ABB IRB1410 Product Manual
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ABB IRB1410 Product Manual

Articulated robot
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Articulated robot
IRB1410
M2004

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Summary of Contents for ABB IRB1410

  • Page 1 Product manual Articulated robot IRB1410 M2004...
  • Page 3 Product manual IRB 1410 M2004 ID: 3HAC026320-001 Revision: A...
  • Page 4 Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fit- ness for a specific purpose or the like.

  • Page 5: Table Of Contents

    Table of Contents Overview ..............7 Product documentation, M2004 .
  • Page 6 Table of Contents 3.1: Instructions for maintenance ............57 3.1.1 Oil in gears 1-4.
  • Page 7 Table of Contents 4.8: Motor units ..............111 4.8.1 General .
  • Page 8 Table of Contents...

  • Page 9: Overview

    Prerequisites A maintenance/repair/ installation craftsman working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Organization of chapters The manual is organized in the following chapters:...
  • Page 10 Overview References Reference Document Id Revisions Revision Description First edition. Changes made in: • Prerequisites in section Overview • Oil change in section Maintenance 3HAC026320-001 Revision: A...

  • Page 11: Product Documentation, M2004

    This means that any one delivery of robot products will not contain all documents listed, but only some of them. However, all documents listed may be ordered from ABB. The documents listed are valid for M2004 robot systems.
  • Page 12 Product documentation, M2004 • Examples of how to use the application Operating Manuals This group of manuals is aimed at those having first hand operational contact with the robot, i.e. production cell operators, programmers and trouble shooters, and include: • Operating Manual - IRC5 with FlexPendant •...

  • Page 13: 1: Safety

    1 Safety 1: Safety 1.1: Introduction Overview The safety information in this manual is divided in two categories: • general safety aspects, important to attend to before performing any service work on the robot. These are applicable for all service work and are found in section General safety information on page •...

  • Page 14: General Safety Information

    Limitation of liability Any information given in this manual regarding safety, must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. Related information...

  • Page 15: Safety Risks

    Nation/region specific regulations To prevent injuries and damage during the installation of the robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with. Non-voltage related risks •...
  • Page 16 1 Safety 1.3.1 Safety risks during installation and service work on 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. •...
  • Page 17 1 Safety 1.3.1 Safety risks during installation and service work on robot Gearboxes and motors Safety risk Description Gears may be damaged if excessive force is used! Caution! Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! 3HAC026320-001 Revision: A...

  • Page 18: Safety Risks Related To Tools/Workpieces

    1 Safety 1.3.2 Safety risks related to tools/workpieces 1.3.2 Safety risks related to tools/workpieces Safe handling It must be possible to safely turn off tools, such as milling cutters, etc. Make sure that guards remain closed until the cutters stop rotating. It should be possible to release parts by manual operation (valves).

  • Page 19: Safety Risks Related To Pneumatic/Hydraulic Systems

    1 Safety 1.3.3 Safety risks related to pneumatic/hydraulic systems 1.3.3 Safety risks related to pneumatic/hydraulic systems General Special safety regulations apply to pneumatic and hydraulic systems. Residual energy • Residual energy may be present in these systems. After shutdown, particular care must be taken.

  • Page 20: Safety Risks During Operational Disturbances

    1 Safety 1.3.4 Safety risks during operational disturbances 1.3.4 Safety risks during operational disturbances General • The industrial robot is a flexible tool which can be used in many different industrial applications. • All work must be carried out professionally and in accordance with the applicable safety regulations.

  • Page 21: Risks Associated With Live Electric Parts

    1 Safety 1.3.5 Risks associated with live electric parts 1.3.5 Risks associated with live electric parts Voltage related risks, general • Although troubleshooting may, on occasion, have to be carried out while the power supply is turned on, the robot must be turned off (by setting the mains switch to OFF) when repairing faults, disconnecting electric leads and disconnecting or connecting units.

  • Page 22: Safety Actions

    1 Safety 1.4.1 Safety fence dimensions 1.4: Safety actions 1.4.1 Safety fence dimensions General Install a safety cell around the robot to ensure safe robot installation and operation. Dimensioning Dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed.

  • Page 23: Fire Extinguishing

    1 Safety 1.4.2 Fire extinguishing 1.4.2 Fire extinguishing NOTE! Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the robot (manipulator or controller)! 3HAC026320-001 Revision: A...

  • Page 24: Emergency Release Of The Robot's Arm

    1 Safety 1.4.3 Emergency release of the robot’s arm 1.4.3 Emergency release of the robot’s arm Description In an emergency situation, any of the robot's axes may be released manually by pushing the brake release buttons on the robot. How to release the brakes is detailed in section: •...

  • Page 25: Brake Testing

    1 Safety 1.4.4 Brake testing 1.4.4 Brake testing When to test During operation the holding brake 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 the holding brake of each axis motor may be checked as detailed below: 1.

  • Page 26: Risk Of Disabling Function "Reduced Speed 250 Mm/S

    1 Safety 1.4.5 Risk of disabling function "Reduced speed 250 mm/s" 1.4.5 Risk of disabling function "Reduced speed 250 mm/s" NOTE! Do not change "Transm gear ratio" or other kinematic parameters from the FlexPendant or a PC. This will affect the safety function Reduced speed 250 mm/s. 3HAC026320-001 Revision: A...

  • Page 27: Safe Use Of The Flexpendant

    1 Safety 1.4.6 Safe use of the FlexPendant 1.4.6 Safe use of the FlexPendant NOTE! The enabling device is a push button located on the side of the FlexPendant 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.

