ABB IRBT 4003S Product Manual
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ABB IRBT 4003S Product Manual

ABB IRBT 4003S Product Manual

Track motion
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Product Manual
Track Motion
IRBT 4003S/6003S
IRC5, M2004
3HEA 800 970-001 Rev. D, Mars 2006

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Summary of Contents for ABB IRBT 4003S

  • Page 1 Product Manual Track Motion IRBT 4003S/6003S IRC5, M2004 3HEA 800 970-001 Rev. D, Mars 2006...
  • Page 2 The document, or parts thereof, may not be reproduced or copied without prior permission from ABB Automation Technologies AB. It may neither be imparted to a third party nor otherwise be used without authorization. Infringement hereof will be subject to action in accordance with applicable laws.
  • Page 3 Contents Specification Tab 1: Description Product Manual Track Motion Safety instructions IRBT 4003S/ 6003S Technical specifications and requirements Variants and options Installation and operation Tab 2: Unpacking and handling Mechanical installation Electrical installation Commissioning Maintenance Tab 3: Maintenance intervals Maintenance instructions Spare parts 3HEA 800 970-001 Rev.
  • Page 4 3HEA 800 970-001 Rev. D, Mars 2006...

  • Page 5: Table Of Contents

    Tab 1: Specification 1 Description 1.1 General 1.2 Principle layout 1.3 Terms and concepts 1.3.1 Definitions 2 Safety instructions 2.1 Description 2.2 Unpacking and handling safety 2.2.1 Lifting instructions 2.3 Mechanical installation safety 2.3.1 Adjusting the level 2.3.2 Assembly of cable tray and manipulator safety 2.3.3 Electrical installation safety 2.3.4 Commissioning safety 2.3.5 Mechanical maintenance safety...
  • Page 6 Specification ii 3HEA 800 970-001 Rev. D, Mars 2006...

  • Page 7: Description

    Description General 1 Description 1.1 General Track Motion IRBT6003S/4003S expands the movement pattern of the robot with an extra degree of programmable freedom. The IRBT6003S/4003S has a powerful motor and an advanced gearbox. Together High performance - High precision they give the track motion good acceleration and speed performance at the same time as precision is extremely high.

  • Page 8: Principle Layout

    Description Principle layout 1.2 Principle layout Track Motion IRBT6003S/4003S is available in two basic designs, Compact and Covered. Compact has an open cable tray adapted for materials handling. Compact Covered has a protected, covered cable tray adapted for spot welding. Covered IRBT 6003S/4003S Compact The illustration shows the principle layout of the track motion in the Compact...
  • Page 9 Description Principle layout IRBT 6003S/4003S Covered The illustration shows the principle layout of the track motion in the protected design. Figure 2 IRBT 6003S/4003S Covered Item Description Item Description Gear rack End plates Linear guides Cable chain End plates Cable tray Motor Gearbox Serial measurement box/...

  • Page 10: Terms And Concepts

    Description Terms and concepts 1.3 Terms and concepts 1.3.1 Definitions The table below lists terms and concepts used in the documentation. Name Definition Robot system Robot and track motion together. Robot Manipulator and controller together (IRB 4400/IRB 6600). Manipulator The mechanical, moving part of the robot. Controller Control equipment of type IRC5.

  • Page 11: Safety Instructions

    Safety instructions Description 2 Safety instructions 2.1 Description This chapter contains safety instructions for all steps that involve risk of personal injury or material damage. In addition, they are written out by the instruction for each step. General warnings, where the intention is to avoid problems, are only included in the pertinent instructions.

  • Page 12: Unpacking And Handling Safety

    Safety instructions Unpacking and handling safety 2.2 Unpacking and handling safety Read carefully through the safety instructions before the track motion is unpacked and installed. 2.2.1 Lifting instructions Only units that are 6 meters or shorter may be lifted. If the units are joined, the joints must be prefitted on delivery.

  • Page 13: Commissioning Safety

    Safety instructions Commissioning safety 2.3.4 Commissioning safety Calibration Make sure no one is on the track motion when the carriage moves. Also make sure that the track motion's cover plates are free from foreign objects; these can otherwise become trapped between the carriage and the plates. Checking the work area The track motion's work area must be inspected before the system is put into service.
  • Page 14 Safety instructions Mechanical maintenance safety 3HEA 800 970-001 Rev. D, Mars 2006...

  • Page 15: Technical Specifications And Requirements

    Adaptor for IRB 4400 160 kg Degree of protection IP 54 Static play Contact ABB for information Dynamic play Contact ABB for information 1. Repeated stopping in a travel direction, at the same point. 3HEA 800 970-001 Rev. D, Mars 2006...
  • Page 16 270 kg/m Degree of protection IP 54 Static play Contact ABB for information Dynamic play Contact ABB for information 1. Repeated stopping in a travel direction, at the same point. The table below contains important technical data for the performance of track 1.5 m/s...

