Usage This manual should be used during: • installation, from lifting the robot to its work site and securing it to the foundation, to making it ready for operation • maintenance work •
Trang 1Product manual
IRB 460
Trang 2Workspace R18-2 version a18Checked in 2018-11-20Skribenta version 5.3.012
Trang 4be construed as a commitment by ABB ABB assumes no responsibility for any errorsthat may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall beconstrued as any kind of guarantee or warranty by ABB for losses, damages topersons or property, fitness for a specific purpose or the like
In no event shall ABB be liable for incidental or consequential damages arising fromuse of this manual and products described herein
This manual and parts thereof must not be reproduced or copied without ABB'swritten permission
Keep for future reference
Additional copies of this manual may be obtained from ABB
Original instructions.
© Copyright 2012-2018 ABB All rights reserved
Specifications subject to change without notice
ABB AB, RoboticsRobotics and MotionSe-721 68 VästeråsSweden
Trang 5Table of contents
9 Overview of this manual
13 Product documentation
15 How to read the product manual
17
1 Safety
17 1.1 General safety information
17 1.1.1 Limitation of liability
19 1.1.2 Protective stop and emergency stop
20 1.2 Safety actions
20 1.2.1 Fire extinguishing
21 1.2.2 Emergency release of the robot axes
22 1.2.3 Make sure that the main power has been switched off
23 1.3 Safety risks
23 1.3.1 Safety risks during installation and service work on robots
25 1.3.2 Moving robots are potentially lethal
26 1.3.3 First test run may cause injury or damage
27 1.3.4 Work inside the working range of the robot
28 1.3.5 Enabling device and hold-to-run functionality
29 1.3.6 Risks associated with live electric parts
31 1.3.7 The unit is sensitive to ESD
32 1.3.8 Hot parts may cause burns
33 1.3.9 Safety risks related to pneumatic/hydraulic systems
34 1.3.10 Brake testing
35 1.3.11 Safety risks during handling of batteries
36 1.3.12 Safety risks during work with gearbox lubricants (oil or grease)
38 1.4 Safety signals and symbols
38 1.4.1 Safety signals in the manual
40 1.4.2 Safety symbols on product labels
47
2 Installation and commissioning
47 2.1 Introduction
48 2.2 Unpacking
48 2.2.1 Pre-installation procedure
52 2.2.2 Working range and type of motion
54 2.2.3 Risk of tipping/stability
55 2.3 On-site installation
55 2.3.1 Lifting the robot with fork lift accessory
55 2.3.1.1 Fitting the fork lift accessory
58 2.3.1.2 Lifting the robot with fork lift truck
61 2.3.2 Lifting robot with roundslings
63 2.3.3 Manually releasing the brakes
65 2.3.4 Lifting the base plate
66 2.3.5 Securing the base plate
71 2.3.6 Orienting and securing the robot
75 2.3.7 Fitting equipment on robot
79 2.3.8 Loads fitted to the robot, stopping time and braking distances
80 2.3.9 Installation of signal lamp, upper arm (option)
84 2.4 Installation of options
84 2.4.1 Option 87-1 - Installing the cooling fan for axis-1 motor
90 2.5 Restricting the working range
90 2.5.1 Introduction
91 2.5.2 Mechanically restricting the working range of axis 1
93 2.6 Robot in cold environments
93 2.6.1 Start of robot in cold environments
94 2.7 Electrical connections
94 2.7.1 Robot cabling and connection points
Trang 63 Maintenance
97 3.1 Introduction
98 3.2 Maintenance schedule and expected component life
98 3.2.1 Specification of maintenance intervals
99 3.2.2 Maintenance schedule
101 3.2.3 Expected component life
102 3.3 Inspection activities
102 3.3.1 Inspecting the oil level in axis-1 gearbox
104 3.3.2 Inspecting, oil level gearbox axes 2 - 3
107 3.3.3 Inspecting, oil level gearbox axis 6
109 3.3.4 Inspecting, cable harness
111 3.3.5 Inspecting the information labels
