Assembly Instruction IRB 840/A
Assembly Instruction IRB 840/A
Assembly Instruction IRB 840/A
Table of Contents
Sida
1 Introduction ..................................................................................................................... 3
1.1 General.................................................................................................................... 3
1.2 How to read the assembly instructions ................................................................... 3
1.3 Safety ...................................................................................................................... 4
1.4 Marking .................................................................................................................. 4
2 Preparations for assembly .............................................................................................. 5
2.1 Lifting instructions ................................................................................................. 5
2.2 Unloading and unpacking....................................................................................... 5
2.3 Delivery inspection................................................................................................. 6
2.4 Tools and measuring equipment ............................................................................. 6
2.5.1 Assembly tools............................................................................................. 6
2.6.2 Using the laser aligner.................................................................................. 7
2.7 Requirements for installation area.......................................................................... 7
3 Assembly .......................................................................................................................... 9
3.1 General.................................................................................................................... 9
3.2 Preparations for assembly work on the frame ........................................................ 9
3.3 Measuring up and inspecting the assembly area .................................................... 11
3.4 Assembling the frame............................................................................................. 13
3.4.1 Assembling and aligning frame legs............................................................ 13
3.4.2 Aligning the top brackets for the aluminium beams, axis 1......................... 15
3.5 Assembling axis 1................................................................................................... 17
3.6 Assembling axis 2................................................................................................... 19
3.7 Assembling axis 3................................................................................................... 22
3.8 Adjusting parallelity of aluminium beams, axis 2.................................................. 23
3.9 Assembling drive mechanism, axis 1 ..................................................................... 24
3.10 Connecting the cabling and hoses ........................................................................ 25
3.11 Adjusting parallelity of beams, axis 1 .................................................................. 30
4 Assembling the base frame and intermediate legs ....................................................... 35
4.1 General.................................................................................................................... 35
4.2 Measuring up and inspecting assembly area .......................................................... 35
4.3 Assembling the intermediate legs........................................................................... 36
4.4 Assembling axis 1................................................................................................... 39
4.5 Fitting drive belt on axis 1...................................................................................... 43
5 Assembly inspection ........................................................................................................ 47
5.1 Checks and measures before start-up ..................................................................... 47
5.2 Checks with the robot system started ..................................................................... 48
6 Supplementary documents
Parallell Adjustment Tool Axis 1, 3HAC 5931-1
Parallell Adjustment Tool Axis 2, 3HAC 5931-2
Lift Instruction, 3HAC 6692-1
1 Introduction
1.1 General
This manual contains information about unpacking, lifting, and final assembly of the
IRB 840/A. The manual is intended for assembly technicians with a good knowledge
of both mechanical and electrical systems. The manual is not a replacement for the
assembly training course that ABB Flexible Automation offers.
N.B. The warranty commitments of ABB Robotics AB only take effect when the
assembly leader has participated in the assembly training course.
N.B. The assembly is described in a number of basic steps. These should be seen
as requirements to ensure that the product requirements are achieved and that
ABB Robotics AB’s warranty commitments take effect.
All the users of this manual must also have access to the IRB 840/A Product Manual
in order to be able to interpret references in the assembly instructions.
See the spare parts list in the Product Manual for information about the position num-
bers in the figures.
A number of expressions are used in the assembly instructions to refer to the manipu-
lator movements and locations on the base frame, see Figure 1.
Axis 1 (X)
Axis 2 (Y)
Axis 3 (Z)
Axis 4
Reference leg (C)
Reference side
1.3 Safety
See Safety in the Product Manual.
1.4 Marking
See Introduction in the Product Manual.
- Case 1, axis 1, and the aluminium beams for axis 2. The aluminium beams are
at the top.
- Case 2, frame.
- Case 3, axis 3, and drive shafts and drive motor for axis 1.
- Case 4, control cabinet.
- The nuts, bolts, washers, etc. are located in the respective cases.
1 ,1 m C a se 1
11 m
2,35 m
C a se 2 C a se 3
Case 4
5,5 m 3 m
12 m
1) X & Y beam s
2) F ra m e
3) Z
4,5) C a b in e t 1 0 2 0 x 7 5 0
Figure 2 Plan view of packed container. The dimensions shown are approximate and depend on
the size of the manipulator.
To unload the container, attach a chain or lifting strap to the pallet under the case and
carefully pull it out of the container. The attachment points are clearly marked with red
paint. It may be possible to drive a fork-lift truck into the container and carefully pull
out the cases. The cases must be lifted in accordance with the instructions on the
respective case.
Check that all cables are hanging loose and that there is no damage to them.
Check on the series measurement box that no cables have been pulled out of their
screwed glands.