  • Page 17: Dimensions

    Technical specifications and requirements Dimensions 3.1.2 Dimensions Length measurement The illustration shows the IRBT 6003S/4003S from the front. Figure 3 IRBT 6003S/4003S, length measurement The table shows the value of N in the figure above with different travel lengths. Travel length Total length of the stand Quantity N 1.7 m...
  • Page 18 Technical specifications and requirements Dimensions Cable chain IRBT 4003S Figure 4 Dimensions for cable chain IRBT 4003S IRBT 6003S Figure 5 Dimensions for cable chain IRBT 6003S 1-12 3HEA 800 970-001 Rev. D, Mars 2006...

  • Page 19: Width And Height Measurements

    Technical specifications and requirements Width and height measurements 3.1.3 Width and height measurements IRBT 6003S/4003S Compact The illustration shows the IRBT 6003S/4003S Compact from the end. Figure 6 IRBT 6003S/4003S Compact, width and height measurements IRBT 6003S/4003S Covered In-line The illustration shows the IRBT 6003S/4003S In-line from the end. Figure 7 IRBT 6003S/4003S In-line, width and height measurements 3HEA 800 970-001 Rev.
  • Page 20 Technical specifications and requirements Width and height measurements IRBT 6003S/4003S Covered 90° The illustration shows the IRBT 6003S/4003S Covered 90° from the end. Figure 8 IRBT 6003S/4003S Covered, width and height measurements 1-14 3HEA 800 970-001 Rev. D, Mars 2006...

  • Page 21: Technical Requirements For The Robot

    The track motion is designed to work together with IRC5 controller; please contact ABB for information about compatibility with other control systems. Hardware requirements The robot hardware must be equipped with the following options to drive an external axis 7 (track motion).
  • Page 22 Technical specifications and requirements Technical requirements for the robot 1-16 3HEA 800 970-001 Rev. D, Mars 2006...

  • Page 23: Variants And Options

    Variants and options Variants and options for the IRBT 6003S/4003S 4 Variants and options 4.1 Variants and options for the IRBT 6003S/4003S 4.1.1 Connection cable The robot's standard cables can be used to connect the track motion to the controller. 4.1.2 Power cable The power cable to the seventh axis is 7, 15 or 30 meters long, measured from the connection point in the center of the track motion.

  • Page 24: Zone Division

    Variants and options Zone division 4.1.4 Zone division The purpose of the zone division is to divide the conveyor into zones. It consists of switches that sense when the carriage comes into respective zones, an aluminium section and brackets for the aluminium section. 1 set of switches is used for 2 zones, and 2 sets of switches for 4 zones.

  • Page 25: Ordering List

    4.1.5 Ordering list The tables describe the variants and options that can be order for the IRBT 6003S/4003S. Please contact ABB for further specializations. Symbol explanations Where the last number of the article number is replaced by x, the track motion's “x”...
  • Page 26 Variants and options Ordering list Variants Variants Art. no. Track motion IRBT 6003S/4003S 3HXD 1567-x Cable chain for IRBT 6003S/4003S, Compact IRB 4400 3HEA 800 763-0** IRB 6600 MH 3HEA 800 749-0** IRB 6600 RSG 3HEA 800 750-0** Cable chain for IRBT 6003S/4003S, Covered In-line IRB 4400 3HEA 800 764-0** IRB 6600 MH...
  • Page 27 Variants and options Ordering list Options Options Art. no. Extra carriage Compact, IRB 4400 3HEA 800 939-0** Compact, IRB 6600, MH 3HEA 800 933-0** Compact, IRB 6600, RSG 3HEA 800 935-0** In-line Covered, IRB 4400 3HEA 800 946-0** In-line Covered, IRB 6600, MH 3HEA 800 944-0** In-line Covered, IRB 6600, RSG 3HEA 800 940-0**...
  • Page 28 These supplement packs are described in the table below. Description Art. no. Supplementary pack, IRBT 4003S 506 342-880 Supplementary pack, IRBT 4003S, high voltage 3HXD 0100-339 4 Ball elements 1 Motor flange 1 Motor 1 Gearbox...
  • Page 29 Tab 2: Installation and operation 1 Unpacking and handling 1.1 Lift 1.1.1 Lifting instructions 1.1.2 Lifting the track motion 1.2 Acceptance inspection 1.2.1 Identification 1.2.2 Contents 1.2.3 Inspection 1.2.4 Cleaning 1.3 Moving the carriage manually 1.3.1 Release the brake from the BRB 2 Mechanical installation 2.1 Foundation 2.1.1 Robustness...
  • Page 30 3.2.1 Introduction 3.3 IRB 6600 M2004, MH, high voltage 3.3.1 Wiring diagram 3.3.2 Standard cables 3.3.3 Option cables 3.4 IRB 6600 M2004, SSG, high voltage 3.4.1 Wiring diagram 3.4.2 Standard cables 3.4.3 Option cables 3.5 IRB 6600 M2004, RSG, high voltage 3.5.1 Wiring diagram 3.5.2 Standard cables 3.5.3 Option cables...

