Product Manual: IRBT 6003S IRBT 4003S

Product Manual
Track Motion
IRBT 6003S
IRBT 4003S
3HXD 7111-1 Rev. 8, November 2005
The information in this document is subject to alteration without prior notice and should not be regarded
as an undertaking from ABB Automation Technologies AB. ABB Automation Technologies AB assumes
no responsibility for errors that may occur in this document.
ABB Automation Technologies AB bears no responsibility for damage that is a consequence of using this
document or the software or hardware described in this document.
The document, or parts of it, may not be reproduced or copied without prior permission from ABB
Automation Technologies AB. It may neither be imparted to a third party nor otherwise be used without
authorization. Infringement hereof will be subject to action in accordance with applicable laws.
Further copies of this document can be obtained from ABB Automation Technologies AB at current prices.
© 2003 ABB Automation Technologies AB
ABB Automation Technologies AB

Robotics & Manufacturing
SE-69582 Laxå
Sweden
Contents Specification Tab 1:
Product Manual Description 1

Track Motion
3HXD 7111-1 Rev. Safety instructions 5
8, November 2005 Technical specifications and requirements 7
Variants and options 13
Installation and operation Tab 2:
Unpacking and handling 1
Mechanical installation 5
Electrical installation 23
Commissioning 37
Maintenance Tab 3:
Maintenance intervals 1
Maintenance instructions 3
Spare parts 19
3HXD 7111-1 Rev. 8, November 2005 i

ii 3HXD 7111-1 Rev. 8, November 2005
Tab 1: Specification
Chapter 1: Description 1
General 1
Principle layout 2
IRBT 6003S/4003S Compact 2
IRBT 6003S/4003S Covered 3
Terms and concepts 4
Definitions 4
Chapter 2: Safety instructions 5

Description 5
Safety with Unpacking and handling 5
Specification
Lifting instructions 5
Safety with mechanical installation 5
Adjusting the level 5
Safety with Assembling the cable channel and robot 5
Assemble the robot 5
Safety with Electrical installation 6
The robot’s cable harness 6
Safety with Commissioning 6
Calibration 6
Checking the working area 6
Safety with Mechanical maintenance 6
Refilling the lubricant 6
3HXD 7111-1 Rev. 8, November 2005 Specification i

Chapter 3: Technical specifications and requirements 7
Performance 7
IRBT 4003 7
IRBT 6003 7
Dimensions 9
Length measurement 9
Cable chain IRB 4400 9
Cable chain IRB 6600 9
Cable chain IRB 6400R 10
Width and height measurements 10
IRBT 6003/4003S Compact 10
IRBT 6003/4003S Covered In-line 11
IRBT 6003/4003S Covered 90° 11
Specification
Technical requirements for the robot 12

Hardware requirements 12
Chapter 4: Variants and options 13

Variants and options for IRBT 6003S/4003S 13
Connection cable 13
Power cable 13
Double carriages 13
Ordering list 13
Variants 14
Options 15
Supplementary pack 16
Specification ii 3HXD 7111-1 Rev. 8, November 2005

Specification
Description
General
Chapter 1: Description
General
Track Motion IRBT 6003S/4003S expands the movement pattern of the robot with an
extra degree of programmable freedom.
High performance IRBT 6003S/4003S has a powerful motor and an advanced gearbox. Together they give
- High precision the track motion good acceleration and speed performance at the same time as precision
is extremely high.
Function The track motion is supplied with carriage and adapter plate for robot models: ÏRB 6600,
IRB 6400R, IRB 6400, IRB 4400 or IRB 640. No further adaptation is necessary, which
means easy installation. The design of the track motion has also been adapted to give the
shortest possible installation time.
Movement on the track motion is programmed using the robot controller in the same way
as the robot's other axes.
Two types of IRBT 6003S/4003S is available in two designs, Compact and Covered. Compact,
cable chains adapted for materials handling, where the overall width is less than for the spot welding
variant. Covered is adapted for spot welding and the cable chain is then protected by cover
plates.
Nevertheless, the cable chain is easy to access for cleaning and other maintenance on both
models.
Flexibility As the track motion is based on two and three metre modules makes it very flexible. There
is also a possibility to add one or more modules at a later date.
Fully-fitted cover The track motion's cover plates are fully-fitting. This means the IRBT 6003S/4003S is
plates sealed and easy to keep clean. In addition, it is equipped with an anti-slip surface coating,
which makes it safe to walk on.
3HXD 7111-1 Rev. 8, November 2005 1-1

Specification
Description
Principle layout
Principle layout
Track Motion IRBT 6003S/4003S is available in two basic designs, Compact and
Covered. Compact has an open cable tray adapted for materials handling. Covered has a
protected, covered cable tray adapted for spot welding.
IRBT 6003S/ The illustration shows the principle layout of the track motion in the Compact design.
4003S Compact
2
3
1
11 9
10
Fig. 1: IRBT 6003S/4003S Compact
Component parts The table refers to the positions in the illustration above.
Description Item
Carriage 7
Cable chain 9
Cable tray 10
Motor 5
Gearbox 11
Serial Measurement Box / Brake release box 6
Gear rack 1
Linear guides 2
End plates 3 and 8
1-2 3HXD 7111-1 Rev. 8, November 2005

Specification
Description
Principle layout
IRBT 6003S/ The illustration shows the principle layout of the track motion in the protected design.
4003S Covered
2
3
1
12
11 9
10
Fig. 2: IRBT 6003S/4003S Covered
Component parts The table refers to the positions in the illustration above.
Description Item
Carriage 7
Cable chain 9
Cable tray 10
Motor 5
Gearbox 11
Serial Measurement Box / Brake release box 6
Gear rack 1
Linear guides 2
End plates 3 and 8
Protective covers for the cable chain 12
3HXD 7111-1 Rev. 8, November 2005 1-3

Specification
Description
Terms and concepts
Terms and concepts
Definitions The table below lists terms and concepts used in the documentation.
Name Definition
Robot system Robot and Track Motion together.
Robot Manipulator and controller together (IRB 6400R/IRB 6400/IRB 4400/
IRB 640/IRB 6600).
Manipulator The mechanical, moving part of the robot.
Controller Controller of the type S4Cplus.
Track Motion Carriage, stand and cable chain as well as associated parts,
assembled (IRBT 6003S/4003S).
Carriage The moving part, on which the manipulator is mounted.
Stand The assembled framework for the track motion.
Stand module Track motion systems with a travel length greater than 4.7
metres are supplied with the stand in modules that are
interconnected according to the instructions in “Mechanical
installation” på sid 2-5.
Travel length The carriage's maximum movement range.
1-4 3HXD 7111-1 Rev. 8, November 2005

Specification
Safety instructions
Description
Chapter 2: Safety instructions

Description
There are safety instructions in this chapter for all steps that involve a risk of personal
injury or material damage. In addition, they are written out by the instructions for each
step.
General warnings where the intention is to avoid difficulties are only set out by the
instruction in question.
Key to symbols The different types of warnings are set out in the following chapters according to the table
below:
Symbol Importance
Warns for the risk of personal injury or serious damage to the product. Always follow
the instructions expressed in association with this symbol.
Draws your attention to the fact that damage to the product can occur if a measure is
not performed or is performed incorrectly.
Information about important details.
Safety with Unpacking and handling
Read carefully through the safety instructions, before the track motion is unpacked and
installed.
Lifting Only units that are 6 metres or shorter may be lifted. If the units are joined, the joints must
instructions be prefitted on delivery.
Safety with mechanical installation
Adjusting the The distance between the levelling bolts and the top edge of the ground plates must be at
level least 10 mm.
Safety with Assembling the cable channel and robot
Assemble the Always refer to the documentation for the manipulator when the manipulator is to be
robot lifted.
3HXD 7111-1 Rev. 8, November 2005 1-5

Specification
Safety instructions
Safety with Electrical installation
Safety with Electrical installation
The robot’s cable Make sure that the cable harness cannot come into contact with any moving parts.
harness
Safety with Commissioning
Calibration Make sure no persons are on the track motion when the carriage moves. Also make sure
that the track motion’s cover plates are free from loose objects, otherwise these can
become trapped between the carriage and the plates.
Checking the The track motion’s working area must be inspected before the system is commissioned.
working area
Safety with Mechanical maintenance
Refilling the Only use grease injectors with 3 months supply or shorter.
lubricant
1-6 3HXD 7111-1 Rev. 8, November 2005

Specification
Technical specifications and requirements
Performance
Chapter 3: Technical specifications and requirements

Performance
IRBT 4003 The table below contains important technical data for the performance of the track
motion.
Function Performance
Travel length 0.7–43.7 metres in increments of 1 metre.
Travel speed IRBT 4003 1.6 m/s
Stand length travel length + 1.3 metres
Acceleration 1.4 m/s2
Retardation 1.9 m/s2
1
Repeater accuracy ± 0.1 mm
Maximum load IRB 4400 the robot weight + 100 kg
Weight carriage 600 kg
stand 270 kg/m
adaptor for IRB 4400 160 kg
Degree of protection IP 54
Static play Contact ABB for information
Dynamic play Contact ABB for information
1. Repeated stopping in the travel direction, at the same point.
IRBT 6003
1.0 m/s The table below contains important technical data for the performance of Track Motion
IRBT 6003.
Travel speed IRB 6003 1.0 m/s
Repeater accuracy1 ± 0.1 mm
Maximum load IRB the robot weight + 400 kg
6600
stand 270 kg/m
adaptor for IRB 6400 193 kg
3HXD 7111-1 Rev. 8, November 2005 1-7

Specification
Performance
1.5 m/s The table below contains important technical data for the performance of Track Motion
IRBT 6003.
Travel speed IRB 6003 1.5 m/s
Repeater accuracy1 ± 0.1 mm
Maximum load IRB the robot weight + 400 kg
6600
stand 270 kg/m
1-8 3HXD 7111-1 Rev. 8, November 2005

Specification
Dimensions
Dimensions
Length The illustration shows the IRBT 6003S/4003S from the front.
measurement
484 1000 530

1000xN max 300
Fig. 3: IRBT 6003S/4003S, length measurement
The table shows the value of N in the figure above with different travel lengths.
Travel length Total length of the stand Quantity N
1.7 m 3m 2
2.7 m 4m 3
3.7 m 5m 4
4.7 m 6m 5
etc.
Cable chain
IRB 4400
Fig. 4: Dimensions for cable chain, IRBT 4003S
Cable chain
IRB 6600
Dimensions for cable chain, IRBT 6003S
3HXD 7111-1 Rev. 8, November 2005 1-9

Specification
Width and height measurements
Cable chain
IRB 6400R
Fig. 5: Dimensions for cable chain, IRBT 6003S
IRBT 6003/4003S The illustration shows IRBT 6003S/4003S Compact from the end.
Compact
824,5
442
507
569,5
1000
1285
Fig. 6: IRBT 6003S/4003S Compact, width and height measurements
1-10 3HXD 7111-1 Rev. 8, November 2005

Specification
IRBT 6003/4003S The illustration shows IRBT 6003S/4003S Covered In-line from the end.
Covered In-line
824,5
442
507
569,50
1000
1584
Fig. 7: IRBT 6003S/4003S In-line, width and height measurements
IRBT 6003/4003S The illustration shows the IRBT 6003S/4003S Covered 90° from the end.
Covered 90°
824,5
442
507
569,5
1000
1754
Fig. 8: IRBT 6003S/4003S Covered, width and height measurements
3HXD 7111-1 Rev. 8, November 2005 1-11

Specification
Technical requirements for the robot
Technical requirements for the robot
On robots of the type IRB 6400R/IRB 6400/IRB 4400/IRB 640 the track motion acts as
an integrated seventh axis. In order for it to work satisfactorily the robot’s equipment must
comply with a number of minimum requirements.
The track motion is designed to work together with the controller of the type S4Cplus,
please contact ABB for information about compatibility with other controllers.
Hardware The robot hardware must be equipped with the following options in order to drive an
requirements external axis 7 (Track Motion).
Unit Option Notes

