ABB Robotics IRB 1520 Product Manual

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IRB 1520

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Summary of Contents for ABB Robotics IRB 1520

Page 1 ROBOTICS Product manual IRB 1520...
Page 2 Trace back information: Workspace 20B version a12 Checked in 2020-05-28 Skribenta version 5.3.033...
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, damage to persons or property, fitness for a specific purpose or the like.
Page 5: Table Of Contents
Inspecting the oil level, axis 3 gearbox ............3.3.4 Inspecting the oil level, axis 4 gearbox ............3.3.5 Inspecting the oil level, axis 5 gearbox ............Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 6 Changing the oil in axes 5 and axis 5 and 6 gearboxes, IRB 1520ID ....3.4.6 Replacing the battery pack ................ Cleaning activities ..................... 3.5.1 Cleaning the IRB 1520 ................Repair Introduction ...................... General procedures ................... 4.2.1 Performing a leak-down test ..............
Page 7 Standard tools ....................Special tools ....................Lifting accessories and lifting instructions .............. Spare parts Spare part lists and illustrations ................Circuit diagram Circuit diagrams ....................Index Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
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Page 9: Overview Of This Manual
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 1520. Some variants and designs may have been removed from the business offer and are no longer available for purchase.
Page 10 References Documentation referred to in the manual, is listed in the table below. Document name Document ID Product manual, spare parts - IRB 1520 3HAC043436-001 Product manual - Arc welding equipment for IRB 1520ID 3HAC043438-001 Circuit diagram - IRB 1520...
Page 11 Published in release 19C. The following updates are done in this revision: • Updated tightening torques of axis-3, -4, -5, 5-6 oil plugs. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 12 Mounting instructions for sealings on page 137. • Added information about Wrist Optimization and Wrist Optimization in calibration chapter. • Replaced article number and name of grease, previously 3HAB3537-1. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 13: 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 14 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 15: 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
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Page 17: Safety
ABB is not liable for damages caused by the use of non-original spare parts and equipment. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 18: Requirements On Personnel
The plant liable must make sure that the personnel is trained on the robot, and on responding to emergency or abnormal situations. Personal protective equipment Use personal protective equipment, as stated in the product manual. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 19: Safety Signals And Symbols
NOTE Signal word used to indicate important facts and conditions. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 20 1.2.1 Safety signals in the manual Continued Symbol Designation Significance Signal word used to indicate where to find additional information or how to do an operation in an easier way. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 21: Safety Symbols On Manipulator Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 22 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 23 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 24 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 25 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 26 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 27: Robot Stopping Functions
Protective stop and emergency stop The protective stops and emergency stops are described in the product manual for the controller. For more information see: • Product manual - IRC5 Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 28: Installation And Commissioning
When the robot is installed at a height, hanging, or other than mounted directly on the floor, there will be additional hazards. Electrical safety The mains power must be installed to fulfill national regulations. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 29 The risk assessment should also consider other hazards, such as, but not limited • Water • Compressed air • Hydraulics Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 30 Before the robot system is put into operation, verify that the safety functions are working as intended and that any remaining hazards identified in the risk assessment are mitigated to an acceptable level. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 31: Operation
Never stay beneath a robot arm. Gravity and the release of braking devices can create additional hazards. A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 33 Operating temperatures are listed in Operating conditions, robot on page See safety instructions for the batteries in Material/product safety data sheet - Battery pack (3HAC043118-001). Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 34 WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Related information See also the safety information related to installation and operation. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 35: 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 36: Brake Testing
3 Inspect and verify that the axis maintains its position. If the manipulator does not change position as the motors are switched off, then the brake function is adequate. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 37: Troubleshooting
Manipulator movements can cause serious injuries on users and may damage equipment. Related information See also the safety information related to installation, operation, maintenance, and repair. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 38: Decommissioning
Never stay beneath a robot arm. Gravity and the release of braking devices can create additional hazards. A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 39: Installation And Commissioning
Note If the IRB 1520 is connected to power, always make sure that the robot is connected to protective earth and a residual current device (RCD) before starting any installation work. For more information see: •...
