repair work on the controller: Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Step
1.
Action
Remove the battery unit by unscrewing its attachment screws (1).
Note/Illustration
X1
X1
X1
X1
X2
X2
X2
X2
X3
xx0200000004
2.
Pull the battery unit out.
107
Controller repair
Step
3.
Action
Disconnect the three cables from the battery unit.
Note/Illustration
xx0200000005
Refitting, battery unit
The procedure below details how to refit the battery unit.
Step
1. 2. 3.
Action
Place the battery unit close to its position. Reconnect the cables and push the unit into position. Secure it with the attachment screws.
Note/Illustration
Art. no. specified above! See illustration above! See illustration above! See illustration above!
Controller repair
Replacement of I/O and gateway units
Location of I/O and gateway units
The I/O and gateway units are located as shown in the figure below.
xx0200000009
A B
I/O and gateway units located beneath the top cover of the cabinet Four available slots for I/O and gateway units
109
Controller repair

Digital 24 VDC I/O Analog I/O AD Combi I/O Digital 120 VAC I/O Digital I/O with relays Gateway for Allen-Bradley, RIO Gateway for Interbus-S Gateway for Profibus DP, slave unit

3HAB 7229-1 3HAB 7230-1 3HAB 7231-1 3HAB 9669-1
Note
DSQC 328 DSQC 327 DSQC 320 DSQC 332
3HNE 00554-1 DSQC 355
3HNE00025-1 DSQC 350 3HNE00006-1 DSQC 351 3HNE00009-1 DSQC 352
Removal
The procedure below details how to remove an I/O or gateway board.

Step
1.
Action
Note/Illustration
Disconnect any connec- The actual number of connectors vary tors from the unit. Note depending on type of unit. which connector goes where, to facilitate reassembly.
Controller repair
Step
2.
Action
Lift the unit until the upper claw, that holds the unit to the rail, is released. Use: a screwdriver when replacing I/O units (position 2a in the figure). by hand when replacing a gateway unit (position 2b in the figure).
Note/Illustration
2a
3a
2b
3b
xx0200000010
3.
With the upper claw released, tip the unit away from the mounting rail and remove it (positions 3a and 3b in the figure).
Refitting
The procedure below details how to refit an I/O or gateway board.

Step
1.
Action
Hook the unit back onto the mounting rail and snap it gently in position.
Note/Illustration
111
Controller repair
Step
2.
Action
Reconnect all connectors disconnected during removal.
Note/Illustration
Controller repair
Replacement of bleeder resistor
Location of bleeder resistor
The bleeder resistor is located behind the drive units, as shown in the figure below.
xx0200000007
A B C D E
Drive units Bleeder resistor unit System fan unit Rectifier (drive unit) Power supply unit
113
Controller repair

Bleeder resistor

3HAC 4560-5
Note
Removal
The procedure below details how to remove the bleeder resistor.

Step
1. 2. 3.
Action
Note/Illustration
Swing the power supply Detailed in section "Replacement of power unit out of the way. supply unit". Remove the drive units. Detailed in section "Replacement of drive units and rectifier". Disconnect the cable secured on top of the bleeder resistor unit (see position 1 in the figure).
1 2
xx0200000015
4.
Remove the bleeder resistor unit from the enclosure (see position 2 in the figure).
Controller repair
Refitting
The procedure below details how to refit the bleeder resistor.

Step
1.
Action
Fit the bleeder resistor into position and secure it with the spring. Secure the cable disconnected during disassembly. Refit the drive unit.
Note/Illustration
Art. no. specified above! Also see the figure above!
2. 3.
Detailed in section "Replacement of drive units and rectifier". Detailed in section "Replacement of power supply unit".
4.
Swing the power supply unit back into position.
115
Controller repair
Replacement of mass storage memory
Location of mass storage memory
The mass storage memory is located in the computer system, which is shown in the figure below.
A
xx0200000105
Computer system
Required equipment Equipment, etc. Spare part no. Art. no. Note
Mass storage memory, 3HAC 7519-2 64 MB Mass storage memory, 3HAC 7519-3 128 MB
Controller repair
Equipment, etc.
Note
Removal
The procedure below details how to remove the mass storage memory.
Step
1. 2.
Action
Put the computer unit in the service position. Remove the cover from the right side of the computer system by unscrewing the ten M5 screws (item 1 in the figure).
Note/Illustration
Detailed in section "Putting the computer in the service position".
1
xx0200000019
3.
Disconnect the connectors X1 and X2 from the front of the mass storage memory (item 2 in the figure).
See figure above!
117
Controller repair
Step
4.
Action
Note/Illustration
Remove the mass storage See figure above! memory by unscrewing its M4 attachment screws as shown in the figure (items 3 and 4 in the figure).
Refitting
The procedure below details how to refit the mass storage memory.
Step
1.
Action
Note/Illustration
Fit the mass storage mem- Art. no. is specified above! ory in position and secure it 1 with its M4 attachment screws (items 3 and 4 in the figure)
3
xx0200000019
2.
Reconnect connectors X1 See the figure above! and X2 to the front of the computer unit (item 2 in the figure).
Controller repair
Step
3.
Action
Note/Illustration
Refit the cover on the right See the figure above! side of the computer unit and secure it with its ten M5 attachment screws (item 1 in the figure). Put the computer system Detailed in section "Putting the computer in back in its regular operation the service position". position.
4.
119
Controller repair
Replacement of internal cooling fan
Location of internal cooling fan
The internal cooling fan is located in the computer system, which is shown in the figure below.
A
xx0200000105
Computer system

