ABB Feather Duster User manual

Product manual
Feather Duster

© Copyright 2013-1016 ABB. All rights reserved.
Product manual
Feather Duster
Document ID: 3HAW050027150
Revision: Revision: C

© Copyright 2013-2016 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
construedasanykindofguarantee or warrantybyABBforlosses,damagestopersons
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.
© Copyright 2013-2016 ABB All rights reserved.
ABB Engineering (Shanghai) Ltd.
N°4528, Kangxin Highway,
Pudong New District,
Shanghai 201319, P.R.CHINA

Table of Contents
33HAW050027150 Revision: C
© Copyright 2013-2016 ABB. All rights reserved.
0.0.1 Overview of this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
0.0.2 Product documentation, M2004. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
0.0.3 How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1 Safety 11
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2.1 Safety in the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Safety risks related to the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.1 Safety risks during installation and service work on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.2 Safety risks related to tools/workpieces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.3 Safety risks related to pneumatic/hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3.4 Safety risks during operational disturbances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3.5 Risks associated with live electric parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.4 Safety actions related to the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4.1 Safety fence dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4.2 Fire extinguishing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.4.3 Emergency release of the robots/manipulators axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.4.4 Brake testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.4.5 Risk of disabling function "Reduced speed 250 mm/s". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.4.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.4.7 Work inside the manipulator's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
1.4.8 Translate the information on safety and information labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.5 Safety stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.5.1 What is an emergency stop?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.6 Safety related instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.6.1 Safety signals in the manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2 System description 31
2.1 System overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.1.1 System basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.1.2 Components overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.1.3 Process diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.2 Feather roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.3 Ionization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.4 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.5 Compressed air system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3 Technical Specification 40
3.1 Feather Duster and robot specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.2 Feather Duster dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4 Installation and commissioning 43
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.2 Mechanical installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.2.2 Carbon fiber covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.2.3 Instructions for the installation of the steel structure frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.2.4 Instructions for the connection of flexible hoses and cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.3 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.4 System start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.4.2 Start up of the Feather Duster motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

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© Copyright 2013-2016 ABB. All rights reserved.
5 Maintenance 65
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.2 Expected components lifetime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.3 Maintenance planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.4 Maintenance activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.4.1 Weekly cleaning and inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.4.2 Feather roller care and replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.4.3 Belt replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.4.4 Motor replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6 Reference information 77
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6.2 Unit conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.3 Bolt, screws, tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
6.4 Standard toolkit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.5 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7 Spare parts 83
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
7.2 Mechanical spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7.3 Electrical spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
8 Appendix 89
8.1 Assembly drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8.2 Wiring diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Table of Contents

53HAW050027150 Revision: C
© Copyright 2013-1016 ABB. All rights reserved.
0.0.1. Overview of this manual
About this manual This manual contains instructions for:
•the characteristics of the Feather Duster
•mechanical and electrical installation instructions for the Feather Duster
•maintenance instructions for the Feather Duster
•spare parts
Usage This manual should be used when working during:
•installation, from lifting the Feather Duster to its work site and securing it to the
foundation, to making it ready for operation
•maintenance work
•repair work.
Who should read this manual?
This manual is intended for:
•installation personnel
•maintenance personnel
•repair personnel.
Prerequisites A maintenance /repair/ installation craftsman working with an ABB Feather Duster must:
•be trained by ABB and have the required knowledge of mechanical and electrical
installation/repair/maintenance work.
Organization of chapters
The manual is organized in the following chapters:
Chapter Content
Safety Safety information that must be read through before performing
any installation or service work on the Feather Duster. Contains
general safety aspects as well as more specific information
about how to avoid personal injuries and damage to the product.
Description and technical
details Specifications and characteristics of the Feather Duster.
Installation Information for installing the Feather Duster and connection to
the control system.
Unpacking, acceptance
and handling Information relative to the steps following the reception of the Feather Duster, until its installation.
Maintenance Step-by-step procedures that describe how to perform
maintenance of the Feather Duster. Based on a maintenance
schedule that may be used in the work of planning periodical
maintenance.
Spare parts List of the spare parts available for the Feather Duster.