Page 40: Unpacking
When these prerequisites are met, the robot can be taken to its installation site as described in section: On-site installation on page 50 Install required equipment, if any. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 41 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 43 Protection classes, robot The table shows the available protection types of the robot, with the corresponding protection class. Protection type Protection class Manipulator, protection type Standard IP40 Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 45 (restricted 1073.2 -482.8 +150º -100º working range) pos4 (unrestric- 636.2 -192.3 +150º -180º ted working range) pos5 -163.1 366.8 +150º +80º Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 46 Minimum turning radius of axis 1 Working range Axis IRB 1520ID - 4/1.5 Note Axis 1 +170º to -170º Axis 2 +150º to -90º Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 47 Default value. +288 to -288 revolutions Maximum value. The default working range for axis 6 can be extended by changing parameter values in the software. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 48: Risk Of Tipping/Stability
This figure shows the robot in its shipping position and transportation position. Axis 4: ±90° xx1100000309 WARNING The robot will be mechanically unstable if not properly secured to the foundation. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 49: 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 50: On-Site Installation
Equipment Art. no. Note Overhead crane Lifting capacity: 1,000 kg. Roundsling Length: 2 m. Quantity: 2 pcs. Lifting capacity: 1,000 kg. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 51 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 52: Lifting And Turning A Suspended Mounted Robot
Special tools on page 298. Any additional equipment required is specified in the instruction for the lifting accessory. Contact ABB for more information. Illustration xx1100000382 Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 53: Manually Releasing The Brakes
The brake will function again as soon as the button is released. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 54 • 0V on pin 12 • 24V on pin 11 Push the brake release button to release the holding brakes, according to the previous procedure. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 55: Orienting And Securing The Robot
Attachment bolts, specification Attachment bolts 4 pcs M16 x 45 Washers 30 x 17 x 3 Quality Tightening torque 200 Nm Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 56 Attachment point, front (no guide sleeve) Manipulator base Screw M16x120 Plain washer Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 57 2 Installation and commissioning 2.3.4 Orienting and securing the robot Continued Guide sleeve Isolator Nut M16 Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 58: Setting The System Parameters For A Suspended Or Tilted Robot
The Gravity Beta is a positive rotation direction around the y-axis in the base coordinate system. The value is set in radians. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 59 B is the mounting angle in radians. Example of position Mounting angle (A°) Gravity Beta Floor mounted 0° 0.000000 (Default) Suspended mounting 180° 3.141593 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 60 2.3.5 Setting the system parameters for a suspended or tilted robot Continued Examples of mounting angles tilted around the Y axis (Gravity Beta) xx1100000373 Suspended mounting, mounting angle 180º Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 61 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 62 Mounting angles and values on page The system parameters are described in Technical reference manual - System parameters. The system parameters are configured in RobotStudio or on the FlexPendant. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 63: 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 64: Fitting Equipment On The Robot (Robot Dimensions)
2.3.7 Fitting equipment on the robot (robot dimensions) Robot dimensions The figure shows the dimension of the robot. 222.5 (63) xx1100000295 Minimum turning radius R=307 mm Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 65 The attachment holes are shown in the figures in this section. xx1100000302 Figure 2.2: Overview of attachment holes and dimensions Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 66 2 Installation and commissioning 2.3.7 Fitting equipment on the robot (robot dimensions) Continued xx1100000303 Figure 2.3: Detailed illustrations of attachment holes on the robot Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 67 When fitting tools on the turning disk, use only screws with quality 12.9. When fitting equipment on other places, standard screws with quality 8.8 can be used. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 68: 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 69: Installation Of Additional Mechanical Stops On Axis 3
Mechanical stop, axis 3 Spare parts on page 301. Technical reference manual - System Art. no. is specified in Refer- parameters ences on page Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 70 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 71: Electrical Connections
Robot cable, power Cable Art. no. Robot cable, power: 7 m 3HAC040503-001 Robot cable, power: 15 m 3HAC040503-002 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 72 3HAC068918-001 Bending radius for static floor cables The minimum bending radius is 10 times the cable diameter for static floor cables. xx1600002016 Diameter Diameter x10 Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 73: 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
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Page 75: Maintenance
Note If the IRB 1520 is connected to power, always make sure that the IRB 1520 is connected to protective earth and a residual current device (RCD) before starting any maintenance work. For more information see: •...
Page 76: Maintenance Schedule And Expected Component Life
3.2.1 Specification of maintenance intervals Introduction The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the IRB 1520: • Calendar time: specified in months regardless of whether the system is running or not.
