4002 Track

Installation/Maintenance
Track Motion
IRBT 6002S/4002S
3HXD 7207-1 Rev.1

April 2001
The information in this document can be subject to change without prior notice and should not be
regarded as an undertaking from ABB Flexible Automation AB. ABB Flexible Automation AB assumes
no responsibility for errors that can appear in this document.
ABB Flexible Automation AB is not responsible for damage incurred by the use of this document or
software or hardware described in this document.
The document, or parts there of, may not be reproduced or copied without prior permission from
ABB Flexible Automation AB. It may neither be imparted to another nor otherwise used without author-
isation. Infringement here of will be subjected to action in accordance with applicable laws.
Further copies of this document can be obtained from ABB Flexible Automation AB at current prices.
© ABB Flexible Automation AB
Article number: 3HXD 7207-1 Rev.1

Issue: April 2001
ABB Flexible Automation AB
System Products
S-721 75 Västerås
Sweden
CONTENTS
Page
1 General............................................................................................................................ 1
1.1 Description.......................................................................................................... 1
1.2 Identification....................................................................................................... 3
2 Safety............................................................................................................................... 5
3 Unpacking and handling ............................................................................................... 7

3.1 General................................................................................................................ 7
3.2 Delivery check .................................................................................................... 7
3.3 Lifting instructions ............................................................................................. 8
3.3.1 Rail module < 1.7 m............................................................................... 8
3.3.2 Rail module > 1.7 m............................................................................... 8
4 Mechanical installation.................................................................................................. 9
4.1 Foundation loads................................................................................................. 9
4.1.1 Static loads ............................................................................................. 9
4.1.2 Dynamic loads........................................................................................ 9
4.1.3 Dimensions, attachment screw pattern................................................... 10
4.2 Mounting, track motion ...................................................................................... 13
4.3 Alignment and levelling ..................................................................................... 14
4.4 Rack assembly .................................................................................................... 15
4.5 Jointing ............................................................................................................... 16
4.6 Mounting of the manipulator.............................................................................. 17
5 Electrical installation ..................................................................................................... 19

5.1 General................................................................................................................ 19
5.2 Connections ........................................................................................................ 20
5.2.1 Robot cabling ......................................................................................... 20
5.2.2 Emergency stop ...................................................................................... 20
5.2.3 Manually releasing the brake ................................................................. 20
5.3 Cable connections............................................................................................... 21
5.3.1 IRBT 6002S with IRB6400 M98A ........................................................ 21
5.3.2 IRBT 6002S med IRB 6400R M99........................................................ 22
5.3.3 IRBT 6002S with IRB 6400R M2000.................................................... 23
5.3.4 IRBT 6002S med IRB 4400 M98A........................................................ 24
5.3.5 IRBT 6002S with IRB 4400 M99-M2000 ............................................. 25
3HXD 7207-1 Rev.1 i

6 Start-up .......................................................................................................................... 27
6.1 General ............................................................................................................... 27
6.2 Before start-up.................................................................................................... 27
6.3 Load function parameters................................................................................... 28
6.4 Activate automatic lubrication system (option) ................................................. 28
6.5 Calibration.......................................................................................................... 29
6.5.1 Calibration ............................................................................................. 29
6.6 Start-up............................................................................................................... 30
6.6.1 Automatic restart.................................................................................... 30
6.6.2 Track motion working range.................................................................. 30
7 Maintenance................................................................................................................... 31
7.1 Interval ............................................................................................................... 31
7.2 Mechanical maintenance.................................................................................... 32
7.2.1 Gear box................................................................................................. 32
7.2.2 Linear guides.......................................................................................... 32
7.2.3 Ball elements.......................................................................................... 32
7.2.4 Rack ....................................................................................................... 33
7.3 Electrical maintenance ....................................................................................... 33
7.3.1 Visual checking...................................................................................... 33
7.3.2 Cable chain ............................................................................................ 33
7.3.3 Cabling and connectors.......................................................................... 33
7.3.4 Replacement of memory backup batteries............................................. 34
7.4 Automatic lubrication system (option) .............................................................. 34
7.4.1 Simalube system .................................................................................... 34
7.5 Adjustments ....................................................................................................... 35
7.5.1 Gear play................................................................................................ 35
8 Spare parts ..................................................................................................................... 37

8.1 IRBT 6002S/4002S ............................................................................................ 37
8.2 Drive unit ........................................................................................................... 38
8.3 Length dependent spare parts............................................................................. 39
8.3.1 IRB 4400, 640, 6400, 6400R ................................................................. 39
8.3.2 IRB 4400 M98 ....................................................................................... 40
8.3.3 IRB 4400 M99-M2000 .......................................................................... 42
8.3.4 IRB640 M98-M2000 ............................................................................. 44
8.3.5 IRB6400 M98-M2000 ........................................................................... 46
8.3.6 IRB6400R M99...................................................................................... 48
8.3.7 IRB 6400R M2000................................................................................. 50
ii 3HXD 7207-1 Rev.1

CONTENTS
Page
8.4 Automatic lubrication system accessories .......................................................... 52
3HXD 7207-1 Rev.1 iii

iv 3HXD 7207-1 Rev.1

Installation/Maintenance General
1 General
This manual provides information on installation and maintenance for the track
motions IRBT6002S and IRBT 4002S. Personnel working with installation and
maintenance imply to be trained expertise in both mechanical and electrical
systems.
For all information about the robot, see the documentation manuals for the IRB
4400 (for IRBT4002S) and IRB 6400/640/6400R (for IRBT 6002S).
NOTE! The robot must be equipped with hardware and software for integrated 7th
axis.
1.1 Description
The Track Motion IRBT 6002S/4002S adds an extra programmable degree of
freedom for the movement pattern of IRB 6400 IRB 640, IRB 6400R and IRB
4400 respectively, and is to be connected to the robot control equipment via a
cable, as an integrated seventh axis.
The length of the track motion may be specified in increments of 1 m from 1.7 m to
43.7 m.
The Track Motion IRBT 6002S/4002S is designed to work with all robot versions,
except for the shelfmounted one.
The Track Motion consists of a drive unit, a carriage and rail modules. The drive
unit consists of an AC motor with a pinion gear mounted. The power is transferred
through a gear to a rack attached to the rail modules. The rail modules are
constructed from sturdy, welded steel profiles. All mounting surfaces have been
machined during the same operation to ensure perfect straightness and parallellity.
The standard track motion is equipped with one carriage, but versions with more
than one carriage are available on request.
Carriage Serial Measurement Box
Connection point
Mechanical stop
Figure 1. Track Motion 6002S/4002S
3HXD 7207-1 Rev.1 1

