Mount

Assembly Instruction IRB 840/A Table of Contents Sida 1 Introduction ..................................................................................................................... 3 1.1 General.................................................................................................................... 3 1.2 How to read the assembly instructions ................................................................... 3 1.3 Safety ...................................................................................................................... 4 1.4 Marking .................................................................................................................. 4 2 Preparations for assembly .............................................................................................. 5 2.1 Lifting instructions ................................................................................................. 5 2.2 Unloading and unpacking....................................................................................... 5 2.3 Delivery inspection................................................................................................. 6 2.4 Tools and measuring equipment ............................................................................. 6 2.5.1 Assembly tools............................................................................................. 6 2.6.2 Using the laser aligner.................................................................................. 7 2.7 Requirements for installation area.......................................................................... 7 3 Assembly .......................................................................................................................... 9 3.1 General.................................................................................................................... 9 3.2 Preparations for assembly work on the frame ........................................................ 9 3.3 Measuring up and inspecting the assembly area .................................................... 11 3.4 Assembling the frame............................................................................................. 13 3.4.1 Assembling and aligning frame legs............................................................ 13 3.4.2 Aligning the top brackets for the aluminium beams, axis 1......................... 15 3.5 Assembling axis 1................................................................................................... 17 3.6 Assembling axis 2................................................................................................... 19 3.7 Assembling axis 3................................................................................................... 22 3.8 Adjusting parallelity of aluminium beams, axis 2.................................................. 23 3.9 Assembling drive mechanism, axis 1 ..................................................................... 24 3.10 Connecting the cabling and hoses ........................................................................ 25 3.11 Adjusting parallelity of beams, axis 1 .................................................................. 30 4 Assembling the base frame and intermediate legs ....................................................... 35 4.1 General.................................................................................................................... 35 4.2 Measuring up and inspecting assembly area .......................................................... 35 4.3 Assembling the intermediate legs........................................................................... 36 4.4 Assembling axis 1................................................................................................... 39 4.5 Fitting drive belt on axis 1...................................................................................... 43 5 Assembly inspection ........................................................................................................ 47 5.1 Checks and measures before start-up ..................................................................... 47 5.2 Checks with the robot system started ..................................................................... 48

Assembly Instruction IRB 840/A

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Montageanvisning IRB 840/A 6 Supplementary documents Parallell Adjustment Tool Axis 1, 3HAC 5931-1 Parallell Adjustment Tool Axis 2, 3HAC 5931-2 Lift Instruction, 3HAC 6692-1

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Assembly Instruction IRB 840/A

Introduktion

1 Introduction 1.1 General This manual contains information about unpacking, lifting, and final assembly of the IRB 840/A. The manual is intended for assembly technicians with a good knowledge of both mechanical and electrical systems. The manual is not a replacement for the assembly training course that ABB Flexible Automation offers. N.B. The warranty commitments of ABB Robotics AB only take effect when the assembly leader has participated in the assembly training course. N.B. The assembly is described in a number of basic steps. These should be seen as requirements to ensure that the product requirements are achieved and that ABB Robotics AB’s warranty commitments take effect. All the users of this manual must also have access to the IRB 840/A Product Manual in order to be able to interpret references in the assembly instructions.

1.2 How to read the assembly instructions The first four chapters of the assembly instructions describe step by step how the manipulator is assembled with the four base frame legs. When differences in the assembly work occur because the manipulator contains more than four base frame legs, there are references to a section in chapter 4 Assembling the base frame and intermediate legs. See the spare parts list in the Product Manual for information about the position numbers in the figures.

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Introduktion A number of expressions are used in the assembly instructions to refer to the manipulator movements and locations on the base frame, see Figure 1.

Axis 1 (X)

Axis 2 (Y) Axis 3 (Z) Axis 4 (C)

Reference leg Reference side

Figure 1 Reference leg, reference side, and axes.

1.3 Safety See Safety in the Product Manual.

1.4 Marking See Introduction in the Product Manual.

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Montageanvisning IRB 840/A

Preparations for assembly

2 Preparations for assembly 2.1 Lifting instructions N.B. It is extremely important that personnel handling the IRB 840/A are trained in lifting and can manage the types of lifting required, which can be of a complex nature. For lifting instructions, see Appendix, Lift Instructions 3HAC 6692-1.

2.2 Unloading and unpacking N.B. Be careful so the cases do not tip over. N.B. Do not walk on the cases. N.B. Do not put anything on the cases. The robot is delivered in a number of cases in a container. See Figure 2. The cases contain the following: - Case 1, axis 1, and the aluminium beams for axis 2. The aluminium beams are at the top. - Case 2, frame. - Case 3, axis 3, and drive shafts and drive motor for axis 1. - Case 4, control cabinet. - The nuts, bolts, washers, etc. are located in the respective cases.

1 ,1 m

C a se 1 11 m

2,35 m

C a se 3 3 m

C a se 2 5,5 m

Case 4

12 m

1) 2) 3) 4,5)

X & Y beam s F ra m e Z C a b in e t 1 0 2 0 x 7 5 0

Figure 2 Plan view of packed container. The dimensions shown are approximate and depend on the size of the manipulator.

To unload the container, attach a chain or lifting strap to the pallet under the case and carefully pull it out of the container. The attachment points are clearly marked with red paint. It may be possible to drive a fork-lift truck into the container and carefully pull out the cases. The cases must be lifted in accordance with the instructions on the respective case.

Assembly instructions IRB 840/A

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Preparations for assembly

2.3 Delivery inspection Check with the packing slip, located on case no. 4, that the delivery corresponds to the order. Check that all cables are hanging loose and that there is no damage to them. Check on the series measurement box that no cables have been pulled out of their screwed glands.

2.4 Tools and measuring equipment 2.5.1 Assembly tools The following assembly tools should be used when assembling the IRB 840/A: Assembly tools: • Parallelity tool, see Appendix 3HAC 5931-1 • Power supply 24VDC, for brake release • Ohm meter to measure 0.1 ohm in the ground protection circuit. I.e. the instrument must have an accuracy >0.01 ohm. • Laser aligner • Measuring tape 40 m • Rotary hammer drill • Screwdriver • Torque wrenches • Large bolt tightener for M24 • Machine spirit level/plummet • Marker string • Greasegun • Ring wrench 36 mm • Overhead crane/fork-lift truck • Skylift/ladder • Other normal handtools

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Assembly instructions IRB 840/A

Preparations for assembly 2.6.2 Using the laser aligner A laser aligner may be used only if the personnel concerned have received separate training in its operation and maintenance. This is essential for the correct assembly of the IRB 840/A and its quality requirements. The following is normal handling: • Marking out the installation area • Aligning the frame • Assembling the frame • Assembling axis 1 • Maintenance / test

2.7 Requirements for installation area For information about the requirements for the installation area, see Installation and commissioning in the Product Manual.

