ABB M2000 User manual


Product manual (part 2 of 2), reference information
Articulated robot
IRB 140
M2000, M2000A, M2004

Product manual (part 2 of 2), reference information
IRB 140
M2000
M2000A
M2004
Document ID: 3HAC023297-001
Revision: A

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 thereofmust not be reproduced or copiedwithout
ABB's written permission, and contents thereof must not be imparted to
a third party nor be used for any unauthorized purpose. Contravention
will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then
current charge.
© Copyright 2004-2008 ABB All right reserved.
ABB Automation Technologies AB
Robotics
SE-721 68 Västerås
Sweden

Table of Contents
33HAC023297-001 Revision: A
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Reference information 11
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Applicable Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.6 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.7 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.8 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.9 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.10 Mounting instructions for bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.11 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 Spare part / part list 27
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2 Spare part / part list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3 Foldouts 33
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4 Circuit diagram 35
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Table of Contents
3HAC023297-001 Revision: A4

Overview
53HAC023297-001 Revision: A
Overview
About this manual This manual contains reference information for all procedures in part 1: Product manual,
procedures.
Usage This manual should be used during:
• installation
• 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 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:
Chapter Contents
Reference information Useful information when performing installation, maintenance
or repair works. Includes lists of necessary tools, additional
documents, safety standards, etc.
Spare part / Part list Complete spare part lists and complete lists of robot
components, shown in the foldouts.
Foldouts Detailedillustrationsoftherobot withreferencenumbers tothe
part list.
Circuit diagram Circuit diagram for the robot.

Overview
3HAC023297-001 Revision: A6
Revisions
Revision Description
-First edition
Replaces previous manuals:
• Installation and commissioning manual
• Maintenance manual
• Repair manual, part 1
• Repair manual, part 2
Changes made in the material from the previous manuals:
• Model M2004 implemented.
•SectionDocument references added to the chapter Reference
information.
• Information about the controller removed from the manual.
• Additional spare part numbers for the motors.
AChanges made in:
• Prerequisites in section Overview
• Oil change in section Maintenance

Product documentation, M2000/M2000A
73HAC023297-001 Revision: A
Product documentation, M2000/M2000A
General The complete product documentation kit for the M2000 robot system, including controller,
robot and any hardware option, consists of the manuals listed below:
Hardware manuals All hardware, robots and controller cabinets, will be delivered with a Productmanual which
is divided into two parts:
Product manual, procedures
• Safety information
• Installation and commissioning (descriptions of mechanical installation, electrical
connections and loading system software)
• 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)
Product manual, reference information
• Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
•Partlist
• Foldouts or exploded views
• Circuit diagrams
Software manuals The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during
operation.
A complete listing of all available software manuals is available from ABB.
Controller hardware option manual
Each hardware option for the controller is supplied with its own documentation. Each
document set contains the types of information specified below:
• Installation information
• Repair information
• Maintenance information
In addition, spare part information is supplied for the entire option.

Product documentation, M2004
3HAC023297-001 Revision: A8
Product documentation, M2004
General The robot documentation may be divided into a number of categories. This listing is based on
the type of information contained within the documents, regardless of whether the products
are standard or optional. This means that any given delivery of robot products will not contain
all documents listed, only the ones pertaining to the equipment delivered.
However, all documents listed may be ordered from ABB. The documents listed are valid for
M2004 robot systems.
Hardware manuals All hardware, robots and controller cabinets, will be delivered with a Productmanualwhich
is divided into two parts:
Product manual, procedures
• Safety information
• Installation and commissioning (descriptions of mechanical installation, electrical
connections and loading system software)
• 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)
Product manual, reference information
• Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
•Partlist
• Foldouts or exploded views
• Circuit diagrams
RobotWare manualsThe following manuals describe the robot software in general and contain relevant reference
information:
•RAPID Overview: An overview of the RAPID programming language.
•RAPID reference manual part 1: Description of all RAPID instructions.
•RAPID reference manual part 2: Description of all RAPID functions and data types.
•Technical reference manual - System parameters: Description of system
parameters and configuration workflows.
Application manualsSpecific applications (e.g. 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 (e.g. cables, I/O boards, RAPID instructions, system parameters)

