340a

Introduction CONTENTS Page 1 Introduction ..................................................................................................................... 1.1 How to use this Manual .......................................................................................... 1.2 What you must know before you use the Robot..................................................... 1.3 Identification........................................................................................................... 1.4 Structure Manipulator.............................................................................................

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Introduction 1 Introduction 1.1 How to use this Manual This manual provides information on installation, preventive maintenance, and how to carry out repairs on the manipulator. Its intended audience is trained maintenance personnel with expertise in both mechanical and electrical systems. The manual does not in any way assume to take the place of the maintenance course offered by ABB Flexible Automation. Servicing and maintenance routines are described in the chapter on Maintenance. There are chapters and paragraphs in this manual that refers to functionality related to a complete robot system (controller and manipulator). As the IBR340A is delivered from ABB Flexible Automation as a mechanical unit these chapters are not fully applicable to this delivery. The following chapters or parts of the chapters will include information that refers to a complete robot system. Chapter 1. Introduction 1.4 Structure manipulator Chapter 3. Safety 1.1 General 1.1.1 Introduction 1.5.1 Normal operations 1.6 Programming. testing and servicing 1.7 Safety functions 1.7.1 The safety control chain of operation 1.7.2 Emergency stops 1.7.3 Mode selection using the operating mode selector 1.7.4 Programming and testing at reduced speed 1.7.5 Testing at full speed 1.7.6 Automatic operation 1.7.7 Enabling device 1.7.8 Hold-to-run control 1.7.9 General mode safeguard stop connection 1.7.10 Automatic mode safeguard stop connection 1.7.11 Limiting the working space 1.7.12 Supplementary functions 1.10 Risks during installation and service 1.12 Risks associated with live electric parts Chapter 4. Decommissioning 1.1.1 Manipulators Product Manual

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Introduction 1.1.2 Controller Chapter 5.Installation and commissioning 1.1 System diskette Chapter 7. Repairs 8 Calibration 8.1 General

1.2 What you must know before you use the Robot Normal maintenance and repair work Usually requires only standard tools. Some repairs, however, require specific tools. These repairs and the type of tool required, are described in more detail in the chapter Repairs. The power supply Must always be switched off whenever work is carried out in the controller cabinet.

All personnel working with the robot system must be very familiar with the safety regulations outlined in the chapter on Safety. Incorrect operation can damage the robot or injure someone.

1.3 Identification Identification plates indicating the type of robot and serial number, etc., are located on the manipulator (see Figure 1). Note! The identification plates and label shown in the figures below, only serve as examples. For exact identification see the plates on the robot in question.

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Introduction

ABB Robotics Products AB S-721 68 Västerås Sweden Made in Sweden IRB 6400R M2000

Type:

IRB 6400R/2.5-150

Robot version:

XXXXXX

Man. order: Nom. load

See instructions

Serial. No:

6400R-XXXX 2000-XX-XX

Date of manufacturing: Net weight 2,5.120 : 2060 kg 2.5-150 : 2060 kg 2,5-200 : 2230 kg

IRB 140(0)

IRB 640

IRB 2400

IRB 340

Identification plate showin the IRB 6400R / M2000

2,8-150 : 2240 kg 2,8-200 : 2390 kg 3.0-100 : 2250 kg

IRB 4400

IRB 140

IRB 6400R

IRB 840/A

Figure 1 Examples of identification plate and its location on different manipulator types.

1.4 Structure Manipulator The robot is made up of two main parts, the manipulator and controller. The controller is described in the Adept Manual. The Manipulator is equipped with maintenance-free AC motors, which have electromechanical brakes. The brakes lock the motors when the robot is inoperative Product Manual

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Introduction for more than 1000 hours. The time can be configured by the user. The following figures show the various ways in which the different manipulators move and their component parts. Motor axis 5 Motor axis 6

Axis 3 Axis 4

Axis 5 Axis 6

Motor axis 4

Upper arm

Lower arm

Axis 2 Motor axis 1

Motor axis 2

Motor axis 3 Axis 1

Base Figure 2 The motion patterns of the IRB 1400 and IRB 140.

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Motor unit axis 4 Motor unit axis 5 Motor unit axis 6

Upper arm Axis 4 Axis 3

Axis 6 Axis 5 Motor unit and gearbox axis 1

Lower arm Axis 2 Motor unit and gearbox axis 2

Motor unit and gearbox axis 3 Axis 1

Base Figure 3 The motion patterns of the IRB 2400.

Axis 5

Upper arm

Axis 4

Motor axis 4 Motor axis 5 Motor axis 6

Axis 6 Axis 3

Lower arm Axis Motor axis Motor axis Axis 1

Motor axis Base

Figure 4 The motion patterns of the IRB 4400

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Introduction

Upper arm

Axis 3

Axis4

Motor axis 4

Motor axis 5 Axis 5 Motor axis 6 Axis 6

Axis 2 Motor axis 1 Motor axis 2 Motor axis 3

Axis 1

Lower arm

Base Figure 5 The motion patterns of the IRB 6400R M99.

Axis 3

Upper arm

Motor axis 6

Axis 6 Axis 2 Motor axis 2 Motor axis 3 Lower arm Motor axis 1

Axis 1

Figure 6 The motion patterns of the IRB 640.

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Motor 1(X)-axis

Motor 3(Z)-axis

Motor 2(Y)-axis Motor 4(C)-axis 2(Y)-axis

3(Z)-axis 4(C)-axis 1(X)-axis

Figure 7 The motion patterns of the IRB 840/A

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Introduction . Axis 3 Axis 2

Axis 3

Upper arm (x3)

Y Axis 2

Base box

Motors encapsulated

Bars (x3)

Axis 1 Axis 4, telescopic shaft (option)

Swivel X

Z Figure 8 The motion patterns of the IRB 340.

Motor axis 4 Motor axis 5 Motor axis 6

Axis 3 Axis 4

Lower arm

Upper arm Axis 5

Axis 2 Axis 6

Motor axis 1 Motor axis 3

Motor axis 2 Axis 1 Base Figure 9 The motion patterns of the IRB 140.

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Product Specifikation IRB 340 1 Description ...................................................................................................................... 1.1 Structure ................................................................................................................. Figure 1 Different robot version........................................................................... 1.2 Safety/Standards..................................................................................................... 1.3 Installation.............................................................................................................. Operating requirements ......................................................................................... Mounting the manipulator .................................................................................... Load diagrams ....................................................................................................... Maximum Pressure Force...................................................................................... Extra equipment mounted on the manipulator arms.............................................. 1.4 Maintenance and Troubleshooting ......................................................................... 1.5 Robot Motion ......................................................................................................... 2 Specification of Variants and Options .......................................................................... 3 Index ................................................................................................................................

Product Specification IRB 340 M2000

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Product Specification IRB 340

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Product Specification IRB 340 M2000

Description

1 Description 1.1 Structure The IRB 340A family consists of 4-axes industrial robots in a modular design, specifically for industries with a great need for flexible automation. The IRB 340A is available as a manipulator only, designed to work only with a controller provided by Adept Technology Inc.

Axis 1

Axis 2

Axis 4 Axis 3

TCP 0 Figure 1 The IRB 340A manipulator.

Different robot version The IRB 340A is available in two versions: - IRB 340A, the 4-axes version with x, y, z and θ movements - IRB 340ASA, the 4-axes Wash Down version with x, y, z and θ=movements Weight:

Manipulator

Airborne noise level: The sound pressure level outside the working space

Product Specification IRB 340A M2000

140 kg < 70 dB (A) Leq (acc. to Machinery directive 89/392 EEC)

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Description

330

Axis 2

Axis 1

860 Axis 3

250

R=566

Axis 2

Axis 1

Axis 3

Figure 2 Views of the manipulator (dimensions in mm).

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Product Specification IRB 340A M2000

Description

1.2 Safety/Standards The mechanical unit conforms to the following standards: EN 292-1 Safety of machinery, terminology EN 292-2 Safety of machinery, technical specifications EN 775 Robot Safety EN 60204 Electrical equipment of industrial machines IEC 529 Degrees of protection provided by enclosures Safety lamp (option) As an option, the robot can be equipped with a safety lamp. This is activated when the motors are in the MOTORS ON/HIGH POWER state.

1.3 Installation An end effector, max. weight 0.5 kg including payload, can be mounted on the robot’s mounting flange. See Load diagrams on page 7-9. Other equipment, such as a hose, can be mounted on the upper and lower arm, max weight 300 g/m. See Extra equipment mounted on the manipulator arms on page 10. Operating requirements Protection standards Manipulator IRB 340A Manipulator IRB 340ASA

IP55 IP67

Explosive environments The robot must not be located or operated in an explosive environment. Ambient temperature Manipulator during operation +5oC (41oF) to +52oC (125oF) Manipulator during transportation and storage -25oC (13oF) to +55oC (131oF) Note If the robot operates in a temperature > +35oC, the air flow, generated by the fan, must be evacuated. The short cut hose (a) or the tube bend (for SA-version) should be b replaced by inlet/outlet for external air (b). Air in Air out b a

Hard environment and a lot of starts and stops can cause condensation inside the base!. For the SA-variants a plate for air circulation, option 061, have to be mounted for external air.

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Description Relative humidity Manipulator during transportation and storage Manipulator during operation

Max. 95% at constant temperature Max. 95% at constant temperature

Mounting the manipulator Maximum force in the fixing points is 1000 N referring to the z-direction in the base coordinate system. Robot frame is not included in the delivery. Required stiffness of frame: Lowest natural frequency of frame with robot > 17 Hz. The working space is shown in Figure 9

Axis 2

R 370

o

) (3x

A

120

A

A Y Axis 3 Clamping plane Area for calibration tool

12

M1 6

X

40

. 0 03)3

o

A

25 H8 + ( 0

30

Axis 1 Clamping plane

A-A

39

Figure 3 Hole configuration (dimensions in mm).

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Product Specification IRB 340A M2000

Description Load diagrams Note The weight permitted for loads includes grippers etc.

IRB 340A and 340ASA 4-axes Load 100 g 0

10 20 30 40 50 60 70

L (mm)

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140

100%

150 160 170

Z (mm) Z = See the above diagram and the coordinate system in Adept manuals. L = Distance in X-Y plane from Z-axis to the mass centre of gravity of the load. Figure 4 Maximum weight permitted for load (100 g) mounting on the mounting flange at different positions (centre of gravity).

