abb robotics product manual...

ABB Robotics

Product manualFlexGun

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

Product manual

FlexGun

Document ID: 3HAW050009061

Revision: F

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

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.

© Copyright 2013 ABB All rights reserved.

ABB Engineering (Shanghai) LtdN°5, Lane 369, Chuangye Rd,

Kangqiao Town, Nanhui District,Shanghai 201319; P.R. China

©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

0.0.1 Overview of this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70.0.2 Product documentation, M2004. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.0.3 How to read the product manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1 Safety 13

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141.2.1 Safety in the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.3 Safety risks related to the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151.3.1 Safety risks during installation and service work on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151.3.2 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171.3.3 Safety risks related to pneumatic/hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181.3.4 Safety risks during operational disturbances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191.3.5 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.4 Safety actions related to the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211.4.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211.4.2 Fire extinguishing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221.4.3 Emergency release of the robots/manipulators axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231.4.4 Brake testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241.4.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251.4.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261.4.7 Work inside the manipulator's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271.4.8 Translate the information on safety and information labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.5 Safety stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291.5.1 What is an emergency stop? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.6 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311.6.1 Safety signals in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311.6.2 Safety risks related to spot welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331.6.3 Personnel safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2 Product description 35

2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352.2 Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.3 Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382.3.1 Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382.3.2 Detailed views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3 Standard and customized offers 43

3.1 Offers overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3.2 Standard offer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443.2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443.2.2 X-gun standard offer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453.2.3 C-gun standard offer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473.2.4 Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503.2.5 Robot interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

3.3 Customized offer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523.3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523.3.2 Maximum force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533.3.3 Copper arm interface design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543.3.4 Arm holder design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

33HAW050009061 Revision: F

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

4 Technical details and requirements 57

4.1 Servo motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574.1.1 Servo motor type 9C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574.1.2 Servo motor type T. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4.2 Centre of gravity and moment of inertia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604.2.1 Gun body with AC transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604.2.2 Gun body with MFDC transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

4.3 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624.4 Water cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 654.5 Temperature and hygrometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4.6 Robot and robot controller requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 684.6.1 Gun used on a robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 684.6.2 Stationary gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714.6.3 Software requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

5 Unpacking and handling 73

5.1 Pre-requisites for reception . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735.2 Unpacking and acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745.3 Lifting weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 755.4 Handling/lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

6 Installation and commissioning 78

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

6.2 Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 796.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 796.2.2 Attachement - FlexGun side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806.2.3 Attachement - robot side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

6.3 Connection to the dresspack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 886.3.1 Principle and pre-requisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 886.3.2 Orientation of the DressPack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 896.3.3 MC plug details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906.3.4 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

6.4 Controllers settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 926.4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 926.4.2 Motion Control file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 936.4.3 System file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 976.4.4 Loading the files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

6.5 Position calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1016.6 Force calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

6.7 Communication between the controller and the Bosch Timer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1056.7.1 Download the IRC5 I/O settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1056.7.2 Bosch Timer Unit settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1066.7.3 Install the BOS6000 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1066.7.4 Connect to the Spot welding cabinet through Serial Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1076.7.5 Check signals from IRC5 to timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1086.7.6 Quick start to welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

7 Maintenance 113

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1137.2 Maintenance planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

7.3 Maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1157.3.1 General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

3HAW050009061 Revision: F 4

©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

7.3.2 Timing belt (tension check, adjustment and replacement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1167.3.3 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1197.3.4 Manual jogging of the mobile carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

7.4 Trouble shooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

8 Repair activities 123

8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

8.2 Dismounting of the arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1248.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1248.2.2 Removal of the fixed arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1258.2.3 Re-assembly of the fixed arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1268.2.4 Removal of the mobile arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1278.2.5 Re-assembly of the mobile arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

8.3 Replacement of the pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1298.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1298.3.2 Pulley replacement procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

8.4 Replacement of the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1328.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1328.4.2 Motor replacement procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

8.5 Replacement of the transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1348.5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1348.5.2 Transformer replacement procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

8.6 Replacement of the roller screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1378.6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1378.6.2 Roller screw replacement procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

9 Decommissioning 143

9.1 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

10 Reference information 145

10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14510.2 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14610.3 Bolt, screws, tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14710.4 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14910.5 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

11 Spare parts 151

11.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15111.2 Motor and linear guiding material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15211.3 Welding power, conductive parts, and harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

11.4 Arms spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15811.4.1 Copper arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15811.4.2 Aluminium arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15911.4.3 Standard tips, electrode clamps and O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

11.5 Robot attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16111.6 Water cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16211.7 Casing and lubrication ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

12 Appendix 167

12.1 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167



© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

0.0.1. Overview of this manual

About this manual

This manual contains instructions for:

• the characteristics of the FlexGun

• mechanical and electrical installation instructions for the FlexGun

• maintenance instructions for the FlexGun

• spare parts

Usage

This manual should be used when working 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.

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 Content

Safety Safety information that must be read through before performing any installation or service work on the FlexGun. Contains general safety aspects as well as more specific information about how to avoid personal injuries and damage to the product.

Description and technical details

Specifications and characteristics of the FlexGun.

Unpacking, acceptance and handling

Information relative to the steps following the reception of the FlexGun, until its installation.

Maintenance Step-by-step procedures that describe how to perform maintenance of the FlexGun. Based on a maintenance schedule that may be used in the work of planning periodical maintenance.

Spare parts List of the spare parts available for the FlexGun.


© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

References

Revisions

Reference (ABB manuals) Document ID

Product manual - IRC5 Robot Controller 3HAC021313-001

Product manual - IRB6640 3HAC026876-001

Product manual - IRB7600 3HAC022033-001

Product manual - DressPack/SpotPack 3HAC025058-001

Service Information System - IRC5 3HAC025709-001

Application manual - Additional axes and stand alone controller 3HAC021395-001

Application manual - Servo-Gun tuning 3HAC026820-001

Application manual - Spot options 3HAC024762-001

Application manual - Mechanical Unit Manager 3HAC028797-001

Operating manual - IRC5 with FlexPendant 3HAC16590-1

System Parameters 3HAC17076-1

Operating manual - Calibration Pendulum 3HAC16578-1

Technical reference manual - RAPID Instructions, Functions, Data types

3HAC16581-1

Reference (Other manuals) Document ID

Timer and I/O Level - Technical Information Bosch Rexroth 1070 087 003-101

PST 6000.XXX Thyristor Power Unit with integrated control function - Technical Information

Bosch Rexroth 1070 080 058-101

Rexroth PSI 6xxx Medium-Frequency Inverter -Technical Information

Bosch Rexroth 1070080059

Rexroth BOS 6000 - User manual Bosch Rexroth 1070087074

PSI 6000 Medium-Frequency Inverters with integrated control function - Technical Information

Bosch Rexroth 1070 080 059-101

PST 6101.321 / PSI 6101.321- Technical Information Bosch Rexroth 1070 080 056-101

Revision Description

E First major revision

F • FlexGun offer for LeanID DressPack including new spare parts

• Arm holders detailed configurations

• Robot attachment detailed configurations

• New wiring diagrams in appendix

• Spare parts addition: water manifold type 1-1 and inverted mobile arm buss bar


©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

0.0.2. Product documentation, M2004

Categories for manipulator documentation

The manipulator documentation is divided into a number of categories. This listing is based

on the type of information in the documents, regardless of whether the products are standard

or optional.

All documents listed can be ordered from ABB on a DVD. The documents listed are valid for

M2004 manipulator systems.

Product manuals

All hardware, manipulators and controllers will be delivered with a Product manual that

contains:

• Safety information.

• Installation and commissioning (descriptions of mechanical installation, electrical

connections).

• Maintenance (descriptions of all required preventive maintenance procedures

including intervals).

• Repair (descriptions of all recommended repair procedures including spare parts).

• Additional procedures, if any (calibration, decommissioning).

• Reference information (article numbers for documentation referred to in Product

manual, procedures, lists of tools, safety standards).

• Parts list.

• Foldouts or exploded views.

• Circuit diagrams (or references to circuit diagrams).

Technical reference manuals

The technical reference manuals describe the manipulator software in general and contain

relevant reference information.

• RAPID Overview: An overview of the RAPID programming language.

• RAPID Instructions, Functions and Data types: Description and syntax for all

RAPID instructions, functions, and data types.

• RAPID Kernel: A formal description of the RAPID programming language.

• System parameters: Description of system parameters and configuration workflows.

Application manuals

Specific applications (for example software or hardware options) are described in

Application manuals. An application manual can describe one or several applications.

An application manual generally contains information about:

• The purpose of the application (what it does and when it is useful).

• What is included (for example cables, I/O boards, RAPID instructions, system

parameters, CD with PC software).

• How to use the application.

• Examples of how to use the application.


© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

Operating manuals

The operating manuals describe hands-on handling of the products. The manuals are aimed

at those having first-hand operational contact with the product, that is production cell

operators, programmers, and trouble shooters.

The group of manuals includes:

• Emergency safety information

• General safety information

• Getting started, IRC5 and RobotStudio

• IRC5 with FlexPendant

• RobotStudio

• Introduction to RAPID

• Trouble shooting, for the controller and manipulator.


©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

0.0.3. How to read the product manual

Reading the procedures

The procedures contain references to figures, tools, material etc. The references are read as

described below.

References to figures

The procedures often include references to components or attachment points located on the

robot/controller. The components or attachment points are marked with italic text in the

procedures and completed with a reference to the figure where the current component or

attachment point is shown.

The denomination in the procedure for the component or attachment point corresponds to the

denomination in the referenced figure.

The table below shows an example of a reference to a figure from a step in a procedure.

Reference to required equipment

The 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, i.e. article number, dimension.

The denomination in the procedure for the component or attachment point corresponds to the

denomination in the referenced list.

The table below shows an example of a reference to a list of required equipment, from a step

in a procedure.

Safety information

The manual includes a separate safety chapter that must be read through before proceeding

with any service or installation procedures. All procedures also include specific safety

information when dangerous steps are to be performed.

Read more in Safety on page 13.

Action Note/Illustration

8. Remove the rear attachment screws, gearbox.

Shown in the figure Location of gearbox on page xx.

Action Note/Illustration

3. Fit a new sealing, axis 2 to the gearbox. Art. no. is specified in Required equipment on page xx.


© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.


1 Safety

1.1. Introduction©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

1 Safety

1.1. Introduction

Overview

The safety information in this manual is divided in two categories:

• general safety aspects, important to attend to before performing any service work on

the robot. These are applicable for all service work and are found in General safety

information on page 14.

• specific safety information, pointed out in the procedure at the moment of the danger.

How to avoid and eliminate the danger is either detailed directly in the procedure, or

further detailed in separate instructions, found in Safety related instructions on page

31.


1 Safety

1.2.1. Safety in the robot system

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

1.2 General safety information

1.2.1. Safety in the robot system

Validity and responsibility

The information does not cover how to design, install and operate a complete system, nor

does it cover all peripheral equipment, which can influence the safety of the total system. To

protect personnel, the complete system must be designed and installed in accordance with the

safety requirements set forth in the standards and regulations of the country where the robot

is installed.

The users of ABB industrial robots are responsible for ensuring that the applicable safety laws

and regulations in the country concerned are observed and that the safety devices necessary

to protect people working with the robot system are designed and installed correctly.

Personnel working with robots must be familiar with the operation and handling of the

industrial robot, described in the applicable documents, e.g. User's Guide and Product

Manual.

Connection of external safety devices

Apart from the built-in safety functions, the robot is also supplied with an interface for the

connection of external safety devices. Via this interface, an external safety function can

interact with other machines and peripheral equipment. This means that control signals can

act on safety signals received from the peripheral equipment as well as from the robot.

Limitation of liability

Any information given in this manual regarding safety, must not be construed as a warranty

by ABB that the industrial robot will not cause injury or damage even if all safety instructions

are complied with.

Related information

Type of information Detailed in document Section

Installation of safety devices Product manual for the robot Installation and commissioning

Changing robot modes Operators manual (RobotWare 5.0)

Operating modes

Restricting the working space Product manual for the robot Installation and commissioning


1 Safety

1.3.1. Safety risks during installation and service work on robot©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

1.3 Safety risks related to the robot

1.3.1. Safety risks during installation and service work on robot

Overview

This section includes information of general safety risks to be considered when performing

installation and service work on the robot.

General risks during installation and service

• The instructions in the Product Manual - Installation and Commissioning must always

be followed.

• Emergency stop buttons must be positioned in easily accessible places so that the robot

can be stopped quickly.

• Those in charge of operations must make sure that safety instructions are available for

the installation in question.

• Those who install the robot must have the appropriate training for the robot system in

question and in any safety matters associated with it.

Nation/region specific regulations

To prevent injuries and damage during the installation of the robot system, the regulations

applicable in the country concerned and the instructions of ABB Robotics must be complied

with.

Non-voltage related risks

• Safety zones, which have to be crossed before admittance, must be set up in front of

the robot's working space. Light beams or sensitive mats are suitable devices.

• Turntables or the like should be used to keep the operator out of the robot's working

space.

• The axes are affected by the force of gravity when the brakes are released. In addition

to the risk of being hit by moving robot parts, you run the risk of being crushed by the

parallel arm.

• Energy, stored in the robot for the purpose of counterbalancing certain axes, may be

released if the robot, or parts thereof, are dismantled.

• When dismantling/assembling mechanical units, watch out for falling objects.

• Be aware of stored heat energy in the controller.

• Never use the robot as a ladder, i.e. do not climb on the robot motors or other part

during service work. There is a serious risk of slipping because of the high temperature

of the motors or oil spills that can occur on the robot.

To be observed by the supplier of the complete system

• The supplier of the complete system must ensure that all circuits used in the safety

function are interlocked in accordance with the applicable standards for that function.

• The supplier of the complete system must ensure that all circuits used in the

emergency stop function are interlocked in a safe manner, in accordance with the

applicable standards for the emergency stop function.


1 Safety

1.3.1. Safety risks during installation and service work on robot

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

Complete robot

Cabling

Gearboxes and motors

Safety risk Description

Hot components!

Removed parts may result in collapse of robot!

Caution signal

Caution!

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

Warning signal

Warning!

Take any necessary measures to ensure that the robot does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.


Cable packs are sensitive to mechanical damage!

Caution signal

Caution!

The cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them!


Gears may be damaged if excessive force is used!

Caution signal

Caution!

Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used!


1 Safety

1.3.2. Safety risks related to tools/workpieces©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

1.3.2. Safety risks related to tools/workpieces

Safe handling

It must be possible to safely turn off tools, such as milling cutters, etc. Make sure that guards

remain closed until the cutters stop rotating.

It should be possible to release parts by manual operation (valves).

Safe design

Grippers/end effectors must be designed so that they retain workpieces in the event of a power

failure or a disturbance of the controller.

CAUTION!

Ensure that a gripper is prevented from dropping a workpiece, if such is used.


1 Safety

1.3.3. Safety risks related to pneumatic/hydraulic systems

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

1.3.3. Safety risks related to pneumatic/hydraulic systems

General

Special safety regulations apply to pneumatic and hydraulic systems.

Residual energy

• Residual energy may be present in these systems. After shutdown, particular care must

be taken.

• The pressure in pneumatic and hydraulic systems must be released before starting to

repair them.

Safe design

• Gravity may cause any parts or objects held by these systems to drop.

• Dump valves should be used in case of emergency.

• Shot bolts should be used to prevent tools, etc., from falling due to gravity.


1 Safety

1.3.4. Safety risks during operational disturbances©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

1.3.4. Safety risks during operational disturbances

General

• The industrial robot is a flexible tool which can be used in many different industrial

applications.

• All work must be carried out professionally and in accordance with the applicable

safety regulations.

• Care must be taken at all times.

Qualified personnel

• Corrective maintenance must only be carried out by qualified personnel who are

familiar with the entire installation as well as the special risks associated with its

different parts.

Extraordinary risks

If the working process is interrupted, extra care must be taken due to risks other than those

associated with regular operation. Such an interruption may have to be rectified manually.


1 Safety

1.3.5. Risks associated with live electric parts

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

1.3.5. Risks associated with live electric parts

Voltage related risks, general

• Although troubleshooting may, on occasion, have to be carried out while the power

supply is turned on, the robot must be turned off (by setting the mains switch to OFF)

when repairing faults, disconnecting electric leads and disconnecting or connecting

units.

• The mains supply to the robot must be connected in such a way that it can be turned

off outside the robot's working space.

Voltage related risks, controller IRC5

A danger of high voltage is associated with the following parts:

• Be aware of stored electrical energy (DC link, Ultra Cap unit) in the controller.

• Units inside the controller, e.g. I/O modules, can be supplied with power from an

external source.

• The mains supply/mains switch

• The transformers

• The power unit

• The control power supply (230 VAC)

• The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)

• The drive unit (700 VDC)

• The drive system power supply (230 VAC)

• The service outlets (115/230 VAC)

• The customer power supply (230 VAC)

• The power supply unit for tools, or special power supply units for the machining

process.

• The external voltage connected to the control cabinet remains live even when the robot

is disconnected from the mains.

• Additional connections.

Voltage related risks, robot

A danger of high voltage is associated with the robot in:

• The power supply for the motors (up to 800 VDC).

• The user connections for tools or other parts of the installation (max. 230 VAC, see

chapter Installation and commissioning in the Product manual).

Voltage related risks, tools, material handling devices, etc.

Tools, material handling devices, etc., may be live even if the robot system is in the OFF

position. Power supply cables which are in motion during the working process may be

damaged.


1 Safety

1.4.1. Safety fence dimensions©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

1.4 Safety actions related to the robot

1.4.1. Safety fence dimensions

General

Install a safety cell around the robot to ensure safe robot installation and operation.

Dimensioning

Dimension the fence or enclosure to enable it to withstand the force created if the load being

handled by the robot is dropped or released at maximum speed. Determine the maximum

speed from the maximum velocities of the robot axes and from the position at which the robot

is working in the work cell (see Product Specification - Description, Robot Motion).

Also consider the maximum possible impact caused by a breaking or malfunctioning rotating

tool or other device fitted to the manipulator.


1 Safety

1.4.2. Fire extinguishing

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

1.4.2. Fire extinguishing

NOTE!

Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot (manipulator

or controller)!


1 Safety

1.4.3. Emergency release of the robots/manipulators axes©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

1.4.3. Emergency release of the robots/manipulators axes

Description

In an emergency situation, any of the robot's/manipulators axes may be released manually by

pushing the brake release buttons on the robot.

How to release the brakes is detailed in the robot product manual.

• The robot arm may be moved manually on smaller robot models, but larger models

may require using an overhead crane or similar.

Increased injury

Before releasing the brakes, make sure that the weight of the arms does not increase the

pressure on the trapped person, further increasing any injury!


1 Safety

1.4.4. Brake testing

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

1.4.4. Brake testing

When to test

During operation the holding brakes of each axis motor wear normally. A test may be per-

formed to determine whether the brake can still perform its function.

How to test

The function of each axis' motor holding brakes may be checked as detailed below:

1. Run each manipulator axis to a position where the combined weight of the

manipulator arm and any load is maximized (max. static load).

2. Switch the motor to the MOTORS OFF position with the Operating mode selector on

the controller.

3. Check that the axis maintains its position.

If the manipulator does not change position as the motors are switched off, then the brake

function is adequate.


1 Safety

1.4.5. Risk of disabling function "Reduced speed 250 mm/s"©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

1.4.5. Risk of disabling function "Reduced speed 250 mm/s"

NOTE!

Do not change Transm. gear ratio or other kinematic parameters from the Teach Pendant Unit

or a PC. This will affect the safety function Reduced speed 250 mm/s.


1 Safety

1.4.6. Safe use of the Teach Pendant Unit

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

1.4.6. Safe use of the Teach Pendant Unit

NOTE!

The enabling device is a push button located on the side of the Teach Pendant Unit (TPU)

which, when pressed halfway in, takes the system to MOTORS ON. When the enabling

device is released or pushed all the way in, the robot is taken to the MOTORS OFF state. To

ensure safe use of the Teach Pendant Unit, the following must be implemented:

• The enabling device must never be rendered inoperative in any way.

