ABB IRB 1600 - 5/1.2 Product Manual
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ABB IRB 1600 - 5/1.2 Product Manual

Articulated robot
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Product manual
Articulated robot
IRB 1600 - 5/1.2
IRB 1600 - 5/1.45
IRB 1600 - 7/1.2
IRB 1600 - 7/1.45
M2004

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Summary of Contents for ABB IRB 1600 - 5/1.2

  • Page 1 Product manual Articulated robot IRB 1600 - 5/1.2 IRB 1600 - 5/1.45 IRB 1600 - 7/1.2 IRB 1600 - 7/1.45 M2004...
  • Page 3 Product manual IRB 1600 - 5/1.2 IRB 1600 - 5/1.45 IRB 1600 - 7/1.2 IRB 1600 - 7/1.45 M2004 Document ID: 3HAC023637-001 Revision: B...
  • Page 4 Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    Table of Contents Overview ................7 Product documentation, M2004 .
  • Page 6 Table of Contents 2.5.2 Robot cabling and connection points ..........80 2.5.3 Customer connections on the robot .
  • Page 7 Table of Contents 5.3 Calibration scales and correct axis position ..........178 5.4 Calibration movement directions for all axes.
  • Page 8 Table of Contents...

  • Page 9: Overview

    Prerequisites A maintenance/repair/ installation craftsman working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Organization of chapters The manual is organized in the following chapters:...
  • Page 10 Overview Continued References Documentation referred to in the manual, is listed in the table below. Document name Document ID Note Product specification - IRB 1600 3HAC023604-001 Product manual - IRC5 3HAC021313-001 Operating manual - IRC5 with FlexPendant 3HAC16590-1 Operating manual - Calibration Pendulum 3HAC16578-1 Operating manual - Service Information System 3HAC025709-001...

  • Page 11: Product Documentation, M2004

    This means that any given delivery of robot products will not contain all documents listed, only the ones pertaining to the equipment delivered. However, all documents listed may be ordered from ABB. The documents listed are valid for M2004 robot systems.
  • Page 12 Product documentation, M2004 Continued Application manuals Specific applications (e.g. software or hardware options) are described in Application manuals. An application manual can describe one or several applications. An application manual generally contains information about: • The purpose of the application (what it does and when it is useful) •...

  • Page 13: How To Read The Product Manual

    How to read the product manual How to read the product manual Reading the procedures The procedures contain references to figures, tools, material etc. The references are read as described below. References to figures The procedures often include references to components or attachment points located on the robot/controller.
  • Page 14 How to read the product manual 3HAC023637-001 Revision: B...

  • Page 15: Safety

    1 Safety 1.1. Introduction 1 Safety 1.1. Introduction Overview The safety information in this manual is divided in two categories: • general safety aspects, important to attend to before performing any service work on the robot. These are applicable for all service work and are found in section General safety information on page •...

  • Page 16: General Safety Information

    Limitation of liability Any information given in this manual regarding safety, must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. Related information...

  • Page 17: Safety Risks

    Nation/region specific regulations To prevent injuries and damage during the installation of the robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with. Non-voltage related risks •...
  • Page 18 1 Safety 1.2.2.1. Safety risks during installation and service work on robot Continued Complete robot Safety risk Description Hot components! CAUTION! Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! Removed parts may result in collapse of robot! WARNING! Take any necessary measures to ensure that the robot...

  • Page 19: Safety Risks Related To Tools/Workpieces

    1 Safety 1.2.2.2. Safety risks related to tools/workpieces 1.2.2.2. Safety risks related to tools/workpieces Safe handling It must be possible to safely turn off tools, such as milling cutters, etc. Make sure that guards remain closed until the cutters stop rotating. It should be possible to release parts by manual operation (valves).

  • Page 20: Safety Risks Related To Pneumatic/Hydraulic Systems

    1 Safety 1.2.2.3. Safety risks related to pneumatic/hydraulic systems 1.2.2.3. Safety risks related to pneumatic/hydraulic systems General Special safety regulations apply to pneumatic and hydraulic systems. Residual energy • Residual energy may be present in these systems. After shutdown, particular care must be taken.

  • Page 21: Safety Risks During Operational Disturbances

    1 Safety 1.2.2.4. Safety risks during operational disturbances 1.2.2.4. Safety risks during operational disturbances General • The industrial robot is a flexible tool which can be used in many different industrial applications. • All work must be carried out professionally and in accordance with the applicable safety regulations.

  • Page 22: Risks Associated With Live Electric Parts

    1 Safety 1.2.2.5. Risks associated with live electric parts 1.2.2.5. Risks associated with live electric parts Voltage related risks, general • Although troubleshooting may, on occasion, have to be carried out while the power supply is turned on, the robot must be turned off (by setting the mains switch to OFF) when repairing faults, disconnecting electric leads and disconnecting or connecting units.

  • Page 23: Safety Actions

    1 Safety 1.2.3.1. Safety fence dimensions 1.2.3. Safety actions 1.2.3.1. Safety fence dimensions General Install a safety cell around the robot to ensure safe robot installation and operation. Dimensioning Dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed.

  • Page 24: Fire Extinguishing

    1 Safety 1.2.3.2. Fire extinguishing 1.2.3.2. Fire extinguishing NOTE! Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the robot (manipulator or controller)! 3HAC023637-001 Revision: B...

  • Page 25: Emergency Release Of The Robot's Arm

    1 Safety 1.2.3.3. Emergency release of the robot’s arm 1.2.3.3. Emergency release of the robot’s arm Description In an emergency situation, any of the robot's axes may be released manually by pushing the brake release buttons on the robot. How to release the brakes is detailed in section: •...

  • Page 26: Brake Testing

    1 Safety 1.2.3.4. Brake testing 1.2.3.4. Brake testing When to test During operation the holding brake of each axis motor wear normally. A test may be performed to determine whether the brake can still perform its function. How to test The function of the holding brake of each axis motor may be checked as detailed below: 1.

  • Page 27: Risk Of Disabling Function "Reduced Speed 250 Mm/S

    1 Safety 1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s" 1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s" NOTE! Do not change "Transm gear ratio" or other kinematic parameters from the Teach Pendant Unit or a PC. This will affect the safety function Reduced speed 250 mm/s. 3HAC023637-001 Revision: B...

  • Page 28: Safe Use Of The Teach Pendant Unit

    1 Safety 1.2.3.6. Safe use of the Teach Pendant Unit 1.2.3.6. Safe use of the Teach Pendant Unit NOTE! The enabling device is a push button located on the side of the Teach Pendant Unit (TPU) which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device is released or pushed all the way in, the robot is taken to the MOTORS OFF state.

  • Page 29: Work Inside The Manipulator's Working Range

    1 Safety 1.2.3.7. Work inside the manipulator's working range 1.2.3.7. Work inside the manipulator's working range WARNING! If work must be carried out within the robot’s work envelope, the following points must be observed: • The operating mode selector on the controller must be in the manual mode position to render the enabling device operative and to block operation from a computer link or remote control panel.

  • Page 30: Translate The Information On Safety And Information Labels

    Drawings detailing the design (text, figure, dimensions) of the standard labels can be ordered from ABB. Notice that each label is identified according to the article number located in the lower corner of the label.

  • Page 31: Safety Related Instructions

    1 Safety 1.3.1. Safety signals, general 1.3 Safety related instructions 1.3.1. Safety signals, general General This section specifies all dangers that may arise from performing the work detailed in the manual. Each danger is detailed in its own section consisting of: •...
  • Page 32 1 Safety 1.3.1. Safety signals, general Continued Symbol Designation Signification ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates DISCHARGE (ESD) electrostatic hazards which could result in severe damage to the product. Electrostatic discharge (ESD) NOTE Note symbols alert you to important facts and conditions.

