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IRB 14000
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Dimension,
class
and
treatment
Screw
Article
number
M5
Steel
8-A2F
Nut
9ADA267-5
446
Product
manual
-
IRB
14000
3HAC052983-001
Revision:
D
©
Copyright
2015
-
2016
ABB.
All
rights
reserved.
7
Reference
information
7.4
Specification
of
screws
Continued
445
447
Table of Contents
Main Page
Default Chapter
5
Table of Contents
5
Organization of Chapters
9
Overview of this Manual
9
References
10
Product Documentation, IRC5
12
Categories for User Documentation from ABB Robotics
12
Product Manuals
12
Technical Reference Manuals
12
Application Manuals
13
Operating Manuals
13
How to Read the Product Manual
14
Safety Information
14
Illustrations
14
Network Security
15
Introduction to Safety Information
17
General Safety Information
18
Introduction to General Safety Information
18
Sections
18
Safety in the Robot System
19
Connection of External Safety Devices
19
Limitation of Liability
19
Validity and Responsibility
19
Safety in Collaborative Operation
20
Certified Safety Functions
20
Mechanical Design Measures
20
Personal Protective Equipment
20
Design of Work Pieces and End Effectors
21
General Risks During Installation and Service
22
Safety Risks During Installation and Service Work on Robots
22
Spare Parts and Special Equipment
22
Cabling
23
Complete Robot
23
Gearboxes and Motors
23
CAUTION - Hot Parts May Cause Burns
24
Elimination
24
Safe Design
25
Safe Handling
25
Safety Risks Related to Tools/Work Pieces
25
Pneumatic System Related Risks
26
Safety Risks Related to Pneumatic Systems
26
Safety Risks with Pressure Relief Valve
27
Extraordinary Risks
28
Qualified Personnel
28
Safety Risks During Operational Disturbances
28
Risks Associated with Live Electric Parts
29
Voltage Related Risks, General
29
Voltage Related Risks, IRC5 Controller
29
Voltage Related Risks, Robot
29
Voltage Related Risks, Tools, Material Handling Devices, Etc.
30
Safe Design of the Robot Cell
31
Safety Risks for Collaborative Robots
31
Safety Risks in Collaborative Operation
31
Safety Actions
32
Fire Extinguishing
32
Emergency Release of the Robot Arm
33
Increased Injury
33
Manually Stopping or Overriding the Arm
34
Brake Testing
35
How to Test
35
Risk of Disabling Function "Reduced Speed 250 MM/S
36
Cabling and Power Supply
37
Handling and Cleaning
37
Handling of the Flexpendant
37
Three-Position Enabling Device
38
Waste Disposal
38
Work Inside the Working Range of the Robot
39
Signal Lamp (Optional)
40
Safety Stops
41
Definition of Emergency Stop
41
Emergency Stop Buttons
41
What Is an Emergency Stop
41
Definition of Safety Stops
42
What Is a Safety Stop or Protective Stop?
42
Definition of Cartesian Speed Supervision
43
What Is Cartesian Speed Supervision?
43
Safety Signals in the Manual
44
Danger Levels
44
Introduction to Safety Signals
44
Safety Symbols on Product Labels
46
Symbols on Safety Labels
46
Types of Labels
46
DANGER - Moving Robots Are Potentially Lethal
52
Safety Related Instructions
52
DANGER - First Test Run May Cause Injury or Damage
53
Elimination, Controller
54
DANGER - Make Sure that the Main Power Has Been Switched off
54
WARNING - the Unit Is Sensitive to ESD
55
WARNING - Safety Risks During Handling of Batteries
56
WARNING - Safety Risks During Work with Gearbox Lubricants (Oil or Grease)
57
2 Installation and Commissioning
59
Introduction
59
Unpacking
60
Pre-Installation Procedure
60
Checking the Pre-Requisites for Installation
60
Loads on Foundation, Robot
61
Table Mounted
61
Weight, Robot
61
Operating Conditions, Robot
62
Requirements, Foundation
62
Storage Conditions, Robot
62
Protection Classes, Robot
63
Dimensions
64
Working Range
65
Front View
65
Illustration, Working Range IRB 14000
65
Side View
66
Top View
66
Isometric View
67
Robot Motion
67
Risk of Tipping/Stability
68
Shipping and Transport Position
68
On-Site Installation
69
Lifting the Robot with Lifting Accessories
69
Required Equipment
69
Lifting the Robot by Two Persons
72
Attachment Screws and Pins
72
Lifting and Transporting the Robot
72
Orienting and Securing the Robot
74
Hole Configuration, Base
74
Specification, Attachment Screws and Pins
75
Manually Releasing the Brakes
77
Introduction to Manually Releasing the Brakes
77
Location of Brake Release Button
77
Releasing the Brakes
78
Loads Fitted to the Robot
79
