ABB IRB 1660 Product Manual
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ABB IRB 1660 Product Manual

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Table Of Contents
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Table of Contents

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ROBOTICS
Product manual
IRB 1600/1660

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Summary of Contents for ABB IRB 1660

  • Page 1 ROBOTICS Product manual IRB 1600/1660...
  • Page 2 Trace back information: Workspace R18-2 version a18 Checked in 2018-11-20 Skribenta version 5.3.012...
  • Page 3 IRB 1600 - 10/1.45 type A IRB 1600ID - 4/1.5 IRB 1600ID - 4/1.5 type A IRB 1660ID - 6/1.55 IRB 1660ID - 4/1.55 IRC5 Document ID: 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved. Specifications subject to change without notice.
  • Page 4 The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    Installation of position switch, axis 1 ............Electrical connections ..................2.5.1 Customer connectors on the robot ............. 2.5.2 Robot cabling and connection points ............2.5.3 Customer connections on the robot ............Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 6: Table Of Contents

    Replacement of motor and timing belt, axis 5, IRB 1600 ......... 4.6.8 Replacement of motor, axis 5, IRB 1600ID ........... 4.6.9 Replacement of motor, axis 5, IRB 1660ID ........... Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 7: Table Of Contents

    Special tools ....................Lifting accessories and lifting instructions .............. Spare part lists Spare part lists and illustrations ................10 Circuit diagram 10.1 Circuit diagrams ....................Index Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 8 This page is intentionally left blank...

  • Page 9: Overview Of This Manual

    Prerequisites Maintenance/repair/installation personnel working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Product manual scope The manual covers covers all variants and designs of the IRB 1600/1660ID. Some variants and designs may have been removed from the business offer and are no longer available for purchase.
  • Page 10 Oil change in section Maintenance Content updated in section: • Making robot ready for operation, Clean Room / Additional install- ation procedure. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 11 Updated spare part numbers, in sections: Base, frame, upper arm, upper arm 1600ID and options. • New and updated safety symbols, see Safety symbols on product labels on page Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 12 A new SMB unit and battery is introduced, with longer battery lifetime. • Added mounting holes on the lower arm, see Fitting equipment on the robot (robot dimensions) on page Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 13 New standard calibration method is introduced (Axis Calibration). Calibration on page 337. • Information about grounding point is added, see Robot cabling and connection points on page 119. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 14 Updated information regarding o-ring replacement for axis-1 and axis-2 motors. Published in release R18.2. The following updates are done in this revi- sion: • Updated reference. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 15: Product Documentation

    Product documentation Categories for user documentation from ABB Robotics The user documentation from ABB Robotics is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.
  • Page 16 The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 17: How To Read The Product Manual

    Likewise, certain work methods or general information that is valid for several robot models, can be illustrated with illustrations that show a different robot model than the one that is described in the current manual. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 18 This page is intentionally left blank...

  • Page 19: Safety

    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. The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment that can influence the safety of the entire system.
  • Page 20 Unauthorized modifications of the originally delivered robot are prohibited. Without the consent of ABB, it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength of the robot could be affected.

  • Page 21: Protective Stop And Emergency Stop

    1.1.2 Protective stop and emergency stop 1.1.2 Protective stop and emergency stop Overview The protective stops and emergency stops are described in the product manual for the controller. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 22: Safety Actions

    1.2 Safety actions 1.2.1 Fire extinguishing Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the manipulator or controller. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 23: Emergency Release Of The Robot Axes

    When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways. Make sure no personnel is near or beneath the robot. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 24: Make Sure That The Main Power Has Been Switched Off

    To avoid these personal injuries, switch off the main power on the controller before proceeding work. Note Switch off all main power switches in a MultiMove system. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 25: Safety Risks

    Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 26 ABB is not liable for damages caused by the use of non-original spare parts and special equipment. ABB is not liable for damages or injuries caused by unauthorized modifications to the robot.

  • Page 27: Moving Robots Are Potentially Lethal

    The hold-to-run function is used in manual mode, not in automatic mode. Make sure no personnel are present within the working range of the robot before pressing the start button. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 28: First Test Run May Cause Injury Or Damage

    If maintenance or repair has been done, pay special attention to the function of the part that was serviced. Collision risks CAUTION When programming the movements of the robot, always identify potential collision risks before the first test run. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 29: Work Inside The Working Range Of The Robot

    Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 30: Enabling Device And Hold-To-Run Functionality

    How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 31: Risks Associated With Live Electric Parts

    The power supply for the motors (up to 800 VDC). • The user connections for tools or other parts of the installation (max. 230 VAC). Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 32 Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 33: The Unit Is Sensitive To Esd

    The mat must be grounded through a current-limit- ing resistor. Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 34: Hot Parts May Cause Burns

    Wait until the potentially hot component has cooled if it is to be removed or handled in any other way. Do not put anything on hot metal surfaces, e.g. paper or plastic. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 35: Safety Risks Related To Pneumatic/Hydraulic Systems

    Gravity may cause any parts or objects held by these systems to drop. Dump valves should be used in case of emergency. Shot bolts should be used to prevent tools, etc., from falling due to gravity. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 36: Brake Testing

    3 Inspect and verify that the axis maintains its position. If the robot does not change position as the motors are switched off, then the brake function is adequate. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 37: Safety Risks During Handling Of Batteries

    Risk of fire or explosion. Operating temperatures are listed in Pre-installation procedure on page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 38: Safety Risks During Work With Gearbox Lubricants (Oil Or Grease)

    Possible pressure build-up in gearbox Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 39 The magnetic oil plugs will take Contaminated oil in care of any remaining metal gear boxes chips. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 40: Safety Signals And Symbols

    ELECTROSTATIC Warns for electrostatic hazards which could result DISCHARGE (ESD) in severe damage to the product. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 41 Symbol Designation Significance NOTE Describes important facts and conditions. Describes where to find additional information or how to do an operation in an easier way. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 42: Safety Symbols On Product Labels

    Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 43 Brake release Pressing this button will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 44 Tip risk when loosening bolts The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 45 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 xx1500002616 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 46 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 47 Shut off with handle Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 48 This page is intentionally left blank...