Page 77: Maintenance Schedule
The following table specifies the required maintenance activities and intervals. Maintenance activity Equipment Interval Cleaning Robot Cleaning the IRB 1520 on page 130 Inspection Oil level in axis-1 gearbox Every 12 months. Inspection Oil level in axis-2 gearbox Every 12 months.
Page 78 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. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 79: 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 80: Inspection Activities
Other tools and procedures may be required. These procedures include references to the See references to these procedures in the tools required. step-by-step instructions below. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 81 How to fill oil is described in section: • Changing the oil, axis 1 gearbox on page 108 Refit the oil plug, inspection. Tightening torque: • 10 Nm Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 82 How to fill oil is described in section: • Changing the oil, axis 1 gearbox on page 108 Refit the oil plug. Tightening torque: • 10 Nm Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 83: Inspecting The Oil Level, Axis 2 Gearbox
Other tools and procedures may be required. These procedures include references to the See references to these procedures in the tools required. step-by-step instructions below. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 84 Before refitting the oil plug in the gearbox, always replace the oil plug sealing washer with a new one. If not there is a risk of leakage. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 85: Inspecting The Oil Level, Axis 3 Gearbox
Other tools and procedures may be required. These procedures include references to the See references to these procedures in the tools required. step-by-step instructions below. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 86 Add oil if required. How to fill oil is described in section: • Changing the oil, axis-3 gearbox on page 117 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 87 3 Maintenance 3.3.3 Inspecting the oil level, axis 3 gearbox Continued Action Note Refit the oil plug. Tightening torque: • 10 Nm Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 88: Inspecting The Oil Level, Axis 4 Gearbox
Action Note WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 89 Measure the oil level at the oil plug hole. Required oil level: • 35 mm ± 3 mm Add oil if required. Refit the oil plug, filling. Tightening torque: • 3 Nm Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 90: Inspecting The Oil Level, Axis 5 Gearbox
Action Note WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 91 30 mm ± 3 mm below the lower edge of the oil plug hole. Add oil if required. Refit the oil plug, filling. Tightening torque: • 3 Nm Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 92: Inspecting The Oil Level, Axis 5-6 Gearbox
Action Note WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 93 Changing the oil in axes 5 and axis 5 and 6 gearboxes, IRB 1520ID on page 122 Refit the oil plug, filling. Tightening torque: • 3 Nm Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 94: Inspecting The Cable Harness
See references to these procedures in the tools required. step-by-step instructions below. Circuit diagram See chapter Circuit diagram on page 303. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 95 Replace the cable harness if wear, cracks or How to replace the cable harness is de- damage is detected. scribed in Repair on page 133. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 96: Inspecting Information Labels
Oil quantity label Instruction plate - Lifting of robot Required equipment Equipment Spare part number Note Labels Spare parts on page 301. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 97 Check all labels. See the figure in Location of information labels on page Replace any missing or damaged labels. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 98: Inspecting The Mechanical Stop Pin, Axis
These procedures include may be required. See refer- references to the tools re- ences to these procedures in quired. the step-by-step instructions below. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 99 Note If the mechanical stop pin has been deformed or damaged, it must be replaced. Check that the mechanical stop pin is prop- erly attached. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 100: Inspecting, Additional Mechanical Stops
Location of additional mechanical stops Additional mechanical stops are provided for axes 3 and 4. xx1100000351 Additional mechanical stop, axis 3 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 101 Check additional stops on axes 3 and 4 for damage. Location of additional mechanical stops on page 100. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 102 101. Correct attachment screws: • Axis 3: M6 x 40, quality 12.9 (2 pcs) • Axis 4: M6 x 8, quality 8.8 (3 pcs) Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 103: Inspecting Dampers
3.3.11 Inspecting dampers Location of dampers The figure shows the location of all dampers to be inspected. xx1100000356 Dampers, axis 2 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 104 Spare part no. Note Damper Spare parts on page 301. Standard toolkit Content is defined in section Standard tools on page 297. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 105 Check all dampers for existing impressions larger than 2-3 mm. Check attachment screws for deformation. If any damage is detected the damper must be replaced. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 106: Replacement Activities