  • Page 28: Work Inside The Manipulator's Working Range

    1 Safety 1.4.7 Work inside the manipulator's working range 1.4.7 Work inside the manipulator's working range WARNING! If work must be carried out within the robot’s work envelope, the following points must be observed: • The operating mode selector on the controller must be in the manual mode position to render the enabling device operative and to block operation from a computer link or remote control panel.

  • Page 29: Translate The Information On Safety And Information Labels

    Drawings detailing the design (text, figure, dimensions) of the standard labels can be ordered from ABB. Notice that each label is identified according to the article number located in the lower corner of the label.

  • Page 30: Safety Related Instructions

    1 Safety 1.5.1 Safety signals, general 1.5: Safety related instructions 1.5.1 Safety signals, general General This section specifies all dangers that may arise from performing the work detailed in the manual. Each danger is detailed in its own section consisting of: •...
  • Page 31 1 Safety 1.5.1 Safety signals, general Symbol Designation Signification ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates DISCHARGE (ESD) electrostatic hazards which could result in severe damage to the product. Electrostatic discharge (ESD) NOTE Note symbols alert you to important facts and conditions.

  • Page 32: Danger - Moving Manipulators Are Potentially Lethal

    1 Safety 1.5.2 DANGER - Moving manipulators are potentially lethal! 1.5.2 DANGER - Moving manipulators are potentially lethal! Description Any moving manipulator is a potentially lethal machine. When running the manipulator, it may perform unexpected and sometimes irrational movements. However, all movements are performed with great force and may seriously injure any personnel and/or damage any piece of equipment located within the manipulator working range.

  • Page 33: Danger - First Test Run May Cause Injury Or Damage

    1 Safety 1.5.3 DANGER - First test run may cause injury or damage! 1.5.3 DANGER - First test run may cause injury or damage! Description Since performing a service activity often requires disassembly of the robot there are several safety risks to take into consideration before the first test run. Elimination Follow the procedure below when performing the first test run after a service activity (repair, installation or maintenance):...

  • Page 34: Warning - The Unit Is Sensitive To Esd

    1 Safety 1.5.4 WARNING - The unit is sensitive to ESD! 1.5.4 WARNING - The unit is sensitive to ESD! Description ESD (electro static discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not grounded may potentially transfer high static charges.

  • Page 35: Warning - Safety Risks During Work With Gearbox Oil

    1 Safety 1.5.5 WARNING - Safety risks during work with gearbox oil 1.5.5 WARNING - Safety risks during work with gearbox oil Description When handling the gearbox oil, there are several dangers to both personal injuries and product damages! Following safety information must be regarded before performing any work with the oil in the gearboxes! Warnings and elimination Warning...
  • Page 36 1 Safety 1.5.5 WARNING - Safety risks during work with gearbox oil Warning Description Elimination / Action Warm oil drains quicker than When changing gearbox oil, first cold oil. run the robot for a time to heat up the oil. Heat up the oil! The specified amount of oil is After refilling, check the oil level.

  • Page 37: 2: Installation And Commissioning

    2 Installation and commissioning 2.0.1 Transporting and Unpacking 2: Installation and commissioning 2.0.1 Transporting and Unpacking Before starting to unpack and install the robot, read the safety regulations and other instructions very carefully. See Safety on page 11. The installation shall be made by qualified installation personnel and should conform to all national and local codes.

  • Page 38: Stability / Risk Of Tipping

    2 Installation and commissioning 2.0.2 Stability / Risk of Tipping 2.0.2 Stability / Risk of Tipping When the manipulator is not fastened to the floor and standing still, the manipulator is not stable in the whole working area. When the arms are moved, care must be taken so that the centre of gravity is not displaced, as this could cause the manipu- lator to tip over.

  • Page 39: System Cd Rom And Diskette

    2 Installation and commissioning 2.0.3 System CD ROM and Diskette 2.0.3 System CD ROM and Diskette The system CD ROM and the manipulator parameter disk are delivered with the robot system. See section RobotWare CD-ROM in the Product manual for the controller. Art.

  • Page 40: Transport Locking Device

    2 Installation and commissioning 2.0.4 Transport Locking Device 2.0.4 Transport Locking Device At delivery, axis 2 (= lower arm) is equipped with a transport locking device (see figure below). Remove the transport locking device before operating the robot. Transport locking device Figure 1: Transport Locking Device, Axis 2.

  • Page 41: On-Site Installation

    2 Installation and commissioning 2.1.1 Lifting the Manipulator 2.1: On-site installation 2.1.1 Lifting the Manipulator The best way to lift the manipulator is to use lifting straps and a traverse crane. Attach the straps to the special eye bolts on the gear boxes for axes 2 and 3 (see figure below). The lifting strap dimensions must comply with the applicable standards for lifting.

  • Page 42: Assembling The Robot

    Tightening torque 190 Nm Two guide sleeves, ABB art. no. 2151 0024-169, can be fitted to the two rear bolt holes, to allow the same robot to be re-mounted without having to re-adjust the program. When bolting a mounting plate or frame to a concrete floor, follow the general instructions for expansion-shell bolts.

  • Page 43: Suspended Mounting

    2 Installation and commissioning 2.1.3 Suspended Mounting 2.1.3 Suspended Mounting The method for mounting the manipulator in a suspended position is basically the same as for floor mounting. With inverted installation, make sure that the gantry or corresponding struc- ture is rigid enough to prevent unacceptable vibrations and deflections, so that optimum performance can be achieved.