General Installation/Maintenance
The carriage is supported on both sides by sealed ball elements (The sealing keeps
dust and dirt away) which runs on two high precision linear guidings. These
components are dimensioned to easily withstand all forces and loads resulting from
operation to ensure long life.
During assembly, the robot base can be positioned in one of two positions, with a
90° displacement. The calibration position of the track motion is located at one of
the end stops in the standard version, but this can be changed to any position on
request.
The track motion movements are programmed and controlled from the robot
programming unit, so programming/controlling the track motion is no different
from any other robot axis.
Control and power cables for track motion and robot are routed through a cable
chain. This also includes an air hose, inside diameter 12.7 mm, for transferring
compressed air to the robot. The option standard customer cabling is also located
here. In the cable chain there is a free space of approx. 60x42 mm, available for
process cables and hoses. As an option, a cable chain for spot welding with higher
capacity can be delivered. This is then located externally, parallel to the track
motion.
At the centre of the track motion, there is a junction point for connecting robot and
control cabinet. This, and all electrical equipment for installing the unit, is included
in the standard delivery. The cable to the motor is 15 m measured from the track
motion centre.
The track motion is fitted with a measurement board which converts the resolver
signals of the track motion drive system to digital signals. The board uses a battery
backup, and this enables the robot to be restarted without any synchronization or
similar after a power break-down. The digital signal transmission is also less
sensitive to radio interference than the traditional analog transmission. This
ensures safe operation, even with very long travel lengths.
The track motion is covered, what prevents the guide plates from dirt and falling
objects. It also makes it possible for the operator to stand on the track, during
service for instance.
Make sure before moving the carriage that no loose objects lie on the cover plates!
Loose objects can be caught between the cover plates and the carriage.
2 3HXD 7207-1 Rev.1

Installation/Maintenance General
1.2 Identification
Identification plates indicating the type of track motion, delivery year etc.
Made in
Sweden
Type IRBT 6002
Cat no: 3HXDXXXX-X
Serie No: 6002-XXX
Deliv year: XXXX
Weight kg: 3200
Order: XXXXXXXX
Figure 2. Identification plate on the Track Motion 6002S/4002S
Parameter diskette
Track Motion
System parameters
Part No: 3HXD 9000-
Configuration files:
IRBT
Property of ABB Västerås/Sweden. All Rights re-
served.Reproduction, modification, use or disclosure to
third parties without express authority is strictly forbidden.
Copyright 1998
$%%)OHFLEOH$WXRPDWLRQ$%
Figure 3. Example of label on parameter diskette
3HXD 7207-1 Rev.1 3

General Installation/Maintenance
4 3HXD 7207-1 Rev.1

Installation/Maintenance Safety
2 Safety
This information on safety covers the installation and maintenance of the track
motion.
OBS! For safety information regarding the industrial robot, see the robot
documentation.
The user´s of the trackmotion are responsible for ensuring that the applicable safety
laws and regulations in the country concerned are observed and the safety devices
necessary to protect people working with the track motion have been designed and
installed correctly.
WARNING!
Make sure nobody is on the track motion when the carriage is in motion!
To protect the personnel, the complete system has to be designed and installed in
accordance with the safety requirements set forth in the standards and regulations
of the country where the robot is installed.
3HXD 7207-1 Rev.1 5

Safety Installation/Maintenance
6 3HXD 7207-1 Rev.1

Installation/Maintenance Unpacking and handling
3 Unpacking and handling

NOTE! Before starting to unpack and install the track motion, read the safety
regulations and other instructions very carefully.
3.1 General
Unpack the equipment and inspect for any transport damage.
The transport unit is protected against rust by a thin film of oil applied before
packing. Wipe off any excess oil with a lintfree cloth before assembly.
• The carriage weighs approx. 800 kg and the rail module approx. 200 kg per
meter.
3.2 Delivery check

A standard track motion contains the following:
• A carriage with drive unit
• Rail module(s) and cablechain. Track Motions with travel lengths > 7.7 m
are made up of more than one rail module, jointed at installation.
• Three robot attachment bolts with washers and two robot guide bushings.
3HXD 7207-1 Rev.1 7

Unpacking and handling Installation/Maintenance
3.3 Lifting instructions
3.3.1 Rail module < 1.7 m

• If the rail modules are to be lifted with a crane, the lifting straps should be
wrapped around the rails, two on each side of the carriage. Before lifting,
the carriage should be run to a position close to the track motions centre
(only track motions < 1.7m).
3.3.2 Rail module > 1.7 m
Lift area
Figure 4. Rail module > 1.7 m
• The rail modules can also be lifted with a fork-lift truck. In this case the
forks should be placed on the long side of the rail module.
NOTE! Avoid placing the forks under the folded down steel edges, located in
some places under the MH version.
8 3HXD 7207-1 Rev.1

Installation/Maintenance Mechanical installation
4 Mechanical installation
4.1 Foundation loads

The foundation should be designed to withstand both the static loads caused by the
weight of the unit and the dynamic loads generated by the movement of the track
motion and robot.
The dynamic loads from the track motion and robot can change direction
irrespective of each other and the foundation must withstand the the combination
of loads in conditions where they add to each other.
Each sleeper for the track motion must be attached to the floor at both ends. The
type of attachment bolts must be chosen to suit the foundation. The sleepers are
fitted with adjustment screws for setting up the track motion. These must press
against contact plates in the floor, and not the floor itself (not included in the
delivery).
Distances between screw positions are given by the included drawings.
The attachment screws for the sleepers are designed to carry the weight of the
robot, carriage, permitted additional load and repeated alternate dynamic forces.
4.1.1 Static loads
IRBT 6002S 4002S
Spread load
Rail system 200 kg/m 180 kg/m
Moveable, in direction of motion:
Robot 2 100 kg (6400) 1010 kg (4400)
Carriage 800 kg 800 kg
Permitted extra load 300 kg 100 kg
4.1.2 Dynamic loads
For dynamic loads for robot, see the robot documentation.
3HXD 7207-1 Rev.1 9