  • Page 49: Installation And Commissioning

    If the IRB 1600/1660ID is connected to power, always make sure that the robot is connected to protective earth before starting any installation work. For more information see: • Product manual - IRC5 Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 50: Unpacking

    It also contains information useful during later re-installation of the robot. Prerequisites for installation personnel Installation personnel working with an ABB product must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work • conform to all national and local codes.
  • Page 51 These forces and torques are extreme values that are rarely encountered during operation. The values also never reach their maximum at the same time! Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 52 Maximum tilt 55° The limit for the maximum payload on the robot is reduced if the robot is tilted from 0°. Contact ABB for further information about accept- able loads. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W...
  • Page 53 The table shows the allowed operating conditions for the robot: Parameter Value Minimum ambient temperature +5º C Maximum ambient temperature +45º C Maximum ambient humidity Max. 95% at constant temperat- Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 54 IRB 1660ID: IP 40 (Wrist: IP 67) Manipulator, protection type Foundry Plus IP 67 Manipulator, protection type Clean Room IP 54 Manipulator, protection type Wash IP 67 Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 55: Working Range

    Range of movement - IRB 1660ID Axis Type of motion Range of movement 1.55 m reach Rotation motion +180° to -180° Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 56 Positions at wrist center 1.2 m reach xx1000000914 Position X (mm) Z (mm) Axis 2 angle (de- Axis 3 angle (de- grees) grees) 1562 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 57 X (mm) Z (mm) Axis 2 angle (de- Axis 3 angle (de- grees) grees) 1187 1787 1450 -639 +150 +150 -245 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 58 X (mm) Z (mm) Axis 2 angle (de- Axis 3 angle (de- grees) grees) 1297 1836 1500 -737 +150 +150 -238 -1200 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 59 Axis 3 angle (de- grees) grees) 1,296.5 1,873.3 332.2 691.7 1,536.8 486.5 843.4 -714.5 +150 413.9 561.7 +150 -238 94.6 723.7 -1,236.8 486.5 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 60 The turning radius for the robot is shown in the figure below. Notice the differences depending on the length of the lower arm. R 335 (A) - 180° xx1500002817 Minimum turning radius axis 1 (all models) Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 61: Risk Of Tipping/Stability

    Do not change the robot position before securing it to the foundation! Shipping and transportation position This figure shows the robot in its shipping position and transportation position. xx1500001247 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 62 2 Installation and commissioning 2.2.3 Risk of tipping/stability Continued xx1500001248 WARNING The robot is likely to be mechanically unstable if not secured to the foundation. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 63: On-Site Installation

    2 Installation and commissioning 2.3.1 Lifting robot with roundslings 2.3 On-site installation 2.3.1 Lifting robot with roundslings Attaching the roundslings xx1500001247 xx1500001248 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 64 All lifting accessories used must be sized ac- cordingly! WARNING Personnel must not, under any circumstances, be present under the suspended load! Raise the overhead crane to lift the robot. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 65: Lifting And Turning A Suspended Mounted Robot

    Introduction How to lift and turn the robot into a suspended position using turning accessory 3HAC037108-001 is described in the lifting instruction (article number 3HAC028664-002) delivered with the turning accessory. Contact ABB for more information. xx1000000320 Product manual - IRB 1600/1660 3HAC026660-001 Revision: W ©...

  • Page 66: Manually Releasing The Brakes

    The brake will function again as soon as the button is released. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 67 • 0V on pin C10 • 24V on pin B8 Push the brake release button to release the holding brakes, according to the previous procedure. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 68: Orienting And Securing The Robot

    Hole configuration, base The figure shows the hole pattern and dimensions of the robot base. xx0400001300 Center of axis 1 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 69 8.8 (wall or angle mounted robot: Quality 12.9) Tightening torque 200 Nm Guiding sleeves Use a pair of guiding sleeves to make the robot installation easier. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 70 Attachment point, front (no guide sleeve) Manipulator base Screw M16x120 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 71 2 Installation and commissioning 2.3.4 Orienting and securing the robot Continued Plain washer Guide sleeve Isolator Nut M16 Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 72: Setting The System Parameters For A Suspended Or Tilted Robot

    If the robot is wall mounted or mounted in a tilted position, it is important that the x-direction of the robot base coordinate system points downwards, as shown in the following figure. xx1200001354 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 73 7 axes high performance motion is set, see Technical reference manual - System parameters. Gamma Rotation Gamma Rotation defines the orientation of the robot foot on the travel carriage (track motion). Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 74 Mounting angle (A°) Gravity Beta Floor mounted 0° 0.000000 (Default) Tilted mounting 30º 0.523599 Wall mounting 90° 1.570796 Suspended mounting 180° 3.141593 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 75 Examples of mounting angles tilted around the Y axis (Gravity Beta) xx0600002779 Floor mounted Tilted mounting, mounting angle 30º Wall mounted, mounting angle 90º Suspended mounting, mounting angle 180º Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 76 90° (Wall) 1.570796 -90° (Wall) -1.570796 Note For suspended robots (180°), it is recommended to use Gravity Beta instead of Gravity Alpha. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 77 The system parameters are described in Technical reference manual - System parameters. The system parameters are redefined in the Configuration Editor, in RobotStudio or on the FlexPendant. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 78: Loads Fitted To The Robot, Stopping Time And Braking Distances

    The performance of the motor brake depends on if there are any loads attached to the robot. For more information, see product specification for the robot. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 79: Fitting Equipment On The Robot (Robot Dimensions)

    0.5 kg 15 kg 15 kg 15 kg IRB 1600-7/X 5 kg 5 kg 0.5 kg 15 kg 5 kg 5 kg Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 80 15 kg IRB 1660ID-6/1.55 15 kg 10 kg 15 kg 15 kg IRB 1660ID-4/1.55 15 kg 12 kg 15 kg 15 kg Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 81 252.5 131 (3x) M8 112 (3x Ø7) L Axis L Axis * IRB 1600-X/1.2 **IRB 1600-X/1.45 xx1000000972 R335 Minimum turning radius Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 82 2 Installation and commissioning 2.3.7 Fitting equipment on the robot (robot dimensions) Continued Dimensions IRB 1600ID IRB 1600ID-4/1.5 xx1000000893 R335 Minimum turning radius Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 83 2.3.7 Fitting equipment on the robot (robot dimensions) Continued Dimensions IRB 1660ID IRB 1660ID-X/1.55 252,5 214,5 112 (3x 7) C L Axis 1 xx1500001250 R335 Minimum turning radius Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 84 From center line axis 3 From center line axis 4 3xM8 depth 16, mounting holes for equipment R175, Axis 3 turning radius Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 85 2xM5 depth 7.5, mounting holes for equipment Design after June 2006, type A xx1500003260 View from E 2xM6 depth 10, mounting holes for equipment Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 86 146,6 xx1000000911 R130, smallest circumscribed radius of axis 4 2xM8 depth 16, mounting holes for equipment 2xM8, mounting holes for equipment Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 87 Lower arms among IRB 1600, IRB 1600ID, and IRB 1660ID are the same. For holes on the lower arm, see Holes for mounting of extra equipment for IRB 1600 on page Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 88 146,6 xx1500001253 R170.4, smallest circumscribed radius of axis 4 2xM8 depth 16, mounting holes for equipment 2xM8, mounting holes for equipment Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 89 Robot tool flange + 0,030 6 H9 0,05 E C 0,05 A-B 4x M6 Not hardened 0,3 E C D xx1000000912 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 90 The length, 9.5mm, refers to the total length of the screw, not just the thread length. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 91 8.8 can be used. Prepared Responsible Department Description Approved Take over department Sheet Status ECO number No. of sh. Document no. Rev. ind. Latest Revision Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 92: Installation Of Signal Lamp For 1600 (Option)

