ABB IRB 640 Product Manual
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ABB IRB 640 Product Manual

4-axis industrial robot
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IRB 640
3HAC 7579-1
M2000

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  • Page 1 Product Manual IRB 640 3HAC 7579-1 M2000...
  • Page 2 ABB Robotics Products AB´s written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted. Additional copies of this document may be obtained from ABB Robotics Products AB at its then current charge.

  • Page 3: Table Of Contents

    3.1 Connection of extra equipment to the manipulator ..........23 3.1.1 Connections on upper arm................23 3.1.2 Connections on upper arm with CanBus............24 3.1.3 Connection of signal lamp on upper arm (option) ........25 Product Manual IRB 640...
  • Page 4 Installation and Commissioning Page Product Manual IRB 640...

  • Page 5: Transporting And Unpacking

    The control system weighs approximately 240 kg. Whenever the manipulator is transported, axis 2 must be bent backwards 30° and axis 3 must be moved down to a position against the rubber stops on axis 2. Product Manual IRB 640...

  • Page 6: Stability / Risk Of Tipping

    The following table shows the positions where there is a risk of tipping and refers to fig- ures in chapter 3.8 in Product Specification IRB 640, for definition of position 0 and 5. Working area, position 0...

  • Page 7: On-Site Installation

    It is also possible to use two lifting devices (option) for use with a fork lift truck (see Figure 4). The right lifting device, the robot seen from behind, must be removed before start-up, see Figure 1. Lifting device View from behind Figure 1 Lifting device that must be removed. Product Manual IRB 640...
  • Page 8 On-Site Installation Installation and Commissioning Crane lift Length=950 Length=1150 Figure 2 Lifting the manipulator using a traverse crane. Product Manual IRB 640...
  • Page 9 Installation and Commissioning On-Site Installation Crane lift, in calibration position Length=950 Length=1150 Figure 3 Lifting the manipulator with the arm system in the calibration position. Product Manual IRB 640...
  • Page 10 On-Site Installation Installation and Commissioning Fork lift 1120 Figure 4 Lifting the manipulator using a fork lift truck. Crane lifting is not permitted using the fork lift arrangement. Product Manual IRB 640...

  • Page 11: Assembling The Robot

    When bolting a mounting plate or frame to a concrete floor, follow the general instructions for expansion-shell bolts. The screw joint must be able to withstand the stress loads defined in Chapter 2.3 Stress forces . Product Manual IRB 640...

  • Page 12: Stress Forces

    ± 32 000 Nm ±39 000 Nm Torque z ±6 000 Nm ±13 000 Nm Force xy and torque xy are vectors that can have any direction in the xy plane. Figure 6 The directions of the stress forces. Product Manual IRB 640...

  • Page 13: Amount Of Space Required

    NB: There are no software or mechanical limits for the working space under the base of the manipulator. 2.4.1 Manipulator IRB 640 TCP 0 2310 1220 2905 All dimensions refer to TCP 0 (mm) Figure 7 The working space required for the manipulator. Product Manual IRB 640...

  • Page 14: Manually Engaging The Brakes

    WARNING: Be very careful when engaging the brakes. The axes become acti- vated very quickly and may cause damage or injury. Axis 3 Buttons 4 and 5 are not connected. Axis 6 Axis 2 Brake release unit Axis 1 Figure 9 The robot axes and motion patterns. Product Manual IRB 640...

  • Page 15: Restricting The Working Space

    Instructions for doing this are supplied with the kit. IMPORTANT! The mechanical stop pin and the extra moveable mechanical stop arm for axis 1 must absolutely be replaced after a hard collision, if the pin or arm has been deformed. Product Manual IRB 640...

  • Page 16: Axes 2 And 3

    Extra stops must be mounted in a row, starting at the fixed stop. Holes for extra stops Figure 10 Mechanically limiting axes 2 and 3. The robot is always delivered with one extra mechanical stop mounted for axis 3. It is not allowed to remove it. Product Manual IRB 640...

  • Page 17: Mounting Holes For Equipment On The Manipulator

    On-Site Installation 2.7 Mounting holes for equipment on the manipulator NB: Never drill a hole in the manipulator without first consulting maintenance staff or the design department at ABB Flexible Automation. M10 (2x) through M10 (4x) through Limit for M10 surfaces...

  • Page 18: Loads

    For more information see chapter 3.4 in Product Specification IRB 640 (Technical specification) for load diagrams, permitted extra loads (equipment) and their positions.
  • Page 19 Installation and Commissioning On-Site Installation Product Manual IRB 640...
  • Page 20 On-Site Installation Installation and Commissioning Product Manual IRB 640...