113 3.3.6 Inspecting the axis-1 mechanical stop pin
115 3.3.7 Inspecting the additional mechanical stops
117 3.3.8 Inspection, dampers
119 3.3.9 Inspecting the signal lamp (option)
121 3.4 Replacement/changing activities
121 3.4.1 Type of lubrication in gearboxes
122 3.4.2 Changing oil, axis-1 gearbox
126 3.4.3 Changing oil, gearbox axes 2 and 3
130 3.4.4 Changing oil, gearbox axis 6
132 3.4.5 Replacing the SMB battery
136 3.5 Cleaning activities
136 3.5.1 Cleaning the IRB 460
139
4 Repair
139 4.1 Introduction
140 4.2 General procedures
140 4.2.1 Performing a leak-down test
141 4.2.2 Mounting instructions for bearings
143 4.2.3 Mounting instructions for seals
145 4.2.4 Cut the paint or surface on the robot before replacing parts
146 4.2.5 The brake release buttons may be jammed after service work
147 4.3 Complete robot
147 4.3.1 Replacing cable harness, lower end (axes 1-3)
157 4.3.2 Replacing the cable harness, upper end (incl axis 6)
164 4.3.3 Replacing the SMB unit
169 4.3.4 Replacing the brake release board
173 4.3.5 Replacing the base, including axis 1 gearbox
182 4.4 Upper and lower arm
182 4.4.1 Replacing the turning disk
188 4.4.2 Replacing the tilthouse unit
209 4.4.3 Replacing the upper arm
225 4.4.4 Replacing linkage - upper link arm
233 4.4.5 Replacing linkage - lower link arm
240 4.4.6 Replacing the linkage - link
256 4.4.7 Replacing the POM sealing for the link system
257 4.4.8 Replacing parallel rod
268 4.4.9 Replacing the complete lower arm system
278 4.4.10 Replacing the parallel arm
285 4.5 Motors
285 4.5.1 Replacing motor, axis 1
294 4.5.2 Replacing motors, axes 2 and 3
305 4.5.3 Replacing motor, axis 6
313 4.6 Gearboxes
313 4.6.1 Replacing the axis 1 gearbox
323 4.6.2 Replacing the axis 2 gearbox
331 4.6.3 Replacing the axis 3 gearbox
Trang 7338 4.6.4 Replacing gearbox axis 6
347
5 Calibration
347 5.1 Introduction to calibration
347 5.1.1 Introduction and calibration terminology
348 5.1.2 Calibration methods
350 5.1.3 When to calibrate
351 5.2 Synchronization marks and axis movement directions
351 5.2.1 Synchronization marks and synchronization position for axes
352 5.2.2 Calibration movement directions for all axes
353 5.3 Updating revolution counters
357 5.4 Calibrating with Axis Calibration method
357 5.4.1 Description of Axis Calibration
359 5.4.2 Calibration tools for Axis Calibration
361 5.4.3 Installation locations for the calibration tools
363 5.4.4 Axis Calibration - Running the calibration procedure
367 5.5 Calibrating with Calibration Pendulum method
368 5.6 Verifying the calibration
369 5.7 Checking the synchronization position
371
6 Decommissioning
371 6.1 Environmental information
373 6.2 Scrapping of robot
375
7 Reference information
375 7.1 Introduction
376 7.2 Applicable standards
378 7.3 Unit conversion
379 7.4 Screw joints
382 7.5 Weight specifications
383 7.6 Standard tools
384 7.7 Special tools
388 7.8 Lifting accessories and lifting instructions
389
8 Spare parts
389 8.1 Spare part lists and illustrations
391
9 Circuit diagrams
391 9.1 Circuit diagrams
393 Index
Trang 9Overview of this manual
About this manual
This manual contains instructions for:
• mechanical and electrical installation of the robot
• maintenance of the robot
• mechanical and electrical repair of the robot.
The manual also contains reference information for all procedures detailed in the manual.
Usage
This manual should be used during:
• installation, from lifting the robot to its work site and securing it to the foundation, to making it ready for operation
• maintenance work
• repair work.
Who should read this manual?
This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
Maintenance/repair/installation personnel working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work.