    The signal lamp is fitted to the upper arm housing of the robot, as shown in the figure below. xx0400001265 Signal lamp Cable gland Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 93 Location of signal upper arm housing cover and refit the cover. lamp on page Make sure the gaskets are not damaged. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 94 (B). xx0400001263 • B: Mounting holes, M8 x 12 The signal lamp is now ready for use and is lit in MOTORS ON mode. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 95: Installation Of Signal Lamp For 1600Id/1660Id (Option)

    Signal lamp Cover, upper arm housing Required equipment Equipment Art. no. Note Signal lamp 3HAC9258-1 Drill Diameter 22.5 mm Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 96 R3.H1 and R3.H2 and connect them with the lamp Refit the cover on the upper arm housing. The signal lamp is now ready for use and is lit in MOTORS ON mode. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 97: Installation Of The Wire Feeder Shelf For 1600Id/1660Id

    Shown in figure Location of shelf, wire feeder on page 97 using the four (4) Hex socket head cap screw (F). Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 98 A Hexagon nut with flange M5 B Knob Fit the wire feeder with the mounted bracket on the Shelf, wire feeder and mount the two knobs. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 99: Restricting The Working Range

    This section describes how to install hardware that restricts the working range. Note Adjustments must also be made in the robot configuration software (system parameters). References to relevant manuals are included in the installation procedures. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 100: Installation Of Additional Mechanical Stops On Axis 1

    Mounting position of two additional stops for maximum working area (±168º) Mounting position of two additional stops for minimum working area (±64º) Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 101 (for tilted or wall mounted robots). The additional stop pin manages to restrict this working area (for tilted or wall mounted robots). Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 102 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 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 103 (Upper joint bound mechanical limitations. and Lower joint bound) are de- scribed in Technical reference manual - System parameters. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 104 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 105: Installation Of Additional Mechanical Stop On Axis 2

    The working range can only be restricted backwards, as shown in the figures below. Notice the different working ranges for the different models! xx0400001289 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 106 Mechanical stop, axis 2 Attachment bolts, mechanical stop (2 pcs) Attachment holes, mechanical stop Damper, axis 2 Washer Attachment screw, damper Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 107 Fit the damper to the mechanical stop, with its Shown in the figure Illustration, attachment screw and washer. Tighten the screw. mechanical stop, axis 2 on page 106. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 108 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 109: Installation Of Additional Mechanical Stops On Axis 3

    Notice the differences between the different models. xx0400001283 Robot models IRB 1600 - x/1.2 Working range A Working range B Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 110 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 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 111 Includes mechanical stop, at- tachment screws and washers. Technical reference manual - System Art. no. is specified in Refer- parameters ences on page Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 112 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 113: Installation Of Position Switch, Axis 1

    Attachment screws, holder ring, 6 pcs: M8 x 12 Bracket Attachment screws, housing, 2 pcs: M6 x 8 Cable straps Attachment screws, attachment plate, 2 pcs: M6 x 16 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 114 Location of position the robot with the two attachment screws. switch, axis 1 on page 113. 2 pcs, M6 x 8. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 115 (system parameter configuration) changed (Upper joint bound and Lower joint to correspond to the mechanical limita- bound) are described in Technical reference tions. manual - System parameters. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 116: Electrical Connections

    The graphics below show the customer connections on the robot base. For description of all connection types see Connection table on page 117. xx1000000918 xx1000000919 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 117 R1.CS Customer signal for integrated wirefeed interface R1.CP Customer power for integrated wirefeed interface R1.FB7 Axis 7 connection, 1.5 m cable Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 118 R2.CP Standard customer power R2.CS Standard customer signal R2.Air Standard air R2.CP Customer power for integrated wirefeed interface R2.CS Customer signal for integrated wirefeed interface Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 119: Robot Cabling And Connection Points

    Robot cable, power: 7 m 3HAC2492-1 Robot cable, power: 15 m 3HAC2529-1 Robot cable, power: 22 m 3HAC2539-1 Robot cable, power: 30 m 3HAC2564-1 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 120 Bending radius for static floor cables The minimum bending radius is 10 times the cable diameter for static floor cables. xx1600002016 Diameter Diameter x10 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 121 Customer cable, power-signal, 15 m 3HAC3354-1 R1.CP/CS Customer cable, power-signal, 22 m 3HAC3355-1 R1.CP/CS Customer cable, power-signal, 30 m 3HAC3356-1 R1.CP/CS Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 122 Customer cable, power-signal, 7 m 3HAC8183-1 R1.CP/CS Customer cable, power-signal, 15 m 3HAC8183-2 R1.CP/CS Customer cable, power-signal, 22 m 3HAC8183-3 R1.CP/CS Customer cable, power-signal, 30 m 3HAC8183-4 R1.CP/CS Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 123: 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 124 UT0 16JC Backshell, standard connection, CP UT0 12JC Backshell, integrated wirefeeder cabling, CS UT0 16JC Backshell, integrated wirefeeder cabling, CP UT0 14JC Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 125 The complete pin connectors for soldering include pin connector, backshell and pins. Connector for soldering Military standard MIL-C-26482 Complete pin connector, CS MS3116*1626S Complete pin connector, CP MS3116*1210S Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 126: Start Of Robot In Cold Environments

    If the program consists of large wrist movements, it is possible that the reorientation velocity, which is always high in predefined velocities, needs to be included in the ramping up. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 127: Maintenance

    If the IRB 1600/1660ID is connected to power, always make sure that the IRB 1600/1660ID is connected to protective earth before starting any maintenance work. For more information see: • Product manual - IRC5 Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 128: Maintenance Schedule And Expected Component Life

    The SIS used in M2004 is further described in the Operating manual - Service Information System. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 129: Maintenance Schedule