  • Page 21: Customer Connections On Manipulator

    (250 V, 2 A). Number of signals with CanBus : 12 signals (50 V, 250 mA), 5 power signals (250 V, 2 A). R3.CP/CS Air R1/2” R3.CB R1.CPV Air R1/2” R1.CP/CS R1.SW R1.CB Figure 13 Location of customer connections. Product Manual IRB 640...
  • Page 22 Socket table below Adaptor 3HAA 2601-3 UTG 18 ADT Burndy EMC 5217 1038-5 UTG 18 AD Burndy Cable clamp 5217 649-36 UTG 18 PG Burndy Shrinking hose 3HAA 2614-3 Bottled shaped Shrinking hose 5217 1032-5 Angled Product Manual IRB 640...
  • Page 23 5217 649-53 UTG 614 12 SN Burndy Sockets See below Adaptor 3HAA 2601-2 UTG 14 ADT Burndy EMC Cable clamp 5217 649-8 UTG 14 PG Burndy Shrinking hose 3HAA 2614-2 Bottled shaped Shrinking hose 5217 1032-4 Angled Product Manual IRB 640...
  • Page 24 Tin bronze (CuSu) 0.14 - 0.5mm AWG 20-26 5217 1021-5 DIN 43 652 Tin bronze (CuSu) 0.5 - 1.5mm AWG 16-20 Figure 14 Customer connector Customer side 4, 5 Manipulator side 1, 3 Figure 15 Burndy connector Product Manual IRB 640...

  • Page 25: Connection Of Extra Equipment To The Manipulator

    R1.CP/CS.A1 R3.CP.A XT6.2 R1.CP/CS.B1 R3.CP.B XT6.3 R1.CP/CS.C1 R3.CP.C XT6.4 R1.CP/CS.D1 R3.CP.D XT6.5 R1.CP/CS.A2 R3.CP.E XT6.6 R1.CP/CS.B2 R3.CP.F XT6.7 R1.CP/CS.C2 R3.CP.J XT6.8 R1.CP/CS.D2 R3.CP.K XT6.9 R1.CP/CS.A3 R3.CP.L XT6.10 R1.CP/CS.B3 R3.CP.M Signals XT5.1.1 R1.CP/CS.B5 R3.CS.A XT5.1.2 R1.CP/CS.C5 R3.CS.B Product Manual IRB 640...

  • Page 26: Connections On Upper Arm With Canbus

    Customer contact on Customer contact controller, see chapter 2 manipulator base, R1 on upper arm, R3 for Controler. (cable not supplied) Power supply XT6.1 R1.CP/CS.1 R3.CP.F XT6.2 R1.CP/CS.2 R3.CP.J XT6.3 R1.CP/CS.3 R3.CP.K XT6.4 R1.CP/CS.4 R3.CP.L XT6.5 R1.CP/CS.5 R3.CP.M Product Manual IRB 640...

  • Page 27: Connection Of Signal Lamp On Upper Arm (Option)

    CanBus DRAIN R1.CB.1 R3.CB.1 +24VCAN R1.CB.2 R3.CB.2 0VCAN R1.CB.3 R3.CB.3 CAN_H R1.CB.4 R3.CB.4 CAN_L R1.CB.5 R3.CB.5 3.1.3 Connection of signal lamp on upper arm (option) Signal lamp RH.3 -BK, +WH Figure 18 Location of signal lamp. Product Manual IRB 640...
  • Page 28 2.7 Lubricating gearboxes, axes 2 and 3............... 12 2.8 Lubricating gear box, axis 6................13 2.9 Checking mechanical stop, axis 1 ..............14 2.10 Changing the battery in the measuring system ..........15 2.11 Changing filter/cooling of motor axis 1 ............16 Product Manual IRB 640...
  • Page 29 Maintenance CONTENTS Page Product Manual IRB 640...
  • Page 30 Compressed air and harsh solvents that can damage the sealing joints, bearings, lacquer or cabling, must not be used. • Check that the sealing joints and cable glands are really airtight so that dust and dirt are not sucked into the cabinet. Product Manual IRB 640...

  • Page 31: Maintenance Schedule

    3. Check the mechanical stop devices for deformation and damage. If the stop pin or the adjustable stop arm is bent, it must be replaced. See section 2.9. 4. Also see section 1.1 regarding axis 1. 5. See Spare Parts, section 1.1, item 205.32. 6. See section 2.10. Product Manual IRB 640...

  • Page 32: Maintenance Intervals For Gear Axes 1 And 6

    Figure 1 Recommended interval for grease exchange axis 1. Life time (operation) (h) 40 000 30 000 20 000 10 000 Cycle time (s) Figure 2 Approx. estimate of operating life of gearbox axis 1 as a function of the cycle time. Product Manual IRB 640...

  • Page 33: Approx. Estimate Of Operating Life Of Base Cable

    Figure 4 Approx. estimate of operating life of gearbox axis 6 as a function of the moment of inertia Ja . Ja according to the Product Specification, chapter 3. 1.2 Approx. estimate of operating life of base cable Approx. estimate of operating life of base cable is 4 million cycles. Product Manual IRB 640...