  • Page 33: Danger - Moving Manipulators Are Potentially Lethal

    1 Safety 1.3.2. DANGER - Moving manipulators are potentially lethal! 1.3.2. DANGER - Moving manipulators are potentially lethal! Description Any moving manipulator is a potentially lethal machine. When running the manipulator, it may perform unexpected and sometimes irrational movements. However, all movements are performed with great force and may seriously injure any personnel and/or damage any piece of equipment located within the manipulator working range.

  • Page 34: Danger - First Test Run May Cause Injury Or Damage

    1 Safety 1.3.3. DANGER - First test run may cause injury or damage! 1.3.3. DANGER - First test run may cause injury or damage! Description Since performing a service activity often requires disassembly of the robot there are several safety risks to take into consideration before the first test run. Elimination Follow the procedure below when performing the first test run after a service activity (repair, installation or maintenance):...

  • Page 35: Warning - The Brake Release Buttons May Be Jammed After Service Work

    1 Safety 1.3.4. WARNING - The brake release buttons may be jammed after service work 1.3.4. WARNING - The brake release buttons may be jammed after service work Description The brake release unit has push buttons for brake release of each axis motor. When service work is performed inside the SMB recess that includes removal and refitting of the brake release unit, the brake release buttons may be jammed after refitting! In case the power is turned on while a brake release button is jammed in depressed position,...

  • Page 36: Warning - The Unit Is Sensitive To Esd

    1 Safety 1.3.5. WARNING - The unit is sensitive to ESD! 1.3.5. WARNING - The unit is sensitive to ESD! Description ESD (electro static discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not grounded may potentially transfer high static charges.

  • Page 37: Warning - Safety Risks During Work With Gearbox Oil

    1 Safety 1.3.6. WARNING - Safety risks during work with gearbox oil 1.3.6. WARNING - Safety risks during work with gearbox oil Description When handling the gearbox oil, there are several dangers to both personal injuries and product damages! Following safety information must be regarded before performing any work with the oil in the gearboxes! Warnings and elimination Warning...
  • Page 38 1 Safety 1.3.6. WARNING - Safety risks during work with gearbox oil 3HAC023637-001 Revision: B...

  • Page 39: Installation And Commissioning

    2 Installation and commissioning 2.1. Introduction 2 Installation and commissioning 2.1. Introduction General This chapter contains information for installing the robot to the working site. More detailed technical data, such as load diagram, permitted extra loads (equipment) and location of extra loads (equipment), may be found in the Product Specification for the robot. 3HAC023637-001 Revision: B...

  • Page 40: Unpacking

    2 Installation and commissioning 2.2.1. Pre-installation procedure 2.2 Unpacking 2.2.1. Pre-installation procedure General This instruction is primarily intended for use when unpacking and installing the robot for the first time. It also contains information useful during later re-installation of the robot. Checking the pre-requisites for installation The check-list below details what must be observed before proceeding with the actual installation of the robot:...
  • Page 41 2 Installation and commissioning 2.2.1. Pre-installation procedure Continued Loads on foundation The table below shows the various forces and torques working on the robot during different kinds of operation. Note! These forces and torques are extreme values that are rarely encountered during operation.

  • Page 42: Working Range

    This section specifies the working ranges for the different robot models. The turning radius is also shown separately in the last figure. Illustration, working range IRB 1600 - 5/1.2 and IRB 1600 - 7/1.2 xx0400001260 Positions at wrist center (mm)
  • Page 43 2 Installation and commissioning 2.2.2. Working range Continued Illustration, working range IRB 1600 - 5/1.45 and IRB 1600 - 7/1.45 xx0400001261 Positions at wrist center (mm) Angle (degrees) axis 2 axis 3 1186.5 0º 0º 1786.5 0º -90º 0º +65º 1450 486.5 +90º...
  • Page 44 2 Installation and commissioning 2.2.2. Working range Continued Working ranges IRB 1600 - 5/1.2 IRB 1600- 5/1.45 Axis Note and - 7/1.2 and -7/1.45 Axis 1 +180º to -180º +180º to -180º Axis 1 working range has the following limitations: •...
  • Page 45 2 Installation and commissioning 2.2.2. Working range Continued Turning radius The turning radius for the robot is shown in the figure below. Notice the differences depending on the length of the lower arm. xx0400001259 Minimum turning radius axis 1 (all models) 3HAC023637-001 Revision: B...

  • Page 46: On-Site Installation

    2 Installation and commissioning 2.3.1. Lifting robot with roundsling 2.3 On-site installation 2.3.1. Lifting robot with roundsling Recommended lifting position The figure below shows the recommended lifting positions. It is important that the roundsling has free space and does not wear against any part of the robot. xx0400001296 Required equipment Equipment...
  • Page 47 2 Installation and commissioning 2.3.1. Lifting robot with roundsling Continued Action Note CAUTION! The robot weighs 250 kg! All lifting equipment must be sized accordingly! WARNING! Personnel must not, under any circumstances, be present under the suspended load! 5. Raise the overhead crane to lift the robot. 3HAC023637-001 Revision: B...

  • Page 48: Manually Releasing The Brakes

    2 Installation and commissioning 2.3.2. Manually releasing the brakes 2.3.2. Manually releasing the brakes General The section below details how to release the holding brakes of each axis' motor. This may be done in one of three ways: • using the brake release unit when the robot is connected to the controller. •...
  • Page 49 2 Installation and commissioning 2.3.2. Manually releasing the brakes Continued Using the brake release unit with an external power supply This section details how to release the holding brakes with the internal brake release unit using an external voltage supply. This is done if the robot is not connected to the controller. Action Note/Illustration Also, be careful not to interchange the...

  • Page 50: Orienting And Securing The Robot

    2 Installation and commissioning 2.3.3. Orienting and securing the robot 2.3.3. Orienting and securing the robot General This section details how to orient and secure the robot at a horizontal level at the installation site. Hole configuration, base The figure below shows the hole pattern and dimensions of the robot base. xx0400001300 Center of axis 1 Continues on next page...
  • Page 51 2 Installation and commissioning 2.3.3. Orienting and securing the robot Continued Dimension, mounting surface and guiding sleeve The figure below shows the dimension of the mounting surface and guiding sleeves, if used. xx0400001306 Attachment bolts, specification Attachment bolts, 3 pcs M16 x 60 (installation directly on foundation of steel) M16 x 70/80 (installation on foundation or base plate, using guiding sleeves)
  • Page 52 2 Installation and commissioning 2.3.3. Orienting and securing the robot Continued Orienting and securing the robot to installation site Action Note 1. Make sure the installation site for the robot conforms to the specifications in section Pre- installation procedure on page 2.

  • Page 53: Suspended Mounting

    2 Installation and commissioning 2.3.4. Suspended mounting 2.3.4. Suspended mounting General Initially the system is configured for mounting on the floor, without leaning. The method for mounting the robot in a suspended position is basically the same as for floor mounting. NOTE! With inverted installation, make sure that the gantry or corresponding structure is rigid enough to prevent unacceptable vibrations and deflections, so that optimum performance can...
  • Page 54 2 Installation and commissioning 2.3.4. Suspended mounting Continued xx0600002779 Floor mounted Tilted mounting, mounting angle 30º Wall mounted, mounting angle 90º Inverted mounting, mounting angle 180º Limitations in working area If tilting a floor mounted robot or mounting the robot on a wall, the working range of axis 1 is limited.
  • Page 55 2 Installation and commissioning 2.3.4. Suspended mounting Continued Defining the parameter in the software The value of the system parameter Gravity Beta must be redefined when changing the mounting angle of the robot. The parameter belongs to the type Robot, in the topic Motion. How to calculate a new value is detailed in Mounting angles and values on page The parameter is further detailed in the Technical reference manual - System parameters.