Product manual scope
The manual covers covers all variants and designs of the IRB 460 Some variants and designs may have been removed from the business offer and are no longer available for purchase.
Organization of chapters
The manual is organized in the following chapters:
Contents Chapter
Safety information that must be read through before performingany installation or service work on robot Contains general safetyaspects as well as more specific information about how to avoidpersonal injuries and damage to the product
Safety
Required information about lifting and installation of the robot.Installation and com-
missioning
Step-by-step procedures that describe how to perform maintenance
of the robot Based on a maintenance schedule that may be used
in the work of planning periodical maintenance
Maintenance
Continues on next page
Trang 10Contents Chapter
Step-by-step procedures that describe how to perform repairactivities of the robot Based on available spare parts
Reference information
Reference to the spare part list for the robot
Spare part list
Reference to the circuit diagram for the robot
Circuit diagram
References
Document ID Reference
3HAC040628-001Product manual, spare parts - IRB 460
3HAC039611-001Product specification - IRB 460
3HAC031045-001Operating manual - General safety informationi
3HAC021313-001Product manual - IRC5
IRC5 with main computer DSQC 639
3HAC047136-001Product manual - IRC5
IRC5 with main computer DSQC1000
3HAC050941-001Operating manual - IRC5 with FlexPendant
3HAC050944-001Operating manual - Service Information System
3HAC050996-001Application manual - Electronic Position Switches
3HAC051016-001Application manual - Additional axes and stand alone con-
troller
3HAC042927-001Technical reference manual - Lubrication in gearboxes
3HAC050948-001Technical reference manual - System parameters
i This manual contains all safety instructions from the product manuals for the manipulators and thecontrollers
Revisions
Description Revision
First edition
-This revision includes the following updates:
A
• Added safety section, Signal lamp (optional)
• A new block, about general illustrations, added in sectionHow to readthe product manual on page 15
• Illustrations improved throughout the Repair chapter
• Method of replacing the base updated and bits holder added in sectionReplacing the base, including axis 1 gearbox on page 173
• Refitting method updated in section Replacing the turning disk
• Re-calibration added in section Replacing the turning disk
• Details about tools added in sectionReplacing the tilthouse unit onpage 188
• Procedures for Removal and Refitting updated in sectionReplacingthe upper arm on page 209
Continues on next page
Continued
Trang 11Description Revision
• Three legged bearing puller added in Required equipment sectionsReplacing linkage - upper link arm on page 225andReplacing linkage
- lower link arm on page 233
• Replacing method updated in sectionReplacing motors, axes 2 and
3 on page 294
• Text updated in sectionReplacing the axis 1 gearbox on page 313
• In previous section Replacing the axis 2 and 3 gearboxes, replacinggearbox axis 3 has been removed and now only describes the axis 2gearbox
• New section included Replacing the axis 3 gearbox
• Changed the weight of the robot, seeWeight, robot on page 48
• Added an illustration that shows the directions of the robot stressforces, seeLoads on foundation, robot on page 49
• Added new section about how to install the signal lamp, seeInstallation
of signal lamp, upper arm (option) on page 80
• Added information that the working range of axis 1 also can be ted by EPS, seeIntroduction on page 90
restric-• Special tools updated
This revision includes the following updates:
B
• Minor corrections and editorial changes made throughout the manual
• Some general tightening torques have been changed/added, see dated values inScrew joints on page 379
up-• Added steps in the instruction for replacing upper end of cabling, seeReplacing the cable harness, upper end (incl axis 6) on page 157
• AddedSafety risks during handling of batteries on page 35.This revision includes the following updates:
• All data about type of lubrication in gearboxes is moved from themanual to a separate lubrication manual, seeType and amount of oil
in gearboxes on page 121
• Added a new sealing structure that contains a support ring, o-ring andradial sealing at the link, seeReplacing the linkage - link on page 240andReplacing the upper arm on page 209
• Three o-rings are added to the equipment list and procedure in sectionReplacing the axis 1 gearbox on page 313
• A new SMB unit and battery is introduced, with longer battery lifetime.This revision includes the following updates:
• New illustrations added for lower arm and lower and upper arm joints
• The maximum allowed deviation in levelness of the base plate andfoundation is changed, seeSecuring the base plate on page 66
• Minor corrections
Continues on next page
Continued
Trang 12Description Revision
This revision includes the following updates:
G
• Splitted instruction for fork lift accessory use in two sections
• Illustrations of SMB battery RMU improved,This revision includes the following updates:
• Corrections due to updates in terminology
Published in release R17.1 The following updates are made in this revision:K