Business Portal, www.mypo- rtal.abb.com. Location of gearboxes The figure shows the location of the gearboxes. xx1100000336 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 107 Includes pump with outlet pipe. Use the suggested dispenser or a similar one: • Orion OriCan article number 22590 (pneumatic) Nipple for quick connect fitting, with o-ring Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 108: Changing The Oil, Axis 1 Gearbox
The axis 1 gearbox is located between the frame and base of the robot. The oil plug is shown in the figure. xx1100000339 Oil plug for filling Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 109 Standard tools on page 297. Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 110 Cut the straps that hold the oil draining hose fastened inside the robot base. Pull out the oil draining hose so that it reaches the oil collecting vessel. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 111 Refit the base cover. Refit the centering piece to the push button unit. Refit the push button guard to the base. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 112 How to inspect the oil level is de- scribed in Inspecting the oil level, axis- 1 gearbox on page Refit the oil plug. Tightening torque: 10 Nm. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 113: Changing The Oil, Axis-2 Gearbox
Type and amount of oil in gearboxes on page 106. Oil collecting vessel The capacity of the vessel must be sufficient to take the complete amount of oil. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 114 Drain the gearbox oil using an oil collecting vessel. Note Draining is time-consuming. Elapsed time varies depending on the temperature of the oil. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 115 Open oil plug, filling. See the figure in: • Location of oil plugs on page 113 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 116 Before refitting the oil plug in the gearbox, always replace the oil plug sealing washer with a new one. If not there is a risk of leakage. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 117: Changing The Oil, Axis-3 Gearbox
The axis-3 gearbox is located in the upper arm rotational center. Oil plugs are shown in the figure. xx1100000341 Oil plug, gearbox xx1100000342 Oil plug, armhouse Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 118 Type of lubrication in gearboxes on page 106 Funnel xx1200000862 Standard toolkit Content is defined in section Standard tools on page 297. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 119 WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 120 • 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 121 How to inspect oil is described in section: • Inspecting the oil level, axis 3 gearbox on page 85 Refit the oil plug. Tightening torque: 10 Nm Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 122: Changing The Oil In Axes 5 And Axis 5 And 6 Gearboxes, Irb 1520Id
Standard tools on page 297. Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 123 The figure shows IRB 1600 but the upper arm ing robot. position is the same for the IRB 1520. • axis 4: - 90º, to a position where the oil plug (A) is faced down- wards.
Page 124 Position the robot as shown in the figure The figure shows IRB 1600 but the upper to the right: arm position is the same for the IRB 1520. • axis 4: + 90º, to a position where the oil plug (A) is faced upwards.
Page 125: Replacing The Battery Pack
See Operating manual - IRC5 with FlexPendant for instructions. WARNING Hazards related to batteries on page Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 126 The battery pack for the measurement system is located inside the base of the robot, as shown in the figure below. xx1100000319 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 127 Battery pack battery (2-pole battery contact) Velcro strap Connector X3 RMU 101 xx1300000330 Battery pack (3-pole battery contact) Serial measurement board RMU 101 BU unit Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 128 Clean cover from metal residues before opening. Metal residues can cause shortage on the boards which can result in hazardous failures. xx1100000315 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 129 Refit the base cover to the robot. Location of battery pack on page 126. Update the revolution counters. Detailed in section Updating revolution counters on page 279. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 130: Cleaning Activities
General To secure high uptime it is important that the IRB 1520 is cleaned regularly. The frequency of cleaning depends on the environment in which the product works. Different cleaning methods are allowed depending on the type of protection of the IRB 1520.
Page 131 3 Maintenance 3.5.1 Cleaning the IRB 1520 Continued Cleaning methods The following table defines what cleaning methods are allowed depending on the protection type. Protection Cleaning method type Vacuum Wipe with cloth Rinse with water High pressure water or cleaner...
Page 132 This page is intentionally left blank...
Page 133: Repair
Repair activities not described in this chapter must only be carried out by ABB. Report replaced units Note When replacing a part on the IRB 1520, report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit.
