ABB IRB 140 Manuel utilisateur

ABB Robotics

Product manual

IRB 140

Trace back information:

Workspace R13-1 version a7

Checked in 2013-04-02

Skribenta version 1184

Product manual

IRB 140 type C

IRB 140T type C

IRB 140-6/0.8 type C

IRB 140T-6/0.8 type C

M2004

Document ID: 3HAC027400-001

Revision: K

The information in this manual is subject to change without notice and should not

be construed as a commitment by ABB. ABB assumes no responsibility for any errors

that may appear in this manual.

Except as may be expressly stated anywhere in this manual, nothing herein shall be

construed as any kind of guarantee or warranty by ABB for losses, damages to

persons or property, fitness for a specific purpose or the like.

In no event shall ABB be liable for incidental or consequential damages arising from

use of this manual and products described herein.

This manual and parts thereof must not be reproduced or copied without ABB's

written permission.

Additional copies of this manual may be obtained from ABB.

The original language for this publication is English. Any other languages that are

supplied have been translated from English.

ABB AB

Robotics Products

SE-721 68 Västerås

Sweden

Table of contents
9Overview of this manual ...................................................................................................................
12Product documentation, M2004 .......................................................................................................
14How to read the product manual ......................................................................................................
151 Safety
151.1 Introduction to safety information ......................................................................... 161.2 General safety information .................................................................................. 161.2.1 Introduction to general safety information .................................................... 171.2.2 Safety in the manipulator system ............................................................... 181.2.3 Safety risks ............................................................................................ 181.2.3.1 Safety risks during installation and service work on manipulators ......... 211.2.3.2 CAUTION - Hot parts may cause burns! ........................................... 221.2.3.3 Safety risks related to tools/work pieces .......................................... 231.2.3.4 Safety risks related to pneumatic/hydraulic systems .......................... 241.2.3.5 Safety risks during operational disturbances ..................................... 251.2.3.6 Risks associated with live electric parts ........................................... 271.2.4 Safety actions ......................................................................................... 271.2.4.1 Safety fence dimensions ............................................................... 281.2.4.2 Fire extinguishing ........................................................................ 291.2.4.3 Emergency release of the manipulator’s arm .................................... 301.2.4.4 Brake testing .............................................................................. 311.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" ........................ 321.2.4.6 Safe use of the FlexPendant .......................................................... 331.2.4.7 Work inside the manipulator's working range ................................... 341.2.5 Safety stops ........................................................................................... 341.2.5.1 What is an emergency stop? .......................................................... 361.3 Safety related instructions .................................................................................. 361.3.1 Safety signals in the manual ...................................................................... 381.3.2 Safety symbols on manipulator labels ......................................................... 431.3.3 DANGER - Moving manipulators are potentially lethal! ................................... 441.3.4 DANGER - First test run may cause injury or damage! ................................... 451.3.5 DANGER - Make sure that the main power has been switched off! .................... 471.3.6 WARNING - The unit is sensitive to ESD! ..................................................... 491.3.7 WARNING - Safety risks during handling of batteries ..................................... 501.3.8 WARNING - Safety risks during work with gearbox lubricants (oil or grease) ......
532 Installation and commissioning
532.1 Introduction ...................................................................................................... 542.2 Unpacking ....................................................................................................... 542.2.1 Pre-installation procedure ......................................................................... 582.2.2 Working range, IRB 140 ........................................................................... 602.2.3 Risk of tipping/stability ............................................................................. 612.3 On-site installation ............................................................................................ 612.3.1 Lifting the manipulator with lifting slings ...................................................... 622.3.2 Lifting and turning the manipulator ............................................................. 632.3.3 Manually releasing the brakes ................................................................... 662.3.4 Orienting and securing the manipulator ....................................................... 672.3.5 Fitting equipment on manipulator .............................................................. 692.3.6 Loads .................................................................................................... 702.3.7 Setting the system parameters for a suspended robot .................................... 722.3.8 Bolt pattern ............................................................................................ 742.3.9 Installation of signal lamp (option) .............................................................. 752.4 Restricting the working range .............................................................................. 752.4.1 Restricting the working range .................................................................... 762.5 Electrical connections ........................................................................................ 762.5.1 Customer connections on manipulator .......................................................
3HAC027400-001 Revision: K 5
© Copyright 2004-2013 ABB. All rights reserved.
Table of contents