  • Page 44: Stress Forces

    2 Installation and commissioning 2.1.4 Stress Forces 2.1.4 Stress Forces Stiffness The stiffness of the foundation must be designed to minimize the influence on the dynamic behaviour of the robot. TuneServo can be used for adapting the robot tuning to a non-optimal foundation. IRB 1400 Force Endurance load (in operation) Max.

  • Page 45: Amount Of Space Required

    2 Installation and commissioning 2.1.5 Amount of Space required 2.1.5 Amount of Space required The amount of working space required to operate the manipulator is illustrated in the figures below. The working range for axis 1 is +/- 170°. NB! There are no software or mechanical limits for the working space under the base of the manipulator.

  • Page 46: Manually Engaging The Brakes

    2 Installation and commissioning 2.1.6 Manually engaging the brakes 2.1.6 Manually engaging the brakes All axes are equipped with holding brakes. If the positions of the manipulator axes are to be changed without connecting the controller, an external voltage supply (24 V d.c.) must be connected to enable engagement of the brakes.

  • Page 47: Restricting The Working Space

    2 Installation and commissioning 2.1.7 Restricting the Working Space 2.1.7 Restricting the Working Space When installing the manipulator, make sure that it can move freely within its entire working range. If there is a risk that it may collide with other objects, its working range should be lim- ited, both mechanically and using parameters.
  • Page 48 2 Installation and commissioning 2.1.7 Restricting the Working Space Under arm Extra stop lugs Figure 9: Mechanically limiting Axis 2. Axis 3 The working range of axis 3 can be limited mechanically by fitting a stop lug under the par- allel arm (see Figure 10).
  • Page 49 2 Installation and commissioning 2.1.7 Restricting the Working Space Instructions for doing this are supplied with the kit. Extra stop lug Figure 10: Extra Stop Lug for limiting Axis 3. 3HAC026320-001 Revision: A...

  • Page 50: Mounting Holes For Equipment On The Manipulator

    2 Installation and commissioning 2.1.8 Mounting Holes for Equipment on the Manipulator 2.1.8 Mounting Holes for Equipment on the Manipulator NB! Never drill a hole in the manipulator without first consulting ABB. Mounting holes for equipment, both sides M8 (3x), R=75...

  • Page 51: Loads

    2 Installation and commissioning 2.1.9 Loads 2.1.9 Loads Regarding load diagram, permitted extra loads (equipment) and locations of extra loads (equipment), see the Product Specification for IRB 1400. The loads must also be defined in the software, see Operating manual - IRC5 with FlexPendant. 3HAC026320-001 Revision: A...

  • Page 52: Customer Connections On Manipulator

    2 Installation and commissioning 2.2.1 Air supply and signals for extra equipment to upper arm 2.2: Customer connections on manipulator 2.2.1 Air supply and signals for extra equipment to upper arm Option 041 Hose for compressed air is integrated into the manipulator. There is an inlet at the base and an outlet on the upper arm housing.
  • Page 53 To connect power and signal conductors to the manipulator base and to the upper arm connectors, the following parts are recommended: • ABB’s recommended contact set, for connector R2.CS, has Art. No. 3HAC 12583-1. • ABB’s recommended contact set, for connector R1.CS, has Art. No. 3HAC 12493-1.

  • Page 54: Connection Of Extra Equipment To The Manipulator

    2 Installation and commissioning 2.2.2 Connection of Extra Equipment to the Manipulator 2.2.2 Connection of Extra Equipment to the Manipulator Technical data for customer connections. Signals Conductor resistance < 3 ohm, 0.154 mm Max. voltage 50 V AC/DC Max. current 250 mA Connections on Upper Arm R2.CS...
  • Page 55 2 Installation and commissioning 2.2.2 Connection of Extra Equipment to the Manipulator Connection of Signal Lamp on Upper Arm (Option) R3.H1 + R3.H2 - Signal lamp Figure 16: Location of Signal Lamp. 3HAC026320-001 Revision: A...
  • Page 56 2 Installation and commissioning 2.2.2 Connection of Extra Equipment to the Manipulator 3HAC026320-001 Revision: A...

  • Page 57: 3: Maintenance

    3 Maintenance 3.0.1 Introduction 3: Maintenance 3.0.1 Introduction The robot is designed to be able to work under very demanding circumstances with a mini- mum of maintenance. Nevertheless, certain routine checks and preventative maintenance must be carried out at given periodical intervals, see the table below. •...

  • Page 58: Maintenance Intervals

    3 Maintenance 3.0.2 Maintenance Intervals 3.0.2 Maintenance Intervals Check Check Maintenance Maintenance Equipment twice/ once/ every 2000 hrs every 4000 hrs Others year year or 6 months or 1 year Mechanical stop axis 1 Cabling Gears axis 1-4 Maintenance free Lubrication of spring brackets Lubrication of...

  • Page 59: Instructions For Maintenance

    3.1.1 Oil in gears 1-4 3.1: Instructions for maintenance 3.1.1 Oil in gears 1-4 The gearboxes are lubricated for life. ABB’s oil, Mobilgear 600XP 320 art. No. 1171 2016-604, corresponds to: BP: Energol GR-XP 320 Castrol: Alpha SP 320 Esso: Spartan EP 320 Klüber: Lamora 320...

  • Page 60: Greasing Axes 5 And 6

    Grease is pressed through the 3 nipples (1), see Figure 17. The tip nozzle of the greasing gun should be of type Orion 1015063, or equivalent. Volume: 2 ml (0.00053 US gallon) Figure 17: Greasing Positions for Axes 5 and 6. Type of grease: ABB’s art. No. 3HAB 3537-1, corresponds to: Shell Alvania WR2 3HAC026320-001 Revision: A...