  • Page 31: Unpacking And Handling

    Unpacking and handling Lift 1 Unpacking and handling Read carefully through the safety instructions, before the track motion is unpacked and installed. 1.1 Lift 1.1.1 Lifting instructions Stand modules can be moved using a fork lift truck or an overhead crane. Only units that are 6 meters or shorter may be lifted.

  • Page 32: Acceptance Inspection

    Mounting bolts with washers and guide sleeves for the robot. 1.2.3 Inspection Unpack the equipment and check for any visible transport damage. If this is the case, contact ABB. 1.2.4 Cleaning Before transport the equipment has been protected against rust by a thin film of oil that has been applied before packing.

  • Page 33: Moving The Carriage Manually

    Unpacking and handling Moving the carriage manually 1.3 Moving the carriage manually 1.3.1 Release the brake from the BRB The carriage can be moved manually if necessary by connecting the power and releasing the brake. Action 1. Press the brake release button. Release the brake when connecting the motor If there is no power to the motor, 24 VDC can be connected to the motor’s power cable.
  • Page 34 Unpacking and handling Release the brake from the BRB 3HEA 800 970-001 Rev. D, Mars 2006...

  • Page 35: Mechanical Installation

    Mechanical installation Foundation 2 Mechanical installation 2.1 Foundation 2.1.1 Robustness The foundation must withstand the static loads caused by the weight of the equipment and the dynamic loads generated by the movement of the carriage and manipulator. 2.1.2 Incline The foundation must be designed so that the track motion can be mounted without the incline exceeding 0.5 mm/m in the direction of travel and 0.1 mm/m across the direction of travel.

  • Page 36: Preparations

    Mechanical installation Preparations 2.2 Preparations 2.2.1 Recommendations for mounting Chemical anchor bolts are recommended for securing the track motion to the floor. However, the mounting bolts are not supplied as these must be selected based on foundation material. Mounting bolts Choose mounting bolts so that they: •...
  • Page 37 Mechanical installation Recommendations for mounting Base dimensions The illustration show the stand's base seen from the front. Figure 4 Base dimensions The table below shows the values of h1-2 and b1-3 in the illustration above. Height dimensions 100 mm 20 mm Width dimensions 180 mm 65 mm...

  • Page 38: Stand Assembly

    Mechanical installation Stand assembly 2.3 Stand assembly 2.3.1 Procedure The track motion should be assembled as described in the procedure below. Detailed descriptions of each stage can be found further on in the manual. Action 1. Assemble the stand modules according to "Positioning the stand"...

  • Page 39: Positioning The Stand

    Mechanical installation Positioning the stand 2.3.2 Positioning the stand Follow the directions below to position the stand modules: Action Info/Illustration 1. Position the leveling plates on one side of the intended installation location. Position the bottom plates for the cable tray modules on the other side of the installation location.

  • Page 40: Adjusting The Level

    Mechanical installation Adjusting the level 2.3.3 Adjusting the level The distance between the leveling bolts and the top edge of the ground plates must be at least 10 mm. It is recommended that a laser level be used in the track motion's direction of travel and a spirit level across this to obtain satisfactory adjustment.

  • Page 41: Fitting The Linear Guides

    Mechanical installation Fitting the linear guides 2.3.4 Fitting the linear guides Follow the instructions below to fit the linear guide. Action Info/Illustration 1. Secure the part of the linear guide to be fitted at the side. 2. Position the part that is to be fitted on top, without securing it.