Mechanical installation Installation/Maintenance
4.1.3 Dimensions, attachment screw pattern
There are two possible mounting angles for the robot; neutral position of axis 1
pointing towards 1 or 2. The 7th axis cable has a free length of 15 m from the
connection point at the side of the track.
Single carriage Track Motion IRB 6400, 4400
W channel, detail Ø26
External cable chain (alt. location)
Connection point Connection point

external cable chain (TG) internal cable chain (MH)
The dimension between the
socket beams at the rail varies
Figure 5. Dimensions, foundation bolt pattern
Travel length 1,7 2,7 3,7 4,7 5,7 6,7 7,7
Number of increments, N 2 3 4 5 6 7 8
10 3HXD 7207-1 Rev.1

Single carriage Track Motion IRB 6400R
Connection point
internal cable chain (MH)
The dimension between the Connection point
socket beams at the rail varies external cable chain (TG)
Figure 6. Dimensions, foundation bolt pattern
3HXD 7207-1 Rev.1 11

Cable chain
External cable chain
Plate (Cable chain)

585
880 min
225 935 max (limited by plate)
Comments for TG:

The cable channel can be mounted on the sill or floor.
The cable channel is attached to the floor by an expander bolt.
Comments for IRB 6400R:

If the robot is positioned at 90º, the cable chain must be
located on the opposite side to the robot’s dead zone.
Figure 7. External cable chain, cross section
Internal cable chain
1172
770
450
1000
1150
Figure 8. Internal cable chain, cross section
12 3HXD 7207-1 Rev.1

4.2 Mounting, track motion

• Place the rail module exactly on its installation site.
• Mark the location of the track motion attachment holes using the rail
module as template.
$%
Figure 9. Levelling (A) and attachment (B) screws
• Insert the steel plates for the levelling screws. Each sleeper requires two
plates.
• Using the aligned rail modules as a template, drill Ø 20 mm holes for the
chemical anchor screws (recommended attachment method).
NOTE! The holes in the rail module are Ø26 mm. Attachment screws are not
included, but must be selected with regard to the foundation material.
• Adjust the rails alternately with the attachment bolts and levelling screws
until they are correctly aligned.
3HXD 7207-1 Rev.1 13

4.3 Alignment and levelling

NOTE! The support nuts must be lightly tightened before the adjustment screws
are tightened.
• The final alignment is performed alternately with the attachment bolts (A)
and adjusting screws (B) until the rails are aligned to wit-hin 0.5 mm/m.
$%
C
Figure 10. Levelling (A) and attachment (B) screws
• The guide rails are parallel when delivered.

• The carriage can be moved by hand if 24V DC is connected to the serial
measurement box and the brake release button is pressed. See the electrical
circuit diagram in the appendix.
• The carriage must be checked with a machinists level in both the direction
of travel and the transverse direction along the entire travel length. Any
divergence must be corrected.
14 3HXD 7207-1 Rev.1

4.4 Rack assembly

Choose both ends and the centre of each rack as assembly ponts.
Joint
Joint
Figure 11. Assembly points
• Preassemble all racks on the rail module. Start approx. 220 mm from the
zero end.
• Press tight rackpieces type A, in all joints.
• Press the assembly rack piece type B, and the spacer tight, using cramp 1.
Assembly tool
Cramp 1
Cramp 2
Spacer 7.9mm
Rack piece B
Figure 12. Rack assembly
• Check whether the assembly rack piece is pressed tight, if not, use cramp 2
and lift the rack so that the assembly rack piece grips.
3HXD 7207-1 Rev.1 15

4.5 Jointing
If the track motion has a travel length longer than 7.7 m, it is made up of more than
one rail module and the rail modules will have to be jointed.
• Mount the first one of the rail modules according to 4.2, ”Mounting track
motion”.
0 mm play
Rail joint
Rack 1 Rack 2
Rack joint
Rail module 1 Rail module 1
Rail module beam joint
Figure 13. Jointing
• Place the second rail module next to the first and align it at the
approximately correct position. Move the second rail module against the
first until the rail ends butt-end.
Track Motion jointing Rack Assembly
Rack piece B
Rack piece C One rack piece
One piece per A in every joint + Spacer 7.9mm
jointed track motion
is included in Assembly tool
delivery
Figure 14. Track motion jointing and rack assembly
• Press the small piece of extra rack type C, tight in place to align the teeth of
the first and second rail modules' racks.
16 3HXD 7207-1 Rev.1

• Tighten the rack screws when the fit is good. When not, the entire rack on
the jointed track must be loosened and remounted. This should normally not
be neccessary.
• Recheck the alignment of the complete rail module. Carefully check that
the rail ends are correctly aligned. Run the carriage over the rail joint to
check that no noise can be heard and that it runs smoothly. The railjoint can
be justified by loosing the screws fixing the guide rail (8-10 screws) closest
to the joint. To align them, place the carriage over the rail joint and then
retighten the screws.
4.6 Mounting of the manipulator

For manipulator lifting instructions ( IRB 4400, IRB640 and IRB 6400), see the
manipulator Product Manual, Installation and commissioning.
The best way to lift the manipulator is to use lifting straps and a traverse crane. The
lifting strap dimensions must comply with the applicable standards for lifting.
WARNING!
The lifting instructions are valid for a “naked” robot. Whenever additional
equipment is put on the robot, the centre of gravity can change and make
lifting dangerous.
WARNING!
Never walk under a suspended load.
3HXD 7207-1 Rev.1 17

18 3HXD 7207-1 Rev.1

Installation/Maintenance Electrical installation
5 Electrical installation
5.1 General
The track motion drive package includes an AC motor with integrated brake and
resolver.
The measurement system uses a resolver and a serial measurement board for
converting the resolver signals to digital form and an accumulator pack for
memory backup. These components are fitted in the measurement board box
located on the side of the motor.
Both ends of the working range are fitted with cams, which activate a switch, fitted
to the carriage, connected to the control system emergency stop circuit.
The connection of the standard cables are made for function as 7th axis.
The cable chain includes, besides the cables required for controlling the track
motion, cables for all connections in the robot control cables, customer signal and
power cables and one air hose, inside diameter 12.7 mm.
3HXD 7207-1 Rev.1 19