The following assembly tools should be used when assembling the IRB 840/A:
Assembly tools:
A laser aligner may be used only if the personnel concerned have received separate
training in its operation and maintenance. This is essential for the correct assembly of
the IRB 840/A and its quality requirements.
3 Assembly
3.1 General
The example below shows the assembly of an IRB 840/A robot with four frame legs.
When there are differences in the assembly because the manipulator has more than four
frame legs, a reference is made in the text to a section in Chapter 4, Assembling the
frame and intermediate legs.
For information about the position numbers in the figures, see the spare parts list
in the Product Manual.
- the footplates are adjusted to the specified basic dimension 60 mm and that
the nuts and washers are correctly fitted, see Figure 3.
Nut M24
Washer 25x44x4
40 mm 60 mm
- the top brackets for the aluminium beams of axis 1 are correctly fitted at right
angles to the frame, see Figure 4. They are torque-tighten later when the legs
are attached to the floor and the top brackets are laser aligned.
M10x40
Washer 10.5x20x2
Before attaching the frame legs to the floor, the following must be done:
- fit the cross-beams between the frame legs. Check that the frame legs are par-
allel before tightening the screws. Tighten to the torques shown in Figure 5.
- fit the cross-beam supports, see Figure 5. Tighten the screw joints but torque-
tighten them later when the legs are attached to the floor and aligned.
M10x40
Washer 10.5x20x2 Cross-beam
47 Nm
Cross-beam support
M16x110
Nut M16
Washer 17x30x3
1 Mark up the floor where the reference leg is to stand. See point 1 in Figure 6.
N.B. The position of the reference leg is very important because it determines the
position of the entire robot in the assembly room.
N.B. A laser aligner may be used only if the personnel concerned have received
separate training in its operation and maintenance. See also section 2.6.2.
2 Mark a straight line on the floor with the marker string in the direction of the
robot’s X axis. See point 2 in Figure 6.
3 Using the measuring tape on the marker string line, measure the distance to the
next frame leg. Mark the position of the leg on the floor. See point 3 in Figure 6.
4 Using the laser aligner, mark up a right angle in the direction of the robot’s Y axis,
starting at the position of the reference leg.
5 Mark a straight line on the floor with the marker string in the direction of the
robot’s Y axis. See point 4 in Figure 6.
6 Using the measuring tape on the marker string line, measure the distance to the
next frame leg. Mark the position of the leg on the floor. See point 5 in Figure 6.
7 Using the laser aligner, mark up a right angle in the direction of the robot’s X axis,
starting at point 5 in Figure 6.
8 Mark a straight line on the floor in the direction of the robot’s X axis. See point 6
in Figure 6.
9 Measure with the measuring tape, on the marker string line, the distance to the next
frame leg. Mark the position of the leg on the floor. See point 7 in Figure 6.
10 Mark a straight line on the floor in the direction of the robot’s Y axis. See point 8
in Figure 6.
11 Check that the angles at points 4 and 8 above are right angles and that the distances
4 and 8 in the figure are equal. See Figure 6.
If the frame has intermediate legs, see section 4.2 before implementing points 12
and 13 below.
12 Check the dimensions of the rectangle marked on the floor using the so-called “diag-
onal method”, i.e. measure the two diagonals from opposite corners and compare the
measurements. The deviation must not exceed 5 mm.
13 Using the laser aligner, check the points where the frame legs are to stand for any
differences in height level. If the deviation exceeds 2 mm, adjust the frame height to
the correct value by adjusting the footplates, see Figure 3.
N.B. It is extremely important that personnel handling the IRB 840/A are trained
in lifting and can manage the types of lifting required, which can be of a complex
nature.
1 Measure up the distances shown in Figure 7 and mark the floor with a pen.
225 mm
150 mm
Marks
Marks from
marker string
225 mm
150 mm
Reference leg
Marks
2 Lift the frame legs to their respective positions. Measure up the distances shown
in Figure 7. Use a rubber mallet and a steel square to position the frame legs cor-
rectly.
3 When the legs are correctly positioned, drill holes in the floor for the foot-plates.
4 Use four expander bolts per leg. Fit washers and nuts on all the bolts.
5 Undo all the locknuts for the footplates, 8 nuts per side with two frame legs with
cross-beams. See Figure 8.
6 Adjust the angle of each pair of legs with the adjuster nuts, see Figure 8, so that
they are vertical to the assembly floor in the x direction. Check the angle using a
plummet. The maximum allowable deviation from vertical is 2 mm on the total
length of the leg
N.B. Before tightening the locknuts, check that the leg is resting on all the adjuster
nuts for the leg in question.