  • Page 42: Geometric Adjustment Of Track Motion

    Mechanical installation Geometric adjustment of track motion 2.3.5 Geometric adjustment of track motion Geometric adjustment of track motion can be performed in accordance with three methods. Method Description Method 1 Adjustment of the track motion with a spirit level for adjustment of the carriage horizontally along the entire travel length.
  • Page 43 Mechanical installation Geometric adjustment of track motion Method 1 Note that the X-axis is the same as the direction of travel. Adjustment of the track motion with a spirit level for adjustment of the carriage horizontally along the entire travel length. Action Info/Illustration 1.
  • Page 44 Mechanical installation Geometric adjustment of track motion Method 2 Adjustment of the track motion with position measurement equipment for adjustment of the carriage horizontally along the entire travel length. Action Info/Illustration 1. Position the track motion at the desired position on the adjustment plates. •...
  • Page 45 Mechanical installation Geometric adjustment of track motion Due to the end cover plates and the tolerance chain, the dimension (739 mm) varies by ±8 mm when the track motion is at position X-zero. Figure 7 Carriage layout Item Description Item Description Vernier scale X positive direction Robot center when track motion is at...
  • Page 46 Mechanical installation Geometric adjustment of track motion Method 3 Method 3 should be used if the robot is already installed on the track motion. Method 3 is based on the available geometric system layout. This requires a laser adjustment instrument for installation. Action Info/Illustration 1.
  • Page 47 Geometric adjustment of track motion Item Description Item Description Robot center when track motion is at Mounting hole position X-zero IRBT 4003S 90°     Figure 9 Carriage layout 4003S, 90° Item Description Item Description Vernier scale X positive direction...
  • Page 48 Mechanical installation Geometric adjustment of track motion IRBT 4003S In- line Figure 10 Carriage layout 4003S, in-line Item Description Item Description Vernier scale X positive direction Robot center when track motion is at Mounting hole position X-zero Action Info/Illustration 2. The values taken from the virtual layout must be...
  • Page 49 Mechanical installation Geometric adjustment of track motion IRBT 6003S Figure 11 Placement of the prism on the linear guides Item Description Top machined surface of carriage Ball element Linear guide 3HEA 800 970-001 Rev. D, Mars 2006 2-19...

  • Page 50: Installing Gear Racks

    Mechanical installation Installing gear racks IRBT 4003S Figure 12 Placement of the prism on the linear guides Item Description Top machined surface of carriage Ball element Linear guide Action Info/Illustration 6. Place the prism above the horizontal With this measurement method, the track...
  • Page 51 Mechanical installation Installing gear racks Action Info/Illustration 1. Lay out the section of the gear rack to be installed against the support edge, and bolt loosely in position. 2. Check using the supplied teeth-meshing gauge that the joints on the laid gear rack proved a smooth transition.

  • Page 52: Securing The Stand To The Foundation

    Mechanical installation Securing the stand to the foundation 2.3.7 Securing the stand to the foundation Note! Make sure that there is free space (1,200 mm) for installation/dismantling of the switching point J1. See "Connection point J1" on page 2 - Follow the instructions below to secure the stand to the foundation.

  • Page 53: Fit The Side Plates

    Mechanical installation Fit the side plates 2.3.9 Fit the side plates Follow the instructions below to fit the side plates. Action Info/Illustration 1. Fit the angle brackets on the ground plates. 2. Fit the side covers by pushing them down between the beam and angle bracket.

  • Page 54: Installation Of Zone Division

    Mechanical installation Installation of Zone Division 2.4 Installation of Zone Division 2.4.1 Installing the Zone Division Följ anvisningarna nedan för att montera zonindelningen: Action Info/Illustration 1. Position the aluminium section (A) and tighten the bracket (B). Make sure that the aluminium section (A) is completely straight.

  • Page 55: Fitting The Cable Tray And Manipulator

    Mechanical installation Fitting the cable tray and manipulator 2.5 Fitting the cable tray and manipulator 2.5.1 Fitting the cable tray Follow the instructions below to position the cable tray and leveling plates. Action Info/Illustration 1. Bolt the cable tray's guide plates to the plates.

  • Page 56: Fitting The Manipulator

    Mechanical installation Fitting the manipulator 2.5.2 Fitting the manipulator Depending on the order, the manipulator should be fitted in one of the following two positions: • Inline Neutral position for axis 1 aligned with the track motion's direction of travel. •...

  • Page 57: Mounting The Drive Unit

    Mechanical installation Mounting the drive unit 2.5.3 Mounting the drive unit Very important that the gear is align with the gear rack. Action Info/Illustration 1. The machined heel on the drive unit shall be placed on the machined heel on the carriage.
  • Page 58 Mechanical installation Mounting the drive unit 2-28 3HEA 800 970-001 Rev. D, Mars 2006...

  • Page 59: Electrical Installation

    Electrical installation Robot cable harness 3 Electrical installation 3.1 Robot cable harness The robot's cable harness is sufficiently long for installation in one of the two possible positions on the carriage. Any surplus length should be placed in a coil on the floor, depending on the local conditions.

  • Page 60: Connections/Wiring Diagrams

    Electrical installation Connections/Wiring diagrams 3.2 Connections/Wiring diagrams 3.2.1 Introduction The following wiring diagrams show the connections between the control gear, manipulator and track motion. The position numbers in the tables refer to the positions in the illustration above. Cables marked with (R) in the illustration are supplied with the robot. When the last numbers of an article number are replaced by “yy”...

  • Page 61: Irb 6600 M2004, Mh, High Voltage

    Electrical installation IRB 6600 M2004, MH, high voltage 3.3 IRB 6600 M2004, MH, high voltage 3.3.1 Wiring diagram MH, (Option 770-4, 7 axes). Carriage Cable chain Floor IRC5 Motor Figure 15 Wiring diagram, IRB 6600 M2004, MH 3.3.2 Standard cables Standard cables Art no Item...