Maintenance
1 Introduction ...................................................................................................... 803.2 Maintenance schedules ...................................................................................... 803.2.1 Specification of maintenance intervals ........................................................ 813.2.2 Maintenance schedule ............................................................................. 833.3 Inspection activities ........................................................................................... 833.3.1 Inspection, damper axes 2, 3 and 5 ............................................................. 853.3.2 Inspection, robot cabling .......................................................................... 863.3.3 Inspection, timing belts ............................................................................ 893.4 Cleaning activities ............................................................................................. 893.4.1 Cleaning, robot ...................................................................................... 913.5 Changing/ replacing activities .............................................................................. 913.5.1 Type of lubrication in gearboxes ................................................................ 923.5.2 Changing the oil in axes 5 and 6 gearboxes .................................................
Repair
1 Introduction ...................................................................................................... 964.2 General procedures ........................................................................................... 964.2.1 Mounting instructions for bearings ............................................................. 984.2.2 Mounting instructions for seals .................................................................. 1004.2.3 Replacing parts on Clean Room robots ....................................................... 1024.3 Complete robot ................................................................................................. 1024.3.1 Replacement of cable harness ................................................................... 1104.3.2 Replacement of complete upper arm .......................................................... 1164.3.3 Replacement of complete lower arm ........................................................... 1204.3.4 Replacement of base ............................................................................... 1244.4 Upper arm ....................................................................................................... 1244.4.1 Replacement of wrist unit ......................................................................... 1284.4.2 Replacing the damper, axis 3 ..................................................................... 1304.4.3 Replacement of damper, axis 5 .................................................................. 1324.4.4 Replacement of cover, arm housing ............................................................ 1354.5 Lower arm ....................................................................................................... 1354.5.1 Replacement of lower arm cover and gasket ................................................ 1394.5.2 Replacing the damper, axis 2 ..................................................................... 1414.6 Frame and base ................................................................................................ 1414.6.1 Replacement of cover, console .................................................................. 1444.6.2 Replacement of console ........................................................................... 1484.6.3 Replacing the serial measurement unit and the battery pack ........................... 1544.6.4 Replacement of control cable .................................................................... 1584.7 Motors ............................................................................................................ 1584.7.1 Replacement of motor, axis 1 ................................................................... 1624.7.2 Replacement of motor, axis 2 .................................................................... 1664.7.3 Replacement of motor and timing belt, axis 3 ............................................... 1724.7.4 Replacement of motor, axis 4 .................................................................... 1764.7.5 Replacement of motor and timing belt, axes 5 or 6 ........................................ 1824.7.6 Adjustments and measurements ................................................................ 1824.7.6.1 Measuring the gear play, axis 5 ...................................................... 1844.7.6.2 Measuring the gear play, axis 6 ...................................................... 1864.8 Gearboxes ....................................................................................................... 1864.8.1 Replacement of gearbox, axes 1-2 and damper, axis 1 ................................... 1924.8.2 Service work on gearbox, axis 4 ................................................................. 1934.8.3 Amount of oil .........................................................................................
Calibration information
1 Introduction ..................................................................................................... 1965.2 Calibration methods ........................................................................................... 1985.3 Calibration scale and correct axis position ............................................................. 1995.4 Calibration movement directions for all axes ..........................................................
3HAC027400-001 Revision: K
© Copyright 2004-2013 ABB. All rights reserved.
Table of contents

2005.5 Updating revolution counters ............................................................................... 2025.6 Checking the calibration position ..........................................................................