  • Page 56: Load Diagrams

    At different arm load and moment of inertia the load diagram will be changed. Accurate load diagram For an accurate load diagram, please use the calculation program ABB RobotLoad IRB 1600, Stand alone application on: • Inside.abb.com/atma, click on Products ---> Robots ---> IRB 1600 or •...
  • Page 57 2 Installation and commissioning 2.3.5. Load diagrams Continued Load diagram - IRB 1600-5/1.2, IRB 1600-5/1.45 xx0500001449 Maximum permitted load mounted on the robot tool flange at different positions (center of gravity) Continues on next page 3HAC023637-001 Revision: B...
  • Page 58 2 Installation and commissioning 2.3.5. Load diagrams Continued Load diagram - IRB 1600-5/1.2, IRB 1600-5/1.45, “Vertical Wrist” (±10º) xx0500001450 Maximum permitted load mounted on the robot tool flange at different positions (center of gravity) at “Vertical Wrist” (±10º) Description Value For wrist down (0º...
  • Page 59 2 Installation and commissioning 2.3.5. Load diagrams Continued Load diagram - IRB 1600-7/1.2, IRB 1600-7/1.45 xx0500001451 Maximum permitted load mounted on the robot tool flange at different positions (center of gravity) Continues on next page 3HAC023637-001 Revision: B...
  • Page 60 2 Installation and commissioning 2.3.5. Load diagrams Continued Load diagram - IRB 1600-7/1.2, IRB 1600-7/1.45, “Vertical Wrist” (±10º) 10 º 10 º L - Distance (m) xx0500001452 Maximum permitted load mounted on the robot tool flange at different positions (center of gravity) at “Vertical Wrist” (±10º) Description Value For wrist down (0º...

  • Page 61: Loads

    2 Installation and commissioning 2.3.6. Loads 2.3.6. Loads General Any loads mounted on the robot must be defined correctly and carefully (with regard to the position of center of gravity and inertia factor) in order to avoid jolting movements and overloading the motors.

  • Page 62: Fitting Equipment On The Robot (Robot Dimensions)

    2 Installation and commissioning 2.3.7. Fitting equipment on the robot (robot dimensions) 2.3.7. Fitting equipment on the robot (robot dimensions) General This section shows the robot dimensions and available mounting holes on the robot. Main dimensions The two figures below show the main dimensions of the robot. The remaining dimensions and mounting holes on the upper arm, frame and turning disk are shown in the following figures.
  • Page 63 2 Installation and commissioning 2.3.7. Fitting equipment on the robot (robot dimensions) Continued Mounting holes on the frame The three available mounting holes for equipment on the frame must be threaded according to the figure below. xx0400001252 Prepared for threading M8 x max depth 20 mm Continues on next page 3HAC023637-001 Revision: B...
  • Page 64 2 Installation and commissioning 2.3.7. Fitting equipment on the robot (robot dimensions) Continued Dimensions of the upper arm and mounting holes The figure below shows the dimensions of the upper arm and available mounting holes for equipment on the arm. xx0400001251 Centerline of axis 3 Centerline of axis 4...
  • Page 65 2 Installation and commissioning 2.3.7. Fitting equipment on the robot (robot dimensions) Continued Dimensions of the turning disk The figure below shows the dimensions of the turning disk. xx0200000063 Fastener quality When fitting tools on the turning disk, use only screws with quality 12.9. When fitting equipment on other places, standard screws with quality 8.8 can be used.

  • Page 66: Installation Of Signal Lamp (Option)

    2 Installation and commissioning 2.3.8. Installation of signal lamp (option) 2.3.8. Installation of signal lamp (option) General A signal lamp with an yellow fixed light can be mounted on the robot, as a safety device. The signal lamp is required on an UL/UR approved robot. The lamp is active in MOTORS ON mode.
  • Page 67 2 Installation and commissioning 2.3.8. Installation of signal lamp (option) Continued Installation, signal lamp The procedure below details how to install the signal lamp to the robot. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.

  • Page 68: Restricting The Working Range

    2 Installation and commissioning 2.4.1. Introduction 2.4 Restricting the working range 2.4.1. Introduction General When installing the robot, make sure that it can move freely within its entire working space. If there is a risk that it may collide with other objects, its working space should be limited. The working range of the following axes may be restricted: •...

  • Page 69: Installation Of Additional Mechanical Stops On Axis 1

    2 Installation and commissioning 2.4.2. Installation of additional mechanical stops on axis 1 2.4.2. Installation of additional mechanical stops on axis 1 General This section details how to install additional mechanical stops on axis 1 in order to restrict the working range of the axis.
  • Page 70 2 Installation and commissioning 2.4.2. Installation of additional mechanical stops on axis 1 Continued Illustration, mechanical stop, axis 1 The additional mechanical stop of axis 1 is fitted to the base of the robot, as shown in the figure below. xx0400001287 Mechanical stop, axis 1 (additional) Attachment bolts and washers, mechanical stop...
  • Page 71 2 Installation and commissioning 2.4.2. Installation of additional mechanical stops on axis 1 Continued Installation of mechanical stop, axis 1 The procedure below details how to install the mechanical stop to axis 1. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.

  • Page 72: Installation Of Additional Mechanical Stop On Axis 2

    2 Installation and commissioning 2.4.3. Installation of additional mechanical stop on axis 2 2.4.3. Installation of additional mechanical stop on axis 2 General This section details how to install an additional mechanical stop on axis 2 in order to restrict the working range of the axis.
  • Page 73 2 Installation and commissioning 2.4.3. Installation of additional mechanical stop on axis 2 Continued Illustration, mechanical stop, axis 2 The additional mechanical stop for axis 2 is fitted together with a damper to the frame, as shown in the figure below. xx0400001291 Mechanical stop, axis 2 Attachment bolts, mechanical stop (2 pcs)
  • Page 74 2 Installation and commissioning 2.4.3. Installation of additional mechanical stop on axis 2 Continued Action Note/Illustration 3. Make sure that the stop is in contact with the lower boss on the gearbox, as the arrow shows in the figure to the right. xx0400001292 Note! It is important that the mechanical stop is fitted in contact...

  • Page 75: Installation Of Additional Mechanical Stops On Axis 3

    2 Installation and commissioning 2.4.4. Installation of additional mechanical stops on axis 3 2.4.4. Installation of additional mechanical stops on axis 3 General This section details how to install an additional mechanical stop on axis 3 in order to restrict the working range of the axis.
  • Page 76 2 Installation and commissioning 2.4.4. Installation of additional mechanical stops on axis 3 Continued xx0400001284 Robot models IRB 1600 - x/1.45 Working range A Working range B Illustration, mechanical stop, axis 3 The mechanical stop is installed at the upper arm housing, as shown in the figure below. xx0400001285 Mechanical stop, axis 3 Attachment screws and washers (2 pcs)
  • Page 77 2 Installation and commissioning 2.4.4. Installation of additional mechanical stops on axis 3 Continued Required equipment Equipment Art. no. Note Working range limit axis 3 3HAC023109-001 Includes mechanical stop, attachment screws and washers. Technical reference manual - Art. no. is specified in section System parameters (RobotWare 5.0) References on page Installation of mechanical stop, axis 3...

  • Page 78: Installation Of Position Switch, Axis 1

    2 Installation and commissioning 2.4.5. Installation of position switch, axis 1 2.4.5. Installation of position switch, axis 1 General This section details how to install the position switch to axis 1. Location of position switch, axis 1 The position switch is installed between the frame and the base, as shown in the figure below. xx0400001356 Position switch Attachment screws, position switch, 2 pcs: M6 x 30...
  • Page 79 2 Installation and commissioning 2.4.5. Installation of position switch, axis 1 Continued Installation, position switch axis 1 The procedure below details how to install the position switch to the robot. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.
  • Page 80 2 Installation and commissioning 2.4.5. Installation of position switch, axis 1 Continued Action Note 9. Connect the position switch cabling. The cabling and connection points are specified in section Position switch cables, robot base to controller (option) on page 10. The software working range limitations The system parameters that must be must be re-defined to correspond to the changed in RobotWare 5.0 (Upper joint...

  • Page 81: Electrical Connections

    2 Installation and commissioning 2.5.1. Connectors on robot 2.5 Electrical connections 2.5.1. Connectors on robot Connectors on the robot The figure below shows all connections of the robot cabling, including the customer connectors. xx0400001262 Connection for air Connection for signal lamp 3HAC023637-001 Revision: B...