Assembly instructions IRB 840/A

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Preparations for assembly

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Assembly instructions IRB 840/A

Assembly

3 Assembly 3.1 General The example below shows the assembly of an IRB 840/A robot with four frame legs. When there are differences in the assembly because the manipulator has more than four frame legs, a reference is made in the text to a section in Chapter 4, Assembling the frame and intermediate legs. For information about the position numbers in the figures, see the spare parts list in the Product Manual.

3.2 Preparations for assembly work on the frame N.B. It is extremely important that personnel handling the IRB 840/A are trained in lifting and can manage the types of lifting required, which can be of a complex nature. Before assembly check that: - the footplates are adjusted to the specified basic dimension 60 mm and that the nuts and washers are correctly fitted, see Figure 3.

Nut M24 Washer 25x44x4

40 mm

60 mm

Figure 3 Footplate basic dimensions.

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Assembly - the top brackets for the aluminium beams of axis 1 are correctly fitted at right angles to the frame, see Figure 4. They are torque-tighten later when the legs are attached to the floor and the top brackets are laser aligned. Top bracket for axis 1 aluminium beams

M10x40 Washer 10.5x20x2

Figure 4 Top brackets for aluminium beams.

Before attaching the frame legs to the floor, the following must be done: - fit the cross-beams between the frame legs. Check that the frame legs are parallel before tightening the screws. Tighten to the torques shown in Figure 5. - fit the cross-beam supports, see Figure 5. Tighten the screw joints but torquetighten them later when the legs are attached to the floor and aligned. M10x40 Washer 10.5x20x2 47 Nm

Cross-beam

Cross-beam support M16x110 Nut M16 Washer 17x30x3

Figure 5 Fitting the cross-beam.

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Assembly instructions IRB 840/A

Assembly

3.3 Measuring up and inspecting the assembly area For an explanation of “reference leg” and “reference side”, see Figure 1 sid 4.??? 1

Mark up the floor where the reference leg is to stand. See point 1 in Figure 6.

N.B. The position of the reference leg is very important because it determines the position of the entire robot in the assembly room. N.B. A laser aligner may be used only if the personnel concerned have received separate training in its operation and maintenance. See also section 2.6.2. 2

Mark a straight line on the floor with the marker string in the direction of the robot’s X axis. See point 2 in Figure 6.

3

Using the measuring tape on the marker string line, measure the distance to the next frame leg. Mark the position of the leg on the floor. See point 3 in Figure 6.

4

Using the laser aligner, mark up a right angle in the direction of the robot’s Y axis, starting at the position of the reference leg.

5

Mark a straight line on the floor with the marker string in the direction of the robot’s Y axis. See point 4 in Figure 6.

6

Using the measuring tape on the marker string line, measure the distance to the next frame leg. Mark the position of the leg on the floor. See point 5 in Figure 6.

7

Using the laser aligner, mark up a right angle in the direction of the robot’s X axis, starting at point 5 in Figure 6.

8

Mark a straight line on the floor in the direction of the robot’s X axis. See point 6 in Figure 6.

9

Measure with the measuring tape, on the marker string line, the distance to the next frame leg. Mark the position of the leg on the floor. See point 7 in Figure 6.

10 Mark a straight line on the floor in the direction of the robot’s Y axis. See point 8 in Figure 6. 11 Check that the angles at points 4 and 8 above are right angles and that the distances 4 and 8 in the figure are equal. See Figure 6. If the frame has intermediate legs, see section 4.2 before implementing points 12 and 13 below.

Assembly instructions IRB 840/A

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Assembly

5

6 Mark from marker string in the X direction

Position of drive motor for axis 1

8 Mark from marker string in the Y direction

4 Mark from marker string in the Y direction

1 Reference leg

7

3

2 Mark from the marker string in the X direction

Figure 6 Measuring up assembly area; plan view of assembly area.

12 Check the dimensions of the rectangle marked on the floor using the so-called “diagonal method”, i.e. measure the two diagonals from opposite corners and compare the measurements. The deviation must not exceed 5 mm. 13 Using the laser aligner, check the points where the frame legs are to stand for any differences in height level. If the deviation exceeds 2 mm, adjust the frame height to the correct value by adjusting the footplates, see Figure 3. The assembly area is now marked and checked.

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Assembly instructions IRB 840/A

Assembly

3.4 Assembling the frame For information about the position number in the figures below, see the spare parts list in the Product Manual.

3.4.1 Assembling and aligning frame legs N.B. It is extremely important that personnel handling the IRB 840/A are trained in lifting and can manage the types of lifting required, which can be of a complex nature. 1

Measure up the distances shown in Figure 7 and mark the floor with a pen. 225 mm 150 mm Marks

Marks from marker string

225 mm

150 mm

Reference leg Marks

Figure 7 Positioning frame legs; plan view of assembly area.

2

Lift the frame legs to their respective positions. Measure up the distances shown in Figure 7. Use a rubber mallet and a steel square to position the frame legs correctly.

3

When the legs are correctly positioned, drill holes in the floor for the foot-plates.

4

Use four expander bolts per leg. Fit washers and nuts on all the bolts.

N.B. The foot-plate expander bolts must be tightened to a torque in accordance with the bolt manufacturer’s recommendations. When determining the length and type of bolts, the thickness and nature of the concrete floor must be taken into consideration. For other information see the Product Specification in the Product Manual.

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Assembly 5

Undo all the locknuts for the footplates, 8 nuts per side with two frame legs with cross-beams. See Figure 8.

6

Adjust the angle of each pair of legs with the adjuster nuts, see Figure 8, so that they are vertical to the assembly floor in the x direction. Check the angle using a plummet. The maximum allowable deviation from vertical is 2 mm on the total length of the leg

N.B. Before tightening the locknuts, check that the leg is resting on all the adjuster nuts for the leg in question. 7

Tighten the locknuts to the torque shown in Figure 8.