  • Page 34: Instructions For Maintenance

    The level in the gearboxes is checked by adding new grease, until grease comes out through the special draining holes. See Chapter 2.7, Lubricating gearboxes, axes 2 and 3 and Chapter 2.8, Lubricating gear box, axis 6. Product Manual IRB 640...

  • Page 35: Lubricating The Large Diameter Bearing, Axis 1

    Figure 5 Lubricating the large diameter bearing. • Remove excess grease with a cloth. Type of grease: - ABB art. no. 1171 4013-301, quality 7 1401-301 - ESSO Beacon EP 2 - Shell Alvanina EP Grease - SKF Grease LGEP 2 - BP Energrease LS-EP 2.

  • Page 36: Lubricating Gear Box, Axis 1

    - 1.3 litres (0.36 US gallon) - About 3.0 litres (0.82 US gallon) should be used when changing the grease. Type of grease: - ABB 3HAC 2331-1 Molywhite RE No 00 Tools: - See Tool list. Figure 6 Lubricating axis 1. Product Manual IRB 640...

  • Page 37: Inspect And Lubricate The Bearings, Balancing Units Axis 2

    Loctite 243 on the KM nuts, not on the shafts, and tighten them to a torque of 50-60 Nm. 12. Chek play (min 0.1 mm) between support washer and bearingseat at both bearings. 13. N.B. Remove the M10x50 screw. For more information about the procedure of replacing bearings, see Repairs. Product Manual IRB 640...

  • Page 38: Lubricating Piston Rod, Balancing Unit Axis 2

    Maintenance Type of grease - ABB art no. 1171 4013-301, quality 7 1401-301. - ESSO Beacon EP 2. - Shell Alvanina EP Grease. - SKF Grease LGEP 2. - BP Energrease LS-EP2. 2.6 Lubricating piston rod, balancing unit axis 2 Move axis 2 to a position where the balancing units are in the horizontal position.

  • Page 39: Lubricating Gearboxes, Axes 2 And 3

    - About 2.0 litres (0.82 US gallon) should be used when changing the grease. Type of grease: - ABB 3HAC 2331-1 Molywhite RE No 00 Tools: See Tool list. WARNING! It is important that the drain plug is removed during lubrication. Figure 7 Drain holes, axes 2 and 3. Product Manual IRB 640...

  • Page 40: Lubricating Gear Box, Axis 6

    - 0.30 litres (0.085 US gallon). - About 0.4 litres (0.11 US gallon) should be used when changing the grease. Type of grease: - ABB 3HAC 2331-1 Molywhite RE No 00 Guide hole Figure 8 Greasing axis 6. Product Manual IRB 640...

  • Page 41: Checking Mechanical Stop, Axis 1

    A bent stop pin must always be replaced by a new one. 3. If any of the adjustable stop arms are bent, they must be replaced by new ones. Article number Stop pin 3HAB 4082-1 Adjustable stop arm 3HAB 4533-3 (Option) Product Manual IRB 640...

  • Page 42: Changing The Battery In The Measuring System

    The benefit with a lithium battery is the extended service life, which can be up to 5 years, compared with a Ni-Cd battery’s max service life of 3 years. Two types of lithium battery are available: - a 3-cell battery, art.no. 3HAB 9999-1 - a 6-cell battery, art.no. 3HAB 9999-2 Product Manual IRB 640...

  • Page 43: Changing Filter/Cooling Of Motor Axis 1

    Figure 10 Fastening of the 3-cell battery. 2.11 Changing filter/cooling of motor axis 1 • Loosen the filter holder at the intake. Insert the new filter and replace the filter holder. The article number of the filter is 3HAA 1001-612. Product Manual IRB 640...
  • Page 44 4.3 Dismounting parallel arm ..................29 4.4 Replacing parallel bar with bearings ..............29 4.5 Dismounting upper arm, complete ................. 30 5 Link system ........................33 5.1 Replacing upper and lower rod................33 5.2 Replacing the link....................35 Product Manual IRB 640...
  • Page 45 9.3 Aligning the tilt housing ................. 51 9.4 Setting the calibration marks on the manipulator........... 52 9.5 Checking the calibration position................55 9.6 Alternative calibration positions ................55 9.7 Calibration equipment .................... 57 10 Special Tools List......................59 Product Manual IRB 640...

  • Page 46: General Description

    Repairs General Description 1 General Description The industrial robot system IRB 640 comprises two separate units; the control cabinet and the mechanical unit. The service of the mechanical unit is described in this docu- ment. As regards service, the mechanical unit is divided into the following main parts: •...
  • Page 47 Special care must be taken when the brakes are operated manually. This applies particularly when the robot is started up, either for the first time or after a stop- page. The safety instructions in the Programming Manual must be complied with at all times. Product Manual IRB 640...