• Added labels to the robot, one warning label (A) on the axis-6 motor,one battery label (N) and one stock robots label (P) SeeInspectingthe information labels on page 111
• New standard calibration method is introduced (Axis Calibration) SeeCalibration on page 347
Published in release R17.2 The following updates are made in this revision:L
• Caution about removing metal residues added in sections about SMBboards
• Information about minimum resonance frequency added
• Bending radius for static floor cables added
• Updated list of applicable standards
• Article number for the Calibration tool box, Axis Calibration is changed
• Added text regarding overhaul in section specification of maintenanceintervals
• Updated the sectionStart of robot in cold environments on page 93
• Updated information regarding replacement of brake release board
• Lifting robot with roundslings updated
• Updated information regarding disconnecting and reconnecting batterycable to serial measurement board
Published in release R18.1 The following updates are made in this revision:M
• Information added about fatigue to Axis Calibration tool, seeCalibrationtools for Axis Calibration on page 359
• Added section, Cut the paint or surface on the robot before replacingparts
• New spare part numbers brake release board
• Note added to calibration chapter to emphasize the requirement ofequally dressed robot when using previously created reference calib-ration values
• Information about myABB Business Portal added
Published in release R18.2 The following updates are done in this revision:N
• Added locating hole position in tool flange view
Published in release R18.2 The following updates are done in this revision:P
• Updated references
Continued
Trang 13Product documentation
Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.
All documents can be found via myABB Business Portal, www.myportal.abb.com
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• References to circuit diagrams.
Technical reference manuals
The technical reference manuals describe reference information for robotics products, for example lubrication, the RAPID language, and system parameters.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
• What is included (for example cables, I/O boards, RAPID instructions, system parameters, software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
Continues on next page
Trang 14Operating manuals
The operating manuals describe hands-on handling of the products The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters.
Continued
Trang 15How to read the product manual
Reading the procedures
The procedures contain references to figures, tools, material, and so on The references are read as described below.
References to figures
The procedures often include references to components or attachment points located on the manipulator/controller The components or attachment points are marked with italic text in the procedures and completed with a reference to the figure where the current component or attachment point is shown.
The denomination in the procedure for the component or attachment point corresponds to the denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a procedure.
Note/Illustration Action
Shown in the figureLocation ofgearbox on page xx
Remove the rear attachment screws, gearbox
8
References to required equipment
The procedures often include references to equipment (spare parts, tools, etc.) required for the different actions in the procedure The equipment is marked with italic text in the procedures and completed with a reference to the section where the equipment is listed with further information, that is article number and dimensions.
The designation in the procedure for the component or attachment point corresponds to the designation in the referenced list.
The table below shows an example of a reference to a list of required equipment from a step in a procedure.
Note/Illustration Action
Art no is specified inRequiredequipment on page xx
Fit a new sealing, axis 2 to the gearbox
3
Safety information
The manual includes a separate safety chapter that must be read through before proceeding with any service or installation procedures All procedures also include specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 17
Trang 17The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment that can influence the safety of the entire system.
In particular, liability cannot be accepted if injury/damage has been caused for any
of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their intended location or in any other way not working.
• When instructions for operation and maintenance are not followed.
• Non-authorized design modifications made in or around the robot.
• Repairs carried out by in-experienced or non-qualified personnel.
• Foreign objects.
• Force majeure.
Nation/region specific regulations
To protect personnel, the complete system must 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.
To be observed by the supplier of the complete system
The integrator is responsible that the safety devices necessary to protect people working with the robot system are designed and installed correctly.
When integrating the robot with external devices and machines:
• The supplier of the complete system must ensure that all circuits used in the safety function are interlocked in accordance with the applicable standards for that function.