Product documentation, M2004
93HAC023297-001 Revision: A
• How to use the application
• Examples of how to use the application
Operator’s manuals This group of manuals is aimed at those having first hand operational contact with the robot,
i.e. production cell operators, programmers and trouble shooters. The group of manuals
include:
•Operator’s manual - IRC5 with FlexPendant
•Operator’s manual - RobotStudioOnline
•Trouble shooting Manual for the controller and robot
Miscellaneous A number of manuals provide generic descriptions of the robot and robot system. These
include:
•Robot fundamentals (describing the fundamental aspects, functions, concept and
similar, of a robot system to provide a basic understanding of the robot system)

Product documentation, M2004
3HAC023297-001 Revision: A10

1 Reference information
1.1. Introduction
113HAC023297-001 Revision: A
1 Reference information
1.1. Introduction
General This chapter includes general information, complementing the more specific information in
the Product manual (part 1 of 2), procedures.

1 Reference information
1.2. Applicable Safety Standards
3HAC023297-001 Revision: A12
1.2. Applicable Safety Standards
Standards, general The robot is designed in accordance with the requirements of:
• EN ISO10218-1 : 2005, Robots for industrial environments - Safety requirements -
Part 1 Robot
• ANSI/RIA 15.06-1999
• ISO/DIS 11161, Industrial automation systems - safety of integrated manufacturing
systems - Basic requirements
• DIN 19258 - Interbus-S, International Standard
Standards, safety fence
The following standards are applicable to the safety fence surrounding the robot cell:
• ISO/DIS 11161, Industrial automation systems -safety of integrated manufacturing
systems - Basic requirements
• prEN 999:1995
Standards, robot cellThe following standards are applicable when the robot is part of a robot cell:
• IEN 294, Safety of machinery - Safety distance to prevent danger zones being reached
by the upper limbs.
• EN 349, Safety of machinery - Minimum gaps to avoid crushing of parts of the human
body.
• EN 811 Safety of machinery - Safety distance to prevent danger zones being reached
by the lower limbs.
• Pr EN 999 Safety of machinery - The positioning of protective equipment in respect
of approach speeds of the human body.
• EN 1088 Safety of machinery - Interlocking device associated with guards principles
for design and selection.

1 Reference information
1.3. Unit conversion
133HAC023297-001 Revision: A
1.3. Unit conversion
Converter table Use the table below to convert units used in this manual.
Quantity Units
Length 1 m 3.28 ft 39.37 in
Weight 1 kg 2.21 lb
Pressure 1 bar 100 kPa 14.5 psi
Force 1 N 0.738 lbf
Moment 1 Nm 0.738 lbf-tn
Volume 1 L 0.264 US gal

1 Reference information
1.4. Screw joints
3HAC023297-001 Revision: A14
1.4. Screw joints
General This section details how to tighten the various types of screw joints on the robot and the
controller.
The instructions and torque values are valid for screw joints comprised of metallic materials
and do not apply to soft or brittle materials.
UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It
features special surface treatment (Gleitmo as described below), and is extremely resistant to
fatigue.
Whenever used, this is specified in the instructions, and in such cases, no other type of
replacement screw is allowed! Using other types of screws will void any warranty and may
potentially cause serious damage or injury!
Gleitmo treated screws
Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.
Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After
this the screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should
be used.
Screws lubricated in other ways
Screws lubricated with Molycote 1000 should only be used when specified in the repair,
maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1. Apply lubricant to the screw thread.
2. Apply lubricant between the plain washer and screw head.
3. Tighten to the torque specified in section Tightening torque below. Screw dimensions
of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or
smaller may be tightened without a torque wrench if this is done by trained and
qualified personnel.
Tightening torque Before tightening any screw, note the following:
• Determine whether a standard tightening torque or special torque is to be applied. The
standard torques are specified in the tables below. Any special torques are specified in
the Repair, Maintenance or Installation procedure description. Any special torque
specified overrides the standard value.
•Usethecorrect tightening torque for each type of screw joint.
Lubricant Art. no.
Molycote 1000 (molybdenum disulphide grease) 1171 2016-618