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

3HAC 6655-1
Note
Two fans required These procedures include references to the tools required.
Controller repair
Removal
The procedure below details how to remove the internal cooling fan.
Step
1.
Action
Put the computer unit in the service position.
Note/Illustration
Detailed in "Putting the computer in the service position".
121
Controller repair
Step
2.
Action
Disconnect the connector E5 or E6 respectively, depending on which fan is to be replaced.
Note/Illustration
E
xx0200000020
3. Remove the internal cooling fan inwards by gently pressing the locking tabs upwards.
A: Upper fan B: Lower fan C: Locking tabs D: Connector E5 E: Connector E6
See the figure above!
Refitting
The procedure below details how to refit the internal cooling fan.
Please observe the following before commencing any repair work on the controller: Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it!
Controller repair
Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar. Many module and unit fronts are fitted with a special ESD protection button for connection of the bracelet. Use it!
Step
1.
Action
Note/Illustration
Tip the internal cooling fan with its top towards Art. no. specified above! the cabinet wall and fit it into the hole (see the figure).
xx0200000021
2. With the wall between the upper lock spring hooks, push the fan unit upward and inward until the locking tab snaps to the wall.
A: Push direction
See the figure above!
123
Controller repair
Step
3. 4.
Action
Reconnect the connector E5 or E6 respectively, depending on which fan was replaced. Put the computer unit back in the regular operation position.
Note/Illustration
Detailed in "Putting the computer in the service position".
Controller repair
Replacement of drive units and rectifier
Location of drive units and rectifier
The drive units and rectifier are located as shown in the figure below.
xx0200000007
A B C D E
125
Controller repair

Drive unit (rectifier) Drive unit, axes 1-6 Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.

3HAB 8101-17 3HAB 8101-18
Note
DSQC 545A DSQC 546A These procedures include references to the tools required.
Removal
The procedure below details how to remove the drive units.

Step
1.
Action
Swing the power supply unit out of the way.
Note/Illustration
Detailed in section "Replacement of power supply unit"
Controller repair
Step
2.
Action
Disconnect connectors X1 and X2, four connectors each (see position 1 in the figure).
Note/Illustration
xx0200000013
3.
Remove the power supply See figure above! bar in front of the drive units (see position 2 in the figure). Lift the spring to release the drive unit and pull it slightly outwards (see position 3 in the figure).
4.
xx0200000014
5.
Tip it out and remove it (see position 4 in the figure).
See figure above!
127
Controller repair
Refitting
The procedure below details how to refit the drive units.

Step
1. 2. 3. 4.
Action
Fit the unit into position and secure it with the spring. Refit the power bar in front of the unit. Reconnect all connectors X1 and X2.
Note/Illustration
Also see figure above!
Swing the power supply unit back into position. Detailed in section "Replacement of power supply unit"
Controller repair
Replacement of system fan unit
Location of system fan unit
The system fan unit is located as shown in the figure below.
xx0200000007
A B C D E
129
Controller repair

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

3HAC 12924-2
Note
Removal
The procedure below details how to remove the system fan unit.
Step
1. 2.
Action
Remove the bleeder resistor unit. Disconnect the cable (see position 1 in the figure).
Note/Illustration
Detailed in "Replacement of bleeder resistor" in the Repair Manual.
xx0200000008
Controller repair
Step
3.
Action
Pull the back of the system fan unit upwards to free it and then tip it out of the enclosure (see position 2 in the figure).
Note/Illustration
Refitting
The procedure below details how to refit the system fan unit.
Step
1. 2.
Action
Note/Illustration
Fit the system fan unit into position and Art. no. specified above! secure it (see position 2 in the figure above). Reconnect the cable disconnected during disassembly (see position 1 in the figure above). Refit the bleeder resistor unit. Detailed in section "Replacement of bleeder resistor" in the Repair Manual.
3.
131
Controller repair
Replacement of power supply unit
Location of power supply unit
The power supply unit is located as shown in the figure below.
xx0200000011
A B
Power supply unit locking spring (view from front) Power supply unit folded out from the cabinet (view from above)

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

3HAB 4297-1
Note
DSQC 506 These procedures include references to the tools required.
Controller repair
Removal
The procedure below details how to remove the power supply unit.
Step
1.
Action
Note/Illustration
Push the power supply Shown in figure above! unit locking spring down to release the power supply unit. Swing the unit out of the cabinet. Remove the cable straps on top of the power supply unit (see position 1 in the figure). Shown in figure above
2. 3.
xx0200000012
4.
Disconnect the cables at the back of the unit (see position 2 in the figure). Remove the screw (see position 3 in the figure).
5.
133
Controller repair
Step
6.
Action
Lift the unit straight up to release it from the hooks and remove it outwards (see position 4 in the figure).
Note/Illustration
Refitting
The procedure below details how to refit the power supply unit.
Step
1.
Action
Fit the power supply unit into position onto its hooks and secure it with the attachment screws (see position 3 and 4 in figure in the section Removal). Reconnect all connectors disconnected during removal (see position 2 in figure). Secure the cables on top of the unit with new cable straps (see position 1 in figure). Swing the unit back into the cabinet and secure it with the locking spring.
Note/Illustration
Art. no. specified above!
2. 3. 4.
Circuit Diagram, IRB 940 Tricept
Chapter 5:Circuit Diagram, IRB 940 Tricept

Introduction
Definitions
This chapter contains all the circuit diagrams for the IRB 940 Tricept.
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135
Circuit Diagram, IRB 940 Tricept - =M1/2, Potentials from control
contact R1 SMB
+EC1
en0200000410
contact R1 MP
+EC1
=M1/2, Potentials from control