Product Specification IRB 340A M2000

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Description

Note The weight permitted for loads includes grippers etc.

IRB 340A and 340ASA 4-axes Load 300 g 0

10 20 30 40 50 60 70

L (mm)

0 10 20 30 40 50 60 70 80 90 100 110

100%

120 130 140 150 160 170

Z (mm) Z = See the above diagram and the coordinate system in Adept manuals. L = Distance in X-Y plane from Z-axis to the mass centre of gravity of the load. Figure 5 Maximum weight permitted for load (300 g) mounting on the mounting flange at different positions (centre of gravity).

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Product Specification IRB 340A M2000

Description Note The weight permitted for loads includes grippers etc.

IRB 340A and 340ASA 4-axes Load 500 g 0

10 20 30 40 50 0

L (mm) 10 20 30 40 50 60 70 80 90 100

100%

110

Z (mm) Z = See the above diagram and the coordinate system in Adept Manuals. L = Distance in X-Y plane from Z-axis to the mass centre of gravity of the load. Figure 6 Maximum weight permitted for load (500 g) mounting on the mounting flange at different positions (centre of gravity).

Maximum Pressure Force Maximum pressure force in X, Y and Z-direction is allowed to be 100 N. Maximum torque of axis 4 = 1,0 Nm.

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Description Extra equipment mounted on the manipulator arms

300 100

50

40

0 30

Limitation lines for centre of gravity for M2

20 40 20

0 50

Limitation lines for centre of gravity for M1 TCP 0 Figure 7 Definition of extra load on robot arms (measures in mm).

The robot is prepared for the medium hose (option 045). If this options is used no extra load should be defined. If the medium hose is not chosen: - and both M1 and M2 are less than 175 g each, the robot can run with full performance and no extra load should be defined - and M1 is more than 175 g, an extra load should be defined in the load definition. The extra load should be M1−175 g. Maximum extra load allowed is 175 g (M1 max = 350 g) - and M2 is more than 175 g, an extra load should be defined in the load definition. The extra load should be M2−175 g. Maximum extra load allowed is 175 g (M2 max = 350 g) The extra load should be defined in TCP 0.

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Product Specification IRB 340A M2000

Description

2xR1/4” Key grip 22 mm, h 6 mm

Ø52 Ø25

Mounting flange R3/8”, depth 14 mm

Figure 8 The mechanical interface (mounting flange), four axis version.

1.4 Maintenance and Troubleshooting The robot requires only a minimum of maintenance during operation. It has been designed to make it as easy to service as possible: - Maintenance-free AC motors are used. - Oil is used for the gear boxes. - The cabling is routed for longevity, and in the unlikely event of a failure, its modular design makes it easy to change. The maintenance intervals depends on the use of the robot. For detailed information on maintenance procedures, see the Maintenance section in the Product Manual.

Product Specification IRB 340A M2000

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Description

1.5 Robot Motion The extreme positions of robot arm is shown in Figure 10

860

Z 250

X

Maximum working space inside cylinder. Working space can be reduced in x-y-z coordinates

Base coordinate system

Axis 2 R

6 56

Y

X

Axis 1

Axis 3 The numbers of the axes are marked at the bottom of the clamping surface respectively Figure 9 Working space of IRB 340A (dimensions in mm).

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Product Specification IRB 340A M2000

Description

Extreme values of arm angles:

P2

Position P1 U = 100o V = 95,5o W = 134,5o

0

Position P2 U = -46,1o V = -50,6o W = 43,9o

+ U

Angles defined according to figure

V W

Mechanical hard-stop: When angle U< -46,1o hard-stop is reached.

P1

Figure 10 The extreme positions of robot arms.

Product Specification IRB 340A M2000

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Description

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Product Specification IRB 340A M2000

Specification of Variants and Options

2 Specification of Variants and Options The different variants and options for the IRB 340A are described below. The same numbers are used here as in the Specification form.

1 MANIPULATOR 026 IRB 340A The 4-axes variant 028 IRB 340ASA The 4-axes variant, Wash Down

APPLICATION INTERFACE Hose to tool point 044 Small hose, D = 6/4 mm 045 Medium hose, D = 15/10 mm Connection to cabinet (Cable lengths) 632 633 634 635

7m 15m 22m 30m Equipment

691 Safety lamp A safety lamp with an orange fixed light can be mounted on the manipulator. The lamp is active in MOTORS ON mode. 061 In/outlet for external air Plate for connecting external air into the base of the manipulator (inlet and outlet, diameter 76 mm) for internal air circulation. Recommended for warm or cold environments.

Product Specification IRB 340A M2000

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Specification of Variants and Options

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Product Specification IRB 340A M2000

Description C cooling device 3 E extra equipment 10 H hard-stop 13 humidity 6 I installation 5 L load 5 load diagrams 7 M maintenance 11 mechanical interface 11 motion 12 mounting extra equipment 10 robot 6 mounting flange 11 N noise level 3 O operating requirements 5 options 15 P payload 5 protection standards 5 S safety 5 safety lamp 5, 15 service 11 space requirements 3 standards 5 structure 3 T temperature 5 troubleshooting 11 V variants 15 W weight 3 working space 12

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Safety CONTENTS Page 1 Safety ................................................................................................................. 1.1 General...................................................................................................... 1.2 Fire-Extinguishing...................................................................................... 1.3 Safe Working Procedures ......................................................................... 1.3.1 Normal operations ........................................................................... 1.4 Programming, Testing and Servicing......................................................... 1.5 Safety Functions........................................................................................ 1.5.1 Emergency stops............................................................................. 1.5.2 Mode selection using the operating mode selector ......................... 1.5.3 Programming and testing at reduced speed.................................... 1.5.4 Automatic operation......................................................................... 1.6 Safety Risks Related to End Effectors ...................................................... 1.6.1 Gripper............................................................................................. 1.6.2 Tools/workpieces ............................................................................. 1.6.3 Pneumatic/hydraulic systems .......................................................... 1.7 Risks during Operation Disturbances........................................................ 1.8 Risks during Installation and Service ........................................................ 1.9 The following standards are of interest when the robot is parts of a cell... 1.10 Risks Associated with Live Electric Parts................................................ 1.11 Emergency Release of Mechanical Arm ................................................. 1.12 Limitation of Liability ................................................................................ 1.13 Related Information .................................................................................

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Safety 1 Safety 1.1 General This information on safety covers functions that have to do with the operation of the industrial robot. 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 has to 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. People who work with robots must be familiar with the operation and handling of the industrial robot, described in applicable documents, e.g. Adept Manuals and Product Manual.

1.2 Fire-Extinguishing Use a CARBON DIOXIDE extinguisher in the event of a fire in the robot (manipulator or controller).

1.3 Safe Working Procedures Safe working procedures must be used to prevent injury. No safety device or circuit may be modified, bypassed or changed in any way, at any time. 1.3.1 Normal operations All normal operations in automatic mode must be executed from outside the safeguarded space.

1.4 Programming, Testing and Servicing The robot is extremely heavy and powerful, even at low speed. When entering into the robot’s safeguarded space, the applicable safety regulations of the country concerned must be observed. Operators must be aware of the fact that the robot can make unexpected movements. A pause (stop) in a pattern of movements may be followed by a movement at high speed. Operators must also be aware of the fact that external signals can affect robot

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Safety programs in such a way that a certain pattern of movement changes without 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. - The robot’s speed is limited to max. 250 mm/s (10 inches/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. Note! do not change “Transm gear ratio” or other kinematic parameters from the teach pendant or a PC. This will affect the safety function Reduced speed 250 mm/s. - During programming and testing, the enabling device must be released as soon as there is no need for the robot to move. Note! the enabling device must never be rendered inoperative in any way. - The programmer must always take the teach pendant with him/her when entering through the safety gate to the robot’s working space so that no-one else can take over control of the robot without his/her knowledge.

1.5 Safety Functions The Safety Functions for the controller and the handling of the robot are further described in the Adept Manuals. 1.5.1 Emergency stops An emergency stop should be activated if there is a danger to people or equipment. Built-in emergency stop buttons are located on the operator’s panel of the robot controller and on the teach pendant. External emergency stop devices (buttons, etc.) can be connected to the safety chain by the user (see Adept Manuals). They must be connected in accordance with the applicable standards for emergency stop circuits. Before commissioning the robot, all emergency stop buttons or other safety equipment must be checked by the user to ensure their proper operation. Before switching to MOTORS ON mode again, establish the reason for the stop and rectify the fault.

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Safety 1.5.2 Mode selection using the operating mode selector The applicable safety requirements for using robots, laid down in accordance with ISO/DIS 10218, are characterised by different modes, selected by means of control devices and with clear-cut positions. One automatic and two manual modes are available: Manual mode: < 250 mm/s - max. speed is 250mm/s 100% - full speed Automatic mode: The robot can be operated via a remote control device The manual mode, < 250 mm/s or 100%, must be selected whenever anyone enters the robot’s safeguarded space. The robot must be operated using the teach pendant and, if 100% is selected, using Hold-to-run control. In automatic mode, the operating mode selector is switched to , and all safety arrangements, such as doors, gates, light curtains, light beams and sensitive mats, etc., are active. No-one may enter the robot’s safeguarded space. All controls, such as emergency stops, the control panel and control cabinet, must be easily accessible from outside the safeguarded space. 1.5.3 Programming and testing at reduced speed Robot movements at reduced speed can be carried out as follows: ◆ Set the operating mode selector to <250 mm/s ◆ Programs can only be started using the teach pendant with the enabling device activated. The automatic mode safeguarded space stop (AS) function is not active in this mode. 1.5.4 Automatic operation Automatic operation may start when the following conditions are fulfilled: ◆

The operating mode selector is set to

The MOTORS ON mode is selected Either the teach pendant can be used to start the program or a connected remote control device. These functions should be wired and interlocked in accordance with the applicable safety instructions and the operator must always be outside the safeguarded space. ◆

1.6 Safety Risks Related to End Effectors 1.6.1 Gripper If a gripper is used to hold a workpiece, inadvertent loosening of the workpiece must be prevented. Product Manual

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Safety 1.6.2 Tools/workpieces 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. Grippers must be designed so that they retain workpieces in the event of a power failure or a disturbance of the controller. It should be possible to release parts by manual operation (valves). 1.6.3 Pneumatic/hydraulic systems Special safety regulations apply to pneumatic and hydraulic systems. 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. 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.