Installing the Signal Lamp
80
Location of Signal Lamp
80
Required Parts
80
Removing the Body Covers
81
Required Tools and Equipment
81
Refitting the Body Covers
83
Electrical Connections
86
Main Cable Categories
86
Main Power Cable
86
Robot Cabling and Connection Points
86
Controller
87
Overview
87
Controller Interface, Left Side
88
Controller Interface, Right Side
89
Connecting Power and the Flexpendant
90
Connecting Power Supply
90
Line Fusing
90
Rated Power
90
Connecting a Flexpendant
91
Connecting Power to the Controller
91
Connecting a PC and Ethernet Based Options
92
Multiple Ethernet Based Options
92
Connectors on the Computer Unit
93
Service Port
93
LAN Ports
94
WAN Port
94
Isolated LAN 3 or LAN 3 as Part of the Private Network
95
USB Ports
96
Connecting I/O Signals
97
Digital Inputs
97
Tool I/O
97
Tool I/O, Left and Right Arm
97
Digital Inputs and Outputs
98
Connecting Fieldbuses
99
Expansion Board for Fieldbus Adapters
100
Fieldbus Adapters
100
Devicenet Master/Slave Board
101
Termination Resistors in the Devicenet Bus
101
Connecting Safety Signals
102
Standalone Safety
102
Safety PLC
103
Safety When Connected to External Devices
103
RT6 Safety Relay (Option 1526-X)
104
Memory Functions
105
SD-Card Memory
105
Connecting an USB Memory
106
Location on the Controller
106
Location on the Flexpendant
106
3 Maintenance
107
Introduction
107
Structure of this Chapter
107
Maintenance Schedule
108
Specification of Maintenance Intervals
108
Activities and Intervals, Standard Equipment
109
Life of each Component
109
Scheduled and Non-Predictable Maintenance
109
Activities and Intervals, Optional Equipment
110
Inspection Activities
111
Inspecting the Information Labels
111
Location of Labels
111
Required Spare Parts
113
Inspecting, Labels
114
Inspecting, Signal Lamp
115
Inspecting, Cable Harness
117
Location of Cable Harness
117
Inspecting the Cable Harness
118
Inspecting, Plastic and Padding
119
Location of Plastic and Padding
119
Replacement/Changing Activities
121
Replacing the Battery Pack
121
Location of Battery Pack
121
Preparations before Removing the Battery Pack
122
Removing the Battery Pack
122
Refitting the Battery Pack
124
Cleaning the IRB 14000
126
Cleaning Activities
126
4 Repair
127
Introduction
127
General Procedures
128
Mounting Instructions for Seals
128
Rotating Seals
128
Flange Seals and Static Seals
129
O-Rings
129
Replacing the Complete Arm
130
Arm and Arm Covers
130
Location of the Complete Arm
130
Covers to be Removed for Access
131
Preparations before Removing the Arm
132
Removing the Axis-1 Covers
133
Removing the Arm from the Body with Cabling Still Connected
135
Disconnecting the Arm Cabling from the Controller
137
Refitting the Arm
138
Refitting the Arm to the Body
138
Connecting the Arm Cabling to the Controller
139
Refitting the Remaining Screws between the Arm and the Body
140
Refitting the Axis-1 Covers
141
Concluding Procedure
144
Information for Replacement
145
Location of Arm Covers
145
Replacing the Arm Covers
145
Replacing the Encapsulation and Covers
145
Location of the Axis-1 Motor
148
Replacing the Axis-1 Motor
148
Location of the Axis-2 Motor
149
Replacing the Axis-2 Motor
149
Consumables
150
Preparations before Removing the Motor
152
Removing the Motor
152
Removing the Axis-2 Covers
157
Removing the Axis-2 Motor
157
Fitting a New O-Ring on the Motor
159
Refitting the Motor
159
Removing the Wave Generator from the Motor
159
Fitting the Wave Generator to the Motor
160
Refitting the Axis-2 Motor
164
Location of the Axis-7 Motor
171
Replacing the Axis-7 Motor
171
Location of the Axis-3 Motor
172
Replacing the Axis-3 Motor
172
Removing the Axis-3 Motor
175
Location of the Axis-4 Motor
185
Replacing the Axis-4 Motor
185
Checking the O-Ring on the Motor
190
Location of the Axis-5 Motor
199
Replacing the Axis-5 Motor
199
Location of the Axis-6 Motor
211
Replacing the Axis-6 Motor
211
Hall Sensors
226
Replacing the Axis-1 Hall Sensor
226
Location of the Hall Sensor
226
Preparations before Removing the Hall Sensor
227
Removing the Hall Sensor
227
Replacing the Axis-2 Hall Sensor
241
Replacing the Axis-7 Hall Sensor
248
Replacing the Axis-3 Hall Sensor
255
Replacing the Axis-4 Hall Sensor
262
Mechanical Stops
270
Replacing the Axis-1 Mechanical Stop
270
Preparations before Removing the Mechanical Stop
271
Refitting the Mechanical Stop
276
Replacing the Axis-2 Mechanical Stop