    2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime can be extended with a battery shutdown service routine. See Operating manual - IRC5 with FlexPendant for instructions. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 130 Generally, the more contaminated environment, the closer the intervals. The more demanding movement pattern (sharper bending cable harness), the closer the intervals. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 131: Expected Component Life

    The life expectancy is based on a test cycle that for every axis goes from the calibration position to minimum angle, to maximum angle and back to the calibration position. Deviations from this test cycle will result in differences in expected life! Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 132: Inspection Activities

    Location of dampers The figure below shows the location of all the dampers to be inspected. xx0400001217 Damper, axis 2 Attachment screw Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 133 3 Maintenance 3.3.1 Inspection, damper axes 2, 3 and 5 Continued xx0400001215 Damper, axis 3 Cast tab xx0600002806 Damper, axis 5 Recess Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 134 Replacing the damper, axis 2 on page 220 • Replacing the damper, axis 3 on page 222 • Replacement of damper, axis 5 on page 226. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 135: Inspecting Information Labels

    Warning label - Electricity (symbol of flash) (6 pcs) UL label Label - Max. air pressure Information sign - AbsAcc Lifting instruction label Oil label Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 136 Check all labels. See the figure in Location of information labels on page 135. Replace any missing or damaged labels. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 137: Replacement Activities

    Before starting any inspection, maintenance, or changing activities of lubrication, always contact the local ABB Service organization for more information. For ABB personnel: Always check ABB Library for the latest revision of the manual Technical reference manual - Lubrication in gearboxes, in order to always get the latest information of updates about lubrication in gearboxes.

  • Page 138: Changing The Oil In Axes 5 And 6 Gearboxes

    Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 159. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 139 Both oil plugs must be removed in order to drain plugs on page 138. the wrist unit properly. Refit the oil plug, vent hole. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 140 Fill oil in the wrist unit through the oil plug. xx0500001435 • A: Oil plug, draining and filling The position for an inverted robot is the opposite. Refit the oil plug. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 141: Changing The Oil In Axes 5 And Axis 5 And 6 Gearboxes, Irb 1600Id/1660Id

    Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 159. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 142 Remove the oil plug (A) and the ventil- Shown in figure Location of oil plugs, axis 5-6 ation plug (B). gearbox on page 141. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 143 Check the oil level to make sure the filled gearboxes on page 137. amount of oil is correct. Refit the oil plug and the ventilation plug. Tightening torque: 3 Nm. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 144: Replacing The 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. Battery pack is located beneath the cover. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 145 The battery pack is attached to the serial measurement unit as shown in the figure below. DSQC 633A xx0500001393 Battery pack battery (2-pole battery contact) Velcro strap Connector X3 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 146 Spare part lists on board page 387. Battery pack Spare part lists on page 387. Gasket, base cover 3HAC 022047-001 Replace if damaged. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 147 Fit the new battery pack and connect it to the Battery pack on serial measure- serial measurement unit (X3). ment unit on page 145. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 148 Refit the base cover to the robot. Location of battery pack on page 144. Update the revolution counters. Detailed in section Updating revolution counters on page 345. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 149: Cleaning Activities

    Never point the water jet at connectors, joints, sealings, or gaskets. • Do not use compressed air to clean the robot. • Never use solvents that are not approved by ABB to clean the robot. • Do not spray from a distance closer than 0.4 m. •...
  • Page 150 Cleaning with water and steam on page 150. Cleaning with water and steam Instructions for rinsing with water ABB robots with protection types Standard, Foundry Plus, Wash, or Foundry Prime can be cleaned by rinsing with water (water cleaner). The following list defines the prerequisites: •...
  • Page 151 3.5.1 Cleaning the IRB 1600/1660ID Continued Instructions for steam or high pressure water cleaning ABB robots with protection types Foundry Plus, Wash, or Foundry Prime can be cleaned using a steam cleaner or high pressure water cleaner. The following list defines the prerequisites: •...
  • Page 152 This page is intentionally left blank...

  • Page 153: Repair

    Each procedure contains all the information required to perform the activity, for example spare parts numbers, required special tools, and materials. WARNING Repair activities not described in this chapter must only be carried out by ABB. Otherwise damage to the mechanics and electronics may occur. Required equipment The details of the equipment required to perform a specific repair activity are listed in the respective procedures.

  • Page 154: General Procedures

    Spray any suspected leak areas with the leak detec- tion spray. Bubbles indicate a leak. When the leak has been localized, take the necessary measures to correct the leak. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 155: Mounting Instructions For Bearings

    Make sure the bearing is properly aligned as this will directly affect the durab- ility of the bearing. Greasing of bearings Note This instruction is not valid for solid oil bearings. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 156 Grooved ball bearings must be filled with grease from both sides. • Tapered roller bearings and axial needle bearings must be greased in the split condition. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 157: Mounting Instructions For Seals

    Never hammer directly on the seal as this may result in leakage. Make sure no grease left on the robot surface. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 158 If the flange surfaces are defective, the parts may not be used because leakage could occur. Clean the surfaces properly in accordance with the recommendations of ABB. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.

  • Page 159: Cut The Paint Or Surface On The Robot Before Replacing Parts

    Use ethanol on a lint free cloth. so that it is free from oil and grease. Place the tooling pin in hot water. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 160 Clean Room. Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 161: The Brake Release Buttons May Be Jammed After Service Work

    Required equipment on page 252. Refit the push button guard and check the buttons again by pressing them down, one by one. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 162: Complete Manipulator

    Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 159. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 163 Upper and lower VK-cover Arm housing cover, with gaskets VK-cover (also shown with the cover removed) Cover, frame, with gasket Base cover, with gasket Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 164 • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 165 Continue pulling down the cable harness through the frame and pull it out at the rear of the base. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 166 Attachment screws, cable clamp unit (2 pcs, only one shown) Clamp, signal cabling Clamp, motor cabling Connector plate Connector holder Cable tie, connector holder Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 167 The cable layout is shown in the fig- and secure it with cable ties. Illustration, cabling inside upper arm housing on page 166. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 168 Signal cabling; connectors for motors on axes 1 and 2: R3.FB1 and R3.FB2 Cable clamp unit (attachment screws behind the fastening plate) Fastening plate Attachment screws and nuts Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 169 Signal cabling Clamp with hexagon nut Attachment screws, cable clamp unit Hexagon nut, SMB plate Fastening plate SMB unit Cable clamp unit Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 170 Before continuing any service work, please observe the safety information in section brake release buttons may be jammed after service work on page 161! Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 171 Axis Calibration is described in Calib- rating with Axis Calibration method on page 349. General calibration information is in- cluded in section Calibration on page 337. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 172: Replacing The Cable Harness, 1600Id/1660Id