  • Page 62: Option Cables

    Electrical installation Option cables 3.3.3 Option cables Accessory cables Art no Item Limit switch cable 3HEA 801 125-001 Cable, central lubrication, 2 m 3HEA 800 675-001 Cable, central lubrication, 20 m 3HEA 800 675-002 Cable, central lubrication, 22 m 3HEA 800 675-003 Cable, central lubrication, 24 m 3HEA 800 675-004 Robot customer cable harness...

  • Page 63: Irb 6600 M2004, Ssg, High Voltage

    Electrical installation IRB 6600 M2004, SSG, high voltage 3.4 IRB 6600 M2004, SSG, high voltage 3.4.1 Wiring diagram SSG (Option 785-4, 770-4, 771-4, 787-1, -2, -3, -4, 635-1 8 axes). Carriage Cable chain Floor IRC5 MO TO R Figure 16 Wiring diagram, IRB 6600 M2004, SSG 3HEA 800 970-001 Rev.

  • Page 64: Standard Cables

    Electrical installation Standard cables 3.4.2 Standard cables Standard cables Art. no. Item Signal cable 3HEA 801 125-001 Signal cable, 2 m 3HEA 800 675-001 Signal cable, 20 m 3HEA 800 675-002 Signal cable, 22 m 3HEA 800 675-003 Signal cable, 24 m 3HEA 800 675-004 Signal cable axes 1-6 3HXD 1455-yy...

  • Page 65: Irb 6600 M2004, Rsg, High Voltage

    Electrical installation IRB 6600 M2004, RSG, high voltage 3.5 IRB 6600 M2004, RSG, high voltage 3.5.1 Wiring diagram SSG, (Option 785-2, 770-4, 771-4, 787-1, -2, -3, -4, 635-1 8 axes). Carriage Cable chain Floor IRC5 Motor Figure 17 Wiring diagram, IRB 6600 M2004, RSG 3.5.2 Standard cables Standard cables Art.

  • Page 66: Option Cables

    Electrical installation Option cables 3.5.3 Option cables Option cables Art. no. Item Limit switch cable 3HEA 801 125-001 Cable, central lubrication, 2 m 3HEA 800 675-001 Cable, central lubrication, 20 m 3HEA 800 675-002 Cable, central lubrication, 22 m 3HEA 800 675-003 Cable, central lubrication, 24 m 3HEA 800 675-004 Robot customer cable harness...

  • Page 67: Irb 4400

    Electrical installation IRB 4400 3.6 IRB 4400 3.6.1 Wiring diagram (Option 770-3) Carriage Cable chain Floor IRC5 Motor Figure 18 Wiring diagram, IRB 4400 3.6.2 Standard cables Standard cables Art. no. Item Serial measurement cable axes 1–6 3HXD 1432-yy Motor cable axis 7 (1.5 m) 3HXD 1249-15 Resolver cable (1.5 m) 3HXD 1250-15...

  • Page 68: Option Cables

    Electrical installation Option cables 3.6.3 Option cables Option cables Art. no. Item Customer cable 3HXD 1296-yy Position switch cable axis 1 3HXD 1433-yy Position switch cable axis 7 3HXD 1381-yy Floor position switch cable axis 7 3HXD 1382-yy Zone switch axis 7 (incl. cable) 3HXD 0100-320 2-38 3HEA 800 970-001 Rev.

  • Page 69: Commissioning

    Commissioning Preparations 4 Commissioning 4.1 Preparations Before the track motion is put in service the system must be prepared. The following steps must be carried out before starting the track motion. Action Info 1. Configure the control Load the operating parameters and configure the control equipment equipment in accordance with "Load the operating...

  • Page 70: Configure The Control Gear

    Commissioning Configure the control gear 4.2 Configure the control gear 4.2.1 Load the operating parameters Before starting, the track motion must be defined in the system with the operating parameters, which can be found on the supplied floppy disk. A description of how to load parameters from the floppy to the control gear can be found in the robot documentation.

  • Page 71: Activating The Automatic Lubrication System

    Commissioning Activating the automatic lubrication system 4.3 Activating the automatic lubrication system If the track motion is equipped with an automatic lubrication system, it must be activated. These may be of different types – automatic lubrication systems with grease injectors or central lubrication systems with timers. These are activated in different ways.

  • Page 72: Setting Timer For Central Lubrication System

    Commissioning Setting timer for central lubrication system 4.3.2 Setting timer for central lubrication system On delivery, the timer on the central lubrication system is set to lubricate in cyclic intervals of 0.5–10 s and with an equivalent waiting time between lubrication. This setting may need to be changed if too much lubricant is pumped out or if lubrication is unsatisfactory.
  • Page 73 For example, the value 8 on the potentiometer changes from 8 seconds to 8 hours if the interval setting is changed from 0.5–10 s to 0.5–10 h. 5. Recommended by ABB. 3HEA 800 970-001 Rev. D, Mars 2006 2-43...