Electrical installation Installation/Maintenance
5.2 Connections
5.2.1 Robot cabling
The cabling normally connected between robot and control cabinet is connected to
the track motion junction point (J1), located on the outer side of the track,
approximately in the middle. Here are one connector for the robot power cable
(Harting), one for control signals and one for customer power/signal (all Burndy)
located.
J1
Figure 15. Connection point J1
The robot cabling is long enough to allow fitting the robot in any one of two
possible angles on the carriage. Any excess cabling is to be located in a loop on the
floor in accordance with the circumstances on site.
Make sure that the loop doesn’t interfere with any moving parts of the track!
5.2.2 Emergency stop
The emergency stop must only be used in case of emergency to stop the track
motion. It must never be used as a stop function to stop the track motion.
5.2.3 Manually releasing the brake
The carriage is usually locked by the motor brake. If manually moving the carriage
is required, the brake must be released. Press, and keep pressed, the button in the
serial measurement box at the robot base. This will release the brake which enables
moving the carriage by hand. The brake will not release the other six robot axes.
Brake release button
Figure 16. Brake release box
20 3HXD 7207-1 Rev.1

5.3 Cable connections

5.3.1 IRBT 6002S with IRB6400 M98A
Carriage Cable chain Floor

Controller
13
1
2 14
3 15
4 16
8 5 12
9
HaPe
10 11
6 7
Figur 17. Wiring diagram IRBT 6002S/4002S
Cable Cable name Article No. Remark

1 Customer signal cable 3HXD 1296-
2 Motor cable 3HXD 1295-
3 Position switch cable axis 1 3HXD 1314-
4 Robot measurement cable 3HXD 1410-
5 7th axis power cable 3HXD 1252-
7 Floor cable for zone detection, axis 7 3HXD 1382
8 External axes measurement cable 3HXD 1251-
9 Limit switch with cable 3HXD 1193-
10 Motor cable, axis 7 3HXD 1249-
11 Resolver cable 3HXD 1250-
12 7th axis Power Floor Cable 3HXD 1253-
13 Customer power cable Lev. med Robot
14 Motor cable, robot Lev. med Robot
15 Position switch cable Lev. med Robot
16 Serial measurement cable Lev. med Robot
3HXD 7207-1 Rev.1 21

5.3.2 IRBT 6002S med IRB 6400R M99

Controller
13
1
2.5 2.4
2.1 14
2.3 2.2
3 15
4 16
8 12
5
9
HaPe
10 11
6 7

2 Motor cable, robot 3HXD 1439-
2.1 Power cable one 3HXD 1435-
2.2 Power cable two 3HXD 1436-
2.3 Power cable three 3HXD 1437-
2.4 Junction box one 3HXD 0100-257
2.5 Junction box two 3HXD 0100-258
7 Floor cable forzone detection, ax 7 3HXD 1382-
15 Position switch cable, axis 1 Lev. med Robot
22 3HXD 7207-1 Rev.1

5.3.3 IRBT 6002S with IRB 6400R M2000

Controller
13
1
2.5 2.4
2.1 14
2.3 2.2
3 15
4 16
8 12
5
9
HaPe
10 11
6 7

2 Motor cable, robot 3HXD 1439-
2.1 Power cable one 3HXD 1435-
2.2 Power cable two 3HXD 1436-
2.3 Power cable three 3HXD 1437-
2.4 Junction box one 3HXD 0100-257
2.5 Junction box two 3HXD 0100-258
7 Floor cable for zone detection, axis 7 3HXD 1382-
3HXD 7207-1 Rev.1 23

5.3.4 IRBT 6002S med IRB 4400 M98A

Controller
13
1
2 14
3 15
4 16
8 12
5
9
HaPe
10 11
6 7
Cable Cable name Article No Remark

24 3HXD 7207-1 Rev.1

5.3.5 IRBT 6002S with IRB 4400 M99-M2000

Controller
13
1
2 14
3 15
4 16
8 12
5
9
HaPe
10 11
6 7
Cable Cable name Article No Remark

3HXD 7207-1 Rev.1 25

26 3HXD 7207-1 Rev.1

Installation/Maintenance Start-up
6 Start-up
6.1 General
Track Motion 6002S
The Track Motion is tuned for robot IRBT 6002 with max load + 300 kg extra load.
Track Motion 4002S
The Track Motion is tuned for robot IRBT 4002 with max load + 100 kg extra load
Reference documentation
Robot: User´s Guide S4C/S4C Plus, Installation Manual S4C/S4C Plus
The system will go to emergency stop mode if the carriage moves at a speed higher
than 25% of the programmable speed.
6.2 Before start-up

Following steps has to be done before start-up.
New drive unit: When booting, select DC2T, for IRB 6400R select DC2U
1. Load function parameters
2. Activate automatic lubrication system (if ordered to this track motion)
3. Calibration
3HXD 7207-1 Rev.1 27

Start-up Installation/Maintenance
6.3 Load function parameters

For loading from a diskette, se the Robot User´s Manual
The IRBT 6002S/4002S commutation offset is a fixed value that has been entered
at the factory. All IRBT 6002S/4002S track motions have the same offset value,
and there is no need to change this value.
The working range of the different travel distances are defined in relation to the
calibration mark. Before starting, the track motion must be defined to the system
with the function parameters delivered on a diskette.
Default parameters: “-do_not_allow_deactivation” is set to “yes!

When using “act_unit” and “deact_unit”, change to “no”
At delivery, travel lenght is set to maximum.
IRBT 6002S
1. Choose File: Add New Parameters
2. Load file T6002.cfg
IRBT 4002S
1. Choose File: Add New Parameters
2. Load file T4002.cfg
6.4 Activate automatic lubrication system (option)

The grease injectors are not activated at delivery.
To activate grease injectors:
1. Set the lubrication time on the driver using a

size 3 mm Allen key. Set the gas generator
for required dispensing time , 1-12 months,
marked on the driver.
2. Note starting date on the label of the grease

injector.
28 3HXD 7207-1 Rev.1

Installation/Maintenance Start-up
6.5 Calibration
Check before moving the carriage that no loose objects lie on the cover plates!
Loose objects can be caught between the cover plates and the carriage.
WARNING!
Make sure that nobody is on the track motion when the carriage is in motion!
6.5.1 Calibration
Check that the carriage stops exactly at the calibration mark when performing the
calibration.
Figure 22. Calibration mark
Save the system parameters. How to save the parameters, see the Robot User´s
Manual.
3HXD 7207-1 Rev.1 29