  • Page 48: Document Guidance

    In such cases, the defective module or component should be replaced on site. The faulty item should be sent to ABB Flexible Automation for service. Calibration. Recalibration of the robot may have to be carried out after replacing mechanical unit parts or when the motor and feedback unit have been separated;...

  • Page 49: Caution

    The bearing must be greased after fitting. The main reason for this is the requirement for cleanliness. Grooved ball bearings should be filled with grease from both sides. Tapered roller bearings and axial needle bearings shall be greased in the split condition. Product Manual IRB 640...

  • Page 50: Seals

    Always mount the seal with a mounting tool. Never hammer directly on the seal, as this may result in leakage. Use a protective sleeve for the sealing lip during mounting, when sliding over threads, keyways, etc. Product Manual IRB 640...
  • Page 51 If flange surfaces are defective, the parts must not to be used, because leakage could result. The surfaces must be properly cleaned in accordance with ABB ROBOTICS PRODUCTS recommendations. Distribute the sealing compound evenly over the surface, preferably with a brush.

  • Page 52: Instructions For Tightening Screw Joints

    Screws with dimension M8 or larger should be tightened with a torque-wrench, if pos- sible. Screws with dimension M6 or smaller may be tightened to the correct torque using tools without torque indication, by personnel with adequate mechanical training and instruction. Product Manual IRB 640...

  • Page 53: Tightening Torques

    “Dry” M 2.5 0.25 1.5.2 Screws with hexagon socket head Tightening torque - Nm Dimension class 8.8 class 10.9 class 12.9 “Dry” Molycote 1000 Molycote 1000 Gleitmo 610 Gleitmo 610 M 10 M 12 M 16 Product Manual IRB 640...

  • Page 54: Axis 1

    10. Mount the motor, grease screw <9> with Molycote 1000 and tighten with a torque of 50 Nm. 11. Calibrate the robot as described in Chapter 9, Calibration. Tightening torque: Screws for motor, item 9: 50 Nm. Screw for motor gear, item 15: 70 Nm. Product Manual IRB 640...

  • Page 55: Cabling Axis 1

    Loosen the base cabling at the frame, screws <2:1/25>. The screws must be removed. Loosen the cover over axis 1 motor, the brake release unit and the serial measure- ment board. Caution! The serial measurement board is an electrostatic sensitive device. Use a wrist strap. Product Manual IRB 640...
  • Page 56 19. Remove screws <3/6> which keep the cabling fixed to the bottom of the base, one at the time and add Loctite 243 and tighten it. 20. Mount support rail <3/3>. Add Loctite 243 and tighten. 21. Assembly all covers, use Loctite 243. Note! All removed straps must be refitted. Product Manual IRB 640...

  • Page 57: Replacing The Gearbox

    13. Lift the arm system and then lower it carefully until the joint bearing is just about to enter the bearing seat. 14. Align the holes in the bearing <4/2> with the holes in the base, with two screws. Product Manual IRB 640...

  • Page 58: Dismounting Joint Bearing

    Apply grease to the bearing seat and push it on with screws <3>. Lubricate screws with Molycote 1000 and tighten with a torque of 120 Nm. Refit the arm system as described in Chapter 2.3, Replacing the gearbox. Tightening torque: Screw joint bearing, item 3: 120 Nm. Product Manual IRB 640...

  • Page 59: Dismounting Cooling Axis 1

    2.5 Dismounting cooling axis 1 Refer to foldout 10. Dismounting: Dismount cover in the frame between axes 2 and 3. Disconnect fan cabling <12>, R3.FAN. Loosen nuts <7>. Remove the fan <1>. Mounting: Mount in reverse order. Product Manual IRB 640...

  • Page 60: Axis 2

    12. Mount motor, lubricate screws <1.31> with Molycote 1000 and tighten with a torque of 50 Nm. Do not forget to remove the locking screws in the lower arm! 13. Calibrate the robot as described in Chapter 9, Calibration. Product Manual IRB 640...

  • Page 61: Replacing The Gearbox

    14. Mount motor as described in Chapter 3.1, Replacing motor. Tightening torque: Screw joint gear box/lower arm, item 1.7: 300 Nm Screw joint gear box/lower arm, item 1.5: 120 Nm Screw joint motor socket/frame, item 1.38.2: 120 Nm Product Manual IRB 640...

  • Page 62: Replacing Lower Arm

    13. Mount the parallel arm as described in Chapter 4.3, Dismounting parallel arm. 14. Lift the lower arm with mounted parallel arm in position. 15. First mount the motor and gearbox for axis 2, as in Chapter 3.2, Replacing the gearbox. Product Manual IRB 640...