• During programming and testing, the enabling device must be released as soon as

there is no need for the robot to move.

• The programmer must always bring the Teach Pendant Unit with him/her, when

entering the robot's working space. This is to prevent anyone else taking control of the

robot without the programmer knowing.


1 Safety

1.4.7. Work inside the manipulator's working range©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

1.4.7. Work inside the manipulator's working range

WARNING!

If work must be carried out within the robot's work envelope, the following points must be

observed:

• The operating mode selector on the controller must be in the manual mode position to

render the enabling device operative and to block operation from a computer link or

remote control panel.

• The robot's speed is limited to max. 250 mm/s when the operating mode selector is in

position < 250 mm/s. This should be the normal position when entering the working

space. The position 100% "full speed" may only be used by trained personnel who are

aware of the risks that this entails.

• Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in

order not to get entangled with hair or clothing. Also be aware of any danger that may

be caused by rotating tools or other devices mounted on the manipulator or inside the

cell.


1 Safety

1.4.8. Translate the information on safety and information labels

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

1.4.8. Translate the information on safety and information labels

Labels on the product

Both the manipulator and the controller are marked with several safety and information

labels, containing important information about the product. The information is useful for all

personnel handling the robot system, e.g. during installation, service or operation.

Translation possibilities

The labels fitted to the product contain space for adding a fourth language underneath the

three standard languages (English, German and French).

Add a local language to the label by:

• using a transparent sticker over the standard label with text added in a fourth language.

Drawings detailing the design (text, figure, dimensions) of the standard labels can be

ordered from ABB. Notice that each label is identified according to the article number

located in the lower corner of the label.

Example of transparent sticker

The figure below shows the location of the free space on one of the labels on the robot, where

the fourth language can be added. The figure also shows a transparent sticker, containing the

text in Swedish.

xx0500002517

A Free space for adding a fourth language


1 Safety

1.5.1. What is an emergency stop?©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

1.5 Safety stops

1.5.1. What is an emergency stop?

Definition of emergency stop

An emergency stop is a state that overrides any other manipulator control, disconnects drivepower from the manipulator motors, stops all moving parts, and disconnects power from any

potentially dangerous functions controlled by the manipulator system.

An emergency stop state means that all power is disconnected from the manipulator except

for the manual brake release circuits. You must perform a recovery procedure, i.e, resetting

the emergency stop button and pressing the Motors On button, in order to return to normal

operation.

The manipulator system can be configured so that the emergency stop results in either:

• An uncontrolled stop, immediately stopping the manipulator actions by disconnecting

power from the motors.

• A controlled stop, stopping the manipulator actions with power available to the motors

so that the manipulator path can be maintained. When completed, power is

disconnected.

The default setting is uncontrolled stop. However, controlled stops are preferred since they

minimize extra, unnecessary wear on the manipulator and the actions needed to return the

manipulator system back to production. Please consult your plant or cell documentation to

see how your manipulator system is configured.

NOTE!

The emergency stop function may only be used for the purpose and under the conditions for

which it is intended.

NOTE!

The emergency stop function is intended for immediately stopping equipment in the event of

an emergency.

NOTE!

Emergency stop should not be used for normal program stops as this causes extra,

unnecessary wear on the manipulator.

Classification of stops

The safety standards that regulates automation and manipulator equipment defines categories

in which each type of stop applies:

If the stop is... ... then it is classified as...

uncontrolled category 0 (zero)

controlled category 1


1 Safety

1.5.1. What is an emergency stop?

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

Emergency stop devices

In a manipulator system there are several emergency stop devices that can be operated in

order to achieve an emergency stop. There are emergency stop buttons available on the Flex-

Pendant and on the controller cabinet (on the Control Module on a Dual Cabinet

Controller).There can also be other types of emergency stops on your manipulator, consult

your plant or cell documentation to see how your manipulator system is configured.


1 Safety

1.6.1. Safety signals in the manual©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

1.6 Safety related instructions

1.6.1. Safety signals in the manual

Introduction to safety signals

This section specifies all dangers that may arise from performing the work detailed in themanual. Each danger is detailed in its own section consisting of:

• A caption specifying the danger level (DANGER, WARNING or CAUTION) and the

type of danger.

• A brief description of what will happen if the operator/service personnel do not

eliminate the danger.

• An instruction of how to eliminate the danger to facilitate performing the activity at

hand.

Danger levels

The table below defines the captions specifying the danger levels used throughout this

manual.

Symbol Designation Signification

danger

DANGER Warns that an accident will occur if the instructions are not followed, resulting in a serious or fatal injury and/or severe damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height etc.

warning

WARNING Warns that an accident may occur if the instructions are not followed, that can lead to serious injury, possibly fatal, and/or great damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height etc.

Electrical shock

ELECTRICAL SHOCK

The electrocution or electrical shock symbol indicates electrical hazards which could result in severe personal injury or death.

caution

CAUTION Warns that an accident may occur if the instructions are not followed, that can result in injury and/or damage to the product. It also applies to warnings of risks that include burns, eye injury, skin injury, hearing damage, crushing or slipping, tripping, impact, fall from height etc. Furthermore, it applies to warnings that include function requirements when fitting and removing equipment, where there is a risk of damaging the product or causing a breakdown.


1 Safety

1.6.1. Safety signals in the manual

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

Electrostatic discharge (ESD)

ELECTROSTATIC DISCHARGE (ESD)

The electrostatic discharge (ESD) symbol indicates electrostatic hazards which could result in severe damage to the product.

Magnetic fields

MAGNETIC FIELDS

An intense and/or variable magnetic field can affect or damage certain electrical devices like cardiac pacemakers.

Protection of eyes

EYES DANGER Wear safety goggles.

Protection of hands

HANDS DANGER Use safety gloves.

Protection of ears

EARS DANGER Use hearing protection devices.

Note

NOTE Note symbols alert you to important facts and conditions.

Tip

TIP Tip symbols direct you to specific instructions, where to find additional information or how to perform a certain operation in an easier way.

Symbol Designation Signification


1 Safety

1.6.2. Safety risks related to spot welding©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

1.6.2. Safety risks related to spot welding

Environment

CAUTION!

The FlexGun is intended to be used in normal indoor industrial environments; it is not

intended for use in extremely dusty, humid or explosive environments.

WARNING!

Spot welding generates fumes. The FlexGun must be used in a ventilated environment.

WARNING!

The FlexGun must be used in a safety cell. Access to the cell must be monitored according to

local safety legislation.

Work pieces

WARNING!

The work pieces for welding should be free of oils and other residues that may cause fire,

poisonous fumes or other inconveniences.


1 Safety

1.6.3. Personnel safety

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

1.6.3. Personnel safety

General

CAUTION!

The FlexGun is intended to be used by specifically appointed and qualified staff.

Unauthorized staff should not handle it.

Personal Protection Equipment

Personnel working with the FlexGun must use the following equipment:

Protection of eyes

Safety goggles should be worn within cell during welding operations. Sparks from the welding may injure the eyes.

Protection of hands

Work pieces may be hot after welding. Always use safety gloves during manual handling of work pieces.

Always let the FlexGun cool down before any mechanical intervention.

Protection of ears

Always use hearing protection devices during work in and around the work cell, as handling of the material as well as surrounding processes may give rise to elevated sound levels.

The sound pressure level excluding the welding process is less than 70 dBA.

During welding process with the FlexGun, the sound pressure level can sporadically reach 75-80 dBA.


2 Product description

2.1. Overview©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.


2.1. Overview

Overview

The FlexGun is a spot welding gun. Available with MFDC or AC welding transformer, it has

a modular design consisting of one standard gun body that receives various X and J/C gun

arm types.

High performance

The FlexGun is servo controlled. It is integrated into the ABB robot as a 7th axis, offering

improved welding quality and cycle time performance.

The FlexGun is able to produce high forces at the electrode tips for welding of high strength

steels.

Complete protection

Stainless steel covers on the FlexGun protect the internal mechanics of the gun from weld

splatter and eliminates the need for expensive welding gun bags.

Easy installation

The FlexGun is designed to suit the ABB welding robots. This includes the interface plugs

and connections to the standard ABB DressPack. The FlexGun comes with the motor tuned

and the Equalization parameters already prepared.

Modularity

The gun body is standardized. This makes it possible to keep a single range of spare parts for

a complete library of different guns, and results in a saving on spare parts.



2.2. Terminology

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

2.2. Terminology

You'll find in the table hereunder some explanations regarding the terms used in this manual:

Designation Definition

Arm A conductive component, made of copper or aluminium, which mates to the arm holder and holds the electrode holder or the electrode. The term arm is sometimes used to refer to the complete arm assembly (arm, electrode holder, electrode adapter, electrode and weld cap).

Arm holder A bracket which mates to the gun body and holds the arm.

Beam The mounting frame of the gun.

Body The standard mechanical unit of the servo-gun including: chassis, linear unit, motor. The arms are not considered as being part of the gun body.

Buss bar A copper component which conducts current from a transformer to a leaf shunt or from a leaf shunt to an arm.

Electrode adapter An electrode which mates to the weld cap and is held by an electrode holder or the arm.

Electrode clamp A clamp which secures the electrode holder to the arm.

Electrode holder A conductive part which mates to the arm and holds the electrode adapter.

Equalization The process which compensates for the bending of the fixed arm during the application of the welding force.

Fixture/Hardtool Parts to be welded are held in fixtures or hardtools.

Linear unit The linear unit is the mechanical assembly that transforms rotational movement from the motor into linear movement. It includes the roller screw, the bearings and spacers, and linear guiding material.

Manipulator The 6 axis mechanical unit of the robot.

MFDC Medium Frequency Direct Current

Mobile carriage The mobile part of the gun body on which the mobile arm holder is attached.

Pedestal gun assembly

Weld gun is mounted to a stand or pedestal, and the metals are supplied by a robot.

Proximity sensor Device which detects whether or not a target is in a predetermined zone.

Robot The manipulator and the controller

Robot mount Surface on the weld gun to which the robot is mounted.

Robotic system The robot controller, the robot manipulator and the servo-gun.

Roller screw A roller screw transforms rotational movement into linear movement. A roller screw uses grooved rollers as the anti-friction device between the nut along the outside of the screw and the screw itself, thus offering much higher efficiency than ball screws.

Servo Motor A motor used for motion control in robots. A servomotor is paired with an encoder to provide position/speed feedback.

Software Equalization

A robot function which uses the robot to move the gun body and fixed arm during the application of the welding force to compensate for the bending of the fixed arm such that the fixed electrode tip remains stationary despite the bending of the arm.

Shunt (leaf shunt) Layered copper sheets used to conduct weld current to moving components on the weld gun

Stroke/window The distance between the caps when the gun is fully opened.



2.2. Terminology©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

Throat depth The distance in a welding machine from the centerline of the electrodes to the nearest point of interference.

Throat gap The distance between the fixed arm and mobile arm when the gun is closed.

Tip alignment The proximity of the two cap axis.

Tip dresser Tooling used to re-shape the electrode welding caps after use.

Tip force The actual force applied to the metal to be welded.

Transformer primary

The terminal on the transformer, where power is supplied.

Transformer secondary

This terminal connects to resistance welding circuit.

Water pressure differential

Difference in water pressure between the in and out ports of a water circuit.

Weld cap The consumable electrode which makes contact with the sheet metal.

Welding current The current flowing through the secondary circuit during the resistance weld.

Designation Definition



2.3.1. Principle

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

2.3 Concept

2.3.1. Principle

Modular design

The FlexGun is a modular unit built around a standard body (chassis).

Its constitutive elements can be categorized as below:

• Linear transmission unit including servomotor, gearbox, roller screw and moving

carriage

• Welding power including transformer

• Gun interface to robot

• Fluid and electrical connections

• Arm holders, arms, shunts, electrode holders and caps



2.3.2. Detailed views©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

2.3.2. Detailed views

Overview

Overview

1 Servo-motor and gear box

2 Welding transformer

3 Primary connection of the transformer

4 Harting connector for OrangeLine DressPack robot connection

5 Manifold for water cooling

6 Gun back plate / Robot mount

7 Mobile carriage

8 Mobile arm

9 Fixed arm

10 Electrode adapter

11 Weld cap (consumable)

12 Laminated leaf shunt

13 Cooling circuit

14 Arm holder

15 Electrode holder




© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

Servo-motor

Servo-motor

Transmission

Transmission

1 4 screws for motor holder fastening

2 Servo-motor

3 Motor holder

4 4 screws for servo-motor fastening

1 4 screws for motor holder fastening

2 2 screws to adjust the belt tension

3 2 nuts to lock the adjustment screws

4 Toothed belt. Power transmission from the servo-motor to the linear unit

5 Primary pinion mounted on the servo-motor shaft

6 Secondary pinion mounted on the roller screw of the linear unit



2.3.2. Detailed views©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

Arm and electrode on X-Gun

Arm & tip on X-gun

Arm and electrode on C-Gun

Arm & tip on C-gun


2 Electrode adapter

3 Threaded electrode adapter

4 Electrode holder

5 Clamp

6 Arm

7 Electrode cooling tube (water inlet)

8 Outlet / water return

9 O-ring joint

10 Copper gasket


2 Electrode adapter

3 Clamp

4 Arm

5 Electrode cooling tube (water inlet)

6 Outlet / water return

7 O-ring joint




© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.


3 Standard and customized offers

3.1. Offers overview©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.


3.1. Offers overview

Overview

The FlexGun offers can be categorized as below:

• The FlexGun standard offer: it consists in a complete servo-gun including the standard

gun body, a transformer, and the arm assemblies. The transformer is chosen between

AC or MFDC. The arms are chosen in the library of standard X or C/J arms.

• The FlexGun standard body with customized arms: it consists in a complete servo-gun

including the standard gun body, a transformer, and the arm assemblies. The

transformer is chosen between AC or MFDC. The arms are manufactured and tested

by ABB but designed by the customer or by an ABB expert according to the

requirements and specifications given by the customer.

• The FlexGun standard body: it consists in the standard gun body. An AC or MFDC

transformer can be supplied. if the standard arms holders and/or arms are not supplied,

they must be designed and manufactured according to the recommendations given in

the following chapters.



3.2.1. Overview

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

3.2 Standard offer

3.2.1. Overview

Modular design

The Standard FlexGun is available in X and C types, which only differ by their arms and a

very limited number of parts:

Standard X-gun

Standard C-gun



3.2.2. X-gun standard offer©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

3.2.2. X-gun standard offer

Depth and maximum tip force

Standard X-gun depth

On a X-gun, the depth depends on the length of the arm.

The maximum tip force depends on the design (length, diameter, etc.) of the arms, electrode

holder and tips.

The maximal gun opening is 255 mm.

The following table shows the maximum force in function of the standard depths, for an

electrode holder which length is 40mm:

The following table shows the maximum force in function of the standard depths, for an

electrode holder which length is 80mm:

D Gun Depth (mm)

Gun Depth (mm) 222 272 322 372 422 472 572 672 772 872 972

Max Force available (daN)

630 630 630 630 630 630 503 410 346 300 264

Gun Depth (mm) 262 312 362 412 462 512 612 712 812 912 1012

Max Force available (daN)

535 535 535 535 535 535 461 382 326 284 252



3.2.2. X-gun standard offer

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

Standard X-gun arm attachments

Arms Type Attachement type

References Illustration

Copper Standard

Complete set3HAW061005100-001

Fixed holder set

3HAW061005100-001-F

Mobile holder set

3HAW061005100-001-M

CopperInverted mobile arm holder


Fixed holder set

3HAW061005100-001-F

Mobile holder set

3HAW061005100-002-M

Aluminium Standard


Fixed holder set

3HAW061005100-003-F

Mobile holder set

3HAW061005100-003-M



3.2.3. C-gun standard offer©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

3.2.3. C-gun standard offer


Standard C-gun depth

On the standard C-gun, the depth is 220mm and the maximum opening is 255mm.

The maximum force allowed is 1000 daN but this forces also depends on the design of the

tips.

The actual parameters are indicated on the machine plate.

There are other available designs for the C-gun. Please contact ABB.

D Gun depth (mm)



3.2.3. C-gun standard offer

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

Standard C-gun arm attachments

Arms Type Attachement type

Reference Illustration

CopperStraight fixed arm holder


Fixed holder set

3HAW061005600-001-F

Mobile holder set

3HAW061005600-001-M

Copper15° fixed arm holder


Fixed holder set

3HAW061005600-002-F

Mobile holder set

3HAW061005600-001-M



Fixed holder set

3HAW061005600-003-F

Mobile holder set

3HAW061005600-001-M



Fixed holder set

3HAW061005600-004-F

Mobile holder set

3HAW061005600-001-M



Fixed holder set

3HAW061005600-005-F

Mobile holder set

3HAW061005600-001-M

Aluminium fixed arm

Copper mobile arm

Straight fixed arm holder


Fixed holder set

3HAW061005600-006-F

Mobile holder set

3HAW061005600-001-M



3.2.3. C-gun standard offer©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

Aluminium fixed arm

Copper mobile arm

15° fixed arm holder


Fixed holder set

3HAW061005600-007-F

Mobile holder set

3HAW061005600-001-M

Aluminium fixed arm

Copper mobile arm



Fixed holder set

3HAW061005600-008-F

Mobile holder set

3HAW061005600-001-M

Aluminium fixed arm

Copper mobile arm



Fixed holder set

3HAW061005600-009-F

Mobile holder set

3HAW061005600-001-M

Aluminium fixed arm

Copper mobile arm



Fixed holder set

3HAW061005600-010-F

Mobile holder set

3HAW061005600-001-M

Aluminium fixed arm

Copper mobile arm



Fixed holder set

3HAW061005600-011-F

Mobile holder set

3HAW061005600-001-M



3.2.4. Transformer

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

3.2.4. Transformer

Characteristics

The FlexGun is available with AC or MFDC transformer:

Other transformers can be offered. Please contact ABB.

Transformer type MFDC_10V AC_10V

Secondary voltage 10V 10V

Primary voltage 500V 400V

Primary frequency 1000 Hz 50 Hz

Power (S50) 91 kV.A 88 kV.A



3.2.5. Robot interface©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

3.2.5. Robot interface

List of robot interface configurations

Positioning Interface Reference Illustration

In line

Basic 3HAW061005250

Standard interface IRB6600 3HAW061005251


Manual tool changer ABB IRB6600 3HAW061005253


Automatic tool changer RSP 350 3HAW061005255

Automatic tool changer Sigma3 3HAW061005256

40°(8 orientations

are possible

using the

same

material)

Basic 3HAW061005260







90°connector side Transformer MFDC

Basic 3HAW061005270







90°connector side Transformer AC_10V

Basic 3HAW061005280







90° motor side

Basic 3HAW061005290







90° left / right side

Basic 3HAW061005300









3.3.1. Overview

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

3.3 Customized offer

3.3.1. Overview

Overview

The FlexGun arm holders, arms and electrodes can be designed and manufactured according

to the customers specific requirements and specifications. The following chapters contain the

rules for the design of such a customized FlexGun.



3.3.2. Maximum force©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

3.3.2. Maximum force


The level of force at the tips depends on the type and length of the arms and tips.

The curve below shows the tip force in relation with the depth:

The maximal gun opening depends on the tips used. It can not exceed 255 mm.

D Gun Depth, in mm (Distance between tips and the mobile carriage).