IRB 4400/6400/640 392 Drive unit T
IRB 6400R 397 Drive unit U
IRB 6600 383 (7 axes) Drive unit W
IRB 6600 382 (8 axes) Drive unit (V) W
Control system Diskette station If the operating parameters are to be
S4Cplus downloaded directly from the parameter diskette
the controller must be equipped with a diskette
station. See the robot documentation for other
transfer methods.
1-12 3HXD 7111-1 Rev. 8, November 2005

Specification
Variants and options
Variants and options for IRBT 6003S/4003S
Chapter 4: Variants and options

Connection cable The robot’s standard cables can be used to connect the track motion to the controller.
Power cable The power cable to the seventh axis is 7, 15 or 22 metres long, measured from the
connection point in the centre of the track motion.
Double carriages When ordering railbound movement of two carriages all options are automatically
doubled.
It is important to state on the specification form (order form) whether the robot is mounted inline
with the installation or at 90 degrees, in order to get the right cable lengths on the carriage.
Ordering list The tables describe the variants and options that can be order for IRBT 6003S/4003S.
Please contact ABB for further specialisations.
Where the last number of the article number is replaced by “x” this defines the track
motion's travel length rounded upwards to the nearest metre. Accordingly, a Track Motion
with a travel length of 2.7 metres has the article number 3HXD 1546-3, with a travel
length of 3.7 metres the article number will be 3HXD 1546-4, etc.
For cables the last numbers are replaced by “yy” and where the cable length is stated in
decimetres.
On length dependent options "zzz" should be replaced with numbers according to the
following table:
Length No.
1,7 m 882
2,7 m 883
3,7 m 884
4,7 m 885
5,7 m 886
6,7 m 887
7,7 m 888
8,7 m 889
9,7 m 890
10,7 m 891
3HXD 7111-1 Rev. 8, November 2005 1-13

Specification
Variants
Variants Art. no.
Track Motion IRBT 6003S/4003S 3HXD 1567-x
Cable chain for IRBT 6003S/4003S, Compact
IRB 6400 M98-M2000/IRB 4400 M98/IRB 640 3HXD 1562-1x
IRB 4400 M99-M2000 3HXD 1562-2x
IRB 6400R M2000 3HXD 1562-3x
IRB 6600 MH 3HXD 1622-5x
IRB 6600 RG 3HXD 1623-5x
Cable chain for IRBT 6003S/4003S, Covered In-line
IRB 4400 M99-M2000 3HXD 1563-2x
IRB 6400R M2000 3HXD 1563-3x
IRB 6600 MH 3HXD 1622-6x
IRB 6600 RG 3HXD 1623-6x
Cable chain for IRBT 6003S/4003S, Covered 90°
IRB 4400 M99-M2000 3HXD 1596-2x
IRB 6400R M2000 3HXD 1596-3x
IRB 6600 MH 3HXD 1622-7x
IRB 6600 RG 3HXD 1623-7x
Carriage, IRB 4400 3HXD 1674-1
Carriage, IRB 6400/IRB 640 3HXD 1674-2
Carriage, IRB 6400R 3HXD 1674-3
Carriage, IRB 6600 MH 3HXD 1621-1
Carriage, IRB 6600 RG 3HXD 1621-3
Axis 7 Power cable floor, IRB 6400R, IRB 6400, IRB 4400, IRB 640 3HXD 1253-yy
Axis 7 Power cable floor, IRB 6600 3HXD 1601-yy
1-14 3HXD 7111-1 Rev. 8, November 2005

Specification
Options
Options Art. no.
Extra carriage
Compact, IRB 6400/IRB 640 506 345-zzz
Compact, IRB 4400 M99-M2000 506 344-zzz
Compact, IRB 6400R M2000 506 346-zzz
Compact, IRB 6600, MH 3HXD 1547-4x
Compact, IRB 6600, RG 3HXD 1547-6x
In-line Covered, IRB 6400/IRB 640 506 348-zzz
In-line Covered, IRB 4400 M99–M2000 506 347-zzz
In-line Covered, IRB 6400R 506 349-zzz
In-line Covered, IRB 6600, MH 3HXD 1548-4x
In-line Covered, IRB 6600, RG 3HXD 1548-6x
Covered 90°, IRB 6400/IRB 640 506 351-zzz
Covered 90°, IRB 4400 M99–M2000 506 350-zzz
Covered 90°, IRB 6400R 506 352-zzz
Covered 90°, IRB 6600, MH 3HXD 1599-4x
Covered 90°, IRB 6600, RG 3HXD 1692-6x
Side cover
Electric collision guard for two carriages 3HXD 0100-308
Automatic lubrication system, (5 x grease injectors) NOT IRB 6400 3HXD 0100-323
Automatic lubrication system, (5 x grease injectors) NOT IRB 6400, mirrored 3HXD 0100-326
Automatic lubrication system, ONLY IRB 6400 3HXD 0100-321
Central lubrication system with timer, low voltage 3HXD 0100-306
Central lubrication system with timer, high voltage 506 321-880
Central lubrication system with timer, mirrored 3HXD 0100-333
Electric limit switch 3HXD 0100-307
Zone Division Axis 7, 2 zones 3HXD 1549-x
Zone Division Axis 7, 4 zones 3HXD 1550-x
Zone Division Cable floor Axis 7 (7, 15 or 22 m) 3HXD 1382-yy
Zone Division Cable axis 1, IRB 6400/IRB 640 3HXD 1314-yy
Cable Position Switch axis 1, IRB 6400R M2000/IRB 4400 M99-M2000 3HXD 1433-yy
Cable Position Switch axis 1, IRB 6600 3HXD 1638-yy
Cable Position Switch axis 2-3, IRB 6600 3HXD 1691-yy
Customer Cable, IRB 6400R 3HXD 1369-yy
Customer Cable, IRB 6600
CP/CS CANBUS/DeviceNet. 3HXD 1551-yy
CP/CS INTERBUS 3HXD 1617-yy
CP/CS PROFIBUS 3HXD 1637-yy
CP/CS Parallel 3HXD 1672-yy
RG, CP/CS CANBUS/DeviceNet 3HXD 1603-yy
RG, CP/CS INTERBUS 3HXD 1639-yy
RG, CP/CS PROFIBUS 3HXD 1600-yy
Spot welding media with 25 mm² power cable 3HXD 1490-x
Spot welding media with 35 mm² power cable 3HXD 1479-x
3HXD 7111-1 Rev. 8, November 2005 1-15

Specification
Supplementary There are two types of supplement packs for IRBT 6003S/4003S to further shorten the
pack time for action in the event of downtime. These supplement packs are described in the
table below.
Name Art. no.
Small supplement pack 3HXD 0100-309
4 Ball element
1 Serial Measurement Card
1 Battery
Large supplement pack, IRBT 4003S Covered 506 342-880
Large supplement pack, IRBT 6003S, low voltage 506 343-880
Large supplement pack, IRBT 6003S, high voltage Compact 3HXD 0100-338
Large supplement pack, IRBT 6003S, high voltage Covered 3HXD 0100-339
1 Small supplement pack
1 Serial Measurement Box
1 Motor
Gearbox1
10 Cable chain links
1-16 3HXD 7111-1 Rev. 8, November 2005

Tab 2: Installation and operation
Chapter 1: Unpacking and handling 1
Lift 1
Lifting instructions 1
Lifting the track motion 1
The lifting zone 1
Acceptance inspection 2
Identification 2
Contents 2
Inspection 2
Cleaning 2
Moving the carriage manually 3
Release the brake from the BRBcase. 3
Installation and operation

Release the brake using 24 V DC. 3
Connections low voltage 3
Connections high voltage 3
Chapter 2: Mechanical installation 5

Foundation 5
Robustness 5
Incline 5
Static loads 5
Dynamic loads 5
Preparations 6
Recommendations for mounting 6
Mounting bolts 6
Hole configuration 6
Base dimensions 7
Stand assembly 8
Procedure 8
Positioning the stand 9
Adjusting the level 10
Assemble the linear guides 11
Geometric levelling of Track Motion 12
Assemble the gear racks 19
Securing the stand to the foundation 19
Assemble the cover plates 20
Assemble the side plates 20
Assembling the cable channel and robot 21
Assemble the cable tray 21
Assemble the robot 21
Mounting the drive unit 22
3HXD 7111-1 Rev. 8, November 2005 Installation and operation i

Chapter 3: Electrical installation 23
The robot’s cable harness 23
Connection point J1 23
Terminations on J1 23
Terminations/Wiring diagram 24
Introduction 24
IRB 6600 M2000 Robot Cabinet 25
Wiring diagram 25
Standard cables 25
Optional cables 26
IRB 6600 M2000, Robot Cabinet 27
Wiring diagram 27
Standard cables 27
Optional cables 28
Wiring diagram 29
Standard cables 29
Optional cables 30
Wiring diagram 31
Standard cables 31
Optional cables 32
IRB 6400R M2000 33
Wiring diagram 33
Standard cables 33
Optional cables 34
IRB 6400R M98A/IRB 4400 M99-M2000/IRB 6400 35
Wiring diagram 35
Standard cables IRB 6400 M98/ IRB 640 35
Optional cables IRB 6400 M98/ IRB 640 36
Standard cables IRB 4400 M99–M2000 36
Optional cables IRB 4400 M99–M2000 36
Installation and operation ii 3HXD 7111-1 Rev. 8, November 2005

Chapter 4: Commissioning 37
Preparations 37
Configuration of the controller 37
Load the operating parameters 37
Commutation offset 37
Travel length 37
Activating the automatic lubrication system 38
Activate the grease injectors 38
Set the timer for the central lubrication system 39
Functionality test of the Trabon lubrication system 41
System overview 41
Instruction 42
Calibration 43

Calibrate the track motion 43
Calibration with a restart 43
Checking the working area 43
Check the working area 43
Check for abnormal wear and noise 44
Linear guide joints 44
Gear rack joints 44
Gear play 44
Adjust cables and covers 45
3HXD 7111-1 Rev. 8, November 2005 Installation and operation iii

Installation and operation iv 3HXD 7111-1 Rev. 8, November 2005

Unpacking and handling
Lift
Chapter 1: Unpacking and handling
Read carefully through the safety instructions, before the track motion is unpacked and
installed.
Lift
Lifting Stand modules can be moved using a fork lift truck or an overhead crane.
instructions
Only units that are 6 metres or shorter may be lifted. If the units are joined, the joints must
be prefitted on delivery.

Lifting the track Proceed as follows to lift the track motion:
motion
Lifting using a fork lift truck Lifting using an overhead crane
1 Move the carriage as close to the centre of the track motion as possible.
2 Position the forks along the rail module in the Dismantle the side covers from the track
lifting zone as according to position (X) in the motion if these are prefitted.
3 figure below. Wrap two lifting straps around each side of
the carriage according to position (Y) in the
figure below.
The lifting zone The illustration shows the zone on the track motion where the forks can be placed.
Y X X Y
Fig. 1: The lifting zone for a fork lift truck (X) and an overhead crane (Y).
3HXD 7111-1 Rev. 8, November 2005 2-1

Acceptance inspection
Acceptance inspection
Identification The identification plates, located by (X), state the carriage type, serial number, delivery
date, etc.
X
Fig. 2: Identification plates (X)
Contents As standard the track motion includes the following on delivery:

• One carriage (with possible adaptor) with the drive unit
The carriage weighs approx.: 600 kg. (+ possible adaptor, 160/193 kg)
• Stand modules and cable chain
The track motion with a travel length greater than 4.7 m are designed with several stand
modules interconnected during installation.
• Mounting bolts and guide sleeves
Mounting bolts with washers and guide sleeves for the robot.
Inspection Unpack the equipment and check for any visible transport damage. If this is the case,
contact ABB.
Cleaning Before transport the equipment has been protected against rust by a thin film of oil that
has been applied before packing. This film of oil must be wiped off before installation.
1 Wipe off any surplus oil using a lintless cloth
2-2 3HXD 7111-1 Rev. 8, November 2005

Moving the carriage manually
Release the brake The carriage can be moved manually if necessary by connecting the power and releasing
from the the brake.
BRBcase.
1 Open the cover on the SMB case.
2 Press in the brake release button.
Release the brake If there is no voltage to the motor, (24V DC) can be connected to the motor’s power cable.
using 24 V DC.
Connections low The following instruction show how to connect 24V DC to a low voltage motor
voltage

1 Connect 24V DC to pins M and L on the cable connection MP.M7 (power cable, 3HXD 1249).
Connections high The following instruction show how to connect 24V DC to a high voltage motor
voltage
1 Connect 24V DC to pins V and W on the cable connection MP.M7/M8 (power cable,
3HXD 1615).
3HXD 7111-1 Rev. 8, November 2005 2-3

2-4 3HXD 7111-1 Rev. 8, November 2005

Mechanical installation
Foundation
Chapter 2: Mechanical installation

Foundation
Robustness The foundation must withstand the static loads caused by the weight of the equipment and
the dynamic loads generated by the movement of the carriage and manipulator, see
“Foundation” on page 2-5.
Incline The foundation must be designed so that the track motion can be mounted without the
incline exceeding 0.5 mm/m in the direction of travel and 0.1 mm/m across this.
Static loads The table shows the static loads that the foundation must be able to bear.