Locknut 665 Nm
Adjuster nut
8 Tighten the screw joints for the cross-beam supports. See Figure 9.
Cross-beam
Cross-beam support
300 Nm
If the frame is equipped with intermediate legs, see section 4.3 about assembling
the intermediate legs.
3.4.2 Aligning the top brackets for the aluminium beams, axis 1
N.B. A laser aligner may be used only if the personnel concerned have received
separate training in its operation and maintenance. See also section 2.6.2.
1 Adjust one of the top brackets on the reference leg as shown in Figure 10. Check
with the spirit level that the top bracket is horizontal.
Use the top bracket on the reference leg as the reference height and adjust the height of
the other top brackets.
N.B. It is important that one of the top brackets on the reference leg is adjusted as
shown in Figure 10, otherwise the difference in height between the beam ends and
the gearbox will be too large when assembling the drive shafts for axis 1.
5 mm
3 Put the laser reference block on the adjusted top bracket on the reference leg.
Adjust the height of the laser aligner so the laser beam hits the centre of the refer-
ence block. Secure the laser aligner. See Figure 11.
Now the height of the laser aligner has been adjusted.
4 Put the laser aligner reference block on another top bracket and adjust the height.
Repeat for all the legs. See Figure 11. Check with the spirit level or laser aligner
that all the top brackets are horizontal.
However, one top bracket on every leg should not be adjusted with the laser aligner.
These brackets are tightened after the aluminium beams of axis 1 have been fitted.
Laser aligner’s
reference block
Top bracket on
aluminium beam
47 Nm
Laser aligner
5 Torque-tighten the screw joints of the adjusted top brackets as shown in Figure 11.
For an explanation about the reference leg and reference side, see Figure 1 sid 4. ???
N.B. It is extremely important that personnel handling the IRB 840/A are trained
in lifting and can manage the types of lifting required, which can be of a complex
nature.
If the frame is equipped with intermediate legs, see section 4.4 for assembly of
axis 1.
1 Check on the number and position of the T-slot nuts in the aluminium beams of
axis 1.
2 Lift up the first aluminium beam of axis 1 (beam with cabling) on to the reference
side of the frame.
3 Adjust the beams longitudinally so that the distance from the aluminium edge on
the beam to the edge of the top bracket is 10 mm, tolerance +/- 1 mm. The adjust-
ment is done on the ends of the beams above the reference leg. See Figure 12.
N.B. It is important that the distance from the aluminium edge on the beam to the
edge of the assembly flange is 10 mm +/- 1 mm, see Figure 12. Otherwise the angle
for the drive axes of axis 1, between the gearbox and the ends of the beam, will be
too large.
10 mm
Reference leg
4 Adjust the beams sideways so that the distance corresponds sideways to the dis-
tance between the edge of the frame and the aluminium beams, i.e. the aluminium
beams must be centred above the frame legs. See Figure 13.
Figure 13 Adjusting the aluminium beams sideways, axis 1; plan view of manipulator.
5 Push up the top brackets, one per leg, that were not aligned earlier with the laser
aligner, against the aluminium beam of axis 1. Tighten the brackets on the frame
legs to a torque of 47 Nm.
6 Attach the aluminium beams to all the top brackets on the frame legs.
Tighten to the torque shown in Figure 14.
7 Fit the aluminium beam’s supports. Tighten to the torque shown in Figure 14.
M10x25
Washer 10.5x20x2
Top brackets Support 47 Nm
M16x110
M10x25 Nut M16
Washer 10.5x20x2 Washer 17x30x3
Washer 300 Nm
47 Nm
Assemble and adjust the second beam for axis 1 in a similar way as above, but do not
tighten the screw joints that hold the top brackets to the beam. They should remain
loose, i.e. the beam should be left “floating” until the parallelity of the aluminium
beams for axis 1 is adjusted later.
N.B. It is extremely important that personnel handling the IRB 840/A are trained
in lifting and can manage the types of lifting required, which can be of a complex
nature.
1 Move the roller block plate for axis 1 to the reference side so that it is up against the
mechanical stop.
Measure the distance from the reference point to the roller block plate, see Figure
15.
2 Move the second roller block plate for axis 1 so it is up against the mechanical stop.
Measure the distance from the reference point to the roller block plate, see Figure
15. If the distance for both roller block plates is not the same, adjust the mechanical
stop.
Top bracket
used as a
reference point.
A-A
Roller block plate
Reference leg
Reference side
The distance between the reference point
and the roller block plate (± 1 mm) must be
the same on both sides when the roller block plates
are up against the mechanical stops.
Figure 15 Position of roller block plates when assembling axis 2; plan view of manipulator.