3HAW050027150 Revision: C6
© Copyright 2013-1016 ABB. All rights reserved.
References
Revisions
Reference - ABB documentation Document ID
Operating manual - General safety information 3HAC031045-001
Product manual - IRC5 Robot Controller with FlexPendant 3HAC021313-001
Service Information System - IRC5 3HAC025709-001
Operating manual - IRC5 with FlexPendant 3HAC16590
Getting started, IRC5 and RobotStudio 3HAC021564-001
Product manual - IRB6640 3HAC026876
Product manual - IRB6700 3HAC044266
Reference - Non-ABB documentation Document ID
System Manual – MOVIDRIVE® MDX60B/61B (09/2010)
Download from:
http://www.seweurodrive.com/download/pdf/16838017_G01.pdf
16838017 / EN
Operating Instructions – MOVIDRIVE® MDX60B/61B (01/2010)
Download from:
http://download.sew-eurodrive.com/download/pdf/16837614.pdf
16837614 / EN
Applications Manuals – MOVIDRIVE® MDX61B - DriveSync via
Fieldbus Application (08/2010)
Download from:
http://www.sew-eurodrive.com/download/pdf/17004411.pdf
17004411 / EN
Operator’sManual–SIMPSONHawk3,H335andH345,31/2Digit
and 4 1/2 Digit, Advanced Digital Controller
Download from:
http://www.simpsonelectric.com/faqs-downloadables/manuals-pdf
06-117287
Revision Description
AUpdated
- Spare parts list
- Requirements for air flow
- Wiring diagrams
BUpdated
- Robot specification
- RB6700 is added
- Electrical diagrams added
CUpdated
- Mechanical assembly instructions (for robots delivered after 2016)
- Electrical installation
- Spare parts list (exhaust pipe support)
- Assembly drawings

73HAW050027150 Revision: C
© Copyright 2013-1016 ABB. All rights reserved.
0.0.2. Product documentation, M2004
Categories for manipulator documentation
The manipulator documentation is divided into a number of categories. This listing is based
on the type of information in the documents, regardless of whether the products are standard
or optional.
All documents listed can be ordered from ABB on a DVD. The documents listed are valid for
M2004 manipulator systems.
Product manuals All hardware, manipulators and controllers will be delivered with a Product manual that
contains:
•Safety information.
•Installation and commissioning (descriptions of mechanical installation, electrical
connections).
•Maintenance (descriptions of all required preventive maintenance procedures
including intervals).
•Repair (descriptions of all recommended repair procedures including spare parts).
•Additional procedures, if any (calibration, decommissioning).
•Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards).
•Parts list.
•Foldouts or exploded views.
•Circuit diagrams (or references to circuit diagrams).
Technical reference manuals
The technical reference manuals describe the manipulator software in general and contain
relevant reference information.
•RAPID Overview: An overview of the RAPID programming language.
•RAPID Instructions, Functions and Data types: Description and syntax for all
RAPID instructions, functions, and data types.
•RAPID Kernel: A formal description of the RAPID programming language.
•System parameters: Description of system parameters and configuration workflows.
Application manualsSpecific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several applications.
An application manual generally contains information about:
•The purpose of the application (what it does and when it is useful).
•What is included (for example cables, I/O boards, RAPID instructions, system
parameters, CD with PC software).
•How to use the application.
•Examples of how to use the application.

3HAW050027150 Revision: C8
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Operating manuals The operating manuals describe hands-on handling of the products. The manuals are aimed
at those having first-hand operational contact with the product, that is production cell
operators, programmers, and trouble shooters.
The group of manuals includes:
•Emergency safety information
•General safety information
•Getting started, IRC5 and RobotStudio
•IRC5 with FlexPendant
•RobotStudio
•Introduction to RAPID
•Trouble shooting, for the controller and manipulator.