Load Value
Distributed load, stand 270 kg/M
Movable, in the direction of travel
Manipulator 2400 kg
Carriage 600 kg
Adaptor, IRB 6400 193 kg
Adaptor, IRB 4400 160 kg
Permitted extra load
IRB4400 100 kg
IRB 6400R 300 kg
IRB 6600 400 kg
Dynamic loads The dynamic loads from the movement of the track motion and manipulator can change
direction independent of each other. In these instances where loads are added to each
other the foundation must be able to bear these combined loads.
The maximum dynamic loads for the track motion are:
(Weight, carriage + Weight, manipulator + Weight extra load) x Acceleration
See the robot documentation with regard to dynamic loads for the robot.
The track motion should not be used so that the maximum loads from the robot and con-
veyor are added to each other. If, for example, the carriage is used at maximum speed in
one direction the robot should be at a standstill or move in the opposite direction.
3HXD 7111-1 Rev. 8, November 2005 2-5

Preparations
Preparations
Recommendations Chemical anchor bolts are recommended to secure the track motion to the floor. However,
for mounting the mounting bolts are not supplied as these must be selected based on the material the
foundation is made of.
Mounting bolts Choose mounting bolts so that they:

• Are suitable for the foundation
• Can bear the dynamic loads
• The bolts must be able to bear the combined dynamic loads that can occur when the
manipulator and carriage move, see Foundation.
• Fit in the holes in the stand, Ø24 mm
Hole The stand’s ground plates have holes with a diameter of 24 mm.
configuration
1000
1000 1000
Ø24 1000xN
Fig. 3: Hole configuration
The table shows the value of N in the figure above with different travel lengths.
Travel length Total length of the stand Quantity N
1.7 m 3m 2
2.7 m 4m 3
3.7 m 5m 4
4.7 m 6m 5
etc.
2-6 3HXD 7111-1 Rev. 8, November 2005

Preparations
Base dimensions The illustration shows the stand’s base seen from the front.
h1
h2
b2 b3
b1
Fig. 4: Base dimensions.
The table below shows the values of h1-2 and b1-3 in the illustration above.

Height measurements
h1 100 mm
h2 20 mm
Width measurement
b1 180 mm
b2 65 mm
b3 50 mm
3HXD 7111-1 Rev. 8, November 2005 2-7

Stand assembly
Stand assembly
Procedure The track motion should be assembled as set out in the he procedure below. A detailed
description of each stage can be found in further on in the manual.
1 Assemble the stand modules according to “Positioning the stand” on page 2-9.
2 Assemble the linear guides according to“Assemble the linear guides” on page 2-11.
3 Assemble the gear racks according to “Assemble the gear racks” on page 2-19.
4 Anchor the stand to the foundation according to “Securing the stand to the foundation” on
page 2-19.
5 Assemble the protective guards and cover plates according to “Assemble the cover plates”
on page 2-20.
6 Assemble the cable tray according to “Assembling the cable channel and robot” on
page 2-21.
The module’s fish bolts are only required on prefitted modules up to six metres that are to
be lifted as a single unit. If the track motion consists of more modules, these should not be
assembled using fish bolts, see the illustration below.
Fig. 5: Assembly without fish bolts.
2-8 3HXD 7111-1 Rev. 8, November 2005

Stand assembly
Positioning the Follow the directions below to position the stand modules:
stand
1 Position the levelling plates on one side of the

intended installation site. 00
10
00
10
Position the bottom plates for the cable tray
modules on the other side of the installation 10
00
xN
site.
The spacing between the centres of the
plates should be 1000 mm.
2 Position the first stand module, with carriage,

precisely on the intended installation site.
3 Adjust the module according to “Adjusting the

level” on page 2-10 so that it is aligned within
the given tolerance
If the track motion is to consist of several
modules, continue to step 4. Otherwise move
to “Assemble the linear guides” on page 2-11.
4 Position the next module in the direction of

travel adjacent to the newly aligned module.
5 Adjust according to “Adjusting the level” on
page 2-10 so that the machined surfaces (for
linear guide and gear rack) of this and the
previous module are flat and level with each
other.
If more modules are to be assembled, repeat
steps 3 and 4. Otherwise move to “Assemble
the linear guides” on page 2-11.
3HXD 7111-1 Rev. 8, November 2005 2-9

Stand assembly
Adjusting the
level
The distance between the levelling bolts and the top edge of the ground plates must be at
least 10 mm.
It is recommended to use a laser level in the track motion’s direction of travel and a spirit
level across this in order to obtain satisfactory adjustment. Always measure on a
machined surface, for example, for the linear guide or gear rack.
Follow the directions below to position the beam units:
1 Screw the levelling bolts in or out to raise or

lower the ground plate in question.
The distance between the levelling bolts and
the top edge of the ground plates must be at
least 10 mm.
2 Repeat all round until the module is aligned
within the given tolerance. Min 10 mm
2-10 3HXD 7111-1 Rev. 8, November 2005

Stand assembly
Assemble the Follow the directions below to assemble the linear guide:
linear guides
1 Secure the part of the linear guide to be fitted
on the side.
2 Position the part that is to be fitted on top,

without securing it.

3 Push forward the carriage so that the first
ball element overlaps half of the joint. 3
The carriage can be moved manually if
24 VDC is connected to the motor, see
“Moving the carriage manually” on page 2-3.
4 Push the carriage forwards and successively
bolt the linear guides on the top.
Tightening torque: 50Nm.
If more sections are to be assembled,
repeat step 1. Otherwise move to
“Assemble the gear racks” on page 2-19.
3HXD 7111-1 Rev. 8, November 2005 2-11

Stand assembly
Geometric Geometric levelling of track motion may be performed according to three different
levelling of Track methods.
Motion
Method Description
Method 1 Levelling the track motion by using a spirit leveller for levelling the carriage
horizontally along the complete travel length.
Method 2 Levelling the track motion by using position measurement equipment for levelling
the carriage horizontally along the complete travel length.
Method 3 Levelling the track motion by using a laser levelling instrument based on available
geometric system layout.
Note that origo is located in the manipulators baseframe zero.

Fig. 6: Geometric levelling of track motion
2-12 3HXD 7111-1 Rev. 8, November 2005

Stand assembly
Method 1
Note that X-direction is the same as the travel direction.
Levelling the track motion by using a spirit leveller for levelling the carriage horizontally
along the complete travel length.
Action Info/Illustration
1 Place the track motion in the requested
position on the levelling plates. 00
10
00
10
(See “Positioning the stand” on page 2-9)
• Position the levelling plates on one 10
00
xN
side of the intended installation site.
• Position the bottom plates for the

cable tray modules on the other side
of the installation site.
• The spacing between the centres of
the plates should be 1000 mm.
2 Start the levelling by placing the carriage
towards on end of the track.
3 Use a spirit leveller to adjust the horizontal The accuracy must at least be ± 0,5 mm along
position in both X- and Y-direction by using the track length and ± 0,1 mm in height
the levelling bolts. between side to side.
X-zero is at the synchronization point and
then growing along the track.
4 Move the carriage in steps of 1 m and make
this procedure along the whole length of the
track motion.
5 After levelling the complete track motion the
attachment bolts needs to be tightened.
3HXD 7111-1 Rev. 8, November 2005 2-13

Stand assembly
Method 2 Levelling the track motion by using position measurement equipment for levelling the
carriage horizontally along the complete travel length.
1 Place the track motion in the requested
position on the levelling plates. 00
10
00
10
(See “Positioning the stand” on page 2-9)
• Position the levelling plates on one 10
00
xN
side of the intended installation site.
• Position the bottom plates for the
cable tray modules on the other side
of the installation site.
• The spacing between the centres of
the plates should be 1000 mm.
2 Place the prisma in one of the fixation holes.
See Fig. 7:.
3 Move the carriage into X-zero. Nonie scales facing each other.
4 Push the complete track into correct X- and
Y-zero position.
5 Use a spirit leveller to reach the horizontal
level (Z-value) by adjusting the levelling bolts.
6 Fixation hole measuring from robot center. Same center point for in-line and 90° robot
position.
2-14 3HXD 7111-1 Rev. 8, November 2005

Stand assembly
Due to end cover plates and tolerance chain the dimension (793 mm) has a variation of
±8mm when the track is in X-zero.
1
4
3

2
Fig. 7: Layout carriage
Pos Description Pos Description

1 Nonie scale 3 X positive direction
2 Robot center, when the track is in position X-zero. 4 Fixation holes
7 When the start position is reached for X-, Y- The accuracy must at least be ± 0,5 mm
and Z-zero: along the track length and ± 0,1 mm in height
Continue to move the carriage along the track between side to side.
to level it horizontally by using a spirit leveller
to adjust the track so that it follows the Y-axis.
8 After levelling the complete track motion the
attachment bolts needs to be tightened.
3HXD 7111-1 Rev. 8, November 2005 2-15

Stand assembly
Method 3
Method 3 should be used if the robot is already mounted on the travel track.
Method 3 is based on the available geometric system layout. A laser levelling instrument
is needed for the installation.
1 Decide the coordinate system at the Fig. 8: shows the zero point with the nonie
installation location for the track motion. scale placed on the opposite side of the cable
Position the track motion on the levelling chain.
plates in the simulation given position.
See “Mechanical installation” on page 2-5.
Use the zero point of the track motion as
reference in X-direction.
X-direction is growing from the zero point

along the track.
Due to end cover plates and tolerance chain the dimension (793 mm) has a variation of
±8mm when the track is in X-zero.
1
4
3
Fig. 8: Layout carriage
Pos Description Pos Description

1 Nonie scale 3 X positive direction
2 Robot center, when the track is in position 4 Fixation holes
X-zero.
2-16 3HXD 7111-1 Rev. 8, November 2005

Stand assembly
2 Values taken out of the virtual layout needs to
be transferred and implemented to the track
by placing the prisma along the track in steps
of 1 m to get the X-, Y- and Z-values
corresponding to the virtual values.
3 The prisma should be placed on the edge of Begin to level the vertical linear guide.
the vertically mounted linear guide and on top
of the horizontally mounted linear guide, see
Fig. 9:.
4 When measuring the vertical linear guide, the
prisma should have an angle fixture bracket
so that both Y- and Z-values can be adjusted.
5 When the vertical linear guide is
corresponding to the virtual layout it is time to

level the horizontal guide with either further
measuring or by using a spirit leveller on the
robot mounting surface of the carriage.
Fig. 9: Placement of the prisma on the linear guides
Item Description
1 Top machined surface of carriage
2 Ball element
3 Linear guide
3HXD 7111-1 Rev. 8, November 2005 2-17

Stand assembly
6 Place the measuring prisma on top of the With this measuring method the track motion
horizontal linear guide and on the upper edge can be installed into ± 0.05 mm accuracy
of the vertical linear guide with an angle compared to the virtual geometry.
fixture bracket.
Values from robot center point and robot Z-
zero.
2-18 3HXD 7111-1 Rev. 8, November 2005

Stand assembly
Assemble the Follow the directions below to assemble the gear racks:
gear racks
1 Lay out the section of the gear rack to be
assembled against the support edge, and bolt
loosely in position.
2 Check using the supplied teeth-meshing

gauge that the joints on the laid gear rack
proved a smooth transition.