Start-up Installation/Maintenance
6.6 Start-up
6.6.1 Automatic restart
A robot system using a serial measurement system does not need to be calibrated
before restart, since the serial measurement system automatically montitors the
robot position within the working range. The resolvers will only need to be
calibrated when commissioning the system.
6.6.2 Track motion working range
Manually run the system with the joystick and check that it is possible to run it in
both directions and that the end positions can be reached.
30 3HXD 7207-1 Rev.1

Installation/Maintenance Maintenance
7 Maintenance
The track motion is designed to work with a minimum of maintenance. Although,
routine checks and preventive maintenance must be carried out at periodical
intervals.
7.1 Interval
4 times/ 6 times/ 5000

Maintenance Every month 5 year
year year hours
Ball elements Lubricate X
Lubrication system* Check, refill X
(Option, Simalube)
Lubrication system** Check, refill X
(Option, Trabon)
Linear guides Inspect and clean X
Rack (7.2.4) Clean and lubricate X
Gear box (7.2.1) Oil change X
Cables Visual checking X
Drive motor Visual checking X
Junction boxes Visual checking X
Function Visual checking X
Backup batteries (7.3.4) Replace X
* Only if option with automatic lubrication sytem Simalube is ordered
** Only if option with automatic lubrication sytem Trabon is ordered
3HXD 7207-1 Rev.1 31

Maintenance Installation/Maintenance
7.2 Mechanical maintenance
7.2.1 Gear box
At delivery, the gearbox is filled with the correct amount of oil. The oil change
interval is 5 years. Shorter intervals will only reduce the gearbox lifetime.
Every second time the oil is changed, the gearbox should be completely
disassembled and all old oil should be rinsed out thoroughly. All parts should be
completely cleaned and their function checked, especially the shaft seals. These
should, at reassemble, be lubricated with transmission grease. Test run the gearbox,
check the oil level and add oil to the prescribed level if required. Oil volume: 2 200
cm3
The oil should meet the standards for high pressure oil under CLP 198–242 mm2/s
/-40 °C ISO VG 220, which include e.g:
Brand:
Statoil: Loadway EP 220
SHELL: Omala Oil 220
MOBIL: Mobilgear 630
7.2.2 Linear guides
The linear guides are to be inspected and cleaned:
7.2.3 Ball elements
See chapter 7.1
Lubricate until grease is pressed out.
Lubricant: Ball element grease acc. to NLGI 2
Example:
Optimal: longtime PD2
Shell: Alvania WR2
32 3HXD 7207-1 Rev.1

7.2.4 Rack
Clean and lubricate with OPTIMOL VISCOGEN 4, or any of the following

brands:
- BP MOG
- Statoil ESL10
- Mobiloil Mobiltac 81
- Texaco Texclade
Lubrication in particularly dirty environment:
If there is a risk of welding spatter or any other airborn particles getting stuck on
the lubricated rack, a special dust and dirt rejectant lubricant, OPTIMOL
VISCOGEN EPL is recommended.
7.3 Electrical maintenance
7.3.1 Visual checking
Visually check once every month:

• Visible cables (damages, squeezing, wear, fastening points and
contaminations).
• Visible cable chain (link system, fastening points, contamination and wear).
• Drive motor (abnormal bearing noise and contamination).
• Junction boxes (damages, contamination, connectors and fastening).
• Function (test of all electrical functions of the track motion, including
emergency stop and limit switch functions).
7.3.2 Cable chain

• Lift the rack side cover plate and examine the whole cable chain (link
system, fastening points, contamination, wear) every 3d month.
7.3.3 Cabling and connectors

• Check that no cables are rubbing against any sharp edges or are routed in
such a way that all connectors are plugged in correctly, etc.
3HXD 7207-1 Rev.1 33

7.3.4 Replacement of memory backup batteries
The measurement board of the track motion uses a memory backup battery to
retain the position data. This battery is to be replaced every 3 years or when the
batteries show any sign of being low on power. This is generally indicated by a
flashing RUN lamp at start up and an error code is shown on the display of the
programming unit. The code is described in the Programming unit, S4C/S4C Plus
(Error message chapter).
The battery unit is fitted along with the measurement board, inside the junction box
on the carriage. To replace the batteries, cut the cable ties holding the battery unit,
disconnect the two-pole cable connected to it, and remove the battery unit. Refit
the new battery unit in reverse order.
In a new system the batteries can be generally low on power, but are fully charged
by the system after a few hours in the STANDBY mode.
7.4 Automatic lubrication system (option)
7.4.1 Simalube system
The grease injector can be refilled. A new driver and a filling nipple can be ordered
from ABB Flexible Automation AB, System Products.
Refilling
To refill the dispenser, a grease gun or grease pump, a refill nipple and a refill-set
are required
1. Remove cover disk. Unscrew gas generator using a socket size 21 mm.
Dispose the complete generator in the recycling system for button type
Zinc/air batteries, where available.
2. Screw refill nipple on to the tube
The grease injector is not activated at delivery.
To activate it, set the lubrication time on the driver using a hexagon spanner. The
lubrication time, 1-12 months, is marked on the driver. Note starting date on the
label of the grease injector.
34 3HXD 7207-1 Rev.1

7.5 Adjustments
7.5.1 Gear play
The play between rack and pinion is determined by a guide roller fitted on the
pinion shaft, rolling against a guide surface on the rack. This means that the play
never needs to be adjusted.
The gear meshing pressure is determined by the spring pressure in the spring
housing (located behind the motor unit, fitted in the direction of the travel) and is
adjusted as following:
Adjustment of the meshing pressure:

X = 6 mm
Figure 23. Adjusting the meshing pressure
1. Release nut B and screw the spring housing until there is a few millimetres
play between the shaft and the gearbox bracket contact surface.
2. Release the locking nut on the rear of the shaft and screw nut A until the
shaft protrudes 6 mm.
3. Screw the spring housing to a position where the shaft touches the contact
surface.
4. Tighten nut B to lock the housing.
5. Switch the control system to RUN mode according to the programming

manual, S4.
3HXD 7207-1 Rev.1 35

6. Run the carriage back and forth a few meters to make sure the rack/pinion
and the guide roller positions settle.
7. Adjust the protrusion X to 6 mm, by loosening B and then screwing the

spring housing against the contact surface of the axis.
8. There is now some millimetres play between the housing and the contact
surface, and the spring pressure is correctly set. Lock with nut B. The
washer is 4 mm thick.
36 3HXD 7207-1 Rev.1