Locknut 665 Nm Adjuster nut Figure 8 Angular adjustment of frame legs.

8

Tighten the screw joints for the cross-beam supports. See Figure 9. Cross-beam

Cross-beam support 300 Nm

Figure 9 Torque-tightening cross-beams and supports.

The frame legs and cross-beams have now been assembled. If the frame is equipped with intermediate legs, see section 4.3 about assembling the intermediate legs.

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Assembly instructions IRB 840/A

Assembly

3.4.2 Aligning the top brackets for the aluminium beams, axis 1 N.B. A laser aligner may be used only if the personnel concerned have received separate training in its operation and maintenance. See also section 2.6.2. 1

Adjust one of the top brackets on the reference leg as shown in Figure 10. Check with the spirit level that the top bracket is horizontal.

Use the top bracket on the reference leg as the reference height and adjust the height of the other top brackets. N.B. It is important that one of the top brackets on the reference leg is adjusted as shown in Figure 10, otherwise the difference in height between the beam ends and the gearbox will be too large when assembling the drive shafts for axis 1.

5 mm

Figure 10 Adjusting top bracket on reference leg.

2

Mount the laser aligner on the reference leg.

3

Put the laser reference block on the adjusted top bracket on the reference leg. Adjust the height of the laser aligner so the laser beam hits the centre of the reference block. Secure the laser aligner. See Figure 11. Now the height of the laser aligner has been adjusted.

4

Put the laser aligner reference block on another top bracket and adjust the height. Repeat for all the legs. See Figure 11. Check with the spirit level or laser aligner that all the top brackets are horizontal.

However, one top bracket on every leg should not be adjusted with the laser aligner. These brackets are tightened after the aluminium beams of axis 1 have been fitted.

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Assembly

Laser aligner’s reference block Top bracket on aluminium beam 47 Nm Laser aligner

Figure 11 Position of laser aligner and reference block when aligning top brackets on aluminium beams.

5

Torque-tighten the screw joints of the adjusted top brackets as shown in Figure 11.

The top brackets have now been aligned.

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Assembly instructions IRB 840/A

Assembly 3.5 Assembling axis 1 For information about the position numbers in the figures below, see the spare parts list in the Product Manual. For an explanation about the reference leg and reference side, see Figure 1 sid 4. ??? N.B. It is extremely important that personnel handling the IRB 840/A are trained in lifting and can manage the types of lifting required, which can be of a complex nature. If the frame is equipped with intermediate legs, see section 4.4 for assembly of axis 1. 1

Check on the number and position of the T-slot nuts in the aluminium beams of axis 1.

2

Lift up the first aluminium beam of axis 1 (beam with cabling) on to the reference side of the frame.

3

Adjust the beams longitudinally so that the distance from the aluminium edge on the beam to the edge of the top bracket is 10 mm, tolerance +/- 1 mm. The adjustment is done on the ends of the beams above the reference leg. See Figure 12.

N.B. It is important that the distance from the aluminium edge on the beam to the edge of the assembly flange is 10 mm +/- 1 mm, see Figure 12. Otherwise the angle for the drive axes of axis 1, between the gearbox and the ends of the beam, will be too large.

10 mm

Reference leg Figure 12 Longitudinal adjustment of aluminium beams, axis 1.

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Assembly 4

Adjust the beams sideways so that the distance corresponds sideways to the distance between the edge of the frame and the aluminium beams, i.e. the aluminium beams must be centred above the frame legs. See Figure 13.

The distance between the aluminium beam and the frame leg must be the same at both frame legs, i.e. centered above the frame legs.

Reference leg

Reference side

Figure 13 Adjusting the aluminium beams sideways, axis 1; plan view of manipulator.

5

Push up the top brackets, one per leg, that were not aligned earlier with the laser aligner, against the aluminium beam of axis 1. Tighten the brackets on the frame legs to a torque of 47 Nm.

6

Attach the aluminium beams to all the top brackets on the frame legs. Tighten to the torque shown in Figure 14.

7

Fit the aluminium beam’s supports. Tighten to the torque shown in Figure 14.

Top brackets

Support

M10x25 Washer 10.5x20x2 47 Nm

M16x110 Nut M16 Washer 17x30x3 300 Nm

M10x25 Washer 10.5x20x2 Washer 47 Nm

Figure 14 Attaching the aluminium beam to the frame.

Assemble and adjust the second beam for axis 1 in a similar way as above, but do not tighten the screw joints that hold the top brackets to the beam. They should remain loose, i.e. the beam should be left “floating” until the parallelity of the aluminium beams for axis 1 is adjusted later.

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Assembly instructions IRB 840/A

Assembly 3.6 Assembling axis 2 For information about the position numbers in the figures below, see the spare parts list in the Product Manual. N.B. It is extremely important that personnel handling the IRB 840/A are trained in lifting and can manage the types of lifting required, which can be of a complex nature. 1

Move the roller block plate for axis 1 to the reference side so that it is up against the mechanical stop. Measure the distance from the reference point to the roller block plate, see Figure 15.

2

Move the second roller block plate for axis 1 so it is up against the mechanical stop. Measure the distance from the reference point to the roller block plate, see Figure 15. If the distance for both roller block plates is not the same, adjust the mechanical stop.

A

A

The distance between the reference point and roller block plate (± 1 mm) must be the same on both sides when the roller block plates are up against the mechanical stops.

Top bracket used as a reference point. A-A Roller block plate

Reference leg Reference side The distance between the reference point and the roller block plate (± 1 mm) must be the same on both sides when the roller block plates are up against the mechanical stops. Figure 15 Position of roller block plates when assembling axis 2; plan view of manipulator.

3

Lift up and position the first aluminium beam for axis 2 on the guide rail blocks of axis 1. Check the distance to the reference point as shown in Figure 15.

4

Mount the parallelity tool for axis 1, 3HAC 5931-1. See Figure 17, view A-A.

The parallelity tool is used to stiffen up axes 1 and 2 when adjusting the parallelity of axis 1, see section 3.11. 5

Check the distance to the reference point as shown in Figure 15. Screw on the lower screwed joints in all the angular brackets.

Assembly instructions IRB 840/A

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Assembly Tighten to the torque shown in view B-B in Figure 16. 6

Undo slightly the upper screwed joints of the angular brackets, i.e. those attached to axis 2. See Figure 16, view B-B.