If the teeth on the test piece and the gear rack
do not mesh, continue with step 3. Otherwise
go directly to step 6.
3 If the teeth on the test piece and the gear rack
do not mesh, loosen the bolts on the prefitted 2
gear racks.
4 Adjust the transition by using the play on the
mountings on the prefitted gear racks.
5 Secure the prefitted gear racks.
6 Secure the assembled gear rack section.
If more sections are to be assembled, repeat
step 1. Otherwise move to “Securing the
stand to the foundation” on page 2-19.
Securing the Follow the directions below to secure the track motion to the foundation:
stand to the
foundation 1 Check that none of the levelling bolts on the track's ground plates are hanging in the air or
that the distance between the levelling bolts and the top edge of the ground plates is at least
10 mm.
Adjust if necessary according to “Adjusting the level” on page 2-10.
2 Move the carriage manually and check using the spirit level along the entire track, both in the
direction of travel and across it.
The carriage can be moved manually if 24 VDC is connected to the motor, see section .
Adjust if necessary according to “Adjusting the level” on page 2-10.
3 Drill holes for the mounting bolts through the ground plates' mounting holes (max. Ø24).
The holes vary depending on the chosen mounting method, see “Recommendations for
mounting” on page 2-6
4 Secure the track motion to the foundation using an appropriate anchoring method.
The anchoring method must be adapted to the foundation and the dynamic loads that the
track motion generates, see“Foundation” on page 2-5 and “Recommendations for mounting”
on page 2-6.
5 Continue to “Assemble the cover plates” on page 2-20.
3HXD 7111-1 Rev. 8, November 2005 2-19

Stand assembly
Assemble the Follow the directions below to assemble the cover plates:
cover plates
1 Assemble cover plates over all joints.
2
2 Assemble the end plates on the track
motion’s short ends.
1
3 Assemble the calibration sign according to
position 3.
3
Assemble the Follow the directions below to assemble the side plates:
side plates
1 Assemble the angle bracket on the ground
plates.
2 Assemble the side covers by pushing then
down between the beam and angle bracket.
Tighten the fixing bolts in angle bracket. 1
2
3 Apply tape over all joints in the side guard.
3
4 Continue to “Assemble the cable tray” on
page 2-21
2-20 3HXD 7111-1 Rev. 8, November 2005

Assembling the cable channel and robot
Assembling the cable channel and robot
Assemble the Follow the directions below to position the cable tray and levelling plates:
cable tray
1 Bolt the cable tray’s guide plates on to the
plates.
Knock gently on the side if the position of the
holes do not align.
2 If the travel length of the completed track
motion is 5.7 metres or more a raised support
for the cable chain should be placed in the
last cable tray. 2
The raised support should be fitted on the
midmost ground plates (with an odd number
1
of ground plates), or one the closest
subsequent ground plate in the direction of

travel (with an even number).
3 Only for IRBT 6003S/4003S Covered:
Assemble the protective plates for the cable
tray by first fitting the angle bracket on the
cable tray and then fitting the side covers on
these.
Assemble the Depending on how the order was made the manipulator should be assembled in one of
robot following two positions:
• InLine
Neutral position for axis 1 aligned with the track motion's direction of travel (1).
• 90°
Neutral position for axis 1 aligned 90° with the track motion's direction of travel (2)
1 Travel direction 2
Fig. 10: Manipulator assembly positions, InLine (1) and 90° (2).
3HXD 7111-1 Rev. 8, November 2005 2-21

Mounting the drive unit
Mounting the drive unit
Very important that the gear is align with the gear rack.
1 The machined heel on the drive unit shall be

placed on the machined heel on the carriage.
Use MC6S-M10×60 (12.9) (6 pcs) and lubricate
the thread and under the screw head with
molycote 1000, tighten them with torque 70Nm.
2 Adjust the play with the two screws A and B
below (M20x1.5).
Grease the screws with molycote grease.
3 First press the motor inwards with screw B until

you have the right play ± 0.1 mm.
See the technical report for tightening torque A B
(approx. 170-190 Nm).
4 Tighten the screw A with 60 Nm.
2-22 3HXD 7111-1 Rev. 8, November 2005

Electrical installation
The robot’s cable harness
Chapter 3: Electrical installation

The robot’s cable harness
The robot’s cable harness is sufficiently long for installation in one of the two possible
positions on the carriage. Any surplus should be placed in a coil on the floor, depending
on the local conditions.
Make sure that the cable harness cannot come into contact with any moving parts.
Connection point The cable harness that normally connects the controller with the manipulator and carriage
J1 is connected to the track motion’s connection point, J1.

J1
Fig. 11: Connection point J1
Terminations on The following terminations can be found on the track motion’s connection point, J1:
J1 • Axis 7 Power Cable
A Harting connector for the track motion's power supply.
• Power Cable axis 1–6
A Harting connector for the Manipulator’s power supply.
• Signal Cable
A Burndy connector for the Manipulator’s control signals.
• Customer Cable
Terminal post for connection of option cables.
• Signal cable axis 7
Burndy connector for the track motion's signals.
3HXD 7111-1 Rev. 8, November 2005 2-23

Terminations/Wiring diagram
Terminations/Wiring diagram
Introduction The wiring diagram below describes the connections between the controller, manipulator
and Track Motion.
The position numbers in the table refer to the positions in the illustration above. Cables
marked with (R) in the illustration are supplied with the robot.
Where the last numbers of the article number are replaced by “yy” in the table, the cable
length should be stated in decimetres (-70 for 7 metres, -150 for 15 metres and -220 for
22 metres)
The abbreviations RG and MH in the following sections stand for: Robot Gun (RG) and
Material Handling (MH).
2-24 3HXD 7111-1 Rev. 8, November 2005

IRB 6600 M2000 Robot Cabinet
Wiring diagram .MH, external axle cabinet for low voltage conveyor.
Carriage Cable chain Floor
13
12
S4Cplus

Fig. 12: Wiring diagram IRB 6600, M2000 Low voltage.
Standard cables
Standard cables Art no Item
Power Cable axis 1–6 3HXD 1519-xx 4
Serial measurement cable axis 1-6 3HXD 1455-yy 5
Serial measurement cable axis 7 3HXD 1443-yy 6
Serial measurement cable floor axis 7 3HXD 1432-yy 9
Power Cable axis 7 3HXD 1252-yy 7
Power Cable floor axis 7 3HXD 1253-yy 10
Motor cable axis 7 (1,5 m) 3HXD 1249-15 1
Resolver cable (1,5 m) 3HXD 1250-15 2
3HXD 7111-1 Rev. 8, November 2005 2-25

Optional cables
Optional cables Art. no. Item
Zone divided cable 3HXD 1381-yy 8
Zone divided cable floor 3HXD 1382-yy 11
Robot customer cable
CANBUS/DeviceNet 3HXD 1551-yy 3
INTERBUS 3HXD 1617-yy 3
PROFIBUS 3HXD 1637-yy 3
Parallel 3HXD 1672-yy 3
Position switch cable axis 1 3HXD 1638-yy 12
Position switch cable axis 2-3 3HXD 1691-yy 13
2-26 3HXD 7111-1 Rev. 8, November 2005

IRB 6600 M2000, Robot Cabinet
Wiring diagram MH, DDU W (ATRP Option 383, 7 axes)

13
12
5 R
6
R
1
2
S4Cplus
7 R

S4Cplus
2
2
8 10
BRB R
Motor 9 11
Fig. 13: Wiring diagram, IRB 6600 M2000, MH, DDU W.
Standard cables
Resolver Cable axis 7 3HXD 1640-yy 1
Power/Signal cable axis 7 3HXD 1615-yy 4
3HXD 7111-1 Rev. 8, November 2005 2-27

Optional cables
Zone dividing cable 3HXD 1381-yy 9
Zone dividing cable floor 3HXD 1382-yy 11
Limit switch 3HXD 1568-1 2
Cable, central greasing 3HXD 1628-yy 3
2-28 3HXD 7111-1 Rev. 8, November 2005

Wiring diagram SG, DDU VW (ATRP Option 705, 382, 8 axes)

15
14
1 R
2
R
3 R

R
R
R
8 R
4 9
10
R
5 11
5 10
6 12
7 13
Fig. 14: Wiring diagram, IRB 6600 M2000, SG, DDU VW
Standard cables

Resolver/power cable axis 8 3HXD 1635-yy 4
Resolver cable axis 8 3HXD 1640-yy 10
Signal cable 3HXD 1651-yy 6
Signal cable floor 3HXD 1650-yy 12
3HXD 7111-1 Rev. 8, November 2005 2-29

Optional cables
Limit switch cable 3HXD 1642-yy 5
Limit switch cable floor 3HXD 1636-yy 11
Zone dividing cable 3HXD 1381-yy 7
Zone dividing cable floor 3HXD 1382-yy 13
2-30 3HXD 7111-1 Rev. 8, November 2005

Wiring diagram RG, DDU VW ATRP Option 706, 382 (8 axes)


Fig. 15: Wiring diagram, IRB 6600 M2000, RG, DDU VW
Standard cables

Serial measurement Cable axis 1-6 3HXD 1455-yy 5
Resolver/power Cable axis 8 3HXD 1615-yy 4
Resolver Cable axis 7 3HXD 1643-yy 1
3HXD 7111-1 Rev. 8, November 2005 2-31

Optional cables
Optional cables Art no Item
Zone dividing cable axis 8 3HXD 1381-yy 10
Zone dividing cable floor axis 8 3HXD 1382-yy 12
Robot customer cable, power cable axis 7
Limit switch 3HXD 1568-1 2
Cable, central greasing 3HXD 1628-yy 3
Power cable, welding 35mm2 3HXD 1474-yy 15
2-32 3HXD 7111-1 Rev. 8, November 2005

IRB 6400R M2000
IRB 6400R M2000
Wiring diagram .
14 R
15 R
6 R
7
R
8 R S4Cplus

1
2
9 R
SMB
10 12
3 4
Motor
5 11 13
Fig. 16: Wiring diagram, IRB 6400R M2000.
Standard cables

Signal Cable axis 1-7 3HXD 1443-yy 9
Serial measurement Cable axis 1-7l 3HXD 1432-yy 1
Power Cable axis 1–6 3HXD 1439-yy 7
Power Cable golv axis 7 3HXD 1253-yy 12
Motor Cable axis 7 (1,5 m) 3HXD 1249-15 3
Resolver Cable axis 7 (1,5 m) 3HXD 1250-15 4
3HXD 7111-1 Rev. 8, November 2005 2-33

IRB 6400R M2000
Optional cables
Electrical Limit Switch (incl. cable) 3HXD 1568-1 2
Zone dividing cable floor axis 7 3HXD 1382-yy 13
Zone dividing cable axis 7 3HXD 1381-yy 11
Zone breaker axis 7 (incl. cable) 3HXD 0100-320 5
Customer Cable 3HXD 1369-yy 6
Power cable, welding 25mm2 3HXD 1465-yy 14
2
Power cable, welding 35mm 3HXD 1474-yy 15
2-34 3HXD 7111-1 Rev. 8, November 2005

IRB 6400R M98A/IRB 4400 M99-M2000/IRB 6400
IRB 6400R M98A/IRB 4400 M99-M2000/IRB 6400
Wiring diagram .
14 R
15 R
6 R
7
R
8 R S4Cplus

1
2
9 R
SMB
10 12
3 4
Motor
5 11 13
,
Fig. 17: Wiring diagram IRB 6400 M98A/IRB 4400 M99–M2000
Standard cables
IRB 6400 M98/
Standard Cables Art no Item
IRB 640
Signal Cable axis 1-7 3HXD 1410-yy 9
Serial measurement Cable axis 1-7l 3HXD 1251-yy 1
Resolver Cable axis 7 (1,5 m) 3HXD 1250-15 4
3HXD 7111-1 Rev. 8, November 2005 2-35

IRB 6400R M98A/IRB 4400 M99-M2000/IRB 6400
Optional cables
IRB 6400 M98/
IRB 640
Electric limit switch (incl. cable) 3HXD 1568-1 2
Zone Divide Cable floor axis 7 3HXD 1382-yy 13
Zone Divide Cable axis 7 3HXD 1381-yy 11
Zone switch axis 7 (incl. cable) 3HXD 0100-320 5
Position switch axis 1 3HXD 1314-yy 8
Standard cables
IRB 4400 M99–
M2000
Serial measurement Cable axis1-7 3HXD 1443-yy 9

Serial measurement Cable axis 1-6 3HXD 1432-yy 1
Resolver Cable (1,5 m) 3HXD 1250-15 4
Optional cables
IRB 4400 M99–
M2000
Electric limit switch (incl. cable) 3HXD 1568-1 2
Zone Divide Cable floor axis 7 3HXD 1382-yy 13
Zone Divide Cable axis 7 3HXD 1381-yy 11
Zone switch axis 7 (incl. cable) 3HXD 0100-320 5
Position switch axis 1 3HXD 1433-yy 8
2-36 3HXD 7111-1 Rev. 8, November 2005

Commissioning
Preparations
Chapter 4: Commissioning
Preparations
Before the track motion is commissioned the system must be prepared. The following
steps should be carried out before starting the track motion.
1. Configure the controller Load the operating parameters and configure the controller
according to “Load the operating parameters” on page 2-37.
2. Correct levelled and Correct the Track Motion according to “Stand assembly” on
installed Track Motion page 2-8.
3. Activate the lubrication Activate the automatic lubrication system according to
system “Activating the automatic lubrication system” on page 2-38.
4. Check greasing system Functional test of the Trabon lubrication system according to
“Functionality test of the Trabon lubrication system” on page 2-41.