  • Page 61: Lubricating Spring Brackets

    3 Maintenance 3.1.3 Lubricating spring brackets 3.1.3 Lubricating spring brackets There are four lubrication places, located over and under the two balancing springs. Type of grease: ABB’s art. No. 3HAA 1001-294, corresponds to: Optimol PDO 3HAC026320-001 Revision: A...

  • Page 62: Changing The Battery In The Measuring System

    3 Maintenance 3.1.4 Changing the battery in the measuring system 3.1.4 Changing the battery in the measuring system The battery to be replaced is located inside the base under the flange cover (see Figure 18). The robot is delivered with a rechargeable Nickel-Cadmium (Ni-Cd) battery with article number 4944 026-4.
  • Page 63 3 Maintenance 3.1.4 Changing the battery in the measuring system User type Exchange 3-cell Exchange 6-cell 1. Vacation (4 weeks) power off Every 5 years Every 5 years 2. Weekend power off + user type 1 Every 2 years Every 4 years 3.

  • Page 64: Checking The Mechanical Stop, Axis 1

    3 Maintenance 3.1.5 Checking the mechanical stop, axis 1 3.1.5 Checking the mechanical stop, axis 1 Check regularly, as follows: • That the stop pin is not bent. If the stop pin is bent, it must be replaced by a new one. See Replacing the mechanical stop on page 78 The article number of the pin is 3HAB 3258-1.

  • Page 65: 4: Repair

    4 Repair 4.1.1 General description 4: Repair 4.1: General information 4.1.1 General description The industrial robot system comprises two separate units: the control cabinet and the manip- ulator. Servicing the manipulator is described in this manual. When servicing the manipulator, it is helpful to service the following parts separately: •...
  • Page 66 4 Repair 4.1.1 General description WARNING! Take special care when manually operating the brakes. Make sure also that the safety instructions described in this manual are followed when starting to operate the robot. 3HAC026320-001 Revision: A...

  • Page 67: Instructions For Reading The Following Sections

    Some maintenance jobs require special experience or specific tools and are therefore not described in this manual. These jobs involve replacing the faulty module or component on-site. The faulty component is then transported to ABB for service.

  • Page 68: Caution

    4 Repair 4.1.3 Caution 4.1.3 Caution The mechanical unit contains several parts which are too heavy to lift manually. As these parts must be moved with precision during any maintenance and repair work, it is important to have a suitable lifting device available. The robot should always be switched to MOTORS OFF before anybody is allowed to enter its working space.

  • Page 69: Fitting New Bearings And Seals

    Greasing Bearings Action Bearings must be greased after they are fitted. Extreme cleanliness is necessary throughout. High quality lubricating grease, such as Shell Alvania WR2 (ABB’s art. No. 3537-1), should be used. Grooved ball bearings should be greased on both sides.
  • Page 70 4 Repair 4.1.4 Fitting new Bearings and Seals Action Bearings must be greased after they are fitted. Extreme cleanliness is necessary throughout. High quality lubricating grease, such as Shell Alvania WR2 (ABB’s art. No. 3537-1), should be used. 3HAC026320-001 Revision: A...
  • Page 71 Grease the seal just before it is fitted – not too early as otherwise dirt and foreign particles may stick to the seal. The space between the dust tongue and sealing lip should 2/3-filled with grease of type Shell Alvania WR2 (ABB’s art. No. 3537-1).
  • Page 72 Tighten the screws evenly. Defective O-rings and O-ring grooves must not be used. If any of the parts fitted are defective, they will cause leakage. Grease the O-ring with Shell Alvania WR2 (ABB’s art. No. 3537-1) before fitting it. 3HAC026320-001 Revision: A...

  • Page 73: Instructions For Tightening Screw Joints

    4 Repair 4.1.5 Instructions for tightening Screw Joints 4.1.5 Instructions for tightening Screw Joints General It is extremely important that all screw joints are tightened using the correct torque. Application The following tightening torques must be used, unless otherwise specified in the text, for all screw joints made of metallic materials.

  • Page 74: Tightening Torques

    4 Repair 4.1.6 Tightening Torques 4.1.6 Tightening Torques Screws with slotted or cross recessed head, property class 4.8 Dimension Tightening Torque Nm Without Oil M2.5 0.25 Screws with hexagon socket head, property class 8.8 Dimension Tightening Torque Nm Tightening Torque Nm Without Oil With Oil 3HAC026320-001 Revision: A...

  • Page 75: Checking For Play In Gearboxes And Wrist

    4 Repair 4.1.7 Checking for play in gearboxes and wrist 4.1.7 Checking for play in gearboxes and wrist When checking for play in gearboxes the brakes must be disengaged. When trying to move an arm manually when the brakes are engaged, some play can be felt. The play that can be felt is between the brake disk and the motor shaft, not in the gearbox itself.

  • Page 76: Axis 1

    4 Repair 4.2.1 Changing the motor of axis 1 4.2: Axis 1 4.2.1 Changing the motor of axis 1 General See foldouts 1 and 5 in chapter, Foldout. The motor and the drive gear constitute one unit. To dismantle Action Note/Illustartion Remove the cover of the motor.

  • Page 77: Changing The Gearbox

    4 Repair 4.2.2 Changing the gearbox 4.2.2 Changing the gearbox General Axis 1 gearbox is of the conventional type, manufactured with a high degree of precision and, together with the gearboxes for axes 2 and 3, forms a complete unit. The gearbox is not normally serviced or adjusted.
  • Page 78 4 Repair 4.2.2 Changing the gearbox Action Note /Illustration NOTE! Make sure that the foot is stable Figure 19: Undo screws. See foldout/pos. <1/4>. Separate the base from the gear unit. To assemble Action Note/Illustration Place a new gear unit on the table. Raise the base.