Installation/Maintenance Spare parts
8 Spare parts
8.1 IRBT 6002S/4002S
13 14 15
Figure 24. IRBT 6002S/4002S
Item Qty Description Item number Remarks

1 1 Drive unit 3HXD 0100-127 IRBT 6002
2 1 Drive unit 3HXD 0100-141 IRBT 4002
3 X Rack, L = 1000 3HXD 1107-7
4 X Rack, L = 2000 3HXD 1107-8
5 X Linear guide, L=1995 mm 2185 0446-1 Qty, see page 39
9 4 Ball element 2185 0445-1
10 1 Spring housing 6399 0002-AVY
11 1 Limit switch 5373 135-1 Housing (Option)
12 1 Roll for limit switch 5373 135-3 (Option)
13 1 Serial measurement box 3HXD 0100-89
14 1 Accumulator unit 49 44 026-4
15 1 Measurement board 3HAB 3700-1
17 1 Cable chain 3HXD 1445-xx MH, see resp. Robot
18 1 Cable chain 3HXD 1446-xx TG, see resp. Robot
* When ordering a complete cable chain, the option cables must be specified..
3HXD 7207-1 Rev.1 37

Spare parts Installation/Maintenance
8.2 Drive unit
0.1/100 8
9
+1.0
66 -0.3
5
4 10
3 7 6
1, 2
Figure 25. Drive unit, IRBT 6002S/4002S

1 1 Gear 2334 0001-16 IRBT 6002S
2 1 Gear 2334 0001-17 IRBT 4002S
3 1 Pinion 3HXD 1000-49
4 1 Bushing 3HXG 1000-56
5 1 Guide roller 3HXD 1000-50
6 1 Motor unit 3HXD 0100-80
7 1 Axle 3HXD 1000-56
8 2 Washer 6399 0003-406
9 1 Bracket 3HXD 1000-54
10 1 Motor cradle 3HXD 1000-55
38 3HXD 7207-1 Rev.1

8.3 Length dependent spare parts
8.3.1 IRB 4400, 640, 6400, 6400R
Included quantity for different travel lengths
Designation 1.7 2.7 3.7 4.7 5.7 6.7 7.7 8.5 8.7 9.7 10.7 11.7 12.7 13.7 14.7
Linear guide L=1995

2185 0446-1 0 0 2 2 0 0 2 0 4 4 4 2 0 0 4
L=3045 2 0 2 0 2 0 2 0 4 2 0 2 4 2 0
2185 0446-2
L=3990 0 2 0 2 2 4 2 4 0 2 4 4 4 6 6
2185 0446-3
L=1785 0 0 0 0 0 0 0 4 0 0 0 0 0 0 0
2185 0446-10
Non rack side coverplate

L=1995 1 2 2 3 3 4 4 4 5 5 6 6 7 7 8
3HXD 1118-1
L=1785 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0
3HXD 1118-3
L=1995 1 0 1 0 1 0 1 0 0 1 0 1 0 1 0
3HXD 1118-1
Rack side cover

L=1995 1 2 2 3 3 4 4 4 5 5 6 6 7 7 8
3HXD 1120-1
L=1785 0 0 0 0 0 0 0 1 1 0 1 0 1 0 1
3HXD 1120-3
L=1050 1 0 1 0 1 0 1 0 0 1 0 1 0 1 0
3HXD 1120-5
Rack
L=999 0 1 0 1 0 1 0 1 1 0 1 0 1 0 1
3HXD 1107-7
L=1998 1 1 2 2 3 3 4 4 4 5 5 6 6 7 7
3HXD 1107-8
Cable chain guide plates

MH 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
3HXD 1149-xx*
Ext. cable chain guide SW

3HXD 1391-xx* 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
* -xx in cable item number designates the cable length in meters. Ex. 5.5 metre
robot cable, 3HXD 1295-55
3HXD 7207-1 Rev.1 39

8.3.2 IRB 4400 M98
Internal Cable Chain

Included length for different travel lengths
Designation 1.7 2.7 3.7 4.7 5.7 6.7 7.7 8.5 8.7 9.7 10.7 11.7 12.7 13.7 14.7
Robot power cable

3HXD 1295-xx* 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0 12.0
Customer power/
signal cable, option 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0 12.0
3HXD 1296-xx
7th axis cable

3HXD 1252-xx 5.0 5.0 6.0 6.0 7.0 7.0 8.0 8.0 8.0 9.0 9.0 10.0 10.0 11.0 11.0
Robot control cable

MH
3HXD 1410-xx* 5.0 5.0 6.0 6.0 7.0 7.0 8.0 8.0 8.0 9.0 9.0 10.0 10.0 11.0 11.0
Position switch cable

axis 1, option
3HXD 1281-xx* 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0 12.0
Zone division cable

MH
3HXD 1381-xx* 5.0 5.0 6.0 6.0 7.0 7.0 8.0 9.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0
Cable chain links 27 35 43 50 58 66 74 77 81 89 97 104 112 120 127

linklenght 62.5 mm
MH 3HXG 1000-52
robot cable with 1.7 m travel length, 3HXD 1295-60
40 3HXD 7207-1 Rev.1

External Cable Chain
Designation 1.7 2.7 3.7 4.7 5.7 6.7 7.7 8.5 8.7 9.7 10.7 11.7 12.7 13.7 14.7
1/2” hose red 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
1855 1940-5
1/2” hose green, SW 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
1855 1940-6
Robot Power Cable

3HXD 1295-xx* 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
Customer power/
3HXD 1296-xx
7th axis cable

3HXD 1252-xx 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
Robot control cable

SW 4.5 5.5 5.5 6.5 6.5 7.5 7.5 8.5 8.5 8.5 9.5 9.5 10.5 10.5 11.5
3HXD 1410-xx*
Positionsswitch cable 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
Axis 1, option
3HXD 1281-xx*
Zone division cable

SW
3HXD 1381-xx 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0

linklenght 62.5 mm
SW 2166 0620-4
3HXD 7207-1 Rev.1 41

8.3.3 IRB 4400 M99-M2000

Designation 1.7 2.7 3.7 4.7 5.7 6.7 7.7 8.5 8.7 9.7 10.7 11.7 12.7 13.7 14.7
Robot power cable

3HXD 1295-xx* 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0 12.0
Customer power/
3HXD 1296-xx
7th axis cable