5. Grase Grease rack and pinion.
6. Calibrate Calibrate the track motion according to “Calibration” on
page 2-43
7. Correct drive unit If abnormal noise, correct according to “Check for abnormal wear
and noise” on page 2-44.
Correct specific torque on adjusting screws according to “Mounting
the drive unit” on page 2-22.
8. Adjust cables and covers Check and adjust cables and covers according to “Adjust cables
and covers” on page 2-45.
Configuration of the controller
Load the The track motion must be defined in the system before starting with the operating
operating parameters, which can be found on the supplied diskette.
parameters
A description of how to load parameters from diskette to the controller can be found in
the robot documentation.
Proceed as follows to load the operating parameters:
1 Select the file: Add New Parameters

2 Load the files T6003S.cfg and T4003S.cfg
Commutation The IRBT commutation offset is a fixed value that is read at the factory. All IRBT 6003S/
offset 4003S track motion units have the same offset value and this does not need to be changed.
Travel length The different travel lengths’ working areas are defined based on the calibration mark. The
travel length is set to maximum in the parameter file for the ordered travel length.
3HXD 7111-1 Rev. 8, November 2005 2-37

Commissioning
Activating the automatic lubrication system
If the track motion is equipped with an automatic lubrication system this needs to be
activated. These may be of different types, automatic lubrication system with grease
injectors or central lubrication system with a timer. These are activated in different ways.
Activate the The grease injectors in the automatic lubrication system are not activated on delivery.
grease injectors When the grease injectors are activated, they will continuously and fully automatically
apply the correct amount of grease for three months.
Activate the grease injectors as follows:
1 Localise the grease injectors (5 units).

1 1
2 Press in the activation pin fully on each

grease injector.
3 Listen so you hear the injector’s grease motor
start (it takes about 10 seconds after the pin 2
has been pressed in).
2-38 3HXD 7111-1 Rev. 8, November 2005

Commissioning
Set the timer for On delivery the timer on the central lubrication system is set to lubricate in cyclic
the central intervals of 0.5-10 s and with an equivalent waiting time between lubrication periods.
lubrication This setting may need to be changed if too much lubricant is pumped out or if lubrication
system
is unsatisfactory.
Set the timer as follows:
1 Localise the central lubrication system. The

control panel is located behind the small
hatch on the lubrication system by pos. 1.

2 Set the function using the dipswitches 4 and
5 as set out in the table below.
4 5
Function Dipswitch
Cyclic lubrication interval:
The lubrication valve opens for ton (see step 3) to then close for toff and open again
for ton, etc.
Inverted cyclic lubrication interval:
The same as above but with the difference that the cycle starts with the valve
closed, i.e. toff - ton -toff, etc.
Switch-on impulse:
When the power is switched on the lubrication valve opens for ton to then close as
long as the power is on.
Switch-on delay:
When the power is switched on a delay is activated for toff before the lubrication
valve opens to then remain open as long as the power is switched on.
3 Set the interval for ton using the dipswitches

1-3 and the interval for toff using the
dipswitches 6-8 as set out in the table below.
1 2 3 6 7 8
3HXD 7111-1 Rev. 8, November 2005 2-39

Commissioning
Time interval Dipswitch Time interval Dipswitch

0.5 s – 10 s 1.5 min. - 30 min.
1.5 s – 30 s 5.0 min. - 100 min.
5.0 s – 100 s 12.0 min. - 240 min.
0.5 min. - 10 min. 0.5 h – 10 h

4 Set the time using the potentiometer.

The scale on the potentiometer is
proportional to the interval setting. For
example, the value 8 on the potentiometer
changes from 8 seconds to 8 hours if the
interval setting is changed from 0.5-10 s to
0.5-10 h.
5 Recommended by ABB.
2-40 3HXD 7111-1 Rev. 8, November 2005

Commissioning
Functionality test of the Trabon lubrication system
Perform the functionality test of the Trabon lubrication system when the Track Motion is
completely set up and power and air supply is connected.
System overview

Fig. 18: Lubrication system overview
Item Description
1 Divider connection
2 Lubrication point
3 Pump connection
4 Indicator pin
5 Oil brush
3HXD 7111-1 Rev. 8, November 2005 2-41

Commissioning
Instruction
1 Open the lid of the serial measurement box/
brake release box (1).
2 Press the brake release button (2) for
1 second. Release the button and wait
1 second then press the button again.
Repeate approx. 20 times.
Check following while pressing the button:

• The movement of the indicator pin.
It shall move in and out of the divider valve.
• That grease is coming out of the four lubrication points positioned in the four corners and
out of the oil brush.
It may be necessary to press the button several times before grease starts coming out!
As long as the indicator pin is moving it is OK!
If the indicator pin is not moving after pressing the button about 40 times start looking for
a blockage.
If it is an air blockage the system needs to be bled. See “Bleed the system” on page 3-6.
For other blockages see “Locating blockage in Series-Flo systems” on page 3-7.
2-42 3HXD 7111-1 Rev. 8, November 2005

Commissioning
Calibration
Calibration
Make sure no persons are on the track motion when the carriage moves. Also make sure
that the track motion’s cover plates are free from loose objects, otherwise these can
become trapped between the carriage and the plates.
Calibrate the Before the robot system can be used the resolvers need to be calibrated.
track motion Perform calibrations according to the instruction below.
1 Calibrate according to the instructions in the

robot documentation.
2 Check that the carriage stops exactly on the
calibration mark.
3 Save the system parameters according to the

instructions in the robot documentation.
Calibration with a A robot system that uses a serial measurement system does not need to be calibrated
restart before a restart, as the robot system automatically monitors the position of the robot in the
working area.
The track motion does not need to be calibrated with a restart. The resolvers only need to
be calibrated when commissioning the system.
Checking the working area
The track motion’s working area must be inspected before the system is commissioned.
Check the Run the system manually using the joystick and check that:
working area • It can be run in both directions
• Both end positions are reached
3HXD 7111-1 Rev. 8, November 2005 2-43

Commissioning
Check for abnormal wear and noise
Check for abnormal wear and noise
In the event of abnormal noise when the track motion is commissioned this may be due
to incorrect assembly of the linear guides or gear racks or the gear play’s meshing pressure
needs to be adjusted.
Linear guide Check and adjust the linear guides joints if necessary according to “Assemble the linear
joints guides” on page 2-11.
Gear rack joints Check and adjust the gear racks joints if necessary according to “Assemble the gear
racks” on page 2-19.
Gear play Gear play is adjusted by two adjuster screws on the motor mounting that are adjusted as
follows:
1 Splitt box (2) and mounting plate (1) for the

splitt box must be removed to gain access to
the adjusting bolts of the drive unit.
2 Press the motor mounting outwards by

turning screw A.
Pull the motor mounting inwards by turning
bolt B.
3 Check the play using a dial indicator by
pushing the carriage back and forth.
Permitted play:
static: ±0,1 mm
dynamic (Contact ABB for info.)
A B
2-44 3HXD 7111-1 Rev. 8, November 2005

Commissioning
Adjust cables and covers
Perform the following adjustments:
1 After transportation and set-up the pinion cover (1)

may need some adjusting. Otherwise it may be in
contact with the pinion and cause noise and
vibration.
If noise:
• Adjust pinion cover before start-up.

2 Adjust cables and covers:
• If the cover for the cable chain is used, make
sure no risk of collision is possible and that they
are well tightened
3 Make sure all cables are well tightened and no risk
for premature ware against plates or additional
equipments.
• Make sure that cables from cable chain to
carriage are well strapped.
• Make sure no floor cables are in risk of collision
with moving parts.
3HXD 7111-1 Rev. 8, November 2005 2-45

Commissioning
2-46 3HXD 7111-1 Rev. 8, November 2005

Tab 3: Maintenance
Chapter 1: Maintenance intervals 1
Routine checks and preventive maintenance 1
Maintenance chart 1
Chapter 2: Maintenance instructions 3

Mechanical maintenance 3
Lubrication of the ball element and rack 3
Inspection of the lubrication system 3
Checking the grease injectors 3
Inspection of the central lubrication system 3
Cleaning and lubrication of the gear racks 4
Cleaning the linear guides 4
Maintenance
Refilling the lubricant 4
Replacing the grease injector 4
Filling the central lubrication system 5
Gearbox 5
Bleed the system 6
Locating blockage in Series-Flo systems 7
Electrical maintenance 16
Inspection of electrical operations 16
Check the emergency stop 16
Inspection of cables and connectors 16
Check the connectors 16
Inspection of the cable chain 16
Inspection of the junction boxes 16
Inspection of the drive motor 16
Backup battery 17
Chapter 3: Spare parts 19

Spare parts independent of length 19
Drive unit, low voltage 19
Drive unit, low voltage mirrored 20
Drive unit, high voltage 1.0 m/s 21
Drive unit, high voltage mirrored 1.0 m/s 22
Drive unit, high voltage 1.5 m/s 23
Drive unit, high voltage mirrored 1.5 m/s 24
Carriage 25
Automatic lubrication system with grease injectors 26
Central lubrication system with timer 27
Spare parts dependent on length 29
Cable tray 29
Stand 31
Cables 32
Cable lengths 32
3HXD 7111-1 Rev. 8, November 2005 Maintenance i

Mintenance
Maintenance ii 3HXD 7111-1 Rev. 8, November 2005

Maintenance intervals
Routine checks and preventive maintenance
Chapter 1: Maintenance intervals

Maintenance The track motion is designed to need a minimum of maintenance. However, routine
chart checks and preventive maintenance always need to be carried out at regular intervals.
The maintenance chart describes the routine maintenance and routine checks in
chronological order.
More
Interval Part Maintenance
info.
Every 250 km Ball element Lubricate page 3-3
(150 miles)
Each month Automatic lubrication Check the level page 3-3
system
Electrical operation Check all electrical operations page 3-16
Cables and connectors Check visible cables page 3-16
Cable chain Check the visible cable chain page 3-16
Junction boxes Check page 3-16
Drive motor Check page 3-16
Every other Gear racks Clean and lubricate (if there is no page 3-4
month automatic lubrication system)
Every third Linear guides Clean if necessary. page 3-4
month Automatic lubrication Replace the grease injector page 3-4
system
Ball element Check tightening torque page 3-5
Every 5000 Gearbox Change the oil page 3-5
operating hours
Every 5 years Backup battery Change the battery with signs of page 3-17
discharge
Maintenance
Maintenance
3HXD 7111-1 Rev. 8, November 2005 3-1

Maintenance intervals
Maintenance
3-2 3HXD 7111-1 Rev. 8, November 2005

Maintenance instructions
Mechanical maintenance
Chapter 2: Maintenance instructions