3 Lift up and position the first aluminium beam for axis 2 on the guide rail blocks of
axis 1.
Check the distance to the reference point as shown in Figure 15.
4 Mount the parallelity tool for axis 1, 3HAC 5931-1. See Figure 17, view A-A.
The parallelity tool is used to stiffen up axes 1 and 2 when adjusting the parallelity of
axis 1, see section 3.11.
6 Undo slightly the upper screwed joints of the angular brackets, i.e. those attached
to axis 2. See Figure 16, view B-B.
7 Adjust the distance on the reference side between the short end of axis 2 and axis 1
to 5-10 mm, see Figure 16. Tighten the upper screwed joints of the angular brackets
to the torque shown in view B-B in Figure 16.
8 Adjust the distance on the opposite side between the short end of axis 2 and axis 1
to 5-10 mm. Tighten the upper screwed joints of the angular brackets to the torque
shown in view B-B in Figure 16.
Upper screw
joint
78 47 Nm
Angular bracket
Lower screw
joint
89 47 Nm
A-A B-B
Adjust so the distance is 5-10 mm between
the short end of axis 2 and axis 1.
Axis 1
A
A
Axis 2
B
B
Axis 1
Axis 2
Position of parallelity
tool when both aluminium
beams of axis 2 are fitted
A
A
Assemble and adjust the second beam for axis 2 in a similar way as above, but do not
tighten the lower screw joints of the angular brackets, i.e. those that attach the roller
block plates to axis 1. They should remain loose, i.e. the beam should be left “floating”
until the parallelity of the aluminium beams for axis 2 is adjusted later when axis 3 is
assembled. See Figure 18.
“Floating”
Aluminium beam
Secured
is secured
Reference side
1 Check the distance of axis 2 from the reference point as shown in Figure 15.
2 Fit the outer nut-washers, see views A-A and B-B in Figure 19. Two per side, four
in total. Attach with two screwed joints, pos. 46, per nut-washer.
Tighten to a torque of 47 Nm.
3 Mount the parallelity tool for axis 2 on axis 3, see views C-C and D-D in Figure 19.
Two per side, four in total. The tool is replaced by nut-washers after the parallelity
of axis 2 has been adjusted. The ground braid must be removed in order to mount
the parallelity tool.
A-A
Axis 3
Nut-washer
Axis 2
B-B
C-C D-D
The assembly of axis 3 is finished when the parallelity of axis 2 has been adjusted.
1 Apply a 24 V power supply to release the brake on axis 2 drive motor, as described
in the instructions in the Product Manual, chapter Installation and commissioning.
Axis 2 (y movement) can now be moved manually. See Figure 20.
3 Move axis 2 (y movement) manually to the other mechanical stop. See Figure 20.
Tighten the lower screw joints of the angular brackets on to the “floating” beam,
see view B-B in Figure 16.
Reference leg
Reference side
4 Check that the movement of axis 2 (y movement) runs easily and smoothly and
that the distance of axis 2 to the reference point is as shown in Figure 15.
5 Remove the parallelity tool for axis 2 from axis 3 and replace with nut-washers.
Secure with two screw joints, pos. 46, per nut-washer. Replace the ground braid.
Tighten the screws to a torque of 47 Nm. See Figure 19.
6 Tighten the upper and lower screw joints on the angular brackets, axis 2, to the
torque shown in view B-B in Figure 16.
M6x25
Washer 6.4x11x1.6
Nut M6
10 Nm
Motor
M8x25
Washer
Gearbox 8.4x16x1.6 Holder
24 Nm Drop protection
4 Fit the tensioning elements on the shafts, from the gearbox and from the end
flanges of axis 1. See Figure 22.
5 Fit the tensioning elements and then the couplings on the ends of both drive shafts.
See Figure 22.
6 Lift the drive shafts into position between the tensioning elements on the shafts
from the gearbox and from the end flanges of axis 1. See Figure 22.
7 Check the locations of the tensioning elements/drive shafts. See Figure 22.
8 Torque-tighten all the screw joints of the tensioning elements except one in the drive
shaft between the “floating” beam of axis 1 and the drive motor. This is to allow the
parallelity of axis 1 to be adjusted later. See Figure 22. Tightening torque 17 Nm.
9 Fit the holder over the drive shaft on the drop protection. See Figure 21.
N.B. One tensioning element, between the “floating” aluminium beam axis 1 and
the drive motor, should not be tightened. This is to allow the parallelity of axis 1
to be adjusted later.
Drive shafts
Figure 22 Assembling the drive shafts, axis 1. Drive shaft on the left of the drive motor, axis 1.