    R3.MP5 R3.MP6 xx0700000038 R4.FB6 R4.FB5 R4.MP6 R4.MP5 Required equipment Equipment Spare part no. Note Standard toolkit Standard tools on page 383 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 173 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 174 • air pressure supply to the robot, before entering the robot working area. Remove the cover to the upper arm. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 175 Removal, cable harness upper arm tube The procedure below describes removal of the complete cable harness in upper arm tube. xx0700000099 Cover plate Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 176 Remove all the Torx pan head screw (A) holding the cover. xx0700000113 A Torx pan head screw M6x12 B Hexagon nut with flange M5 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 177 Axis Calibration is described in Calibrating with Axis Calibration method on page 349. General calibration information is included in section Calibration on page 337. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 178: Replacement Of Complete Arm System

    Used to clean the mating surfaces. Locking liquid Loctite 574 Standard toolkit Content is defined in section Standard tools on page 383. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 179 Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Move the robot to its calibration position. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 180 Secure the cable harness to the arm system in a way that it is not damaged in the continued process. Check the sealing ring. Replace if damaged. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 181 170. Fit a new VK-cover to the lower arm. Art. no. is specified in Required equipment on page 178. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 182 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in the section First test run may cause injury or damage on page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 183: Upper And Lower Arm

    Spare parts - Upper arm, exploded view. xx0400001218 Arm housing cover, including gaskets for the cover and the contact panel VK cover. Upper arm attachment screws inside Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 184 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 185 The complete upper arm weighs 55 kg without any additional equipment fitted! All lifting accessories used must be sized ac- cordingly! Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 186 • A: Sealing ring, spare part no. is specified in Required equip- ment on page 184. • B: Contact surface. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 187 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 188: Replacing The Complete Upper Arm, Irb 1600Id/1660Id

    The figure below shows the location of the upper arm and connection to the lower arm. xx0700000045 VK -Cover Socket head cap screw M10x40 Cable harness V-ring Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 189 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 190 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot work- ing area. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 191 IRB 1600 on page 162 and brackets. CAUTION The robot upper arm weighs 39 kg. All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 192 A Socket head cap screw M10x40 Carefully lift away the upper arm and put it somewhere safe. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 193 Carefully refit the upper arm to the lower arm, making sure that the new upper arm is mounted in the synchronization position. xx0700000075 A Synchronization mark Axis 3 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 194 Refit a new VK-cover to the lower arm. replace Spare part no. is specified in Required it, if damaged. equipment on page 189. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 195 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 196: Replacing The Complete Lower Arm

    Art. no. Note Lower arm Spare part lists on page 387. VK-cover 3HAA2166-23 VK-cover 3HAA2166-21 In the middle of the lower arm. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 197 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 198 Check the sealing ring. Replace it if damaged. Spare part no. is specified in Required equipment on page 196. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 199 VK- cover. Refit the upper arm. See section Replacing the complete upper arm, IRB 1600ID/1660ID on page 188. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 200 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 201: Replacing The Wrist Unit, Irb 1600

    Grease 3HAC 3537-1 For lubricating the o-ring sealing plate. Standard toolkit Content is defined in section Standard tools on page 383. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 202 The procedure below details how to remove the complete wrist unit. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 203 • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 204 3 pcs, M8 x 25, tightening torque: 28 Nm. making sure that the gears mate prop- erly. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 205 These are further detailed in the section First test run may cause injury or dam- age on page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 206: Replacing The Wrist Unit, Irb 1600Id

    Hexagon socket head screw M5x25 Hexagon socket head screw M8x35 Required equipment Equipment Art. No. Note Wrist, ID Spare part lists on page 387. O-ring Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 207 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 208 Remove the VK-Cover. xx0700000054 A VK-Cover Gently pull the cables out through the hole for the VK- cover in the armtube. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 209 This can damage the sealing which will cause oil leakage. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 210 VK cover. xx0700000093 A: String Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 211 Make sure all safety requirements are met when performing the first test run. These are further detailed in section First test run may cause injury or damage on page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 212: Replacing The Wrist Unit, Irb1660Id

    Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 159. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 213 Remove all extra equipment fitted on the upper arm. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 214 • A: Coupling • B: Attachment screw Remove the attachment screws securing the wrist. xx1000000875 • A: Attachment screws (4 pcs) Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 215 Fit two short screws in the holes for the at- tachment screws to temporarily secure the cover. xx1500003257 • A: Short screws (2 pcs) • B: Cover Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 216 Place the wrist with motor axis 6 fitted a little into the upper arm tube. Reconnect the cables R4.MP6 and R4.FB6 R4.MP6 to motor axis 6. R4.FB6 xx1400002575 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 217 Apply locking liquid to the assembly surface The locking liquid is specified in Required on the upper arm tube. equipment on page 212. xx1200000063 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 218 Tightening torque: 14 Nm attachment screw. Fit a new VK-cover. Article number is specified in Required equipment on page 212. xx1000000873 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 219 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 220: Replacing The Damper, Axis 2

    Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 159. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 221 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 222: Replacing The Damper, Axis 3

    Run the robot to a position where it is best Shown in the figure Location of damper, to enable access to the access 3 damper. axis 3 on page 222. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 223 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 224: Replacing The Mechanical Stop Axis 3, Irb 1600Id/1660Id

    Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 159. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 225 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 226: Replacement Of Damper, Axis 5

    Shown in the figure Location of the damper to be pushed into the recess in the wrist damper, axis 5 on page 226. unit. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 227 Make sure all safety requirements are met when perform- ing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 228: Remove Upper Arm Aw Gun

    Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 159. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 229 A Locking sleeve B Locking screw C Welding cable Remove the two screws holding the brace. xx0700000273 A BINZEL Brace Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 230 Remove the locking sleeve (B). Remove all 6x M5 screw (C). xx0700000150 A Locking ring B Locking sleeve C Screw M5 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 231 Refit the locking sleeve (B). Lock the sleeve using the lock- ing ring (A). xx0700000150 A Locking ring B Locking sleeve C Screw M5 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 232 Refit the welding cable (C). Lock the cable using the screw (B). xx0700000151 A Locking sleeve B Locking screw C Welding cable Refit the brace (A). xx0700000273 Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 233: Measuring The Play 1600Id/1660Id, Axis 5

    233. Fit the measuring tool to the turning disk Art. no. is specified in Required equip- adapter. ment on page 233. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 234 IRB 1660ID-X/1.55: F = 30N Remove the load and make a note of the value from the dynamometer, as value a1. xx1500000314 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 235 • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Repeat step 10 step Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 236: Measuring The Play 1600Id/1660Id, Axis 6