  • Page 74: Functionality Test Of The Trabon Lubrication System

    Commissioning Functionality test of the Trabon lubrication system 4.3.3 Functionality test of the Trabon lubrication system Perform the functionality test of the Trabon lubrication system when the Track Motion is completely set up and power and air supply is connected. System overview Figure 19 Lubrication system overview Item Description...
  • Page 75 Commissioning Functionality test of the Trabon lubrication system Instruction Action Info/Illustration 1. Open the lid of the serial measurement box/ brake release box (1). 2. Press the brake release button (2) for 1 second. Release the button and wait 1 second then press the button again. Repeat approx.

  • Page 76: Calibration

    Commissioning Calibration 4.4 Calibration Make sure no one is on the track motion when the carriage moves. Also make sure that the track motion's cover plates are free from foreign objects; these can otherwise become trapped between the carriage and the plates. 4.4.1 Calibrating the track motion Before the robot system can be used, the resolvers must be calibrated.

  • Page 77: Checking The Work Space

    Commissioning Checking the work space 4.4.3 Checking the work space The track motion's work space must be inspected before the system is put in service. Checking the work space Run the system manually using the joystick and check that: • It can be run in both directions. •...
  • Page 78 Pull the motor mount inwards by turning screw B. 3. Check the play by pushing the carriage back and forth. Permitted play: • static ±0.1 mm • dynamic (Please contact ABB for information.) 2-48 3HEA 800 970-001 Rev. D, Mars 2006...

  • Page 79: Adjust Cables And Covers

    Commissioning Adjust cables and covers 4.4.5 Adjust cables and covers Perform the following adjustments: Action Info/Illustration 1. After transportation and set-up the pinion cover (1) may need some adjusting. Otherwise it may be in contact with the pinion and cause noise and vibration. If noise: •...
  • Page 80 Commissioning Adjust cables and covers 2-50 3HEA 800 970-001 Rev. D, Mars 2006...
  • Page 81 Tab 3: Maintenance 1 Maintenance intervals 1.1 Routine checks and preventive maintenance 1.1.1 Maintenance chart 2 Maintenance instructions 2.1 Mechanical maintenance 2.1.1 Lubrication of ball element and gear rack 2.1.2 Checking the lubrication system 2.1.3 Checking the grease injectors 2.1.4 Checking the central lubrication system 2.1.5 Cleaning and lubrication of gear racks 2.1.6 Lubrication in extremely dirty environments 2.1.7 Cleaning the linear guides...
  • Page 82 Maintenance ii 3HEA 800 970-001 Rev. D, Mars 2006...

  • Page 83: Tab 3: Maintenance

    Maintenance intervals Routine checks and preventive maintenance 1 Maintenance intervals 1.1 Routine checks and preventive maintenance 1.1.1 Maintenance chart The track motion is designed for a minimum of maintenance. However, routine checks and preventive maintenance must always be performed at regular intervals. The maintenance chart describes the routine maintenance and routine checks in chronological order.
  • Page 84 Maintenance intervals Maintenance chart 3HEA 800 970-001 Rev. D, Mars 2006...

  • Page 85: Maintenance Instructions

    Maintenance instructions Mechanical maintenance 2 Maintenance instructions 2.1 Mechanical maintenance 2.1.1 Lubrication of ball element and gear rack If there is no automatic lubrication system on the track motion, the ball element must be lubricated manually. Apply grease to the ball until the grease is forced out of the end seals, approximately 4.7 cm³...

  • Page 86: Checking The Central Lubrication System

    Maintenance instructions Checking the central lubrication system 2.1.4 Checking the central lubrication system Check the lubricant level in the grease injectors as follows. Action Info/Illustration 1. Locate the lubrication system. 2. Check the level in the transparent lubricant tank. If low, fill according to "Refilling the lubricant"...

  • Page 87: Refilling The Lubricant

    Maintenance instructions Refilling the lubricant 2.1.8 Refilling the lubricant If the track motion is equipped with an automatic lubrication system, the system must be refilled every third month or when empty. Refilling is accomplished by changing the grease injector. Changing grease injectors If an electromechanical grease injector is empty, the entire grease injector is replaced as follows: Only use grease injectors with 3-month or less capacities.

  • Page 88: Filling The Central Lubrication System

    Maintenance instructions Filling the central lubrication system 2.1.9 Filling the central lubrication system If the central lubrication system is empty, new lubricant is added as follows: Action Info/Illustration 1. Connect the supplied filling nipple at position 1. 2. Fill with lubricant as specified below. •...