1 Reference information
1.4. Screw joints
153HAC023297-001 Revision: A
• Only use correctly calibrated torque keys.
•Alwaystighten the joint by hand, and never use pneumatical tools.
•Usethecorrect tightening technique, i.e. do not jerk. Tighten the screw in a slow,
flowing motion.
• Maximum allowed total deviation from the specified value is 10%!
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with slotted or cross-recess head screws.
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with Allen head screws.
The table below specifies the recommended standard tightening torque for Molycote-
lubricated screws with Allen head screws.
Dimension Tightening torque (Nm)
Class 4.8, oil-lubricated
M2.5 0.25
M3 0.5
M4 1.2
M5 2.5
M6 5.0
Dimension
Tightening torque
(Nm)
Class 8.8, oil-
lubricated
Tightening torque
(Nm)
Class 10.9, oil-
lubricated
Tightening torque
(Nm)
Class 12.9, oil-
lubricated
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340
Dimension Tightening torque (Nm)
Class 10.9, Molycote-lubricated Tightening torque (Nm) Class 12.9, Molycote-lubricated
M8 28 34
M10 55 66
M12 96 115
M16 235 280

1 Reference information
1.4. Screw joints
3HAC023297-001 Revision: A16
The table below specifies the recommended standard tightening torque for water and air
connectors when one or both connectors are made of brass.
Dimension Tightening torque
Nm - Nominal Tightening torque Nm - Min. Tightening torque Nm - Max.
1/8 12 815
1/4 15 10 20
3/8 20 15 25
1/2 40 30 50
3/4 70 55 90

1 Reference information
1.5. Weight specifications
173HAC023297-001 Revision: A
1.5. Weight specifications
Definition In all repair and maintenance procedures, weights of the components handled are sometimes
specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.
To avoid injury, ABB recommends the use of lifting equipment when handling components
with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for
each manipulator model.
Example Below is an example of how a weight specification is presented:
CAUTION!
Caution!
The motor weighs 32 kg! All lifting equipment used must be sized accordingly!

1 Reference information
1.6. Document references
3HAC023297-001 Revision: A18
1.6. Document references
General The contents of this manual may include references to additional documentation necessary to
perform certain procedures. This section specifies the article numbers for the referenced
documentation.
Product specification, robot
The product specification includes generic technical data. The specification listed below is
the English version.
Product manuals, controller
The product manuals include information about installation and service activities. The table
below specifies the article numbers of the product manuals for all controller models. The part
number -001 is the English version.
Operators manual The operators manual contains instructions for daily operation of robot systems. The table
below specifies the article numbers of the operators manuals for different robot systems.
Calibration manuals
Document name Document ID
Product specification 3HAC 9041-1
Document name Document ID
Product manual, S4Cplus M2000 3HAC 021333-001
Product manual, S4Cplus M2000A 3HAC 021128-001
Product manual, IRC5 M2004 3HAC 021313-001
Document name Document ID Note
User’s guide (S4Cplus) 3HAC 7793-1 Contains instructions for daily operation
of S4Cplus based robot systems.
Operator’s manual (IRC5) 3HAC 16590-1
Document name Document ID Note
Calibration Pendulum
Instruction 3HAC 16578-1 EnclosedwiththeCalibrationPendulum Toolkit.
Instructions for Levelmeter
calibration (alternative
method)
3HAC 022907-001 Enclosed with the Levelmeter 2000.
CalibWare 2.0 Users Guide 3HAC 16090-1 Calibration tool for Absolute Accuracy
calibration.