136
+EC1
D6 9.5 Serial measuring board R2.SMB1-4 A3 A4 D8 A5 A6 PE D10 PE PE C3 PE C1
4.0
-R1MP
AWG16 yel/gr
A1
A2
-SMB
4.3 PE1
-XP1-4
14
15
18
-XTPE
PE PE PE PE
AWG16 grey
AWG16 yel/gr AWG20 blue
AWG20 blue
AWG22 blue
-XM1 CE
A C D E G H
-XR1
CE
WM1
10
WR1
+M1
C D E G F H J K L M CE
Motor axis 1
-XM1.1
-XR1.1
-B1 -RT1 -Y1

-
M 3 PE
Resolver 1
www.cadfamily.com EMail:cadserv21@hotmail.com 3HAC 16640-1 The document is for study only,if tort to your rights,please inform us,we will delete =M1/3, Axis 1
en0200000411
Circuit Diagram, IRB 940 Tricept - =M1/3, Axis 1
137
+EC1
A9 A10 A11 A12 9.5 Serial measuring board C5 C4
3.0
-R1MP
A7
A8
-SMB
R2.SMB1-4
3.4
5.3
PE1 -XTPE
PE PE
PE1
-XP1-4
16
17
19
AWG16 grey
AWG20 blue
AWG22 blue
-XM2
C D E F G J K L M H CE
-XR2
CE
WM2
10
WR2
+M2
C D E F G H J K L M CE
Motor axis 2
-XM2.1
-XR2.1
-B2 -RT2 -Y2

Resolver 2
M
PE
en0200000412
138
+EC1
B2 9.5 Serial measuring board R2.SMB1-4 C15 C7 C6
3.0
-R1MP
A13 A14 C13 A15 A16 C14 B1
-SMB
4.3
6.3
PE1 -XTPE
PE PE
PE1
-XP1-4
9
21
10
22
20
AWG16 grey
AWG20 blue
AWG22 blue
-XM3
CE
-XR3
CE
WM3
10
WR3
+M3
C D E F G H J K L M CE
Motor axis 3
-XM3.1
-XR3.1
-B3 -RT3 -Y3

Resolver 3
PE
en0200000414
139
+EC1
B4 D12 D13 C9 C8 9.5 Serial measuring board R2.SMB3-6 B5
3.0
-R1MP
B3
D11
-SMB
5.3
7.3
PE1 -XTPE
PE
PE1
-XP3-6
2
14
15
18
AWG16 grey
AWG16 yel/gr
AWG20 blue
AWG20 blue
AWG22 blue
-XM4
C E G J K L M CE
-XR4
CE
WM4
10
WR4
-XM4.1
L
A E G J K
M CE
-XR4.1
Wmotor4
-XMTR4
2 3 4 8
Wmotor4.1
-XMTR4
Wmotor4.1
12
13
15
14
11
10
+M4
W + PE
Motor axis 4
-B4 -RT4 -Y4

Resolver 4 -
en0200000415
140
+EC1
B6 C11 C10 9.5 Serial measuring board R2.SMB3-6 D14 B8 D9
3.0
-R1MP
B7
D15
-SMB
6.3
8.3
PE1 -XTPE
PE
PE1
-XP3-6
16
17
19
AWG16 grey
AWG16 yel/gr
AWG20 blue
AWG20 blue
AWG22 blue
-XM5
C G K CE L J M E
-XR5
CE
WM5
10
WR5
-XM5.1
C G K L J E
M CE
-XR5.1
Wmotor_5-6 Spiral 28x 2 12

10
-XMTR5-6
3 11
18 Wmotor6_and_brake 5
Wmotor5 18x
-XMTR5-6 -X5
1 2 Wbrake5
21
22
24
23
20
19
25
Wmotor5
+M5
+
Motor axis 5
-B5 -RT5 -Y5

Resolver 5 -
PE
en0200000416
141
+EC1
B10 9.5 Serial measuring board R2.SMB3-6 B11 C2 C12
3.0
-R1MP
B9
-SMB
7.3
9.1
PE1 -XTPE
PE
PE1
-XP3-6
9
21
10
22
20
AWG16 grey
AWG16 yel/gr
AWG20 blue AWG20 blue
AWG22 blue
-XM6
C CE E G J K L M
-XR6
CE
WM6
10
WR6
-XM6.1
C E G J K L
M CE
-XR6.1
Wmotor_5-6
-XMTR5-6
6 7 16 14
15
27
36
30
31
33
32
29
28
34
motor6_and_brake 5
+M6
W + PE
Motor axis 6
-B6 -RT6 -Y6

Resolver 6
en0200000417
142
EC1
D3 D2 D4
3.0
R1MP D1
B C D E F
R1SMB A
M CE
AWG20 blue
WSMB canbus 8x
-G
7,2VDC/4Ah Battery blue black
8.3/ PE PE PE
PE1
-XTPE -SMB
3.6 Serial measuring board
AWG10 yel/gr
R2SMB
CE
R2G 2
earth conn. (screw) distribution box chassie
earth conn. (screw) cover
earth conn. (screw) mounting plate
earth conn. (screw) distribution box outside
AWG10 5m yel/gr
=M1 +FO
earth conn. (screw) manip. foot
www.cadfamily.com EMail:cadserv21@hotmail.com 3HAC 16640-1 The document is for study only,if tort to your rights,please inform us,we will delete =M1/9, Serial Measure board, Earth connections
en0200000418
Circuit Diagram, IRB 940 Tricept - =M1/9, Serial Measure board, Earth connec-
143
Circuit Diagram, IRB 940 Tricept - =M1/10 Brake release unit
B16 B12 B13
AWG16 blue
B14 B15
-R1MP
AWG16 blue
-X8
Brake release unit
-BU
-X9
10
11
en0200000419
+EC1
3.0
=M1/10 Brake release unit