    236. Fit the measuring tool to the turning disk Art. no. is specified in Required equip- adapter. ment on page 236. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 237 Remove the load and make a note of the value from the dynamometer, as value b1. xx1500000317 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 238 • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Repeat step 10 step Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 239: Frame And Base

    Equipment Spare part no. Art. no. Note Base, spare For spare part number, see: • Spare part lists on page 387. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 240 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 241 239. a work bench. Be careful not to damage the motor connectors! Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 242 The robot base weighs 81 kg. All lifting accessories used must be sized ac- cordingly! Lift the base to mounting position. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 243 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 244: Replacing The Serial Measurement Unit

    A more detailed view of the base may be found in the spare part view, see Spare parts - Base, exploded view. xx0500001390 Base cover, including gasket. Serial measurement unit is located beneath the cover. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 245 Hexagon nuts (totally 4 pcs) Hexagon nuts (totally 2 pcs). Only the outer nuts are used. Battery pack (2-pole battery contact) Battery cable connector Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 246 Equipment Art. no. Note Serial measurement unit Spare part lists on page 387. Battery pack Spare part lists on page 387. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 247 The push button guard must be removed to ensure a correct refitting of the push buttons. xx0600002744 A Push button guard Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 248 Do not remove the nuts! Lift and pull the serial measurement unit backwards, over the lip (A), and lift it away. xx0500001455 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 249 The brake release buttons may be jammed after service work on page 161! Refit the push button guard to the robot base. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 250 Update the revolution counters! Detailed in section Updating revolution counters on page 345. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 251: Replacing The Push Button Unit

    Push button unit Hexagon nuts (2 pcs) Hexagon nuts, SMB unit (4 pcs). Only the outer ones are used. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 252 The push button guard must be removed to ensure a correct refitting of the push button unit. xx0600002744 A Push button guard Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 253 Push button unit on button unit. serial measurement unit on page 251. Remove the push button unit by lifting it up. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 254 Make sure the unit is positioned as and secure with the four hexagon nuts. straight as possible! The push buttons can otherwise get jammed. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 255 Before continuing any service work, follow the safety procedure in section The brake release buttons may be jammed after service work on page 161! Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 256 Make sure all safety requirements are met when performing the first test run. These are further detailed in section First test run may cause injury or damage on page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 257: Motors

    For spare part number, Cable harness, motor axes 1- pinion see: 2 must be ordered separately. • Spare part lists on page 387 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 258 Read more about reference calibration for then reference calibration is not possible. Pendulum Calibration in Operating manu- al - Calibration Pendulum. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 259 • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 260 The cable layout is shown in the figure Illustration, cabling inside frame on page 168. Refit the cover, frame. Replace the gasket, if damaged. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 261 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in the section First test run may cause injury or damage on page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 262: Replacement Of Motor, Axis 2

    387 Cable harness, motor axes For spare part num- ber, see: • Spare part lists on page 387 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 263 Read more about reference calibration for then reference calibration is not possible. Pendulum Calibration in Operating manu- al - Calibration Pendulum. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 264 In order to release the brakes, connect the 24 VDC Connect to connector R3.MP2 power supply to the motor. • +: pin 7 • -: pin 8 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 265 Use the rotation tool to rotate the motor pinion, Make sure the motor pinion does when mating it to the gear. not get damaged! Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 266 Cal- ibrating with Axis Calibration meth- od on page 349. General calibration information is included in section Calibration on page 337. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 267 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 268: Replacement Of Motor, Axis 3, Irb 1600

    Rot. ac motor incl pinion For spare part number, see: • Spare part lists on page 387 O-ring 21522012-426 Replace if damaged. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 269 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 270 Lift the motor gently straight out, making sure the motor pinion is not damaged. Disconnect the brake release voltage. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 271 268. Refit any additional mechanical stops. Detailed in section Installation of additional mechanical stops on axis 3 on page 109. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 272 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in the section First test run may cause injury or damage on page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 273: Replacement Of Motor, Axis 3, 1600Id/1660Id

    For spare part number, see: • Spare part lists on page 387. O-ring 3HAB3772-100 Isopropanol Used for cleaning the mating surfaces. Grease Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 274 Removal, motor axis 3 Action Note Decide which calibration routine to use, and take ac- tions accordingly prior to begin- ning the repair procedure. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 275 Location of motor on page 273 ing cover. Disconnect the motor connect- Shown in the figure Location of motor on page 273 ors R3.MP3 and R3.FB3. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 276 C Motor axis 3 D Resolver cover E O-ring Remove the resolver cover for refitting on the new motor. Disconnect the brake release voltage. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 277 Axis Calibration is described in Calibrating with Axis Calibration method on page 349. General calibration information is included in section Calibration on page 337. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 278 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in section First test run may cause injury or damage on page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 279: Replacement Of Motor, Axis 4, Irb 1600

    Spare part no. Art. no. Note Rot. ac motor with pinion For spare part number, see: • Spare part lists on page 387 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 280 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 281 Remove the motor by gently lifting it out. Make sure the motor pinion is not damaged! Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 282 159 Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 283 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 284: Replacement Of Motor, Axis 4, 1600Id/1660Id

    Motor, axis 4 Cover, upper arm housing Connector plate Signal connector, R3.FB4 Power connector, R3.MP4 Attachment screw and washer, motor (4 pcs) Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 285 Read more about reference calibration for then reference calibration is not possible. Pendulum Calibration in Operating manu- al - Calibration Pendulum. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 286 Until the motor shaft is adjusted to the gear, as de- Tightening torque: approx. 2 Nm. scribed in following steps, only tighten the screws 4 pcs, M6 x 20. lightly. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 287 Axis Calibration is described in Calibrating with Axis Calibration method on page 349. General calibration information is included in section Calibration on page 337. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 288: Replacement Of Motor And Timing Belt, Axis 5, Irb 1600

    Rot. ac motor incl pinion 3HAC021800-003 Timing belt 3HAC021304-001 Gasket, upper arm cover 3HAC022049-001 Replace if damaged. Gasket, customer connec- 3HAC022050-001 Replace if damaged. tions Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 289 Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 159. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 290 Detailed in section Removal, motor and timing belt, axis 6 on page 313. Disconnect the axis 5 motor connectors: R3.MP5 and R3.FB5. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 291 Fit the new motor to the motor bracket, previ- 3 pcs, M6 x 20. ously removed from the old motor. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 292 Calib- rating with Axis Calibration method on page 349. General calibration information is in- cluded in section Calibration on page 337. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 293 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 294: Replacement Of Motor, Axis 5, Irb 1600Id