Lubrication of the If there is no automatic lubrication system on the track motion the ball element must be
ball element and lubricated manually.
rack
Lubricate the ball element until the grease is forced out of the end seals, approx.: 4.7 cm³
(1.85 in³).
Use ball element grease as set out in NLGI 2, for example:
Manufacturer Lubricant
OPTIMOL Longtime PD2
Shell Alvania WR2
Inspection of the If the track motion is equipped with an automatic lubrication system the level of the
lubrication lubricant should be checked once a month, even if the system should apply the lubricant
system equally over a longer period. The lubrication system can be of two different types, with
grease injectors or central with a timer.
Checking the Check the lubricant level in the grease injectors as follows:
grease injectors
1 Localise the lubrication system.
2 Read the lubricant level on the
transparent scale. If the lubricant has
been used, fill according to “Replacing the
grease injector” on page 3-4.
1 1
Maintenance
1
Maintenance
Inspection of the Check the lubricant level in the central system as follows:
central
lubrication 1 Localise the lubrication system.
system 2 Check the level in the transparent
lubricant tank. If the lubricant has been
used, fill according to “Filling the central
lubrication system” on page 3-5.
1
3HXD 7111-1 Rev. 8, November 2005 3-3

Cleaning and Clean the gear racks every other month.

lubrication of the
If there is no automatic lubrication system on the track motion the gear racks must be
gear racks
lubricated manually using one of the following lubricants:
OPTIMOL VISCOGEN 4
BP MOG
Statoil ESL10
Mobiloil Mobiltac 81
Texaco Texclade
Lubrication in A special dust and dirt-repelling lubricant is recommended if there is a risk of welding
extremely dirty sparks or other airborne particle becoming attached to the lubricated gear rack:
environments
OPTIMOL VISCOGEN EPL
Cleaning the Inspect and clean the linear guides if necessary.

linear guides
Refilling the If the track motion is equipped with an automatic lubrication system, the system must be
lubricant refilled every third month or when the lubricant has been used up.
Replacing the When the lubricant in the electromechanical grease injectors has been used up the entire
grease injector grease injector should be replaced as follows:
Only use grease injectors with 3 months supply or shorter.
1 Remove the empty grease injector.

1
2 Remove the protective cover on the new
grease injector, see pos.1.
Maintenance
Only use grease injectors with 3 months

supply or shorter.
2
3 Press in the activation pin fully, see pos.2.
4 Assemble the new grease injector.
3-4 3HXD 7111-1 Rev. 8, November 2005

Filling the central When the lubricant in the central lubrication system has run out, new lubricant should be
lubrication added as follows:
system
1 Connect the supplied filling nipple at position
1.
2 Fill with lubricant as set out in the
specification below.
• The tank holds 2.71 kg (6 Lb Cyl)

Use ball element grease as set out in NLGI 1, for example:
Q8 Q8 Rembrandt EP1
Mobil Mobilux EP1
Check ball
element
tightening torque 1 Tighten the screws (16 pcs.) with 70 Nm.
Gearbox The gearbox is filled with oil on delivery. After every 5000 hours of operation the gearbox
should be emptied and filled with new oil.
Maintenance
• The gearbox holds 7.8 litres
The oil must comply with the standards for high pressure oil under CLP 198-242 mm²/s/
40°C. Maintenance
MOBIL Mobilgear 630
Shell Omala Oil 220
Statoil Loadway EP 220
3HXD 7111-1 Rev. 8, November 2005 3-5

Bleed the system

Note!
If the steps below do not make any change start looking for other blockage than air trapped
in the system. See “Locating blockage in Series-Flo systems” on page 3-7.
1 Disconnect the hose between the pump and the divider valve at the See Fig. 1:
pump connection.
2 Press the brake release button in the SMB/BRB for 1 second.
Release the button and wait 1 second then press the button again.
Keep repeating until nothing but grease comes out of the hose.
3 Reconnect the hose to the pump connection and disconnect it at See Fig. 1:
the divider connection.
Repeat step 2 above.
4 Hook up a manual pump to the divider valve and slowly pump in See Fig. 1:
grease, compatible with the grease in the lubrication system.
Keep pumping until the indicator pin starts moving in and out of the
divider valve.
5 Reconnect the hose to the divider valve. See Fig. 1:
6 Press the brake release button in the SMB/BRB for 1 second.
Release the button and wait 1 second then press the button again.
Repeat until the indicator pin starts moving in and out of the divider
valve.
Maintenance
Fig. 1: Lubrication system overview
Item Description
1 Divider connection
2 Lubrication point
3 Pump connection
4 Indicator pin
5 Oil brush
3-6 3HXD 7111-1 Rev. 8, November 2005

Locating
blockage in
Series-Flo
systems
Description In a Trabon Series-Flo system, free flow of lubricant from the pump through the
transmission system and the bearings is necessary.
If any portion of this transmission system (a divider valve, line fitting or any bearing) does
not freely accept and pass its portion of the lubricant a blockage has occurred.
This blockage will cause a higher than normal pumping pressure to be developed by the
pump.
Depending on the application or system design, this blockage with its resultant high pump
pressure will usually cause a complete loss of lubricant flow into the total system and no
bearing will be receiving lubricant.
The loss of flow due to a blockage is first indicated with the higher than normal system
pressure that is developed by the pump as it attempts to overcome this blockage.
Divider valve A Series-Flo type divider valve is a manifolded proportioning device consisting of an
inlet and end section plus a minimum of three intermediate sections.
The divider valve is manifolded together with tie rods and nuts. A master divider valve is
the first divider valve downstream from the lube pump. A secondary divider valve is any
divider valve receiving lubricant from the master divider valve.
Warning!
Never block a lube outlet that is designed to discharge lubricant.
Maintenance
Maintenance
Fig. 2: Divider valve
3HXD 7111-1 Rev. 8, November 2005 3-7

Fig. 3: Intermediate valve & subplate section
Item Description
1 Piston enclosure plug
2 Enclosure plug gasket
3 Piston
4 O-rings
5 Indicator port
6 Plug
7 Check valve
Locating blockage If any blockage exists in a Trabon Series-Flo system it is caused by one of the following
reasons:
• Crushed transmission line in the system
• Blocked bearing in the system
• Improperly drilled fitting in the system
• Blocked divider valve in the system
All servicing and disassembling should be carried out under the cleanest conditions
possible.
A blockage will be centrally signalled by a pressure gauge, pressure switch, controller or

Maintenance
by the pump relief indicator, exhausting lubricant. Before proceeding as outlined make a
visual inspection of the system and check for crushed lines or improper divider valve
installation. Verify that each divider valve outlet required to discharge lubricant can do so
and that no pipe plugs have been installed in an outlet designed to serve bearing or another
divider valve.
Use filtered lubricant only!
Note!
Dirt and foreign material are the worst enemies of any lubricating system!
3-8 3HXD 7111-1 Rev. 8, November 2005

Procedure
Step 1
Action
1 Use a manual pump with gauge. Fill the pump with clean, filtered lubricant common to the
system.
2 Connect the manual pump into the inlet of the master divider valve and slowly operate the
pump. If the system will not cycle freely below 1,500 PSI, see step 2.
Step 2 Master divider valve equipped with performance indicator:
Action
1 With a manual pump connected to the master divider valve as outlined in step 1, raise
pressure to 2,000 PSI, the indicators in the indicator ports will signal the location of the
blockage.
An indicator in the up position indicates pressure is in that outgoing line and signals the
blockage is in the area being served from this outlet, as shown in Fig. 4:. See step 3.
2 If no indicator pins are protruding, the blockage is in the master divider valve.
Maintenance
Fig. 4: Locating blockage with hand pump
Item Description
Maintenance
1 Hand pump
2 Indicator pin up
3 Master divider valve
4 Secondary divider valve
5 Lube outlets
3HXD 7111-1 Rev. 8, November 2005 3-9

Master divider valve without performance indicators:
Action
1 With a manual pump connected to the master divider valve as outlined in step 1, raise
pressure to 2,000 PSI.
2 Remove one at a time each indicator port plug and attempt to operate the manual pump after
each plug is removed.
Do not exceed 2,000 PSI.
If pressure drops and master cycles freely after an indicator port plug is removed then the
blockage is downstream in the area that is being served from that outlet. See step 3.
3 If all indicator port plugs are removed and master will not cycle, the blockage is in this divider
valve.
When indicator port plug of a blocked area is removed a small shot of trapped lubricant
will usually surge out of this outlet as the inlet pressure on the divider valve drops.
If testing in step 2 indicates a blockage in the master divider valve, this divider valve must
be disassembled and cleaned. See step 5 for instructions on correct procedure.
Maintenance
3-10 3HXD 7111-1 Rev. 8, November 2005

Step 3
Action
1 Testing accomplished in step 2 has indicated a blockage is downstream of the master divider
valve.
2 Install the manual pump in the indicator port of the master divider valve that is common to this
blocked area. See Fig. 5:.
3 Proceed to downstream secondary divider valve and remove all indicator port plugs.
4 Slowly operate the manual pump.
If lubricant can be discharged freely through each of the indicator ports of this divider valve
the blockage is not in the supply line or the divider valve. See step 4.
If lubricant is not freely discharged through the open indicator ports of the secondary divider
valve the blockage is in this divider valve or its supply line.
5 Disconnect supply line at secondary inlet fitting and slowly operate the manual pump to verify
the location.
If the blockage is in the divider valve see step 5.
Fig. 5: Locating blockage with hand pump
Maintenance
Item Description
1 Hand pump Maintenance
4 System pump
5 Lube outlets
6 Indicator port, plugs removed
3HXD 7111-1 Rev. 8, November 2005 3-11

Step 4
Action
1 Install a manual pump into each indicator port of secondary divider valve in turn, and slowly
operate the pump. See Fig. 6:.
2 If high pressure exists, blockage has been located.
Look for: crushed line, tight bearing, improperly drilled fittings and/or lube inlet port.
3 Correct as necessary.
Fig. 6: Locating blockage secondary divider valve
Item Description
1 System pump
3 Lube outlets
Maintenance
4 Indicator port, plugs removed

5 Hand pump
7 Bearing
3-12 3HXD 7111-1 Rev. 8, November 2005

Step 5 When testing indicates a blockage has occurred in any divider valve, that divider valve
must be disassembled and cleaned.
Dirt and foreign material are the worst enemies of any lubricating equipment. All servicing
and disassembling should be carried out under the cleanest possible conditions.
Before disassembling any divider valve.
1 Make a sketch and note as to the arrangement of
the intermediate sections.
For example: INLET 10T-20S-10T-30S END.
2 Also remove end plugs only and try to move each

piston back and forth without removing the piston
from the intermediate section.
DO NOT insert hard metal objects into piston bore (i.e., punches, screw drivers, etc.) use a
brass rod and hand pressure only!
Maintenance
Maintenance
3HXD 7111-1 Rev. 8, November 2005 3-13

If all pistons are movable and there is no indication of a more serious problem:
Action
1 Replace end plugs and using a new gasket apply the correct torque. See torque table below.
2 Re-test this divider valve using the manual pump. If a piston is jammed, or a hard wax-like
substance, or dirt is noted at the end of the piston chamber, proceed with disassembly.
3 The divider valve can be dismantled by removing the tie rod nuts.
4 With the individual sections on the bench remove the end plug from both ends of the section.
Taking one section at a time remove the piston, if it appears to be jammed, try removing it
from the other direction.
With badly jammed pistons it may be necessary to use a brass rod and lightly tap piston out.
5 Clean sections and pistons in a suitable clean solvent until all lubricant has been removed.
6 Use compressed air to dry and blow out all ports thoroughly.
7 A small wire probe should be used to make sure all passages are clean and open.
8 Inspect the cylinder bore and piston carefully for scratches, score marks or other damage.
Note! If either piston or cylinder bore is damaged a new section must be installed. All
pistons are selectively fitted to the bore for proper clearance. Care must be taken to
install piston only into the intermediate section from which it was removed.
9 If divider valve section and piston both appear in good condition, reassemble section making
certain that piston slides smoothly but snugly in cylinder bore.
10 Repeat cleaning and inspection of each section.
11 After all sections have been cleaned, blown out, inspected and found to be in good condition,
reassemble the divider valve as indicated by the notes and sketches.
Use all new gaskets and correct torque ratings listed below.
Test operation of divider valve using a manual pump.
Assembly Torque (Ft. Lbs)