144
-X10
Circuit Diagram, S4Cplus
Chapter 6:Circuit Diagram, S4Cplus

Introduction
Definitions
This chapter contains the circuit diagram for the controller S4Cplus. The chapter is divided into the separate systems..
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145
Circuit Diagram, S4Cplus - Sheet 1-1.
System 1: General information
www.cadfamily.com EMail:cadserv21@hotmail.com 3HAC 16640-1 The document is for study only,if tort to -your rights,please inform us,we will delete
Sheet 1-1. Block Diagram
146
Sheet 1-2. View of Control Cabinet
147
Sheet 1-3. View of Control Cabinet
148
Sheet 1-4. Designation
149
150
System 2: Mains Connection and Power Supply
Sheet 2-1. Mains Connection
151
Sheet 2-2. Transformer Unit
152
Sheet 2-3. Power Supply
153
Sheet 2-4. Power Supply
154
Sheet 2-5. External transformer unit 200-500V IRB6600/7600
155
Sheet 2-6. Transformer unit 400-475V IRB 6600/7600
156
System 3: Computer Unit and Connector Unit
Sheet 3-1. Block Diagram/Computer Unit
157
Sheet 3-2. Cabling in Computer Unit
158
Sheet 3-3. Main Computer and Hard Disk / Flash Disk Drive
159
Sheet 3-4. Compute Cooling
160
Sheet 3-5. Base Connector Board and I/O Computer
161
Sheet 3-6. Connector Board and I/O Computer
162
Sheet 3-7. Connector Board and Axis Computer
163
Sheet 3-8. Base Connector Unit
164
Sheet 3-9. Connector Plate on Controller Panel
165
System 4: Emergency Stops and Run Chain
Sheet 4-1. Emergency Stop
166
Sheet 4-2. Run Chain
167
Sheet 4-3. Run Chain
168
Sheet 4-4. Power Unit Servo Disconnector
169
System 5: Drive System and Robot Cable
170
Sheet 5-2. Rectifier, Fans and Bleeder
171
Sheet 5-3. Drive System Signal Connection 2 Drive Units
172
Sheet 5-4. Drive System Signal Connection 3 Drive Units
173
Sheet 5-5. Servo Drive Units / IRB 140
174
Sheet 5-6. Servo Drive Units / IRB 340
175
Sheet 5-7. Servo Drive Units / IRB 640, 840
176
Sheet 5-8. Servo Drive Units / IRB 1400, 2400
177
Sheet 5-9. Servo Drive Units / IRB 4400, 6400S/PE
178
Sheet 5-10. Servo Drive Units / IRB 6400R
179
Sheet 5-11. Control Cable IRB 140
180
Sheet 5-12. Control Cable IRB 340, 1400 and 2400
181
Sheet 5-13. Control Cable IRB 640, 840, 4400 and 6400S/PE
182
Sheet 5-14. Control Cable IRB 6400R
183
Sheet 5-15. Rectifier, fans and bleeder
184
Sheet 5-16. Servo Drive System
185
Sheet 5-17. Control cable
186
System 6: External axes
Sheet 6-1. External axes
187
Sheet 6-2. Axes Computer 2 and Connector Board
188
Sheet 6-3. Expansion Board Axis Connector Board
189
Sheet 6-4. Drive System Signal Connection External Axes
190
Sheet 6-5. External axes no. 7th - 9th Control Signal Connection
191
Sheet 6-6. Axis Computer 2 and Axis Connector Unit if External Axis Cabinet
192
Sheet 6-7. Connection to External Axis Cabinet
193
Sheet 6-8. Servogun-SMB power/signals cable
194
System 7: I/O Units and Field Bus Modules
Sheet 7-1. I/O Unit Position
195
Sheet 7-2. Digital Part of Combi I/O and Digital I/O Unit Input Part
196
Sheet 7-3. Digital I/O Unit Output Part
197
Sheet 7-4. Combi I/O Unit Digital and Analogue Output Part
198
Sheet 7-5. Digital Input Part of 120V AC I/O Unit
199
Sheet 7-6. Digital Output Part of 120V AC I/O Unit
200
Sheet 7-7. Relay I/O Unit Input 1-16
201
Sheet 7-8. Digital with Relays I/O Output 1-8
202
Sheet 7-9. Digital with Relays I/O Output 9-16
203
Sheet 7-10. Analogue I/O Unit
204
Sheet 7-11. Remote I/O Unit For Allen Bradley PLC
205
Sheet 7-12. Interbus-S Master/Slave - Interbus-S Master
206
Sheet 7-13. Profibus DP SLave
207
Sheet 7-14. Encoder Unit
208
Sheet 7-15. Profibus DP Master/Slave
209
Sheet 7-16. Interbus master/slave optical fibre and copper wire
210
System 8: Other options
Sheet 8-1. Floppy Disk
211
Sheet 8-2. Service Equipment Supply
212
Sheet 8-3. External Connections System Signals
213
Sheet 8-4. Position Switches on Manipulator
214
Sheet 8-5. Customer Signals
215
Sheet 8-6. Sustomer Power/SIgnal IRB 2400, 4400, 6400S/PE
216
Sheet 8-7. Customer Cable Power/Signal/CAN IRB 6400R
217
Sheet 8-8. External Control Panel
218
Sheet 8-9. Extension Cable Teach Pendant
219
Sheet 8-10. Time Relay
220
Sheet 8-11. Customer Precess / Power / Signal / Profibus DP M/S
221
Sheet 8-12. Optional customer power/signal Profibus IRB 6400R
222
Sheet 8-13. LAN Ethernet connection
223
Sheet 8-14. Customer power/CAN-BUS IRB 640/6400S
224
Sheet 8-15. Customer cable power/signal CAN-BUS IRB 6600/7600
225
Sheet 8-16. Customer cable power/signal Profibus IRB 6600/7600
226
Sheet 8-17. Optional customer power/signal Profibus IRB 6400R
227
System 9: External Axis Cabinet
228
Sheet 9-2. View of External Axis Cabinet
229
230
Sheet 9-4. Mains Connection
231
Sheet 9-5. Transformer Unit
232
Sheet 9-6. Power Supply, I/O Supply
233
Sheet 9-7. Power Unit
234
Sheet 9-8. Rectifier, Fans and Bleeder
235
Sheet 9-9. Drive Unit Signal Connection 1 External Drive Unit
236
Sheet 9-10. Drive Unit Signal Connection 2 External Drive Units
237
Sheet 9-11. Drive Unit Signal Connection 3 External Drive Units
238
Sheet 9-12. Drive Unit and Control Cable Drive Unit GT
239
Sheet 9-13. Drive Unit and Control Cable Drive Unit GT+CCB
240
Sheet 9-14. Drive Unit and Control Cable
241
Sheet 9-15. Service Equipment Supply
242
Index
243
Index
Maintenance Manual
Maintenance Manual, IRB 940 Tricept

