ABB FlexPendant User manual

Product manual
FlexPendant Retractable Cable

Trace back information:
Workspace Main version a182
Checked in 2016-10-06
Skribenta version 4.6.320

Product manual
FlexPendant Retractable Cable
Document ID: 3HAC048816-001
Revision: B
© Copyright 2015-2016 ABB. All rights reserved.

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Additional copies of this manual may be obtained from ABB.
The original language for this publication is English. Any other languages that are
supplied have been translated from English.
© Copyright 2015-2016 ABB. All rights reserved.
ABB AB
Robotics Products
Se-721 68 Västerås
Sweden

Table of contents
7Overview of this manual ...................................................................................................................
91 Safety
91.1 Safety in the robot system .................................................................................. 111.2 Safety risks during installation and service work on robots ........................................ 141.3 Risks associated with live electric parts ................................................................. 161.4 WARNING - The unit is sensitive to ESD! ............................................................... 171.5 Safe use of the jogging device .............................................................................
192 Installation
192.1 Installing the bracket for standard robots ............................................................... 212.2 Installing the bracket for paint robots .................................................................... 232.3 Connecting the cables ........................................................................................
313 Maintenance
313.1 Maintenance schedule and expected component life ............................................... 323.2 Inspecting the complete FlexPendant Retractable Cable ........................................... 353.3 Cleaning the complete FlexPendant Retractable Cable .............................................
374 Repair
374.1 Replacing the brake ........................................................................................... 394.2 Replacing the cable stopper ................................................................................
415 Spare parts
43Index
Product manual - FlexPendant Retractable Cable 5
3HAC048816-001 Revision: B
© Copyright 2015-2016 ABB. All rights reserved.
Table of contents

This page is intentionally left blank

Overview of this manual
About this manual
This manual contains instructions for installing, maintaining, and repairing the
FlexPendant Retractable Cable unit for S4C, S4C+, IRC5, and IRC5P.
Prerequisites
A maintenance/repair/installation craftsman working with an ABB manipulator
must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
References
Document IDReference
3HAC031045-001
Operating manual - General safety information i
3HAC050941-001Operating manual - IRC5 with FlexPendant
3HNA008861-001Product Manual - IRC5P
3HAC7793-1User’s guide - S4Cplus (BaseWare OS 4.0)
3HAC5784-1User’s guide - S4C (BaseWare OS 3.2)
iThis manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Revisions
DescriptionRevision
First edition-
Added IRC5P.A
Added information about external panel, see Limitation on page 20.B
Product manual - FlexPendant Retractable Cable 7
3HAC048816-001 Revision: B
© Copyright 2015-2016 ABB. All rights reserved.
Overview of this manual

This page is intentionally left blank

1 Safety
1.1 Safety in the robot system
Validity and responsibility
The 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. 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.
The users of ABB industrial robots are responsible for ensuring that the applicable
safety laws and regulations in the country concerned are observed and that the
safety devices necessary to protect people working with the robot system are
designed and installed correctly. Personnel working with robot must be familiar
with the operation and handling of the industrial robot as described in the applicable
documents, for example:
•User’s guide - S4Cplus (BaseWare OS 4.0)
•Operating manual - IRC5 with FlexPendant
•Operating manual - General safety information I
•Product Manual - IRC5P
•Product manual
IThis manual contains all safety instructions from the product manuals for the robots and the
controllers.
The robot system shall be designed and constructed in such a way as to allow safe
access to all areas where intervention is necessary during operation, adjustment,
and maintenance.
Where it is necessary to perform tasks within the safeguarded space there shall
be safe and adequate access to the task locations.
Users shall not be exposed to hazards, including slipping, tripping, and falling
hazards.
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.
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial robot will not cause injury or damage even if
all safety instructions are complied with.
Continues on next page
Product manual - FlexPendant Retractable Cable 9
3HAC048816-001 Revision: B
© Copyright 2015-2016 ABB. All rights reserved.
1 Safety
1.1 Safety in the robot system