MJ M MV MVH MSP/ MX MXP MG
MH
Tie rod nuts 12 20 20 24 8 23 9 12
Indicator plugs 7 15 15 15 10 18 15 18
Maintenance
End plugs 15 15 15 15 11 35 35 15
Valve section 9 13
mounting screw
3-14 3HXD 7111-1 Rev. 8, November 2005

Contamination If dirt, foreign material or any other form of contamination is found in a divider valve,
blockage cleaning will only temporarily solve contamination blockage problems.
The source of the contamination must be eliminated for satisfactory service.
• The system filtering method must be investigated, filter elements should be inspected or
changed as required.
• The reservoir must be inspected and cleaned if necessary.
• The reservoir filling method should be reviewed to eliminate any chance of foreign material
entering the reservoir during filling.
• All lubricating systems require filtered lubricant.
Separation If a hard wax or soap like material is found in the intermediate section grease separation
blockage is occurring.
This means that the oil is being squeezed from the grease at normal system operating
pressure and the grease thickener is being deposited in the divider valve.
Cleaning the divider valve will usually result in only temporarily solving the problem.
Consult your lubricant supplier for recommendations on alternate lubricants and your
local Trabon distributor to verify compatibility with centralized lubricating systems.
Maintenance
Maintenance
3HXD 7111-1 Rev. 8, November 2005 3-15

Electrical maintenance
Inspection of The track motion should be checked monthly with regard to:
electrical • All electrical operations
operations
• End position operations
Run the carriage and check that both end positions are reached.
Check the The operation of the emergency stop should be checked monthly as follows:
emergency stop
1 Let the carriage be still.
2 Press in the emergency stop.
3 Try to start the track motion.
Inspection of Check monthly:

cables and
connectors If any cables... then...
have been damaged through wear or pinching replace the cable.
rub against sharp edges route the cable so that it runs freely.
Check the Check monthly:

connectors • that all connectors are made correctly and there is no risk for loose contact.
Inspection of the Check monthly the visible part of the cable chain with regard to:
cable chain • The link system, replace if necessary.
• Points of attachment, replace if necessary.
Inspection of the Check, and rectify, if necessary, the junction boxes monthly with regard to:
junction boxes • Damage
• Connections
Maintenance
• Tightness
Inspection of the Check the drive motor monthly with regard to:
drive motor • Abnormal bearing noise
• Connections
3-16 3HXD 7111-1 Rev. 8, November 2005

Backup battery The track motions serial measurement box (SMB) contains a serial measurement card and
use a battery for the memory backup in order to maintain position data.
The battery is a rechargeable lithium battery.
The battery should be replaced:
• Every five years
or
• When the battery is about to be spent.
This is generally shown by an error code on the teach pendant's character display.
Information about error codes can be found in the controller documentation.
In a new system the batteries are charged to full capacity after a few hours in STANDBY
mode.
Replace the battery as follows:
1 Localise the battery inside the junction box.

2 Cut off the cable tie holding the battery.
Bromslossnings knappar
2
3 Disconnect the two-wire cable and remove Brake release buttons
7 10
the battery. 8 11
9 12
4 Fit the battery in the reverse order.
Maintenance
Maintenance
3HXD 7111-1 Rev. 8, November 2005 3-17

Maintenance
3-18 3HXD 7111-1 Rev. 8, November 2005

Spare parts
Spare parts independent of length
Chapter 3: Spare parts

Drive unit, Spare parts for the drive unit for IRBT 6003S/4003S:
low voltage
1
5
7 6
Fig. 7: Drive unit IRBT 6003S/4003S
Quantity Description Art. no. Item

1 Drive unit, IRB 4400 3HEA 801 287-001 -
Maintenance
1 Drive unit, IRB 6400, IRB 6400R, IRB 640 3HEA 801 372-001 -
1 Motor mounting 3HEA 801 171-001 4 Maintenance
2 Socket head cap screw 3HXG 1138-3 5
1 Motor IRB 4400, IRB 6400, 506 262-880 1
IRB 6400R, IRB 640
1 Motor flange 3HXD 1000-459 2
1 Gear drive, IRB 4400 3HXG 1141-1 3
1 Gear drive
IRB 6400, IRB 6400R, IRB 640 3HXG 1141-2 3
1 Spacer 3HXD 1000-492 6
1 Gear wheel 3HXD 1000-490 7
1 Retainer sleeve 3HXG 1000-506 8
1 Gear wheel cover (not in fig.) 3HXD 0100-348 -
3HXD 7111-1 Rev. 8, November 2005 3-19

Spare parts
Drive unit, Spare parts for the drive unit for IRBT 6003S/4003S:
low voltage
mirrored 1
5
6 7
Fig. 8: Drive unit IRBT 6003S/4003S

1 Drive unit, IRB 6400, IRB 6400R, IRB 640 3HEA 801 366-001 -
1 Motor mounting 3HEA 801 185-001 4
1 Motor 506 262-880 1
Maintenance
1 Gear drive, IRB 4400 3HXG 1147-1 3

1 Gear drive
IRB 6400, IRB 6400R, IRB 640 3HXG 1147-2 3
1 Spacer 3HXD 1000-492 6
3-20 3HXD 7111-1 Rev. 8, November 2005

Spare parts
Drive unit, Spare parts for the drive unit for IRBT 6003S:
high voltage
1.0 m/s 1
5
7 6
Fig. 9: Drive unit IRBT 6003S

1 Motor 3HXD 0100-355 1
Motor flange 3HXD 1000-459 2
Maintenance
1 Gear drive 3HXG 1141-2 3
1 Spacer 3HXD 1000-492 6 Maintenance
3HXD 7111-1 Rev. 8, November 2005 3-21

Spare parts
high voltage
mirrored 1.0 m/s 1
5
6 7

1 Motor 3HXD 0100-355 1
Maintenance
1 Spacer 3HXD 1000-492 6

3-22 3HXD 7111-1 Rev. 8, November 2005

Spare parts
high voltage
1.5 m/s 1
5
7 6

1 Drive unit 3HEA 800 687-001 -
1 Motor 3HXD 0100-355 1
Motor flange 3HXD 1000-459 2
Maintenance
1 Spacer 3HXD 1000-492 6 Maintenance
3HXD 7111-1 Rev. 8, November 2005 3-23

Spare parts
high voltage
mirrored 1.5 m/s 1
5
6 7

1 Drive unit 3HEA 800 689-001 -
1 Motor 3HXD 0100-355 1
Maintenance
1 Spacer 3HXD 1000-492 6

3-24 3HXD 7111-1 Rev. 8, November 2005

Spare parts
Carriage Spare parts to the carriage for IRBT 6003S/4003S:
3 4 5
7
10 9
8 6
7
Fig. 13: Carriage IRBT 6003S/4003S

Adaptors for robots
Adaptor for IRB 4400 3HXD 1566-1 1
Adaptor for IRB 6400 3HXD 1566-2 2
Maintenance
2 Guide sleeve 3HXD 1000-273 3
8 Washer 3HXD 1000-274 4
8 Bolt 2121 2017-733 5 Maintenance
4 Ball element 2185 0445-4 7
2 Bracket SMB 3HXD 0100-357 8
1 Serial measurement box axis 7, low voltage 3HXD 0100-89 6
1 Serial measurement box axis 7, high voltage, 3HXD 1616-1 6
IRB 6600R
1 Brake release box, IRB 6600R, MH 3HXD 0100-363 6
1 Bracket Nonie-scale 3HXD 1000-471 9
1 Sign Nonie-scale 2948 3216-2 10
1 Bracket junction box 3HXD 1000-505 -
3HXD 7111-1 Rev. 8, November 2005 3-25

Spare parts
Automatic Spare parts for the automatic lubrication system with grease injectors:
lubrication 1
system with
grease injectors
2
7 6
5 4
16
15
14
10
9
10
13 11
12
9
Fig. 14: Automatic lubrication system with grease injectors,

2 Bracket 3HXD 1000-493 10
1 Bracket oil brush 3HXD 1000-494 3
1 Oil brush 3HXG 1000-562 4
5 Stabiliser 3HXG 1000-563 2
5 Single pipe clamp 3HXG 1145-1 15
1 Straight threaded coupling 3HXG 1000-558 6
4 Reducing nipple 3HXG 1000-556 13
4 Thread elbow coupling 3HXG 1000-561 12
15 Pipe clamp 3HXG 1145-1 8
Maintenance
1 Hydraulic pipe 3HXD 1559-9 7

Standard design pipes
Pipes in a mirrored design intended for an extra carriage
5 Grease injector 3HXG 1000-513 1
1 Brush 3HXG 1000-516 5
3-26 3HXD 7111-1 Rev. 8, November 2005

Spare parts
Central Spare parts for the central lubrication system with timer:
lubrication
system with timer
21
22
20
36
23
17
18
5
19
20
4
15
22
16
21
17
18
35
22
21
7
2
1
32
28
27
3
30
26
14
31
33
Maintenance
14
11
10
Maintenance
12
9
13
37
24
29
25
12
26
6
8
34
Fig. 15: Central lubrication system with timer.
3HXD 7111-1 Rev. 8, November 2005 3-27

Spare parts

4 Reducing nipple 3HXG 1000-556 1
4 Thread elbow coupling 3HXG 1000-561 2
1 Grease tank bracket 3HXD 1000-525 3
1 Distribution block bracket 3HXD 1000-524 4
1 Timer bracket 3HXD 1000-522 5
1 Bracket oil brush 3HXD 1000-523 6
1 Grease tank 3HXG 1000-587 7
1 E-pump 3HXG 1000-588 8
1 Distribution block 3HXG 1000-589 9
1 Solenoid valve 3HXG 1000-585 10
1 Timer 3HXG 1000-586 11
2 Straight coupling 3HXG 1000-590 12
1 Hose 3HXG 1000-598 13
6 Straight threaded coupling 3HXG 1000-591 14
1 Distribution piece air 2529 1928-3 15
1 Blanking plug 2529 1920-4 16
2 Hose nipple 2529 2084-33 17
2 Hose clip 0252 9004 05 18
1 Reducing nipple 2529 1921-3 19
2 Reducing nipple 2529 1921-2 20
4 Banjo bolt 2529 1926-2 21
4 Single banjo coupling 2529 1008-2 22
4 Sealing washer 2152 0417-5 23
1 Oil brush 3HXG 1000-562 24
1 Brush 3HXG 1000-516 25
2 Straight coupling 3HXG 1000-615 26
5 Double pipe clamp 3HXG 1145-2 27
16 Single pipe clamp 3HXG 1145-3 28
Standard design pipes
Maintenance

1 Polyamide hose 3HXD 1583-1 34
Pipes in a mirrored design intended for an extra carriage
1 Central lubrication cable 3HXD 1318-20 37
3-28 3HXD 7111-1 Rev. 8, November 2005

Spare parts
Spare parts dependent on length
Cable tray Spare parts for the cable tray for IRBT 6003S/4003S Compact:
4
4 2
1
5
2 1
4
5
2 1
3
2
1
2
1
Fig. 16: Cable tray IRBT 6003S/4003S Compact
Quantity with different travel lengths

Description 1,7 2,7 3,7 4,7 5,7 6,7 7,7 8,7 9,7 10,7 Art. no. Item
Levelling plates 4 5 7 8 8 9 10 11 12 13 3HXD 1000-414 1
Lower bracket for the 2 3 3 4 6 7 8 9 10 11 3HXD 1000-410 2
cable chain
Guide plate for the 1 1 1 1 1 1 1 1 1 1 3HXD 1000-488 3
cable chain
Guide plate for the - 1 1 2 3 4 5 6 7 8 3HXD 1000-489 4
cable chain
Guide plate, angled - - - - 1 1 1 1 1 1 3HXD 1000-540 -
Slide strip, angled - - - - 2 2 2 2 2 2 3HXD 1000-539 -
Maintenance
Spacer for the cable - - - - 3 3 4 4 5 5 3HXD 1000-473 5
chain
Maintenance
3HXD 7111-1 Rev. 8, November 2005 3-29