  • Page 82: Robot Cabling And Connection Points

    2 Installation and commissioning 2.5.2. Robot cabling and connection points 2.5.2. Robot cabling and connection points General Connect the robot and controller to each other after securing them to the foundation. The lists below specify which cables to use for each respective application. Main cable categories All cables between the robot and controller are divided into the following categories: Cable category...
  • Page 83 2 Installation and commissioning 2.5.2. Robot cabling and connection points Continued Robot cable, power, for robots with foundry and wash protection Cable (foundry) Art. no. Robot cable, power, 7 m 3HAC 9038-1 Robot cable, power, 15 m 3HAC 9038-2 Robot cable, power, 22 m 3HAC 9038-3 Robot cable, power, 30 m 3HAC 9038-4...

  • Page 84: Customer Connections On The Robot

    0.8 MPa / 115 psi Customer connectors R2.CS and R2.CP The customer connectors R2.CS and R2.CP can be used with either: • a connector set from ABB for standard connection • specified connector components from Souriau, or • connectors that meet Military standard MIL-C-26482 series 1.
  • Page 85 2 Installation and commissioning 2.5.3. Customer connections on the robot Continued Recommended pin connectors Pin connector Souriau art. no. Pin connector, standard connection, CS (Customer Signal) UT0W6 1626 P-H Pin connector, standard connection, CP (Customer Power) UT0W6 1210 P-H Pin connector, integrated wirefeeder cabling, CS UT0W6 1626 P-H Pin connector, Integrated wirefeeder cabling, CP UT06 1412 P-H04...
  • Page 86 2 Installation and commissioning 2.5.3. Customer connections on the robot 3HAC023637-001 Revision: B...

  • Page 87: Maintenance

    3 Maintenance 3.1. Introduction 3 Maintenance 3.1. Introduction Structure of this chapter This chapter details all maintenance activities recommended for the robot and any external units of the robot. It is based on the maintenance schedule, located in the beginning of the chapter. The schedule contains information about required maintenance activities including intervals and refers to procedures for the activities.

  • Page 88: Maintenance Schedule And Expected Component Life

    3 Maintenance 3.2.1. Specification of maintenance intervals 3.2 Maintenance schedule and expected component life 3.2.1. Specification of maintenance intervals Description The intervals may be specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the robot: •...

  • Page 89: Maintenance Schedule

    3 Maintenance 3.2.2. Maintenance schedule 3.2.2. Maintenance schedule General The robot must be maintained regularly to ensure proper function. The maintenance activities and intervals are specified in the table below. Non-predictable situations also give rise to inspections of the robot. Any damages must be attended to immediately! The inspection intervals do not specify the life of each component.

  • Page 90: Expected Component Life

    3 Maintenance 3.2.3. Expected component life 3.2.3. Expected component life General The life of any component depends on how hard it is run, and it can vary greatly. Expected life Component Expected life Note Robot cable harness 2,000,000 cycles See note 1) Cabling for position switch 2,000,000 cycles See note 1)

  • Page 91: Inspection Activities

    3 Maintenance 3.3.1. Inspection, damper axes 2, 3 and 5 3.3 Inspection activities 3.3.1. Inspection, damper axes 2, 3 and 5 Location of dampers The figure below shows the location of all the dampers to be inspected. xx0400001217 Damper, axis 2 Attachment screw xx0400001215 Damper, axis 3...
  • Page 92 3 Maintenance 3.3.1. Inspection, damper axes 2, 3 and 5 Continued xx0200000429 Damper, axis 5 Recess Required equipment Equipment Art. no. Note Standard toolkit The contents are defined in section Standard toolkit on page 194, in part 2 of the Product manual. Inspection, dampers The procedure below details how to inspect the dampers.

  • Page 93: Replacement Activities

    3 Maintenance 3.4.1. Oil in gearboxes 3.4 Replacement activities 3.4.1. Oil in gearboxes Location of gearboxes xx0500001427 Gearbox, axis 1 Gearbox, axis 2 Gearbox, axis 3 Gearbox, axis 4 Gearboxes, axes 5 and 6 Type and amount of oil in gearboxes Gearbox Type of oil Art.

  • Page 94: Oil Change, Gearbox Axes 5 And 6

    3 Maintenance 3.4.2. Oil change, gearbox axes 5 and 6 3.4.2. Oil change, gearbox axes 5 and 6 Location of oil plugs The gearboxes for axes 5 and 6 are located in the wrist unit as shown in the figure below. xx0200000475 Oil plug, draining and filling Oil plug, vent hole...
  • Page 95 3 Maintenance 3.4.2. Oil change, gearbox axes 5 and 6 Continued Draining, wrist unit The procedure below details how to drain oil from the gearboxes in the wrist unit. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! WARNING! Handling gearbox oil involves several safety risks.
  • Page 96 3 Maintenance 3.4.2. Oil change, gearbox axes 5 and 6 Continued Filling oil, wrist unit The procedure below details how to fill oil in the gearboxes in the wrist unit. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! WARNING! Handling gearbox oil involves several safety...

  • Page 97: Replacement Of Measurement System Battery Pack

    3 Maintenance 3.4.3. Replacement of measurement system battery pack 3.4.3. Replacement of measurement system battery pack Location of battery pack The battery pack for the measurement system is located inside the base of the robot, as shown in the figure below. xx0500001390 Base cover, including gasket.
  • Page 98 3 Maintenance 3.4.3. Replacement of measurement system battery pack Continued Required equipment Equipment Spare part no. Note Battery pack 3HAC 16831-1 Gasket, base cover 3HAC 022047-001 Replace if damaged. Standard toolkit The contents are defined in section Standard toolkit on page 194, in part 2 of the Product manual.

  • Page 99: Cleaning Activities

    3 Maintenance 3.5.1. Cleaning, complete robot 3.5 Cleaning activities 3.5.1. Cleaning, complete robot General The protection class of Foundry and Wash versions is IP 67, i.e. the robot is watertight. Required equipment Equipment, etc. Art. no. Note May be used on Foundry •...
  • Page 100 3 Maintenance 3.5.1. Cleaning, complete robot 3HAC023637-001 Revision: B...

  • Page 101: Repair

    4 Repair 4.1. Introduction 4 Repair 4.1. Introduction Structure of this chapter This chapter details all repair activities recommended for the robot and any external units of the robot. It is made up of separate procedures, each detailing a specific repair activity. Each procedure contains all information required to perform the activity, e.g.

  • Page 102: General Procedures

    4 Repair 4.2.1. Performing a leak-down test 4.2 General procedures 4.2.1. Performing a leak-down test General After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test. Required equipment Equipment, etc.

  • Page 103: Mounting Instructions For Bearings

    4 Repair 4.2.2. Mounting instructions for bearings 4.2.2. Mounting instructions for bearings General This section details how to mount and grease different types of bearings on the robot. Equipment Equipment, etc. Art. no. Note Grease 3HAB 3537-1 Used to grease the bearings, if not specified otherwise.

  • Page 104: Mounting Instructions For Seals

    4 Repair 4.2.3. Mounting instructions for seals 4.2.3. Mounting instructions for seals General This sections details how to mount different types of seals to the robot. Equipment Equipment, etc. Art. no. Note Grease 3HAB 3537-1 Used to lubricate the seals. Rotating seals The procedure below details how to fit rotating seals.
  • Page 105 If the flange surfaces are defective, the parts may not be used because leakage could occur. 2. Clean the surfaces properly and in accordance with ABB recommendations. 3. Distribute the sealing compound evenly over the surface, preferably with a brush.