7

Adjust the distance on the reference side between the short end of axis 2 and axis 1 to 5-10 mm, see Figure 16. Tighten the upper screwed joints of the angular brackets to the torque shown in view B-B in Figure 16.

8

Adjust the distance on the opposite side between the short end of axis 2 and axis 1 to 5-10 mm. Tighten the upper screwed joints of the angular brackets to the torque shown in view B-B in Figure 16. Upper screw joint 78 47 Nm

Angular bracket Lower screw joint 89 47 Nm A-A

B-B Adjust so the distance is 5-10 mm between the short end of axis 2 and axis 1.

Axis 1

A A

Axis 2

B B

Figure 16 Assembling axis 2; plan view of manipulator.

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Assembly instructions IRB 840/A

Assembly

Axis 1 Axis 2 Position of parallelity tool when both aluminium beams of axis 2 are fitted

A A A-A

Reference side

Parallelity tool art. no. 3HAC 5931-1

Figure 17 Mounting parallelity tool, axis 2; plan view of manipulator.

Assemble and adjust the second beam for axis 2 in a similar way as above, but do not tighten the lower screw joints of the angular brackets, i.e. those that attach the roller block plates to axis 1. They should remain loose, i.e. the beam should be left “floating” until the parallelity of the aluminium beams for axis 2 is adjusted later when axis 3 is assembled. See Figure 18.

“Floating” Aluminium beam is secured

Secured

Reference side Figure 18 “Floating” aluminium beam, axis 2; plan view of manipulator.

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Assembly 3.7 Assembling axis 3 N.B. It is extremely important that personnel handling the IRB 840/A are trained in lifting and can manage the types of lifting required, which can be of a complex nature. 1

Check the distance of axis 2 from the reference point as shown in Figure 15.

1

Lift up and position axis 3 on the roller block plates on axis 2.

2

Fit the outer nut-washers, see views A-A and B-B in Figure 19. Two per side, four in total. Attach with two screwed joints, pos. 46, per nut-washer. Tighten to a torque of 47 Nm.

3

Mount the parallelity tool for axis 2 on axis 3, see views C-C and D-D in Figure 19. Two per side, four in total. The tool is replaced by nut-washers after the parallelity of axis 2 has been adjusted. The ground braid must be removed in order to mount the parallelity tool.

A-A Axis 3

Nut-washer B-B

Outer nutwasher

Axis 2

Inner nut-washer. Fitted when the parallelity of axis 2 has been adjusted

C-C

Position of parallelity tool for axis 2. Art. no. 3HAC 5931-2 D-D

Parallelity tool for axis 2

Mounted parallelity tool

Figure 19 Position of nut-washers and parallelity tool, axis 2.

The assembly of axis 3 is finished when the parallelity of axis 2 has been adjusted.

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Assembly instructions IRB 840/A

Assembly

3.8 Adjusting parallelity of aluminium beams, axis 2 N.B. The parallelity tool for axis 2 must be mounted on axis 3. See section 3.7. 1

Apply a 24 V power supply to release the brake on axis 2 drive motor, as described in the instructions in the Product Manual, chapter Installation and commissioning. Axis 2 (y movement) can now be moved manually. See Figure 20.

Adjust the parallelity of the “floating” beam of axis 2. One of the aluminium beams is secured and the other is “floating”. When axis 2 is moved in a y movement, the beam will be automatically adjusted so that both beams are parallel. 2

Move axis 2 (y movement) manually, forwards and backwards. Stop at the mechanical stop on the reference side. See Figure 20. Check the distance from axis 2 to the reference point as shown in Figure 15. Tighten the lower screw joints of the angular brackets on the “floating” beam, when the table of axis 3 is above them. See view B-B in Figure 16.

3

Move axis 2 (y movement) manually to the other mechanical stop. See Figure 20. Tighten the lower screw joints of the angular brackets on to the “floating” beam, see view B-B in Figure 16.

y movement

Screw joints in lower angular brackets, axis 2, are tightened when the table of axis 3 is above them.

Axis 2 drive motor Reference leg Reference side Figure 20 Adjusting parallelity of aluminium beams, axis 2.

4

Check that the movement of axis 2 (y movement) runs easily and smoothly and that the distance of axis 2 to the reference point is as shown in Figure 15.

5

Remove the parallelity tool for axis 2 from axis 3 and replace with nut-washers. Secure with two screw joints, pos. 46, per nut-washer. Replace the ground braid. Tighten the screws to a torque of 47 Nm. See Figure 19.

6

Tighten the upper and lower screw joints on the angular brackets, axis 2, to the torque shown in view B-B in Figure 16.

7

Remove the 24 V power supply from axis 2 drive motor.

Axes 2 and 3 have now been assembled. Assembly instructions IRB 840/A

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Assembly

3.9 Assembling drive mechanism, axis 1 1

Fit the drive motor gearbox attachments to the cross-beam. See Figure 21.

2

Fit the motor and gearbox. See Figure 21.

3

Fit the drive shafts’ drop protection. See Figure 21.

Motor Gearbox

Fitting gearbox 13 81 Nm

M6x25 Washer 6.4x11x1.6 Nut M6 10 Nm M8x25 Washer 8.4x16x1.6 24 Nm

Holder Drop protection

Gearbox attachment Fitting gearbox attachment M10x35 Washer 10.5x20x26 47 Nm

Series measurement box

Figure 21 Assembling shafts, drive motor axis 1.

4

Fit the tensioning elements on the shafts, from the gearbox and from the end flanges of axis 1. See Figure 22.

5

Fit the tensioning elements and then the couplings on the ends of both drive shafts. See Figure 22.

N.B. The tensioning elements can withstand an angular displacement of 0.5º in operation. 6

Lift the drive shafts into position between the tensioning elements on the shafts from the gearbox and from the end flanges of axis 1. See Figure 22.

7

Check the locations of the tensioning elements/drive shafts. See Figure 22.

8

Torque-tighten all the screw joints of the tensioning elements except one in the drive shaft between the “floating” beam of axis 1 and the drive motor. This is to allow the parallelity of axis 1 to be adjusted later. See Figure 22. Tightening torque 17 Nm.

9

Fit the holder over the drive shaft on the drop protection. See Figure 21.