F Tip Force, in DaN

L1 Mechanical unit limit, in DaN

L2 User defined tip and arm limit, in DaN



3.3.3. Copper arm interface design

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

3.3.3. Copper arm interface design

Drawing

When ABB arm holders are used, the end of the arm (interface) must be designed as shown

below (for copper arms):

arm shaft



3.3.4. Arm holder design©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

3.3.4. Arm holder design

Mobile arm holder mounting

If the ABB mobile arm holder is not used, it is recommended to design the interface of the

holder in accordance with the mounting surface of the carrier shown below:

Mobile arm holder mount surface

Mobile arm holder interface

Mobile arm carriage maximum loads

The following gives the maximum loads applicable to the mobile arm carriage:

Maximum loads

Torque Maximum value Force Maximum value

To.x 3580 N.m Fx (not relevant)

To.y 6070 N.m Fy (not relevant)

To.z 580 N.m Fz 100% duty cycle: 7600 N

50% duty cycle: 11000 N



3.3.4. Arm holder design

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

Fixed arm holder mounting

If the ABB fixed arm holder is not used, it is recommended to design the interface of the

holder in accordance with the beam mounting surface shown below:

Fixed arm holder mount

Fixed arm holder interface


4 Technical details and requirements

4.1.1. Servo motor type 9C4©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.


4.1 Servo motor

4.1.1. Servo motor type 9C4

Overview

The servo motor type 9C4 was used on the FlexGun until 2012.

The standard version of this motor is not equipped with a brake. Below are its main

characteristics:

Resolver

The resolver is of the type “speed one” There is only one pair pole. It fulfills the ABB robot

requirements. It is connected to a 17 pins male industrial connector.

17 pins resolver connector

# Attribute Symbol Value Unit

1 Continuous torque at zero speed M07.5 Nm

2 Peak torque MMAX22.5 Nm

3 Torque constant KT1.232 Nm/A

4 Rated speed NN4000 rpm

5 Resistance between phases RU-V1.81 Ω

6 Self between phases (U-V) LU-V11.9 mH

7 Number of pair poles PP5 /

Pin Signal Detail

1 S1 Cos +

2 S2 Sin+

3 S3 Cos-

4 S4 Sin-

5 Not used

6 Not used

7 R1 Reference +

8 R2/R3 Reference -



4.1.1. Servo motor type 9C4

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

Power

A temperature sensor (PTC) is implemented inside the phases winding.

8 pins motor connector

Pin Signal Detail

1 V Motor phase V

2 GND To be connected to earth protection

3 U Motor phase U

4 W Motor phase W

A B+ Brake + (optional)

B B- Brake - (optional)

C PTC Temperature sensor

D PTC Temperature sensor



4.1.2. Servo motor type T©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

4.1.2. Servo motor type T

Overview

This servo motor was introduced on the FlexGun in 2012. Its characteristics and

performances are similar to those of the motor type 9C4, with the notable exception that the

motor type T is equipped with a brake.

Below are its main characteristics:

1) Torque produced on motor shaft at speed n>=10 rpm for an infinite period of time.2) Same as T0 but at the speed nN

3) Same as T0 but at the speed n=nRMS

Brake

Below are the main characteristics of the motor brake:

# Attribute Symbol Value Unit

1 Low speed rotor torque1)T0

10 Nm

2 Rated torque2)TN

6 Nm

3 RMS torque3)TRMS

8.3 Nm

4 Maximum motor shaft torque at zero speed T0MAX18 Nm

5 Rated speed nN4780 rpm

6 Speed at RMS torque nRMS2265 rpm

7 Nominal winding resistance per phase at 20 °C R202.25 Ω

8 Nominal winding inductance per phase at zero current

L011.9 mH

9 Number of poles Poles 8 /

# Attribute Value Unit

1 Static min torque 10.5 Nm

2 Dynamic max torque 16.8 Nm

3 Min dynamic torque Nm at speed (~ 0.8*nN) 3830 rpm 9.5 Nm

4 Maximum motor shaft torque at zero speed 18 Nm

5 Power consumption 31.6 W

6 Inertia 2.79 kg.cm²



4.2.1. Gun body with AC transformer

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

4.2 Centre of gravity and moment of inertia

4.2.1. Gun body with AC transformer

Overview

The following details are given for a standard Flexgun body without arms and with a

transformer AC.

Data

Centre of gravity

Mass

Total mass: 110.54 kg

Inertia matrix/G

IoxG: 1.075 kg.m² IoyG: 5.097 kg.m² IozG: 5.036 kg.m²

IxyG: -0.088 kg.m² IxzG: -0.081 kg.m² IyzG: -0.005 kg.m²

Principal Moments/G

M1: 1.071 kg.m² M2: 5.037 kg.m² M3: 5.099 kg.m²



4.2.2. Gun body with MFDC transformer©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

4.2.2. Gun body with MFDC transformer

Overview

The following details are given for a standard Flexgun body without arms and with a

transformer type MFCD.

Data

Centre of gravity

Mass

Total mass: 93.8 kg

Inertia matrix/G

IoxG: 0.933 kg.m² IoyG: 4.196 kg.m² IozG: 4.138 kg.m²

IxyG: -0.077 kg.m² IxzG: -0.043 kg.m² IyzG: -0.005 kg.m²

Principal Moments/G

M1: 0.991 kg.m² M2: 4.138 kg.m² M3: 4.199 kg.m²



4.3. Electrical connections

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.


Principle

The electrical signals from the welding gun transformer, motor and resolver are transferred

through a harting socket (for OrangeLine DressPack) or 3 circular sockets (for LeanID

DresspPack).

The power is transferred through the MC Plug.

Electrical plugs for OrangeLine DressPack

A Harting socket.

B MC Plug. For 3 phase power.



4.3. Electrical connections©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

Connectors for OrangeLine DressPack

A socket is prepared for direct connection to the harting plug on the Orange Line DressPack.

Harting plug

Plug details

For details, see Wiring diagrams on page 167.

Connectors for LeanID DressPack

There are 3 circular sockets prepared for direct connection to the LeanID DressPack.

FlexGun connectors for LeanID DressPack

For details, see Wiring diagrams on page 167.

A Harting modular connector from IRB robot

B Resolver: Sin, Cos, Ref. Temperature sensor

Motor: U, V, W phases. Brake (motor type T only)

C Transformer. Current sensor. Temperature sensor

A R3.CPS: Transformer. Current sensor. Temperature sensor

B R4.FB: Resolver Sin, Cos, Ref. Temperature sensor

C R3.SP: Motor: U, V, W phases. Brake




© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

MC Plug

The FlexGun comes with an MC female plug 25mm² (LeanID DressPack) or 35mm²

(OrangeLine DressPack) for connection of the welding power to the guns transformer.

The plug is shown below:

MC plug



4.4. Water cooling©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

4.4. Water cooling

Overview

Resistance welding equipment develops very high secondary currents. The heat is generated

primarily at the electrode tips where the resistance is greatest and internally inside the

transformer. Inadequate water cooling can cause failure to welding equipment, reduce the

durability of components and produce poor welds. Therefore the water flow should be

monitored regularly.

Diagram

Cooling circuit

Connections

Water manifold

A Water inlet to transformer (DN12)

Connect PROC2 on ABB Orange Line DressPack

B Water outlet from mobile arm (DN12)


C Water outlet from fixed arm (DN12)




4.4. Water cooling

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

Network requirementsThe input and output water circuits should be equipped with manual valves.To avoid water leaks, it is recommended to install a bleeder system in order to release the pressure in the cooling circuit before maintenance operation.

The following shows the requirements for FlexGun water coolant network:

(1) Cooling water must be free of contaminants. The flow passages in the weld gun can become blocked by contaminants causing restricted water flow and overheating. Use only neutral water without chlorides, sulfates,...

Parameter Value Unit

Minimal differential pressure between inlet and outlet 1.5 bars

Maximal pressure 10 bars

Maximal temperature at inlet 30 °C

Minimal temperature at inlet 10 °C

Minimal water flow at transformer level 8 L/min

Minimal water flow at arm level 4 L/min

Minimal filtration (1) 0.2 mm



4.5. Temperature and hygrometry©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

4.5. Temperature and hygrometry

RequirementsThe following table shows the requirements for FlexGun operation and storage:

Category Value Unit

Ambient temperature

Operating 10 to 50 °C

Storage 10 to 70 °C

Ambient hygrometry

Max ambient humidity at constant temperature (for operating and storage condition)

80 %



4.6.1. Gun used on a robot

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

4.6 Robot and robot controller requirements


Overview

When the FlexGun is associated with an IRB 6640 or 7600 robot, it is controlled like an

external axis. However, the robot controller must satisfy some requirements to get an

optimum integration. The FlexGun has been designed for ABB IRC5 controller, for

compatibility with other control systems please contact ABB.

Orange Line DressPack (left) and LeanID DressPack (right)

NOTE!

The servo gun uses the robot serial measurement board. The servo gun dresspack connects

the gun resolver to the robot serial measurement board. Thus there is no additional signal

cable from the robot base to the IRC5.

If a stationery gun is however used, an additional signal cable is required. This runs from the

robot base to the gun and is called a “Process cable”.

NOTE!

The FlexGun can be used with orange line, silver line, and integrated LeanID DressPacks.

Robot cabling

A servo gun requires at least three cables between the IRC5 and the robot:

• Spot welding power cable - 3 phases 35mm²/25mm² welding cable

• Servo Gun Motor Power cable - 3 phases power to the gun motor

• CP/CS - Signals from the welding gun: temperature, etc.



4.6.1. Gun used on a robot©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

Requirements for the robot and controller - with Orange Line DressPackThe robot and controller equipment must fulfill the following requirements to integrate a FlexGun:

Option number

Type Description

16-1 Connection to cabinet

Floor cables and connections inside the I/O section for the DressPack are chosen. The length and configuration of the floor harness is specified under the options below.

Option 94-1,-2,-3,-4 and 455-1 for parallel communication

Option 90-2,-3,-4,-5 and 455-4 for parallel communication and field bus communication with Can/DeviceNet.

Option 92-2,-3,-4,-5 and 455-4 for parallel communication and field bus communication with Profibus.

Option 859-1,-2,-3,-4 and 455-8 for parallel communication and field bus communication with Ethernet.

455-1 Parallel communication

Offers the signal cables needed for parallel communication in lower and upper arm DressPack.

Note: The FlexGun only requires parallel communication for the dresspack and floor cables. This is for signals from the transformer and gun motor

455-4 Parallel and Bus communication

Offers the signal cables needed for the combination of parallel and bus communication in lower and upper arm DressPack.

455-8 Parallel and Ethernet communication

Offers the signal cables needed for the combination of parallel and Ethernet communication in lower and upper arm DressPack.

635-3

or -5

Spot software Spot Servo or Spot Servo Equalizing

907-1 Single drive unit

Drive unit for 7th axis with corresponding cables assembled inside Drive cabinet.

778-2 Robot gun Spot welding

785-1 Robot gun This option includes: Cables within manipulator for servo power signals (servo gun/axis 7).

798-2 and

780-2

Or

781-2

Base to axis 2 and axis 2 to axis 6

Or

Base to axis 6

864-1 Resolver connection, axis7

630-1 OptionServo tool changer

Can be added if servo gun tool changer is required.

608-1 Option World Zones

610-1 Option Independent axis

613-1 Option Collision Detection

626-1 Option Advanced RAPID

629-1 Option Servo Tool Control

793-1 OptionSecond water return

Used to safeguard against overheating of the gun arms and transformer. One water return for each arm.




© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

Requirements for the robot and controller - with integrated LeanID DressPackThe robot and controller equipment must fulfill the following requirements to integrate a FlexGun:

Option number

Type Description

16-1 Connection to cabinet

Floor cables and connections inside the I/O section for the DressPack are chosen. The length and configuration of the floor harness is specified under the options below.

Option 94-1,-2,-3,-4 and 455-1 for parallel communication

Option 90-2,-3,-4,-5 and 455-4 for parallel communication and field bus communication with Can/DeviceNet.

Option 92-2,-3,-4,-5 and 455-4 for parallel communication and field bus communication with Profibus.

Option 859-1,-2,-3,-4 and 455-8 for parallel communication and field bus communication with Ethernet.

455-1 Parallel communication

Offers the signal cables needed for parallel communication in lower and upper arm DressPack.

Note: The FlexGun only requires parallel communication for the dresspack and floor cables. This is for signals from the transformer and gun motor

455-4 Parallel and Bus communication

Offers the signal cables needed for the combination of parallel and bus communication in lower and upper arm DressPack.

455-8 Parallel and Ethernet communication

Offers the signal cables needed for the combination of parallel and Ethernet communication in lower and upper arm DressPack.

635-3

or -5

Spot software Spot Servo or Spot Servo Equalizing

907-1 Single drive unit

Drive unit for 7th axis with corresponding cables assembled inside Drive cabinet.

778-2 Robot gun Spot welding

785-1 Robot gun This option includes: Cables within manipulator for servo power signals (servo gun/axis 7).

798-3 and

780-4

Base to axis 3

Int. Axis 3 to 6

864-1 Resolver connection, axis7

630-1 OptionServo tool changer

Can be added if servo gun tool changer is required.

608-1 Option World Zones

610-1 Option Independent axis

613-1 Option Collision Detection

626-1 Option Advanced RAPID

629-1 Option Servo Tool Control

793-1 OptionSecond water return

Used to safeguard against overheating of the gun arms and transformer. One water return for each arm.



4.6.2. Stationary gun©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

4.6.2. Stationary gun

Stationary gun

The FlexGun can be mounted on a stationary frame/pedestal.

Please contact ABB to define the controller configuration.



4.6.3. Software requirements

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

4.6.3. Software requirements

Requirements

Use Robware version 5.12 or later.

A corresponding version of Robot Studio should also be installed.


5 Unpacking and handling

5.1. Pre-requisites for reception©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.


5.1. Pre-requisites for reception

Pre-requisites

The check-list below details what must be observed before proceeding with the unpacking

and/or installation of the FlexGun:

Action Note

1. Make sure that only qualified installation personnel conforming to all national and local codes are allowed to perform the installation.

Specified in Personnel safety on page 34.

2. Make sure that the FlexGun has not been damaged, by visual inspection.

Specified in Unpacking and acceptance on page 74.

3. Make sure that the lifting device to be used is dimensioned to handle the weight of the FlexGun.

Specified in Lifting weight on page 75.

4. If the FlexGun is not to be installed directly, it must be stored.

Read Temperature and hygrometry on page 67.

5. Make sure the appointed operating environment of the FlexGun conforms to the specifications.

Specified in Safety risks related to spot welding on page 33.

6. When these prerequisites have been met, the FlexGun may be taken to its storage or installation site.



5.2. Unpacking and acceptance

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

5.2. Unpacking and acceptance

TIP!

Before unpacking the unit, quickly check that the package is not damaged, and that the goods

are as ordered.

Contents

The content of the delivery package should be detailed on the delivery note.

A standard delivery package generally contains (not including options):

• The FlexGun

• The robot attachment

Inspection

The FlexGun is wrapped in a protective bag. Unpack it and check for any visible transport

damage. If the FlexGun is damaged, stop unpacking and contact ABB.

Make sure that all parts of the packing list have been delivered.

It is recommended to photograph the unit immediately after unpacking to document the

conditions of delivery.

Cleaning

If the unit seems to have been contaminated by impurities during the transport, clean them

with a clean lint-free cloth.

Identification plate

To identify the delivery, read the identification plate and compare it to the delivery note.

The identification plate is located on the side of the gun body (see fig. below) and indicates

in particular the FlexGun type, serial number and weight:

ID Plate location



5.3. Lifting weight©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

5.3. Lifting weight

Weight

The actual weight of the FlexGun depends on the configuration.

The weight of a FlexGun body with transformer but without arms is approximately 90 kg.

The weight of a FlexGun with arms is usually between 110 and 140 kg, depending on the arms

type. The actual weight is indicated on the machine plate.



5.4. Handling/lifting

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

5.4. Handling/lifting

Before lifting

CAUTION!

Before lifting the FlexGun, read through the safety instructions carefully.

If the Gun is mounted on the robot or pedestal, disconnect and secure the power supply and

water coolant circuit.

Handling equipment for FlexGun

CAUTION!

Only use straps for lifting the FlexGun. Chains could damage the FlexGun.

Recommended equipment

4 Eye-bolts with a M10 thread

4 U-shackles

2 lifting straps rated for a minimum of 200kg



5.4. Handling/lifting©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

Lifting the FlexGun

There are 4 M10 threaded holes on the gun body (2 on each side):

Eye bolt holes

At least two eye-bolts must be tightened to the FlexGun body, one on each side.

Make sure that the strap is not in position to damage any leaf shunt, tube or any other piece

of equipment.

Lift slowly and carefully.

Lifting with straps


6 Installation and commissioning

6.1. Introduction

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.


6.1. Introduction

Safety information

Before any service work is commenced, it is extremely important that all safety information

is observed! There are general safety aspects that must be read through, as well as more

specific safety information that describe danger and safety risks when performing the

procedures. Read Safety on page 13 before performing any service work.

Pre-requisites for installation

The check-list specified in Pre-requisites for reception on page 73 must be observed before

proceeding with the actual installation of the FlexGun.

Required equipment

Bolts and screws and tightening torques

Specified in Bolt, screws, tightening torques on page 147.

Equipment Note

Handling equipment Specified in Handling/lifting on page 76.

Standard toolkit Specified in Standard toolkit on page 149.

Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.

Specified in Special tools on page 150.



6.2.1. Introduction©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

6.2 Mechanical installation

6.2.1. Introduction

Overview

The FlexGun can be mounted on a robot or on a pedestal. It can be connected to the robot via

a manual or automatic tool changer.

The gun can be mounted on a robot with different orientations. This is done through different

robot-to-gun interface attachments (see Robot interface on page 51).

Handling of the FlexGun

The FlexGun must be handled and positioned such as this operation is safe and comfortable.

Use proper handling equipment as described in Handling/lifting on page 76 and make sure

that the weight of the unit does not rest on fragile equipment such as connectors.

Mounting of the FlexGun onto the robot - general principles

Actions Info/Illustration

1 Either jog the robot down to marry the back plate with the gun on the floor or use the handling equipment to lift the gun to the robot role-face.

The body back plate or interface bracket should be attached to the robot 6th axis flange.

Use the dowel pin location to correctly orientate the gun.

See the details of the robot role-faces in the robot product manuals.

See the details of the assembly on the ABB assembly drawings provided with the FlexGun and in: Attachement - FlexGun side on page 80, and

Attachement - robot side on page 83

Robot roleface

Use screws as recommended in the robot product manual.

For fastening of tool-flange to robot-flange, every other one of the bolt holes for 6 bolts class 12.9 shall be used.

Attached FlexGun



6.2.2. Attachement - FlexGun side

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.


In-line positioning back side 3HAW06100525x

40° positioning 3HAW06100526x

It is possible to orientate the bracket in 8 positions:

8 possible orientations of the 40° positioning bracket


1 Fix the standard gun interface or the manual tool changer to the interface plate of the gun.

See the details of the assembly on the ABB assembly drawings provided with the FlexGun or in:

Attachement - robot side on page 83

Standard attachement (left) and attachement with manual changer (right)



6.2.2. Attachement - FlexGun side©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

90° positioning connector side 3HAW06100527x (MFDC) - 3HAW06100528x (AC)


1 Gun plate interface and bracket:

• Install the M6 screw for mistake-proofing at the chosen location (A), and lock it. Once all the parts are assembled, the head of the screw will be in the hole (D)

• Install the two dowel pins (E)

• Install the bracket on the plate interface of the gun, and fix it

End bracket side:

• Install the locator W060005262 and fix it with the M6 screw

• Install the dowel pin (B) and the screw (C) at the chosen location

40° Positioning


1 (3HAW061005270: used with MFDC transformer

3HAW061005280: used with AC 10V transformer)

• Install the holder (A or B), and fix it on the gun with the 2 screws (C)

• Install the 2 dowel pins (D)

• Install the bracket (3HAW060005263) on the plate interface of the gun, and fix it with the 2 screws (F) and the 5 screws (G)

• Install the locator 3HAW060005262 and fix it with the M6 screw

90° Positioning - connector side - MFDC transfomer

90° Positioning - connector side - AC transfomer




© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

90° positioning motor side 3HAW06100529x (X-Gun only)

90° positioning left/right side 3HAW06100530x


1 • Install the holder (A), and fix it on the gun with the 2 screws (B).