2 Fit the hose connections and connect the hoses. See Figure 23.
Cylinder air
Opt. air
Custom air
Series measurement box
Figure 23 Series measurement box and hose connections fitted on the reference leg.
3 Connect the cables to the drive motor axis 1, see Figure 24. Run the cables between
the motor and the series measurement box through the drop protection and attach
them to the upper side of the cross-member with cable ties. See Figure 21.
R2.MP1
R3.FB1
N.B. It is very important that the cable chains do not scrape against the sides of
the cable chain trays. Check therefore that the upper clamp of the cable chain is
mounted vertically and correctly mounted sideways.
4 Fit the cable chain for axis 1 to axis 2. See view A-A in Figure 25.
Check that the upper clamp of the cable chain is mounted vertically and correctly
mounted sideways.
5 Connect the connectors and hose to axis 2. See views B-B and C-C in Figure 25.
6 Connect the connectors to the drive motor, axis 2. See view D-D in Figure 25.
R3.MP2-4 R.FB2-4
A-A B-B R2.CP/CS Cylinder air
Custom air Opt. air
C C
B B
D D
A A
7 Fit the attachment plate for the cable chain and the cabling on the table of axis 3.
See view A-A in Figure 26.
N.B. It is very important that the cable chains do not scrape against the sides of
the cable chain trays. Check therefore that the upper clamp of the cable chain is
mounted vertically and correctly mounted sideways.
8 Attach the cable chain for axis 2 to the attachment plate. See view A-A in Figure
26. Check that the upper clamp of the cable chain is mounted vertically and cor-
rectly mounted sideways.
9 Attach the cabling and hoses to the attachment plate. See view B-B in Figure 26.
10 Connect the cables to the drive motor, axis 3. See view D-D in Figure 26.
A-A
Connecting cabling to B-B R4.FB3-4 Opt. air
drive motor, axis 3. R3.CP/CS Custom air
R4.MP3-4
B
A
B C A
C
D
D
Start with axis 1 (x movement) up against the mechanical stops nearest to the drive
motor, axis 1. The “floating” aluminium beam is then adjusted to the correct sideways
position nearest to the drive motor, axis 1. If axis 1 is not hard up against the mechanical
stops, release the brake on axis 1 and move the axis manually up against the stops.
Instructions for releasing the brake can be found in the Product Manual chapter Instal-
lation and commissioning.
1 Check that the available adjusting range of the “floating” beam, axis 1, is not fully
utilised. It is important that there is adjusting allowance on both the right and left-
hand sides. See Figure 27. If there is no adjusting allowance in one direction, the
axis must be readjusted as described in section 3.8.
Secured by screws
“Floating” “Floating”
There must be
adjusting allowance
on the left and right
at all attachment
points for the
“floating” beam.
Reference side
is secured by screws.
2 Tighten the screw joints of the upper brackets and the supports of the “floating”
beam, closest to the drive motor axis 1, to a torque of 47 Nm. Axis 2 should be posi-
tioned above the top bracket or the support being tightened. See Figure 28.
3 Tighten the untightened screws in the tensioning element in the drive mechanism,
axis 1, to a torque of 17 Nm. See Figure 22.
4 Start the manipulator’s control cabinet. Using the joystick on the teach pendant,
move axis 1 (x movement) carefully forwards and backwards between the mechan-
ical stops a number of times. Finish by leaving axis 2 against the mechanical stop
on the far side.
5 Check the adjusting allowances as described in point 4 and Figure 27. Tighten the
screw joints of the top bracket and supports of the “floating” beam on the far side
to a torque of 47 Nm.
When tightening the screws, axis 2 should be located above the top bracket or sup-
port being tightened.
See Figure 28.
M10x25
Washer 10.5x20x2
Top brackets Support 47 Nm M16x110
Nut M16
M10x25 Washer 17x30x3
Washer 10.5x20x2 300 Nm
Washer
47 Nm
6 Undo slightly the screw joints of the tensioning elements in the driving mechanism
of axis 1. The purpose of this is to release any stresses that have arisen when
adjusting the parallelity of axis 1. Retighten the screw joints to a torque of 17 Nm.
See Figure 22.
The parallelity of axis 1 has now been adjusted. The tension in the drive belt of axis 1
will now be checked and adjusted if necessary.
N.B. When adjusting the alignment of the angles as shown in view A-A in Figure
29, the screws must be adjusted in pairs on the respective sides. If only one screw
at a time is adjusted, the box may become askew and the service life of the bear-
ings will be radically reduced.