N.B. One tensioning element, between the “floating” aluminium beam axis 1 and the drive motor, should not be tightened. This is to allow the parallelity of axis 1 to be adjusted later. 24

Assembly instructions IRB 840/A

Assembly

End flange drive side

Tensioning elements

Coupling

Torque-tighten tensioning elements 17 Nm

Gearbox

Drive shafts The distance between the drive shaft and tensioning elements must be the same on both sides of the drive motor. One tensioning element, between the “floating” beam and the drive motor, should be left untightened to allow the parallelity of axis 1 to be adjusted later. Figure 22 Assembling the drive shafts, axis 1. Drive shaft on the left of the drive motor, axis 1.

3.10 Connecting the cabling and hoses 1

Fit the series measurement box on the reference leg. See Figure 23.

2

Fit the hose connections and connect the hoses. See Figure 23.

Cylinder air Opt. air Custom air Series measurement box

Figure 23 Series measurement box and hose connections fitted on the reference leg.

Assembly instructions IRB 840/A

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Assembly 3

Connect the cables to the drive motor axis 1, see Figure 24. Run the cables between the motor and the series measurement box through the drop protection and attach them to the upper side of the cross-member with cable ties. See Figure 21.

R2.MP1 R3.FB1

Figure 24 Connecting the cables to the drive motor, axis 1.

N.B. It is very important that the cable chains do not scrape against the sides of the cable chain trays. Check therefore that the upper clamp of the cable chain is mounted vertically and correctly mounted sideways.

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4

Fit the cable chain for axis 1 to axis 2. See view A-A in Figure 25. Check that the upper clamp of the cable chain is mounted vertically and correctly mounted sideways.

5

Connect the connectors and hose to axis 2. See views B-B and C-C in Figure 25.

6

Connect the connectors to the drive motor, axis 2. See view D-D in Figure 25.

Assembly instructions IRB 840/A

Assembly Fitting cable chain to axis 2. 18

Connecting the electrical connectors and hose to axis 2.

B-B

A-A

Custom air Opt. air Cylinder air

D

R.FB2-4 Cylinder air Opt. air

Connecting electrical connectors to drive motor, axis 2.

Connecting hose to axis 2.

C-C

R3.MP2-4 R2.CP/CS Custom air

D-D

C

C

B

B

A

A

R4.MP2 R2.MP2

D

Figure 25 Connecting electrical connectors and hoses; plan view of manipulator.

Assembly instructions IRB 840/A

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Assembly 7

Fit the attachment plate for the cable chain and the cabling on the table of axis 3. See view A-A in Figure 26.

N.B. It is very important that the cable chains do not scrape against the sides of the cable chain trays. Check therefore that the upper clamp of the cable chain is mounted vertically and correctly mounted sideways. 8

Attach the cable chain for axis 2 to the attachment plate. See view A-A in Figure 26. Check that the upper clamp of the cable chain is mounted vertically and correctly mounted sideways.

9

Attach the cabling and hoses to the attachment plate. See view B-B in Figure 26.

10 Connect the cables to the drive motor, axis 3. See view D-D in Figure 26. 11 Connect the hose to axis 3. See view C-C in Figure 26.

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Assembly instructions IRB 840/A

Assembly

Fitting attachment plate.

Attaching cable chain.

7

14

Attaching cabling and hoses.

6

A-A Connecting cabling to drive motor, axis 3.

B-B

R4.FB3-4 R3.CP/CS R4.MP3-4

Opt. air Custom air

Connecting hose, rigid axis 3.

R4.MP3 R5.FB3

D-D

C-C

Cylinder air

Connecting hose, telescopic axis 3.

B B

C

A C

A

D D

C-C

Cylinder air

Figure 26 Connecting cabling and hoses to axis 3; plan view of manipulator.

Assembly instructions IRB 840/A

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Assembly

3.11 Adjusting parallelity of beams, axis 1 Before making these adjustments, the drive belt for axis 1 must be fitted and correctly tensioned. See section 4.5. Start with axis 1 (x movement) up against the mechanical stops nearest to the drive motor, axis 1. The “floating” aluminium beam is then adjusted to the correct sideways position nearest to the drive motor, axis 1. If axis 1 is not hard up against the mechanical stops, release the brake on axis 1 and move the axis manually up against the stops. Instructions for releasing the brake can be found in the Product Manual chapter Installation and commissioning. 1

Check that the available adjusting range of the “floating” beam, axis 1, is not fully utilised. It is important that there is adjusting allowance on both the right and lefthand sides. See Figure 27. If there is no adjusting allowance in one direction, the axis must be readjusted as described in section 3.8.

“Floating”

Secured by screws

“Floating”

There must be adjusting allowance on the left and right at all attachment points for the “floating” beam.

Reference side is secured by screws. Figure 27 Adjusting allowance for “floating” aluminium beam, axis 1; plan view of manipulator.

30

2

Tighten the screw joints of the upper brackets and the supports of the “floating” beam, closest to the drive motor axis 1, to a torque of 47 Nm. Axis 2 should be positioned above the top bracket or the support being tightened. See Figure 28.

3

Tighten the untightened screws in the tensioning element in the drive mechanism, axis 1, to a torque of 17 Nm. See Figure 22.

4

Start the manipulator’s control cabinet. Using the joystick on the teach pendant, move axis 1 (x movement) carefully forwards and backwards between the mechanical stops a number of times. Finish by leaving axis 2 against the mechanical stop on the far side.

5

Check the adjusting allowances as described in point 4 and Figure 27. Tighten the

Assembly instructions IRB 840/A

Assembly screw joints of the top bracket and supports of the “floating” beam on the far side to a torque of 47 Nm. When tightening the screws, axis 2 should be located above the top bracket or support being tightened. See Figure 28.

Support

Top brackets

M10x25 Washer 10.5x20x2 Washer 47 Nm

M10x25 Washer 10.5x20x2 M16x110 47 Nm Nut M16 Washer 17x30x3 300 Nm

Figure 28 Tightening the “floating” beam, axis 1.

6

Undo slightly the screw joints of the tensioning elements in the driving mechanism of axis 1. The purpose of this is to release any stresses that have arisen when adjusting the parallelity of axis 1. Retighten the screw joints to a torque of 17 Nm. See Figure 22.

The parallelity of axis 1 has now been adjusted. The tension in the drive belt of axis 1 will now be checked and adjusted if necessary. N.B. When adjusting the alignment of the angles as shown in view A-A in Figure 29, the screws must be adjusted in pairs on the respective sides. If only one screw at a time is adjusted, the box may become askew and the service life of the bearings will be radically reduced. 7

Move axis 1 carefully forwards and backwards between the mechanical stops. Check that the drive belts are positioned in the middle of the rollers when axis 1 is moving. Adjust if necessary using the adjuster screws at the ends of the beam, axis 1. See Figure 29.