1.7 Risks during Operation Disturbances 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. Remedial action must only ever be carried out by trained personnel who are familiar with the entire installation as well as the special risks associated with its different parts. 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 applicable safety regulations. Care must be taken at all times.

1.8 Risks during Installation and Service 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. Note! 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. Special attention must be paid to the following points: - 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

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Safety that function. - The instructions in the Product Manual/Installation must always be followed. - The mains supply to the robot must be connected in such a way that it can be turned off outside the robot’s working space. - 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. - Emergency stop buttons must be positioned in easily accessible places so that the robot can be stopped quickly. - 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 away from the robot’s working space. - 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. 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. Even if the power supply for the robot is turned off, you can still injure yourself. - The axes are affected by the force of gravity when the brakes are released. In addition to the risk of being hit by moving robot parts, you run the risk of being crushed by the tie rod. - Energy, stored in the robot for the purpose of counterbalancing certain axes, may be released if the robot, or parts thereof, is dismantled.

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Safety - When dismantling/assembling mechanical units, watch out for falling objects. - Be aware of stored energy (DC link) and hot parts in the controller. - Units inside the controller, e.g. I/O modules, can be supplied with external power.

1.9 The following standards are of interest when the robot is parts of a cell EN 294

Safety of machinery - Safety distance to prevent danger zones being reached by the upper limbs.

EN 349

Safety of machinery - Minimum gaps to avoid crushing of parts of the human body.

EN 811

Safety of machinery - Safety distance to prevent danger zones being reached by the lower limbs.

Pr EN 999

Safety of machinery - The positioning of protective equipment in respect of approach speeds of the human body.

EN 1088

Safety of machinery - Inter locking device associated with guards principles for design and selection.

1.10 Risks Associated with Live Electric Parts Controller A danger of high voltage is associated with the following parts: - The mains supply/mains switch - The power unit - The power supply unit for the computer system - The rectifier unit - The drive unit - The service outlets - The power supply unit for tools, or special power supply units for the machining process

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Safety - The rectifier unit - The drive unit - The service outlets - 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 Manipulator A danger of high voltage is associated with the manipulator in: - The power supply for the motors (up to 370 V DC) - The user connections for tools or other parts of the installation (see Installation, max. 230 V AC) 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.

1.11 Emergency Release of Mechanical Arm If an emergency situation occur where a person is trapped by the mechanical robot arm, the brake release buttons should be pressed whereby the arms can be moved to release the person. To move the arms by manpower is normally possible on the smaller robots (1400 and 2400), but for the bigger ones it might not be possible without a mechanical lifting device, like an overhead crane. If power is not available the brakes are applied, and therefore manpower might not be sufficient for any robot. Before releasing the brakes, be sure that the weight of the arms does not enhance the pressure on the trapped person.

1.12 Limitation of Liability The above information 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.

1.13 Related Information See the Adept Manuals

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Safety

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Decommissioning CONTENTS Page 1 Decommissioning ............................................................................................. 1.1 General...................................................................................................... 1.1.1 Manipulators .................................................................................... 1.1.2 Controller ......................................................................................... 1.2 Scrapping .................................................................................................. 1.2.1 General warning .............................................................................. 1.2.2 Oil and grease ................................................................................. 1.2.3 Parts requiring special treatment when scrapping........................... 1.3 IRB 4400 ................................................................................................... 1.4 IRB 6400 and IRB 640 .............................................................................. 1.4.1 Scraping Balancing cylinders ..........................................................

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Decommissioning CONTENTS Page

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Decomissioning

1 Decommissioning 1.1 General The components of the robot are manufactured from many different materials. Some of them are listed below to facilitate scrapping, i.e. so that the components can be disposed of in a way that does not have a detrimental effect on anyone’s health or the environment. 1.1.1 Manipulators

Material

Examples of components

Part of

Lead

Counter-weight

IRB 6400

Batteries, NiCad or Lithium

Serial measurement board

All robot types

Copper

Cables, motors

All robot types

Cast iron/nodular iron

Base, lower arm, upper arm, parallel bar/arm

All robot types

Steel

Gears, screws, base-frame, etc.

All robot types

Samarium-Cobalt

Brakes, motors

IRB 1400, 2400, 4400

Neodymium

Brakes, motors

IRB 6400, 640

Plastic/rubber (PVC)

Cables, connectors, drive belts, etc.

All robot types

Oil, grease

Gearboxes

All robot types

Aluminium

Covers, sync. brackets

All robot types

Castings in wrist, upper arm tubular

IRB 1400, 2400

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Decomissioning

1.1.2 Controller

Material

Examples of components

Copper

Transformers, cables

Tin

Cables

Alu-Zinc sheeting

Control cabinets, various sheet metal parts

Iron

Transformers

Polyester

Circuit boards

Plastic/rubber (PVC)

Cables, connectors, teach pendant, covers (drive units, I/O units) etc.

Lithium

Batteries

1.2 Scrapping The Counter-weight for 6400 and 640 contains lead and must therefore always be recycled. 1.2.1 General warning Before removing any parts from the manipulator, study the dismantling instructions for the component in question. Dismantling instructions can be found in under Repairs. 1.2.2 Oil and grease Where possible, arrange for the oil and grease to be recycled. Dispose of via an authorised person/contractor in accordance with local regulations. Do not dispose of oil and grease near lakes, ponds, ditches, down drains, or on to soil. Incineration may be carried out under controlled conditions in accordance with local regulations. Also note that: - Spills may form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. - Spillage may penetrate the soil causing ground water contamination.

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Decomissioning 1.2.3 Parts requiring special treatment when scrapping Special care is needed when removing certain parts from the robot, before scrapping the part in question. The types of robot on which there are such parts are listed below together with a description of how they should be removed. IRB 140, 1400, 2400 and 4400 Motors The manipulators mentioned above are equipped with spring-loaded brakes. There a tensioned spring inside the brake. When the unit is scrapped the spring can fly out and cause an eye injury. IRB 4400 Balancing cylinder The balancing cylinder contains 3 preloaded spiral springs. Before scrapping (melting down, or other form of destruction) the springs must be unloaded in a safe way. Spiral spring

Free length of spiral spring: L = 470 mm Figure 1Balancing cylinder IRB 4400.

IRB 6000/6400/6400R and IRB 640 Balancing cylinder The balancing cylinder contains 1-2 preloaded spiral springs. (see Balancing cylinder, IRB 6400 and 640. on page 6) Before scrapping (melting down, or other form of destruction) the springs must be unloaded in a safe way, (see chapter Scraping Balancing cylinders on page 6). There are different types of balancing cylinder with a preloading force between 45008000 N. Free length of unloaded springs = is about 300 - 400 mm. besides the length of the balancing cylinder.

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Decomissioning

Double Spiral spring

Singel Spiral spring

Figure 2Balancing cylinder, IRB 6400 and 640.

1.2.4 Scraping Balancing cylinders Normal way to Scrap the balancing cylinders is using a so-called shredder or scrapping mill, all the balancing cylinders can be treated this in way. An all covered mill where the scrap is ground to ships by e.g “Newell heavy duty shredder plant 2205” or similar, scrapping mills are available at all bigger scrapmerchants. Alternative ways If scrapping mills are not available the balancing cylinders except 3HAA 0001-EZ can be opened by means of a blowpipe acc. to the sketches (see Scraping Balancing cylinders on page 7). It is most important that no closed rooms remains when the scrap is shipped to the steel plant for recycling.

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Product Manual

Decomissioning

Balancing unit for IRB 6X00/6400R. Cut a hole (250 x 150 mm) in the mantel surface, and then cut all the uncovered spring. Finally cut a hole (40 mm) in the piston rod (alt.A) or cut off the piston rod end (alt.B) see Scraping Balancing cylinders on page 8. ◆ Balancing unit for Shelf version. Cut a hole (250 x 150 mm) in the outer mantel surface and cut the uncovered spring so it will be possible to cut another hole (200 x 100 mm) in the inner mantel surface, cut the inner spring., cut off the piston rod end see Scraping Balancing cylinders on page 7. ◆ Part no. 3HAA 0001-EZ and 3HAA 0001-EX (IRB 6000). This type of Balancing cylinder has an outer jacket of aluminium which means it can not be opened by means of a blowpipe, besides, the aluminium must be separated from steel before recycling, and that can only be done in a shredder or by the manufacturer. see Scraping Balancing cylinders on page 9. ◆

ca. 250

Cut off Piston rod

ca. 200

Figure 3Scraping Balancing cylinders

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Decomissioning

ca. 250 Ca Ø 40mm Cut off Spiral spring

Hole in the Piston rod

Alternative A

ca. 250

Cut off Piston rod

Cut off Spiral spring

Alternative B

Figure 4Scraping Balancing cylinders

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Product Manual

Decomissioning

Figure 5Scraping Balancing cylinders

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Decomissioning

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Product Manual

Installation and Commissioning CONTENTS Page 1 Transporting and Unpacking ......................................................................................... 3 1.1 System diskette ....................................................................................................... 3 2 On-Site Installation ......................................................................................................... 5 2.1 Lifting the manipulator........................................................................................... 5 2.2 Assembling the robot.............................................................................................. 7 2.2.1 Manipulator.................................................................................................. 7 2.2.2 Mounting the arm system and movable plate .............................................. 8 2.2.3 Mounting the telescopic shaft, axis 4........................................................... 8 2.2.4 Mounting the ventilation hose...................................................................... 8 2.2.5 Hose to tool point......................................................................................... 9 2.3 Stress forces ............................................................................................................ 9 2.3.1 Stiffness........................................................................................................ 9 2.3.2 Forces ........................................................................................................... 9 2.4 Amount of space required....................................................................................... 9 2.4.1 Manipulator.................................................................................................. 10 2.5 Manually engaging the brakes................................................................................ 11 2.6 Mounting equipment on the manipulator ............................................................... 11 2.7 Loads ...................................................................................................................... 12 2.8 Cabling.................................................................................................................... 12

Product Manual IRB 340A

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Installation and Commissioning CONTENTS Page

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Product Manual IRB 340A

Installation and Commissioning

Transporting and Unpacking

1 Transporting and Unpacking NB: Before starting to unpack and install the robot, read the safety regulations and other instructions very carefully. The installation shall be made by qualified installation personnel and should conform to all national and local codes. When you have unpacked the robot, check that it has not been damaged during transport or while unpacking. Check especially following items: - composite arms (upper arms and bar system); no hacks - joint balls; no scratches - ventilation hose; no holes Operating conditions: Ambient temperature

+ 5° to +52°C (manipulator)

Relative humidity

Max. 95% at constant temperature

Storage conditions: If the equipment is not going to be installed straight away, it must be stored in a dry area at an ambient temperature between -25°C and +55°C. When air transport is used, the robot must be located in a pressure-equalized area. The net weight of the manipulator is approximately 140 kg. Whenever the manipulator is transported, it must be in mounting position, it’s not allowed to turn the manipulator up side down.