  • Page 106: Complete Manipulator

    4 Repair 4.3.1. Replacement of cable harness 4.3 Complete manipulator 4.3.1. Replacement of cable harness Location of cable harness The cable harness is run through the robot from the base to the upper arm housing. The location of the harness is shown in several figures, next to the procedures, later on in this section.
  • Page 107 4 Repair 4.3.1. Replacement of cable harness Continued Illustration, covers to remove The figure below shows all the covers that must be removed from the robot in order to get access to the cable harness and all the brackets. xx0400001248 Upper and lower VK-cover Arm housing cover, with gaskets VK-cover (also shown with the cover removed)
  • Page 108 4 Repair 4.3.1. Replacement of cable harness Continued Removal, cable harness The procedure below details how to remove the complete cable harness from the robot. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.
  • Page 109 4 Repair 4.3.1. Replacement of cable harness Continued Illustration, cabling inside upper arm housing The figure below shows how the cabling is run inside the upper arm housing. xx0400001250 Signal cabling; connectors for motors on axes 3, 4, 5 and 6: R3.FB3, R3.FB4, R3.FB5 and R3.FB6 Power cabling;...
  • Page 110 4 Repair 4.3.1. Replacement of cable harness Continued Refitting, cable harness in upper arm housing and lower arm The procedure below details how to refit the cabling inside the upper arm housing. The cable layout is shown in the figure Illustration, cabling inside upper arm housing on page 107.
  • Page 111 4 Repair 4.3.1. Replacement of cable harness Continued Action Note/Illustration 11. Fit new VK-covers to the lower arm. Spare part no. is specified in Required equipment on page 104. 12. Continue refitting the cable harness according to procedure Refitting, cable harness in frame and base on page 111.
  • Page 112 4 Repair 4.3.1. Replacement of cable harness Continued Illustration, cabling inside base The figure below shows how the cabling is run inside the base. Optional cabling is also shown in the figure, but not further specified. xx0500001388 Power cabling Signal cabling Clamp with hexagon nut Attachment screws, cable clamp unit Hexagon nut, SMB plate...
  • Page 113 4 Repair 4.3.1. Replacement of cable harness Continued Refitting, cable harness in frame and base The procedure below details how to refit the cabling inside the frame and the base. The cable layout is shown in the figures Illustration, cabling inside frame on page 109 Illustration, cabling inside base on page 110.
  • Page 114 4 Repair 4.3.1. Replacement of cable harness Continued Action Note 11. Connect the: Shown in the figure Illustration, cabling inside base on page 110. • signal cable connectors to the SMB unit • power cable connector to the housing in the base •...

  • Page 115: Replacement Of Complete Arm System

    4 Repair 4.3.2. Replacement of complete arm system 4.3.2. Replacement of complete arm system Location of complete arm system The complete arm system includes complete upper and lower arm. xx0500001443 VK-cover (attachment screws underneath cover) Cover, frame Cover, base Required equipment Equipment Art.
  • Page 116 4 Repair 4.3.2. Replacement of complete arm system Continued Removal, complete arm system The procedure below details how to remove the complete arm system from the robot. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.
  • Page 117 4 Repair 4.3.2. Replacement of complete arm system Continued Refitting, complete arm system The procedure below details how to refit the complete arm system to the robot. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.
  • Page 118 4 Repair 4.3.2. Replacement of complete arm system Continued Action Note/Illustration 10. Recalibrate the robot! Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information on page 175. DANGER! Make sure all safety requirements are met when performing the first test run.

  • Page 119: Upper And Lower Arm

    4 Repair 4.4.1. Replacement of complete upper arm 4.4 Upper and lower arm 4.4.1. Replacement of complete upper arm General The complete upper arm is considered a spare part, including wrist, gearboxes and motors. Location of upper arm The figure below shows the location of the upper arm on the robot and some of the upper arm components.
  • Page 120 4 Repair 4.4.1. Replacement of complete upper arm Continued Equipment Spare part no. Art. no. Note Lifting slings Standard toolkit The contents are defined in section Standard toolkit on page 194, in part 2 of the Product manual. Other tools and procedures These procedures include may be required.
  • Page 121 4 Repair 4.4.1. Replacement of complete upper arm Continued Refitting, complete upper arm The procedure below details how to refit the complete upper arm to the robot. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.
  • Page 122 4 Repair 4.4.1. Replacement of complete upper arm Continued Action Note/Illustration 9. Connect all the connectors in the arm housing Refitting of the cabling in the upper and secure the cabling with brackets and straps. arm housing is further detailed in section Refitting, cable harness in upper arm housing and lower arm on...

  • Page 123: Replacement Of Complete Lower Arm

    Lower arm, spare 3HAC 023558-001 IRB 1600 - 7/.12 IRB 1600 - 7/1.45 Lower arm, short, spare 3HAC 023559-001 IRB 1600 - 5/1.2 IRB 1600 - 5/1.45 VK-cover 3HAA 2166-23 VK-cover 3HAA 2166-21 In the middle of the lower arm.
  • Page 124 4 Repair 4.4.2. Replacement of complete lower arm Continued Equipment Spare part no. Note Locking liquid Loctite 574 Standard toolkit The contents are defined in section Standard toolkit in the Product manual, reference information! Other tools and procedures These procedures include references may be required.
  • Page 125 4 Repair 4.4.2. Replacement of complete lower arm Continued Refitting, lower arm The procedure below details how to refit the complete lower arm. Action Note/Illustration 1. Clean the mating surfaces on both the lower arm and on the frame with isopropanol. Also clean the area where the sealing ring is fitted.
  • Page 126 4 Repair 4.4.2. Replacement of complete lower arm Continued Action Note/Illustration 11. Recalibrate the robot! Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information on page 175. DANGER! Make sure all safety requirements are met when performing the first test run.

  • Page 127: Replacement Of Wrist Unit

    4 Repair 4.4.3. Replacement of wrist unit 4.4.3. Replacement of wrist unit Location of wrist unit The wrist unit is located in the frontmost part of the upper arm. A more detailed view of the upper arm, including the wrist unit, is found in the spare part view .Upper arm, exploded view 1 on page 207 in part 2 of the Product manual.
  • Page 128 4 Repair 4.4.3. Replacement of wrist unit Continued Removal, wrist unit The procedure below details how to remove the complete wrist unit. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Drain the oil from the wrist unit. Detailed in section Oil change, gearbox axes 5 and 6 on page...
  • Page 129 4 Repair 4.4.3. Replacement of wrist unit Continued Action Note 8. Recalibrate the robot! Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information on page 175. DANGER! Make sure all safety requirements are met when performing the first test run.

  • Page 130: Replacement Of Damper, Axis 2

    4 Repair 4.4.4. Replacement of damper, axis 2 4.4.4. Replacement of damper, axis 2 Location of damper, axis 2 The damper, axis 2, is located as shown in the figure below. xx0400001217 Damper, axis 2 Attachment screw and washer Required equipment Equipment, etc.
  • Page 131 4 Repair 4.4.4. Replacement of damper, axis 2 Continued Removal, damper axis 2 The procedure below details how to remove the damper, axis 2. Action Note 1. Run the robot to a position that enables you to access the attachment screw of damper, axis 2. DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

  • Page 132: Replacement Of Damper, Axis 3

    4 Repair 4.4.5. Replacement of damper, axis 3 4.4.5. Replacement of damper, axis 3 Location of damper, axis 3 The damper, axis 3, is shown in the figure below. A more detailed view of the damper and its position may be found in the spare part view Upper arm, exploded view 2 on page 208 in part 2 of the Product manual.
  • Page 133 4 Repair 4.4.5. Replacement of damper, axis 3 Continued Refitting, damper axis 3 The procedure below details how to refit the damper, axis 3. Action Note 1. Run the robot to a position that enables access to the Shown in the figure Location of location where the damper, axis 3, is fitted.

  • Page 134: Replacement Of Damper, Axis 5

    4 Repair 4.4.6. Replacement of damper, axis 5 4.4.6. Replacement of damper, axis 5 Location of damper, axis 5 The damper, axis 5, is located as shown in the figure below! xx0200000429 Damper, axis 5 Recess Required equipment Equipment, etc. Spare part no.
  • Page 135 4 Repair 4.4.6. Replacement of damper, axis 5 Continued Refitting, damper axis 5 The procedure below details how to refit the damper, axis 5. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.