Assembly instructions IRB 840/A

31

Assembly

A-A Only adjusting of the angular alignment

B-B Adjusting the drive belt tension

Figure 29 Adjusting drive belts, axis 1.

32

Assembly instructions IRB 840/A

Assembly 8

After adjustment, remove the parallelity tool for axis 1 and replace by the breakthrough protector. Tighten to the torque shown in Figure 30.

The break-through protector is fitted to prevent overloading the rubber elements in the event of an emergency stop/abnormal loading. 90 20 Nm

90 47 Nm

85 Break-through protector

Axis 1 Figure 30 Break-through protector.

Assembly of the manipulator has now been finished. Now carry out assembly inspection as described in chapter 5, Assembly Inspection.

Assembly instructions IRB 840/A

33

Assembly

34

Assembly instructions IRB 840/A

Assembling base frame with intermediate legs

4 Assembling the base frame and intermediate legs 4.1 General The example below shows the assembly of an IRB 840/A robot with: - six base frame legs. - Axis 1, both aluminium beams comprise two parts that are joined together. To assemble the manipulator with intermediate legs, first follow the instructions in chapters 1, 2, and 3. When there are intermediate legs on the base frame, additional instructions are needed and a reference is made to this chapter in which the detailed instructions can be found. For information about the position numbers in the figures, see the spare parts list in the Product Manual for the 840A.

4.2 Measuring up and inspecting assembly area First measure up the positions of the outer legs on the assembly area, see section 3.3. 1

Then use a tape measure along the marks from the marker string, to measure up the distances to the intermediate legs. Make a mark on the floor at the leg position. Mark from marker string in the X direction

Mark for intermediate leg

Position of axis 1 drive motor

Mark from marker string in the Y direction

Mark for intermediate leg

Reference leg

Figure 31 Measuring up assembly area for location of intermediate legs.

Finish by inspecting the assembly area as described in points 12-13 in section 3.3.

Assembly instructions IRB 840/A

35

Assembling base frame with intermediate legs

4.3 Assembling the intermediate legs N.B. It is extremely important that personnel handling the IRB 840/A are trained in lifting and can manage the types of lifting required, which can be of a complex nature. N.B. A laser level may be used only if the personnel concerned have received separate training in its operation and maintenance. See also section 2.6.2. First assemble the outer legs as described in section 3.4. 1

Measure up the distances shown in Figure 32 and mark the floor with a pen. 225 mm

Marks 150 mm

Marks from marker string

Position of axis 1 drive motor

225 mm 1 Reference leg Marks

150 mm

Figure 32 Positioning intermediate legs; plan view of assembly area.

36

2

Lift the intermediate legs into their respective positions. Measure up the distances shown in Figure 32. Use a rubber mallet and a steel square to position the base frame legs correctly.

3

When the intermediate legs are correctly positioned, drill holes in the floor for the foot-plates.

Assembly instructions IRB 840/A

Assembling base frame with intermediate legs 4

Use four expander bolts per leg. Fit washers and nuts on all the bolts.

N.B. The foot-plate expander bolts must be tighetened with a torque in accordance with the bolt manufacturer’s recommendations. When determining the length and type of bolts, the thickness and nature of the concrete floor must be taken into consideration. For other information see the Product Specification in the Product Manual. 5

Undo all the locknuts for the foot-plates, see Figure 33 view A-A, four nuts per leg in all.

6

Adjust the angle of the intermediate legs with the adjuster nut, see Figure 33 view A-A, so that they are vertical to the assembly floor in the x direction. Check the angle using a plummet. The maximum allowable deviation from vertical is 2 mm on the entire length of the leg.

7

Adjust the intermediate leg in the y direction, using the adjuster nut, so that the highest points of the base frame legs are in line with each other, see Figure 33. Use the laser level for the alignment.

N.B. Before tightening the locknuts of an intermediate leg, check that the leg is resting on all the adjuster nuts for the leg in question. 8

Tighten the locknuts to the torque shown in Figure 33.

Position of laser level

A

Upper points of base frame legs must be in line with each other

A x direction

Locknut 665Nm

y direction

Adjuster nut Position of laser level

View A-A

A A

Upper points of base frame legs must be in line with each other

Figure 33 Angular adjustment of intermediate legs; plan view of manipulator.

Assembly instructions IRB 840/A

37

Assembling base frame with intermediate legs There is a support for each pair of intermediate legs. It can be fitted inwards or outwards. See Installation and Commissioning in the Product Manual. 9

Fit the floor support in the intermediate legs. See Figure 34.

M16x110 Nut M16 Washer 17x30x3 300 Nm Intermediate leg

Floor support

Figure 34 Fitting the intermediate leg floor support.

10 When the foot-plates are in position, drill the holes in the floor. 11 Use four expander bolts per leg. Fit washers and nuts on all the bolts. N.B. The foot-plate expander bolts must be tighetened with a torque in accordance with the bolt manufacturer’s recommendations. When determining the length and type of bolts, the thickness and nature of the concrete floor must be taken into consideration. For other information see the Product Specification in the Product Manual. 12 Screw the foot-plates to the floor. See Figure 34. 13 Tighten the screw joints on the floor supports for the intermediate legs. Tightening torque as shown in Figure 34. The intermediate legs are now assembled. See section 3.4.2 concerning Alignment of the upper attachment for axis 1 aluminium beams.

38

Assembly instructions IRB 840/A

Assembling base frame with intermediate legs

4.4 Assembling axis 1 N.B. It is extremely important that personnel handling the IRB 840/A are trained in lifting and can manage the types of lifting required, which can be of a complex nature. The upper attachments of the base frame legs must be adjusted before axis 1 is fitted. See section 3.4.2. 1

Lift up the first aluminium beam (beam with cabling) of axis 1 on to the reference side of the base frame.

2

Adjust the beams longitudinally so that the distance from the aluminium edge on the beam to the edge of the upper attachment is 10 mm, tolerance +/- 1 mm. The beam is adjusted at its ends which are above the reference leg. See Figure 35.