  • Page 63: Replacing Bearing In Lower Arm

    Heat up the bearing <3> to max. 120 C before mounting it on the parallel arm <2>. Mount parallel arm as in Chapter 4.3, Dismounting parallel arm. Mount lower arm as in Chapter 3.3, Replacing lower arm. Product Manual IRB 640...

  • Page 64: Dismounting Balancing Unit

    12 Check play (min. 0,1) between support washers <2, 5> and bearing seat <7> at both bearings. 13. Remove the M10x50 screw at the top of the cylinder. Remove the M16x140 screw on the lower arm. Product Manual IRB 640...
  • Page 65 Axis 2 Repairs Inner race Aux. shaft 3HAB 6558-1 Loctite 243 50 Nm min 0.1 min 0.1 Figure 2 Mounting the balancing unit. Product Manual IRB 640...

  • Page 66: Replacing Guiding Ring, Balancing Unit

    Locate the ring in the end cover. Use tool 3HAC 0879-1. See Figure 3 Install the circlip. Lubricate the piston rod, see Maintenance, Chapter 2.6, Lubricating piston rod, balancing unit axis 2. Tool 3HAC 0879-1 Guide ring Circlip Circlip Figure 3 Guiding ring, balancing unit. Product Manual IRB 640...

  • Page 67: Replacing Bearings, Balancing Unit

    New bearing Support Figure 5 Mounting of bearing. Replace the guiding ring and the circlip according to Chapter 3.6, Replacing guid- ing ring, balancing unit. Mount the balancing unit according to Chapter 3.5, Dismounting balancing unit. Product Manual IRB 640...

  • Page 68: Dismounting Cables, Lower Arm/Upper Arm

    The cable that comes out from the upper arm forms a loop down against the parallel bar. The loop should be big enough so that it runs quite close to the inside of the cover. Product Manual IRB 640...
  • Page 69 Axis 2 Repairs Product Manual IRB 640...

  • Page 70: Axis 3

    Ensure that the assembly surfaces are clean and unscratched. Mount O-ring <1.28>, applying some grease. Mount motor, lubricate screws <1.31> with Molycote 1000 and tighten to torque 50 Nm. Do not forget to remove the two extra mechanical stops, if they are used. Product Manual IRB 640...

  • Page 71: Replacing Gearbox

    Put the motor socket on the 2 guide pins. Note! The position of the magnetic plugs. Mount screws <1.38.2>, lubricate with Molycote 1000 and tighten to a torque of 120 Nm. Mount the motor as described in Chapter 4.1, Replacing motor. Product Manual IRB 640...

  • Page 72: Dismounting Parallel Arm

    Attach a hoist to the parallel bar. NOTE! Mark the clamps so that they can be refitted in the same place. Dismount clamps, screws <3.142> by the parallel arm. Dismount clamps, screws <3.160> by the upper arm. Lift the bar away. Product Manual IRB 640...

  • Page 73: Dismounting Upper Arm, Complete

    Dismount the linkage as described in Chapter 5, Link system. Unscrew the clamps, screws <1/3.143> on the upper arm for the parallel bar. Let the bar rest on the weights. NOTE! Mark the clamps. Remove the KM nut<1:1/136> on each shaft. Product Manual IRB 640...
  • Page 74 Mount the cabling as described in Chapter 3.8, Dismounting cables, lower arm/ upper arm. Mount the balancing units as described in Chapter 3.5, Dismounting balancing unit or Chapter 3.6, Replacing guiding ring, balancing unit. NOTE! Remove the 2 extra mechanical stops! Product Manual IRB 640...
  • Page 75 Axis 3 Repairs Tightening torque: Shafts, item 1:1/203: 300 Nm KM nut, item 1:1/136: 90 Nm Screws, clamps, item 1/3.142, 1/3.160: 300 Nm Product Manual IRB 640...

  • Page 76: Link System

    Secure the link <205.40> so it cannot rotate when the lower rod is removed. Remove screw <205.29>. Dismount support washer <205.28> together with friction washer <205.32>. Attach a hoist to the lower rod and remove it. Product Manual IRB 640...
  • Page 77 Mount sealing ring <205.3>, support washer <205.5> and KM-nuts <205.6>, use Loctite 243. Tighten to a torque of 50 Nm. Calibrate the robot as described in Chapter 9, Calibration. Tightening torque: KM-nut, item 205.6: 50 Nm Product Manual IRB 640...

  • Page 78: Replacing The Link

    KM-nut <205.6> again. Fit a new cover <205.46>. Refill the bearings with grease, remove plug <205.48> and insert a nipple. Calibrate the robot as described in Chapter 9, Calibration. Tightening torque: KM-nut, item 205.6: 90 Nm Product Manual IRB 640...
  • Page 79 Link system Repairs Product Manual IRB 640...