2036 Decommissioning

2036.1 Environmental information ..................................................................................

2057 Robot description

2057.1 Type C of IRB 140 .............................................................................................

2078 Reference information

2078.1 Introduction ...................................................................................................... 2088.2 Applicable safety standards ................................................................................ 2108.3 Unit conversion ................................................................................................. 2118.4 Screw joints .................................................................................................... 2148.5 Weight specifications ......................................................................................... 2158.6 Standard tools .................................................................................................. 2168.7 Special tools .................................................................................................... 2178.8 Performing a leak-down test ............................................................................... 2188.9 Lifting accessories and lifting instructions ..............................................................

2199 Spare part lists

2199.1 Introduction ...................................................................................................... 2209.2 Spare parts - robot IRB 140 .................................................................................

22910 Circuit diagram

22910.1 About circuit diagrams .......................................................................................

231Index

3HAC027400-001 Revision: K 7

Table of contents

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Overview of this manual

About this manual

This manual contains instructions for:

• mechanical and electrical installation of the robot

• maintenance of the robot

• mechanical and electrical repair of the robot.

Usage

This manual should be used during:

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

foundation to making it ready for operation

• maintenance work

• repair work and calibration.

Who should read this manual?

This manual is intended for:

• installation personnel

• maintenance personnel

• repair personnel.

Prerequisites

A maintenance/repair/installation craftsman working with an ABB Robot must:

• be trained by ABB and have the required knowledge of mechanical and

electrical installation/repair/maintenance work.

Organization of chapters

The manual is organized in the following chapters:

ContentsChapter

Safety information that must be read through before performing

any installation or service work on robot. Contains general

safety aspects as well as more specific information about how

to avoid personal injuries and damage to the product.

Safety, service

Required information about lifting and installation of the robot.Installation and commis-

sioning

Step-by-step procedures that describe how to perform mainten-

ance of the robot. Based on a maintenance schedule that may

be used in the work of planning periodical maintenance.

Maintenance

Step-by-step procedures that describe how to perform repair

activities of the robot. Based on available spare parts.

Repair

Procedures that does not require specific calibration equipment.

General information about calibration.

Calibration information

Environmental information about the robot and its components.Decommissioning

Useful information when performing installation, maintenance

or repair work. Includes lists of necessary tools, additional

documents, safety standards, etc.

Reference information

Continues on next page

3HAC027400-001 Revision: K 9

Overview of this manual

ContentsChapter

Complete spare part list and complete list of robot components,

shown in exploded views.

Spare parts and exploded

views

References to the circuit diagrams for the robot.Circuit diagram

References

Document IDReference

3HAC6816-3Circuit diagram - IRB 140 type C

3HAC021313-001Product manual - IRC5

3HAC041346-001Product specification - IRB 140

3HAC16590-1Operating manual - IRC5 with FlexPendant

3HAC16578-1Operating manual - Calibration Pendulum

3HAC025709-001Operating manual - Service Information System

3HAC042927-001Technical reference manual - Lubrication in gearboxes

3HAC16581-1Technical reference manual - RAPID Instructions, Functions and

Data types

3HAC030421-001Application manual - CalibWare Field 5.0

Revisions

DescriptionRevision

First edition, see also Type C of IRB 140 on page 205.-

IRB 140-6/0.8 and IRB 140T-6/0.8 added.A

Clean room added.B

Changes made in:

•Prerequisites in section Overview

•Oil change in section Maintenance

Content updated in section:

•Making robot ready for operation, Cleanroom ,Additional installa-

tion procedure.

Content updated in section:

•Repair, exchange of parts on Clean room robots

•Maintenance, Cleaning of robot

•Maintenance schedule: Interval for replacement of battery pack

changed.

• Section What is an emergency stop? added to chapter Safety.

Content updated in sections:

• Article numbers added or replaced in sections Replacement of

complete upper arm on page 110,Replacement of complete lower

arm on page 116,Replacement of gearbox, axes 1-2 and damper,

axis 1 on page 186, and Type C of IRB 140 on page 205.

Continues on next page

10 3HAC027400-001 Revision: K

Overview of this manual

Continued

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