N.B. It is important that the distance from the aluminium edge on the beam to the edge of the assembly flange is 10 mm +/- 1 mm, see Figure 35. Otherwise the angle for the drive axes of axis 1, between the gearbox and the ends of the beam, will be too large. 3

Lift up the second part of the aluminium beam for axis 1 on to the reference side of the base frame. Position it so that there is no space between the beams.

10 mm

Reference leg Figure 35 Adjusting the aluminium beams longitudinally, axis 1.

4

Check the position of the aluminium beams on the reference leg. See Figure 35.

Assembly instructions IRB 840/A

39

Assembling base frame with intermediate legs 5

Adjust the beams sideways so that the distance corresponds sideways to the distance between the edge of the base frame and the aluminium beams, i.e. the aluminium beams must be centred above the base frame legs. See Figure 36. The distance between the aluminium beam and the base frame leg must be the same at all of the legs, i.e. centered above the frame legs.

Reference side Reference leg Figure 36 Adjusting the aluminium beams sideways, axis 1; plan view of the manipulator.

6

Screw the parts of the aluminium beams together using the joint plate, axis 1. Tighten the screws to the torque specified in Figure 37.

N.B. Position the joint plate on the outside of the beams. If it is positioned on the inside it will collide with axis 2.

3

4 47 Nm

Joint plate

Figure 37 Joint plate; axis 1.

40

Assembly instructions IRB 840/A

Assembling base frame with intermediate legs The linear guide can now be fitted. Normally the linear guide is attached with a screw in every second hole. Exceptions to this are at the: - beam joints, where 3-4 screws are used across the joint. See Figure 38. - joint in the linear guide, where 4 screws are used above the joint. See Figure 38. - linear guide ends, where 2 screws are used. See Figure 38. N.B. When making a joint on the linear guide, ensure that the mating ends of the joint are surface ground. 7

Position the first linear guide against one of the edges and tighten the screws to a torque of 24 Nm +/- 10%. The screws in the other linear guide should not be tightened.

8

The joints in the linear guide are adjusted using the trolley plate. Position the trolley plate over a joint and then tighten the screws in the second linear guide to a torque of 24 Nm +/- 10%.

N.B. It is very important that the joints in the linear guides are correctly adjusted otherwise noise will occur when the trolley plate moves across the joints. Beam joint Joint on linear guide

50 24 Nm ±10% Linear guide for axis 1

Joint plate End of linear guide

Figure 38 Attaching the linear guide to axis 1. Plan view of aluminium beam, axis 1.

Assembly instructions IRB 840/A

41

Assembling base frame with intermediate legs 9

Push up the upper attachments, that were not adjusted earlier using the laser level, one upper attachment per leg, against the aluminium beam for axis 1. Screw them to the frame legs and tighten to a torque of 47 Nm.

10 Screw the aluminium beam to all the assembly flanges on the frame legs and tighten to the torques specified in Figure 39. 11 Fit the supports for the aluminium beams. Tighten to the torque specified in Figure 39.

Upper attachment

Support M10x25 Washer 10.5x20x2 Washer 47 Nm

M10x25 Washer 10.5x20x2 M16x110 47 Nm Nut M16 Washer 17x30x3 300 Nm

Figure 39 Screwing the aluminium beam to the base frame.

The second aluminium beam for axis 1 is assembled and adjusted in a similar way to above. However, the screw joints between the beam and the upper attachments and the beam and the supports should not be tightened. The beam should be left “floating” and will be tightened later when the parallelity of the beams on axis 1 is adjusted. Fit the axis 1 drive belt as described in section 4.5.

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Assembly instructions IRB 840/A

Assembling base frame with intermediate legs 4.5 Fitting drive belt on axis 1 1

Push the belt through the beam. Move the trolley plate to one end of the drive belt so that the belt meshes on the teeth of the clamping plate. See Figure 40.

2

Centre the belt in the beam and then fit the key. See Figure 40.

3

Check that the belt tensioning wheel is adjusted to its bottom position.

4

Measure and cut the belt so it can be attached to the other side of the trolley plate. Mesh the belt with the teeth on the clamping plate. See Figure 40.

5

Centre the belt in the beam and then fit the key. See Figure 40.

14 7 Key Drive belt Clamping plate Attachment of drive belt to axis 2 assembly table

Attachment of drive belt to axis 2 assembly table

Trolley plate Figure 40 Fitting drive belt; axis 1.

Assembly instructions IRB 840/A

43

Assembling base frame with intermediate legs The belt must now be tensioned. 6

Draw a line across the aluminium beam and the drive belt. See Figure 41.

7

Pre-tension the drive belt using the tensioning screws at the end of the beam, two turns at a time (one screw at a time), until the belt just begins to move. See Figure 41. Check that the tensioning wheel is tightened straight.

8

The drive belt is then further tensioned a certain number of turns on the tensioning screws as shown in Figure 42, depending on the working area of axis 1, specified in metres. Finish tensioning by finely adjusting the screws one quarter of a turn at a time.

Mark Beam Drive belt

A-A

Pre-tensioning of drive belt

A A Figure 41 Pre-tensioning the drive belt, axis 1. Plan view of axis 1.

30

29

28

27

26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

N o . o f te n s io n in g tu rn s fo r d riv e b e lt (Ax is 1 )

L e n g th o f m o v em e n t (m )

Figure 42 Number of tensioning turns on tensioning screws for drive belt, axis 1.

The drive belt for axis 1 is now assembled. For fine adjustment see section 3.8. 44

Assembly instructions IRB 840/A

Assembling base frame with intermediate legs Assemble axis 2 as described in section 3.6.

Assembly instructions IRB 840/A

45

Assembling base frame with intermediate legs

46

Assembly instructions IRB 840/A

Assembly inspection

5 Assembly inspection 5.1 Checks and measures before start-up Logbook OK

Not checked

Create a logbook. The logbook should be used each time that the robot behaves abnormally or when a planned activity is implemented on the robot. Suggestions for suitable logbook pages can be found at the end of this chapter. This chapter should also be included in the logbook. The logbook is also used to document all maintenance activities. A condition for the validity of ABB Flexible Automation’s warranty is that the maintenance activities are entered in the logbook in chronological order Ground cable route Check the ground cable route before start-up. The resistance must be <0.1 Ohm from any random point on the manipulator to the ground cable (yellow/green) where it exits from the underneath the series measurement box. Check that the ground braids between axes 1 and 2 and axes 2 and 3 are correctly fitted. Check the ground connection between the ground cable (yellow/green), where it exits underneath the series measurement box, and the following points. See also Figure 43. 1

Transport plates on axis 1.