Page 134: 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 135: 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 136 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 137: Mounting Instructions For Sealings
If the sealing is without dust lip, just lubricate the main lip with a thin layer of grease. xx2000000071 A Main lip B Grease C Dust lip Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 138 Check the o-ring for surface defects, burrs, Defective o-rings, including damaged shape accuracy, or deformation. or deformed o-rings, may not be used. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 139 Lubricate the o-ring with grease. Tighten the screws evenly while assembling. Check that the o-ring is not squashed outside the o-ring groove. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 140: Cut The Paint Or Surface On The Robot Before Replacing Parts
Carefully grind the paint edge that is left on the structure to a smooth surface. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 141: The Brake Release Buttons May Be Jammed After Service Work
If a button gets jammed in the depressed position, the alignment of the brake release unit must be adjusted so that the buttons can move freely in their tubes. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 142: Complete Manipulator
Location of cable harness - lower end The lower end of the cable harness is located as shown in the figure. xx1100000313 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 143 • 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 144 Remove the armhouse cov- xx1100000349 Disconnect all connectors inside the armhouse. Note Make a note of how the cables are run on the brack- Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 145 R3.MP6 xx0700000105 Unscrew the attachment screws (2 pcs) that holds the bracket of the cable harness to the upper arm. xx1100000327 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 147 Unscrew the attachment screws (2 pcs) of the brack- et that holds the cable har- ness inside the frame. xx1100000323 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 148 Replacing motors on axis 1 and 2 on page 229. axes 1 and 2 motors and disconnect all connectors - R2.MP1, R2.FB1, R2.MP2 and R2.FB2, Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 149 This is done in order to be able to refit the push buttons correctly later. xx1100000314 Remove the base cover. xx1100000315 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 150 SMB and push button Replacing the push button unit on page 222. units. Unscrew the two connectors on the plate for connector. xx1100000317 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 151 Replacing the serial measurement unit on page 214. to SMB and push button Replacing the push button unit on page 222. units. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 152 (2 + 2 pcs). xx1100000321 Refit all cable clamps and straps securing the cable harness to the fastening plate. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 153 CAUTION Be careful not to damage the cable harness in the process. The space is cramp. xx1100000316 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 154 Continued Action Note Secure the plate for con- nector with its attachment screws (4 pcs). xx1100000329 Refit the base cover. xx1100000315 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 155 (2 + 2 pcs) in the lower arm and secure the cable harness. xx1100000326 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 157 Location of cable harness - lower end on ness is placed correctly in page 142. the base and frame. Fit the cover on the frame. xx1100000322 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 158 Secure the cable harness to the armhouse by fitting the bracket with its attach- ment screws (4 pcs). xx1100000328 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 159 (2 pcs). xx1100000327 Reconnect the connectors on page to motors axes 3 and 4. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 160 Calibration is described in a separate calibration manual enclosed with the calibration tools. General calibration information is included in section Cal- ibration information on page 273. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 161 4.3.1 Replacing the cable harness - lower end Continued Action Note DANGER Make sure all safety re- quirements are met when performing the first test run. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 162: Replacing The Cable Harness - Upper End
R3.FB4 R3.FB5 R3.FB6 R3.MP3 R3.MP4 R3.MP5 R3.MP6 xx0700000038 Required equipment Equipment Art. no. Note Cable harness Spare parts on page 301. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 164 Fit two threaded bars (M8) with nuts fitted at the bottom end. Length: 120 mm xx1100000473 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 165 Unscrew the attachment screws (3 pcs) holding the cover with mechanical stop and remove the cover. xx1100000411 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 166 6 motors from the arm tube. Remove the support ring and V-ring from the arm tube and place them temporarily on the cable harness spiral. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 167 Carefully lower the arm tube without causing any damage to the cable harness and put it somewhere safe. Remove the support ring and V-ring. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 168 The cable harness spiral is shown in the figure: xx0700000099 Cover plate Clamp R4.FB5 R4.FB6 R4.MP6 R4.MP5 R3.MP5 R3.MP6 R3.FB5 R3.FB6 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 170 Wrap the connectors with some plastic film and tape in order to protect them from con- tamination. Pull the cable harness carefully out off the armhouse. xx0700000114 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 171 Place the cover and the cable harness spiral into its position. Note Do not remove the cable strap at this point! xx1000001004 A: Cable strap Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 172 Lower the arm tube carefully and let it rest on the nuts. xx1100000474 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 173 3/4 of a revolu- tion. Note Check that the cable harness spiral is fitted correctly. The two cables must not cross each other! Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 174 5-6 cable spiral as possible, to avoid grease to accumulate on the resolver connector. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 175 In order to release the brakes for axis 4 see Manually releasing the brakes on page Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 176 Concluding refitting Action Note Reconnect the connectors in the armhouse. R3.FB3 R3.FB4 R3.FB5 R3.FB6 R3.MP3 R3.MP4 R3.MP5 R3.MP6 xx0700000105 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 177 General calibration information is included in section Calibration information on page 273. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 178: Replacing The Complete Arm System
The complete armsystem is located as shown in the figure. xx1100000438 Required equipment Equipment Art. no. Note Standard toolkit Content is defined in section Standard tools on page 297. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 179 142. CAUTION The robot arm system weighs 55 kg. All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 180 2. xx1100000440 Carefully lift away the complete arm system and put it somewhere safe. xx1100000441 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 181 M8x40 (18 pcs) Refit the cable harness in the lower arm and Replacing the cable harness - lower armhouse. end on page 142. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 182 General calibration information is included in section Calibration information on page 273. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 183: Upper And Lower Arm
Recalibration of robot axis 3-6 is required after replacement of upper arm. Location of the complete upper arm The complete upper arm is located as shown in the figure. xx1100000347 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 184 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot work- ing area. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 185 162. and brackets. Remove the bracket holding the cable har- ness to the armhouse and pull out the cable harness. xx1100000328 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 186 See figure! xx0700000060 The figure shows IRB 1600ID but the way to secure the upper arm with the round- sling is the same on IRB 1520. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L...