    Note Rot. ac motor with pinion For spare part number, see: • Spare part lists on page 387 VK cover 3HAA2166-19 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 295 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 296 A Arm Tube B Torx pan head screw M6X12 C Cover D Torx pan head screw M6X12 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 297 Remove the VK- Cover to access the cable connections inside the arm. xx0700000054 A VK-Cover Gently pull the cables out of the upper arm. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 298 Location of motor, axis 5 on socket head cap screw M8X20, page 294. holding the upper arm. Remove the upper arm. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 299 Fit the rotation tool to the end of Part number is specified in Required equipment motor shaft. on page 294 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 300 These are further detailed in the section First test run may cause injury or damage on page Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 301 Axis Calibration is described in Calibrating with Axis Calibration method on page 349. General calibration information is included in section Calibration on page 337. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 302: Replacement Of Motor, Axis 5, Irb 1660Id

    Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 159. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 303 Move the lower arm to the position shown in the figure. xx1500003066 • A: 75° approximately Move the upper arm to a horizontal position. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 304 This is due to risk of damage to the cable harness. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 305 Note The screws are secured with locking liquid Loctite 243. xx1500001262 • A: Attachment screws (7 pcs) Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 306 6. CAUTION Be careful not to damage the cable harness to motor axis 6 in the process. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 307 Refitting motor axis 5 Use this procedure to refit motor axis 5. Action Information Place motor axis 5 in the upper arm tube. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 308 Examine the spiral of the cable harness to See section make sure it is fitted correctly. • Replacing the cable harness, 1600ID/1660ID on page 172 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 309 See figure above. ment screws. Apply Sikaflex 521FC on the surface along the red curve in the figure. xx1500001269 Refit the mechanical stop. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 310 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 311: Replacement Of Motor And Timing Belt, Axis 6, Irb 1600

    Distance console with cable bracket and contact panel Cable tie Required equipment Equipment Spare part no. Art. no. Note Rot. ac motor incl pinion 3HAC021800-003 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 312 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 313 The procedure below details how to refit the motor and timing belt of axis 6. Action Note Clean the mating surfaces on the motor and in the upper arm housing. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 314 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 315: Replacement Of Motor, Axis 6, Irb 1600Id

    Equipment Art. no. Note Rot. ac motor incl pinion For spare part number, see: • Spare part lists on page 387 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 316 Move the upper arm to the synchronization position. Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 317 Tighten the lock screw on the coupling. Tightening torque: 6 Nm Fit the cable protection cover. Tightening torque: 6 Nm Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 318 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in the section First test run may cause injury or damage on page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 319: Replacement Of Motor, Axis 6, Irb 1660Id

    Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 159. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 320 Remove all extra equipment fitted on the upper arm. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 321 • A: Coupling • B: Attachment screw Remove the attachment screws securing the wrist. xx1000000875 • A: Attachment screws (4 pcs) Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 322 Fit two short screws to the holes for the at- tachment screws to temporarily secure the cover. xx1500003257 • A: Short screws (2 pcs) • B: Cover Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 323 Open the flexible coupling securing motor axis 6. xx1000000930 • A: Attachment screw, coupling • B: Flexible coupling • C: Motor, axis 6 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 324 D: Cylindrical pins (2 pcs) • E: Motor axis 6 Secure the motor with its attachment Tightening torque: 6 Nm screws. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 325 Place the wrist with motor axis 6 fitted a little into the upper arm tube. Reconnect the cables R4.MP6 and R4.FB6 R4.MP6 to motor axis 6. R4.FB6 xx1400002575 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 326 Apply locking liquid to the assembly surface The locking liquid is specified in Required on the upper arm tube. equipment on page 319. xx1200000063 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 327 Tightening torque: 14 Nm attachment screw. Fit a new VK-cover. Article number is specified in Required equipment on page 319. xx1000000873 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 328 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 329: Gearboxes

    Spare parts - Frame, exploded view. xx0500001400 Gearbox unit, axes 1-2 Attachment screws and washer, base-gearbox unit (VK-cover is removed) Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 330 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 331 Remove the oil plug and drain all oil from gearbox axis 1 using a drain pump. xx0800000260 A Oil plug B Drain pump Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 332 Secure the weight of the base with lifting slings. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 333 1-2 on page 329. washer. 16 pcs, M10 x 40, tightening torque: 70 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 334 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 335: Service Work On Gearboxes, Axes 3, 4, 5 And 6

    5 and 6: the complete wrist unit is to be replaced. This procedure is detailed in section Replacing the wrist unit, IRB 1600 on page 201. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 336 This page is intentionally left blank...

  • Page 337: Calibration

    Term Definition Calibration method A collective term for several methods that might be available for calibrating the ABB robot. Each method contains calibration routines. Synchronization position Known position of the complete robot where the angle of each axis can be checked against visual synchronization marks.

  • Page 338: Calibration Methods

    Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant. If no data is found related to standard calibration, Calibration Pendulum is used as default. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 339 Brief description of calibration methods Calibration Pendulum method Calibration Pendulum is a standard calibration method for calibration of all ABB robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S). Two different routines are available for the Calibration Pendulum method: •...

  • Page 340: When To Calibrate

    The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration, according to information in this manual. If the robot has absolute accuracy calibration, it is also recommended, but not always necessary to calibrate for new absolute accuracy.

  • Page 341: Synchronization Marks And Axis Movement Directions

    This section shows the position of the synchronization marks and the synchronization position for each axis. Synchronization marks, IRB 1600/IRB 1660ID IRB 1600 xx0600002876 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 342 The illustration shows the synchronization marks of axes 4, 5 and 6 for IRB 1600ID. Refer to illustration valid for IRB 1600 for axes 1, 2 and 3. xx1500001256 IRB 1660ID xx1700000115 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 343 5 Calibration 5.2.1 Synchronization marks and synchronization position for axes Continued xx1700000116 Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 344: Calibration Movement Directions For All Axes

    Note! The graphic shows an IRB 7600. The positive direction is the same for all 6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in the opposite direction! xx0200000089 Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 345: Updating Revolution Counters

    At delivery the manipulator is in the correct position, do NOT rotate axis 4 or 6 at power up before the revolution counters are updated. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 346 Step 2 - Updating the revolution counter with the FlexPendant Use this procedure to update the revolution counter with the FlexPendant (IRC5). Action On the ABB menu, tap Calibration. xx1500000942 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 347 Calibration method used at factory for each axis is shown, as well as calibration method used during last field calibration. Tap Manual Method (Advanced). xx1500000944 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 348 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 368. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 349: Calibrating With Axis Calibration Method