• Install the 2 dowel pins (C)

• Install the bracket (D) on the plate interface of the gun, and fix it with the 2 screws (E) and the 5 screws (F)


90° Positioning - motor side


1 (The bracket may be oriented on the right or left of the FlexGun)

• Install the two dowel pins (B)

• Install the bracket 3HAW0600052623 on the interface plate of the gun, and fix it with the 2 screws (C) and the 7 screws (D)


90° Positioning - right side



6.2.3. Attachement - robot side©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

6.2.3. Attachement - robot side

Standard interface for IRB6640 - procedure


1 Robot side:


• Install the dowel pin (A)

• Fix the plate 3HAW060005274 on the robot with the 11x M12x25 screws (F)

Gun side:

• Install the dowel pin (B) and the mistake-proofing screw (C) at the chosen location

• Install the dowel pin (D)

• Install the gun plate 3HAW060005273 on the gun bracket or the gun back plate.

• Fix it with the 10x M10 screws

Robot and gun assembly:

• Move the robot and/or the gun to have contact between the gun plate and the robot axis 6 plate

• Fix the two plates with the 11x M10 screws (E)

See the assembly drawing W060005275 on next page

standard IRB6640 interface




© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

Standard interface for IRB6640 - drawing (from ABB drawing n°W060005275)

Interface IRB6640

Mark Quantity Description Standard or ABB number

1 1 Interface plate 3HAW060005274

2 1 Interface plate 3HAW060005273

3 2 Locating 3HAW060005262

4 11 Socket Head Cap Screw

Washer

ISO 4762 M12x25

DIN 6798 - A 12

5 1 Dowel DIN EN ISO 8736-A-12x32

6 2 Hex Screw

Washer

ISO 4017 - M6x16

DIN 433 - 6x12.2




Washer

ISO 4762 M10x30

DIN 6798-A 10


Washer

ISO 4762 M10x25

DIN 6798-A 10




Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

Standard interface for IRB7600 - procedure


1 Robot side:


• Install the dowel pin (A)

• Fix the plate 3HAW060005287 on the robot with the 12x M16 screws (F)

Gun side:

• Install the dowel pin (B) and the mistake-proofing screw (C) at the chosen location

• Install the dowel pin (D)

• Install the gun plate 3HAW060005288 on the gun bracket or the gun back plate.

• Fix it with the 10x M10 screws



• Fix the two plates with the 12x M10 screws (E)

See the assembly drawing W061005252 on next page

standard IRB7600 interface




© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

Standard interface for IRB7600 - drawing (from ABB drawing n°W061005252)

Interface IRB7600

Mark Quantity Description Standard or ABB number

1 / FlexGun back plate Included with the gun body


3 1 Interface Plate 7600, tool side 3HAW060005288

4 22 Washer DIN 6798-A 10.5

5 10 Socket Head Cap Screw ISO 4762 M10x25

6 2 Locating 3HAW060005289

7 2 Washer DIN 433 - 6.4

8 2 Hex Screw ISO 4017 - M6x16


10 12 Washer DIN 6798-A 17

11 1 Interface Plate 7600, robot side 3HAW060005287


13 / IRB7600 Axis 6 /






Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

Manual tool changer IRB6640

Automatic tool changers


1 Gun bracketside:

• Install the locator 3HAW060005262 and fix it

• Select one of the 2 locating holes (A)

• Install the dowel pin (B)

• Install a screw (C) in the unused locating hole

• Install the gun plate 3HAW060005252 on the gun bracket or plate

• Fix it with the 10 M10 screws (D)



• Install the 2 half brackets 3HAW060005253

• Tighten the 2 screws (E)

Manual tool changer IRB6640


1 RSP TA350-SWS:

• The automatic tool changer RSP is fixed directly on the bracket attachment

Applied Sigma 3.1:

• The automatic tool changer Applied Sigma 3.1 needs an interface plate to be fixed on all gun attachments.

RSP TA350-SWS

Applied Sigma 3.1



6.3.1. Principle and pre-requisites

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

6.3 Connection to the dresspack

6.3.1. Principle and pre-requisites

General

The FlexGun is connected to the drive unit of the robot controller, to the measurement board

of the robot or to an external one, and to a welding cabinet.

When the FlexGun is mounted onto an ABB robot, all electrical connections including the

welding signal and the servo motor power and signal, but not the welding power, are made

through a modular Harting connector, The ABB electrical drawing number is W060005802

(see Wiring diagrams on page 167).

The welding power is transferred through the MC Plug (see Electrical connections on page

62).

This chapter describes the connection of the FlexGun to an ABB IRB robot equipped with

welding dresspack. For other type of connection, contact ABB.

CAUTION!

Before connecting the FlexGun, make sure that all power supplies are secured and that the

water-cooling circuit is out of pressure.

DANGER!

Only authorized staff may carry out electrical operations!

Appropriate tools must be used!

Safety procedure must be respected!

Earth grounding must be done properly!

Required equipment

The standard toolkit is described in Standard toolkit on page 149.

Electrical tools are also necessary to connect the dresspack to the MC plug of the FlexGun,

see Special tools on page 150.



6.3.2. Orientation of the DressPack©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

6.3.2. Orientation of the DressPack

Orientation of the dresspack support plate

It is possible to orientate the support plate of the DressPack on the left or the right of the

FlexGun:

DressPack orientation

The orientation chosen depends on the required movement of the gun, as there can be an

interference issue if the gun is required to move at a very tight angle on axis 5 of the robot.

If this is the case, mount the dresspack on the opposite side.

Note that once the MC plug is crimped to the welding power, the orientation can not be

changed without ordering new crimping pins from MC.

NOTE!

The recommended orientation of the DressPack bracket is shown in option A.

It is the safest way to keep the cables and hoses away from the moving leaf shunt of the gun

mobile arm.



6.3.3. MC plug details

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

6.3.3. MC plug details

MC Plug

The flexGun comes with an MC plug for connection of the welding power from the robot

dresspack to the guns transformer. The assembled plug is shown below:

MC plug

Details

The dresspack has 2 phases plus an earth core that need to be connected to the MC plug. The

dresspack cables should be labelled V & U, with the earth being a green/yellow color.

The cores should be connected as shown in the picture below:

Multi-contact plug details

A Earth

B V terminal

C U terminal

D PG36 cable gland

Can be connected on either the left or right side.

E Welding lug: 35mm² for Orange Line DressPack and 25mm² for Lean ID DressPack

F Welding swivel joint: 35mm² for Orange Line DressPack and 25mm² for Lean ID DressPack



6.3.4. Procedure©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

6.3.4. Procedure

Procedure

The steps below describe the necessary actions required for connecting the ABB DressPack

the MC plug used for the gun.

Action Info/Illustration

1. The FlexGun must be first mechanically attached to the robot as described in Mechanical installation on page 79.

2. Position the DressPack supporting plate on either the left or right side of the gun as described in Orientation of the DressPack on page 89.

3. Check that the gun can open and close completely without interference of its components with the cables or any other equipment.

This is a critical step as the gun leaf shunt and water tubes move into the vicinity of the electrical cables, and water hoses.

4. Cut the cables to the appropriate length.

NOTE!

The MC plug allows for the cable to enter from either the left side or the right. The pins inside the plug can be rotated for either direction. However note that once crimped, it is impossible to change the entry location of the cable.

5. If it is assembled on the Gun, remove the MC plug and open it.

Feed the cable into the MC plug before crimping. This cannot be done afterward.

6. Choose the correct phase and pin connection.

For MFDC transformer, there are two phases plus the earth.

See MC plug details on page 90.

NOTE!

When used with MFDC transformer, the mobile arm is live while the stationary arm is neutral. The current flows from the mobile arm to the stationary arm.

7. Crimp the 25 or 35mm² cores and reassemble the MC plug. Reattach the MC plug back onto the gun.

Follow the Multi-Contact Assembly Instructions manual MA228

8. Cut the water dresspack water hoses and connect them to the FlexGun.

See Water cooling on page 65.

All the necessary fittings are supplied with the FlexGun.

9. Plug the connector to the FlexGun Harness (Harting connector or circular connectors)

See Electrical connections on page 62.



6.4.1. Overview

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

6.4 Controllers settings

6.4.1. Overview

Overview

The gun is controlled as a 7th axis of the robot. In order for the robot to identify that the gun

exists and to control it, configuration files must be loaded into the IRC5 system.

Two files need to be set to add the Servo gun and have it controlled by the system:

• The Motion Control file: MOC.cfg

• The System file: SYS.cfg

The robot controller has existing MOC.cfg and SYS.cfg files with specific settings related to

the robot and robot system. The servo gun settings simply need to be added to these files.

The Motion control file is provided with the FlexGun.

The system file depends on the robot to which the gun will be attached.

The system file should be set depending on your existing system.

NOTE!

Up to 4 FlexGuns can be added to one system.



6.4.2. Motion Control file©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

6.4.2. Motion Control file

Motion control file

The motion control settings file (MOC.cfg) contains information that is specific to the

particular gun. The specific parameters for the gun will be supplied.

The following settings are provided in the motion control setting file with the FlexGun:

• ARM:

• ACC_DATA:

• TRANSMISSION:

• BRAKE:

• BRAKE_TYPE:

• SUPERVISION_TYPE:

• SG_PROCESS:

• FORCE_MASTER:

• FORCE_MASTER_CONTROL:

• AXC_FILTER:

• MOTOR_TYPE:

• MOTOR_CALIB:

• STRESS_DUTY_CYCLE:

• UCCM0:

• LCM0:

The gun will be provided with tuned position and force settings. These settings should not be

changed.

Settings for the drive unit and measurement channel used to control the guns motor may need

to be changed depending on the robot system’s hardware configuration.

The easiest way to do this is to use the ABB software called “Mechanical unit manager”. This

software is specifically designed for the modification of the configuration files for Servo

Guns and Tracks. “Mechanical unit manager” can be found on the Robot Studio DVD under

“Tools\Mechanical Unit Manager” or can be downloaded from the ABB internal software

website at the following address:

http://solutionsbank.us.abb.com




© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

Below is the process for importing and modifying the standard FlexGun configuration file, and exporting the file ready to be loaded into the robot controller.:

Action

1. Open the mechanical Unit Manager:

Open the software

2. Open the project “FlexGun*.data” downloaded from the ABB library:

Open the file



6.4.2. Motion Control file©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

3. Choose to export the file:

Export the file

4. Select the version of the FlexGun. This depends on the shipment date of the gun as described in the file information overview.

Choose the version




© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

The following file is also required: “FlexGun_Mechanical_Unit_Manager.data”

This file is available on the FlexGun page of http://inside.abb.com

For more information about this package, see the application manual IRC5 Unit Manager -

3HAC028797-001.

The following settings are specific for every gun depending on the arm shape, and as a result

the parameters under these subjects are gun specific and supplied with each gun.

• ARM:

• SG_PROCESS:

• FORCE_MASTER:

• FORCE_MASTER_CONTROL:

5. If necessary, adjust the following parameters according to the physical layout and connection of the FlexGun to the robot

Adjust the parameters

6. Save the new CFG and import this into the robot.



6.4.3. System file©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

6.4.3. System file

System file

In order for the robot controller to be able to control the gun, the gun needs to be assigned to

a “task”.

In a standard system without multi-move, the gun is automatically part of the robot task.

However when the gun is being used on a multi-move system, it must be added to the robot

“Mechanical Unit Group”.

This can be done in the SYS.CFG file.

Procedure for modifying the system file

The existing SYS.CFG can be downloaded from the controller and modified on any

computer.

Using Robot Studio, connect to the IRC5 and follow the procedure below:

MECHANICAL_UNIT_GROUP:

-Name “Rob1”-Robot “ROB_1”-MechanicalUnit_1 “SERVOGUN”

-UseMotionPlanner "motion_planner_1"


1. Open Robot Studio and Connect Online to the Robot Controller. Then click Save Parameters.

Robot Studio menu

2. Select Controller and click on Save...

Save system parameters

3. Save the file on your local system in an appropriate location.

Modify the file using a text editor such as Notepad, then load the SYS.cfg file back onto the IRC5. See instruction below on how to load CFG files onto the IRC5.



6.4.4. Loading the files

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.


Procedure for loading the files into the controller

To load the files back into the controller, there are two methods: you can either use a USB

stick and load them directly into the IRC5, or use Robot Studio Online.

The procedure below describes the first method:


1. Start the IRC5 and tap on the ABB logo of the TeachPendant.

NOTE!

Create a backup of the existing system before bringing any modification!

2. In the menu, tap on Control Panel.

3. Tap on Configuration.



6.4.4. Loading the files©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

4. Tap on File.

5. Tap on Load parameters.

6. Tap on Load parameters and replace duplicates.

7. Browse for the appropriate *.CFG files to add, and tap OK.

Do not restart the controller yet.

8. Repeat Steps 2-8 for all *.CFG files that need to be loaded, and then warm restart the controller.





© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

Jogging

Now the system has the basic set of parameters needed to carefully jog the servo gun.

WARNING!

At this stage, the system limitation of force, motor torque and working range is incomplete.

It is therefore possible to move beyond the software limits and damage the gun. If moving the

gun, make sure that the carriage remains within the mechanical limits.

9. Once both the Motion Control and the System CFG files have been loaded on the IRC5, it should be possible to see the mechanical unit in the Jogging Window, as well as to jog the Gun.

Besides, the gun will now be controllable using the Spot Robware instructions.

If the IRC5 reboots without error, then the *.CFG files have been loaded correctly. If an error occurs, record the error message and number and send the back up of the original system, the system layout and the error information to the After-sales support to get help.

If the system enters “System failure state”, it is necessary to perform a cold start. This will restore the system to default settings with no mechanical units or programs. Then restore the original backup taken before loading the CFG files. Retry loading the CFG files.




6.5. Position calibration©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

6.5. Position calibration

Pre-requisite

NOTE!

The position calibration must be done with unused tips. Make sure that they are new and

replace them if it is necessary.

Fine calibration

Close the gun until the tips are in contact without force. the robot power and execute a fine

calibrate.

Follow the calibration procedure in the manual 3HAC026820-001 - Servo Gun Tuning -

section Fine Calibration.

The position limits are now available.

Check that the gun can move up to the upper limit, without damage to any components such

as cable, fitting, tube,...

Position calibration

In manual mode execute the service routine ManServiceCalib.

Follow the calibration procedure in the manual 3HAC026820-001 - Servo Gun Tuning -

section Position control



6.5. Position calibration

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

Test jogging the servo-gun

TIP!

If it is impossible to jog the gun, and instead you get a joint collision error, verify that:

• the gun is not physically stuck

• the motor phases are connected correctly

• the resolver is connected correctly

• that commutation is OK


1. Start the IRC5 and tap on the ABB logo of the TeachPendant.

2. Choose Mechanical unit and select SERVOGUN.

Tap OK.

3. Try jogging the SERVOGUN slowly back and forth. Make sure that the jogging is carried out away from the end limits as the gun position is not yet calibrated.

WARNING!

When the gun revolution counter is not updated, it is possible to move beyond the software limit and damage the gun. When moving the gun, make sure that the carriage remains within the mechanical limits.



6.6. Force calibration©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

6.6. Force calibration

Required equipment

The standard toolkit is described in Standard toolkit on page 149.

A Vernier caliper and a spot welding gun calibration kit are also required to perform force

calibration:

TIP!

You can order the Miyachi calibration kit to ABB under the reference number

3HAW05000904. See Special tools on page 150

Qty Tool Product

1 A welding gun calibration kit with electronic force sensor (range 0-10kN) and an electronic kilo Ammeter, able to measure the secondary voltage (range 0-20V) and secondary current (range 3-40kA).

The calibration tool sensor thickness must not exceed 40mm.

Kistler type 9831C

or

Miyachi MM380 with MA771 Sensor

Miyachi welding gun calibration kit

1 Caliper



6.6. Force calibration

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

Force calibration procedure


1. Use the caliper to measure the thickness of the force sensor.

Be sure to take into account the indent of the force sensor as shown on the picture.

D: Distance between electrode tips when clamping on force sensor

2. If the Gun is mechanically attached to a robot, the gun must be first positioned such as the gravity does not affect the force calibration: The axis of the electrodes must be horizontal (parallel to the plan of the floor).

A gravity compensation software is available from ABB. Please contact ABB.

3. Follow the calibration procedure in the manual 3HAC026820-001 - Servo Gun Tuning - section Force Calibration and execute the service routine ManForceCalib.

NOTE!

When measuring the force, it is important to take the actual force value, and not an average value.

The reason is that the average force includes the ramp up and ramp down of the force. This results in the average force being slightly lower than the constant applied force.

If the average value is used, it will result in a poor calibration, where the applied force is greater that the desired force.

Use the following parameters to set up force calibration data:Number of Force: 5

Force max: 90% of the maximum force allowed for this gun (Unit: N)

Thickness: the actual thickness of the force sensor (Unit: mm)

Time: 1or 2 (Unit: s)



6.7.1. Download the IRC5 I/O settings©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

6.7 Communication between the controller and the Bosch Timer

6.7.1. Download the IRC5 I/O settings

Instructions

In order for the Bosch timer to communicate with the IRC5, the device needs to be defined in

the IRC5 I/O settings.

The following tasks must be performed:

1.)The possible EIO unit types should be added to the EIO.cfg.

2.)The Bosch Timer Unit should be defined with a DeviceNet Address.

3.)The IO signals should be assigned to the Bosch Timer Unit.

4.)Communication should be tested between the Bosch Timer and the IRC5.

The EIO settings can be altered by first downloading the existing EIO.CFG. The file can then

be modified and uploaded again. Using Robot Studio, connect to the IRC5:


1. Open Robot Studio and Connect Online to the Robot Controller. Then click Save Parameters.

Robot Studio menu

2. Select I/O and click on Save...

Save I/O parameters

3. Save the file on your local system in an appropriate location.

Modify the file using a text editor such as Notepad, as shown in the following procedures.



6.7.2. Bosch Timer Unit settings

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

6.7.2. Bosch Timer Unit settings

EIO Unit TypesThe following settings are the standard EIO Unit Type for the standard MFDC and the AC Bosch Timers:

Bosch timer unit

The Bosch timer is typically connected on the “DeviceNet1” with the DeviceNet address 21.

This should be checked with the Bosch Timer Manual.

The baud rate is typically set to 500kbs.

Once these settings have been made to the EIO.cfg, load the file back in to the IRC5 and

perform a warm restart. The communication can then be checked.

After the restart, ensure that no error appears on the teach pendent related to the DeviceNet.

Then check the Bosch timer DeviceNet signal is without error.

6.7.3. Install the BOS6000 Software

General

The BOS6000 Software is used to interface with the Bosch Timer.

This software can be acquired from your local Bosch supplier.

EIO_UNIT_TYPE:

For MFDC timer:

-Name “PSX6100_630” -BusType “DNET” -VendorName “Robert BOSCH Gmbh”\

-ProductName “PSI6100.630L2” -DN_VendorId 255 -DN_ProductCode 9\

-DN_DeviceType 12 -DN_MajorRev 2 -DN_MinorRev 2 -DN_C1Type “COS”\

-DN_C1OutputSize 9 -DN_C1InputSize 9

For AC timer:

-Name “PST6100_630” -BusType “DNET” -VendorName “Robert BOSCH Gmbh”\

-ProductName “PST6100.630L1” -DN_VendorId 255 -DN_ProductCode 9\

-DN_DeviceType 12 -DN_MajorRev 2 -DN_MinorRev 2 -DN_ExplicitMsgEnabled \

-DN_C1Type “COS” -DN_C1OutputSize 9 -DN_C1InputSize 9

EIO_BUS:

-Name “DeviceNet1” -BusType “DNET” -ConnectorID “PCI1”\

-ConnectorLabel “First DeviceNet”

EIO_UNIT:

For PSX6100_630

-Name “SWTimer1_PC1” -UnitType “PSX6100_630” -Bus “DeviceNet1”\

-UnitLabel “SWTimer1_PC1” -DN_Address 21

For PST6100_630

-Name “SWTimer1_PC1” -UnitType “PST6100_630” -Bus “DeviceNet1”\

-UnitLabel “SWTimer1_PC1” -DN_Address 21



6.7.4. Connect to the Spot welding cabinet through Serial Link©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

6.7.4. Connect to the Spot welding cabinet through Serial Link

Cabling

To connect the Bosch Timer, a Serial cable or a USB to Serial Adaptor cable is required:

Qty Tool Info

1 USB to Serial Adaptor

USB to serial adapter

Or:

1 Female to Female Serial Cable

Female to Female Serial Cable

Note that here are different types of female to female serial cable connectors. The Spot welding cabinet only works with the following internal wiring:

Female to Female Serial Cable wiring



6.7.5. Check signals from IRC5 to timer

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

6.7.5. Check signals from IRC5 to timer

Diagnosis

The Bosch Timer interface has a function to view the signals into and out of the timer. The

user can use this view to check that signals to the IRC5 are being received by the Bosch Timer

and to see what signals are being sent by the Bosch Timer:

Diagnosis

Background Information on Bosch IO signals

Note that the parity bit is used to invert the parity of the program number. The default is to

have this bit set. One of the outcomes of this is that the Program number will be high on the

Bosch timer, when the Program1 bit is low on the IRC5.