1.1 System diskette The diskette, should be copied (in a PC) before it is used. Never work with the original diskette. When you have made copies, store the original in a safe place. Do not store the diskette near the controller due to the high temperatures there.

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Transporting and Unpacking

4

Installation and Commissioning

Product Manual IRB 340A

Installation and Commissioning

On-Site Installation

2 On-Site Installation 2.1 Lifting the manipulator

Never walk under a suspended load. The best way to lift the manipulator is to use lifting straps and a traverse crane. Attach the straps to the three lifting eyes on the base box (see Figure 1). The lifting strap dimensions must comply with the applicable standards for lifting.

Crane lift

Ventilation hose

L=1000 mm / 40 inch

Figure 1 Lifting the manipulator using a traverse crane.

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On-Site Installation

Installation and Commissioning

It is also possible to lift the manipulator using a fork lift. To do that let the manipulator rest in it’s standard delivery loading stool.

Fork lift

Figure 2 Lifting the manipulator using a fork lift.

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Product Manual IRB 340A

Installation and Commissioning

On-Site Installation

2.2 Assembling the robot

2.2.1

Manipulator The three support points of the manipulator base box shall be mounted against three flat surfaces with a flatness within the specification. Use shims if necessary. The rest of the surface must be flat within ± 2 mm. Footprint diagram, see Figure 3. The levelness requirement for the surface is as follows: 0.5

Area for calibration tool

o

60

7 R7

28

40

67

o

67

= available footprint of frame

Axis 2

R 370

o

) (3x

A

y

B

120

A

A

Axis 3 12

3

25 H8 + ( 00.03

B

)

30 o

M1 6

x

40

A Axis 1 Clamping plane

A-A

Figure 3 Bolting the manipulator (dimensions in mm).

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On-Site Installation

Installation and Commissioning

The manipulator is fixed with three M16 bolts, tightened alternately. Suitable bolts:

M16x45 8.8 Socket screw with washer (the length of the screws depends on the design of the frame)

Tightening torque:

150 Nm (oil lubricated)

Guide sleeves can be added to two of the bolt holes, to allow the same manipulator to be re-mounted without program adjustment (see Figure 3). The screw joint must be able to withstand the stress loads defined in Chapter 2.3.

2.2.2 Mounting the arm system and movable plate After the manipulator has been mounted, as described in section 2.2.1, the arm system and movable plate are assembled as described in the chapter regarding repairs.

2.2.3 Mounting the telescopic shaft, axis 4 After the arm system has been mounted, as described in section 2.2.2, the telescopic shaft is assembled as described in chapter 7, Repairs.

2.2.4

Mounting the ventilation hose Standard Mount the ventilation hose (see Figure 1) with two hose clips, 3HAC 4428-1, supplied with the robot. 340SA (Wash Down) Mount the ventilation tube with seven screws, 9ADA 181-11 and gasket 3HAC 3400-1 supplied with the robot, tightening torque 4 Nm.

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Product Manual IRB 340A

Installation and Commissioning 2.2.5

On-Site Installation

Hose to tool point Mount the hose from the Air filler down to the movable plate as shown in chapter 8, Spare Parts, foldout 1.

2.3 Stress forces

2.3.1 Stiffness The stiffness of the frame must be designed to minimize the influence on the dynamic behaviour of the robot. For optimal performance the frequency of the frame with the robot weight must be higher than 17 Hz.

2.3.2 Forces Maximum force in the fixing points is 1000 N referring to the z-direction in the base coordinate system, regarding coordinate system see Product Specification IRB 340A. Robot frame is not included in the delivery.

2.4 Amount of space required The amount of working space required to operate the manipulator is illustrated in Figure 4.

If work must be carried out within the robot’s work envelope, the robot’s speed should not exceed 250 mm/s (10 inches/s).

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On-Site Installation

2.4.1

Installation and Commissioning

Manipulator

R=362.5 ∅=1246 324

397

34

270

795

1110

Figure 4 The working space required for the manipulator.

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Product Manual IRB 340A

Installation and Commissioning

On-Site Installation

2.5 Manually engaging the brakes All axes (except axis 4) come equipped with holding brakes. When the position of a manipulator axis needs to be changed without connecting the controller, an external voltage supply (24 V DC) must be connected to enable engagement of the brakes. The voltage supply should be connected to the Burndy contact under the cover (see Figure 5). 1 4 7

2

3

5

6

0V

8

91

+ 24 V DC

10

11

12

13

14

15

Internal connector Burndy contact: R1.MP4-6

Figure 5 Connection of external voltage to enable engagement of the brakes.

When the controller or the voltage device is connected, illustrated above, the brakes can be engaged by means of the push-button, location shown in Figure 6.

Brake release button

Figure 6 Location of brake release button.

2.6 Mounting equipment on the manipulator External equipment, e.g. hoses and wiring mounted on the arms of the manipulator must have a maximum weight of 300 g/m, also see Product Specification. NB: Never drill a hole in the manipulator without first consulting maintenance staff or the design department at ABB Flexible Automation.

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On-Site Installation

Installation and Commissioning

NB: The key grip must be used when mounting any equipment at the mechanical interface to prevent a large torque on the telescopic shaft.

2xR1/4”

Ø52

Key grip 22 mm, h 6 mm Mounting flange R3/8”, depth 14 mm

Ø25

Figure 7 The mechanical interface (mounting flange), four axis version.

2.7 Loads It is important to define the loads properly (with regard to the position of centre of gravity and inertia factor) in order to avoid breakdown of arm system. For more information see Product Specification IRB 340A (Technical specification) for load diagrams, permitted extra loads (equipment) and their positions. The loads must also be defined in the software, see Adept Documentation.

2.8 Cabling When the controller is coupled up to the mechanical unit, the signal cable must be connected to ground; both at the controller and in the mechanical unit. The shield is exposed at both sides of the cable and can be connected directly, or via a cable, to a ground connection. The shield of the control cable must be connected to ground both in the mechanical unit and the controller.

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Product Manual IRB 340A

Maintenance CONTENTS Page 1 Maintenance Schedule .................................................................................................... 2 Instruction for Maintenance .......................................................................................... 2.1 General instructions for the manipulator ................................................................. 2.2 Telescopic shaft, axis 4 ............................................................................................ 2.3 Bar system ............................................................................................................... 2.4 Joint Balls ................................................................................................................ 2.5 Upper arms .............................................................................................................. 2.6 Hoses ....................................................................................................................... 2.7 Spring units.............................................................................................................. 2.8 Movable plate and swivel ........................................................................................ 2.9 Gearboxes, axes 1-3................................................................................................. 2.10 Manipulator fan ..................................................................................................... 2.11 Location of maintenance points.............................................................................

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1

Maintenance

Maintenance The robot is designed to be able to work under very demanding conditions with a minimum of maintenance. Nevertheless, certain routine checks and preventative maintenance must be carried out at specified periodic intervals, as shown in the table below. • The exterior of the robot should be cleaned as required. Use a vacuum cleaner or wipe it with a cloth. Compressed air and harsh solvents that can damage the sealing joints, bearings, lacquer or cabling, must not be used. • Check that the sealing joints and cable glands are really airtight so that dust and dirt are not sucked into the mechanical unit. • Lubricate sealings at regular intervals and when needed, recommended lubrication see 2.4 Section Bar system

1 Maintenance Schedule Prescribed maintenance

Maintenance intervals

MANIPULATOR

Check every 500 h

Check twice a year

4.000 h or 2 years

Telescopic shaft, axis 4

X

X

Bar system

X

X

Upper arms Spring unit

12,000 h or 3 years

30,000h or 5 years

X X

Movable plate and swivel Gearboxes, axis 1, 2 and 3 Manipulator Fan

X X

X X1

1. Check Roller Bearing.

2 Instructions for Maintenance Number inside < > refers to maintenance points on the manipulator, see Figure 3.

2.1 General instructions for the manipulator Check regularly: Product Manual IRB 340A

3

Maintenance • wear of bearing ring in joints of the arm system, lubricate. • wear of plain bearings in telescopic shaft (SA version). • for any oil leaks. If a major oil leak is discovered, call for service personnel. • for excessive play in gears. If play develops, call for service personnel. • that the cabling between the control cabinet and robot is not damaged. Cleaning: • Clean the robot exterior with a cloth when necessary. Do not use aggressive solvents which may damage the mechanical unit. • Cleaning instructions for Wash Down version see section 3.

2.2 Telescopic shaft, axis 4, ball bushing Interval 500 h Apply grease at <1>. Type of grease:

Mobilgrease FM 102

Optimol Obeen UF 2 Volume: 1.3 ml Check and retighten set screws. Interval 4,000 h or 2 years Exchange the part as described in chapter 7, Repairs.

2.3 Telescopic shaft, axis 4, plain bearing The wear on the bearings depends on the payload, cycle, environment and lubrication. Interval 500 h Rods Check the wear of the rods on the inside of the plain bearing. If the rods are damaged or worn out, replace the telescopic shaft as described in section 3.3, Repairs.

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Product Manual IRB 340A

Maintenance Apply a small amount of grease on the rods. Plain bearing If the plain bearings are worn out or if the becklash is excessive, replace the plain bearings as described in section 3.4, Repairs. Interval 4,000 h or 2 years Replace the part of bearings as described in 3.4, Repairs. Type of grease:

Mobilgrease FM 102 Optimol Obeen UF 2

2.4 Bar system The wear on the bearings depends on the payload, cycle , environment and lubrication. Interval 500 h Check wear rings <5>. Listen for screech. If necessary apply grease. Type of grease:

Mobilgrease FM 102 Optimol Obeen UF 2

Volume: 0.5 ml Interval 4,000 h or 2 years Check surface of tube <10> for cracks or damages. Check the distance between the wear ring holders <11>. Normal dimension should be 126 mm. If distance is less than 124 mm, the ring is worn out and must be replaced, see Figure 1. If necessary, replace parts as described in chapter 3, Repairs.