  • Page 89: Bleed The System

    Maintenance instructions Bleed the system 2.1.10 Bleed the system Note! If the steps below do not make any change start looking for other blockage than air trapped in the system. See "Locating blockage in Series-Flo systems" on page 3 - Action Info/Illustration 1.

  • Page 90: Locating Blockage In Series-Flo Systems

    Maintenance instructions Locating blockage in Series-Flo systems 2.1.11 Locating blockage in Series-Flo systems Description In a Trabon Series-Flo system, free flow of lubricant from the pump through the transmission system and the bearings is necessary. If any portion of this transmission system (a divider valve, line fitting or any bearing) does not freely accept and pass its portion of the lubricant a blockage has occurred.
  • Page 91 Maintenance instructions Locating blockage in Series-Flo systems Figure 3 Intermediate valve & subplate section Item Description Item Description Piston enclosure plug Indicator port Enclosure plug gasket Plug Piston Check valve O-rings 3HEA 800 970-001 Rev. D, Mars 2006...
  • Page 92 Maintenance instructions Locating blockage in Series-Flo systems Locating blockage If any blockage exists in a Trabon Series-Flo system it is caused by one of the following reasons: • Crushed transmission line in the system • Blocked bearing in the system •...
  • Page 93 Maintenance instructions Locating blockage in Series-Flo systems Procedure Step 1 Action 1. Use a manual pump with gauge. Fill the pump with clean, filtered lubricant common to the system. 2. Connect the manual pump into the inlet of the master divider valve and slowly operate the pump.
  • Page 94 Maintenance instructions Locating blockage in Series-Flo systems Master divider valve without performance indicators: Action 1. With a manual pump connected to the master divider valve as outlined in step 1, raise pressure to 2,000 PSI. 2. Remove one at a time each indicator port plug and attempt to operate the manual pump after each plug is removed.
  • Page 95 Maintenance instructions Locating blockage in Series-Flo systems Step 3 Action 1. Testing accomplished in step 2 has indicated a blockage is downstream of the master divider valve. 2. Install the manual pump in the indicator port of the master divider valve that is common to this blocked area.
  • Page 96 Maintenance instructions Locating blockage in Series-Flo systems Step 4 Action 1. Install a manual pump into each indicator port of secondary divider valve in turn, and slowly operate the pump. See Figure 2. If high pressure exists, blockage has been located. Look for: crushed line, tight bearing, improperly drilled fittings and/or lube inlet port.
  • Page 97 Maintenance instructions Locating blockage in Series-Flo systems When testing indicates a blockage has occurred in any divider valve, that divider Step 5 valve must be disassembled and cleaned. Dirt and foreign material are the worst enemies of any lubricating equipment. All servicing and disassembling should be carried out under the cleanest possible conditions.
  • Page 98 Maintenance instructions Locating blockage in Series-Flo systems If all pistons are movable and there is no indication of a more serious problem: Action 1. Replace end plugs and using a new gasket apply the correct torque. See torque table below. 2.
  • Page 99 Maintenance instructions Locating blockage in Series-Flo systems Contamination blockage If dirt, foreign material or any other form of contamination is found in a divider valve, cleaning will only temporarily solve contamination blockage problems. The source of the contamination must be eliminated for satisfactory service. •...
  • Page 100 Maintenance instructions Check torque ball element 2.1.12 Check torque ball element Action Info/Illustration 1. Tighten the 16 screws to 70 Nm. 2.1.13 Gearbox The gearbox is filled with oil on delivery. After every 5000 hours of operation the gearbox should be emptied and filled with new oil. •...
  • Page 101 Maintenance instructions Electrical maintenance 2.2 Electrical maintenance 2.2.1 Inspection of electrical operations The track motion should be checked monthly with regard to: • All electrical operations • Limit position operation Run the carriage and check that both end positions are reached. 2.2.2 Checking the emergency stop The operation of the emergency stop should be checked monthly as follows: Action...