Input E00 “Program number / Spot name select”

If the serial input E06 = 1; The timer regards the input bits 32... 51 and the input bits 57 to 68

as a program number selection. When the entered number is above 255, the timer stops with

the error message: “Program number out of range”.

If the serial input E06 = 0; The timer regards the input bits 32... 51 and the input bits 57 to 68

as a spot number selection. When the entered spot number is below 256, the timer stops with

the error message: “Spot number out of range”.

Output bit 6: “Program number / Spot name selection confirmation” confirms the mode of

selection:

Serial input bit 06 = 1 => Serial output bit 06 =1;

Serial input bit 06 = 0 => Serial output bit 06 =0;

Electrode tip and tip dresser maintenance:

For 4 tips and 4 dresser knifes, by separate signals.

Tip 1 = Knife 1, Tip 2 = Knife 2 etc.

Admissible electrode number: 1....4



6.7.6. Quick start to welding©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

6.7.6. Quick start to welding

Instructions

Reference the Bosch Software manual BOS6000 User Manual (1070087074 ed 1) for more

information on how to use the BOS6000 Software.

Below are the setting for a simple MFDC spot that can be used to verify that the spot welding gun is working correctly:

Action

1. Start the BOS6000 software. The standard password is bos6000 (note that this is case sensitive).

Login

2. Add a new Timer, and choose the correct COM port for the serial connection to the Bosch Timer:

Add Timer

Note: The COM port of the serial cable can be checked in the computer device manager. Check what the required port number is under Ports (COM & LPT):

Device manager




© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

3. Click OK followed by Continue to proceed to the next screen.

If communication cannot be established, the Status will be RED:

Red status

In this case, check the following:

• Serial Cable connection to the Bosch Timer is correctly connected.

• The Correct COM port has been selected for the this serial connection

• The correct type of serial cable is being used

If communication is established, the Status will be YELLOW:

Yellow status

The software will also prompt the user to select the synchronization direction.

If the timer has later settings which are to be kept, then choose Timer -> DB

If the PC has later settings, then choose DB -> Timer

4. Once synchronization has been completed, the following window will automatically open:

Sequence tab



6.7.6. Quick start to welding©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

5. Before completing any welding, the transformer settings should be set.

Choose the Electrode tab, and under Transformer and Diodes fields input the following:

For MFDC:

MFDC Settings

For AC:

AC settings




© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.


7 Maintenance

7.1. Introduction©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

7 Maintenance

7.1. Introduction

General

This chapter details all maintenance activities recommended for the FlexGun.

It is based on the maintenance schedule, located in the beginning of the chapter. The schedule

contains information about required maintenance activities including intervals and refers to

procedures for the activities. Each procedure contains all information required to perform the

activity, e.g. required tools and materials. The procedures are gathered in different sections,

divided according to the maintenance activity.

Safety information





Precautions

The precautions below should be observed before proceeding with the maintenance of the

FlexGun:

CAUTION!

• Welding arms and cooling systems are hot after welding. Let them cool down before

any intervention.

• All power supplies to the FlexGun as well as to other machines within the danger zone

must be turned off.

• If required, the main switch should be locked.

• Make sure that the cooling system is not pressurized.

• Use only original ABB spare parts. The use of unauthorized parts or others than

original parts will void the warranty.

Required equipment



Equipment Note



Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.



7 Maintenance

7.2. Maintenance planning

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

7.2. Maintenance planning

Even though the FlexGun is designed to require few maintenance operations, it is important

to check the points mentioned hereafter and follow the maintenance time intervals and

instructions.

Time interval Item Maintenance More info.

Every 250,000 weld strokes and once a year

Welding splatters

Clean the unit from welding splatters.

Use a metallic brush.

Cables and harness

Look for premature wearing. General Inspection on page 115.

Water cooling circuit

Look for water leakage or premature hose wearing

General Inspection on page 115.

Laminated leaf shunts

• Re-tighten the bolted joints.

• Remove broken leaves.

• Replace the leaf shunt if 10% of the leaves are damaged.


Bolt, screws, tightening torques on page 147.

Every 500,000 weld strokes

Robot attachment

Re-tighten the bolted joints Bolt, screws, tightening torques on page 147.

Mechanical installation on page 79.

Arms Inspect the condition of the arms

Re-tighten the bolted joints Bolt, screws, tightening torques on page 147.

Every 2,500,000 weld strokes

General condition

Covers removed, inspect the condition of the unit and clean it thoroughly.

Timing belt • Look for premature wearing.

• Measure the belt tension and adjust it if necessary.

• Replace the belt in case of apparent damage.

Timing belt (tension check, adjustment and replacement) on page 116.

Linear unit Lubrication of the roller screw, Lubrication on page 119.Lubrication of the carriage

guideways and ball bearing blocks

Every 10,000,000 weld strokes

Major overhaul Inspection and testing of the FlexGun by an ABB expert.


7 Maintenance

7.3.1. General Inspection©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

7.3 Maintenance instructions

7.3.1. General Inspection

General

A general inspection of the FlexGun should be done every 250,000 cycles and once a year.

The welding gun should be taken off the robot. Read the necessary precautions in this chapter

Introduction on page 113.

Clean the gun from welding splatters with a metallic brush.

Leaf shunts

Inspect the condition of the laminated leaf shunts and the fasteners. Verify that no abnormal

wear, cracks or deformation have occurred.

If required, retighten the fasteners. See Bolt, screws, tightening torques on page 147

Remove the damaged leaves. If more than 10% of the leaves are damaged, the shunt should

be replaced.

See Welding power, conductive parts, and harness on page 155

WARNING!

Damaged shunts or shunts with less than 90% of their initial leaves may cause severe over-

heating, and ultimately, the destruction of the gun!

Water cooling

Inspect the condition of the hoses, connectors fittings and make sure that there is no coolant

leaking.

If required, retighten the connectors or fitting with a thread sealant for conical fittings such

as Loctite 577. See Bolt, screws, tightening torques on page 147

If necessary, replace the damaged hoses or fittings. See Water cooling on page 162

WARNING!

Malfunction of the water cooling circuit may cause severe over-heating, and ultimately, the

destruction of the gun!

Electrical harness and connectors

Verify that cables and connectors are intact, properly fastened and protected, and that there is

no risk of them getting caught or being damaged in any way.

Verify that all the communication signals function properly.

Verify that the earthing is properly done. The FlexGun must not be connected or used if this

is not the case.

See Connection to the dresspack on page 88

DANGER!

Only authorized staff may carry out electrical operations!

Appropriate tools must be used!

Safety procedure must be respected!

Earth grounding must be done properly!


7 Maintenance

7.3.2. Timing belt (tension check, adjustment and replacement)

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.


Inspection

The belt is located under the fixed arm of the gun, protected by a cover. Remove the cover

and inspect the condition of the belt. Wearing of the belt is normal and the presence of a

reasonable quantity of black dust should not be alarming. If however the belt shows signs of

advanced wearing, it should be replaced (see Motor and linear guiding material on page

152).

Location of the timing belt

In any case, you must measure the tension of the belt and, if necessary, adjust it.

1 Motor mounting screws and washers (4x socket head cap screws CHC M8x25)

2 Tension adjustment locknuts (2x hex nut H8)

3 Tension adjustment screws (2x socket head cap screws CHC M8x40)

4 Timing belt

5 Motor shaft pulley

6 Roller screw shaft pulley


7 Maintenance

7.3.2. Timing belt (tension check, adjustment and replacement)©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

Tension of the belt

The easiest and most reliable method to measure the belt tension is to use a tension gauge with

an optical resonance frequency meter, such as the Continental CONTITECH VSM-1.

You can also measure the belt tension by measuring the rib/strand deflection distance of the

belt when applying a force.

Below are the correct values for the belt tension:

TIP!

You can order a tension gauge (Continental CONTITECH VSM-1) to ABB under the

reference number 3HAW050009048. See Special tools on page 150

Tension gauge method Deflection method

New belt 189 ± 5 Hz F = 25 to 27 N

d = 1.95 mm

Used belt 160 ± 5 Hz F= 20 to 21 N

d = 1.95 mm


7 Maintenance


© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

Adjustment or replacement of the belt

Steps Actions Info/Illustration

1. • For the replacement of the belt, the fixed arm and its holder must be removed first.

• For a tuning, simply remove the cover.

2. • For a replacement, loosen the 4 motor mounting screws but do not remove them. Loosen the locknuts and the adjustment screws until you can lift the motor mounting such as the belt is loose enough to be removed. Replace the belt. Make sure that the replaced belt is perfectly vertical.

• For a tuning, simply slightly loosen the 4 motor mounting screws. The engine mounting must be kept flat against the beam surface but now able to move up and down for the belt tensioning.

NOTE!

When planning to remove and re-install used belts, measure and record the tension before removing. If the belt is functioning correctly and its resonance frequency is within the ranges indicated on the previous page (i.e. not less than 155 Hz), re-install at the recorded tension.

Loosen the screws

For a replacement, pull up the motor mounting

3. Measure the tension of the belt, preferably with a tension gauge.

Loosen the locknuts and screw/unscrew the 2 adjustment screws to respectively increase/decrease the tension.

Do it bit by bit: try to balance the adjustment on both sides of the motor mounting.

Measure the tension

Adjust the tension

4. When the tension is correct, lock the two nuts, tighten the screws of the motor mounting, and measure the tension again to make sure it has not changed. Put the cover back.


7 Maintenance

7.3.3. Lubrication©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

7.3.3. Lubrication

Lubrication

Lubrication should be performed every 2,500,000 cycles.

Make sure that the gun is fully open to make the lubrication nipples match the ports.

There are 6 lubrication ports on the FlexGun:

Grease fittings

The mobile arm carriage must be in its upper position (end of stroke, transformer side) to

carry out the lubrication of the carriage linear ball bearing blocks.

Inject 2 cm3 of grease into each port.

NOTE!

To remove old grease or grease in excess, use a spatula and/or a clean lint-free cloth. Do not

use a brush, which hair could contaminate the unit.

WARNING!

Use only lithium base grease, with a mineral oil base, and the following characteristics:

• NLGI consistency 2

• Base oil viscosity ISO VG68 to ISO VG 100

• Doped with EP additives.

Recommended product:

1 5 plugs to be removed to clear access to the lubrication nipples

2 Port for the lubrication of the roller nut

3 Port for the lubrication of the carriage linear ball runner blocks

4 Port for the lubrication of the ball bearings

Equipment Note

Lubricant TOTAL LICAL EP 2


7 Maintenance

7.3.4. Manual jogging of the mobile carriage

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

7.3.4. Manual jogging of the mobile carriage

Principle

The FlexGuns with motor type 9C4 without brake can be manually jogged easily using the

ABB tool 3HAW060005711 and 2 long M6 screws, applied on the roller screw or motor

pulley (see Special tools on page 150).

Manual jogging with 3HAW060005711

On the FlexGuns with motor type T, the brake needs to released by applying 24V power

between the pins 13 and 15 of the Harting socket of the gun, or the pins 2and 5 of the motor

power connector (see Wiring diagrams on page 167).


7 Maintenance

7.4. Trouble shooting©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

7.4. Trouble shooting

Only skilled and authorized staff should perform trouble-shooting. Read the necessary

precautions in this chapter Introduction on page 113.

Trouble Possible cause Action More info.

Motor is not running

Brake is not released (only for motors with brake)

Verify the brake circuit Servo motor type 9C4 on page 57.

A wire is cut Verify the motor and resolver wiring

Change cable

Electrical connections on page 62.

Drive unit failure Replace the drive unit Robot and robot controller requirements on page 68.

Shunt or transformer over temperature

Screws are loosen Verify that shunts and contacts are not damaged. Replace the part if it is necessary and/or tighten the screws with torque wrench


Water cooling flow rate too low

Verify the cooling circuit Water cooling on page 65.

Secondary current overload

Verify that the actual permanent current is lower than the rated current expected

Welding current too low (1)

Primary voltage too low

Verify the voltage of the welding power supply

No or bad feedback from current sensor

Verify its resistance is about 30 Ohm

Verify the wiring


Some screws are loosen

Tighten the screws with torque wrench


Welding current too high (2)

No or bad feedback from current sensor

Verify its resistance is about 30 Ohm

Verify the wiring


Tips abnormal wear or weld spot bent

Electrode are not perpendicular to the sheets

Verify/modify the robot target

Electrode misalignment

Perform a correct alignment of the electrode

Stuck spot weld Worn tips Dress/change the tips

Sheets are dirty Clean the sheets

Welding current too low

See above (1)

Welding force too high Perform a force calibration Force calibration on page 103.


7 Maintenance

7.4. Trouble shooting

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

Large splatter during welding

Abnormal tips wear Check the cooling circuit

Dress/change the tips

Water cooling on page 65.

Sheets are dirty Clean the sheets

Welding current too low

See above (2)

Welding force too low Check the programmed force Perform a force calibration

Force calibration on page 103.

Tips are dirty Clean/dress the tips

Stuck tips Insufficient cooling of the tips

Check the cooling circuit

Dress/change the tips

Water cooling on page 65.

Secondary current overload

Verify that the actual permanent current is lower than the expected rated current

Welding force too low Check the programmed force Perform a force calibration

Force calibration on page 103.

Shock/noise when gun closing

Wrong value of the sheet programmed thickness

Check/change the programmed thickness

Sheet geometrical issue

Check/Fix the issue

Unstable force at tips level

Bad gun parameters Check them, reload if it is necessary

Do a gun parameter tuning

Controllers settings on page 92.

Abnormal friction and/or clearance on mechanical unit

Check the belt, the motor fasteners, the linear unit

Timing belt (tension check, adjustment and replacement) on page 116.

Trouble Possible cause Action More info.


8 Repair activities

8.1. Introduction©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

8 Repair activities

8.1. Introduction

General

This chapter details some common activities that may be required for a thorough inspection

of the unit or in case of failure of the FlexGun. Each procedure contains all information

required to perform the activity, e.g. required tools and materials.

Safety information





Precautions

The precautions below should be observed before proceeding with the maintenance of the

FlexGun:

CAUTION!


any intervention.


must be turned off.



• Use only original ABB spare parts. The use of unauthorized parts or others than

original parts will void the warranty.

Required equipment



Equipment Note



Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.



8 Repair activities

8.2.1. Introduction

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

8.2 Dismounting of the arms

8.2.1. Introduction

General

The following instructions are based on the procedures required to dismount the arms of a

standard X-Gun. The principle is however applicable for operations on most types of

FlexGuns.

The required equipment is the standard toolkit, and in particular:

Besides, it is recommended to use strong braided thread to fix the position of the leaf shunt.

Toolkit, illustration.

1. Spanner 17, 19

2. Hex keys (Allen keys) 5, 6, 8

3. Hex keys (Allen key) 8 with short neck (no longer than 30mm)

4. Dowel pin remover + long M5 screw

5. Plastic mallet


8 Repair activities

8.2.2. Removal of the fixed arm©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

8.2.2. Removal of the fixed arm

Procedure


1. Disconnect the water cooling pipes from the buss bar with the spanner 19.Be careful as there might be residual water in the pipes and shunt.

fixed arm removal, step1

2. Remove the 4 screws to disconnect the leaf shunt from the buss bar with the hex key 5.

fixed arm removal, step 2

3. Remove the 5 screws that attach the arm to the main beam with the hex key 8. Use the short hex key 8 for the screw located under the buss bar.


4. Use the spanner 17 to remove the screw that is located under the arm.


5. Remove the 2 dowel pins. It is not necessary to extract them completely from the arm holder. Be careful because the dowel pins are now the only attachment of the holder to the beam.

The arm can now be taken off from the Flexgun body.



8 Repair activities

8.2.3. Re-assembly of the fixed arm

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

8.2.3. Re-assembly of the fixed arm

Procedure


1. If the pins are still in the arm holder, leave them. If they are not, insert them completely. Position the arm holder on the gun body and use the mallet to insert the pins in the gun body, but not completely yet. It is preferable to start tightening the screws first.

fixed arm re-assembly, step1

2. Use the hex key 8 to tighten all the screws but do not tighten them completely yet. Use the short hex key to tighten the screw located under the buss bar.Finish inserting the dowel pins with the mallet and then torque-tighten all screws (use the spanner 17 for the one located under the arm).

3. Attach the leaf shunt to the buss bar. If present, don’t forget the aluminium and copper plates, located between the screws and the leaf shunt, and between the leaf shunt and the buss bar.

Reconnect the water cooling pipes to the buss bar with the spanner 19.

Copper and aluminium plate, example


8 Repair activities

8.2.4. Removal of the mobile arm©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

8.2.4. Removal of the mobile arm

Procedure


1. Disconnect the water cooling pipes from the buss bar with the spanner 19.Be careful as there might be residual water in the pipes and shunt.

mobile arm removal, step1

2. Remove the 4 screws to disconnect the leaf shunt from the buss bar with the hex key 5.

TIP!

To prevent the leaf shunt from being damaged during following maintenance operations, use the braided wire to keep it bent and attached to the transformer buss bar. mobile arm removal, step 2

3. Remove the 8 screws that attach the arm to the mobile carriage with the hex key 8.

mobile arm removal, step 3

4. Remove the 2 dowel pins. It is not necessary to extract them completely from the holder. Be careful because the dowel pins are now the only attachment of the bracket to the carriage.

The arm can now be removed from the carriage.

mobile arm removal, step 4


8 Repair activities

8.2.5. Re-assembly of the mobile arm

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

8.2.5. Re-assembly of the mobile arm

Procedure


1. Position the arm bracket on the carriage.Insert the pins with the mallet, but not completely yet. It is preferable to start tightening the screws first.

mobile arm re-assembly, step1

2. Use the hex key 8 to tighten all the screws but do not tighten them completely yet.Finish inserting the dowel pins with the mallet and then torque-tighten all screws.

3. Attach the leaf shunt to the buss bar. Don’t forget the intermediate aluminium and copper plates, located between the screws and the leaf shunt, and between the leaf shunt and the buss bar.

Reconnect the water cooling pipes to the buss bar with the spanner 19.

Copper and aluminium plates, example


8 Repair activities


Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

8.3 Replacement of the pulleys

8.3.1. Introduction

General

To replace either one of the pulleys, it is necessary to first dismount the fixed arm and the belt.

See Pulley replacement procedure on page 130 and Timing belt (tension check, adjustment

and replacement) on page 116.