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Maintenance

126 mm

Figure 1 Wear ring holder distance

2.5 Joint Balls Check surface of the joint balls. If cracks or burrs replace them, else excessive wear on rings. If necessary replace the part according to chapter 7, Repairs.

2.6 Upper arms Check the surface of tube <12>, no cracks. If necessary exchange the part according to chapter 7, Repairs.

2.7 Hoses Interval 500 h Check the entire hose <6> so that there are no folds or surface damages. If necessary exchange the part according to chapter 7, Repairs.

2.8 Spring units Check the roller <7> for wear. If necessary exchange the part according to chapter 7, Repairs. 6

Product Manual IRB 340A

Maintenance

2.9 Movable plate and swivel Check joint balls <13, 14> and axis rotation joint <15> for surface damage, and that the rotation is smooth. If necessary, replace the part as described in chapter 7, Repairs.

2.10 Gearboxes, axes 1-3 Interval 4,000 h or 2 years Check for backlash in outgoing shafts <17>. Total backlash should be < ±0.0167o (1 minute of arc). If necessary exchange the part according to chapter 7, Repairs. Interval 12,000 h or 3 years Oil should only be changed the first 12,000 h Change oil according to below. Type of oil:

Mobil DTE FM 220

Volume:

0.9l (per gearbox)

Drain the gearbox, alt. no. 1: • Unscrew base cover. • Remove oil plugs (see Figure 2).

Motor/gear box for axis 4 must be removed. Oil plug (3x)

Also the consol must be removed.

Figure 2 Location of oil plugs.

• Suck up the oil with a smooth hose. • The oil is filled through the plug holes, with specified volume. Product Manual IRB 340A

7

Maintenance • Mount base cover. Drain the gearbox, alt. no. 2: • Remove the transmission cover and arms. • The oil is drained through the lower drain plug <18> holes (see Figure 3). • The oil is filled through the upper plug holes, with specified volume. • Mount transmission cover and arms. • Calibrate axes 1-3, according to the Adept manual.

2.11 Manipulator Fan Interval 30,000 h or 5 years Check Roller Bearings. If necessary, replace the part as described in chapter Repairs.

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Product Manual IRB 340A

Maintenance

2.12 Location of maintenance points

19 5, 11 (12x) 12 (3x) 13

14

1 7 10

8

2(2x)

9(2x)

Upper oil plug

15

Lower oil plug, 18

17

Figure 3 Maintenance points.

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Maintenance

3 Cleaning of robot The manipulator is tested to fulfil IP66 (Standard) and IP 67 (Wash Down) according to IEC 529. The test is performed under the following conditions: IP66 The capping is sprayed with water from all possible angles with a nozzle. - Nozzle inside diameter: 12.5 mm. - Water flow: 100 l/min. ± 5%. - Water pressure1 at the nozzle: approx. 100 kN/m² (1bar). - Test time / m² of the capping area: 1 min. - Shortest test time: 3 min. - Distance from the nozzle to the capping: approx. 3 m. IP67 The capping is lowered into water to fulfil the following conditions. - The water surface should be min. 150 mm above the highest part of the capping. - The lowest part of the capping should be at least 1 m below the water surface. - The length of the test should be at least. 30 min. - The water temperature should not deviate more than 5° C from the temperature of the material. This requirement could be changed by the technical committee in question if the test is to be done when the material is powered or in motion.

3.1 Standard cleaning The standard version of IRB 340A is not manufactured for wash down applications and should only be cleaned by wiping off the dirt and dust using a dry or moistened cloth.

3.2 Wash Down cleaning Note! Only for IRB 340A SA, Wash Down version. 1.

Flush with water max 60°C, low pressure, see Figure 4 for sensitive points.

2.

Foam with “P3-Topax 12” with a concentration of approximately 3% depending on the type of dirt. The water temperature should be 40-60°C. The solvent should be applied to the whole external surface.

1. The pressure is adjusted so that the given amount of water is obtained. At 100 kN/m², the free vertical piezometric level should be 8 m.

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Product Manual IRB 340A

Maintenance 3.

Wait about 15 minutes so the solvent takes effect. To retain effective cleaning properties, ensure that the solvent does not dry on the surface.

4.

Flush thoroughly with water.

5.

Apply the disinfectant, we recommend “P3-Topax 99”. Time, concentration, and water temperature are chosen to reach the desired effect. - Concentration = 1-2% - Temperature = 10-40°C - Time approx. 20 min.

6.

Flush thoroughly with water. Sealings and joints should be lubricated after cleaning, for good functionality. Be careful flushing sealings.

After cleaning bearing races and “swivel cup” sealing, lubricate them with provision classified grease.

Due to the risk of damaging the roller bearing do not clean with any detergent when the “swivel cup” is removed. Only use a moistened cloth.

Figure 4 Sensitive points

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Maintenance

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Product Manual IRB 340A

Repairs CONTENTS Page 1 General Description ........................................................................................................ 3 1.1 Document Guidance ............................................................................................... 5 1.2 Caution.................................................................................................................... 6 1.3 Mounting Instructions for Bearings and Seals ....................................................... 6 1.3.1 Bearing rings ................................................................................................ 6 1.3.2 Seals ............................................................................................................. 6 1.4 Instructions for Tightening Screw Joints................................................................ 8 1.5 Tightening Torques ................................................................................................. 9 1.5.1 Collar screw ................................................................................................. 9 1.5.2 Torx screw.................................................................................................... 9 1.5.3 Screws with hexagon socket head................................................................ 9 1.5.4 Special screws .............................................................................................. 10 2 Axis 1, 2 and 3................................................................................................................. 11 2.1 Replacing motor/gearbox unit......................................................................... 11 2.2 Exchange of motor or gearbox ............................................................................... 12 2.3 Replacing the upper arm......................................................................................... 13 2.4 Replacement of joint balls ...................................................................................... 14 2.5 Replacement of hard stops...................................................................................... 14 3 Axis 4 ................................................................................................................................ 15 3.1 Replacing motor/gearbox unit ................................................................................ 15 3.2 Exchange of motor or gearbox ............................................................................... 16 3.3 Replacing the telescopic shaft ................................................................................ 17 3.4 Replacing the plain bearings, Wash Down version ................................................ 18 3.5 Replacing on-board calibration .............................................................................. 19 4 Movable plate and swivel................................................................................................ 21 4.1 Dismounting movable plate.................................................................................... 21 4.2 Replacement of joint balls ...................................................................................... 21 5 Parallel arm system......................................................................................................... 23 5.1 Replacing parallel arms .......................................................................................... 23 5.2 Replacing the spring units ...................................................................................... 23 5.3 Exchange of wear rings .......................................................................................... 24 6 Cabling ............................................................................................................................. 27 6.1 Dismounting the complete cabling ......................................................................... 27 6.2 Replacing pushbutton unit and warning lamp ........................................................ 27 6.3 Replacing the fan .................................................................................................... 28 6.4 Replacing on-board calibration .............................................................................. 28

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Repairs CONTENTS Page 7 Hoses................................................................................................................................. 7.1 Exchange of hoses .................................................................................................. 8 Calibration....................................................................................................................... 8.1 General ................................................................................................................... 9 Special Tools List.............................................................................................................

2

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Repairs

General Description

1 General Description The industrial robot system IRB 340A comprises a separate unit; the mechanical unit. The service of the mechanical unit is described in this document. As regards service, the mechanical unit is divided into the following main parts: • Electrical System • Motor Units • Mechanical System The Electrical System is routed for longevity. The power cabling feeds the robot axes' motor units. The signal cabling feeds the various controlling parameters like axis positions, motor revs, etc. The AC type Motor Units provide the motive power for the various robot axes via gears. Mechanical brakes, electrically released, lock the motor units when the robot is inoperative. The Mechanical System a 4 axes version, enabling the flexible robot motions.

Axis 1

Axis 2

Axis 4 Axis 3

TCP0 Figur 1 The robot axes and working space, IRB 340A.

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3

General Description

Repairs

Axis No. 1, 2 and 3 moves the end effector parallel with the working surface. Axis No. 4 is a telescopic shaft that rotates the tool. The Control Cabinet must be switched off during all service work on the robot! The Brake Release Button should be connected as indicated in Section 5, Installation and Commissioning, to enable movements of the axes. Special care must be taken when the brakes are operated manually. This applies particularly when the robot is started up, either for the first time or after a stoppage. The safety instructions in the Manual must be complied with at all times.

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Repairs

General Description

1.1 Document Guidance The subsequent chapters describe the type of service work that can be carried out by the Customer´s own service staff on site. Certain types of work, requiring special experience or special aids, are not dealt with in this manual. In such cases, the defective module or component should be replaced on site. The faulty item should be sent to ABB Flexible Automation for service. Calibration. A power-on calibration have to be carried out after each power down or restart of the system. During the process axis 1-3 are using hardstops and axis 4 a sensor positioned inside the gearbox. The procedure is described in detail in the Adept Manuals. IMPORTANT! When work is done on the robot signal cabling, this may result in the robot moving to incorrect positions.

Tools. Two types of tools are required for various service jobs involving dismantling; on the one hand, conventional tools like socket and ratchet spanners, etc.; on the other hand, special tools may be necessary, depending on what type of service is being carried out. The conventional tools are not dealt with in this manual, based on the assumption that the service personnel have sufficient technical basic competence. However, service work requiring the use of special tools is described in this manual. Foldouts. In the Spare Parts chapter of this manual, there are a number of foldouts illustrating the robot parts, intended to facilitate quick identification of both the type of service required and the composition of the various components. The parts are item numbered on the foldouts. The foldouts are referred to in the Manual text within “arrow heads” (< >) as exploded view numbers. Where reference is made to foldouts, other than those specified in the paragraph title, the foldout number is included in the item number reference, for example <5/19> or <10:2/5>, the digit(s) before the stroke referring to the foldout number. Numbers in brackets ( ) refer to figures in the text. The foldouts also include information such as article number, designation and relevant data. N.B. This manual is not to be considered as a substitute for a proper training course. This document is intended for use after the course has been completed.