7 Move axis 1 carefully forwards and backwards between the mechanical stops.
Check that the drive belts are positioned in the middle of the rollers when axis 1 is
moving. Adjust if necessary using the adjuster screws at the ends of the beam, axis
1. See Figure 29.
A-A B-B
Only adjusting of the angular alignment Adjusting the drive belt tension
8 After adjustment, remove the parallelity tool for axis 1 and replace by the break-
through protector. Tighten to the torque shown in Figure 30.
The break-through protector is fitted to prevent overloading the rubber elements in the
event of an emergency stop/abnormal loading.
90 20 Nm 90 47 Nm
85 Break-through
protector
Axis 1
Assembly of the manipulator has now been finished. Now carry out assembly inspec-
tion as described in chapter 5, Assembly Inspection.
4.1 General
The example below shows the assembly of an IRB 840/A robot with:
To assemble the manipulator with intermediate legs, first follow the instructions in
chapters 1, 2, and 3. When there are intermediate legs on the base frame, additional
instructions are needed and a reference is made to this chapter in which the detailed
instructions can be found.
For information about the position numbers in the figures, see the spare parts list in the
Product Manual for the 840A.
1 Then use a tape measure along the marks from the marker string, to measure up
the distances to the intermediate legs. Make a mark on the floor at the leg position.
Finish by inspecting the assembly area as described in points 12-13 in section 3.3.
N.B. A laser level may be used only if the personnel concerned have received sep-
arate training in its operation and maintenance. See also section 2.6.2.
1 Measure up the distances shown in Figure 32 and mark the floor with a pen.
225 mm
Marks
150 mm
Marks from
Position of axis 1 marker string
drive motor
225 mm
1 Reference leg
Marks
150 mm
2 Lift the intermediate legs into their respective positions. Measure up the distances
shown in Figure 32. Use a rubber mallet and a steel square to position the base
frame legs correctly.
3 When the intermediate legs are correctly positioned, drill holes in the floor for the
foot-plates.
4 Use four expander bolts per leg. Fit washers and nuts on all the bolts.
N.B. The foot-plate expander bolts must be tighetened with a torque in accord-
ance with the bolt manufacturer’s recommendations. When determining the
length and type of bolts, the thickness and nature of the concrete floor must be
taken into consideration.
For other information see the Product Specification in the Product Manual.
5 Undo all the locknuts for the foot-plates, see Figure 33 view A-A, four nuts per leg
in all.
6 Adjust the angle of the intermediate legs with the adjuster nut, see Figure 33 view
A-A, so that they are vertical to the assembly floor in the x direction. Check the
angle using a plummet. The maximum allowable deviation from vertical is 2 mm
on the entire length of the leg.
7 Adjust the intermediate leg in the y direction, using the adjuster nut, so that the
highest points of the base frame legs are in line with each other, see Figure 33. Use
the laser level for the alignment.
N.B. Before tightening the locknuts of an intermediate leg, check that the leg is
resting on all the adjuster nuts for the leg in question.
x direction
Locknut
y direction
665Nm
Adjuster nut
A
Position of
laser level
View A-A A Upper points of base frame legs
must be in line with each other
There is a support for each pair of intermediate legs. It can be fitted inwards or outwards.
See Installation and Commissioning in the Product Manual.
9 Fit the floor support in the intermediate legs. See Figure 34.
M16x110
Nut M16
Washer 17x30x3
300 Nm
Floor support
Intermediate leg
10 When the foot-plates are in position, drill the holes in the floor.
11 Use four expander bolts per leg. Fit washers and nuts on all the bolts.
N.B. The foot-plate expander bolts must be tighetened with a torque in accordance
with the bolt manufacturer’s recommendations. When determining the length and
type of bolts, the thickness and nature of the concrete floor must be taken into con-
sideration.
For other information see the Product Specification in the Product Manual.
13 Tighten the screw joints on the floor supports for the intermediate legs. Tightening
torque as shown in Figure 34.
See section 3.4.2 concerning Alignment of the upper attachment for axis 1 alumin-
ium beams.
The upper attachments of the base frame legs must be adjusted before axis 1 is fitted.
See section 3.4.2.
1 Lift up the first aluminium beam (beam with cabling) of axis 1 on to the reference
side of the base frame.
2 Adjust the beams longitudinally so that the distance from the aluminium edge on
the beam to the edge of the upper attachment is 10 mm, tolerance +/- 1 mm. The
beam is adjusted at its ends which are above the reference leg. See Figure 35.
N.B. It is important that the distance from the aluminium edge on the beam to the
edge of the assembly flange is 10 mm +/- 1 mm, see Figure 35. Otherwise the angle
for the drive axes of axis 1, between the gearbox and the ends of the beam, will be
too large.