  • Page 79: Position Indicator In Axis 1 (Optional)

    4 Repair 4.2.3 Position indicator in axis 1 (optional) 4.2.3 Position indicator in axis 1 (optional) General See foldouts 3 and 4 in chapter, Foldout. To dismantle Action Note/Illustration Remove the flange plate. See foldout/pos. <4/138> Loosen the connector R1.LS. Dismantle the two limit switches.

  • Page 80: Replacing The Mechanical Stop

    4 Repair 4.2.4 Replacing the mechanical stop 4.2.4 Replacing the mechanical stop General If the stop pins are bent, they must be replaced. See foldout 1 in chapter, Foldout. Replacement Action Note/Illustration Remove the old stop pin. Fit the new pin according to the illustration.

  • Page 81: Axis 2

    4 Repair 4.3.1 Changing the motor of axis 2 4.3: Axis 2 4.3.1 Changing the motor of axis 2 General See foldouts 1 and 5 in chapter, Foldout. The motor and the drive gear constitute one unit. To dismantle Action Note/Illustration WARNING! Lock the arm system before dismantling the...
  • Page 82 4 Repair 4.3.1 Changing the motor of axis 2 Action Note/Illustration Screw the 3HAB 1201-1 crank tool into the end of the motor shaft. Make sure there is no play. Tighten screws. See foldout/pos. <1/10> Torque of 8.3 Nm ±10% Fill with oil.

  • Page 83: Changing The Gearbox

    4 Repair 4.3.2 Changing the gearbox 4.3.2 Changing the gearbox General Axis 2 gearbox is of a conventional type, manufactured with a high degree of precision and, together with the gearbox for axes 1 and 3, forms a complete unit. See foldout 1 in chapter, Foldout.

  • Page 84: Dismantling The Lower Arm

    4 Repair 4.3.3 Dismantling the lower arm 4.3.3 Dismantling the lower arm General See foldouts 1 in chapter, Foldout. To dismantle Action Note/Illustration Remove the balancing springs. Described in section: Dismantling the balancing springs on page Remove the cabling down to axis 1. Described in section: Cabling and serial measuring board on page...
  • Page 85 4 Repair 4.3.3 Dismantling the lower arm Action Note/Illustration Replace the balancing springs. Detailed in section: Dismantling the balancing springs on page Replace the cabling as described in . Detailed in section: Cabling and serial measur- ing board on page 102.

  • Page 86: Changing The Bearings In The Upper Arm

    4 Repair 4.3.4 Changing the bearings in the upper arm 4.3.4 Changing the bearings in the upper arm General See foldout 1in chapter, Foldout. To dismantle Action Note/Illustration Loosen the upper bracket of the tie rod. Described in section: Changing the tie rod on page Unscrew screws which hold the parallel arm to See foldout/pos.

  • Page 87: Dismantling The Balancing Springs

    4 Repair 4.3.5 Dismantling the balancing springs 4.3.5 Dismantling the balancing springs See foldouts 1 and 2 in chapter, Foldout. To dismantle Action Note/Illustration Place the lower arm in a vertical position. Loosen the locking nut. See foldout/pos. <1/76> Release the spring using tool 3HAB 1214-6 and undo See foldout/pos.

  • Page 88: Axis 3

    4 Repair 4.4.1 Changing the motor of axis 3 4.4: Axis 3 4.4.1 Changing the motor of axis 3 General See foldouts 1 and 5 in chapter, Foldout. The motor and the drive gear constitute one unit. To dismantle Action Note/Illustration Remove the cover of the motor.
  • Page 89 4 Repair 4.4.1 Changing the motor of axis 3 Action Note/Illustration Connect the cabling. Calibrate the robot. Detailed in section: Calibration methods on page 115 3HAC026320-001 Revision: A...

  • Page 90: Changing The Gearbox

    4 Repair 4.4.2 Changing the gearbox 4.4.2 Changing the gearbox General See this chapter, section Changing the gearbox on page 81.General Axis 3’s gearbox is of a conventional type, manufactured with a high degree of precision and, together with the gearbox for axes 1 and 2, forms a complete unit. See foldout 1 in chapter, Foldout.

  • Page 91: Dismantling The Parallel Arm

    4 Repair 4.4.3 Dismantling the parallel arm 4.4.3 Dismantling the parallel arm See foldout 1 in chapter, Foldout. To dismantle Action Note/Illustration Loosen the upper bracket of the tie rod. Detailed in section: Changing the tie rod on page Unscrew screws which fix the parallel arm to gear See foldout/pos.

  • Page 92: Changing The Tie Rod

    4 Repair 4.4.4 Changing the tie rod 4.4.4 Changing the tie rod General See foldout 2 in chapter, Foldout. To dismantle Action Note/Illustration WARNING! Lock the upper arm in a horizontal position with the help of a hoist and lifting slings. Unscrew screw.
  • Page 93 4 Repair 4.4.4 Changing the tie rod Action Note/Illustration Lock using Loctite 242 or 243. 3HAC026320-001 Revision: A...