• 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.
Continues on next page 1.1.1 Limitation of liability
Trang 18The integrator of the final application is required to perform an assessment of the hazards and risks (HRA).
be safe and adequate access to the task locations.
Safety zones, which must 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 out of the robot's working space.
A safety fence is recommended to ensure safeguarded space Sufficient space must be provided around the manipulator to protect those working with or on it from hazards such as crushing.
The fence or enclosure must be dimensioned to withstand the force created if the load being handled by the robot is dropped or released at maximum speed Determine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot is working in the work cell (see the section Robot motion in the Product specification).
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot.
is provided, to indicate its designated safety function.
Grippers/end effectors must be designed so that they do not drop work pieces/tools
in the event of a power failure or a disturbance to the controller.
Unauthorized modifications of the originally delivered robot are prohibited Without the consent of ABB, it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings The strength of the robot could
be affected.
1.1.1 Limitation of liability
Continued
Trang 191.1.2 Protective stop and emergency stop
Trang 211.2.2 Emergency release of the robot axes
Description
In an emergency situation, the brakes on a robot axis can be released manually
by pushing a brake release button.
How to release the brakes is described in the section:
The robot may be moved manually on smaller robot models, but larger models may require using an overhead crane or similar equipment.
Make sure no personnel is near or beneath the robot.
1.2.2 Emergency release of the robot axes
Trang 221.2.3 Make sure that the main power has been switched off
Description
Working with high voltage is potentially lethal Persons subjected to high voltage may suffer cardiac arrest, burn injuries, or other severe injuries To avoid these personal injuries, switch off the main power on the controller before proceeding work.
Note
Switch off all main power switches in a MultiMove system.
1.2.3 Make sure that the main power has been switched off
Trang 231.3 Safety risks
1.3.1 Safety risks during installation and service work on robots
Requirements on personnel
Only persons who know the robot and are trained in the operation and handling
of the robot are allowed to maintain the robot Persons who are under the influence
of alcohol, drugs or any other intoxicating substances are not allowed to install, maintain, repair, or use the robot.
• Those in charge of operations must make sure that safety instructions are available for the installation in question.
• Those who install or service/maintain the robot must have the appropriate training for the equipment in question and in any safety matters associated with it.
• Personnel should be trained on responding to emergency or abnormal situations.
General risks during installation and service
The instructions in the product manual must always be followed.
Never turn the power on to the robot before it is properly fixed and bolted to its foundation/support.
Make sure that no one else can turn on the power to the controller and robot while you are working with the system A good method is to always lock the main switch
on the controller cabinet with a safety lock.
Make sure that no one else can turn on the power to the controller and robot while you are working with the system A good method is to remove the power cable to the controller.
If the robot is installed at a height, hanging, or other than standing directly on the floor, there may be additional risks than those for a robot standing directly on the floor.
Energy stored in the robot for the purpose of counterbalancing certain axes may
be released if the robot, or parts thereof, are dismantled.
Never use the robot as a ladder, which means, do not climb on the controller, motors, or other parts during service work There is a risk of slipping because of the high temperature of the motors and oil spills that can occur on the robot There
is also a risk of the robot being damaged.
To avoid damaging the product, make sure that there are no loose screws, turnings,
or other parts inside the product after work has been performed.
Safety risks during operational disturbances
Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts.
Continues on next page 1.3.1 Safety risks during installation and service work on robots
Trang 24If 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.
Spare parts and special equipment
ABB does not supply spare parts and special equipment which have not been tested and approved by ABB The installation and/or use of such products could negatively affect the structural properties of the robot and as a result of that affect the active or passive safety operation ABB is not liable for damages caused by the use of non-original spare parts and special equipment ABB is not liable for damages or injuries caused by unauthorized modifications to the robot.
Connection of external safety devices
Apart from the built-in safety functions, the robot is also supplied with an interface for the connection of external safety devices An external safety function can interact with other machines and peripheral equipment via this interface This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot.
Personal protective equipment
Always use suitable personal protective equipment, based on the risk assessment for the installation.
Allergenic material
in the product, if any.