3 Lift up the second part of the aluminium beam for axis 1 on to the reference side
of the base frame. Position it so that there is no space between the beams.
10 mm
Reference leg
4 Check the position of the aluminium beams on the reference leg. See Figure 35.
5 Adjust the beams sideways so that the distance corresponds sideways to the dis-
tance between the edge of the base frame and the aluminium beams, i.e. the alu-
minium beams must be centred above the base frame legs. See Figure 36.
Reference side
Reference leg
Figure 36 Adjusting the aluminium beams sideways, axis 1; plan view of the manipulator.
6 Screw the parts of the aluminium beams together using the joint plate, axis 1.
Tighten the screws to the torque specified in Figure 37.
N.B. Position the joint plate on the outside of the beams. If it is positioned on the
inside it will collide with axis 2.
3 4 47 Nm Joint plate
Normally the linear guide is attached with a screw in every second hole.
Exceptions to this are at the:
- beam joints, where 3-4 screws are used across the joint. See Figure 38.
- joint in the linear guide, where 4 screws are used above the joint.
See Figure 38.
- linear guide ends, where 2 screws are used. See Figure 38.
N.B. When making a joint on the linear guide, ensure that the mating ends of the
joint are surface ground.
7 Position the first linear guide against one of the edges and tighten the screws to a
torque of 24 Nm +/- 10%. The screws in the other linear guide should not be tight-
ened.
8 The joints in the linear guide are adjusted using the trolley plate. Position the trol-
ley plate over a joint and then tighten the screws in the second linear guide to a
torque of 24 Nm +/- 10%.
N.B. It is very important that the joints in the linear guides are correctly adjusted
otherwise noise will occur when the trolley plate moves across the joints.
Joint plate
End of linear guide
Figure 38 Attaching the linear guide to axis 1. Plan view of aluminium beam, axis 1.
9 Push up the upper attachments, that were not adjusted earlier using the laser level,
one upper attachment per leg, against the aluminium beam for axis 1. Screw them
to the frame legs and tighten to a torque of 47 Nm.
10 Screw the aluminium beam to all the assembly flanges on the frame legs and
tighten to the torques specified in Figure 39.
11 Fit the supports for the aluminium beams. Tighten to the torque specified in Figure
39.
M10x25
Washer 10.5x20x2
Upper attachment Support 47 Nm M16x110
Nut M16
M10x25 Washer 17x30x3
Washer 10.5x20x2 300 Nm
Washer
47 Nm
The second aluminium beam for axis 1 is assembled and adjusted in a similar way to
above. However, the screw joints between the beam and the upper attachments and the
beam and the supports should not be tightened. The beam should be left “floating” and
will be tightened later when the parallelity of the beams on axis 1 is adjusted.
2 Centre the belt in the beam and then fit the key. See Figure 40.
3 Check that the belt tensioning wheel is adjusted to its bottom position.
4 Measure and cut the belt so it can be attached to the other side of the trolley plate.
Mesh the belt with the teeth on the clamping plate. See Figure 40.
5 Centre the belt in the beam and then fit the key. See Figure 40.
14 7
Key
Drive belt
Clamping plate
Trolley plate
6 Draw a line across the aluminium beam and the drive belt. See Figure 41.
7 Pre-tension the drive belt using the tensioning screws at the end of the beam, two
turns at a time (one screw at a time), until the belt just begins to move. See Figure
41. Check that the tensioning wheel is tightened straight.
8 The drive belt is then further tensioned a certain number of turns on the tensioning
screws as shown in Figure 42, depending on the working area of axis 1, specified
in metres.
Finish tensioning by finely adjusting the screws one quarter of a turn at a time.
Mark
Beam
Drive belt
A-A
Pre-tensioning
of drive belt
A
A
Figure 41 Pre-tensioning the drive belt, axis 1. Plan view of axis 1.
N o . o f te n s io n in g tu rn s fo r d riv e b e lt (Ax is 1 )
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
1
L e n g th o f m o v em e n t (m )
Figure 42 Number of tensioning turns on tensioning screws for drive belt, axis 1.
The drive belt for axis 1 is now assembled. For fine adjustment see section 3.8.
5 Assembly inspection
Logbook Not
OK checked
Create a logbook. The logbook should be used each time that the
robot behaves abnormally or when a planned activity is implemented
on the robot. Suggestions for suitable logbook pages can be found at
the end of this chapter. This chapter should also be included in the
logbook.
Check the ground cable route before start-up. The resistance must be
<0.1 Ohm from any random point on the manipulator to the ground
cable (yellow/green) where it exits from the underneath the series
measurement box.