  • Page 136: Frame And Base

    4 Repair 4.5.1. Replacement of base 4.5 Frame and base 4.5.1. Replacement of base Location of base The base is located at the bottom of the robot as shown in the figure below. A more detailed view of the base may be found in the spare part view Base, exploded view on page 199 in part 2 of the Product manual.
  • Page 137 4 Repair 4.5.1. Replacement of base Continued Equipment Spare part no. Art. no. Note Isopropanol For cleaning the mating surfaces. Standard toolkit The contents are defined in section Standard toolkit on page 194, in part 2 of the Product manual. Other tools and These procedures include procedures may be...
  • Page 138 4 Repair 4.5.1. Replacement of base Continued Action Note 9. Secure the weight of the base and remove the Shown in the figure Location of base gearbox/base attachment screws and washer. on page 134. 10. Separate the base from the gearbox unit. Refitting, base The procedure below details how to refit the base to the robot.
  • Page 139 4 Repair 4.5.1. Replacement of base Continued Action Note 14. Refit the serial measurement unit. Detailed in section Refitting, serial measurement unit on page 140. 15. Recalibrate the robot. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools.

  • Page 140: Replacement Of Serial Measurement Unit

    4 Repair 4.5.2. Replacement of serial measurement unit 4.5.2. Replacement of serial measurement unit Location of serial measurement unit The serial measurement unit is located inside the base of the robot, as shown in the figure below. A more detailed view of the unit and its position may be found in the spare part view Base, exploded view on page 199 in part 2 of the Product manual.
  • Page 141 4 Repair 4.5.2. Replacement of serial measurement unit Continued Required equipment Equipment Spare part no. Note Serial measurement unit 3HAC 023424-001 Gasket, base cover 3HAC 022047-001 Centering piece 3HAC025815-001 Fitted to the push button unit in order to align it correctly. Replace if damaged.
  • Page 142 4 Repair 4.5.2. Replacement of serial measurement unit Continued Action Note/Illustration 6. Unscrew the four hexagon nuts on the Shown in the figure Serial measurement serial measurement unit enough to enable unit layout on page 138. lifting the unit. Do not remove the nuts. 7.
  • Page 143 4 Repair 4.5.2. Replacement of serial measurement unit Continued Action Note/Illustration 4. Refit the centering piece (B) to the push button unit in order to align it vertically. Also make sure that the unit is correctly aligned sideways: the measurements x1 and x2 in the figure to the right should not differ more than 1 mm from eachother! xx0600002777...

  • Page 144: Replacement Of Push Button Unit

    4 Repair 4.5.3. Replacement of push button unit 4.5.3. Replacement of push button unit Location of push button unit The push button unit for brake release is located inside the base of the robot, as shown in the figure below. A more detailed view of the component and its location is shown in the spare part view Base, exploded view on page 199...
  • Page 145 4 Repair 4.5.3. Replacement of push button unit Continued Required equipment Equipment Spare part no. Note Push button unit 3HAC 020967-001 Includes brake release board and push buttons. Gasket, base cover 3HAC 022047-001 Centering piece 3HAC025815-001 Fitted to the push button unit in order to align it correctly.
  • Page 146 4 Repair 4.5.3. Replacement of push button unit Continued Action Note/Illustration 7. Lift and pull the serial measurement unit backwards, over the lip (A), and lift it away. xx0500001455 8. Remove the two hexagon nuts from the push Shown in the figure Push button unit on button unit.
  • Page 147 4 Repair 4.5.3. Replacement of push button unit Continued Action Note WARNING! Before continuing any service work, please observe the safety information in section WARNING - The brake release buttons may be jammed after service work on page 8. Reconnect all the connectors to the board. 9.

  • Page 148: Motors

    4 Repair 4.6.1. Replacement of motor, axis 1 4.6 Motors 4.6.1. Replacement of motor, axis 1 Location of motor The axis 1 motor is located on the frame, as shown in the figure below. A more detailed view of the motor and its position may be found in the spare part view Frame, exploded view on page 203 in part 2 of the Product manual.
  • Page 149 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Equipment Spare part no. Art. no. Note Power supply 24 VDC, max 1.5 A For releasing the brakes. Isopropanol Used to clean mating surfaces. Grease 3HAB 3537-1 Rotation tool, motor 3HAC022266- Standard toolkit The contents are defined in section...
  • Page 150 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Refitting, motor axis 1 The procedure below details how to refit the motor, axis 1. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.
  • Page 151 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Action Note 16. Recalibrate the robot! Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information on page 175. DANGER! Make sure all safety requirements are met when performing the first test run.

  • Page 152: Replacement Of Motor, Axis 2

    4 Repair 4.6.2. Replacement of motor, axis 2 4.6.2. Replacement of motor, axis 2 Location of motor axis 2 The motor axis 2 is located on the front of the robot as shown in the figure below. A more detailed view of the motor and its position may be found in the spare part view Frame, exploded view on page 203 in part 2 of the Product manual.
  • Page 153 4 Repair 4.6.2. Replacement of motor, axis 2 Continued Equipment, etc. Spare part no. Art. no. Note Other tools and These procedures include procedures may be references to the tools required. See required. references to these procedures in the step-by-step instruc- tions below.
  • Page 154 4 Repair 4.6.2. Replacement of motor, axis 2 Continued Action Note 10. Remove the motor by gently pulling it out, making sure the motor pinion does not get damaged while moving it away from the gear. 11. Disconnect the brake release voltage. 12.
  • Page 155 4 Repair 4.6.2. Replacement of motor, axis 2 Continued Action Note 15. Refit the cover, frame. Replace the gasket, if Shown in the figure Location of damaged. motor axis 2 on page 150. Art. no. for the gasket is specified in section Required equipment on page...

  • Page 156: Replacement Of Motor, Axis 3

    4 Repair 4.6.3. Replacement of motor, axis 3 4.6.3. Replacement of motor, axis 3 Location of motor The motor of axis 3 is located inside the upper arm housing, as shown in the figure below. A more detailed view of the motor and its position may be found in the spare part view Upper arm, exploded view 1 on page 207 in part 2 of the Product manual.
  • Page 157 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Equipment Spare part no. Art. no. Note Isopropanol Used for cleaning the mating surfaces. Grease 3HAB 3537-1 Used for lubricating the o- ring. Rotation tool, motor 3HAC022266-003 For adjusting the gear play.
  • Page 158 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note DANGER! Secure the weight of the upper arm properly before releasing the brakes of motor, axis 3. When releasing the holding brakes of the motor, the upper arm will be movable and may fall down! 7.
  • Page 159 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note 12. Refit any additional mechanical stops. Detailed in section Installation of additional mechanical stops on axis 3 on page 13. Recalibrate the robot! Calibration is detailed in a separate calibration manual, enclosed with the calibration tools.

  • Page 160: Replacement Of Motor, Axis 4

    4 Repair 4.6.4. Replacement of motor, axis 4 4.6.4. Replacement of motor, axis 4 Location of motor The axis 4 motor is located inside the upper arm housing, as shown in the figure below. A more detailed view of the component and its position may be found in the spare part view Upper arm, exploded view 1 on page 207 in part 2 of the Product manual.
  • Page 161 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Equipment, etc. Spare part no. Art. no. Note Standard toolkit The contents are defined in section Standard toolkit on page 194, in part 2 of the Product manual. Power supply 24 VDC, max. 1,5 A. For releasing the brakes.
  • Page 162 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Refitting, motor axis 4 The procedure below details how to refit the motor, axis 4. Action Note 1. Clean the mating surfaces on the motor and the Shown in the figure Location of motor gearbox.