281
Location of the Mechanical Stop
281
Replacing the Axis-7 Mechanical Stop
289
Replacing the Axis-3 Mechanical Stop
294
Replacing the Computer
302
Location of the Computer
302
Controller
302
Product Manual - IRB
303
Replacing the Controller Fan
310
Location of the Controller Fan
310
Preparations before Removing the Fan
311
Removing the Fan
311
Refitting the Fan
312
Replacing the Fan
312
Replacing the Capacitor Bank
314
Location of the Capacitor Bank
314
Pulling the Controller out Partially
315
Removing the Capacitor Bank
315
Replacing the Power Supply
321
Location of the Power Supply
321
Preparations before Removing the Power Supply
322
Removing the Power Supply
322
Refitting the Power Supply
323
Replacing the Power Distribution Board
325
Location of the Power Distribution Board
325
Removing the Power Distribution Board
326
Replacing the External Power Distribution Board
332
Location of the External Power Distribution Board
332
Removing the External Power Distribution Board
333
Refitting the External Power Distribution Board
335
Refitting the External Power Supply
335
Replacing the Axis Computer
338
Location of the Axis Computer
338
Removing the Axis Computer
339
Refitting the Axis Computer
341
Pushing the Controller in and Fastening It
342
Replacing the Left Arm's Drive Board
345
Location of the Drive Board
345
Removing the Left Arm's Drive Board
346
Removing the I/O Board
347
Removing the SMB Board
347
Refitting the Left Arm's Drive Board
349
Refitting the I/O Board
351
Refitting the SMB Board
351
Replacing the Right Arm's Drive Board
354
Removing the Right Arm's Drive Board
355
Refitting the Right Arm's Drive Board
357
Replacing the I/O Board
361
Location of the I/O Board
361
Remove the Body Cover
362
Replacing the SMB Boards
366
Location of the SMB Board
366
Replacing the Ethernet Switch
372
Location of the Ethernet Switch
372
Removing the Ethernet Switch
373
Replacing the Mass Memory Card
376
Location of the Mass Memory Card
376
Removing the Mass Memory Card
377
Replacing the Expansion Board Complete
379
Location of the Expansion Board Complete
379
Removing the Computer
380
Removing the Expansion Board Complete
383
Removing the Fieldbus Adapter
383
Refitting the Expansion Board Complete
385
Replacing the Devicenet Master
393
Location of the Devicenet Master
393
Removing the Devicenet Master
397
Replacing the Fieldbus Adapter
404
Location of the Fieldbus Adapter
404
Brake Release Harness
409
Replacing the Brake Release Harness
409
Location of the Brake Release Harness
409
Removing the Brake Release Harness
410
5 Calibration
417
Introduction
417
The Resolver Values Are Changed
417
The Revolution Counter Memory Is Lost
417
When to Calibrate
417
Calibration Method
418
Type of Calibration
418
Calibration Scale and Correct Axis Position
419
Calibrating the Robot
420
Exact Axis Positions in Degrees
420
Illustration of Robot in Synchronization Position
420
Synchronization Position
420
Calibrating the Robot with Fine Calibration Procedure
421
Moving the Robot to Its Calibration Position
421
Selecting the Calibration with Hall Sensors (Calhall) Routine
421
Setting the Running Speed to 100%
421
Selecting the Function Fine Calibration
422
Manually Moving the Manipulator to the Calibration Position
428
Updating Revolution Counters
428
Selecting the Function Update of Revolution Counters
429
Storing the Revolution Counter Setting
431
Calibration Movement Directions for All Axes
434
Calibration Movement Directions, 7 Axes
434
Using a Moveabsj Instruction
435
Using the Jogging Window
435
Verifying the Calibration Position
435
6 Decommissioning
437
Introduction
437
Environmental Information
438
Hazardous Material
438
Oil and Grease
438
Scrapping of Robot
439
Important When Scrapping the Robot
439
7 Reference Information
441
Introduction
441
Applicable Safety Standards
442
Standards, en ISO
442
Deviations from ISO 10218-1:2011
442
Unit Conversion
444
Converter Table
444
Specification of Screws
445
Screws Handled as Spare Part
445
Screws Not Handled as Spare Parts
445
Screw Joints
447
UNBRAKO Screws
447
Gleitmo Treated Screws
447
Screws Lubricated in Other Ways
447
Weight Specifications
448
Definition
448
Standard Toolkit
449
Contents, Standard Toolkit
449
Special Tools
450
Lifting Accessories and Lifting Instructions
452
Index
453
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