93HAW050027150 Revision: C
© Copyright 2013-1016 ABB. All rights reserved.
0.0.3. How to read the product manual
Reading the procedures
The procedures contain references to figures, tools, material etc. The references are read as
described below.
References to figures
The procedures often include references to components or attachment points located on the
robot/controller. The components or attachment points are marked with italic text in the
procedures and completed with a reference to the figure where the current component or
attachment point is shown.
The denomination in the procedure for the component or attachment point corresponds to the
denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a procedure.
Reference to required equipment
The proceduresoften include references to equipment (spare parts, tools etc.) required for the
different actions in the procedure. The equipment is marked with italic text in the procedures
and completed with a reference to the section where the equipment is listed with further
information, i.e. article number, dimension.
The denomination in the procedure for the component or attachment point corresponds to the
denomination in the referenced list.
The table below shows an example of a reference to a list of required equipment, from a step
in a procedure.
Safety information The manual includes a separate safety chapter that must be read through before proceeding
with any service or installation procedures. All procedures also include specific safety
information when dangerous steps are to be performed.
Read more in Safety on page 11.
Action Note/Illustration
8. Remove the rear attachment screws,
gearbox. Shown in the figure Location of gearbox on page xx.
Action Note/Illustration
3. Fit a new sealing, 2 to the gearbox. Art. no. is specified in Required
equipment on page xx.

3HAW050027150 Revision: C10
© Copyright 2013-1016 ABB. All rights reserved.

1 Safety
1.1. Introduction
113HAW050027150 Revision: C
© Copyright 2013-1016 ABB. All rights reserved.
1 Safety
1.1. Introduction
Overview The safety information in this manual is divided in two categories:
•general safety aspects, important to attend to before performing any service work on
the robot. These are applicable for all service work and are found in General safety
information on page 12.
•specific safety information, pointed out in the procedure at the moment of the danger.
How to avoid and eliminate the danger is either detailed directly in the procedure, or
further detailed in separate instructions, found in Safety related instructions on page
29.

1 Safety
1.2.1. Safety in the robot system
3HAW050027150 Revision: C12
© Copyright 2013-1016 ABB. All rights reserved.
1.2 General safety information
1.2.1. 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, which can influence the safety of the total 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.
TheusersofABBindustrial robots areresponsiblefor ensuring that theapplicablesafety 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 robots must be familiar with the operation and handling of the
industrial robot, described in the applicable documents, e.g. User's Guide and Product
Manual.
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. Via this interface, an external safety function can
interact with other machines and peripheral equipment. 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.
Related information
Type of information Detailed in document Section
Installation of safety devices Product manual for the robot Installation and
commissioning
Changing robot modes Operators manual
(RobotWare 5.0) Operating modes
Restricting the working space Product manual for the robot Installation and
commissioning

1 Safety
1.3.1. Safety risks during installation and service work on robot
133HAW050027150 Revision: C
© Copyright 2013-1016 ABB. All rights reserved.
1.3 Safety risks related to the robot
1.3.1. Safety risks during installation and service work on robot
Overview This section includes information of general safety risks to be considered when performing
installation and service work on the robot.
General risks during installation and service
•The instructions in the Product Manual - Installation and Commissioning must always
be followed.
•Emergencystop buttonsmustbe positioned ineasilyaccessible placessothat the robot
can be stopped quickly.
•Those in charge of operationsmust make sure that safety instructions are available for
the installation in question.
•Those who install the robot must have the appropriate training for the robot system in
question and in any safety matters associated with it.
Nation/region specific regulations
To prevent injuries and damage during the installation of the robot system, the regulations
applicable in the country concerned and the instructions of ABB Robotics must be complied
with.
Non-voltage related risks
•Safety zones, which have to be crossed before admittance, must be set up in front of
the robot's working space. Light beams or sensitive mats are suitable devices.
•Turntables or the like should be used to keep the operator out of the robot's working
space.
•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, you run the risk of being crushed by the
parallel arm.
•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, i.e. do not climb on the robot motors or other part
duringservicework. There is a seriousriskof slipping becauseofthe high temperature
of the motors or oil spills that can occur on the robot.
To be observed by the supplier of the complete system
•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.