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General Description

Repairs

1.2 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. Entering the robot working space when the HIGH POWER (motors on) light is illuminated can result in severe injury.

1.3 Mounting Instructions for Bearings and Seals

1.3.1 Bearing rings 1.

Let a new bearing remain in its wrapping until it is time for fitting, to avoid contamination of the bearing.

2.

Ensure that all parts included in the bearing fitting are free from burrs, grinding waste and other contamination.

3.

The bearing must be greased after fitting. The main reason for this is the requirement for cleanliness and a minimum of wear.

4.

The bearings must not be completely filled with grease. However, if space is available beside the bearing fitting, the bearing may be totally filled with grease when mounted, as surplus grease will be thrown out from the bearing when the robot is started up.

5.

During operation, the bearing should be filled to 70-80% of the available volume.

6.

Ensure that grease is handled and stored properly, to avoid contamination.

1.3.2 Seals 1.

The commonest cause of leakage is incorrect fitting.

Rotating Seals

6

2.

The sealing surfaces should be protected during transport and mounting.

3.

The seal should be kept in the original wrappings or be well protected.

4.

Sealing surfaces must be inspected before mounting. If scratches or damage are found, that may result in future leakage, the seal must be replaced.

Product Manual IRB 340A

Repairs

General Description 5.

Seals should also be checked before mounting to ensure that: • there is no damage to the sealing edge (feel with a fingernail) • the seal is of the correct type (provided with cutting edge) • there is no other damage.

6.

Grease the seal just before fitting it, but not too early as there is a risk of dirt and foreign particles adhering to the seal. The space between the dust tongue and sealing lip should be filled to 2/3 with grease. The rubber coated external diameter must also be greased.

7.

The fitting of seals and gears must be carried out on clean workbenches.

8.

Mount the seal correctly. If it is misaligned, there is a risk of leakage due to the pumping effect.

9.

Always mount the seal with a mounting tool. Never hammer directly on the seal, as this may result in leakage.

10.

Use a protective sleeve for the sealing lip during mounting, when sliding over threads, keyways, etc.

Flange Seals and Static Seals 11.

Check the flange surfaces. They must be even and free from pores. It is easy to check flatness using a gauge on the fastened joint (without sealing compound).

12.

Differences in surface level or the presence of burrs due to incorrect machining are not permissible. If flange surfaces are defective, the parts must not to be used, because leakage could result.

13.

The surfaces must be properly cleaned in accordance with ABB ROBOTICS PRODUCTS recommendations.

14.

Distribute the sealing compound evenly over the surface, preferably with a brush.

15.

Tighten the screws evenly when fastening the flange joint.

O-rings 16.

Check the O-ring grooves. The grooves must be geometrically correct and free from pores and contamination.

17.

Check the O-ring with regard to surface defects, burrs, shape accuracy, etc.

18.

Ensure that the correct O-ring size is used.

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General Description

Repairs

19.

Tighten the screws evenly when assembling.

20.

Defective O-rings and O-ring grooves must not be used.

21.

Fitting defective parts will result in leakage. Grease the O-ring with lubricant before mounting.

1.4 Instructions for Tightening Screw Joints General It is of the utmost importance that all screw joints be tightened with the correct torque. Application The following tightening torques are to be used for all screw joints in metallic materials unless otherwise specified in the text. These instructions do not apply to screw joints comprising soft or brittle materials. For screws with a higher property class than 8.8, the data for 8.8 must be used unless otherwise specified. Screws treated with Gleitmo (lubricated) When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should be used. Screws treated with Gleitmo can be unscrewed and screwed in again 3-4 times before the slip coating disappears. Screws can also be treated with Molycote 1000. When screwing in new screws that are not Gleitmo treated, these should first be lubricated with Molycote 1000 and tightened to the specified torque. Assembly Lubrication with molybdenum disulphide grease (Molycote 1000) should only be used when specified in the text. Screws lubricated with Molycote 1000 and then torque tightened, should also to be lubricated between the washer and the head of the screw. Screws must be tightened with a torque-wrench.

8

Product Manual IRB 340A

Repairs

General Description

1.5 Tightening Torques

1.5.1 Collar screw Tightening torque - Nm Dimension

class 12.9

M6

11.0

1.5.2 Torx screw Tightening torque - Nm Dimension

class 8.8 Gleitmo 610 Molycote 1000

M6

7.0

1.5.3 Screws with hexagon socket head Tightening torque - Nm Dimension

class 8.8 Molycote 1000 Gleitmo 610

M4

class 12.9 Molycote 1000 Gleitmo 610

2.8

M6

7

M8

17

M 10

33

Product Manual IRB 340A

class 8.8 Oil Loctite

11

9

General Description

Repairs

1.5.4 Special screws Tightening torque - Nm

10

Dimension

Loctite

Location

M8

11.0

ball joints

M12

20

swivel

Product Manual IRB 340A

Repairs

Axis 1, 2 and 3

2 Axis 1, 2 and 3 2.1 Replacing motor/gearbox unit Refer to foldout no. 3 and 4. Dismounting: 1.

Remove the parallel arms according to chapter 5.1.

2.

Dismount the upper arms according to section 2.3.

3.

Dismount telescopic shaft according to 3.3.

4.

Remove flange cover <3/16>.

5.

Dismount the transmission cover <10>.

6.

Unscrew screws <4/38> for the base cover <4/33>.

7.

Disconnect the cable for the fan, contact R4.FAN, and the manipulator cables.

8.

Remove the base cover.

9.

Disconnect the motor cabling. If motor/gearbox for axis 3 is to be dismounted must axis 4 be dismounted first (see chapter 3). If motor/gearbox for axis 2 is to be dismounted must axis 4 and the consol be removed first (see chapter 3 and 6).

10. Unscrew screws <3/5> and remove the motor/gearbox unit. Mounting: 11. Place the motor/gearbox in position, 2 guide pins. 12. Mount the unit with screws <3/5> and washers <3/4>. Tightening torque 33 Nm. 13. Connect the motor cabling. 14. Mount back the transmission cover <3/10> with screws >3/9>, torque 9 Nm. 15. Mount back flange cover<3/16> and telescopic shaft. 16. Connect the cable for the fan, R4.FAN. 17. Tighten screws <4/38> for the base cover <4/33> with torque 14 Nm. 18. Mount the upper arm according to section 2.3. 19. Mount the parallel arms according to chapter 5.1.

Product Manual IRB 340

11

Axis 1, 2 and 3

Repairs

Tightening torque: Screw joint motor unit/base box, item <3/5>: Screw joint base cover/base box, item <4/38>: Screws for transmission cover, item <3/10>:

33 Nm 14 Nm 9 Nm

2.2 Exchange of motor or gearbox Motor 1.

Remove the transmission cover according to section 2.1.

2.

Drain the gearbox according to chapter Maintenance.

3.

Unscrew the three screws (1) holding to motor to the gearbox (see Figure 2). 1

Figure 2 Motor and gearbox axis 1-3.

4.

Remove the motor.

5.

Mount O-ring (2) onto the motor flange (see Figure 3).

1

3

2 Figure 3 Mounting of motor axis 1-3.

6. 12

Insert the new motor, do not tighten the screws (1). Product Manual IRB 340

Repairs

Axis 1, 2 and 3 7.

Mount back the upper arm temporarily, to be used to feel the backlash.

8.

Push the motor gently downwards with help of a screw driver at the same time as you feel for the backlash by moving the upper arm back and forward.

9.

Tighten the screws (1) with torque 11 Nm.

10. Check through the upper oil level hole that gear wheel (3) is axially movable (see Figure 3). 11. Fill the gearbox with oil according to chapter Maintenance. 12. Mount back transmission cover according to section 2.1. Gearbox 13. Dismount the motor/gear unit according to section 2.1. 14. Follow points 2. to 11. above. 15. Mount back the unit (motor/gearbox) according to section 2.1.

2.3 Replacing the upper arm Refer to foldout no. 1 and 3. Dismounting: 1.

Remove the parallel arms <1/1> according to section 5.1

2.

Remove the VK-cover <3/42>. Knock a screw driver or similar through the VKcover and bend it out. A new cover must be mounted back.

3.

Unscrew screws <3/41>.

4.

Pull the upper arm <3/40> out.

Mounting: 5.

Remove the flange cover <3/16>, screws <3/19>.

6.

Mount the flange cover onto the upper arm shaft. Make sure that the sealing ring <3/17> is in the right position on the shaft.

7.

Place the upper arm <3/40> in position, on the guide pin.

8.

Tighten screws <3/41> with torque 11 Nm.

9.

Tighten screws <3/19> with torque 9 Nm.

10. Perform a new calibration procedure according to the Adept manual. 11. Mount back the parallel arms according to section 5.1. Product Manual IRB 340

13

Axis 1, 2 and 3

Repairs

Tightening torque: Screw joint upper arm/gearbox, item <3/41>: Screw joint flange cover/gearbox, item <3/19>:

11 Nm 9 Nm

2.4 Replacement of joint balls Refer to foldout no. 1. Dismounting: 1.

Remove the parallel arms according to section 5.1.

2.

Unscrew the joint balls <6> in the upper arm.

Mounting: 3.

Mount new joint balls, torque 11 Nm. Use Loctite 243.

4.

Mount parallel arm system according to 5.1.

Tightening torque: Joint balls/upper arm, item <6>:

11 Nm

2.5 Replacement of hard stops 1.

Remove the two screws holding the hard stop

2.

Mount the new hard stops, torque 9 Nm.

3.

Perform a new calibration procedure according to the Adept manual.

Tightening torque: Screw joint hard stops/base cover:

14

9 Nm

Product Manual IRB 340

Repairs

Axis 4

3 Axis 4 3.1 Replacing motor/gearbox unit Refer to foldout no. 1, 3 and 4. Dismounting: 1.

Remove base cover <4/33>, screws <4/38>.

2.

Disconnect the cable for the fan, contact R4.FAN, and the manipulator cables.

3.

Disconnect the motor contacts, R3.FB4 and R3.MP4.

4.

Disconnect the sensor according to section 8.4.

5.

Loosen the set screw <1/12> at the upper coupling on the telescopic shaft.

6.

Unscrew screws <3/24>.

7.

Remove the motor/gearbox <4/22>.