The required equipment is the addition of the tool 3HAW060005711 (see Special tools on

page 150) and the standard toolkit, and in particular:


1. Spanner 19

2. Hex keys (Allen keys) 3, 5 and 6 (6 for ball screw pulley only)

3. Lock wrench

4. The following screws:

• 2x CHc M6x25 or 2x CHc M6x30 (to be associated with 3HAW060005711)

• 1x H M12x45 or 1x H M12x50 (removal of the pulley)

• 1x CHc M8x50 (reassembly of the pulley on the roller screw shaft)

• 1x CHc M8x35 (reassembly of the pulley on the roller screw shaft)

• 1x CHc M6x50 (reassembly of the pulley on the motor shaft)

• 1x CHc M6x35 (reassembly of the pulley on the motor shaft)

• 1x plain washer inner diameter 6.2


8 Repair activities

8.3.2. Pulley replacement procedure

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

8.3.2. Pulley replacement procedure

Procedure


1. Unscrew the lock screw (type hpc M6x6) with the hex key 3.

pulley replacement, step1

2. Use the 2 screws M6x25 or M6x30 to attach the tool 3HAW060005711 to the pulley. Then start screwing the M12 screw in the central hole.

pulley replacement, step 2

3. Use the spanner 19 to screw the M12 screw while you hold the tool 3HAW060005711 with the other hand. This will pull the pulley away from the motor or ball screw shaft.If the M12 screw is not long enough, you can finish the extraction by gently tapping behind the pulley with a soft mallet.

pulley replacement, step 3-1

pulley replacement, step 3-2


8 Repair activities

8.3.2. Pulley replacement procedure©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

4. If necessary, use the lock wrench to extract the key from the shaft.


5. If you need to replace the pulley, detach the tool 3HAW060005711 from the current one and use the 2 screws M6x25 or M6x30 to attach it to the new one.


6. Position the pulley onto the shaft and use the hex key (5 for the motor shaft or 6 for the ball screw shaft) to start screwing the M6x50 or M8x50 screw with the washer on. This will push the pulley onto the shaft.

When you reach the maximum you can screw with the 50mm screw, replace it with the 35mm screw and keep screwing until the pulley is back into the position it originally was. Make sure that the pulley doesn’t come in contact with the gun body surface.The 2 pulleys must be perfectly aligned on a vertical plan.


7. Finally, re-tighten the lock screw (type hpc M6x6) with the hex key 3.



8 Repair activities

8.4.1. Introduction

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

8.4 Replacement of the motor

8.4.1. Introduction

General

To dismount the motor, it is necessary to first dismount the fixed arm and the belt. See Pulley

replacement procedure on page 130 and Timing belt (tension check, adjustment and

replacement) on page 116.

For a replacement of the motor, you need to transfer the pulley from the old motor shaft to the

new one. See Pulley replacement procedure on page 130


8.4.2. Motor replacement procedure

Procedure

1. Spanners 10 and 13

2. Hex key (Allen key) 6


1. Position the gun on the worktable such as the motor cables can be easily disconnected and the motor easily extracted.

motor replacement, step1

2. Disconnect the motor cables. See Electrical connections on page 62.

motor replacement, step 2


8 Repair activities

8.4.2. Motor replacement procedure©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

3. If the belt is present, remove it as explained inTiming belt (tension check, adjustment and replacement) on page 116. For a replacement of the motor, you need to transfer the pulley from the old motor shaft to the new one. See Pulley replacement procedure on page 130.

NOTE!

When planning to remove and re-install used belts, measure and record the tension before removing. If the belt is functioning correctly and its resonance frequency is within the indicated ranges (i.e. not less than 155 Hz), re-install at the recorded tension.

4. Use the Allen key 6 to remove the motor mounting screws. Be sure to hold the motor mounting with your other hand as these screws are its last attachment to the gun body.

You can now extract the motor and its mounting out of the gun body.

motor replacement, step 4

5. Remove the 4 screws with the Allen key 6 to separate the motor from its mounting.


6. To re-assemble, proceed in the opposite order. Torque-tighten all screws and perform a tuning of the belt tension!



8 Repair activities

8.5.1. Introduction

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

8.5 Replacement of the transformer

8.5.1. Introduction

General

To replace the transformer, it is necessary to first dismount the FlexGun back plate. It is

recommended to dismount the arms as well.

Before proceeding, the gun carriage should be in “open” position to clear the access to the

buss bar fasteners.



1. Spanner 8 and 10 (socket wrenches recommended)

2. Hex keys (Allen keys) 6 and 8

3. Dowel pin remover + long M5 screw (for the removal of the back plate)


8 Repair activities

8.5.2. Transformer replacement procedure©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

8.5.2. Transformer replacement procedure

Procedure


1. Use the spanners 8 and 10 to remove the 4 screws of the top cover. Remove the cover by sliding it out.

transformer replacement, step 1

2. Use the hex key 6 to detach the manifold from the gun beam.


3. From the top of the gun, use the hex key 6 to remove the 6 screws that attach the buss bars to the transformer.


4. Use the spanner 8 to remove the 4 screws of the screen plate and remove the plate.


5. Disconnect the quick connect fittings of the water cooling circuit (you can pull the “WATER IN” fitting from outside of the beam).



8 Repair activities

8.5.2. Transformer replacement procedure

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

6. Use the hex key 6 to remove the 8 screws (4 on each side) that hold the transformer.


7. Extract the transformer from the bottom of the Flexgun. It is preferable to use the help of another person as the transformer is very heavy and can be difficult to extract.


8. To re-assemble, proceed in the opposite order.If necessary, use a mallet to push the transformer back in.Torque-tighten all screws!




8 Repair activities


Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

8.6 Replacement of the roller screw

8.6.1. Introduction

General

The roller screw is an essential high-technology component of the FlexGun linear unit. It is

designed to sustain very high loads and, if lubrication is performed according to the related

instructions of the maintenance section, it should last for the whole lifetime of the FlexGun.

In case of failure of the linear drive unit, make sure that you first identify and, when required,

fix all the possible root causes other than a failure of the roller screw.

Unless there is a confirmed need to dismount the roller screw, do not do it. The roller nut

(locked in the mobile carriage) is precisely synchronised to the screw and removing it implies

a risk of problematic re-assembly and/or damage.

To dismount the roller screw, it is necessary to first dismount the mobile and fixed arms, and

the timing belt. See Dismounting of the arms on page 124 and Timing belt (tension check,

adjustment and replacement) on page 116.

The required equipment is the addition of the tools 3HAW060005708, 3HAW060005711 (see

Special tools on page 150) and the standard toolkit (in particular, the tools required in

Dismounting of the arms on page 124, Timing belt (tension check, adjustment and

replacement) on page 116 and Pulley replacement procedure on page 130).

It is also recommended to use ball bearing blocks plastic protections (shaped like the rails) to

prevent the balls from falling off the block when sliding them off the rails.



8 Repair activities

8.6.2. Roller screw replacement procedure

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.


Procedure


1. Use the spanners 8 and 10 to remove the 4 screws of the top cover. Remove the cover by sliding it out.

roller screw replacement, step 1

2. Use the hex key 6 to remove the 3 screws on the end cover (connector side). Use the wrench 8 to remove the screws on each side cover.Remove the end cover.


3. If necessary, manually jog the carriage with the tool 3HAW060005711 as shown in Manual jogging of the mobile carriage on page 120 to move the carrier until you can see the hard stop bumper attached to the beam.

Use the hex key 6 to remove the 2 screws of the bumper and take it off the beam.


The reason of doing this is that the roller screw cannot be extracted from the body as long as the roller nut (locked in the carriage) does not reach the un-threaded part of the screw. To achieve so, the carriage must be manually jogged beyond its normal mechanical limit.


8 Repair activities

8.6.2. Roller screw replacement procedure©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

4. Manually jog the carriage with the tool 3HAW060005711 as shown in Manual jogging of the mobile carriage on page 120 to move the carrier to the connector side, until you reach the position shown on the picture.

CAUTION!

Be careful as there is a risk of losing ball bearings from the runner block. Use the plastic protection (shaped like the rails) if possible

roller screw replacement, step 4-1


5. Remove the roller screw shaft pulley as shown in Pulley replacement procedure on page 130.

6. Use the (socket) wrench 10 to remove the locknut.

Then use the Allen key 3 to remove the screw.



7. Remove the sealing threaded ring using the tool 3HAW060005708. The ring is torque-wrenched (43 N.m) so you might need a long wrench.




8 Repair activities


© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

8. Extract the roller screw.

If the roller nut (located in the mobile carriage) is still on the threaded part of the screw, you need to rotate the shaft counter-clock wise until it can be extracted.

The spacer 3HAW060005311 should come with the roller screw.


9. For a replacement of the roller screw, the roller nut contained in the carriage must be replaced as well (screw and nut are strictly paired).

To do so, take the carriage off the rails (with the necessary precautions explained above) and

remove the lock screw and threaded ring using the tool 3HAW060005708. the roller nut can now be replaced.Re-tighten the threaded ring with the ABB tool 3HAW060005708 and the torque wrench set at 43 N.m with a drop of thread-locker. roller screw replacement, step 9

10. To reassemble, gently tap the ball screw with the mallet to insert the set of bearings deep in the beam slot and use your hand to manually start screwing it in the carriage roller nut.

Leave the ball bearing protections in position until the runner blocks are back onto the rails.

NOTE!

The screw should be perfectly clean of any impurity, and covered with a clean film of oil. See the requirements in Lubrication on page 119.

11. Insert the spacer 3HAW060005311. Pay attention to the spacer orientation, the notches must appear outside.

You can use a couple of screws to fully push the spacer in its slot.




8 Repair activities

8.6.2. Roller screw replacement procedure©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

12. Re-tighten the threaded ring with the ABB tool 3HAW060005708 and the torque wrench set at 43 N.m with a drop of thread-locker.

Use the Allen key 3 to lock the ring by screwing the M6X12 screw with Delrin tip. Tighten it with a low torque (6-7 N.m max.).

Tighten the locknut on it with the socket wrench 10.


13. Re-assemble the pulley as shown in Pulley replacement procedure on page 130.

Manually jog the carriage back and forth to make sure that the carriage movement is smooth and fiction-free.

Re-assemble the hard stop bumper onto the beam.

14. Re-assemble the timing belt as shown in Timing belt (tension check, adjustment and replacement) on page 116.

Put all the covers back



9 Decommissioning

9.1. Decommissioning©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

9 Decommissioning

9.1. Decommissioning

Safety information





Precautions

The precautions below should be observed before proceeding with the decommissioning of

the FlexGun:

CAUTION!


any intervention.


must be turned off.



Required equipment

Hazardous materialThe table specifies some of the materials in the track motion and their respective use throughout the product. Dispose of the components properly to prevent health or environmen-tal hazards.

Equipment Note



Material Example application

Copper alloy Cable, motor, transformer, arm, tip, shunt, etc.

Steel Gears, screws, nuts, etc.

Stainless steel Cover, screws for primary connection of transformer, etc.

Plastic / Rubber (PVC) Cables, connectors, belt, etc.

Aluminium Beam, mobile carriage, motor holder, arm holders, etc.


9 Decommissioning

9.1. Decommissioning

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

Oil and grease

Where possible, arrange for the oil and grease to be recycled. Dispose of oil and grease via

an authorized person/contractor in accordance with local regulations. Do not dispose of oil

and grease near lakes, ponds, ditches, down drains or onto soil. Incineration must be carried

out under controlled conditions in accordance with local regulations.

Also note that:

• Spills may form a film on water surfaces causing damage to organisms. Oxygen

transfer could also be impaired.

• Spillage may penetrate the soil causing ground water contamination.


10 Reference information

10.1. Introduction©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.


10.1. Introduction

General

This chapter includes general information, complementing the more specific information in

the different procedures in the manual.



10.2. Unit conversion

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

10.2. Unit conversion

Converter table

Use the following table to convert units used in this manual.

Quantity Unit

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 N.m 0.738 lbf-tn

Volume 1 L 0.264 US gal



10.3. Bolt, screws, tightening torques©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

10.3. Bolt, screws, tightening torques

Bolt and screws

Before tightening any screw, observe the following:

• Determine whether a standard tightening torque or special torque is to be applied.

The standard torques are specified in the following tables. Any special torques are

specified in the repair, maintenance or installation procedure descriptions. Any

special torque specified overrides the standard torque!

• Use the correct tightening torque for each type of screw joint.

• Only use correctly calibrated torque keys.

• Always tighten the joint by hand, and never use pneumatic tools.

• Use the correct tightening technique, tighten the screw in a slow, flowing motion.

• Maximum allowed total deviation from the specified value is 10%!

NOTE!

The bolts used on (or provided with) the FlexGun are of 3 different classes: 8.8, 10.9, and

12.9. Unless indicated otherwise, the screws are by default of class 8.8.

NOTE!

Unless indicated otherwise, all bolts must be clean of oil or grease and tightened with a mild

thread-locker such as Loctite 243.

Standard tightening torques

The following table specifies the recommended standard tightening torques for hex screws

and socket head cap screws:

The following table specifies the recommended standard tightening torque for water and air

connectors when one or both connectors are made of bras:

Screw thread size M5 M6 M8 M10 M12

Tightening torque

CLASS 8.8

5.5 N.m 9.5 N.m 23 N.m 46 N.m 79 N.m

Tightening torque

CLASS 10.9

8.1 N.m 14 N.m 34 N.m 67 N.m 116 N.m

Tightening torque

CLASS 12.9

9.5 N.m 16.4 N.m 40 N.m 79 N.m 136 N.m

Dimension Tightening torque Nm - Nominal

Tightening torque Nm - Minimal

Tightening torque Nm - Maximum

1/8 12 N.m 8 N.m 15 N.m

1/4 15 N.m 10 N.m 20 N.m

3/8 20 N.m 15 N.m 25 N.m

1/2 40 N.m 30 N.m 50 N.m

3/4 70 N.m 55 N.m 90 N.m



10.3. Bolt, screws, tightening torques

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

Notable tightening torques

The following table specifies the tightening torques for notable parts of the unit, which

fastener are not standard class 8.8 screws:

Parts Fasteners Tightening torque

Standard electrode holder clamping

Clamping

4x

socket head cap screws M6x25

CLASS 12.9

16.4 N.m

Threaded rings that hold the ball bearings on the beam, and the roller nut in the carriage

Threaded rings

To be tightened with ABB tool 3HAW060005708 + torque wrench.

43 N.m

Fastening of the carriage onto the ball bearing blocks

Carriage and runner blocks

4x

4x


CLASS 10.9

14 N.m

Fastening of the guideways onto the beam

Guideways fastening

2x

10x


CLASS 12.9

16.4 N.m

Transformer primary pins

Transformer primary pins

/ 6 N.m



10.4. Standard toolkit©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

10.4. Standard toolkit

General

All service (repairs, maintenance and installation) procedures contain lists of tools required

to perform the specified activity.

All special tools required are listed directly in the procedures while all the tools that are

considered standard are gathered in the standard toolkit and defined in the table below.

This way, the tools required are the sum of the standard toolkit and any tools listed in the

instruction.

Contents, standard toolkit

Qty Tool

1 Set of spanners 8-22 mm

1 Hex keys (Allen key) 3, 4, 5, 6, 8 and 10 mm

1 Torque wrench 10-140 Nm

1 Ratchet head for torque wrench 1/2

1 Socket head cap 5mm, 6mm, 8mm, 10mm socket 1/2" bit L 20 MM

(for socket head cap screws - ISO 4762 - sometimes referred to as “CHC screws”)

1 Hex head cap 8mm, 10mm, 13mm, 19mm socket 1/2" bit L 20 MM

(for hex screws - ISO 4017 - sometimes referred to as "H screws")

1 Plastic mallet

1 Dowel Pin remover

1 Mild thread-locker (Recommended: Loctite 243)



10.5. Special tools

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

10.5. Special tools

General

All service instructions contain lists of tools required to perform the specified activity. The

required tools are a sum of standard tools, defined in the section Standard toolkit on page 149,

and of special tools, listed directly in the instructions and also gathered in this section.

Special tools

The following table specifies the special tools required during several of the service

procedures. The tools are also specified directly in concerned instructions in the Product

manual.

Special tools available from ABB

The following table specifies the special tools required during several of the service

procedures. The tools may be ordered separately and are also specified directly in concerned

instructions in the Product manual.

For operations on water cooling circuit connectors:

Qty Tool Product

1 Thread sealant for conical fittings Loctite 577

For operations on conductive parts:

Qty Tool Product

1 Conductive grease Molydal Thermolub SP

1 Insulation meter

For operations on electrical parts:

Qty Tool Product

1 Crimping pliers for 35mm² lug and insertsORCrimping pliers for 25mm² lug and inserts

The type of needed pliers depends on the type of DressPack: 35mm² lugs for the Orange Line 25mm² for the Integrated DressPack IRB 6640 LeanID

- Multi Contact (MC):

Crimping pliers 18.3710 - M-PZ-T2600 with

35mm² cores 18.3712 - TB9-13

or

25mm² cores 18.3704 - MES-PZ-TB11/25

A: Crimping pliers, B: Inserts

1 Wire stripper

1 Cable cutter

Qty Tool ABB Article no.

1 ABB wrench tool for pulley 3HAW060005711

1 ABB wrench tool for threaded rings 3HAW060005708

1 Welding Gun force and current calibration kit 3HAW050009047

1 Tension gauge 3HAW050009048


11 Spare parts

11.1. Introduction©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

11 Spare parts

11.1. Introduction

General

This chapter specifies all spare parts and replacement articles of the FlexGun.

Unless indicated otherwise, the listed parts are suitable for all standard X-type and C-type

FlexGuns.

The parts specific to one type are marked as such.

The list of the spare parts specific to your FlexGun(s) (typically, the constitutive parts of the

arms and robot attachment) should be provided with the delivery.


11 Spare parts

11.2. Motor and linear guiding material

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.


Motor and motor mounting

The following parts depend on the version of the motor used.

All FlexGuns assembled before 2012 use a motor type 9C (without brake).

If you do not know which version you have, contact ABB.

Motor and motor mounting

Item Quantity ABB part reference no. Note

A 1 3HAWL000101 Servomotor type 9C

3HAWL000325 Servomotor type T

B 1 3HAW060005003 Motor holder for motor type 9C

3HAW060005143 Motor holder for motor type T


11 Spare parts

11.2. Motor and linear guiding material©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

Linear guiding and roller screw

Linear guiding and roller screw

NOTE!

Contact ABB if you do not know whether your FlexGun requires Bosch Rexroth or SBC linear

guiding material.

Item Quantity ABB part reference no. Description

A 4 3HAWL000103 Ball bearing block (Bosch Rexroth)

3HAWL000178 Ball bearing block (SBC)

B 2 3HAW060005033 Guideway (Bosch Rexroth)

3HAWL000177 Guideway (SBC)

C 1 3HAWD06000001 Roller screw kit (including bearings)

D 1 3HAW060005026 Toothed pulley 36 - 5M25

(Order in addition the tool 3HAW060005711. See Special tools on page 150.)

- 1 3HAWL000132 Key 6x6x35 (for roller screw shaft)

You can also obtain it from a standard components supplier.

Example: Misumi, ref. KESH6-35

E 1 3HAWL000138 Timing belt

F 1 3HAW060005025 Toothed pulley 28 - 5M25


- 1 3HAWL000320 Key 6x6x30 (for motor shaft)

You can also obtain it from a standard components supplier.

Example: Misumi, ref. KESH6-30

- 1 3HAW060005012 Hard stop for mobile arm carriage


11 Spare parts


© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

Threaded rings for roller screw nut and bearings

Threaded rings


A 1 3HAW060005308 Threaded ring for beam - holds the roller screw bearings.


B 1 3HAWL000111 Sealing for threaded ring

C 1 3HAWL000104 Threaded ring for carriage - holds the roller nut.


D 1 - Screw with Delrin tip M6x16

+ flat M6 nut

You can obtain it from a standard components supplier.

Example: Misumi, ref. SBPP6-16

E 1 - Screw with Delrin tip M6x12

You can obtain it from a standard components supplier.

Example: Misumi, ref. SBPP6-12


11 Spare parts

11.3. Welding power, conductive parts, and harness©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

11.3. Welding power, conductive parts, and harness

Transformers

Buss bars and insulation, standard gun body

Buss bars and insulation, standard gun body

ABB part reference no. Description

3HAWL000102 DC Transformer (Elesa type)10V, 500V, 1000Hz, 91kVA

3HAWL000170 AC Transformer (Elesa type)10V, 400V, 50Hz, 88kVA

3HAWL000317 DC Transformer (Roman type)10.8 V, 500V, 1000Hz, 91kVA


A 2 3HAW060005017 Nylon shunt holder

B 1 3HAW060005015 Insulating plate between beam and buss bars

C 1 3HAW060005016 Insulating plate between buss bars

D 2 3HAW060005410 Nylon dowel pin

E 1 3HAW060005055 Transformer buss bar - fixed arm side

F 1 3HAW060005082 Transformer buss bar - mobile arm side


11 Spare parts

11.3. Welding power, conductive parts, and harness

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

Buss bars and leaf shunts, standard X- and C-types

The following picture shows the assembly of a standard X-Gun with copper arms.