1.3.1 Safety risks during installation and service work on robots
Continued
Trang 251.3.2 Moving robots are potentially lethal
Description
Any moving robot is a potentially lethal machine.
When running, the robot may perform unexpected and sometimes irrational movements Moreover, all movements are performed with great force and may seriously injure any personnel and/or damage any piece of equipment located within the working range of the robot.
Safe handling
Note Action
Emergency stop equipment such as gates,tread mats, light curtains, etc
Before attempting to run the robot, makesure all emergency stop equipment is cor-rectly installed and connected
1
How to use the hold-to-run function is scribed in section How to use the hold-to-run function in the Operating manual - IRC5with FlexPendant
de-Usually the hold-to-run function is activeonly in manual full speed mode To in-crease safety it is also possible to activatehold-to-run for manual reduced speed with
3
1.3.2 Moving robots are potentially lethal
Trang 261.3.3 First test run may cause injury or damage
Description
After installation and performing service activities, there are several safety risks
to take into consideration before the first test run.
2
Verify that any safety equipment installed to secure the position or restrict the robotmotion during service activity is removed
3Verify that the fixture and work piece are well secured, if applicable
4Install all safety equipment properly
5Make sure all personnel are standing at a safe distance from the robot, and is out ofits reach behind safety fences, or similar
Trang 271.3.4 Work inside the working range of the robot
• The maximum speed of the robot is limited to 250 mm/s when the operating mode selector is in the position Manual mode with reduced speed This should be the normal position when entering the working space.
The position Manual mode with full speed (100%) may only be used by trained personnel who are aware of the risks that this entails Manual mode with full speed (100%) is not available in USA or Canada.
• Pay attention to the rotating axes of the robot Keep away from axes to not get entangled with hair or clothing Also, be aware of any danger that may
be caused by rotating tools or other devices mounted on the robot or inside the cell.
• Keep clear of moving parts so that limbs, hands, or fingers do not get trapped
or crushed by the robot.
• To prevent anyone else from taking control of the robot, always put a safety lock on the cell door and bring the three-position enabling device with you when entering the working space.
WARNING
NEVER, under any circumstances, stay beneath any of the robot's axes! There
is always a risk that the robot will move unexpectedly when robot axes are moved using the three-position enabling device or during other work inside the working range of the robot.
1.3.4 Work inside the working range of the robot
Trang 281.3.5 Enabling device and hold-to-run functionality
Three-position enabling device
The three-position enabling device is a manually operated, constant pressure push-button which, when continuously activated in one position only, allows potentially hazardous functions but does not initiate them In any other position, hazardous functions are stopped safely.
The three-position enabling device is of a specific type where you must press the push-button only half-way to activate it In the fully in and fully out positions, operating the robot is impossible.
Note
The three-position enabling device is a push-button located on the teach pendant which, when pressed halfway in, switches the system to MOTORS ON When the enabling device is released or pushed all the way in, the manipulator switches
to the MOTORS OFF state.
To ensure safe use of the teach pendant, the following must be implemented:
• The enabling device must never be rendered inoperational in any way.
• During programming and testing, the enabling device must be released as soon as there is no need for the robot to move.
• Anyone entering the working space of the robot must always hold the teach pendant This is to prevent anyone else from taking control of the robot without his/her knowledge.
Hold-to-run function
The hold-to-run function allows movement when a button connected to the function
is actuated manually and immediately stops any movement when released The hold-to-run function can only be used in manual mode.
How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant.
1.3.5 Enabling device and hold-to-run functionality
Trang 291.3.6 Risks associated with live electric parts
Voltage related risks, general
Work on the electrical equipment of the robot must be performed by a qualified electrician in accordance with electrical regulations.
Although troubleshooting may, on occasion, need to be carried out while the power supply is turned on, the robot must be turned off (by setting the main switch to OFF) when repairing faults, disconnecting electric leads, and disconnecting or connecting units.
The main supply to the robot must be connected in such a way that it can be turned off from outside the working space of the robot.
Make sure that no one else can turn on the power to the controller and robot while you are working with the system A good method is to always lock the main switch
on the controller cabinet with a safety lock.