  • Page 80: Pushbutton Unit For Releasing Brakes

    Pushbutton unit for releasing brakes 6 Pushbutton unit for releasing brakes 6.1 Replacing pushbutton unit Refer to foldout no. 2 Dismounting: Remove the pushbutton unit <3> located in the frame. Disconnect connectors R3.BU1-6(X8), R3.BU1-3(X9), R3.BU4-6(X10). Mounting: In reverse order. Product Manual IRB 640...
  • Page 81 Pushbutton unit for releasing brakes Repairs Product Manual IRB 640...

  • Page 82: Axis 6

    3HAC 2347-1 in the gap. This is important so that the pressing force is applied over the tilt housing and the mounted bearing. Then press the shaft into position (max. pressing force 6 tons). Product Manual IRB 640...

  • Page 83: Replacing Motor/Gear Axis 6

    Tighten screw <9/5>, apply Loctite 243. NOTE! Be very careful not to tap or hit the shaft axially, nor displace the shaft axially in any way, as this could give rise to an incorrect air gap in the brake. Product Manual IRB 640...

  • Page 84: Checking Play In Axis 6

    Mount screws <7/6> and washers <7/7>. Tightening torque 70 Nm. Mount shaft <7/5>, screws <7/13>, tightening torque 24 Nm. Pour grease into axis 6 as described in the Maintenance Manual IRB 640. Calibrate the robot as described in Chapter 9, Calibration.
  • Page 85 Axis 6 Repairs Product Manual IRB 640...

  • Page 86: Motor Units

    - The motor, resolver and brake is to be regarded as an replacement motor unit. Faulty motor units are repaired by the motor manufacturer at the request of the ABB Robotics service organisation. - The cable routing is shown in Figure 8. Note that the signal connection cable and the power connection cable must not be entwined.

  • Page 87: Checking Brake Performance

    When calculating the brake torque, the arm and gear reduction ratio must be taken into consideration. The coefficient of efficiency for the gear is assumed to be 1.0. Product Manual IRB 640...

  • Page 88: Calibration

    5. Press the enable device on the programming unit and operate the robot manually with the joystick until the measuring rod is positioned within the flat surface on the calibration fixture’s elbow. Be careful! Risk of injury! Product Manual IRB 640...
  • Page 89 2. Both sensors should be posi- tioned in the same direction. See also Figure 11. Note that the sensor unit must always be mounted on top of the fixture. Product Manual IRB 640...
  • Page 90 Axis 3 Tilt housing Axis 2 View from above Sync fixture axis 6, see Figure 12. Inclination instrument 6807 081-D Reference Aligning the turning disc Axis 3 Axis 6 Figure 11 Movement directions for calibration, reference surface. Product Manual IRB 640...
  • Page 91 The reason why the calibration position is always adjusted in the directions shown in the figure, is that the friction and gravity forces then work together against the direction of the movement. In this way adjustment is simplified. Product Manual IRB 640...
  • Page 92 All axes are fine-calibrated but one (or more) of the axes has a counter that is NOT updated. That axis, or those axes, must therefore be updated as described in Chapter 9.4, Setting the calibration marks on the manipulator. Product Manual IRB 640...
  • Page 93 23. Start the calibration by pressing OK. An alert box is displayed during calibration. The Status window appears when the fine calibration is complete. The revolution counters are always updated at the same time as the calibration is performed. Product Manual IRB 640...

  • Page 94: Aligning The Tilt Housing

    4. Move the tilt housing so that the digital levelling gauge indicates zero. The gauge should read ±12 increments (0.3 mm/m). 5. Tighten the screw joint again, tightening torque 70 Nm. 6. Check the alignment again. Product Manual IRB 640...

  • Page 95: Setting The Calibration Marks On The Manipulator

    It takes 36 hours’ operation to recharge the battery unit without any power interrup- tions. If the resolver values must be calibrated, this should be done as described in the chapter on Repairs in the IRB 640 Product Manual. WARNING Working in the robot work cell is dangerous.
  • Page 96 6. Press the function key All to select all axes, if all axes are to be updated. Otherwise, select the desired axis and press the function key Incl (the selected axis is marked with an x). Product Manual IRB 640...
  • Page 97 9. Check the calibration as in Chapter 9.5, Checking the calibration position. *) axis number Figure 22 Calibration marks on the manipulator. 10. Save the system parameters on a floppy disk. Product Manual IRB 640...

  • Page 98: Checking The Calibration Position

    Cal.pos. 1 -90 Figure 23 Calibration positions 0, 1 and 2 (Normal, Right and Left). Note! If the final installation makes it impossible to reach the calibration 0 position, an alternative calibration position must be set before installation. Product Manual IRB 640...
  • Page 99 The angle is in radians, see Figure 23. 6. Restart the robot by selecting File: Restart. 7. Move the sync.plate, on the base, for axis 1 to its new position. 8. Save the system parameters on a floppy disk. Product Manual IRB 640...