Page 187 All lifting accessories used must be sized accord- ingly! Attach a roundsling to the upper arm and lift it. Move the upper arm to the mounting position. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 188 Replacing motors on axes 3 and 4 on page 239. Insert the cable harness through the hole and into the armhouse. xx1100000330 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 189 5 on page 246 Replacing the axis 6 motor on page 250. Check the gaskets in the armhouse cover. Re- place if damaged! Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 190 General calibration information is in- cluded in section Calibration informa- tion on page 273. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 191: Replacing The Complete Lower Arm
Used to clean the mating sur- faces. Locking liquid Loctite 574 Standard toolkit Content is defined in section Standard tools on page 297. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 192 All lifting accessories used must be sized accordingly! Secure the weight of the lower arm with a roundsling in an overhead crane or similar. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 193 Secure the weight of the lower arm with a roundsling in an overhead crane or similar and lift it in position. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 194 General calibration information is included in section Calibration information on page 273. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 195: 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 parts on page 301. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 196 Remove all extra equipment fitted on upper arm and wrist. Remove the plug covering the attachment screw below. xx1100000354 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 197 Remove the VK-Cover. xx1100000394 Gently pull the cables out through the hole for the VK- cover in the armtube. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 198 Apply a string or similar to the cable harness and run it out through the hole for the VK cover. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 199 Secure the flexible coupling with the M5x16 Tightening torque 6 Nm screw. xx1100000355 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 200 General calibration information is included in section Calibration information on page 273. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 201: Replacing The Damper, Axis 2
These procedures include may be required. See refer- references to the tools re- ences to these procedures in quired. the step-by-step instructions below. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 202 Secure the damper with the attachment screw M6x60 quality 8.8-A2F and washer. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 203: Replacing The Damper, Axis 3
Note Damper, axis 3 Spare parts on page 301. Standard toolkit Content is defined in section Standard tools on page 297. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 204 Secure the damper with the attachment screw M6x60 quality 8.8-A2F and washer. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 205: Replacing The Mechanical Stop Axis 3, Irb 1520Id
Art. no. Note Mechanical stop Spare parts on page 301. Standard tools Content is defined in section Standard tools on page 297. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 206 Refit the mechanical stop with its attachment Attachment screws: M6x35 quality 8.8- screws. A2F (2 pcs) DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 207: Frame And Base
4.5 Frame and base 4.5.1 Replacing the base Location of the base The location of the base is shown in the figure. xx1100000437 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 208 Lifting robot with roundslings on page CAUTION The IRB 1520 robot weighs 170 kg. All lifting accessories used must be sized accordingly! Secure the weight of the robot with a round- sling in an overhead crane or similar.
Page 209 Note The figure shows IRB 4600 but the prin- Lift the robot and put it safely on its side on ciple is the same for IRB 1520. some pallets or similar. Let it rest on the lower arm. See figure! xx0800000352 •...
Page 210 Unscrew the attachment screws holding the Keep it in a clean place. It will be refitted base cable protection and remove it. on the new base. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 211 Replace if damaged! xx1100000536 • A: O-ring, 6 pcs (15.5x1.5) • B: O-ring, 1 pc (131x2) Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 212 Refit the oil drain hose to the base. Secure the oil tube with cable straps inside the base. CAUTION The IRB 1520 robot weighs 170 kg. All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L ©...
