ABB IRB 140 User manual

ABB Robotics
Product manual
IRB 140

Trace back information:
Workspace R13-1 version a7
Checked in 2013-04-02
Skribenta version 1184

Product manual
IRB 140 type C
IRB 140T type C
IRB 140-6/0.8 type C
IRB 140T-6/0.8 type C
M2004
Document ID: 3HAC027400-001
Revision: K
© Copyright 2004-2013 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 2004-2013 ABB. All rights reserved.
ABB AB
Robotics Products
SE-721 68 Västerås
Sweden

Table of contents
9Overview of this manual ...................................................................................................................
12Product documentation, M2004 .......................................................................................................
14How to read the product manual ......................................................................................................
151 Safety
151.1 Introduction to safety information ......................................................................... 161.2 General safety information .................................................................................. 161.2.1 Introduction to general safety information .................................................... 171.2.2 Safety in the manipulator system ............................................................... 181.2.3 Safety risks ............................................................................................ 181.2.3.1 Safety risks during installation and service work on manipulators ......... 211.2.3.2 CAUTION - Hot parts may cause burns! ........................................... 221.2.3.3 Safety risks related to tools/work pieces .......................................... 231.2.3.4 Safety risks related to pneumatic/hydraulic systems .......................... 241.2.3.5 Safety risks during operational disturbances ..................................... 251.2.3.6 Risks associated with live electric parts ........................................... 271.2.4 Safety actions ......................................................................................... 271.2.4.1 Safety fence dimensions ............................................................... 281.2.4.2 Fire extinguishing ........................................................................ 291.2.4.3 Emergency release of the manipulator’s arm .................................... 301.2.4.4 Brake testing .............................................................................. 311.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" ........................ 321.2.4.6 Safe use of the FlexPendant .......................................................... 331.2.4.7 Work inside the manipulator's working range ................................... 341.2.5 Safety stops ........................................................................................... 341.2.5.1 What is an emergency stop? .......................................................... 361.3 Safety related instructions .................................................................................. 361.3.1 Safety signals in the manual ...................................................................... 381.3.2 Safety symbols on manipulator labels ......................................................... 431.3.3 DANGER - Moving manipulators are potentially lethal! ................................... 441.3.4 DANGER - First test run may cause injury or damage! ................................... 451.3.5 DANGER - Make sure that the main power has been switched off! .................... 471.3.6 WARNING - The unit is sensitive to ESD! ..................................................... 491.3.7 WARNING - Safety risks during handling of batteries ..................................... 501.3.8 WARNING - Safety risks during work with gearbox lubricants (oil or grease) ......
532 Installation and commissioning
532.1 Introduction ...................................................................................................... 542.2 Unpacking ....................................................................................................... 542.2.1 Pre-installation procedure ......................................................................... 582.2.2 Working range, IRB 140 ........................................................................... 602.2.3 Risk of tipping/stability ............................................................................. 612.3 On-site installation ............................................................................................ 612.3.1 Lifting the manipulator with lifting slings ...................................................... 622.3.2 Lifting and turning the manipulator ............................................................. 632.3.3 Manually releasing the brakes ................................................................... 662.3.4 Orienting and securing the manipulator ....................................................... 672.3.5 Fitting equipment on manipulator .............................................................. 692.3.6 Loads .................................................................................................... 702.3.7 Setting the system parameters for a suspended robot .................................... 722.3.8 Bolt pattern ............................................................................................ 742.3.9 Installation of signal lamp (option) .............................................................. 752.4 Restricting the working range .............................................................................. 752.4.1 Restricting the working range .................................................................... 762.5 Electrical connections ........................................................................................ 762.5.1 Customer connections on manipulator .......................................................
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Table of contents