  • Page 94: Dismantling The Complete Upper Arm

    4 Repair 4.4.5 Dismantling the complete upper arm 4.4.5 Dismantling the complete upper arm General See foldout 2 in chapter, Foldout. To dismantle Action Note/Illustration WARNING! Attach a hoist with lifting slings to the upper arm. Unscrew the upper bracket of the tie rod as Detailed in section: specified in.
  • Page 95 4 Repair 4.4.5 Dismantling the complete upper arm Action Note/Illustration Attach the measuring instrument 3HAB 1205-1 to the shaft spindle on axis 3. NOTE! Tool no. 3HAB 1205-1 If measuring instrument is not available, you can use a micrometer thickness gauge.
  • Page 96 4 Repair 4.4.5 Dismantling the complete upper arm Action Note/Illustration If the old arm houde is mounted, adjust the cal- ibration washer according to the punch mark. If the arm house is new, adjust the washer according to Figure 24 and make new punch marks for axes 3 and 4, accordiong to Calibra- tion scales, IRB 1400 on page...

  • Page 97: Axis 4

    4 Repair 4.5.1 Changing the motor 4.5: Axis 4 4.5.1 Changing the motor General See foldouts 5 and 8 in chapter, Foldout. The motor and the drive gear constitute one unit. Position the arm system in such a way that the motor of axis 4 points upwards. To dismantle Action Note/Illustration...
  • Page 98 4 Repair 4.5.1 Changing the motor Action Note/Illustration Calibrate the robot. Detaild in section: Calibration methods on page 115. 3HAC026320-001 Revision: A...

  • Page 99: Changing The Intermediate Gear Including Sealing

    4 Repair 4.5.2 Changing the intermediate gear including sealing 4.5.2 Changing the intermediate gear including sealing General See foldout 8 in chapter, Foldout. To dismantle Action Note/Illustration Dismantle the wrist as described in. Detailed in section: Dismantling the wrist on page 106.
  • Page 100 4 Repair 4.5.2 Changing the intermediate gear including sealing Action Note/Illustration Bend the pinion towards the large drive gear and then rotate it around the tubular shaft a couple of times so that the clearance in the gears can adjust itself in relation to the highest point of the large drive gear.

  • Page 101: Dismantling The Drive Gear On The Tubular Shaft

    4 Repair 4.5.3 Dismantling the drive gear on the tubular shaft 4.5.3 Dismantling the drive gear on the tubular shaft General See foldout 8 in chapter, Foldout. To dismantle Action Note/Illustration Dismantle the wrist. Detailed in section: Dismantling the wrist on page 106.
  • Page 102 4 Repair 4.5.3 Dismantling the drive gear on the tubular shaft To assemble Action Note/Illustration Shim between drive gear and the rear bear- See foldout/pos. <8/17> and ing. <8/3> Shim thickness = B - A + 0.05 mm, see Fig- ure 24.

  • Page 103: Dismantling The Tubular Shaft And Changing Bearings

    4 Repair 4.5.4 Dismantling the tubular shaft and changing bearings 4.5.4 Dismantling the tubular shaft and changing bearings General See foldout 8 in chapter, Foldout. To dismantle Action Note/Illustration Dismantle the drive gear. . Detailed in section: Dismantling the drive gear on the tubular shaft on page Push out the tubular shaft.

  • Page 104: Cabling And Serial Measuring Board

    4 Repair 4.6.1 Changing serial measuring boards 4.6: Cabling and serial measuring board 4.6.1 Changing serial measuring boards General See foldout 4 in chapter, Foldout. To dismantle Action Note/Illustration Remove flange plate. See foldout/pos. <4/138> Cut tie around bundle. See foldout/pos. <4/144> Unscrew the serial measuring board using screws .

  • Page 105: Changing The Cabling In Axes 1, 2 And 3

    4 Repair 4.6.2 Changing the cabling in axes 1, 2 and 3 4.6.2 Changing the cabling in axes 1, 2 and 3 General See foldouts 3 and 4 in chapter, Foldout. To dismantle Action Note/Illustration Remove the cover of the motors. Remove the flange plate.

  • Page 106: Changing The Cabling In Axes 4, 5 And 6

    4 Repair 4.6.3 Changing the cabling in axes 4, 5 and 6 4.6.3 Changing the cabling in axes 4, 5 and 6 General See foldouts 2, 3 and 4 in chapter, Foldout. To dismantle Action Note/Illustration Remove the cover of the motors. Remove the flange plate.

  • Page 107: The Wrist And Axes 5 And 6

    It is of such a complex design that it is not normally serviced on-site, but should be sent to ABB to be serviced. NOTE! ABB recommends to carry out only the following servicing and repair work on the wrist. 1. Grease the wrist according to the table in section Maintenance Intervals on page...

  • Page 108: Dismantling The Wrist

    4 Repair 4.7.2 Dismantling the wrist 4.7.2 Dismantling the wrist General See foldouts 1 and 9 in chapter, Foldout. To dismantle Action Note/Illustration Remove the 2 plastic plugs on the rear of the wrist. Release the brake in axes 5 and 6. Rotate axes 5 and 6 so that you can see screws in See foldout/pos.

  • Page 109: Dismantling The Complete Drive Mechanism Of Axes 5 And 6

    4 Repair 4.7.3 Dismantling the complete drive mechanism of axes 5 and 6 4.7.3 Dismantling the complete drive mechanism of axes 5 and 6 General See foldouts 8 and 9 in chapter, Foldout. To dismantle Action Note/Illustration Dismantle the wrist. Detailed in section: Dismantling the wrist on page 106.