The table below also provides their equivalent for standard guns with copper or aluminium

arms, X- and C types.

Buss bars and leaf shunts, Standard X- and C-types

Item Quantity ABB part no. Description

A 1 3HAW060005057 Mobile arm leaf shunt (all types of gun)

B 1 3HAW060005058 X-Gun fixed arm leaf shunt

3HAW050023065 C-Gun 0° fixed arm leaf shunt





C 1 3HAW060005059 X-Gun mobile copper arm buss bar

3HAW060005062 X-Gun mobile copper arm buss bar - inverted

3HAW050009018 X-Gun mobile aluminium arm buss bar

3HAW060005077 C-Gun mobile copper or aluminium arm buss bar

D 1 3HAW060005060 X-Gun fixed copper arm buss bar

3HAW050009019 X-Gun fixed aluminium arm buss bar

3HAW060005078 C-Gun fixed copper arm buss bar

3HAW060005027 C-Gun fixed aluminium arm buss bar

E 4 3HAW060005411 Aluminium plate for leaf shunts fixation

F 2 3HAWL000133 O Ring 2.1X1.6 for buss bar


11 Spare parts

11.3. Welding power, conductive parts, and harness©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

Adapter plate and female plug

Adapter plate and female plug

Gun Harness


A 1 3HAWL000140 Adapter Plate

B 13HAWL000141 Female plug 35mm²

3HAWL000381 Female plug 25mm²

Quantity ABB part no. Description

1 3HAW050008639 Electrical harness (for guns with motor type 9C) - OrangeLine DressPack

1 3HAW050008653 Electrical harness (for guns with motor type T) - OrangeLine DressPack

1 3HAW050008658 Electrical harness (for guns with motor type T) - LeanID DressPack


11 Spare parts

11.4.1. Copper arms

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

11.4 Arms spare parts

11.4.1. Copper arms

Copper arm holders, X-Gun

Arm holders - X-type

Copper arm holders, C-Gun

Arm holders - C-type

Copper arm insulation

Insulating sleeve and washer


A 1 3HAW060005005 X-Gun mobile arm holder

B 1 3HAW060005004 X-Gun fixed arm holder


A 1 3HAW060005269 C-Gun mobile arm holder

B 1 3HAW061017002 C-Gun 0° fixed arm holder

3HAW061017012 C-Gun 15° fixed arm holder




A 2 3HAW060005605 Insulating sleeve

B 2 3HAW060005606 Insulating washer


11 Spare parts

11.4.2. Aluminium arms©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

11.4.2. Aluminium arms

Aluminium arm holders, X-Gun

Aluminium arm holders, C-Gun

Aluminium arms insulation

Quantity ABB part reference no. Description

1 3HAW060005023 Arm holder for X-type fixed aluminium arm

1 3HAW060005022 Arm holder for X-type mobile aluminium arm


1 3HAW060005030 Arm holder for C-type 0° fixed aluminium arm






1 3HAW060005269 Arm holder for C-type mobile aluminium arm


4 3HAW050008766 Insulation Plate 1-1/1-3, for X-type alu. arms gun

2 3HAW050008769 Insulation Plate 1-2 for, X-type alu. arms gun

2 3HAW050008771 Insulation Plate 1-4, for X-type alu. arms gun

2 3HAW050008767 Insulation Plate 2, for X-type alu. arms gun

2 3HAW050008768 Side Plate, for X-type alu. arms gun

2 3HAW060005605 Insulating sleeve, for C-type aluminium arm

2 3HAW060005606 Insulating plate, for C-type aluminium arm


11 Spare parts

11.4.3. Standard tips, electrode clamps and O-rings

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

11.4.3. Standard tips, electrode clamps and O-rings

List of tips, clamps and o-rings

Caps B


3HAW060005910 Copper electrode cap B D13 (see drawing below)



3HAW060005085 Electrode clamp D20

3HAW060005086 Electrode clamp D25

3HAW060005974 Electrode clamp D31.5

3HAWL000356 O-ring D10×1.8

3HAWL000354 O-ring D10×2.65

3HAWL000364 O-ring D12x1

3HAWL000355 O-ring D20x1.8


3HAWL000358 O-ring D22×1.9

3HAWL000133 O-ring D22.1X1.6



3HAWL000351 O-ring D25×2.65


3HAWL000357 O-ring D28×2.4


3HAWL000134 O-ring D31.47x1.78

3HAWL000359 O-ring D31.5×1.8

3HAWL000353 O-ring D31.5×2.65



3HAWL000352 O-ring D35.5×2.65


11 Spare parts

11.5. Robot attachment©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

11.5. Robot attachment

Robot attachment parts

See Attachement - FlexGun side on page 80 and Attachement - robot side on page 83, or the

assembly drawing delivered with your FlexGun for the parts details and needed quantities.


3HAW060005268 FlexGun back plate

3HAW060005262 Locating ring

3HAW060005261 Holder for 40° positioning - connector side

3HAW060005263 Holder for 90° positioning - connector side

3HAW060005273 Interface plate IRB6640 - gun side

3HAW060005274 Interface plate IRB6640 - robot side

3HAW060005288 Interface plate IRB7600 - gun side

3HAW060005287 Interface plate IRB7600 - robot side

3HAW060005289 Locating ring for IRB7600


11 Spare parts

11.6. Water cooling

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

11.6. Water cooling

Water manifold

Water manifold 1 input - 2 outputs

Hose: Transformer buss bar to mobile arm

Hose: transformer buss bar to mobile arm

Hose: Transformer buss bar to fixed arm

Hose: transformer buss bar to fixed arm

Item Qty ABB part reference no. Note

- 1 3HAW060005054 Water manifold1 input - 2 outputs

- 1 3HAW050009020 Water manifold1 input - 1output


11 Spare parts

11.6. Water cooling©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

Hose: Fixed arm to output, X-gun

Hose: from fixed arm to output (X-gun)

Hose: Fixed arm to output, C-gun

Hose: from fixed arm to output (C-gun)

Hose: Mobile arm to output, X-gun

Hose: from mobile arm to output (X-gun)

Hose: Mobile arm to output, C-gun

Hose: from mobile arm to output (C-gun)

Connector and closing plug used on buss bars

Buss bar connector and closing plug


11 Spare parts

11.6. Water cooling

© C

opyr

ight

201

3 A

BB

. All

rig

hts

rese

rved

.

List of the water connectors

You can find below the details of the FlexGun water connectors and hoses, and their reference

number from the original supplier (Parker-Legris or Festo).

ABB ref. no.Qty Xgun

Qty Cgun

Description Supplier ref. no.

3HAWC101125 5 5 Plug BSP G1/8

Legris 0205 10 00

3HAWL000116 7 7 EO Male stud connector with seal G1/4-M16X1.5

Parker GE10LREDOMDMS

3HAWL000117 1 1 Swivel connector with seal G1/2-M22X1.5

Parker EVGE-15LREDMS

3HAWL000118 2 2 Union male with seal G1/2-M22X1.5

Parker F4UCOB16 1/2

3HAWL000119 1 1 Male elbow R1/4-M16X1.5

Parker C4UCOB10 1/4

3HAWL000120 2 2 Female swivel M22x1.5 DN12

Parker 3C382-15-8B

3HAWL000121 1 1 Male straight M22x1.5 DN12

Parker 3D082-15-8B

3HAWL000122 5 4 Female swivel M16x1.5 DN10

Parker 3C382-10-6B

3HAWL000123 1 2 Female swivel elbow45 M16x1.5 DN10

Parker 39B82-10-6BK

3HAWL000124 2 2 Female swivel elbow90 M16x1.5 DN10

Parker 3C582-10-6B

3HAWL000125 2m 2m Push-lock hose DN10 (green)

Parker 837PU-6-GRN-RL

Connectors and hose used for the cooling of the transformer:

3HAWL000114 1 1 Equal elbow male taper R1/4

Legris 0152 13 13

3HAWL000126 3 3 Push-in fitting straight male R1/4-D10

Festo 153073 QSL-10

3HAWL000127 1 1 Equal elbow D10 D10

Festo 153073 QSL-10

3HAWL000128 1 1 Push-in fitting straight female G1/4-D10

Festo 153028 QSF-1/4-10-B

3HAWL000130 4 4 Push-in fitting with tailpieceD10

Festo 153059

3HAWL000131 1 1 Distributor G1/4 D10 D10

Festo 153217

3HAWL000129 1m 1m Anti spark tube D10

Festo 160552


11 Spare parts

11.7. Casing and lubrication ports©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

11.7. Casing and lubrication ports

Casing

Casing pieces

Lubrication ports and nipples


A 1 3HAW060005018 X-Type motor cover

3HAW060005021 C-Type motor cover

B 1 3HAW060005306 Left side cover

C 1 3HAW060005305 Right side cover

D 1 3HAW060005009 Upper cover

E 1 3HAW060005307 End cover (transformer side)

F 1 3HAW060005013 Cover support


1 3HAW060005020 Grease nipple(Located on the side of the body, used for the lubrication of the roller screw bearings)

5 3HAWL000113 Plug to lubrication ports on end cover


12 Appendix

12.1. Wiring diagrams©

Cop

yrig

ht 2

013

AB

B. A

ll r

ight

s re

serv

ed.

12 Appendix

12.1. Wiring diagrams

List

This chapter contains the following wiring diagrams:

• 3HAW060008639: Electrical harness, motor type 9C4, OrangeLine DressPack

• 3HAW050008653: Electrical harness, motor type T, OrangeLine DressPack

• 3HAW050008658: Electrical harness, motor type T, LeanID DressPack


Page

Total Page

FlexGun Harness For ABB MotorHousing With 2xM25 Cable Gland

+

Date Replaced by

Title page / cover sheet

1

Prepare by,

0 76

Replacement of

8 93

16

1

4

0

2

=

Approve by,

5W

ere

serv

eal

lrig

hts

inth

isdo

cum

ent

and

inth

ein

form

atio

nco

ntai

ned

ther

ein

Repr

oduc

tion,

use

ordi

sclo

sure

toth

irdpa

rtie

sw

ithou

tex

pres

sau

thor

ityis

sric

tlyfo

rbid

den.

Copy

right

ABB

3HAW050008639

ApprovedStatus:

Document no. Rev.IndDate A,Stapelberg 2011/10/10N,Cao 2013/6/7 004

2011/10/10

Respsonsible Department: RS / BIW

F26_ABB_Cover

Document Number

Number of pages


16

Project Discription

3HAW050008639Revision 004

Page

Total Page


1

+

Date Replaced by

Layout

1

Prepare by,

0 76

Replacement of

8 93

16

2.a

4

2

2

=

Approve by,

5W

ere

serv

eal

lrig

hts

inth

isdo

cum

ent

and

inth

ein

form

atio

nco

ntai

ned

ther

ein

Repr

oduc

tion,

use

ordi

sclo

sure

toth

irdpa

rtie

sw

ithou

tex

pres

sau

thor

ityis

sric

tlyfo

rbid

den.

Copy

right

ABB

3HAW050008639

ApprovedStatus:


2011/10/10


ac

4

8

73

26

51

1725

1687

1524236

145

132221

1243

112019

1021

918

ac

7

21

8

93

104

5 11

126

3.7

7.60.8

0.8

W2

W3

W4

W5

13.5W1

MP

1

2

3

4

1

2

3

4

MR

X2:1 X2:2

1.7M

1.5M

1.1M 1.1M 0.2M

X1S X1P

4

1 3PE

A

B C

D

12

3

4

5 6 7

8

9

1011

17

12

13

14 15

16

2

3HAW050008639

4 X Harting:09 14 000 99084 Guide Pin Inastalled on connector

Page

Total Page


2.a

+

Date Replaced by

Connection

1

Prepare by,

0 76

Replacement of

8 93

16

4

4

3

2

=

Approve by,

5W

ere

serv

eal

lrig

hts

inth

isdo

cum

ent

and

inth

ein

form

atio

nco

ntai

ned

ther

ein

Repr

oduc

tion,

use

ordi

sclo

sure

toth

irdpa

rtie

sw

ithou

tex

pres

sau

thor

ityis

sric

tlyfo

rbid

den.

Copy

right

ABB

3HAW050008639

ApprovedStatus:


2011/10/10


FlexGunConnector

Motor PowerConnector

Motor ResolverConnector

WeldingTransformer(Supply By ABB)

VoltageMeasurement

FixArm

MoveArm

TransformerTS maybe 2 or 3

GUNFlex Gun

Connector

-b

11 1213 1415 24 25 16 17

PE

-c

123 4

PE PE

-MPFlexGun


43 1 2

PE

CA B D

-MRFlexGun


PE-TSFR

CTCurrent

Meter

CT+

M

CT-

M

TS1Temperature

Sensor

TS2Temperature

Sensor

TS+

T1

TS-

T1

TS+

T2

TS-

T2

-X2 1 2 3 4

-X2 1 2

-W2 SH1-WH1-BN 2-YE2-GN 3-PK3-GY -W6

11

-W4 BK

BNWH BUBU BKBKX2 5

TS3Temperature

Sensor

6YEYE

TS+

T3

TS-

T3

-W5 BKBUBN BKWH

-a

1 23 4

1 23 4

-X1S

-X1P

-W3 WH BKBN BU

-W1 SH2-V1-U Y/G3-W 65 87

1 3 24 78

18 19 2120 23 22

Page

Total Page


3

+

Date Replaced by

Cable diagram =+-W1

1

Prepare by,

0 76

Replacement of

8 93

16

5

4

4

2

=

Approve by,

5W

ere

serv

eal

lrig

hts

inth

isdo

cum

ent

and

inth

ein

form

atio

nco

ntai

ned

ther

ein

Repr

oduc

tion,

use

ordi

sclo

sure

toth

irdpa

rtie

sw

ithou

tex

pres

sau

thor

ityis

sric

tlyfo

rbid

den.

Copy

right

ABB

3HAW050008639

ApprovedStatus:


2011/10/10


F09_002_ABBCable diagram

Page / columnTarget designation from conductor Target designation to Connectionpoint

cable type

no. of conductorsfunction text

function text

cross-section Length

Page / columnfunction text

Cable name

Connectionpoint

=+-W1

24G1.5+2x(2x0.75)

Igus:CF210.UL.15.07.02.02

3 3 U1-U-GUN-cU -MP /3.1/3.1

2 1 V2-V-GUN-cV -MP /3.1/3.1

1 4 W3-W-GUN-cW -MP /3.1/3.1

13 A 24V BK5-GUN-b24V BK -MP /3.2/3.2

15 B 0V BK6-GUN-b0V BK -MP /3.2/3.2

11 C PTC7-GUN-bPTC -MP /3.2/3.2

12 D 0V PTC8-GUN-b0V PTC -MP /3.3/3.3

PE SH-GUN /3.3/3.3 PE-MP

PE Y/G-GUN /3.1/3.1 2 PE-MP

Page

Total Page


4

+

Date Replaced by

Cable diagram =+-W2

1

Prepare by,

0 76

Replacement of

8 93

16

6

4

5

2

=

Approve by,

5W

ere

serv

eal

lrig

hts

inth

isdo

cum

ent

and

inth

ein

form

atio

nco

ntai

ned

ther

ein

Repr

oduc

tion,

use

ordi

sclo

sure

toth

irdpa

rtie

sw

ithou

tex

pres

sau

thor

ityis

sric

tlyfo

rbid

den.

Copy

right

ABB

3HAW050008639

ApprovedStatus:


2011/10/10




cable type


function text



Cable name

Connectionpoint

=+-W2

1.63x2x0.25mm

Igus:CF211.02.03.02

1-BN18 1 S1-GUN-bX (S1,Cos+) -MR /3.4/3.4

1-WH19 3 S3-GUN-b0V-X(S3,Cos-) -MR /3.4/3.4

2-GN20 4 S4-GUN-bY(S4,Sin+) -MR /3.4/3.4

2-YE21 2 S2-GUN-b0V-Y(S2,Sin-) -MR /3.4/3.4

3-GY23 8 R1-GUN-bEXC(R1,24V) -MR /3.4/3.4

3-PK22 7 R2-GUN-b0V-EXC(R2,0V) -MR /3.4/3.4

PE 11SH-GUN -MR /3.5/3.5 PE

Page

Total Page


5

+

Date Replaced by

Cable diagram =+-W3

1

Prepare by,

0 76

Replacement of

8 93

16

7

4

6

2

=

Approve by,

5W

ere

serv

eal

lrig

hts

inth

isdo

cum

ent

and

inth

ein

form

atio

nco

ntai

ned

ther

ein

Repr

oduc

tion,

use

ordi

sclo

sure

toth

irdpa

rtie

sw

ithou

tex

pres

sau

thor

ityis

sric

tlyfo

rbid

den.

Copy

right

ABB

3HAW050008639

ApprovedStatus:


2011/10/10




cable type


function text



Cable name

Connectionpoint

=+-W3

0.25 0.44

IFM:EVC150

14 4BK-GUN-bTMP OK -X1S /3.6/3.6

24 1BN-GUN-bKSR -X1S /3.6/3.6

25 3BU-GUN-b= -X1S /3.6/3.6

4 2WH-GUN-c24V+ -X1S /3.6/3.1

Page

Total Page


6

+

Date Replaced by

Cable diagram =+-W4

1

Prepare by,

0 76

Replacement of

8 93

16

8

4

7

2

=

Approve by,

5W

ere

serv

eal

lrig

hts

inth

isdo

cum

ent

and

inth

ein

form

atio

nco

ntai

ned

ther

ein

Repr

oduc

tion,

use

ordi

sclo

sure

toth

irdpa

rtie

sw

ithou

tex

pres

sau

thor

ityis

sric

tlyfo

rbid

den.

Copy

right

ABB

3HAW050008639

ApprovedStatus:


2011/10/10




cable type


function text



Cable name

Connectionpoint

=+-W4

0.5mm 1.21

Lappkabel:4550114

16 1BK-GUN-bV Reg+ -X2 /3.8/3.8

Page

Total Page


7

+

Date Replaced by

Cable diagram =+-W5

1

Prepare by,

0 76

Replacement of

8 93

16

9

4

8

2

=

Approve by,

5W

ere

serv

eal

lrig

hts

inth

isdo

cum

ent

and

inth

ein

form

atio

nco

ntai

ned

ther

ein

Repr

oduc

tion,

use

ordi

sclo

sure

toth

irdpa

rtie

sw

ithou

tex

pres

sau

thor

ityis

sric

tlyfo

rbid

den.

Copy

right

ABB

3HAW050008639

ApprovedStatus:


2011/10/10




cable type


function text



Cable name

Connectionpoint

=+-W5

0.5mm 1.21

Lappkabel:4550114

17 2BK-GUN-bV Reg- -X2 /3.8/3.8

Page

Total Page


8

+

Date Replaced by

Cable diagram =+-W6

1

Prepare by,

0 76

Replacement of

8 93

16

10

4

9

2

=

Approve by,

5W

ere

serv

eal

lrig

hts

inth

isdo

cum

ent

and

inth

ein

form

atio

nco

ntai

ned

ther

ein

Repr

oduc

tion,

use

ordi

sclo

sure

toth

irdpa

rtie

sw

ithou

tex

pres

sau

thor

ityis

sric

tlyfo

rbid

den.