793 Maintenance
793.1 Introduction ...................................................................................................... 803.2 Maintenance schedules ...................................................................................... 803.2.1 Specification of maintenance intervals ........................................................ 813.2.2 Maintenance schedule ............................................................................. 833.3 Inspection activities ........................................................................................... 833.3.1 Inspection, damper axes 2, 3 and 5 ............................................................. 853.3.2 Inspection, robot cabling .......................................................................... 863.3.3 Inspection, timing belts ............................................................................ 893.4 Cleaning activities ............................................................................................. 893.4.1 Cleaning, robot ...................................................................................... 913.5 Changing/ replacing activities .............................................................................. 913.5.1 Type of lubrication in gearboxes ................................................................ 923.5.2 Changing the oil in axes 5 and 6 gearboxes .................................................
954 Repair
954.1 Introduction ...................................................................................................... 964.2 General procedures ........................................................................................... 964.2.1 Mounting instructions for bearings ............................................................. 984.2.2 Mounting instructions for seals .................................................................. 1004.2.3 Replacing parts on Clean Room robots ....................................................... 1024.3 Complete robot ................................................................................................. 1024.3.1 Replacement of cable harness ................................................................... 1104.3.2 Replacement of complete upper arm .......................................................... 1164.3.3 Replacement of complete lower arm ........................................................... 1204.3.4 Replacement of base ............................................................................... 1244.4 Upper arm ....................................................................................................... 1244.4.1 Replacement of wrist unit ......................................................................... 1284.4.2 Replacing the damper, axis 3 ..................................................................... 1304.4.3 Replacement of damper, axis 5 .................................................................. 1324.4.4 Replacement of cover, arm housing ............................................................ 1354.5 Lower arm ....................................................................................................... 1354.5.1 Replacement of lower arm cover and gasket ................................................ 1394.5.2 Replacing the damper, axis 2 ..................................................................... 1414.6 Frame and base ................................................................................................ 1414.6.1 Replacement of cover, console .................................................................. 1444.6.2 Replacement of console ........................................................................... 1484.6.3 Replacing the serial measurement unit and the battery pack ........................... 1544.6.4 Replacement of control cable .................................................................... 1584.7 Motors ............................................................................................................ 1584.7.1 Replacement of motor, axis 1 ................................................................... 1624.7.2 Replacement of motor, axis 2 .................................................................... 1664.7.3 Replacement of motor and timing belt, axis 3 ............................................... 1724.7.4 Replacement of motor, axis 4 .................................................................... 1764.7.5 Replacement of motor and timing belt, axes 5 or 6 ........................................ 1824.7.6 Adjustments and measurements ................................................................ 1824.7.6.1 Measuring the gear play, axis 5 ...................................................... 1844.7.6.2 Measuring the gear play, axis 6 ...................................................... 1864.8 Gearboxes ....................................................................................................... 1864.8.1 Replacement of gearbox, axes 1-2 and damper, axis 1 ................................... 1924.8.2 Service work on gearbox, axis 4 ................................................................. 1934.8.3 Amount of oil .........................................................................................
1955 Calibration information
1955.1 Introduction ..................................................................................................... 1965.2 Calibration methods ........................................................................................... 1985.3 Calibration scale and correct axis position ............................................................. 1995.4 Calibration movement directions for all axes ..........................................................
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Table of contents

2005.5 Updating revolution counters ............................................................................... 2025.6 Checking the calibration position ..........................................................................
2036 Decommissioning
2036.1 Environmental information ..................................................................................
2057 Robot description
2057.1 Type C of IRB 140 .............................................................................................
2078 Reference information
2078.1 Introduction ...................................................................................................... 2088.2 Applicable safety standards ................................................................................ 2108.3 Unit conversion ................................................................................................. 2118.4 Screw joints .................................................................................................... 2148.5 Weight specifications ......................................................................................... 2158.6 Standard tools .................................................................................................. 2168.7 Special tools .................................................................................................... 2178.8 Performing a leak-down test ............................................................................... 2188.9 Lifting accessories and lifting instructions ..............................................................
2199 Spare part lists
2199.1 Introduction ...................................................................................................... 2209.2 Spare parts - robot IRB 140 .................................................................................
22910 Circuit diagram
22910.1 About circuit diagrams .......................................................................................
231Index
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Table of contents