Related information
SectionDetailed in documentType of information
Installation and
commissioning
Product manual for the robotInstallation of safety devices
Start-upUser’s guide - S4Cplus (BaseWare OS
4.0)
Changing operating modes
Operating modes
Operating manual - IRC5 with FlexPend-
ant
Operator's Manual - IRC5P
Installation and
commissioning
Product manual for the robotRestricting the working space
10 Product manual - FlexPendant Retractable Cable
3HAC048816-001 Revision: B
© Copyright 2015-2016 ABB. All rights reserved.
1 Safety
1.1 Safety in the robot system
Continued

1.2 Safety risks during installation and service work on robots
Overview
This section includes information on general safety risks to be considered when
performing installation and service work on the robot.
These safety instructions have to be read and followed by any person who deals
with the installation and maintenance of the robot. 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 maintain, repair, or use the robot.
General risks during installation and service
• The instructions in the product manual in the chapters Installation and
commissioning, and Repair must always be followed.
• Emergency stop buttons must be positioned in easily accessible places so
that the robot can be stopped quickly.
• 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.
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 system.
Personal protective equipment
Always use suitable personal protective equipment, based on the risk assessment
for the robot installation.
Nation/region specific regulations
To prevent injuries and damages during the installation of the robot, the regulations
applicable in the country concerned and the instructions of ABB Robotics must be
complied with.
Non-voltage related risks
• 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.
• 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.
Continues on next page
Product manual - FlexPendant Retractable Cable 11
3HAC048816-001 Revision: B
© Copyright 2015-2016 ABB. All rights reserved.
1 Safety
1.2 Safety risks during installation and service work on robots

• Turntables or the like should be used to keep the operator out of the robot's
working space.
• 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.
• The axes are affected by the force of gravity when the brakes are released.
In addition to the risk of being hit by moving robot parts, there is a risk of
being crushed by the parallel arm (if there is one).
• Energy stored in the robot for the purpose of counterbalancing certain axes
may be released if the robot, or parts thereof, are dismantled.
•When dismantling/assembling mechanical units, watch out for falling objects.
• Be aware of stored heat energy in the controller.
• Never use the robot as a ladder, which means, do not climb on the robot
motors or other parts during service work. There is a serious risk of slipping
because of the high temperature of the motors and oil spills that can occur
on the robot.
• Never use the robot as a ladder, which means, do not climb on the
manipulator motors or other parts during service work. There is a risk of the
robot being damaged.
To be observed by the supplier of the complete system
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.
Complete robot
DescriptionSafety risk
CAUTION
Motors and gearboxes are HOT after running
the robot! Touching motors and gearboxes
may result in burns!
With a higher environment temperature, more
surfaces on the manipulator will get HOT and
may also result in burns.
Hot components!
WARNING
Take any necessary measures to ensure that
the robot does not collapse as parts are re-
moved. For example, secure the lower arm
according to the repair instruction if removing
the axis-2 motor.
Removed parts may result in collapse of
the robot!
Continues on next page
12 Product manual - FlexPendant Retractable Cable
3HAC048816-001 Revision: B
© Copyright 2015-2016 ABB. All rights reserved.
1 Safety
1.2 Safety risks during installation and service work on robots
Continued

DescriptionSafety risk
WARNING
If the internal cables for the measurement
system have been disconnected during repair
or maintenance, then the revolution counters
must be updated.
Removed cables to the measurement sys-
tem
Cabling
DescriptionSafety risk
CAUTION
The cable packages are sensitive to mechan-
ical damage. Handle the cable packages and
the connectors with care in order to avoid
damage.
Cable packages are sensitive to mechanical
damage!
Product manual - FlexPendant Retractable Cable 13
3HAC048816-001 Revision: B
© Copyright 2015-2016 ABB. All rights reserved.
1 Safety
1.2 Safety risks during installation and service work on robots
Continued