  • Page 100: Calibration Equipment

    Measuring rod 6808 0011-LP Angle bracket 3HAC 1904-1 Sync fixture, axis 6 Calibration tools for TCP check Tool for TCP adjustment 3HAA 0001-UA X= -15 mm, Z= -150 mm Calibration set for Opti Master 3HAA 0001-XR Product Manual IRB 640...
  • Page 101 Calibration Repairs Product Manual IRB 640...

  • Page 102: Special Tools List

    The need for special tools has been reduced to a minimum. When tools are needed for dismounting/mounting work, a description is given in the Product Manual, Chapter Repairs. During the ordinary service training courses arranged by ABB Flexible Automation, detailed descriptions of the tools are given together with their use. Axis 1...
  • Page 103 D=18/12 mm, L=1000 mm Hose clip D=15-20 mm Socket Square 1/2” / hexagon 10 mm Extender 1/2” / L=250 mm Ratchet wrench Axis 2-3, 6 Nipple 3HAA 7601-091 Hose D=18/12 mm, L=1000 mm Allen key 6 mm Product Manual IRB 640...
  • Page 104 Wedge for adjustment of tilt house/upper 3HAC 2347-1 Pressing tool for shaft 3HAC 3409-1 Ratchet wrench, socket 4 - KM8, graduated Tool for dismounting bearing in tilt house Inner expanded socket Standard pullet Dismounting of axis/tilt house Puller 3HAC 2486-1 Product Manual IRB 640...
  • Page 105 Special Tools List Repairs Product Manual IRB 640...
  • Page 106 Spare Parts CONTENTS Page 1 Manipulator ......................2 1.1 IRB 640 ......................2 1.2 Axis 1, complete ..................... 5 1.3 Base......................... 7 1.4 Frame, complete....................8 1.5 Axes 2 and 3....................9 1.6 Lower arm ....................... 11 1.7 Upper arm ....................... 12 1.8 Parallel rod ......................

  • Page 107: Manipulator

    2166 2058-2 17x11.1 Measure card unit 3HAB 4259-1 Torx pan head roll. screw 9ADA 629-56 M6x16 Cover 3HAA 0001-SZ 3HAA 1001-199 Taper roller bearing 2213 3802-8 32013X Sealing ring 2216 264-16 Nilos ring 2216 0085-5 65x98.4x6.3 Product Manual IRB 640...
  • Page 108 Pos switch axis 1 3HAC 1031-2 2 switches Pos switch axis 1 3HAC 1031-3 3 switches Pos switch axis 2 3HAC 3732-1 2.214 1 Motor aixs 2/3 3HAB 8278-1 2.179 1 Stop 3HAA 10001-89 2.180 1 Washer 3HAA 1001-632 Product Manual IRB 640...
  • Page 109 205.43 Lock nut 2126 2851-107 M35x1.5 205.44 Locking liquid 1269 0014-410 Loctite 243 2 ml 205.45 Grease 3HAC 2331 Molywhite 205.46 VK-cover 3HAA 2166-11 D=80 B=10 205.47 Support ring 3HAC 1717-1 205.48 Plug 2529 1920-2 R1/8” Product Manual IRB 640...

  • Page 110: Axis 1, Complete

    Sync. bracket 3HAB 4649-1 Sync. plate axis 1 3HAA 1001-73 Screw 9ADA 629-32 M4x8 Plain washer 9ADA 312-4 4.3x9x0.8 Bracket 3HAB 4648-1 Sync. plate nonie 3HAA 1001-79 Protective plate 2155 187-11 Screw 2121 0596-31 M8x12 10.9 Product Manual IRB 640...
  • Page 111 Screw 3HAB 7700-94 M16x140 12.9 Unbrako Spring washer 3HAA 1001-181 Screw 3HAB 7700-84 M12x140 12.9 Unbrako Support washer 3HAA 1001-200 12.5x24x5.9 Axis 2 cabling 3HAC 0703-1 Axis 3 cabling 3HAB 8737-1 Screw 9ADA 618-55 M6x12 8.8 Product Manual IRB 640...

  • Page 112: Base

    Spare Parts 1.3 Base Itm Qty Name Art. no. Base, complete 3HAC 3806-1 Base 3HAC 0517-2 Bottom plate 3HAA 1001-695 Cable guide rail 3HAA 1001-691 Stop shaft 3HAB 4082-1 Screw 9ADA 618-56 M6x16 8.8 Angle 3HAA 1001-154 Product Manual IRB 640...