3HAC 16639-1
-
Table of Contents
1 3 5 5 6
7

7 7 8
9
9 9 9 10 10 11
13
Safety fence dimensions Fire extinguishing Emergency release of the manipulator's arm Brake testing Risk of disabling function "Reduced speed 250 mm/s" Safe use of the Teach Pendant Unit Work inside the manipulators working range Chapter 2: Reference Information Introduction Screw joints Weight specifications Chapter 3: Maintenance activities, manipulator Introduction
Section A: Maintenance intervals
13 13 14 14 15 15 15 17 17 18 20 21 21
22
Specification of maintenance intervals Maintenance schedule, IRB 940 Tricept

Section B: Daily maintenance
22 23
24
Daily maintenance, complete robot
24
Table of Contents
Section C: Lubrication activities
25
Lubrication, linear bearings Lubrication, actuators

Section D: Replacement activities
25 27
29
Replacement of filter element, OP-unit Adjusting the overpressure unit Chapter 4: Maintenance activities, controller Introduction
Section A: Maintenance intervals
29 31 33 33
34
Specification of maintenance intervals Maintenance schedule, controller S4CPlus

Section B: Inspection activities
34 35
36
Inspection of controller cabinet, S4Cplus

Section C: Replacement activities
36
37
Replacement of air filter, controller Replacement of battery unit, controller Replacement of system fan unit
Section D: Cleaning activities
37 40 44
47
Cleaning of controller cabinet Cleaning of air filter Chapter 5: Disposal Disposal
47 49 51 51
Overview
About This Manual
This information product is a manual containing instructions for maintenance of the complete robot system, mechanically as well as electrically.
Usage
This manual should be used during maintenance work.

maintenance personnel in the user's organization. maintenance personnel in other organizations.
Prerequisites

be a trained maintenance craftsman have the required knowledge of mechanical maintenance work OR have the required knowledge of electrical maintenance work.
The information product is organized in the following chapters:
Chapter
1. 2. 3. 4. 5.
Contents
Safety, service Reference information Maintenance activities, manipulator Maintenance activities, controller Disposal
Circuit diagram, Manipulator Circuit diagram, Controller
Document Id
3HAC 16640-1, Repair Manual part 2 3HAC 16640-1, Repair Manual part 2
Revisions Revision
-
Description
First edition
General


Safety, service

Introduction
Definitions
Sections
The chapter "Safety, service" is divided into the following sections: A. References contains lists of:
Safety, service
Safety, service
References
General
Standards

Safety, service
References
Related information
General

Section
Start-up
Safety, service
Safety risks

Safe handling
Safe design
General
Residual energy
Safe design
Safety, service
Safety risks
General
Qualified personnel
Extraordinary risks
Safety, service
Safety risks
11
Safety, service
Safety risks


Safety, service
Safety actions
General

- withstand any impact from a tool failure. Due to the high kinetic energy associated with HSM (High Speed Machining), a tool failure poses a serious risk as any debris can cause serious personal injury. Both walls and ceilings must be designed and dimensioned so that they can withstand any projectiles that they may be subjected to. Windows must be made from suitable safety glass. Study the planned process to determine the forces involved and appropriate materials. - insulate against sound pollution from the machining process. Typically the safety cell should be able to reduce sound from the machining process down to 75dBA, though individual installations may stipulate other values. Study the planned process to determine the allowable noise pollution levels and appropriate sound insulation. - isolate gases and mist generated by the machining process and spray mist lubrication. Study the planned process to determine the fumes involved and appropriate ventilation/filtering system.
Fire extinguishing
13
Safety, service
Safety actions
Description
Increased injury
Brake testing
When to test
How to test
Safety, service
Safety actions



15
Safety, service
Safety actions

Introduction
General
17
Screw joints
General
This section details how to tighten the various types of screw joints in the manipulator as well as the controller. The instructions and torque values are valid for screw joints comprising metallic materials and does not apply to soft or brittle materials. Any instructions given in the repair, maintenance or installation procedure description override any value or procedure given here, i.e. these instruction are only valid for standard type screw joints.
Tightening torque
Dimension
M2.5 M3 M4 M5 M6