Check that the ground braids between axes 1 and 2 and axes 2 and 3
are correctly fitted. Check the ground connection between the
ground cable (yellow/green), where it exits underneath the series
measurement box, and the following points. See also Figure 43.
4 Z table.
8 Axis 4, turntable.
5 1
7 3
4 2
Check that all the automatic lubrication cartridges (nine) are acti-
vated as described in the chapter Maintenance in the Product Manual.
WARNING! Be very careful when releasing the brakes! Axis 3 can start to move
very quickly indeed, resulting in a risk of personal injury.
Before testing axis 3, check that the air pressure is connected and that
the pressure is adjusted to balance the load, see the Product Specifi-
cation in the Product Manual. Jog axis 3 to a position in the middle
of its work range. Press the brake release button for axis 3, in the
series measurement box, very briefly and note whether axis 3 moves
(if the balancing is correct, it should not move).
If the load moves but stops immediately the button is released, the
brake is OK but the balancing is not optimal. The brake can manage
the max. load without balancing, but the stopping distance is longer.
Press the brake release button for the axis in question. Listen for a
clicking sound in the motor. Let another person move the axis in
question. Release the brake release button when the axis moves and
verify that the axis in question stops immediately. Not
OK changed
- axis 1
- axis 2
- axis 4
Check that the drive belts for axes 1 and 2 lie in the neutral position
between the side guides, or alternatively move between the side
guides on the drive wheels and turn wheels when the robot is run
with the application program. When in operation, the belts must not
press at any time against the side guides (guide flange on the drive
wheels and turn wheels). This must be carefully checked over the
whole working range.
Axis 1
Check that the sync signs are fitted on both of the aluminium beams
belonging to axis 1 and that the manipulator is positioned there when
synchronising.
Check that the distance between the mechanical stops for axis 1 have
the same distance to axis 2, when it is positioned as close to them as
possible. If this is not the case, the mechanical stops must be adjusted
as described in section 3.6.
Axis 2
Check that the sync signs are fitted on both aluminium beams
belonging to axis 2 and that the manipulator is positioned there when
synchronising.
Axis 3 Not
OK changed
Check that the sync signs are fitted and that the manipulator is posi-
tioned there when synchronising.
Axis 1
Check that the cable chain is in the middle of the guide during the
whole of the stroke. It is important that the chain is not pressed
against the side of the guide.
Check that all the cables lie loose in the cable chain and that none of
them have been squeezed in between the intermediate walls of the
chain. Check that the cables do not run in zigzag through the cable
chain, i.e. the cables should lie in the same lateral position all through
the cable chain.
Check that when the cable chain glides on itself, the contact surfaces
are the side plates of the chain, i.e. that the links are centred on top of
each other.
Check that the cables, hoses, and the cable chain itself, show no signs
of any external physical damage after the transport and assembly on
site.
Check that the air hose can move >50 mm in and out at the lower end
of the chain, i.e. do not tie the air hose to the cable chain. (Variations
in air can cause movement in the hose).
Axis 2
Check that the cable chain is in the middle of the guide during the
whole of the stroke. It is important that the chain is not pressed
against the side of the guide.
Check that all the cables lie loose in the cable chain and that none of
them have been squeezed in between the intermediate walls of the
chain. Check that the cables do not run in zigzag through the cable
chain, i.e. the cables should lie in the same lateral position all through
the cable chain.
Check that when the cable chain glides on itself, the contact surfaces
are the side plates of the chain, i.e. that the links are centred on top of
each other.
Check that the cables, hoses, and the cable chain itself, show no signs
of any external physical damage after the transport and assembly on
site.
Axis 3
Check that the cable chain is in the middle of the guide during the
whole of the stroke. It is important that the chain is not pressed
against the side of the guide.
Check that all the cables lie loose in the cable chain and that none of
them have been squeezed in between the intermediate walls of the
chain. Check that the cables do not run in zigzag through the cable
chain, i.e. the cables should lie in the same lateral position all
through the cable chain.
Check that when the cable chain glides on itself, the contact surfaces
are the side plates of the chain, i.e. that the links are centred on top
of each other.
Check that the cables, hoses, and the cable chain itself, show no signs
of any external physical damage after the transport and assembly on
site.
Check that the air hose can move >50 mm in and out at the lower end
of the chain, i.e. do not tie the air hose to the cable chain. (Variations
in air can cause movement in the hose).
Suspicious sounds
Jog the axes one after another and listen for any abnormal sounds in
the motors, gearboxes, and transmission. If it is possible, increase the
load on the robot successively to 100% load and listen for abnormal
sounds.
- axis 1
- axis 2
- axis 3
- axis 4
(Name)
(Function)
(Company)
(Tel.)