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Overview of this manual
About this manual
This manual contains instructions for:
• mechanical and electrical installation of the robot
• maintenance of the robot
• mechanical and electrical repair of the robot.
Usage
This manual should be used during:
• installation, from lifting the robot to its work site and securing it to the
foundation to making it ready for operation
• maintenance work
• repair work and calibration.
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 Robot 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:
ContentsChapter
Safety information that must be read through before performing
any installation or service work on robot. Contains general
safety aspects as well as more specific information about how
to avoid personal injuries and damage to the product.
Safety, service
Required information about lifting and installation of the robot.Installation and commis-
sioning
Step-by-step procedures that describe how to perform mainten-
ance of the robot. Based on a maintenance schedule that may
be used in the work of planning periodical maintenance.
Maintenance
Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.
Repair
Procedures that does not require specific calibration equipment.
General information about calibration.
Calibration information
Environmental information about the robot and its components.Decommissioning
Useful information when performing installation, maintenance
or repair work. Includes lists of necessary tools, additional
documents, safety standards, etc.
Reference information
Continues on next page
3HAC027400-001 Revision: K 9
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Overview of this manual

ContentsChapter
Complete spare part list and complete list of robot components,
shown in exploded views.
Spare parts and exploded
views
References to the circuit diagrams for the robot.Circuit diagram
References
Document IDReference
3HAC6816-3Circuit diagram - IRB 140 type C
3HAC021313-001Product manual - IRC5
3HAC041346-001Product specification - IRB 140
3HAC16590-1Operating manual - IRC5 with FlexPendant
3HAC16578-1Operating manual - Calibration Pendulum
3HAC025709-001Operating manual - Service Information System
3HAC042927-001Technical reference manual - Lubrication in gearboxes
3HAC16581-1Technical reference manual - RAPID Instructions, Functions and
Data types
3HAC030421-001Application manual - CalibWare Field 5.0
Revisions
DescriptionRevision
First edition, see also Type C of IRB 140 on page 205.-
IRB 140-6/0.8 and IRB 140T-6/0.8 added.A
Clean room added.B
Changes made in:
•Prerequisites in section Overview
•Oil change in section Maintenance
Content updated in section:
•Making robot ready for operation, Cleanroom ,Additional installa-
tion procedure.
C
Content updated in section:
•Repair, exchange of parts on Clean room robots
•Maintenance, Cleaning of robot
•Maintenance schedule: Interval for replacement of battery pack
changed.
• Section What is an emergency stop? added to chapter Safety.
D
Content updated in sections:
• Article numbers added or replaced in sections Replacement of
complete upper arm on page 110,Replacement of complete lower
arm on page 116,Replacement of gearbox, axes 1-2 and damper,
axis 1 on page 186, and Type C of IRB 140 on page 205.
E
Continues on next page
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Overview of this manual
Continued

DescriptionRevision
Content updated in sections:
• Required equipment updated in Replacement of motor and timing
belt, axis 3 on page 166.
• Spare part list updated regarding Foundry Plus cable guard and
new wrist.
• Circuit diagrams are not included in this document but delivered
as separate files. See Circuit diagram on page 229.
• List of standards updated, see Applicable safety standards on
page 208.
• Sealing compound updated in Replacing parts on Clean Room
robots on page 100.
• Decommissioning chapter added.
The chapter Safety updated with:
•Updated safety signal graphics for the levels Danger and Warning,
see Safety signals in the manual on page 36.
• New safety labels on the manipulators, see Safety symbols on
manipulator labels on page 38.
• Revised terminology: robot replaced with manipulator.
F
This revision includes the following additions:
• New section, Restricting the working range on page 75.
•Lifting and turning the manipulator on page 62.
This revision includes the following updates:
• Corrected amount of oil in axes 3, 5, and 6, see Amount of oil on
page 193.
• Updates in chapter Calibration.
G
This revision includes the following updates:
• Corrected article number for VK cover, see Replacement of com-
plete upper arm on page 110 and Replacement of motor and timing
belt, axes 5 or 6 on page 176.
H
This revision includes the following updates:
• A new block, about general illustrations, added in section How to
read the product manual on page 14.
• The option Foundry Plus Cable Guard is removed.
• Some general tightening torques have been changed/added, see
updated values in Screw joints on page 211.
• The figure of the base is updated in concerned sections.
• Added WARNING - Safety risks during handling of batteries on
page 49.
J
This revision includes the following updates:
• Information regarding disassembly of Clean Room robots added
to concerned repair instructions.
•Changed the instruction for how to fit the o-ring of the axis-4 motor
when refitting the motor, see Replacement of motor, axis 4 on
page 172.
• Added figures that show an alternative layout inside the base, see
Replacing the serial measurement unit and the battery pack on
page 148.
• All data about type of lubrication in gearboxes is moved from the
manual to a separate lubrication manual, see Type and amount of
oil in gearboxes on page 91.
• Corrected article number for battery pack, see Spare parts - robot
IRB 140 on page 220.
• A new SMB unit and battery is introduced, with longer battery
lifetime.
K
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Overview of this manual
Continued