  • Page 110: Changing The Motor Or Driving Belt Of Axes 5 And 6

    4 Repair 4.7.4 Changing the motor or driving belt of axes 5 and 6 4.7.4 Changing the motor or driving belt of axes 5 and 6 General See foldout 9 in chapter, Foldout. To dismantle Action Note/Illustration Dismantle the wrist. Detailed in section: Dismantling the wrist on page 106.
  • Page 111 4 Repair 4.7.4 Changing the motor or driving belt of axes 5 and 6 Action Note/Illustration Calibrate the robot. Detailed in section: Calibration methods on page 3HAC026320-001 Revision: A...

  • Page 112: Measuring Play In Axes 5 And 6

    4 Repair 4.7.5 Measuring play in axes 5 and 6 4.7.5 Measuring play in axes 5 and 6 Axis 5 Axis 4 shall be turned 90 . The maximum accepted play in axis 5 is 4.7 arc.minutes when loading axis 5 with a moment of 4.8 Nm in one direction, unloading to 0.24 Nm and start mea- suring the play, loading in the other direction with 4.8 Nm unloading to 0.24 Nm and reading the play.

  • Page 113: Motor Units

    4 Repair 4.8.1 General 4.8: Motor units 4.8.1 General General Each axis (6 axes) of the manipulator has its own motor unit, and is regarded as one complete unit, comprising: • A synchronous motor • A brake (built into the motor) •...
  • Page 114 4 Repair 4.8.1 General 3HAC026320-001 Revision: A...

  • Page 115: 5: Calibration Information

    The resolver val- If resolver values are changed, the robot must be recalibrated using the calibration methods ues are changed supplied from ABB. Calibrate the robot carefully with standard calibration. The different methods are briefly described in section Calibration methods on page 115, and further detailed in separate Calibration manuals.

  • Page 116: Calibration Methods

    5 Calibration information 5.0.2 Calibration methods 5.0.2 Calibration methods Overview This section specifies the different types of calibration and the calibration methods that are supplied from ABB. Types of calibration Type of Description Calibration method calibration Standard calibra- The calibrated robot is positioned at home...
  • Page 117 Each calibration method is detailed in a separate manual. Below is a brief description of the methods available. Calibration Pen- Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB dulum - standard 6400R, IRB 640 and IRB 4400S) and is also the most accurate method for the standard type method of calibration.
  • Page 118 5 Calibration information 5.0.2 Calibration methods Levelmeter Cali- Levelmeter Calibration is referred to as the alternative method for calibration of ABB robots, bration - alterna- because of the less accurate values obtained during calibration. The method uses the same tive method principles as Calibration Pendulum but does not have as good of mechanical tolerances to the toolkit parts as the standard method with Calibration Pendulum.

  • Page 119: Calibration Scales And Correct Axis Position

    5 Calibration information 5.0.3 Calibration scales and correct axis position 5.0.3 Calibration scales and correct axis position Introduction This section specifies the calibration scale positions and/or correct axis position for all robot models. Calibration scales, IRB 1400 The illustration below shows the calibration scale positions on IRB 1400: en0200000272 3HAC026320-001 Revision: A...

  • Page 120: Calibration Movement Directions For All Axes

    5 Calibration information 5.0.4 Calibration movement directions for all axes 5.0.4 Calibration movement directions for all axes Overview When calibrating, the axis must consistently be run towards the calibration position in the same direction, in order to avoid position errors caused by backlash in gears etc. Positive directions are shown in the figure below.

  • Page 121: Updating Revolution Counters

    This procedure details the second step when updating the revolution counter; storing the rev- olution counter setting with the FlexPendant (RobotWare 5.0). Action On the ABB menu, tap Calibration. All mechanical units connected to the system are shown along with their calibration status.
  • Page 122 5 Calibration information 5.0.5 Updating revolution counters Action Tap Update Revolution Counters..A dialog box is displayed, warning that updating the revolution counters may change programmed robot positions: Tap Yes to update the revolution counters. Tap No to cancel updating the revolution counters. Tapping Yes displays the axis selection window.

  • Page 123: Checking The Calibration Position

    This section describes how to create a program, which runs all the robot axes to their zero position. Action Note On ABB menu tap Program Editor. Create a new program. Use MoveAbsJ in the Motion&Proc menu. Create the following program: MoveAbsJ...

  • Page 125: 6: Reference Information, Irb 1400

    6 Reference information, IRB 1400 6.0.1 Introduction 6: Reference information, IRB 1400 6.0.1 Introduction General This chapter includes general information, complementing the more specific information in the following chapters. 3HAC026320-001 Revision: A...

  • Page 126: Applicable Safety Standards

    6 Reference information, IRB 1400 6.0.2 Applicable Safety Standards 6.0.2 Applicable Safety Standards Standards, The robot is designed in accordance with the requirements of: general • EN ISO 10218-1 : 2006, Robots for industrial environments - Safety requirements - Part 1 Robot •...

  • Page 127: Unit Conversion

    6 Reference information, IRB 1400 6.0.3 Unit conversion 6.0.3 Unit conversion Converter table Use the table below to convert units used in this manual. Quantity Units Length 3.28 ft 39.37 in Weight 1 kg 2.21 lb Pressure 1 bar 100 kPa 14.5 psi Force 0.738 lbf...

  • Page 128: Screw Joints

    UNBRAKO UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It fea- screws tures special surface treatment (Gleitmo as described below), and is extremely resistant to fatigue.
  • Page 129 6 Reference information, IRB 1400 6.0.4 Screw joints Tightening torque Before tightening any screw, note the following: • Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure description.
  • Page 130 6 Reference information, IRB 1400 6.0.4 Screw joints The table below specify the recommended standard tightening torque for Molycote-lubri- cated screws with Allen head screws. Tightening torque (Nm) Tightening torque (Nm) Dimension Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated The table below specify the recommended standard tightening torque for water and air con- nectors when one or both connectors are made of brass.