    FlexPendant. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. WARNING The calibration tool must be fully inserted into the calibration bushing, until the steel spring ring snaps into place.
  • Page 350 A benefit with reference calibration is that the current state of the robot is stored and not the state when the robot left the ABB factory. The reference value will be named according to tool name, date etc.
  • Page 351 To calibrate a suspended or wall mounted robot with the fine calibration routine, the robot must first be taken down and mounted standing on the floor. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 352: Calibration Tools For Axis Calibration

    There is no risk for bad calibrations as long as the calibration tool is in one piece. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. Equipment, etc. Article number...
  • Page 353 • Outer diameter within Ø12g4 mm, Ø8g4 mm or Ø6g5 mm (depending on calibration tool size). • Straightness within 0.005 mm. xx1500000951 Outer diameter Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 354: Installation Locations For The Calibration Tools

    This is shown in the figure. IRB 1600 xx1700000113 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 355 5 Calibration 5.4.3 Installation locations for the calibration tools Continued xx1700000114 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 356 5 Calibration 5.4.3 Installation locations for the calibration tools Continued IRB 1660ID xx1700000111 xx1700000112 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 357 Contains replacement calibration pin covers and protective plugs for the bushing. Protective plug on turning disc 3HAC057676-001 Replace if damaged or missing. (IRB 1660ID) 3HAC061134-001 (IRB 1600) Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 358: Axis Calibration - Running The Calibration Procedure

    WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration holes may cause severe damage to the robot and/or personnel. Equipment, etc.
  • Page 359 Refit the protection plug(s) to the turning disc, push until the steel spring ring snaps into place. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 360 Use this procedure to call for the Axis Calibration method on the FlexPendant. Action Note On the ABB menu, tap Calibration. xx1500000942 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 361 The three-position enabling device on the Press and hold the three-position enabling FlexPendant has been released during robot device and press Play. movement. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 362 Confirm unsynchronized state by pressing Ac- knowledge to continue Axis Calibration proced- ure. Restart Axis Calibration procedure by pressing Play. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 363 SafeMove generates the message "Unsynchron- ized time limit expired" (anytime). xx1500002482 Press OK to continue Axis Calibration procedure. Restart Axis Calibration procedure by pressing Play. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 364 Replace the plug and the sealing with new spare part, if missing or damaged. xx1500000952 Protection cover and plug set: 3HAC059487-001. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 365 IRB 1660ID xx1700000411 Remove the tool from the protection plug. IRB 1600 xx1700000901 IRB 1660ID xx1700000902 Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 366: Calibrating With Calibration Pendulum Method

    Where to find information for Calibration Pendulum Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 367: Verifying The Calibration

    341. Write down the values on a new label and stick it on top of the calibration label. Remove any calibration equipment from the robot. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 368: Checking The Synchronization Position

    If they do not, up- ization position for axes on page 341 date the revolution counters. Updating revolution counters on page 345. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 369: Decommissioning

    Incineration must be carried out under controlled conditions in accordance with local regulations. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 370 Spills can form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. • Spillage can penetrate the soil causing ground water contamination. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 371: Scrapping Of Robot

    • When motors are removed from the robot, the robot will collapse if it is not properly supported before the motor is removed. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 372 This page is intentionally left blank...

  • Page 373: Robot Description

    Some cable harnesses have been replaced. For details, see Base, spare part list and Frame, spare part list, in Product manual, spare parts - IRB 1600/1660. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 374: Type A Of Irb 1600Id

    Robotics After Sales for more information and purchase of a new key. After the upgrade the existing programs may require a touch-up of positions. Further information Technote 110912 includes more detailed information. Contact Robotics After Sales. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 375: Reference Information

    8.1 Introduction 8 Reference information 8.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 376: Applicable Standards

    Terminology and general principles EN 574:1996 + A1:2008 Safety of machinery - Two-hand control devices - Functional aspects - Principles for design Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 377 Safety requirements for industrial robots and robot systems ANSI/UL 1740 Safety standard for robots and robotic equipment CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require- ments Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 378: Unit Conversion

    1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 379: 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 380 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 381 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm - Nominal Min. Max. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 382: Weight Specifications

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

  • Page 383: Standard Tools

    Socket head cap no: 6, socket 1/2" bit L 20 mm Socket head cap no: 8, socket 1/2" bit L 20 mm Small cutting plier T-handle with ball head Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 384: Special Tools

    If no data is found related to standard calibration, Calibration Pendulum is used as default. Description Art. no. Note Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes operating manual. Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 385 Required if Axis Calibration is the valid calibration method for the robot. Contains a removal tool for removing special protection plugs on the turning disc. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 386: Lifting Accessories And Lifting Instructions

    This implies that the instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 387: Spare Part Lists

    Spare parts and exploded views are not included in the manual but delivered as a separate document for registered users on myABB Business Portal, www.mypo- rtal.abb.com. Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 388 This page is intentionally left blank...

  • Page 389: Circuit Diagram

    Circuit diagram - IRB 6400RF 3HAC8935-1 Circuit diagram - IRB 6600 type A 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6600 type B 3HAC13347-1 3HAC025744-001 Continues on next page Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 390 3HAC029940-001 Circuit diagram - IRB 6700 3HAC043446-005 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 Circuit diagram - Product.ProductName 3HAC050778-003 Circuit diagram - IRB 910SC 3HAC056159-002 Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.

  • Page 391: Index

    4, 281 replacing, 222 spare part number, 222 damper, axis 5 cabinet lock, 25, 31 inspection, 132 cable harness replacing, 226 Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 392 129 measurement system battery pack, spare part number, 146 hanging mechanical stop axis 2 installed hanging, 25 article number, 107 hazardous material, 369 installation, 105 Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 393 5 and 6, intervals, 129 when filling oil in wrist unit, 140 safety risks, 38 rubber wrist unit, 138 disposal, 369 wrist unit, intervals, 129 operating conditions, 53 Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 394 126 screws, tightening torque, 187 steel spare part number, 184 disposal, 369 storage conditions, 53 suspended mounting, 72 validity and responsibility, 19 Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 395 204 spare part number, 201 wall mounting, 72 weight, 51 arm, 180–181 zero position base, 242, 332, 334 checking, 368 gearbox 1, 332–334 Product manual - IRB 1600/1660 3HAC026660-001 Revision: W © Copyright 2006-2018 ABB. All rights reserved.
  • Page 398 PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics and Motion 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2006-2018 ABB. All rights reserved. Specifications subject to change without notice.

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