0.25 0.5 1.2 2.5 5.0
Dimension
M5 M6 M8 M10 M12

6 10 24 47 82

28 55 95

17 40 70 120
Dimension
M16

200

235

300
19
Definition
In all repair and maintenance instructions, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way. ABB recommends handling all components with a weight exceeding 22 kg using lifting equipment to avoid inflicting injury.
Example

Maintenance activities, manipulator
Chapter 3:Maintenance activities, manipulator

Introduction
Definitions
This chapter details all maintenance activities recommended for the manipulator. This chapter is made up of separate units, each detailing a specific maintenance activity. Each unit contains all the information required to perform the activity, e.g. spare parts numbers, required special tools and materials.
21

Maintenance intervals
Section A: Maintenance intervals Specification of maintenance intervals
Description
The intervals may be specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the robot.
Calendar time: specified in months regardless of whether the robot system is run or not. Operating time: specified in operating hours. More frequent running of the robot means more frequent maintenance activities.

Maintenance schedule, IRB 940 Tricept
General
The robot, consisting of manipulator and controller cabinet, must be maintained regularly to ensure its function. The maintenance activities and their respective intervals are specified in the table below. Non-predictable situations also give rise to inspections of the robot. If damage is discovered, attend to it immediately!
Activities and intervals
The section referred to in the table can be found in the different chapters for every maintenance activity. The table below specifies the required maintenance activities and intervals:
Maintenance activity
Daily maintenance Lubrication Lubrication Changing Changing
Equipment
Complete robot Linear bearings Actuator Filter, overpressure unit Battery, distribution box
Interval
Daily 1000h
1
Detailed in section
"Daily maintenance" "Lubrication, linear bearings" "Lubrication, actuators" Replacement of filter element, OP-unit Removal/Refitting of battery, distribution box in the Repair Manual.
1000h 1
1)
The interval is based on utilization under normal operating conditions. Operation under severe conditions such as increased ambient temperature or the presence of abrasive or grease absorbent dust will require a more regular maintenance cycle.
23

Daily maintenance
Section B: Daily maintenance Daily maintenance, complete robot
General
The IRB 940 Tricept requires regular maintenance. It is therefore important to adhere to the following maintenance chart as well as applying the preventive maintenance schedules set out in any auxiliary equipment chapters. When maintaining the robot it is important to:
Clean the robot and its surrounding environment daily. Not to use compressed air in sections of the machinery which may suffer from chips or dust being blown into sensitive areas. Only use soft cloths when cleaning so as not to cause abrasions on the machine surfaces. Not to use any solvents that may have an abrasive or corrosive effect on the machine surfaces.
Daily maintenance
The daily maintenance of the robot and its surrounding environment includes:
Removing all chips and/or dust that result from the machining process. Performing checks on all safety related equipment such as safety switches and barriers. Checking for signs of damage or wear on all cables, hoses and other components that can lead to a safety risk or interrupted production in case of failure. Checking levels of all lubrication and cooling fluids on both the manipulator and auxiliary equipment. Checking that all media supplies, such as compressed air and water, maintain the correct pressures and flows.

Lubrication activities
Section C: Lubrication activities Lubrication, linear bearings
Location
The figure below shows the location of the grease lubrication nipple on the linear guide bearing. The other linear bearing is located on the other side of the center tube.
xx0200000293
Grease lubrication nipple (one on either side of the center tube)

Lubricant
Note
Klber Isoflex NBU 15 2 x 4 ml per linear bearing.
25

Lubrication
The procedure below details how to lubricate the linear bearings.

Please observe the following before commencing any repair work on the manipulator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them! - Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! - When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures. - Before lubrication, always clean lubrication interfaces to prevent contamination entering the lubrication system. - After lubrication, always clean any spillage around lubrication interfaces.
Step
1. 2.
Action
Clean the rails from old grease and dust.
Note/Illustration
Apply 4 ml lubricant through the nipple at the Shown in figure above! bottom end of the linear guide bearing. Lubricant specified Both sides must be lubricated! above! Note! The ends of the linear bearing are made from plastic and can crack if not sufficient care is taken when lubricating the bearings. Run the robot back and forth in the Z-direction several times. Apply a further 4 ml lubricant through the same nipples at both side of the center tube.
3. 4.

Lubrication, actuators
Location
The three actuators require lubrication with grease. There are four separate grease nipples for the lubrication on each actuator. The grease nipple that faces up is used so that as the grease is applied it falls onto the lead screw inside the actuator housing. The figure below shows the location of the grease lubrication nipples on the actuator.
xx0200000294
Grease lubrication nipples on the actuator

Lubricant Klberplex BEM 34-132
Note
2 x 4 ml per actuator. For lubrication of the actuators.
27

Lubrication
The procedure below details how to lubricate the actuators.

Please observe the following before commencing any repair work on the manipulator: - Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them! - Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! - When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures. - Before lubrication, always clean lubrication interfaces to prevent contamination entering the lubrication system. - After lubrication, always clean any spillage around lubrication interfaces.
Step
1.
Action
Extend the actuators to their maximum allowable length. If a fixture or other work area restrictions affect the positioning of the robot, run it so that one of the actuators is extended, lubricate it and move on to the other two in turn. Apply 4 ml of lubricant to each actuator through the topmost grease nipple. Note! Ensure that the grease nipple that faces upwards is used, as any other orientated grease nipple will not ensure that the grease is applied to the lead screw correctly. Run the actuators through their whole stroke several times. Note! The actuators must be extended prior to lubrication in order to get the correct application onto the actuator screw. Lubricating a contracted actuator will not apply any grease on the screw threads. Apply a further 4 ml through the same grease nipple.
Note/Illustration
2.
Lubricant specified above! Shown in the figure above!
3.
4.