1.3 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 system during
construction, commissioning, and maintenance is guaranteed if the valid regulations
are followed.
All work must be performed:
• by qualified personnel
• on machine/robot system in deadlock
• in an isolated state, disconnected from power supply, and protected against
reconnection.
Voltage related risks, S4C and S4Cplus controller
A danger of high voltage is associated with, for example, the following parts:
• Be aware of stored electrical energy (DC link) in the controller.
• Units such as I/O modules, can be supplied with power from an external
source.
• The mains supply/mains switch
• The power unit
• The control power supply (S4C 55 VAC, and S4Cplus 230 VAC)
• The rectifier unit (262/430 VAC and 400/800 VDC. Note: Capacitors!)
• The drive unit (400/800 VDC)
• The service outlets (115/230 VAC)
• The power supply unit for additional tools, or special power supply units for
the machining process.
•The external voltage connected to the control cabinet remains live even when
the robot is disconnected from the mains.
• Additional connections.
Continues on next page
14 Product manual - FlexPendant Retractable Cable
3HAC048816-001 Revision: B
© Copyright 2015-2016 ABB. All rights reserved.
1 Safety
1.3 Risks associated with live electric parts

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, robot
A danger of high voltage is associated with the robot 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).
Voltage 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.
Product manual - FlexPendant Retractable Cable 15
3HAC048816-001 Revision: B
© Copyright 2015-2016 ABB. All rights reserved.
1 Safety
1.3 Risks associated with live electric parts
Continued

1.4 WARNING - 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.
Elimination
NoteAction
Wrist straps must be tested frequently to ensure
that they are not damaged and are operating cor-
rectly.
Use a wrist strap.1
The mat must be grounded through a current-limit-
ing resistor.
Use an ESD protective floor mat.2
The mat should provide a controlled discharge of
static voltages and must be grounded.
Use a dissipative table mat.3
Location of wrist strap button
The wrist strap is located on the left side on the inside of the controller door.
The location of the wrist strap button is shown in the following illustration.
16 Product manual - FlexPendant Retractable Cable
3HAC048816-001 Revision: B
© Copyright 2015-2016 ABB. All rights reserved.
1 Safety
1.4 WARNING - The unit is sensitive to ESD!

1.5 Safe use of the jogging device
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 jogging device
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 jogging device, 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 bring the
jogging device with him/her. 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 S4Cplus is described in User’s
guide - S4Cplus (BaseWare OS 4.0).
How to operate the hold-to-run function for IRC5 is described in Operating
manual - IRC5 with FlexPendant.
Product manual - FlexPendant Retractable Cable 17
3HAC048816-001 Revision: B
© Copyright 2015-2016 ABB. All rights reserved.
1 Safety
1.5 Safe use of the jogging device

This page is intentionally left blank

2 Installation
2.1 Installing the bracket for standard robots
Introduction
The bracket holding the retractable cable unit should be installed in a location that
is suitable for your robot cell. ABB does not recommend installing it on the robot
controller cabinet.
The size and quality of the attachment screws depend on the installation place.
For information about the bracket for paint robots, see Installing the bracket for
paint robots on page 21.
Note
The retractable cable unit must be installed vertically with the cable outlet at the
top and the connection cable to the controller pointing down, see figure.
xx1300002384
Required equipment
NoteEquipment
Retractable cable unit
3 piecesAttachment screws and
washers The screw holes in the bracket has a diameter of 8 mm. ABB
recommends using M8 socket head cap screws and wide
flat washers. Screws and washers are not included in the
delivery.
Continues on next page
Product manual - FlexPendant Retractable Cable 19
3HAC048816-001 Revision: B
© Copyright 2015-2016 ABB. All rights reserved.
2 Installation
2.1 Installing the bracket for standard robots

Dimensions, small version
Dimensions, large version
Installing the bracket
Use this procedure to install the bracket holding the FlexPendant Retractable Cable.
NoteAction
Center distance of the holes: 70
mm
Make holes for the bracket screws.1
Continue with connecting the
cables, see Connecting the cables
on page 23.
Hold the FlexPendant Retractable Cable bracket
in place and secure it with the screws.
2
Limitation
Do not install the FlexPendant Retractable Cable when a robot system is equipped
with any of the following options:
• 733-3 External panel
• 733-4 External panel small box
• 734-1 Panel cable - 15 m
• 734-3 Panel cable - 30 m
• 734-5 Panel cable - 7 m
20 Product manual - FlexPendant Retractable Cable
3HAC048816-001 Revision: B
© Copyright 2015-2016 ABB. All rights reserved.
2 Installation
2.1 Installing the bracket for standard robots
Continued