  • Page 102 Maintenance instructions Checking junction boxes 2.2.6 Checking junction boxes Check, and correct if necessary, the junction boxes monthly with regard to: • Damage • Connections • Tightness 2.2.7 Checking the drive motor Check the drive motor monthly with regard to: •...
  • Page 103 Spare parts Spare parts independent of length 3 Spare parts 3.1 Spare parts independent of length 3.1.1 Low voltage drive unit Spare parts for drive unit for IRBT 6003S/4003S: Description Art. no Item Drive unit, IRB 4400 3HEA 801 287-001 Motor IRB 4400 506 262-880 Motor flange for motor...
  • Page 104 Spare parts Low voltage drive unit, mirrored 3.1.2 Low voltage drive unit, mirrored Spare parts for mirrored drive unit for IRBT 6003S/4003S: Description Art. no Item Drive unit, IRB 4400 3HEA 801 288-001 Motor 506 262-880 Motor flange for motor 3HXD 1000-459 Gear unit, IRB 4400 3HXG 1147-1...
  • Page 105 Spare parts High voltage drive unit 1.0 m/s 3.1.3 High voltage drive unit 1.0 m/s Spare parts for mirrored drive unit for IRBT 6003S: Description Art. no Item Drive unit, IRB 6600 3HEA 800 684-001 Motor 3HXD 0100-355 Motor flange for motor 3HXD 1000-459 Gear unit 3HXG 1141-2...
  • Page 106 Spare parts High voltage mirrored drive unit 1.0 m/s 3.1.4 High voltage mirrored drive unit 1.0 m/s Spare parts for mirrored drive unit for IRBT 6003S: Description Art. no Item Drive unit, IRB 6600 3HEA 800 690-001 Motor 3HXD 0100-355 Motor flange for motor 3HXD 1000-459 Gear unit...
  • Page 107 Spare parts High voltage drive unit 1.5 m/s 3.1.5 High voltage drive unit 1.5 m/s Spare parts for drive unit for IRBT 6003S: Description Art. no Item Drive unit 3HEA 800 687-001 Motor 3HXD 0100-355 Motor flange for motor 3HXD 1000-459 Gear unit 3HXG 1141-1 Motor mount...
  • Page 108 Spare parts High voltage mirrored drive unit 1.5 m/s 3.1.6 High voltage mirrored drive unit 1.5 m/s Spare parts for mirrored drive unit for IRBT 6003S: Description Art. no Item Drive unit 3HEA 800 689-001 Motor 3HXD 0100-355 Motor flange for motor 3HXD 1000-459 Gear unit 3HXG 1141-1...
  • Page 109 Spare parts Carriage 3.1.7 Carriage Spare parts for carriage for IRBT 6003S/4003S: Description Art. no Item Adaptors for robots Adaptor for IRB 4400 3HXD 1566-1 Guide sleeve 3HXD 1000-273 Washer 3HXD 1000-274 Bolt 2121 2017-733 Serial measurement box axis 7 3HXD 0100-89 Brake release box, IRB 6600 MH 3HEA 800 805-001...
  • Page 110 Spare parts Automatic lubrication system with grease injectors 3.1.8 Automatic lubrication system with grease injectors Spare parts for automatic lubrication system with grease injectors: Description Art. no Item Grease injector 3HXG 1000-513 Stabilizer 3HXG 1000-563 Bracket oil brush 3HXD 1000-494 Oil brush 3HXG 1000-562 Brush holder...
  • Page 111 Spare parts Central lubrication system with timer 3.1.9 Central lubrication system with timer Spare parts for central lubrication system with timer 3HEA 800 970-001 Rev. D, Mars 2006 3-29...
  • Page 112 Spare parts Central lubrication system with timer Description Art. no Item Reducing nipple 3HXG 1000-556 Threaded elbow coupling 3HXG 1000-561 Grease tank bracket 3HXD 1000-525 Distribution block bracket 3HXD 1000-524 Timer bracket 3HXD 1000-522 Bracket oil brush 3HXD 1000-523 Grease tank 3HXG 1000-587 E-pump 3HXG 1000-588...
  • Page 113 Spare parts Spare parts dependent on length 3.2 Spare parts dependent on length 3.2.1 Cable tray compact Spare parts for cable tray for IRBT 6003S/4003S compact: Quantity for different travel lengths Description 1.7 2.7 3.7 4.7 5.7 6.7 7.7 8.7 9.7 10.7 Art. no Item Leveling plates 10 11 12 13...
  • Page 114 Spare parts Cable tray covered 3.2.2 Cable tray covered Spare parts for cable tray for IRBT 6003S/4003S covered: Quantity for different travel lengths Description 1.7 2.7 3.7 4.7 5.7 6.7 7.7 8.7 9.7 10.7 Art. no Item Leveling plate 10 11 12 3HXD 1000-414 1 Lower bracket for 10 11 12...
  • Page 115 Spare parts Stand 3.2.3 Stand Spare parts for the stand for IRBT 6003S/4003S: 13 14 13 14 Quantity for different travel lengths Description 1.7 2.7 3.7 4.7 5.7 6.7 7.7 8.7 9.7 10.7 Art. no Item Linear guide 45 3HXG 1127-1 L=1000 Linear guide 45 3HXG 1127-2...
  • Page 116 Spare parts Cables 3.2.4 Cables Cable lengths The tables show the cable lengths required for the different connections with various travel lengths. The article numbers for the cables can be found in "Electrical installation" on page 2 - Cable lengths for IRBT 6003S/4003S compact Compact Cable lengths with different travel lengths Description...
  • Page 118 3HEA 800 970-001 Rev. D, Mars 2006...

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