3HXD 1252-xx 5.0 5.0 6.0 6.0 7.0 7.0 8.0 8.0 8.0 9.0 9.0 10.0 10.0 11.0 11.0
Robot control cable

MH
3HXD 1443-xx* 5.0 5.0 6.0 6.0 7.0 7.0 8.0 8.0 8.0 9.0 9.0 10.0 10.0 11.0 11.0

axis 1, option
3HXD 1433-xx* 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0 12.0
Zone division cable

MH
3HXD 1381-xx* 5.0 5.0 6.0 6.0 7.0 7.0 8.0 9.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0

linklenght 62.5 mm
MH 3HXG 1000-52
42 3HXD 7207-1 Rev.1

Designation 1.7 2.7 3.7 4.7 5.7 6.7 7.7 8.5 8.7 9.7 10.7 11.7 12.7 13.7 14.7
1/2” hose red 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
1855 1940-5
1/2” hose green, SW 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
1855 1940-6
Robot Power Cable

3HXD 1295-xx* 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
Customer power/
3HXD 1296-xx
7th axis cable

3HXD 1252-xx 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
Robot control cable

SW 4.5 5.5 5.5 6.5 6.5 7.5 7.5 8.5 8.5 8.5 9.5 9.5 10.5 10.5 11.5
3HXD 1443-xx*
Positionsswitch cable 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
Axis 1, option
3HXD 1433-xx*
Zone division cable

SW
3HXD 1381-xx 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0

linklenght 62.5 mm
SW 2166 0620-4
3HXD 7207-1 Rev.1 43

8.3.4 IRB640 M98-M2000

Designation 1.7 2.7 3.7 4.7 5.7 6.7 7.7 8.5 8.7 9.7 10.7 11.7 12.7 13.7 14.7
Robot power cable

3HXD 1275-xx* 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0 12.0
Customer power/
3HXD 1369-xx
7th axis cable

3HXD 1252-xx 5.0 5.0 6.0 6.0 7.0 7.0 8.0 8.0 8.0 9.0 9.0 10.0 10.0 11.0 11.0
Robot control cable

MH
3HXD 1410-xx* 5.0 5.0 6.0 6.0 7.0 7.0 8.0 8.0 8.0 9.0 9.0 10.0 10.0 11.0 11.0

axis 1, option
3HXD 1314-xx* 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0 12.0
Zone division cable

MH
3HXD 1381-xx* 5.0 5.0 6.0 6.0 7.0 7.0 8.0 9.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0

linklenght 62.5 mm
MH 3HXG 1000-52
robot cable with 1.7m travel length, 3HXD 1275-60
44 3HXD 7207-1 Rev.1

Designation 1.7 2.7 3.7 4.7 5.7 6.7 7.7 8.5 8.7 9.7 10.7 11.7 12.7 13.7 14.7
1/2” hose red 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
1855 1940-5
1/2” hose green, SW 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
1855 1940-6
Robot power cable

3HXD 1275-xx* 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
Customer power/
3HXD 1369-xx
7th axis cable

3HXD 1252-xx 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
Robot control cable

SW 4.5 5.5 5.5 6.5 6.5 7.5 7.5 8.5 8.5 8.5 9.5 9.5 10.5 10.5 11.5
3HXD 1410-xx*
Position switch cable 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
axis 1, option
3HXD 1314-xx*
Zone division cable

SW
3HXD 1381-xx 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0

linklength 62.5 mm
SW 2166 0620-4
3HXD 7207-1 Rev.1 45

8.3.5 IRB6400 M98-M2000

Designation 1.7 2.7 3.7 4.7 5.7 6.7 7.7 8.5 8.7 9.7 10.7 11.7 12.7 13.7 14.7
Robot power cable

3HXD 1295-xx* 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0 12.0
Customer power/
3HXD 1296-xx
7th axis cable

3HXD 1252-xx 5.0 5.0 6.0 6.0 7.0 7.0 8.0 8.0 8.0 9.0 9.0 10.0 10.0 11.0 11.0
Robot control cable

MH
3HXD 1410-xx* 5.0 5.0 6.0 6.0 7.0 7.0 8.0 8.0 8.0 9.0 9.0 10.0 10.0 11.0 11.0

axis 1, option
3HXD 1314-xx* 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0 12.0
Zone division cable

MH
3HXD 1381-xx* 5.0 5.0 6.0 6.0 7.0 7.0 8.0 9.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0

linklenght 62.5 mm
MH 3HXG 1000-52
46 3HXD 7207-1 Rev.1

Designation 1.7 2.7 3.7 4.7 5.7 6.7 7.7 8.5 8.7 9.7 10.7 11.7 12.7 13.7 14.7
SW Power Cable 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
3HXD 1134-xx*
1/2” hose red 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
1855 1940-5
1/2” hose green, SW 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
1855 1940-6
Robot power cable

3HXD 1295-xx* 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
Customer power/
3HXD 1296-xx
7th axis cable

3HXD 1252-xx 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
Robot control cable

SW 4.5 5.5 5.5 6.5 6.5 7.5 7.5 8.5 8.5 8.5 9.5 9.5 10.5 10.5 11.5
3HXD 1410-xx*
Position switch cable 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
axis 1, option
3HXD 1314-xx*
Zone division cable

SW
3HXD 1381-xx 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0

linklength 62.5 mm
SW 2166 0620-4
3HXD 7207-1 Rev.1 47

8.3.6 IRB6400R M99

Designation 1.7 2.7 3.7 4.7 5.7 6.7 7.7 8.5 8.7 9.7 10.7 11.7 12.7 13.7 14.7
Robot power cable

3HXD 1439-xx* 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Customer power/
3HXD 1369-xx
7th axis cable

3HXD 1252-xx 5.0 5.0 6.0 6.0 7.0 7.0 8.0 8.0 8.0 9.0 9.0 10.0 10.0 11.0 11.0
Robot control cable

MH
3HXD 1410-xx* 5.0 5.0 6.0 6.0 7.0 7.0 8.0 8.0 8.0 9.0 9.0 10.0 10.0 11.0 11.0

axis 1, option
3HXD 1314-xx* 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0 12.0
Zone division cable,

Axis 7, MH, option
3HXD 1381-xx* 5.0 5.0 6.0 6.0 7.0 7.0 8.0 9.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0

linklenght 62.5 mm
MH 3HXG 1000-52
robot cable with travel length 1.7 m, 3HXD 1410-60
48 3HXD 7207-1 Rev.1