2

Axis 1, aluminium beams.

3

Axis 2, aluminium beams.

4

Z table.

5

Axis 1, drive motor.

6

Axis 2, drive motor.

7

Axis 3, drive motor.

8

Axis 4, turntable.

9

All base frame legs.

Assembly instructions IRB 840/A

47

Assembly inspection

1

5

3

7

2

4 6 Series measurement box

8 Ground cable yellow/green

9 Figure 43 Ground check points on the manipulator.

Breakthrough stops OK

Not checked

Check that the breakthrough stops for axis 1 are fitted and tightened to the correct torque, see Figure 43. Automatic lubrication cartridges Check that all the automatic lubrication cartridges (nine) are activated as described in the chapter Maintenance in the Product Manual.

5.2 Checks with the robot system started Balancing and brake release for axis 3. WARNING! Be very careful when releasing the brakes! Axis 3 can start to move very quickly indeed, resulting in a risk of personal injury. Before testing axis 3, check that the air pressure is connected and that the pressure is adjusted to balance the load, see the Product Specification in the Product Manual. Jog axis 3 to a position in the middle of its work range. Press the brake release button for axis 3, in the series measurement box, very briefly and note whether axis 3 moves (if the balancing is correct, it should not move). If the load moves but stops immediately the button is released, the brake is OK but the balancing is not optimal. The brake can manage the max. load without balancing, but the stopping distance is longer. To obtain the correctly adjusted balancing, check that axis 3 moves upwards by itself or with just a little manual help <200N, with no load.

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Assembly instructions IRB 840/A

Assembly inspection Brake release (excluding axis 3) WARNING! Be very careful when releasing the brakes! The axes can start to move very quickly indeed, resulting in a risk of personal injury. Press the brake release button for the axis in question. Listen for a clicking sound in the motor. Let another person move the axis in question. Release the brake release button when the axis moves and verify that the axis in question stops immediately. OK

Not changed

- axis 1 - axis 2 - axis 4 Belt control axes 1 and 2 Check that the drive belts for axes 1 and 2 lie in the neutral position between the side guides, or alternatively move between the side guides on the drive wheels and turn wheels when the robot is run with the application program. When in operation, the belts must not press at any time against the side guides (guide flange on the drive wheels and turn wheels). This must be carefully checked over the whole working range. Synchronisation signs / mechanical stops Axis 1 Check that the sync signs are fitted on both of the aluminium beams belonging to axis 1 and that the manipulator is positioned there when synchronising. Check that the distance between the mechanical stops for axis 1 have the same distance to axis 2, when it is positioned as close to them as possible. If this is not the case, the mechanical stops must be adjusted as described in section 3.6. Check that the mechanical stops are positioned 5 mm outside the software limits. Axis 2 Check that the sync signs are fitted on both aluminium beams belonging to axis 2 and that the manipulator is positioned there when synchronising. Check that the mechanical stops are positioned 5 mm outside the software limits.

Assembly instructions IRB 840/A

49

Assembly inspection Axis 3 OK

Not changed

Check that the sync signs are fitted and that the manipulator is positioned there when synchronising. Check that the (external) mechanical stops are positioned 5 mm outside the software limits. Cable chain movements in the cable chain guides Axis 1 Check that the cable chain is in the middle of the guide during the whole of the stroke. It is important that the chain is not pressed against the side of the guide. Check that all the cables lie loose in the cable chain and that none of them have been squeezed in between the intermediate walls of the chain. Check that the cables do not run in zigzag through the cable chain, i.e. the cables should lie in the same lateral position all through the cable chain. Check that when the cable chain glides on itself, the contact surfaces are the side plates of the chain, i.e. that the links are centred on top of each other. Check that the cables, hoses, and the cable chain itself, show no signs of any external physical damage after the transport and assembly on site. Check that the air hose can move >50 mm in and out at the lower end of the chain, i.e. do not tie the air hose to the cable chain. (Variations in air can cause movement in the hose). Axis 2 Check that the cable chain is in the middle of the guide during the whole of the stroke. It is important that the chain is not pressed against the side of the guide. Check that all the cables lie loose in the cable chain and that none of them have been squeezed in between the intermediate walls of the chain. Check that the cables do not run in zigzag through the cable chain, i.e. the cables should lie in the same lateral position all through the cable chain. Check that when the cable chain glides on itself, the contact surfaces are the side plates of the chain, i.e. that the links are centred on top of each other. Check that the cables, hoses, and the cable chain itself, show no signs of any external physical damage after the transport and assembly on site. 50

Assembly instructions IRB 840/A

Assembly inspection OK

Not changed

Check that the air hose can move >50 mm in and out at the lower end of the chain, i.e. do not tie the air hose to the cable chain. (Variations in air can cause movement in the hose). Axis 3 Check that the cable chain is in the middle of the guide during the whole of the stroke. It is important that the chain is not pressed against the side of the guide. Check that all the cables lie loose in the cable chain and that none of them have been squeezed in between the intermediate walls of the chain. Check that the cables do not run in zigzag through the cable chain, i.e. the cables should lie in the same lateral position all through the cable chain. Check that when the cable chain glides on itself, the contact surfaces are the side plates of the chain, i.e. that the links are centred on top of each other. Check that the cables, hoses, and the cable chain itself, show no signs of any external physical damage after the transport and assembly on site. Check that the air hose can move >50 mm in and out at the lower end of the chain, i.e. do not tie the air hose to the cable chain. (Variations in air can cause movement in the hose). Suspicious sounds Jog the axes one after another and listen for any abnormal sounds in the motors, gearboxes, and transmission. If it is possible, increase the load on the robot successively to 100% load and listen for abnormal sounds. - axis 1 - axis 2 - axis 3 - axis 4

Assembly instructions IRB 840/A

51

Inspection carried out by

(Name)

(Function)

(Company)

(Tel.)

(Date and signature)

(A copy of this filled-in document should be sent to ABB Flexible Automation).

Date

Time

Running hours from control system

No. of cycles in PLC

Activity/Service

Notes

Check before start according to instructions

Table 1 Suggestion for logbook page 1.

Page __

Date

Time

Running hours from the control system

No. of cycles in PLC

Activity/Service

Notes

Table 2 Suggestion for logbook page 2 and further pages.

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