  • Page 131: Weight Specifications

    All components exceeding 22 kg (50 lbs) are high-lighted in this way. To avoid injury, ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each manipulator model.

  • Page 132: Document References

    6 Reference information, IRB 1400 6.0.6 Document references 6.0.6 Document references General The contents of this manual may include references to additional documentation necessary to perform certain procedures. This section specifies the article numbers for the referenced doc- umentation. Product specifi- The product specification includes generic technical data.

  • Page 133: Standard Toolkit, Irb 1400

    6 Reference information, IRB 1400 6.0.7 Standard toolkit, IRB 1400 6.0.7 Standard toolkit, IRB 1400 General All service (repair, maintenance and installation) instructions contain lists of tools required to perform the specified activity. All special tools, i.e. all tools that are not considered standard as defined below, are listed in their instructions respectively.

  • Page 134: Performing A Leak-Down Test

    6 Reference information, IRB 1400 6.0.8 Performing a leak-down test 6.0.8 Performing a leak-down test General After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test. Required equip- ment Equipment, etc.

  • Page 135: Lifting Equipment And Lifting Instructions

    6 Reference information, IRB 1400 6.0.9 Lifting equipment and lifting instructions 6.0.9 Lifting equipment and lifting instructions General Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each procedure. The use of each piece of lifting equipment is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting equipment.

  • Page 137: 7: Recommended Spare Parts

    7 Recommended Spare parts 7.0.1 Spare parts 7: Recommended Spare parts 7.0.1 Spare parts The following table is showing the recommended spare parts delivered from ABB. There may be other spare parts, please contact ABB Robotics/After sales for information. Art. no Description...
  • Page 138 7 Recommended Spare parts 7.0.1 Spare parts Revision: A 3HAC026320-001...

  • Page 139: 8: Foldouts

    8 Foldouts 8.0.1 Introduction 8: Foldouts 8.0.1 Introduction Overview This chapter includes foldouts with illustrations of the robot. 3HAC026320-001 Revision: A...
  • Page 140 8 Foldouts 8.0.1 Introduction 3HAC026320-001 Revision: A...
  • Page 151 9 Circuit diagram 9.0.1 Introduction 9: Circuit diagram 9.0.1 Introduction Overview This chapter includes the complete circuit diagram for the robot. 3HAC026320-001 Revision: A...
  • Page 152 9 Circuit diagram 9.0.2 Sheet 101 List of contents 9.0.2 Sheet 101 List of contents 3HAC026320-001 Revision: A...

  • Page 153: Sheet 102 Connection Point Location

    9 Circuit diagram 9.0.3 Sheet 102 Connection point location 9.0.3 Sheet 102 Connection point location 3HAC026320-001 Revision: A...

  • Page 154: Sheet 103 Serial Measurement Board

    9 Circuit diagram 9.0.4 Sheet 103 Serial measurement board 9.0.4 Sheet 103 Serial measurement board 3HAC026320-001 Revision: A...

  • Page 155: Sheet 104 Motor Axes 1 - 3

    9 Circuit diagram 9.0.5 Sheet 104 Motor axes 1 - 3 9.0.5 Sheet 104 Motor axes 1 - 3 3HAC026320-001 Revision: A...

  • Page 156: Sheet 105 Feedback Axes 1 - 3

    9 Circuit diagram 9.0.6 Sheet 105 Feedback axes 1 - 3 9.0.6 Sheet 105 Feedback axes 1 - 3 3HAC026320-001 Revision: A...

  • Page 157: Sheet 106 Motor Axes 4 - 6

    9 Circuit diagram 9.0.7 Sheet 106 Motor axes 4 - 6 9.0.7 Sheet 106 Motor axes 4 - 6 3HAC026320-001 Revision: A...

  • Page 158: Sheet 107 Feedback Axes 4 - 6

    9 Circuit diagram 9.0.8 Sheet 107 Feedback axes 4 - 6 9.0.8 Sheet 107 Feedback axes 4 - 6 3HAC026320-001 Revision: A...

  • Page 159: Sheet 108 Customer Connection (Option)

    9 Circuit diagram 9.0.9 Sheet 108 Customer connection (Option) 9.0.9 Sheet 108 Customer connection (Option) 3HAC026320-001 Revision: A...

  • Page 160: Sheet 109 Integrated Wirefeed Cabling (Option)

    9 Circuit diagram 9.0.10 Sheet 109 Integrated wirefeed cabling (Option) 9.0.10 Sheet 109 Integrated wirefeed cabling (Option) 3HAC026320-001 Revision: A...

  • Page 161: Sheet 110 Position Indicator Axis 1

    9 Circuit diagram 9.0.11 Sheet 110 Position indicator axis 1 9.0.11 Sheet 110 Position indicator axis 1 3HAC026320-001 Revision: A...

  • Page 162: Sheet 111 External Connections (Option)

    9 Circuit diagram 9.0.12 Sheet 111 External connections (Option) 9.0.12 Sheet 111 External connections (Option) 3HAC026320-001 Revision: A...
  • Page 163 Index Absolute Accuracy, calibration negative directions, axes brakes oil change testing function, safety risks, calibrating position, robot roughly, positive directions, axes calibration Absolute Accuracy type, revolution counters alternative method, storing on FlexPendant, Calibration Pendulum, updating, Levelmeter calibration, robot position marks/scales, rough, Safety, service standard method,...
  • Page 164 Index 3HAC026320-001...
  • Page 166 ABB AB Robotics Products S-721 68 VÄSTERÅS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592...

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