  • Page 163: Replacement Of Motor And Timing Belt, Axis 5

    4 Repair 4.6.5. Replacement of motor and timing belt, axis 5 4.6.5. Replacement of motor and timing belt, axis 5 Location of motor The motor and timing belt of axis 5 is located inside the upper arm housing, as shown in the figure below.
  • Page 164 4 Repair 4.6.5. Replacement of motor and timing belt, axis 5 Continued Required equipment Equipment Spare part no. Art. no. Note Rot. ac motor incl pinion 3HAC 021800-001 Timing belt 3HAC 021304-001 Gasket, upper arm cover 3HAC 022049-001 Replace if damaged. Gasket, customer 3HAC 022050-001 Replace if damaged.
  • Page 165 4 Repair 4.6.5. Replacement of motor and timing belt, axis 5 Continued Removal, motor axis 5 and timing belt The procedure below details how to remove the motor and the timing belt of axis 5. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.
  • Page 166 4 Repair 4.6.5. Replacement of motor and timing belt, axis 5 Continued Action Note/Illustration 4. Follow the steps below when fitting the motor: Art. no. is specified in Required equipment on page 162. • Place the timing belt (B) round the motor pinion and place the belt round the axis 5 as fitting the motor in the upper arm housing.

  • Page 167: Replacement Of Motor And Timing Belt, Axis 6

    4 Repair 4.6.6. Replacement of motor and timing belt, axis 6 4.6.6. Replacement of motor and timing belt, axis 6 Location of motor The motor and timing belt of axis 6 are located inside the upper arm housing, as shown in the figure below.
  • Page 168 4 Repair 4.6.6. Replacement of motor and timing belt, axis 6 Continued Equipment Spare part no. Art. no. Note Gasket, customer 3HAC 022050-001 Replace if damaged. connections Hook 3HAC024045-001 Dynamometer Capacity: 100N Standard toolkit The contents are defined in section Standard toolkit on page 194, in part 2 of...
  • Page 169 4 Repair 4.6.6. Replacement of motor and timing belt, axis 6 Continued Refitting, motor and timing belt, axis 6 The procedure below details how to refit the motor and timing belt of axis 6. Action Note/Illustration 1. Clean the mating surfaces on the motor and in the upper arm housing.
  • Page 170 4 Repair 4.6.6. Replacement of motor and timing belt, axis 6 Continued Action Note/Illustration 8. Recalibrate the robot! Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information on page 175.

  • Page 171: Gearboxes

    4 Repair 4.7.1. Replacement of gearbox, axes 1-2 4.7 Gearboxes 4.7.1. Replacement of gearbox, axes 1-2 Location of gearbox unit, axes 1-2 The gearboxes of axes 1 and 2 are located as shown in the figure below. Note that both gearboxes, 1 and 2, are a single unit! A more detailed view of the gearbox and its position may be found in the spare part view Frame, exploded view on page 203...
  • Page 172 4 Repair 4.7.1. Replacement of gearbox, axes 1-2 Continued Equipment Spare part no. Art. no. Note Grease 3HAB 3537-1 For lubricating the V-ring. Locking liquid Loctite 574 Lifting slings Standard toolkit The contents are defined in section Standard toolkit on page 194, in part 2 of the Product manual.
  • Page 173 4 Repair 4.7.1. Replacement of gearbox, axes 1-2 Continued Action Note 10. Secure the weight of the base with lifting slings. 11. Remove the gearbox/base attachment screws Shown in the figure Location of and washer. gearbox unit, axes 1-2 on page 169.
  • Page 174 4 Repair 4.7.1. Replacement of gearbox, axes 1-2 Continued Action Note 11. Secure the base to the foundation. Attachment bolts and the tightening torque are specified in section Attachment bolts, specification on page 12. Refit the complete arm system. Detailed in section Refitting, complete arm system on page 115.

  • Page 175: Service Work On Gearboxes, Axes 3, 4, 5 And 6

    4 Repair 4.7.2. Service work on gearboxes, axes 3, 4, 5 and 6 4.7.2. Service work on gearboxes, axes 3, 4, 5 and 6 Gearboxes, replacement The gearboxes of axes 3, 4, 5 and 6 are intended to run without requiring any repairs or maintenance work.
  • Page 176 4 Repair 4.7.2. Service work on gearboxes, axes 3, 4, 5 and 6 3HAC023637-001 Revision: B...

  • Page 177: Calibration Information

    The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied from ABB. Calibrate the robot carefully with standard calibration. The different methods are briefly described in section Calibration methods on page 176, and further detailed in separate Calibration manuals.

  • Page 178: Calibration Methods

    5 Calibration information 5.2. Calibration methods 5.2. Calibration methods Overview This section specifies the different types of calibration and the calibration methods that are supplied from ABB. Types of calibration Type of calibra- Description Calibration method tion Standard The calibrated robot is positioned at home...
  • Page 179 Calibration Pendulum - standard method Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB 6400R, IRB 640, IRB 1400H and IRB 4400S) and is also the most accurate method for the standard type of calibration. It is the recommended method in order to achieve proper performance.

  • Page 180: Calibration Scales And Correct Axis Position

    5 Calibration information 5.3. Calibration scales and correct axis position 5.3. Calibration scales and correct axis position Introduction This section specifies the calibration scale positions and/or correct axis position for all robot models. Calibration marks, IRB 1600 The illustration below shows the calibration marks and correct positions of the six axes of the robot.

  • Page 181: Calibration Movement Directions For All Axes

    5 Calibration information 5.4. Calibration movement directions for all axes 5.4. Calibration movement directions for all axes Overview When calibrating, the axis must consistently be run towards the calibration position in the same direction, in order to avoid position errors caused by backlash in gears etc. Positive directions are shown in the figure below.

  • Page 182: Updating Revolution Counters

    5 Calibration information 5.5. Updating revolution counters 5.5. Updating revolution counters General This section details how to perform a rough calibration of each robot axis, i.e. updating the revolution counter value for each axis, using the pendant. Step 1 - Manually running the robot to the calibration position This procedure details the first step when updating the revolution counter;...
  • Page 183 This procedure details the second step when updating the revolution counter; storing the revolution counter setting with the FlexPendant (RobotWare 5.0). Action 1. On the ABB menu, tap Calibration. All mechanical units connected to the system are shown along with their calibration status.
  • Page 184 5 Calibration information 5.5. Updating revolution counters Continued Action 5. A dialog box is displayed, warning that the updating operation cannot be undone: • Tap Update to proceed with updating the revolution counters. • Tap Cancel to cancel updating the revolution counters. Tapping Update updates the ticked revolution counters and removes the tick from the list of axes.

  • Page 185: Checking The Calibration Position

    This section describes how to create a program, which runs all the robot axes to their zero position. Action Note 1. On ABB menu tap Program Editor. 2. Create a new program. 3. Use MoveAbsJ in the Motion&Proc menu. 4. Create the following program: MoveAbsJ...

  • Page 187: Overview

    Prerequisites A maintenance/repair/ installation craftsman working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Organization of chapters The manual is organized in the following chapters:...
  • Page 188 Overview Continued Revisions Revision Description First edition. • Document references are moved from a separate section to the table References on page • Information about changing working range limitations in the software is added to the sections in Restricting the working range on page •...

  • Page 189: Reference Information

    6 Reference information 6.1. Introduction 6 Reference information 6.1. Introduction General This chapter includes general information, complementing the more specific information in Product manual (part 1 of 2), procedures. 3HAC023637-001 Revision: B...

  • Page 190: Applicable Safety Standards

    6 Reference information 6.2. Applicable safety standards 6.2. Applicable safety standards Health and safety standards, robot The robot, controlled by the IRC5, conforms to the following standards: Standard Description EN ISO 12100-1 Safety of machinery, terminology EN ISO 12100-2 Safety of machinery, technical specifications EN 954-1 Safety of machinery, safety related parts of control systems ISO EN 10218-1:2006...

  • Page 191: Unit Conversion

    6 Reference information 6.3. Unit conversion 6.3. Unit conversion Converter table Use the table below to convert units used in this manual. Quantity Units Length 3.28 ft 39.37 in Weight 1 kg 2.21 lb Pressure 1 bar 100 kPa 14.5 psi Force 0.738 lbf Moment...