Designation 1.7 2.7 3.7 4.7 5.7 6.7 7.7 8.5 8.7 9.7 10.7 11.7 12.7 13.7 14.7
SW Power Cable 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
25mm²
3HXD 1465-xx*
SW Power Cable
35mm² 5 6 6 7 7 8 8 9 9 9 10 10 11 11 12
3HXD 1474-xx
1/2” hose red 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
1855 1940-5
1/2” slang grön, SW 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
1855 1940-6
Robot power cable

3HXD 1439-xx* 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
Customer power/
3HXD 1369-xx
7th axis cable

3HXD 1252-xx 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
Robot control cable

SW 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
3HXD 1410-xx*

axis 1, option 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
3HXD 1314-xx*
Zone division cable

SW 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
3HXD 1381-xx
Cable chain links

linklength 62.5 mm 28 36 44 52 60 68 76 80 84 92 100 108 116 124 132
SW 2166 0620-4
3HXD 7207-1 Rev.1 49

8.3.7 IRB 6400R M2000

Designation 1.7 2.7 3.7 4.7 5.7 6.7 7.7 8.5 8.7 9.7 10.7 11.7 12.7 13.7 14.7
Robot power cable

3HXD 1439-xx* 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0
Customer power/
3HXD 1369-xx
7th axis cable

3HXD 1252-xx 5.0 5.0 6.0 6.0 7.0 7.0 8.0 8.0 8.0 9.0 9.0 10.0 10.0 11.0 11.0
Robot control cable

MH
3HXD 1443-xx* 5.0 5.0 6.0 6.0 7.0 7.0 8.0 8.0 8.0 9.0 9.0 10.0 10.0 11.0 11.0

axis 1, option
3HXD 1433-xx* 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0 12.0
Zone division cable,

Axis 7, MH, option
3HXD 1381-xx* 5.0 5.0 6.0 6.0 7.0 7.0 8.0 9.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0

linklenght 62.5 mm
MH 3HXG 1000-52
50 3HXD 7207-1 Rev.1

Designation 1.7 2.7 3.7 4.7 5.7 6.7 7.7 8.5 8.7 9.7 10.7 11.7 12.7 13.7 14.7
SW Power Cable
25mm² 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
3HXD 1465-xx*
SW Power Cable
35mm² 5 6 6 7 7 8 8 9 9 9 10 10 11 11 12
3HXD 1474-xx
1/2” hose red 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
1855 1940-5
1/2” slang grön, SW 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
1855 1940-6
Robot power cable

3HXD 1439-xx* 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
Customer power/
3HXD 1369-xx
7th axis cable

3HXD 1252-xx 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
Robot control cable

SW 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
3HXD 1443-xx*

axis 1, option 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
3HXD 1433-xx*
Zone division cable

SW 5.0 6.0 6.0 7.0 7.0 8.0 8.0 9.0 9.0 9.0 10.0 10.0 11.0 11.0 12.0
3HXD 1381-xx
Cable chain links

linklength 62.5 mm 28 36 44 52 60 68 76 80 84 92 100 108 116 124 132
SW 2166 0620-4
3HXD 7207-1 Rev.1 51

8.4 Automatic lubrication system accessories
1 2
Figure 26. Options

1 Grease injector 6399 0003-594
1 Gas driver 6399 0003-595
1 1 Refill nipple 6399 0003-596
2 1 Clamp 6399 0003-597
52 3HXD 7207-1 Rev.1

Notes:
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
3HXD 7207-1 Rev.1

__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
3HXD 7207-1 Rev.1

3HXD 7207-1 Rev.1

4002 Track

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

4002 Track

Uploaded by

Copyright:

Available Formats

Installation/Maintenance

3HXD 7207-1 Rev.1

© ABB Flexible Automation AB

Article number: 3HXD 7207-1 Rev.1

3 Unpacking and handling ............................................................................................... 7

5 Electrical installation ..................................................................................................... 19

3HXD 7207-1 Rev.1 i

8 Spare parts ..................................................................................................................... 37

ii 3HXD 7207-1 Rev.1

8.4 Automatic lubrication system accessories .......................................................... 52

3HXD 7207-1 Rev.1 iii

iv 3HXD 7207-1 Rev.1

Carriage Serial Measurement Box

Figure 1. Track Motion 6002S/4002S

3HXD 7207-1 Rev.1 1

2 3HXD 7207-1 Rev.1

Figure 2. Identification plate on the Track Motion 6002S/4002S

ABB Flexible Automation AB

Figure 3. Example of label on parameter diskette

3HXD 7207-1 Rev.1 3

4 3HXD 7207-1 Rev.1

3HXD 7207-1 Rev.1 5

6 3HXD 7207-1 Rev.1

3 Unpacking and handling

3.2 Delivery check

3HXD 7207-1 Rev.1 7

3.3 Lifting instructions

3.3.1 Rail module < 1.7 m

3.3.2 Rail module > 1.7 m

Figure 4. Rail module > 1.7 m

8 3HXD 7207-1 Rev.1

4.1 Foundation loads

Distances between screw positions are given by the included drawings.

4.1.1 Static loads

IRBT 6002S 4002S

Moveable, in direction of motion:

Robot 2 100 kg (6400) 1010 kg (4400)

Carriage 800 kg 800 kg

Permitted extra load 300 kg 100 kg

4.1.2 Dynamic loads

For dynamic loads for robot, see the robot documentation.

3HXD 7207-1 Rev.1 9

4.1.3 Dimensions, attachment screw pattern

Single carriage Track Motion IRB 6400, 4400

W channel, detail Ø26

External cable chain (alt. location)

Connection point Connection point

Figure 5. Dimensions, foundation bolt pattern

Travel length 1,7 2,7 3,7 4,7 5,7 6,7 7,7

10 3HXD 7207-1 Rev.1

Single carriage Track Motion IRB 6400R

Figure 6. Dimensions, foundation bolt pattern

3HXD 7207-1 Rev.1 11

External cable chain

Plate (Cable chain)

Comments for TG:

Comments for IRB 6400R:

Figure 7. External cable chain, cross section

Internal cable chain

Figure 8. Internal cable chain, cross section

12 3HXD 7207-1 Rev.1

4.2 Mounting, track motion

Figure 9. Levelling (A) and attachment (B) screws