Mounting: 8.

Mount motor and gearbox with screws <3/24>, tightening torque 9 Nm.

9.

Remount the telescopic shaft, lock with set screw <1/12> and Loctite 243, tightening torque 4 Nm.

10. Connect the cables to the motor. 11. Connect the sensor according to section 8.4. 12. Connect the cabling and mount cover <4/33> with screws <4/38>, tightening torque 14 Nm. Tightening torque: Screw joint motor/basebox, item <3/24>:

9 Nm

Screw joint base cover/basebox, item <4/38>:

14 Nm

Product Manual IRB 340A

15

Axis 4

Repairs

3.2 Exchange of motor or gearbox Motor 1.

Remove motor/gearbox unit according to section 3.1.

2.

Knock a screw driver or similar through the VK-cover (2) and bend it out, be carefull not to hit the on-board calibration device. A new cover must be mounted (see Figure 4).

3.

Pour out the oil.

4.

Unscrew screws (1) and remove the motor.

2 6

1

5

3 4

Figure 4 Motor/gear unit axis 4.

5.

Open screw (3) a bit and wind the gear (5) down.

6.

Mount O-ring (4) in the gear house.

7.

Mount the motor with screws (1), tightening torque 9 Nm.

8.

Rotate gear (5) upwards so that there is no play between the gears.

9.

Ensure that the gear is kept absolutely still. Apply Loctite 243 and tighten the screw (3), torque 9 Nm.

10. Check the play again. 11. Apply Loctite 290 to lock the shaft (see Figure 4). 16

Product Manual IRB 340A

Repairs

Axis 4 12. Calibate the robot as specified in Chapter 8, Calibration. 13. Fill the gearbox with oil to the centre of the motor pinion (see Figure 4). 14. Unscrew screw (6) so that the sealing ring does not pop out when mounting the VK cover. 15. Mount the VK cover (2). 16. Remount screw (6). Tightening torque: Screw joint motor/gearbox, item (1):

9 Nm

Locking screw, item (3):

9 Nm

3.3 Replacing the telescopic shaft Refer to foldout no. 1 and 3. Dismounting: 1.

Lift up the sealing ring (v-ring) and unscrew the lower set screw <1/12>.

2.

Unscrew the upper set screw <1/12> , see Figure 5.

3.

Push the shaft together and remove it.

Set Screws

Figure 5 Set Screws

Mounting: The set screws for the telescopic shaft must be tightened as described below othProduct Manual IRB 340A

17

Axis 4

erwise there is a risk that the shaft becomes loose and damages the arms and can cause personal injuries. Repairs 4.

Tighten set screws <1/12> with torque 4 Nm. Use Loctite 243.

5.

Press the sealing ring back in place.

Note! Do not press the sealing down to hard when this will cause heavy wear, see Figure 6.

Push against chamfer(9mm)

Figure 6 Sealing ring.

3.4 Replacing the plain bearings, Wash Down version

18

1.

Remove the telescopic shaft as described in section 3.3.

2.

Unscrew the nuts (1) gently (see Figure 7).

3.

Take the components apart.

4.

Remove the three plain bearings in each bearing holder (see Figure 7).

5.

Replace with new plain bearings. Ensure that the small notch is located so it fits in the hole.

Product Manual IRB 340A

Repairs

Axis 4 6.

Assemble the parts of the telescopic shaft together, torque 4 Nm. Check that the bars are parallel.

7.

Test that the movement of the telescopic shaft is smooth along its whole length.

8.

Mount the telescopic shaft as described in section 3.3. 1

1

Plain bearing Figure 7 Plain bearings, Wash Down version.

Tightening torque: Nuts, telescopic shaft, item (1):

4 Nm

3.5 Replacing on-board calibration Refer to foldout no. 5. Dismounting: 1.

Remove the cable <5/68> from the sensor.

2.

Loosen the lock nut.

3.

Remove the sensor from the housing.

Product Manual IRB 340A

19

Axis 4

Repairs Mounting:

20

4.

Knock a screw driver or similar through the VK-cover (2) and bend it out, be carefull not to hit the on-board calibration device. A new cover must be mounted (see Figure 4)

5.

Screw the new sensor about a centimeter into the housing.

6.

Apply Loctite 542 on the sensor and screw it into the housing. The distance between the sensor and giver should be 0.9 mm (use a thickness gauge).

7.

Attach the lock nut to the sensor and tighten it.

8.

Calibrate the sensor for axis 4 as specified in Adept Manuals.

Product Manual IRB 340A

Repairs

Movable plate and swivel

4 Movable plate and swivel 4.1 Dismounting movable plate Refer to foldout no. 1 Dismounting: 1.

Pull the parallel arms apart by hand or use tool 3HAC 5819-1, and remove the plate.

Mounting: 2.

Mount the movable plate by pulling the parallel arms apart by hand or use tool 3HAC 5819-1.

4.2 Replacement of joint balls Refer to foldout no. 1. Dismounting: 1.

Dismount movable plate according to sections 4.1.

2.

Unscrew joint balls <6>.

Mounting: 3.

Mount new joint balls, torque 11 Nm. Use Loctite 243.

4.

Mount movable plate according to section 4.1

Tightening torque: Joint balls/movable plate, item <6>:

Product Manual IRB 340

11 Nm

21

Movable plate and swivel

22

Repairs

Product Manual IRB 340

Repairs

Parallel arm system

5 Parallel arm system 5.1 Replacing parallel arms Refer to foldout no. 1 Dismounting: 1.

Remove the vacuum hose from the arm system.

2.

Use tool 3HAC 5819-1 (or by hand), and pull the arms apart in both ends (see Figure 8).

Figure 8 Parallel arms with spring units.

3.

Remove the arms.

Mounting: 4.

Mount in reversed order.

5.2 Replacing the spring units Refer to foldout no. 1 Dismounting: 1.

Remove the affected arm system according to section 5.1.

2.

Push the bar as shown in Figure 9.

Product Manual IRB 340

23

Parallel arm system

Repairs

Rollers (x4) Figure 9 Removing the spring unit.

3.

Take out the rollers (see Figure 9).

4.

Remove the spring unit.

5.

Both sides identical.

Mounting: 6.

Place the spring unit in position.

7.

Mount the rollers onto the pin (see Figure 9).

8.

Pull the arm backwards into position.

9.

Mount back the arm system according to section 5.1

5.3 Exchange of wear rings Refer to foldout no. 1 Dismounting: 1.

Remove the parallel arm according to section 5.1.

2.

Remove the spring unit according to section 5.2.

3.

Insert a screw driver, and bend carefully the wear ring out (see Figure 10).

Mounting: 4. 24

Place a new wear ring into the joint socket (see Figure 10). Product Manual IRB 340

Repairs

Parallel arm system 5.

Place the arm bar in dolly 3HAC 4182-1.

6.

Put drifter 3HAC 4184-1 into the wear ring and knock it gently down to its position.

7.

Mount the spring units back according to section 5.2.

8.

Apply grease according to chapter Maintenance. Drifter 3HAC 4184-1

Wear ring Dolly 3HAC 4182-1 Figure 10 Exchange of wear rings.

9.

Mount the parallel arms according to section 5.1.

Product Manual IRB 340

25

Parallel arm system

26

Repairs

Product Manual IRB 340

Repairs

Cabling

6 Cabling 6.1 Dismounting the complete cabling Refer to foldout no. 5 Dismounting: 1.

Remove the base cover according to first points in chapter 3.1, Replacing motor/ gearbox unit.

2.

Make a note or small drawing of the location of the cabling.

3.

Cut all the straps holding the cabling.

4.

Disconnect all contacts.

5.

Dismount the transmission cover according to the first points in chapter 2.2, Exchange of motor or gearbox.

6.

Disconnect the cables for the warning lamp and brake release button.

Mounting: 7.

In reversed order.

Note! Make sure that no cables are in the marked area according to foldout 5.

6.2 Replacing pushbutton unit and warning lamp Refer to foldout no. 3 and 5 Dismounting: 1.

Remove the parallel arm system according to chapter 5, Parallel arm system.

2.

Remove the upper arms according to chapter 2, Axis 1, 2 and 3.

3.

Dismount the transmission cover <3/10>, screws <3/59>.

4.

Disconnect and unscrew the push button or lamp unit.

Mounting: 5.

Mount in reversed order.

Product Manual IRB 340

27

Cabling

Repairs

6.3 Replacing the fan Refer to foldout no. 4 Dismounting: 1.

Remove the ventilation connection <46>, screws <19>.

2.

Remove the base cover <33>, screws <38>.

3.

Remove the fan cover <37>, screws <60>.

4.

Disconnect the cable <35>, R4.FAN.

5.

Unscrew screws <36> and remove the fan <34>. One of the screws <36> is hidden under the ventilation gasket.

Mounting: 6.

Mount in reversed order.

6.4 Replacing on-board calibration Refer to foldout no. 3 and 5. Dismounting: 1.

Remove the cable from the sensor.

2.

Loosen the lock nut .

3.

Remove the sensor from the housing.

Mounting:

28

4.

Knock a screw driver or similar through the VK-cover (2) and bend it out, be carefull not to hit the on-board calibration device. A new cover must be mounted (see Figure 4)

5.

Screw the new sensor about a centimeter into the housing.

6.

Apply Loctite 542 on the sensor and screw it into the housing. The distance between the sensor and giver should be 0.9 mm (use a thickness gauge).

7.

Attach the lock nut to the sensor and tighten it.

8.

Calibrate the sensor for axis 4 as specified in Adept Manuals

Product Manual IRB 340

Repairs

Hoses

7 Hoses 7.1 Exchange of hoses Dismount and mount according to foldout 6. 1.

Open straps <12>.

2.

Pull the hose out from the swivel

3.

Pull the hose out from the air filter.

4.

Mount a new hose on the swivel.

5.

Fix the hose, do not tighten, against the three clamps <11> on the parallel arm.

6.

Twist the hose and mount it on the air filter.

7.

Then adjust the hose according to foldout no. 6.

8.

Tighten the straps.

9.