Replacement activities
Section D: Replacement activities Replacement of filter element, OP-unit
Location
The filter element is located in the overpressure (OP) unit as shown in the figure below.
xx0200000420
Removal of the filter element

Filter
Spare part no.

3HAC 17158-1
Art. no.
Note
29

Replacement of filter
The procedure below details how to replace the filter element in the overpressure unit.
Step
1. 2. 3. 4. 5.
Action
Exhaust the system and the unit. Unscrew the filter bowl in an anti-clockwise direction. Grasp a new filter element only at the lower end. Refit the parts in the reverse order from dismantling. Recommission the overpressure unit.
Note/Illustration
Detailed in the section "Adjusting the overpressure unit".

Adjusting the overpressure unit
Location
The overpressure unit is installed as shown in figure below.
C
xx0200000421
A B C D
Regulator Pressure guard Pressure indicator light Air input
31

Adjusting
The procedure below details how to adjust the overpressure unit after installation or after replacement of the filter element.
Step
1. 2. 3.
Action
Slowly pressurize the complete system. Pull the pressure setting button upwards (away from the housing). Turn the pressure setting until the desired pressure (1 bar) is shown on the manometer. The input pressure must be at least 1 bar greater than the output pressure. Press the pressure setting button downwards (towards the housing) to secure it against unintentional turning.
Note/Illustration
4.
The output pressure must under no circumstances exceed 1 bar!
Maintenance activities, controller
Chapter 4:Maintenance activities, controller

Introduction
Definitions
This chapter details all maintenance activities recommended for the control cabinet. This chapter is made up of separate units, each detailing a specific maintenance activity. Each unit contains all the information required to perform the activity, e.g. spare parts numbers, required special tools and materials.
33

Section A: Maintenance intervals Specification of maintenance intervals
Description
The intervals may be specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the robot.
Calendar time: specified in months regardless of whether the robot system is run or not. Operating time: specified in operating hours. More frequent running of the robot means more frequent maintenance activities.

Maintenance schedule, controller S4CPlus
General
The robot controller must be maintained at regular intervals to ensure its function. The maintenance activities and their respective intervals are specified in the table below:
Intervals Maintenance activity

Inspection Cleaning Cleaning Replacement Replacement Replacement
Equipment
Controller cabinet Controller cabinet Air filter Air filter Battery unit System fan unit
Interval
6 mths
Detailed in section
"Inspection, controller cabinet" "Cleaning, controller cabinet" "Cleaning, air filter"
4 000 h/ 24 mths 1 12 000 h/ 36 mths 1 60 mths
"Replacement, air filter" "Replacement, battery unit" "Replacement, system fan unit".
1)
Hours denotes operational time whereas months denotes actual calender time.
35

Inspection activities
Section B: Inspection activities Inspection of controller cabinet, S4Cplus
Inspection
The procedure below details how to inspect the controller cabinet.

Step
1.
Action
Note/Illustration
Inspect the cabinet interior to make sure Replace any faulty seals there is no contamination. as required. If any contamination is found, the cabinet interior must be cleaned and all gaskets and seals to the cabinet inspected. Inspect all sealing joints and cable glands to make sure they are airtight in order to prevent dust and dirt from being sucked into the cabinet. Inspect connectors and cabling to make sure they are securely fastened and cabling not damaged. Inspect any air filters to make sure they are clean. Inspect any fans to make sure they function correctly. Clean any contaminated filters as detailed in "Cleaning, air filter". Replace any malfunctioning fans as detailed in their sections respectively.
2.
3.
4.
5.

Section C: Replacement activities Replacement of air filter, controller
The air filter is located in the air filter magazine in the front hatch.
A
xx0200000284
Air filter magazine

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

3HAB 8028-1
Note
37

Removal, air filter
The procedure below details how to remove the air filter.
Step
1.
Action
Open the bottom of the air filter magazine as shown in the figure.
Note/Illustration
xx0200000001
2. 3.
Unlock the lower springs. Lower the magazine and remove. Remove the old filter by releasing the lock shackle and lifting it. Note! In cases of less contamination, the air filter may be cleaned and refitted. The procedure for this is detailed in section "Cleaning the air filter, controller" in the Maintenance Manual.
xx0200000003

Refitting, air filter
The procedure below details how to refit the air filter.
Step
1. 2.
Action
Note/Illustration
Fit the air filter in the Art. no. is specified above! magazine. Fit the spring at the top of the air filter magazine into the cabinet door and push upwards inwards. Push until the lower springs snap into the cabinet door.
xx0200000006
39

Replacement of battery unit, controller
Location of battery unit
The battery unit is located at the bottom of the controller.
A
xx0200000103
Battery unit


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

3HAC 5393-2
Note
To be replaced as a complete unit These procedures include references to the tools required.
Removal, battery unit
The procedure below details how to remove the battery unit.
41

Step
1.
Action
Remove the battery unit by unscrewing its attachment screws (1).
Note/Illustration
X1
X1
X1
X1
X2
X2
X2
X2
X3
xx0200000004
2. 3.
Pull the battery unit out (2). Disconnect the three cables from the battery unit (3).
xx0200000005

Refitting, battery unit
The procedure below details how to refit the battery unit.
Step
1. 2. 3.
Action
Place the battery unit close to its position. Reconnect the cables (3) and push the unit into position. Secure it with the attachment screws (1).
Note/Illustration
Art. no. specified above! See illustration above! See illustration above! See illustration above!
43

Replacement of system fan unit
Location of system fan unit
The system fan unit is located as shown in the figure below.
A D A A A B
xx0200000007
A B C D E


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

3HAC 12924-2
Note
Removal
The procedure below details how to remove the system fan unit.
Step
1. 2.
Action
Remove the bleeder resistor unit. Disconnect the cable (see position 1 in the figure).
Note/Illustration
Detailed in "Replacement of bleeder resistor" in the Repair Manual.
xx0200000008
45

Step
3.
Action
Pull the back of the system fan unit upwards to free it and then tip it out of the enclosure (see position 2 in the figure).
Note/Illustration
Refitting
The procedure below details how to refit the system fan unit.
Step
1. 2.
Action
Note/Illustration
Fit the system fan unit into position and Art. no. specified above! secure it (see position 2 in the figure above). Reconnect the cable disconnected during disassembly (see position 1 in the figure above). Refit the bleeder resistor unit. Detailed in section "Replacement of bleeder resistor" in the Repairs Manual.
3.