The necessary protection for the electrical equipment and robot during installation, commissioning, and maintenance is guaranteed if the valid regulations are followed.
Voltage related risks, IRC5 controller
A danger of high voltage is associated with, for example, the following parts:
• Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in the controller.
• Units such as I/O modules, can be supplied with power from an external source.
• The main supply/main switch
• The transformers
• The power unit
• The control power supply (230 VAC)
• The rectifier unit (262/400-480 VAC and 400/700 VDC Note: capacitors!)
• The drive unit (400/700 VDC)
• The drive system power supply (230 VAC)
• The service outlets (115/230 VAC)
• The customer power supply (230 VAC)
• The power supply unit for additional tools, or special power supply units for the machining process.
• The external voltage connected to the controller remains live even when the robot is disconnected from the mains.
• Additional connections.
Voltage related risks, manipulator
A danger of low voltage is associated with the manipulator in:
• The power supply for the motors (up to 800 VDC).
• The user connections for tools or other parts of the installation (max 230 VAC).
Continues on next page 1.3.6 Risks associated with live electric parts
Trang 30Voltage related risks, 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.
1.3.6 Risks associated with live electric parts
Continued
Trang 311.3.7 The unit is sensitive to ESD
Description
ESD (electrostatic discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field When handling parts or their containers, personnel not grounded may potentially transfer high static charges This discharge may destroy sensitive electronics.
Safe handling
Note Action
Wrist straps must be tested frequently to ensurethat they are not damaged and are operating cor-rectly
• Product manual - IRC5
• Product manual - IRC5 Compact
• Product manual - IRC5 Panel MountedController
Use a wrist strap The wrist strapbutton is located inside the control-ler
Trang 321.3.8 Hot parts may cause burns
Wait until the potentially hot component has cooled if it is to be removed or handled
in any other way.
Do not put anything on hot metal surfaces, e.g paper or plastic.
1.3.8 Hot parts may cause burns
Trang 331.3.9 Safety risks related to pneumatic/hydraulic systems
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.
1.3.9 Safety risks related to pneumatic/hydraulic systems
Trang 341.3.10 Brake testing
When to test
During operation, the holding brake of each axis normally wears down A test can
be performed to determine whether the brake can still perform its function.
2 Switch the motor to the MOTORS OFF.
3 Inspect and verify that the axis maintains its position.
If the robot does not change position as the motors are switched off, then the brake function is adequate.
1.3.10 Brake testing
Trang 351.3.11 Safety risks during handling of batteries
Description
Under normal conditions of use, the electrode materials and liquid electrolyte in the batteries are not exposed to the outside, provided the battery integrity is maintained and seals remain intact.
There is a risk of exposure only in case of abuse (mechanical, thermal, electrical) which leads to the activation of safety valves and/or the rupture of the battery container Electrolyte leakage, electrode materials reaction with moisture/water or battery vent/explosion/fire may follow, depending upon the circumstances.
Note
Appropriate disposal regulations must be observed.
Safe handling
Use safety glasses when handling the batteries.
In the event of leakage, wear rubber gloves and chemical apron.
In the event of fire, use self-contained breathing apparatus.
Do not short circuit, recharge, puncture, incinerate, crush, immerse, force discharge
or expose to temperatures above the declared operating temperature range of the product Risk of fire or explosion.
Operating temperatures are listed in Pre-installation procedure on page 48
1.3.11 Safety risks during handling of batteries
Trang 361.3.12 Safety risks during work with gearbox lubricants (oil or grease)
Description
When handling gearbox lubricants, there is a risk of both personal injury and product damage occurring The following safety information must be regarded before performing any work with lubricants in the gearboxes.
Note
When handling oil, grease, or other chemical substances the safety information
of the manufacturer must be observed.