Make a small program (low velocity) and check that the hose runs freely

Product Manual IRB 340A

29

Hoses

30

Repairs

Product Manual IRB 340A

Repairs

Calibration

8 Calibration 8.1 General The IRB340A does not involve a serial measurement board that keeps track of the robot positions at power off. Due to this a power-on calibration has to take place after each restart. The power-on calibration is described more in detail in the Adept Manuals. Make sure that all the arms are below -10o before a power-on calibration takes place. In other cases the spring unit of the axis that performs the calibration can hit the upper arm. For axes 1-3 the calibration is made so each upper arm is running into a mechanical hard-stop. For axis 4 the calibration is performed as a sensor is placed in the axis 4 gearbox (on-board calibration). If the gearbox is changed or the sensor in other ways is removed a new calibration procedure must take place. During this procedure a calibration tool (3HAC 4456-1) must be used. The calibration can be ordered from ABB Flexible Automation, see section 8, Spare Parts List. The new calibration procedure is further described in the Adept Manuals. Do not power-on calibrate axes with incorrect calibration offset. If a new calibration procedure has been done, always make a course check of the new calibration offset by jogging the robot to a well known position and read the degrees of each axis from the teach pendant (some positions are described in the IRB340A Product Specification).

Product Manual IRB 340

31

Calibration

32

Repairs

Product Manual IRB 340

Repairs

Special Tools List

9 Special Tools List The need for special tools has been reduced to a minimum. When tools are needed for dismounting/mounting work, a description is given in that section. During the ordinary service training courses arranged by ABB Flexible Automation, detailed descriptions of the tools are given together with their use. Calibration Calibration fixture

3HAC 9596-1

Arm system Tool for mounting the parallel arms

3HAC 6194-1

Drifter for mounting wear rings

3HAC 4184-1

Dolly for joint socket when inserting new wear rings

3HAC 4182-1

Product Manual IRB 340

33

Special Tools List

34

Repairs

Product Manual IRB 340

Spare Parts CONTENTS Page 1 Manipulator ............................................................................................................. 3 1.1 Arm system and external details ..................................................................... 3 1.2 Manipulator base............................................................................................. 7

Product Manual IRB 340 A

1

Spare Parts

Spare Parts 1 Manipulator Item numbers refer to item numbers on the foldouts. Article numbers in bold text are specially designed as spare parts (painted etc.). Remark Text - IRB 340A

=

- IRB 340ASA =

4 Axes Standard version 4 Axes Wash Down version

1.1 Arm system and external details Itm Qty

Name

Art. no.

1 2 3 4

6 12 6 24

Bar Wear-ring Spring unit Roller

3HAC 2090-1 3HAC 2091-1 3HAC 3958-1 3HAC 3062-1

6 7 8

12 Joint ball 4x3ml Locking liquid 3 ml cont. 1 Movable Plate with Swivel

3HAC 5176-1 3HAC 7181-1 3HAC 6913-1

10 11

1 1

Sealing ring (V-ring) Telescopic shaft, axis 4

3HAB 3732-16 3HAC 5115-1

12

2

Set screw, dog point

9ADA 203-5

15 16 17 18 19 20 21 22 23 4 24

1 1 1 1 8 1 1 1 3

Customer connection Dust cap Dust cap Cover Hexagon head screw External cable connection Dust cap Labels IRB 340 Parallel arms

3HAC 4256-1 5217 649-9 3HAA 1001-630 3HAC 7024-1 9ADA 181-12 3HAC 4285-1 5217 649-9 3HAC 3919-1 3HAC 5234-1

1

Movable Plate

3HAC 6921-1

Product Manual IRB 340A

Remark

Loctite 243 (incl. items 24-31) V-20S (incl. item 12) IRB340A M5x16 Not IRB340A/ASA Not IRB340A/ASA Not IRB340A/ASA opt. 041 M6x16 8.8 Not IRB340A/ASA Not IRB340A/ASA Incl. items 1, 2, 3,

3

Spare Parts 25 26 27 28 29 30 31

1 1 1 1 2 1 1

Parallel Pin Swivel Cup Swivel Axis Lock nut Groove Ball Bearing Sealing Spring Washer

3HAC 6912-1 3HAC 6922-1 3HAC 6923-1 3HAC 6925-1 3HAB 3643-16 3HAC 3296-4 3HAC 2864-14

33 34 35 36 37 37 37 37 38 39

3 9 9 9 1 1 1 1 1 1

Arm Stop Hexagon head screw Plain washer O-ring Internal Control cable 7m Internal Control cable 15m Internal Control cable 22m Internal Control cable 30m External Air Connection Telescopic Shaft, axis 4

3HAC 9193-1 9ADA 123-22 9ADA 316-3 3HAB 3772-35 3HAC 9316-1 3HAC 9316-3 3HAC 9316-4 3HAC 9316-5 3HAC 7056-1 3HAC 9265-1

Product Manual IRB 340A

3x6

25x37x7 25x32x4

M6x20 Not IRB340A/ASA

IRB340ASA

4

Axis 2

Foldout 1

Axis 2

Axis 3

Axis 1

Axis 2

Foldout 2

Spare Parts

1.2 Manipulator base Itm Qty

1 2

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

23 24 25 26 27 28

Name

Art. no.

Manipulator base, complete

3HAC 2108-1

1 3 3 3 6 18 18

Basebox Gear-motor unit, axis 1-3 Motor axis 1-3 Gear axis 1-3 Parallel pin, hardened Plain washer Hex socket head cap screw

3HAC 5354-1

White

3HAC 5226-1 3HAC 5228-1 3HAC 3785-3 9ADA 312-8 3HAB 3402-51

White White

6 3 1 30 ml 1 1 1 1 1 7 3 3 3 9 1 4 1 1 1 1 3 3 1 1 1 1

Distance screw Distance screw Sealing strip Cyanoacrylate adhesive Transmission cover axis 1-3 Push-button Bracket Membrane Lamp unit Hexagon head screw Flange cover Sealing ring Flange gasket, axis 1-3 Hexagon head screw Console Connector bracket Gearbox axis 4 Gearbox axis 4 Inductive switch Motor-pin, axis 4 Plain washer Hex socket head cap screw Back-up washer Flange gasket axis 4 Jumper Serial measurement board with bracket

Product Manual IRB 340A

3HAC 3030-11 3HAC 3030-12 3HAC 2989-1 1234 1919-37 3HAC 5153-1 1SFA616100R1006 SK 616 013-F SK 615 503-2 3HAC 4401-1 9ADA 123-20 3HAC 4250-1 3HAC 3934-1 3HAC 4309-1 9ADA 123-22 3HAC 4272-1 3HAC 4232-1 3HAC 5093-1 3HAC 5124-1 3HAC 6003-1 3HAC 5113-1 9ADA 312-6 9ADA 183-25 3HAC 0110-1 3HAC 5329-1 3HAC 4298-1 3HAB 3700-1

Remark

10.5x20x2 M10x30 8.8 Gleitmo 610 M8 M6 Loctite 406 White, Flex logo Black

opt. 691 M6x12 D=60/70 B=10 M6x16

IRB340A/ASA Not IRB340A/ASA

6.4x12x1.6 M6x20 8.8

Not IRB340A/ASA Not IRB340A/ASA

7

Spare Parts 29 30 31 32 33 34 35 36 37 38 39 40 41

5 1 1 1 1 1 1 1 2 1 6 3 3 18

Torx pan head screw Power cable Signal cable Base cover gasket Base cover Base cover Fan Fan cable Torx counters roll screw Fan cover Hexagon head bolt Lifting eye Upper arm Hex socket head cap screw

9ADA 618-44 3HAC 1761-1 3HAC 1762-1 3HAC 3399-1 3HAC 5355-1 3HAC 5356-1 3HAB 7311-1 3HAC 3196-1 9ADA 633-37 3HAC 3029-1 9ADA 59-20 3HAC 3175-1 3HAC 2078-1 3HAB 3409-29

42 43 44 45 46 47 48 49 50 51 52 53 54 55

3 1 1 1 1 1 2 17 1 1 3 3 1 10 ml

VK-cover Ventilation gasket Top cover gasket Gasket Internal Air Tube Internal Ventilation hose Hose clip Cable straps, outdoors Earth symbol Membrane Sync. cover Hex socket head cap screw Label Grease

3HAA 2166-21 3HAC 3400-1 3HAC 3401-1 3HAB 7957-1 3HAC 7095-1 3HAC 7108-1 3HAC 4428-1 2166 2055-3 3HAB 5617-1 SK 615 503-2 3HAC 2094-1 9ADA 183-34 3HAC 2151-1 3HAC 3262-1

56 57 58 59 60 61

1 1 1 6 3 18

Cover Flange cover axis 4 Sealing ring with dust lip Hexagon head screw Hexagon head screw Plain washer

3HAC 5330-1 3HAC 5328-1 3HAB 3701-2 9ADA 123-20 9ADA 123-20 9ADA 312-6

Product Manual IRB 340A

M5x12 8.8

Orange White

M4x25 8.8 M8x50

M6x40 12.9 Gleitmo 610 D=68, B=8

IRB340ASA IRB340A D=73-83 IRB340A 4.8x208 opt. 691 M8x12 8.8 Resolver values Approved for consumer goods industry Not IRB340A/ASA

M6x12 M6x12 6.4x12x1.6

8

Spare Parts 63

1

Battery pack

4944 026-4

64

2

Cable straps, outdoors

2166 2055-6

65 66 67 68

1 7 1 1

Instruction plate Hexagon head screw Signal Cable Sync. Cable set

3HAC 2589-1 9ADA 123-20 3HAC 9880-1 3HAC 9318-1

Product Manual IRB 340A

NiCd 7.2V 4Ah Not IRB340A/ASA 7.6x368 Not IRB340A/ASA Not IRB340A/ASA M6x12 Not IRB340A/ASA

9

Axis 3

Axis 3

Axis 2

Axis 1

Axis 1

Axis 2, 4 Axis 3

Axis 2

Axis 1

Foldout 3

Axis 3

Axis 1

Axis 2

Axis 2

Axis 1

Axis 3

Foldout 4

Axis 3

Axis 2, 4

Axis 1

Foldout 5

Circuit Diagram CONTENTS Page 1 Manipulator, diagram 3HAC 10043-1, Rev. 0 ..............................................................101-106

Product Manual IRB 340

List of contents Product Manual IRB 340A

Product Manual IRB 340A

Connection point Locations

Motor axis 1-3 Product Manual IRB 340A

Axis 4 Product Manual IRB 340A

Feed-Back Axis 1-4 Product Manual IRB 340A