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
Manipulators, controllers, DressPack/SpotPack, and most other hardware will be
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
•Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
•Reference information (safety standards, unit conversions, screw joints, lists
of tools ).
• Spare parts list with exploded views (or references to separate spare parts
lists).
• Circuit diagrams (or references to circuit diagrams).
Technical reference manuals
The technical reference manuals describe reference information for robotics
products.
•Technical reference manual - Lubrication in gearboxes: Description of types
and volumes of lubrication for the manipulator gearboxes.
•Technical reference manual - RAPID overview: An overview of the RAPID
programming language.
•Technical reference manual - RAPID Instructions, Functions and Data types:
Description and syntax for all RAPID instructions, functions, and data types.
•Technical reference manual - RAPID kernel: A formal description of the
RAPID programming language.
•Technical reference manual - System parameters: Description of system
parameters and configuration workflows.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
Continues on next page
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Product documentation, M2004

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, DVD with PC software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
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 (among others):
•Operating manual - Emergency safety information
•Operating manual - General safety information
•Operating manual - Getting started, IRC5 and RobotStudio
•Operating manual - Introduction to RAPID
•Operating manual - IRC5 with FlexPendant
•Operating manual - RobotStudio
•Operating manual - Trouble shooting IRC5, for the controller and manipulator.
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Product documentation, M2004
Continued

How to read the product manual
Reading the procedures
The procedures contain references to figures, tools, material, and so on. The
references are read as described below.
References to figures
The procedures often include references to components or attachment points
located on the manipulator/controller. The components or attachment points are
marked with italic text in the procedures and completed with a reference to the
figure where the current component or attachment point is shown.
The denomination in the procedure for the component or attachment point
corresponds to the denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a
procedure.
Note/IllustrationAction
Shown in the figure Location of
gearbox on page xx.
Remove the rear attachment screws, gearbox.8.
References to required equipment
The procedures often include references to equipment (spare parts, tools, etc.)
required for the different actions in the procedure. The equipment is marked with
italic text in the procedures and completed with a reference to the section where
the equipment is listed with further information, that is article number and
dimensions.
The designation in the procedure for the component or attachment point
corresponds to the designation in the referenced list.
The table below shows an example of a reference to a list of required equipment
from a step in a procedure.
Note/IllustrationAction
Art. no. is specified in Required
equipment on page xx.
Fit a new sealing, axis 2 to the gearbox.3.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 15.
Illustrations
The robot is illustrated with general figures that does not take painting or protection
type in consideration.
Likewise certain work methods or general information, that is valid for several robot
models, can be illustrated with pictures that show a different robot model that the
one described in the current manual.
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How to read the product manual

1 Safety
1.1 Introduction to safety information
Overview
The safety information in this manual is divided into 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 16.
• Specific safety information, pointed out in the procedures. How to avoid and
eliminate the danger is either described directly in the procedure, or in specific
instructions in the section Safety related instructions on page 36.
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1 Safety
1.1 Introduction to safety information