1 Safety
1.3.1. Safety risks during installation and service work on robot
3HAW050027150 Revision: C14
© Copyright 2013-1016 ABB. All rights reserved.
Complete robot
Cabling
Gearboxes and motors
Safety risk Description
Hot components!
Removed parts may result
in collapse of robot!
Caution signal
Caution!
Motors and gears are HOT after running the robot! Touching the
motors and gears may result in burns!
Warning signal
Warning!
Take any necessary measures to ensure that the robot does not
collapse as parts are removed, e.g. secure the lower arm with
fixtures if removing motor, axis 2.
Safety risk Description
Cable packs are sensitive
to mechanical damage!
Caution signal
Caution!
The cable packs are sensitive to mechanical damage! They
must be handled with care, especially the connectors, in order
to avoid damaging them!
Safety risk Description
Gears may be damaged if
excessive force is used!
Caution signal
Caution!
Whenever parting/mating motor and gearbox, the gears may be
damaged if excessive force is used!

1 Safety
1.3.2. Safety risks related to tools/workpieces
153HAW050027150 Revision: C
© Copyright 2013-1016 ABB. All rights reserved.
1.3.2. Safety risks related to tools/workpieces
Safe handling It must be possible to safely turn off tools, such as milling cutters, etc. Make sure that guards
remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design Grippers/endeffectorsmustbedesigned so thattheyretain workpieces in theeventofa power
failure or a disturbance of the controller.
CAUTION!
Ensure that a gripper is prevented from dropping a workpiece, if such is used.

1 Safety
1.3.3. Safety risks related to pneumatic/hydraulic systems
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© Copyright 2013-1016 ABB. All rights reserved.
1.3.3. Safety risks related to pneumatic/hydraulic systems
General Special safety regulations apply to pneumatic and hydraulic systems.
Residual energy •Residual energy may be present inthese systems.Aftershutdown,particular care must
be taken.
•The pressure in pneumatic and hydraulic systems must be released before starting to
repair them.
Safe design •Gravity may cause any parts or objects held by these systems to drop.
•Dump valves should be used in case of emergency.
•Shot bolts should be used to prevent tools, etc., from falling due to gravity.

1 Safety
1.3.4. Safety risks during operational disturbances
173HAW050027150 Revision: C
© Copyright 2013-1016 ABB. All rights reserved.
1.3.4. Safety risks during operational disturbances
General •The industrial robot is a flexible tool which can be used in many different industrial
applications.
•All work must be carried out professionally and in accordance with the applicable
safety regulations.
•Care must be taken at all times.
Qualified personnel •Corrective maintenance must only be carried out by qualified personnel who are
familiar with the entire installation as well as the special risks associated with its
different parts.
Extraordinary risks If the working process is interrupted, extra care must be taken due to risks other than those
associated with regular operation. Such an interruption may have to be rectified manually.

1 Safety
1.3.5. Risks associated with live electric parts
3HAW050027150 Revision: C18
© Copyright 2013-1016 ABB. All rights reserved.
1.3.5. Risks associated with live electric parts
Voltage related risks, general
•Although troubleshooting may, on occasion, have to be carried out while the power
supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
•The mains supply to the robot must be connected in such a way that it can be turned
off outside the robot's working space.
Voltage related risks, controller IRC5
A danger of high voltage is associated with the following parts:
•Be aware of stored electrical energy (DC link, Ultra Cap unit) in the controller.
•Units inside the controller, e.g. I/O modules, can be supplied with power from an
external source.
•The mains supply/mains switch
•The transformers
•The power unit
•The control power supply (230 VAC)
•The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
•The drive unit (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 tools, or special power supply units for the machining
process.
•Theexternalvoltage connected to the controlcabinetremains live evenwhenthe 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, see
chapter Installation and commissioning in the Product manual).
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.