  • Page 192: Screw Joints

    UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below), and is extremely resistant to fatigue.
  • Page 193 6 Reference information 6.4. Screw joints Continued Tightening torque Before tightening any screw, note the following: • Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure description.
  • Page 194 6 Reference information 6.4. Screw joints Continued The table below specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass. Tightening torque Tightening torque Tightening torque Dimension Nm - Nominal Nm - Min.

  • Page 195: Weight Specifications

    All components exceeding 22 kg (50 lbs) are high-lighted in this way. To avoid injury, ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each manipulator model.

  • Page 196: Standard Toolkit

    6 Reference information 6.6. Standard toolkit 6.6. Standard toolkit General All service (repairs, maintenance and installation) procedures contain lists of tools required to perform the specified activity. All special tools required are listed directly in the procedures while all the tools that are considered standard are gathered in the Standard toolkit and defined in the table below.

  • Page 197: Special Tools

    6 Reference information 6.7. Special tools 6.7. Special tools General All service instructions contain lists of tools required to perform the specified activity. The required tools are a sum of standard tools, defined in section Standard toolkit on page 194, and of special tools, listed directly in the instructions and also gathered in this section.

  • Page 198: Lifting Equipment And Lifting Instructions

    6 Reference information 6.8. Lifting equipment and lifting instructions 6.8. Lifting equipment and lifting instructions General Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each procedure. The use of each piece of lifting equipment is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting equipment.

  • Page 199: Spare Parts And Exploded Views

    7 Spare parts and exploded views 7.1. Introduction 7 Spare parts and exploded views 7.1. Introduction Overview This section specifies all articles considered spare parts of the robot. The spare parts are also specified as required equipment directly in the repair instruction of the current spare part. The list of required equipment in each instruction also specifies necessary replacement articles and all required service tools.

  • Page 200: Spare Parts - Base

    7 Spare parts and exploded views 7.2. Spare parts - base 7.2. Spare parts - base Base, spare part list The spare parts for the base are listed below and shown in the following figure. Item no. Description Spare part no. Dimension Base, spare 3HAC 023552-001...
  • Page 201 7 Spare parts and exploded views 7.2. Spare parts - base Continued Base, exploded view xx0500001382 3HAC023637-001 Revision: B...

  • Page 202: Spare Parts - Base Connections

    7 Spare parts and exploded views 7.3. Spare parts - base connections 7.3. Spare parts - base connections Base connections, spare part list The spare parts for connections at the base are listed below and shown in the following figure. Item no.
  • Page 203 7 Spare parts and exploded views 7.3. Spare parts - base connections Continued Base connections, illustrations xx0500001383 3HAC023637-001 Revision: B...

  • Page 204: Spare Parts - Frame

    7 Spare parts and exploded views 7.4. Spare parts - frame 7.4. Spare parts - frame Frame, spare part list The spare parts are listed below and shown in the following figure. Item no. Description Spare part no. Dimension Torx pan head screw 9ADA 618-56 Steel 8.8-A2F M6 x 16...
  • Page 205 7 Spare parts and exploded views 7.4. Spare parts - frame Continued Frame, exploded view xx0500001384 3HAC023637-001 Revision: B...

  • Page 206: Spare Parts - Lower Arm

    7 Spare parts and exploded views 7.5. Spare parts - lower arm 7.5. Spare parts - lower arm Lower arm, spare part list The spare parts are listed below and shown in the following figure. Item no. Description Spare part no. Dimension Lower arm, spare 3HAC 023558-001...
  • Page 207 7 Spare parts and exploded views 7.5. Spare parts - lower arm Continued Lower arm, exploded view xx0500001385 3HAC023637-001 Revision: B...

  • Page 208: Spare Parts - Upper Arm

    7 Spare parts and exploded views 7.6. Spare parts - upper arm 7.6. Spare parts - upper arm Spare part list, upper arm The spare parts listed below are shown in the exploded views, located on the next two pages. Item no.
  • Page 209 7 Spare parts and exploded views 7.6. Spare parts - upper arm Continued Upper arm, exploded view 1 xx0500001386 Continues on next page 3HAC023637-001 Revision: B...
  • Page 210 7 Spare parts and exploded views 7.6. Spare parts - upper arm Continued Upper arm, exploded view 2 xx0500001387 3HAC023637-001 Revision: B...

  • Page 211: Spare Parts - Options

    7 Spare parts and exploded views 7.7. Spare parts - options 7.7. Spare parts - options General This section specifies available options for the robot. Spare parts - options Option no. Description Spare part no. Note 213-1 Lamp unit 3HAC022235-001 Installed as detailed in section Installation of signal lamp (option) on page...
  • Page 212 7 Spare parts and exploded views 7.7. Spare parts - options 3HAC023637-001 Revision: B...

  • Page 213: Circuit Diagram

    8 Circuit diagram 8.1. Introduction 8 Circuit diagram 8.1. Introduction Overview This chapter includes the circuit diagram for the robot. 3HAC023637-001 Revision: B...
  • Page 214 Circuit diagram 3HAC 021351-003/Rev. 00 Contents Sheet List of contents ......................101 Connection point location..................... 102 Brake release unit, serial measuring board..............103 Motor, axes 1-2......................104 Feedback, axes 1-2 ....................... 105 Motor, axes 3-4......................106 Feedback, axes 3-4 ....................... 107 Motor, axes 5-6......................

  • Page 215: Index

    Circuit diagram 3HAC 021351-003/Rev. 00 Contents Sheet Circuit diagram IRB 1600...
  • Page 216 Circuit diagram 3HAC 021351-003...
  • Page 217 Circuit diagram 3HAC 021351-003...
  • Page 218 Circuit diagram 3HAC 021351-003...
  • Page 219 Circuit diagram 3HAC 021351-003...
  • Page 220 Circuit diagram 3HAC 021351-003...
  • Page 221 Circuit diagram 3HAC 021351-003...
  • Page 222 Circuit diagram 3HAC 021351-003...
  • Page 223 Circuit diagram 3HAC 021351-003...
  • Page 224 Circuit diagram 3HAC 021351-003...
  • Page 225 Circuit diagram 3HAC 021351-003...
  • Page 226 Circuit diagram 3HAC 021351-003...
  • Page 227 Circuit diagram 3HAC 021351-003...
  • Page 229 Index standard type 176 when to calibrate 175 Absolute Accuracy, calibration 177 calibration manuals 177 Absolute Accuracy, guiding sleeves 49 Calibration Pendulum 177 air connections, pressure 82 calibration position 180 arm system checking 183 replacing 113 jogging to, FlexPendant 183 attachment bolts, robot-foundation 49 scales 178 calibration, Absolute Accuracy 177...
  • Page 230 Index base, hole configuration 48 upper arm, exploded 207 brake release buttons 46 inspection 89 cabling inside base 110 installation cabling inside frame 109 checking site prior robot installation 38 cabling inside upper arm housing 107 equipment 60 connectors on robot 79 mechanical stop axis 2 70 gearboxes 91 mechanical stops axis 3 73...
  • Page 231 Index replacing 154 requirements, foundation 39 screws, tightening torque 156 restricting working range spare part number 154 axis 1 67 motor axis 4 axis 2 70 brake release with power supply 159 axis 3 73 replace 158 revolution counters screws, tightening torque 160 storing on FlexPendant 181 spare part number 158 updating 180...
  • Page 232 Index base-gearbox unit 136 wrist unit lower arm-frame 123 amount and type of oil 92 mechanical stop axis 1 69 oil change 92 mechanical stop axis 2 72 replacing 125 mechanical stop axis 3 75 screws, tightening torque 126 motor axis 1 148 spare part number 125 motor axis 2 152 motor axis 3 156...
  • Page 234 ABB Automation Technologies AB Robotics S-721 68 VÄSTERÅS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592...

This manual is also suitable for:

Irb 1600 - 5/1.45Irb 1600 - 7/1.2Irb 1600 - 7/1.45

Table of Contents