Warning
Make sure that protective gearlike goggles and gloves are al-ways worn during this activity
Changing and draining gearboxoil or grease may require hand-ling hot lubricant heated up to
90 °C
Hot oil or grease
Make sure that protective gearlike goggles and gloves are al-ways worn
When working with gearbox ricant there is a risk of an allergicreaction
lub-Allergic reaction
Open the plug carefully and keepaway from the opening Do notoverfill the gearbox when filling
When opening the oil or greaseplug, there may be pressurepresent in the gearbox, causinglubricant to spray from theopening
Possible pressure build-up in gearbox
Continues on next page
1.3.12 Safety risks during work with gearbox lubricants (oil or grease)
Trang 37Elimination/Action Description
Warning
Make sure not to overfill thegearbox when filling it with oil orgrease
Overfilling of gearbox lubricantcan lead to internal over-pres-sure inside the gearbox which inturn may:
• damage seals and kets
gas-• completely press outseals and gaskets
• prevent the robot frommoving freely
by the manufacturer
Mixing types of oil may causesevere damage to the gearbox
Do not mix types of oil
When changing gearbox oil, firstrun the robot for a time to heat
up the oil
Warm oil drains quicker thancold oil
Heat up the oil
After filling, verify that the level
is correct
The specified amount of oil orgrease is based on the totalvolume of the gearbox Whenchanging the lubricant, theamount refilled may differ fromthe specified amount, depending
on how much has previouslybeen drained from the gearbox
Specified amount pends on drained volume
de-When draining the oil make surethat as much oil as possible isdrained from the gearbox Thereason for this is to drain asmuch oil sludge and metal chips
as possible from the gearbox
The magnetic oil plugs will takecare of any remaining metalchips
Contaminated oil in gear boxes
1.3.12 Safety risks during work with gearbox lubricants (oil or grease)
Continued
Trang 381.4 Safety signals and symbols
1.4.1 Safety signals in the manual
Introduction to safety signals
This section specifies all safety signals used in the user manuals Each signal consists of:
• A caption specifying the danger level (DANGER, WARNING, or CAUTION) and the type of danger.
• A brief description of what will happen if the the danger is not eliminated.
• Instruction about how to eliminate danger to simplify doing the work.
Danger levels
The table below defines the captions specifying the danger levels used throughout this manual.
Significance Designation
Symbol
Warns that an accident will occur if the instructionsare not followed, resulting in a serious or fatal injuryand/or severe damage to the product It applies towarnings that apply to danger with, for example,contact with high voltage electrical units, explosion
or fire risk, risk of poisonous gases, risk of crushing,impact, fall from height, and so on
DANGER
Warns that an accident may occur if the instructionsare not followed that can lead to serious injury, pos-sibly fatal, and/or great damage to the product Itapplies to warnings that apply to danger with, forexample, contact with high voltage electrical units,explosion or fire risk, risk of poisonous gases, risk
of crushing, impact, fall from height, etc
WARNING
Warns for electrical hazards which could result insevere personal injury or death
ELECTRICALSHOCK
Warns that an accident may occur if the instructionsare not followed that can result in injury and/ordamage to the product It also applies to warnings
of risks that include burns, eye injury, skin injury,hearing damage, crushing or slipping, tripping, im-pact, fall from height, etc Furthermore, it applies towarnings that include function requirements whenfitting and removing equipment where there is a risk
of damaging the product or causing a breakdown.CAUTION
Warns for electrostatic hazards which could result
in severe damage to the product
ELECTROSTATICDISCHARGE (ESD)
Continues on next page
1.4.1 Safety signals in the manual
Trang 39Significance Designation
Trang 401.4.2 Safety symbols on product labels
Introduction to labels
This section describes safety symbols used on labels (stickers) on the product Symbols are used in combinations on the labels, describing each specific warning The descriptions in this section are generic, the labels can contain additional information such as values.
The safety labels are language independent, they only use graphics See Symbols
The information labels can contain information in text (English, German, and French).
Symbols on safety labels
Description Symbol
Warning!
xx0900000812
Warns that an accident may occur if the instructions are notfollowed that can lead to serious injury, possibly fatal, and/orgreat damage to the product It applies to warnings that apply
to danger with, for example, contact with high voltage electricalunits, explosion or fire risk, risk of poisonous gases, risk ofcrushing, impact, fall from height, etc
Prohibition
xx0900000839
Used in combinations with other symbols
Continues on next page
1.4.2 Safety symbols on product labels