Copy

right

ABB

3HAW050008639

ApprovedStatus:


2011/10/10




cable type


function text



Cable name

Connectionpoint

=+-W6

0.54x0.25mm

IFM:E11190

4 4BK-X1P -X2 /3.6/3.6

1 1BN-X1P -X2 /3.6/3.6

3 2BU-X1P -X2 /3.6/3.6

2 3WH-X1P -X2 /3.6/3.6

Page

Total Page

FlexGun Harness For Tamagawa MotorHousing With 2xM25 Cable Gland

+

Date Replaced by


1

Prepare by,

0 76

Replacement of

8 93

16

1

4

0

2

=

Approve by,

5W

e re

serv

e al

l rig

hts

in t

his

docu

men

t an

d in

the

info

rmat

ion

cont

aine

d th

erei

nRe

prod

uctio

n, u

se o

r di

sclo

sure

to

third

par

ties

with

out

expr

ess

auth

ority

is s

rictly

for

bidd

en. C

opyr

ight

ABB

3HAW050008653

ApprovedStatus:

Document no. Rev.IndDate A,Stapelberg 2012-2-23N,Cao 2012-3-14 002

2012-2-23

Respsonsible Department: RS/BIW

F26_ABB_Cover

Document Number

Number of pages


16

Project Discription


Page

Total Page


1

+

Date Replaced by

Layout

1

Prepare by,

0 76

Replacement of

8 93

16

2.a

4

2

2

=

Approve by,

5W

e re

serv

e al

l rig

hts

in t

his

docu

men

t an

d in

the

info

rmat

ion

cont

aine

d th

erei

nRe

prod

uctio

n, u

se o

r di

sclo

sure

to

third

par

ties

with

out

expr

ess

auth

ority

is s

rictly

for

bidd

en. C

opyr

ight

ABB

3HAW050008653

ApprovedStatus:


2012-2-23


Technical Provisions

Supplementary Document Doc Type Document DescriptionTP 3HAB8053-1 Barcodes

Technical Provisions TP 3HAB8053-1 Manufact Moving Cable

ac

4

8

73

26

51

1725

1687

1524236

145

132221

1243

112019

1021

918

ac

7

2

1

8

93

104

5 11

126

3.7∅

7.6∅0.8∅

0.8∅

W2

W3

W4

W5

14.5∅

W1

MP 3HAW050008653

1

2

34

1

2

3

4

MR

X2:1 X2:2

1.7M

1.5M

1.1M 1.1M

0.2M

X1S X1P

D-Sub 9 Pin Female

12

3

4

5

6

7

8

9

1011

12

DO NOT installsocket into connector

Heat Shrink L=30mm

Heat Shrink L=30mm

150 mm

100 mm 1500 mm

1700 mm

Need RemoveCover

Page

Total Page


2.a

+

Date Replaced by

Connection

1

Prepare by,

0 76

Replacement of

8 93

16

4

4

3

2

=

Approve by,

5W

e re

serv

e al

l rig

hts

in t

his

docu

men

t an

d in

the

info

rmat

ion

cont

aine

d th

erei

nRe

prod

uctio

n, u

se o

r di

sclo

sure

to

third

par

ties

with

out

expr

ess

auth

ority

is s

rictly

for

bidd

en. C

opyr

ight

ABB

3HAW050008653

ApprovedStatus:


2012-2-23


FlexGunConnector

Motor PowerConnectorTamagawa Motor

Motor ResolverConnectorTamagawa Motor


VoltageMeasurement

FixArm

MoveArm


FlexGunMotor Power

GUNFlex Gun

Connector

-b

11 1213 1415 18 19 2120 23 22 24 25 16 17

PE

-c

123 4

PE PE

-MPFlexGun


71 3 9

PE

82 5 11 6 1 27 83

-TSFR

CTCurrent

Meter

CT+

M

CT-

M

TS1Temperature

Sensor

TS2Temperature

Sensor

TS+

T1

TS-

T1

TS+

T2

TS-

T2

-X2 1 2 3 4

-X2 1 2

-W1 SH2-V1-U Y/G3-W 65 87 -W2 SH1-WH1-BN 2-YE2-GN 3-PK3-GY -W6

-W4 BK

BNWH BUBU BKBKX2 5

TS3Temperature

Sensor

6YEYE

TS+

T3

TS-

T3

-W5 BKBUBN BKWH

-a

1 23 4

1 23 4

-X1S

-X1P

-W3 WH BKBN BU

-MRFlexGun


Page

Total Page


3

+

Date Replaced by

Cable diagram =+-W1

1

Prepare by,

0 76

Replacement of

8 93

16

5

4

4

2

=

Approve by,

5W

e re

serv

e al

l rig

hts

in t

his

docu

men

t an

d in

the

info

rmat

ion

cont

aine

d th

erei

nRe

prod

uctio

n, u

se o

r di

sclo

sure

to

third

par

ties

with

out

expr

ess

auth

ority

is s

rictly

for

bidd

en. C

opyr

ight

ABB

3HAW050008653

ApprovedStatus:


2012-2-23



Page / columnTarget designation from conductor Target designation to Connection point

cable type


function text



Cable name

Connection point

=+-W1

24G1.5+2x(2x0.75)

Igus:CF210.UL.15.07.02.02

3 1 U1-U-GUN-cU -MP /3.1/3.1

2 3 V2-V-GUN-cV -MP /3.1/3.1

1 7 W3-W-GUN-cW -MP /3.1/3.1

13 2 24V BK5-GUN-b24V BK -MP /3.2/3.2

15 5 0V BK6-GUN-b0V BK -MP /3.2/3.2

11 8 PTC7-GUN-bPTC -MP /3.2/3.2

12 11 0V PTC8-GUN-b0V PTC -MP /3.3/3.3

PE SH-GUN /3.2/3.3

PE SH-GUN /3.3/3.3

PE SH-GUN /3.3/3.3

PE 9 PEY/G-GUN -MP /3.1/3.1

Page

Total Page


4

+

Date Replaced by

Cable diagram =+-W2

1

Prepare by,

0 76

Replacement of

8 93

16

6

4

5

2

=

Approve by,

5W

e re

serv

e al

l rig

hts

in t

his

docu

men

t an

d in

the

info

rmat

ion

cont

aine

d th

erei

nRe

prod

uctio

n, u

se o

r di

sclo

sure

to

third

par

ties

with

out

expr

ess

auth

ority

is s

rictly

for

bidd

en. C

opyr

ight

ABB

3HAW050008653

ApprovedStatus:


2012-2-23




cable type


function text



Cable name

Connection point

=+-W2

1.73x2x0.25mm

Igus:CF211.02.03.02

18 6 Cos+1-BN-GUN-bCos+ -MR /3.4/3.4

19 1 Cos-1-WH-GUN-bCos- -MR /3.4/3.4

20 7 Sin+2-GN-GUN-bSin+ -MR /3.4/3.4

21 2 Sin-2-YE-GUN-bSin- -MR /3.4/3.4

23 3 24V+3-GY-GUN-b24V -MR /3.4/3.4

22 8 0V3-PK-GUN-b0V -MR /3.4/3.4

PESH -GUN /3.5/3.5

Page

Total Page


5

+

Date Replaced by

Cable diagram =+-W3

1

Prepare by,

0 76

Replacement of

8 93

16

7

4

6

2

=

Approve by,

5W

e re

serv

e al

l rig

hts

in t

his

docu

men

t an

d in

the

info

rmat

ion

cont

aine

d th

erei

nRe

prod

uctio

n, u

se o

r di

sclo

sure

to

third

par

ties

with

out

expr

ess

auth

ority

is s

rictly

for

bidd

en. C

opyr

ight

ABB

3HAW050008653

ApprovedStatus:


2012-2-23




cable type


function text



Cable name

Connection point

=+-W3

0.25 0.44

IFM:EVC150

14 4BK-GUN-bTMP OK -X1S /3.6/3.6

24 1BN-GUN-bKSR -X1S /3.6/3.6

25 3BU-GUN-b= -X1S /3.6/3.6

4 2WH-GUN-c24V+ -X1S /3.6/3.1

Page

Total Page


6

+

Date Replaced by

Cable diagram =+-W4

1

Prepare by,

0 76

Replacement of

8 93

16

8

4

7

2

=

Approve by,

5W

e re

serv

e al

l rig

hts

in t

his

docu

men

t an

d in

the

info

rmat

ion

cont

aine

d th

erei

nRe

prod

uctio

n, u

se o

r di

sclo

sure

to

third

par

ties

with

out

expr

ess

auth

ority

is s

rictly

for

bidd

en. C

opyr

ight

ABB

3HAW050008653

ApprovedStatus:


2012-2-23




cable type


function text



Cable name

Connection point

=+-W4

0.5mm 1.21

Lappkabel:4550114

16 1BK-GUN-bV Reg+ -X2 /3.8/3.8

Page

Total Page


7

+

Date Replaced by

Cable diagram =+-W5

1

Prepare by,

0 76

Replacement of

8 93

16

9

4

8

2

=

Approve by,

5W

e re

serv

e al

l rig

hts

in t

his

docu

men

t an

d in

the

info

rmat

ion

cont

aine

d th

erei

nRe

prod

uctio

n, u

se o

r di

sclo

sure

to

third

par

ties

with

out

expr

ess

auth

ority

is s

rictly

for

bidd

en. C

opyr

ight

ABB

3HAW050008653

ApprovedStatus:


2012-2-23




cable type


function text



Cable name

Connection point

=+-W5

0.5mm 1.21

Lappkabel:4550114

17 2BK-GUN-bV Reg- -X2 /3.8/3.8

Page

Total Page


8

+

Date Replaced by

Cable diagram =+-W6

1

Prepare by,

0 76

Replacement of

8 93

16

10

4

9

2

=

Approve by,

5W

e re

serv

e al

l rig

hts

in t

his

docu

men

t an

d in

the

info

rmat

ion

cont

aine

d th

erei

nRe

prod

uctio

n, u

se o

r di

sclo

sure

to

third

par

ties

with

out

expr

ess

auth

ority

is s

rictly

for

bidd

en. C

opyr

ight

ABB

3HAW050008653

ApprovedStatus:


2012-2-23




cable type


function text



Cable name

Connection point

=+-W6

0.54x0.25mm

IFM:E11190

4 4BK-X1P -X2 /3.6/3.6

1 1BN-X1P -X2 /3.6/3.6

3 2BU-X1P -X2 /3.6/3.6

2 3WH-X1P -X2 /3.6/3.6

Page

Total Page

FlexGun Harness For Tamagawa Motor for IRB6640 Dresspack LeanID

+

Date Replaced by


1

Prepare by,

0 76

Replacement of

8 93

17

1

4

0

2

=

Approve by,

5

We

rese

rve

all r

ight

s in

thi

s do

cum

ent

and

in t

he in

form

atio

n co

ntai

ned

ther

ein

Rep

rodu

ctio

n, u

se o

r di

sclo

sure

to

third

par

ties

with

out

expr

ess

auth

ority

is s

rictly

for

bidd

en. C

opyr

ight

ABB

3HAW050008658

ApprovedStatus:


2012-11-10


F26_ABB_Cover

Document Number

Number of pages


17

Project Discription


Page

Total Page


1

+

Date Replaced by

Layout

1

Prepare by,

0 76

Replacement of

8 93

17

2.a

4

2

2

=

Approve by,

5

We

rese

rve

all r

ight

s in

thi

s do

cum

ent

and

in t

he in

form

atio

n co

ntai

ned

ther

ein

Rep

rodu

ctio

n, u

se o

r di

sclo

sure

to

third

par

ties

with

out

expr

ess

auth

ority

is s

rictly

for

bidd

en. C

opyr

ight

ABB

3HAW050008658

ApprovedStatus:


2012-11-10


Technical Provisions

Supplementary Document Doc Type Document DescriptionTP 3HAB8053-1 Barcodes

Technical Provisions TP 3HAB8053-1 Manufact Moving Cable

MP 3HAW050008658

1

2

3

41

2

3

4

MR

X2:1 X2:2

1.7M

1.5M

1.1M 1.1M

0.2M

X1S X1P

D-Sub 9 Pin Female

12

3

4

5

6

7

8

9

1011

12

Heat Shrink L=30mm

Heat Shrink L=30mm

RemoveCover

W060005144

150

100 W1=1700

AB

C

D

E

F

GHJ

K

L

M

N

P

RS

T

UV

W

X

Y

Z

4

1 3PE

A

B C

D

2

W2=1500

R4.FB

R3.SP

R3.CPS

12

3

4

5 6 7

8

9

1011

17

12

13

14 15

16

Page

Total Page


2.b

+

Date Replaced by

Connection

1

Prepare by,

0 76

Replacement of

8 93

17

4

4

3

2

=

Approve by,

5

We

rese

rve

all r

ight

s in

thi

s do

cum

ent

and

in t

he in

form

atio

n co

ntai

ned

ther

ein

Rep

rodu

ctio

n, u

se o

r di

sclo

sure

to

third

par

ties

with

out

expr

ess

auth

ority

is s

rictly

for

bidd

en. C

opyr

ight

ABB

3HAW050008658

ApprovedStatus:


2012-11-10


Motor PowerConnectorTamagawa Motor

Motor ResolverConnectorTamagawa Motor


VoltageMeasurement

FixArm

MoveArm


FlexGunMotor Power

C DA AB 1 3 24 7 8 K L M N

PE

413 EPE

PE

-MPFlexGun


71 3 9

PE

82 5 11 6 1 27 83

-TSFR

CTCurrent

Meter

CT+

M

CT-

M

TS1Temperature

Sensor

TS2Temperature

Sensor

TS+

T1

TS-

T1

TS+

T2

TS-

T2

-X2 1 2 3 4 -X3 1 2

-W1 SH2-V1-U Y/G3-W 65 87 -W2 SH1-WH1-BN 2-YE2-GN 3-PK3-GY -W6

-W4 BK

BNWH BUBU BKBKX2 5

TS3Temperature

Sensor

6YEYE

TS+

T3

TS-

T3

-W5 BK

BUBN BKWH

1 23 4

1 23 4

-X1S

-X1P

-W3 WH BKBN BU

-MRFlexGun


-W060005144

-R3_CPSCPCS Plug

-R4_FBSignal Plug

-R3_SPPower Plug

Page

Total Page


3

+

Date Replaced by

Cable diagram =+-W1

1

Prepare by,

0 76

Replacement of

8 93

17

5

4

4

2

=

Approve by,

5

We

rese

rve

all r

ight

s in

thi

s do

cum

ent

and

in t

he in

form

atio

n co

ntai

ned

ther

ein

Rep

rodu

ctio

n, u

se o

r di

sclo

sure

to

third

par

ties

with

out

expr

ess

auth

ority

is s

rictly

for

bidd

en. C

opyr

ight

ABB

3HAW050008658

ApprovedStatus:


2012-11-10




cable type


function text



Cable name

Connection point

=+-W1

24G1.5+2x(2x0.75)

Igus:CF210.UL.15.07.02.02

1 3 U1-U-MPU -R3_SP /3.1/3.1

3 1 V2-V-MPV -R3_SP /3.1/3.1

7 4 W3-W-MPW -R3_SP /3.1/3.1

2 A 24V BK5-MP24V BK -R3_SP /3.2/3.2

5 B 0V BK6-MP0V BK -R3_SP /3.2/3.2

8 C PTC7-MPPTC -R3_SP /3.2/3.2

11 D 0V PTC8-MP0V PTC -R3_SP /3.2/3.2

PESH -R3_SP /3.2/3.2

PESH -R3_SP /3.2/3.2

PESH -R3_SP /3.2/3.2

9 PEY/G-MPPE -R3_SP /3.1/3.1

Page

Total Page


4

+

Date Replaced by

Cable diagram =+-W2

1

Prepare by,

0 76

Replacement of

8 93

17

6

4

5

2

=

Approve by,

5

We

rese

rve

all r

ight

s in

thi

s do

cum

ent

and

in t

he in

form

atio

n co

ntai

ned

ther

ein

Rep

rodu

ctio

n, u

se o

r di

sclo

sure

to

third

par

ties

with

out

expr

ess

auth

ority

is s

rictly

for

bidd

en. C

opyr

ight

ABB

3HAW050008658

ApprovedStatus:


2012-11-10




cable type


function text



Cable name

Connection point

=+-W2

1.73x2x0.25mm

Igus:CF211.02.03.02

6 1 X (S1,Cos+)1-BN-MRS1 -R4_FB /3.3/3.3

1 3 0V-X(S3,Cos-)1-WH-MRS3 -R4_FB /3.3/3.3

7 4 Y(S4,Sin+)2-GN-MRS4 -R4_FB /3.4/3.4

2 2 0V-Y(S2,Sin-)2-YE-MRS2 -R4_FB /3.4/3.4

3 7 EXC(R1,24V)3-GY-MRR1 -R4_FB /3.4/3.4

8 8 0V-EXC(R2,0V)3-PK-MRR2 -R4_FB /3.4/3.4

PESH -R4_FB /3.4/3.4

Page

Total Page


5

+

Date Replaced by

Cable diagram =+-W3

1

Prepare by,

0 76

Replacement of

8 93

17

7

4

6

2

=

Approve by,

5

We

rese

rve

all r

ight

s in

thi

s do

cum

ent

and

in t

he in

form

atio

n co

ntai

ned

ther

ein

Rep

rodu

ctio

n, u

se o

r di

sclo

sure

to

third

par

ties

with

out

expr

ess

auth

ority

is s

rictly

for

bidd

en. C

opyr

ight

ABB

3HAW050008658

ApprovedStatus:


2012-11-10




cable type


function text



Cable name

Connection point

=+-W3

0.25 0.44

IFM:EVC150

A 4BK-R3_CPSTMP OK -X1S /3.6/3.6

K 1BN-R3_CPSKSR -X1S /3.6/3.6

L 3BU-R3_CPS= -X1S /3.6/3.6

E 2WH-R3_CPS24V+ -X1S /3.6/3.6

Page

Total Page


6

+

Date Replaced by

Cable diagram =+-W4

1

Prepare by,

0 76

Replacement of

8 93

17

8

4

7

2

=

Approve by,

5

We

rese

rve

all r

ight

s in

thi

s do

cum

ent

and

in t

he in

form

atio

n co

ntai

ned

ther

ein

Rep

rodu

ctio

n, u

se o

r di

sclo

sure

to

third

par

ties

with

out

expr

ess

auth

ority

is s

rictly

for

bidd

en. C

opyr

ight

ABB

3HAW050008658

ApprovedStatus:


2012-11-10




cable type


function text



Cable name

Connection point

=+-W4

0.5mm 1.21

Lappkabel:4550114

M 1BK-R3_CPSV Reg+ -X3 /3.8/3.8

Page

Total Page


7

+

Date Replaced by

Cable diagram =+-W5

1

Prepare by,

0 76

Replacement of

8 93

17

9

4

8

2

=

Approve by,

5

We

rese

rve

all r

ight

s in

thi

s do

cum

ent

and

in t

he in

form

atio

n co

ntai

ned

ther

ein

Rep

rodu

ctio

n, u

se o

r di

sclo

sure

to

third

par

ties

with

out

expr

ess

auth

ority

is s

rictly

for

bidd

en. C

opyr

ight

ABB

3HAW050008658

ApprovedStatus:


2012-11-10




cable type


function text



Cable name

Connection point

=+-W5

0.5mm 1.21

Lappkabel:4550114

N 2BK-R3_CPSV Reg- -X3 /3.8/3.8

Page

Total Page


8

+

Date Replaced by

Cable diagram =+-W6

1

Prepare by,

0 76

Replacement of

8 93

17

10

4

9

2

=

Approve by,

5

We

rese

rve

all r

ight

s in

thi

s do

cum

ent

and

in t

he in

form

atio

n co

ntai

ned

ther

ein

Rep

rodu

ctio

n, u

se o

r di

sclo

sure

to

third

par

ties

with

out

expr

ess

auth

ority

is s

rictly

for

bidd

en. C

opyr

ight

ABB

3HAW050008658

ApprovedStatus:


2012-11-10




cable type


function text



Cable name

Connection point

=+-W6

0.54x0.25mm

IFM:E11190

4 4BK-X1P -X2 /3.6/3.6

1 1BN-X1P -X2 /3.6/3.6

3 2BU-X1P -X2 /3.6/3.6

2 3WH-X1P -X2 /3.6/3.6

3HA

W05

0009

061

Rev

F, e

n

Contact us

ABB Engineering (Shanghai) Ltd.FlexLean ProductsNo.5, Lane 369, Chuangye Road, Kangqiao Town, Nanhui District, Shanghai 201319 P.R.CHINATelephone +86 (0) 21 6105 6666

www.abb.com

abb robotics product manual...

Documents