  • Page 113: Frame, Complete

    Gleitmo 610 Washer 3HAA 1001-632 Plug 2522 2021-113 KR 1/2” Hex socket head cap screw 3HAB 3409-75 M12x90 12.9 Gleitmo 610 O-ring 2152 0431-15 245.0x3.0 Reduction gear 3HAC 0665-1 Friction ring 3HAA 1001-614 Cover 3HAB 6130-1 Product Manual IRB 640...

  • Page 114: Axes 2 And 3

    4.3x9x0.8 1.39.7 4 Screw 9ADA 618-55 M6x12 Brake release unit 3HAA 0001-ADY Screw 9ADA 629-56 M6x16 2.112 Cover 3HAA 0001-ZK 2.114 Screw 2125 0442-1 2.115 Mounting base 2166 2058-2 17x11,1 2.116 Screw 9ADA 618-23 M3x8 8.8 Product Manual IRB 640...
  • Page 115 2.121 1 Cover 3HAA 0001-SZ 2.146 1 Battery pack 4944 026-4 2.163 1 Grease tube 3HAA 1001-716 2.167 2 Screw 9ADA 629-59 M6x30 2.172 3 Screw 9ADA 629-57 M6x20 2.178 1 Guide for cabling 3HAA 1001-721 Product Manual IRB 640...

  • Page 116: Lower Arm

    3HAA 1001-90 Support plate 3HAA 1001-282 Screw 2121 2763-364 M6x10 Damper 3HAA 1001-622 Screw 9ADA 618-56 M6x16 Plain washer 9ADA 312-6 6.4x12x1.6 Sealant 1269 1907-1 Loctite 577, 1 ml Locking fluid 1269 0014-410 Loctite 243, 1 ml Product Manual IRB 640...

  • Page 117: Upper Arm

    VK-cover 3HAA 2166-20 D=90 B=8 Cabling upper front c.-conn. 3HAC 0710-1 Bracket motor 6 3HAC 1087-1 Toex pan head roll. screw 9ADA 629-54 M6x10 Plastic cover 3HAC 1854-1 Torx pan head roll. screw 9ADA 629-59 M6x30 Product Manual IRB 640...

  • Page 118: Parallel Rod

    Art. no. Parallel rod 3HAA 0001-ER Parallel rod 3HAA 1001-71 Shaft 3HAA 1001-88 Ring 3HAA 1001-86 Spherical bearing 3HAA 1001-189 Adapter sleeve 2213 1905-21 Retaining ring 9ADA 137-33 Lubricating grease 1171 4012-201 40 g Both ends identical Product Manual IRB 640...
  • Page 119 Six point socket screw 9ADA 629-32 M4x8 Plain washer 9ADA 312-4 4.3x9x0.8 Grease 3HAC 2331-1 Molywhite 300 ml Locking fluid 1290 014-410 Loctite 243 1 ml * when exchanging the reduction gear a new item 11 must be fitted Product Manual IRB 640...

  • Page 120: Cooling Device Axis 1

    Cabling upper front 3HAC 3954-1 Fan cabling 3HAA 0001-ACE See section 1.10 1.12 Position switches, axes 1 and 2 Spare part list for position switches on axes 1 and 2 is supplied if the option is ordered. Product Manual IRB 640...

  • Page 121: Signal Lamp

    Cable gland 3HAB 7417-1 Sealing plug 2522 253-2 Receptacles for pin 23p 3HAA 2599-3 Keying pin 5217 649-29 2969 105-11 Document set (CPV) 3HAC 3236-1 Plate: Max. pressure 3HAC 4242-1 Plate: Cust. power vac. 3HAC 2776-1 Product Manual IRB 640...
  • Page 141 Circuit Diagram CONTENTS Page Circuit Diagram 3HAC 1352-1 Rev. 00 Contents ......................... 3 Connection Point Location ................... 4 Legend .......................... 5 Brake Unit........................6 Axis 1..........................7 Axis 2..........................8 Axis 3..........................9 Axis 6..........................10 Customer Power Connection (Option) ................. 11 Customer Signal Connection ..................
  • Page 142 Circuit Diagram Page Product Manual S4Cplus...
  • Page 143 sheet No. of sheets Revision Contents...

  • Page 144: Connection Point Location

    sheet No. of sheets Revision Connection Point Location...

  • Page 145: Legend

    sheet No. of sheets Revision Legend...

  • Page 146: Brake Unit

    sheet No. of sheets Revision Brake Unit...
  • Page 147 sheet No. of sheets Revision Axis 1...
  • Page 148 sheet No. of sheets Revision Axis 2...
  • Page 149 sheet No. of sheets Revision Axis 3...
  • Page 150 sheet No. of sheets Revision Axis 6...

  • Page 151: Customer Power Connection (Option)

    sheet No. of sheets Revision Customer Power Connection (Option)

  • Page 152: Customer Signal Connection

    sheet No. of sheets Revision Customer Signal Connection...

Table of Contents