Spare parts
Spare parts for the cable tray for IRBT 6003S/4003S Covered:
5
8
5
7 9
5
4
9 2 1
7
5
4
9 2 1
6
5
4
2 1
3
2 1
2 1
Fig. 17: Cable tray IRBT 6003S/4003S Covered

Levelling plates 3 4 5 6 7 8 9 10 11 12 3HXD 1000-414 1
Lower bracket for the 3 4 5 6 7 8 9 10 11 12 3HXD 1000-415 2
cable chain
Guide plate for the 1 1 1 1 1 1 1 1 1 1 3HXD 1000-488 3
cable chain
Guide plate for the - 1 1 2 4 5 6 7 8 9 3HXD 1000-489 4
cable chain
Guide plate, angled - - - - 1 1 1 1 1 1 3HXD 1000-540 -
Upper bracket for the 3 4 5 6 7 8 9 10 11 12 3HXD 1000-416 5
Maintenance
cable chain
Cover plate L=1505 1 1 1 1 1 1 1 1 1 1 3HXD 1000-419 6
Cover plate L=1000 - 1 2 3 4 5 6 7 8 9 3HXD 1000-420 7
Cover plate L=1505 1 1 1 1 1 1 1 1 1 1 3HXD 1000-421 8
Spacer for the cable - - - - 3 3 4 4 5 5 3HXD 1000-473 9
chain
3-30 3HXD 7111-1 Rev. 8, November 2005

Spare parts
Stand Spare parts for the stand for IRBT 6003S/4003S.
8 9
4 5 6
8 9
2
4 5 6
1
Fig. 18: Stand IRBT 6003S/4003S

Linear guide 45 L=1000 - 2 - - 2 - - - - - 3HXG 1127-1 6
Linear guide 45 L=2000 - - 2 6 6 2 6 4 2 6 3HXG 1127-2 4
Linear guide 45 L=3000 2 2 2 - - 4 2 4 6 4 3HXG 1127-3 5
Gear rack L=1000 - 1 - 1 - 1 2 1 2 3 3HXD 1557-1 8
Gear rack L=2000 1 1 2 2 3 3 3 4 4 4 3HXD 1557-2 9
Cover plate end 1 1 1 1 1 1 1 1 1 1 3HXD 1000-393 1
Cover plate end 1 1 1 1 1 1 1 1 1 1 3HXD 1000-394 7
Bracket Nonie-scale 1 1 1 1 1 1 1 1 1 1 3HXD 1000-472 2
Sign Nonie-scale 1 1 1 1 1 1 1 1 1 1 2948 3216-1 3
Side cover L=1000 (opt.) - 1 - - - - - 1 - - 3HXD 1472-1 -
Maintenance
Side cover L=1500 (opt.) 2 2 2 2 2 2 2 2 2 2 3HXD 1472-2 -
Side cover L=2000 (opt.) - - 1 - 2 1 - - 1 - 3HXD 1472-3 - Maintenance
Side cover L=3000 (opt.) - - - 1 - 1 2 2 2 3 3HXD 1472-4 -
3HXD 7111-1 Rev. 8, November 2005 3-31

Spare parts
Cables
Cables
Cable lengths The table shows the cable lengths required for the different connections with different
travel lengths. The article numbers for the cables can be found in “Electrical installation”
on page 2-23.
Cable lengths for IRBT 6003S/4003S Compact:
Cable lengths with different travel
lengths
Description 1,7 2,7 3,7 4,7 5,7 6,7 7,7 8,7 9,7 10,7 Art. no.
Cables for the manipulator 5 6 6 7 7 8 8 9 9 10 see page 2-24

Cables for the SMB 5 6 6 7 7 8 8 9 9 10 see page 2-24
Cables between the SMB and 1 1 1 1 1 1 1 1 1 1 see page 2-24
Motor
Cable between the SMB and 1,5 1,5 1,5 1,5 1,5 1,5 1,5 1,5 1,5 1,5 see page 2-24
manipulator
Number of links in the cable 33 48 48 63 63 78 78 93 93 108 see page 2-24
chain
Cable lengths for IRBT 6003S/4003S Covered:

Cable lengths with different travel
lengths
Description 1,7 2,7 3,7 4,7 5,7 6,7 7,7 8,7 9,7 10,7 Art. no.
Cables for the manipulator 6 6 7 7 8 8 9 9 10 10 see page 2-24

Cables for the SMB 6 6 7 7 8 8 9 9 10 10 see page 2-24
Cables between the SMB and 1 1 1 1 1 1 1 1 1 1 see page 2-24
Motor
Cable between the SMB and 1,5 1,5 1,5 1,5 1,5 1,5 1,5 1,5 1,5 1,5 see page 2-24
manipulator
Number of links in the cable 33 48 48 63 63 78 78 93 93 108 see page 3-29
chain
Maintenance
3-32 3HXD 7111-1 Rev. 8, November 2005

Specification
Index
A I S
Acceleration .............. 1-7, 1-8 InLine .............................2-21 S4Cplus................see Controller
Automatic lubrication system ... IRB 7600 .................... see Robot Safety ............................... 1-5
1-15 IRBT 7003S ....................1-14 Serial Measurement Box ... 1-2,
Activate ............. 2-38, 2-39 Also see Track Motion 1-3, ............................... 1-16
Compact ............ 1-10, 1-14 Serial measurement card .. 1-16
B Compact.........see IRBT 7003S SMBsee Serial Measurement Box
Ball element .................... 1-16 Compact .............................................. 1-2
Covered ............. 1-11, 1-14
Battery ............................ 1-16 Spot welding media ......... 1-15
Description ....................1-1
Brake release box ...... 1-2, 1-3 IRBT 7003S Compact .....1-2 Stand ................................ 1-4
IRBT 7003S Covered ......1-3 Assembly ...................... 2-8
C Principle layout ..............1-2 Dimension table ......1-9, 2-6
Cable chain ............... 1-2, 1-3 Protected ........see IRBT 7003S Length ...................1-7, 1-8
Covered Spare parts .................. 3-31
Cable tray ....... 1-2, 1-3, 2-21
Weight ...................1-7, 1-8
Calibration ........................ 1-6
K Stand module .................... 1-4
Calibration sign ............... 2-20
Key to symbols ..................1-5 Supplementary pack ........ 1-16
Carriage table ... 1-2, 1-3, 1-4,
1-14, ................................ 2-5 T
Carriage.........see Carriage table L
Length ..............................1-9 Tape ............................... 2-20
Compact ............... 1-10, 1-14
Levelling bolts ....... 2-10, 2-19 Terminal post J1 .............. 2-23
Compact .................see Compact
Levelling plates .................2-9 The lifting zone ................. 2-1
Control Cabinet
Lift ...................................1-5 Track Motion .....1-4, 1-5, 1-6
Terminal post J1 ........... 2-23
Dimensions ................... 1-7
Controller ............... 1-4, 1-12 Limit position switch ........1-15
Calibration .................. 2-43
Connection cable .......... 1-13 Linear guide .... 1-2, 1-3, 2-11 Connection point J1 ..... 2-23
Controller ............ see Controller Lifting .......................... 2-1
Cover plates .................... 2-20 M Performance ...........1-7, 1-8
Covered ................ 1-11, 1-14 Manipulator ............... 1-4, 2-5 Principle layout ............. 1-2
Customer Cable ............... 1-15 Assemble ............. 1-5, 2-21 Variants ...................... 1-14
Cable length .................3-32 Track...............see Track Motion
D Dynamic loads ...............2-5 Travel length ....1-4, 1-7, 1-8,
Static load ......................2-5 1-9, ... 1-13, 2-6, 2-21, 2-37,
Degree of protection .. 1-7, 1-8 Terminal post J1 ...........2-23 3-29, ..........3-30, 3-31, 3-32
Maximum load ..........1-7, 1-8 Travel speed ..............1-7, 1-8
E
Motor ............. 1-2, 1-3, 1-16
End plates ....... 1-2, 1-3, 2-20
W
Extra load ......................... 2-5 P Weight ......................1-7, 1-8
Power cable floor .............1-14 Width ............................. 1-10
F
Protected................. see Covered Working area .................. 2-43
Foundation ........................ 2-5
Protective covers for the cable
chain .................................1-3 Z
G
Zone Division ................. 1-15
Gear play ........................ 2-44 R
Gear rack .................. 1-2, 1-3 Rail module .... see Stand module
Gear racks ....................... 2-19 Repeater accuracy ...... 1-7, 1-8
Gearbox ...1-2, 1-3, 1-16, 3-5 Retardation ................ 1-7, 1-8
Globalube .............see Automatic Robot ................................1-4
lubrication system .............. 1-15 Connection cable ..........1-13
Technical requirements .1-12
H also see Manipulator
Height ............................ 1-10 Robot system ........... 1-4, 2-43
3HXD 7111-1 Rev. 8, November 2005 index-i

Specification
index-ii 3HXD 7111-1 Rev. 8, November 2005

3HXD 7111-1 Rev. 8, November 2005

Product Manual: IRBT 6003S IRBT 4003S

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Product Manual

© 2003 ABB Automation Technologies AB

ABB Automation Technologies AB

Product Manual Description 1

Variants and options 13

Installation and operation Tab 2:

Unpacking and handling 1

3HXD 7111-1 Rev. 8, November 2005 i

Chapter 2: Safety instructions 5

3HXD 7111-1 Rev. 8, November 2005 Specification i

Technical requirements for the robot 12

Chapter 4: Variants and options 13

Specification ii 3HXD 7111-1 Rev. 8, November 2005

3HXD 7111-1 Rev. 8, November 2005 1-1

Fig. 1: IRBT 6003S/4003S Compact

1-2 3HXD 7111-1 Rev. 8, November 2005

Fig. 2: IRBT 6003S/4003S Covered

3HXD 7111-1 Rev. 8, November 2005 1-3

Terms and concepts

1-4 3HXD 7111-1 Rev. 8, November 2005

Chapter 2: Safety instructions

Information about important details.

Safety with Unpacking and handling

Safety with mechanical installation

Safety with Assembling the cable channel and robot

3HXD 7111-1 Rev. 8, November 2005 1-5

Safety with Electrical installation

Safety with Commissioning

Safety with Mechanical maintenance

1-6 3HXD 7111-1 Rev. 8, November 2005

Chapter 3: Technical specifications and requirements

3HXD 7111-1 Rev. 8, November 2005 1-7

1-8 3HXD 7111-1 Rev. 8, November 2005

484 1000 530

Fig. 3: IRBT 6003S/4003S, length measurement

Fig. 4: Dimensions for cable chain, IRBT 4003S

Dimensions for cable chain, IRBT 6003S

3HXD 7111-1 Rev. 8, November 2005 1-9

Fig. 5: Dimensions for cable chain, IRBT 6003S

Width and height measurements

Fig. 6: IRBT 6003S/4003S Compact, width and height measurements

1-10 3HXD 7111-1 Rev. 8, November 2005

Fig. 7: IRBT 6003S/4003S In-line, width and height measurements

Fig. 8: IRBT 6003S/4003S Covered, width and height measurements

3HXD 7111-1 Rev. 8, November 2005 1-11

Technical requirements for the robot

Unit Option Notes

1-12 3HXD 7111-1 Rev. 8, November 2005

Chapter 4: Variants and options

3HXD 7111-1 Rev. 8, November 2005 1-13

1-14 3HXD 7111-1 Rev. 8, November 2005

3HXD 7111-1 Rev. 8, November 2005 1-15

1-16 3HXD 7111-1 Rev. 8, November 2005

Installation and operation

Chapter 2: Mechanical installation 5

3HXD 7111-1 Rev. 8, November 2005 Installation and operation i

Installation and operation ii 3HXD 7111-1 Rev. 8, November 2005

Installation and operation

3HXD 7111-1 Rev. 8, November 2005 Installation and operation iii

Installation and operation iv 3HXD 7111-1 Rev. 8, November 2005

Chapter 1: Unpacking and handling

Installation and operation

3HXD 7111-1 Rev. 8, November 2005 2-1