1.2 General safety information
1.2.1 Introduction to general safety information
Definitions
This section details general safety information for personnel performing installation,
repair and maintenance work.
Sections
The general safety information is divided into the following sections.
ContainingContents
• safety, service
• limitation of liability
• related information
General information
• safety risks during installation or service
• risks associated with live electrical parts
Safety risks lists dangers relevant when
working with the product. The dangers are
split into different categories.
• fire extinguishing
• safe use of the FlexPendant
Safety actions describes actions which
may be taken to remedy or avoid dangers.
• stopping functions
• description of emergency stop
• description of safety stop
• description of safeguarding
Safety stops describes different types of
stops.
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1 Safety
1.2.1 Introduction to general safety information

1.2.2 Safety in the manipulator 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 manipulator is installed.
The users of ABB industrial manipulators 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 manipulator
system are designed and installed correctly. Personnel working with manipulators
must be familiar with the operation and handling of the industrial manipulator as
described in the applicable documents, for example:
•Operating manual - IRC5 with FlexPendant
•Product manual
Connection of external safety devices
Apart from the built-in safety functions, the manipulator 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 manipulator.
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial manipulator will not cause injury or damage
even if all safety instructions are complied with.
Related information
SectionDetailed in documentType of information
Installation and
commissioning
Product manual for the manipulatorInstallation of safety devices
Operating modesOperating manual - IRC5 with FlexPend-
ant
Changing operating modes
Installation and
commissioning
Product manual for the manipulatorRestricting the working space
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1 Safety
1.2.2 Safety in the manipulator system

1.2.3 Safety risks
1.2.3.1 Safety risks during installation and service work on manipulators
Overview
This section includes information on general safety risks to be considered when
performing installation and service work on the manipulator.
These safety instructions have to be read and followed by any person who deals
with the installation and maintenance of the manipulator. Only persons who know
the manipulator and are trained in the operation and handling of the manipulator
are allowed to maintain the manipulator. Persons who are under the influence of
alcohol, drugs or any other intoxicating substances are not allowed to maintain,
repair, or use the manipulator.
General risks during installation and service
• The instructions in the product manual in the chapter Installation and
commissioning must always be followed.
• Emergency stop buttons must be positioned in easily accessible places so
that the manipulator 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 the manipulator 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 manipulator 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 manipulator
system.
Nation/region specific regulations
To prevent injuries and damages during the installation of the manipulator, the
regulations applicable in the country concerned and the instructions of ABB
Robotics must be complied with.
Non-voltage related risks
• Safety zones, which must be crossed before admittance, must be set up in
front of the manipulator'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
manipulator's working space.
Continues on next page
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1 Safety
1.2.3.1 Safety risks during installation and service work on manipulators

• The axes are affected by the force of gravity when the brakes are released.
In addition to the risk of being hit by moving manipulator parts, there is a risk
of being crushed by the parallel arm (if there is one).
• Energy stored in the manipulator for the purpose of counterbalancing certain
axes may be released if the manipulator, 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 manipulator as a ladder, which means, do not climb on the
manipulator 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 manipulator.
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.
Complete manipulator
DescriptionSafety risk
CAUTION
Motors and gears are HOT after running the
manipulator! Touching motors and gears 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 manipulator does not collapse as parts
are removed, e.g. secure the lower arm ac-
cording to repair instruction if removing mo-
tor, axis 2.
Removed parts may result in collapse of
manipulator!
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
Continues on next page
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1 Safety
1.2.3.1 Safety risks during installation and service work on manipulators
Continued

Cabling
DescriptionSafety risk
CAUTION
The cable packs are sensitive to mechanical
damage! They must be handled with care,
especially the connectors, in order to avoid
damaging them!
Cable packs are sensitive to mechanical
damage!
Gearboxes and motors
DescriptionSafety risk
CAUTION
Whenever parting/mating motor and gearbox,
the gears may be damaged if excessive force
is used!
Gears may be damaged if excessive force
is used!
DescriptionSafety risk
WARNING
Do not under any circumstances, deal with
the balancing device in any other way than
that detailed in the product documentation!
For example, attempting to open the balan-
cing device is potentially lethal!
Dangerous balancing device!
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1 Safety
1.2.3.1 Safety risks during installation and service work on manipulators
Continued