Cleaning activities
Section D: Cleaning activities Cleaning of controller cabinet

Vacuum cleaner Cleaning agent, exterior cleaning Use rag with e.g. alcohol, if necessary
Note
Cleaning of functional components
The procedure below details how to clean the functional components of the controller cabinet.
Step
1. 2.
Action
Clean the cabinet interior with a vacuum cleaner if necessary. If the cabinet is equipped with heat exchangers, it is of the utmost importance that these are cleaned. Heat exchangers are normally found: on the rear of power supplies on the rear of computer modules on drive units
Note/Illustration
If required, remove any heat exchangers before cleaning as detailed in the "Repair Manual".
47

Cleaning activities
Dos and donts!
The section below specifies special considerations when cleaning the controller cabinet.
Always!
Always use cleaning equipment as specified above! Any other cleaning equipment may shorten the life of paintwork, rust inhibitors, signs, or labels! Always check that all protective covers are fitted to the controller before cleaning!
Never!
Never remove any covers or other protective before cleaning the controller! Never use any cleaning agents, e.g. compressed air or solvents, other than those specified above! Never spray with a high pressure cleaner!

Cleaning activities
Cleaning of air filter
The air filter is located as shown in the figure below:

B C
A
xx0200000002
A B C D E
Air filter I/O and gateway units Power supply unit Drive system Computer system

Cleaning agent
Note
Water 30-40C with washing-up liquid or detergent
Compressed air
49

Cleaning activities
Cleaning
The procedure below details how to clean the air filter.

Please observe the following before commencing any repair work: Turn off all electric power supplies to the robot! Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. securing the lower arm with fixtures before removing gearbox, axis 2.
Step
1. 2. 3.
Action
Clean with the rough surface (on the clean-air side) turned inwards. Clean the filter three or four times. Allow the filter to dry in one of these ways: Lying flat on a flat surface Blow dry with compressed air from the clean-air side.
Note/Illustration
Do not wring the filter out!
Disposal
Chapter 5:Disposal
Disposal
General
All used grease/oils and dead batteries must be disposed of in accordance with the current legislation of the country in which the robot and the control unit have been installed. If the robot or the control unit is partially or completely disposed of, the various parts must be grouped together according to their nature (e.g. all iron together and all plastic together), and disposed of accordingly. These parts must also be disposed of in accordance with the current legislation of the country in which the robot and control unit have been installed.
51
Disposal
Index
53
Index

ABB-S4C+IRB 940 M2000 Electrical Maintenance Training Manual

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ABB-S4C+IRB 940 M2000 Electrical Maintenance Training Manual

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Installation and Commissioning Manual

Industrial Robot IRB 940 Tricept

Installation and Commissioning Manual IRB 940 Tricept

Limitation of Liability Applicable Safety Standards Related information

Pre-installation procedure Working range, IRB 940 Tricept Risk of tipping/Stability

Lifting manipulator in a horizontal orientation

Transporting and unpacking, S4Cplus

Inspection before start-up Start-up

162 164 166 168 173 175 180 182

BootImage Start window Reboot Window Boot Disk Window

184 185 187 188

189 190 192 193 194 198

200 201 202 203 204 207 207

How to calibrate the robot system Calibration tool kit, contents

211 215 216 219

Directions for all axes Fine calibration, all axes

Post calibration procedure

About This Manual

Who Should Read This Manual?

This manual is intended for:

The reader should...

The manual is organized in the following chapters:

Product Documentation, IRB 940 Tricept

Overview, Installation and Commissioning Manual

Overview, Repair Manual

The Repair Manual contains the following main chapters:

Overview, Maintenance Manual

The Maintenance Manual contains the following main chapters:

Maintenance schedules Maintenance activities Disposal

Chapter 1:Safety, service

Safety, service - General

Validity and responsibility

Connection of external safety devices

Section A: References Limitation of Liability

Applicable Safety Standards

The robot is designed in accordance with the requirements of:

The list below specifies documents which contain useful information:

Documents Type of information

Section B: Safety risks Safety risks related to end effector

Safety risks related to tools/workpieces

Safety risks related to pneumatic/hydraulic systems

Special safety regulations apply to pneumatic and hydraulic systems.

Safety risks during operational disturbances

Safety risks during installation and service

General risks during installation and service

Nation/region specific regulations

Non-voltage related risks

To be observed by the supplier of the complete system

Risks associated with live electric parts

Voltage related risks, general

Voltage related risks, controller, S4Cplus

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

Voltage related risks, manipulator, IRB 940 Tricept

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

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

Section C: Safety actions Safety fence dimensions

Dimensioning the fence or enclosure

Design the safety cell such that it will:

Emergency release of the manipulators arm

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

Safe use of the Teach Pendant Unit

Work inside the manipulators working range

Chapter 2:Reference Information

Screws with slotted or cross recess head