Page 213 General calibration information is included in section Calibration information on page 273. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 214: Replacing The Serial Measurement Unit
Location of serial measurement unit The serial measurement unit is located inside the base of the robot, as shown in the figure. xx1100000332 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 215 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 216 Standard toolkit Content is defined in section Standard tools on page 297. Circuit diagram See chapter Circuit diagram on page 303. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 217 Remove the centering piece from the push button unit. xx0600002776 • B: Centering piece Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 218 Disconnect the battery cable by pressing down the upper lip of the R2.G connector to release the lock while pulling the connector upwards. xx1700000993 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 219 215. Make sure the lock on the battery cable con- nector R2.G snaps into place during refitting. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 220 Be careful not to damage any of the components or cable harness in the process! xx1100000316 Secure the plate for connector with its attach- ment screws. xx1100000329 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 221 Update the revolution counters! Detailed in section Updating revolution counters on page 279. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 222: Replacing The Push Button Unit
Hexagon nuts, SMB unit (4 pcs). Only the outer ones are used. Required equipment Equipment Article number Note Brake release board/Push 3HAC064944-001 DSQC1054 button unit Gasket, base cover 3HAC022047-001 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 223 Remove the push button guard from the base. The push button guard must be removed to ensure a correct refitting of the push button unit. xx1100000314 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 224 Unscrew the nuts securing the push button unit to the SMB unit. xx1100000345 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 225 The unit is sensitive to ESD. Before handling the unit read the safety information in section The unit is sensitive to ESD on page Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 226 Eliminate all risks of contact between screened cables and the brake release board. Check the gasket of the base cover. Replace it if damaged. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 227 Before continuing any service work, follow the safety procedure in section The brake release buttons may be jammed after service work on page 141! Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 228 Update the revolution counters! Detailed in section Updating revolution counters on page 279. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 229: Motors
Replacing the axis 6 motor on page 250. Location of motors on axes 1 and 2 The motors are located as shown in the figure. xx1100000282 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 230 Place the robot in the recommended position in order to facilitate replacement of motors. Motor Position Axis 1 motor Calibration position. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 231 The figure shows the IRB 4600 but the prin- ciple is the same for IRB 1520. Draining gearboxes The table specifies if the oil needs to be drained from the gearboxes. Note These recommendations are valid if the method how to position the robot described above, is followed.
Page 232 Only applicable to the axis 2 motor! Changing the oil, axis-2 gearbox on page 113. Drain the axis 2 gearbox. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 233 A: Axis 1 motor • B: Axis 2 motor Disconnect the connectors inside. Unscrew the attachment screws that holds the motor plate. xx1100000376 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 234 Use a 300 mm extension for bits 1/2". xx1100000378 Only applicable to the axis 2 motor! Fit two guide pins in opposite holes. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 235 Fit two guide pins in opposite holes. Make sure the o-ring on the circumference Replace the o-ring if damaged! of the motor is seated properly. xx1100000380 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 236 A: Axis 1 motor • B: Axis 2 motor Carefully insert the motor cables through the connection box of the motor. xx1100000377 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 237 Only applicable to the axis 2 motor! Changing the oil, axis-2 gearbox on page 113. Refill the axis 2 gearbox with oil. Refit the motor cover. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 238 General calibration information is included in section Calibration information on page 273. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 239 Replacing the axis 6 motor on page 250. Location of motors on axes 3 and 4 The motors are located as shown in the figure. xx1100000282 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 240 The table specifies if the oil needs to be drained from the gearboxes. Note These recommendations are valid if the method how to position the robot described above, is followed. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 241 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot work- ing area. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 242 Remove the motor by lifting it carefully straight out, making sure the motor pinion is not damaged while moving it away from the gear. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 243 Make sure the o-ring on the circumference of the motor is seated properly. Replace if damaged! xx1100000479 Lubricate the o-ring with grease. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 244 Only applicable to the axis 3 motor! Changing the oil, axis-3 gearbox on page 117. Refill the axis 3 gearbox with oil. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 245 General calibration information is included in section Calibration information on page 273. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 246: Replacing Motor On Axis
250. Location of the axis 5 motor The motors are located as shown in the figure. xx1100000282 Axis 1 motor Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 247 Removing the axis 5 motor Use this procedure to remove the axis 5 motor. Action Note Jog the robot to the recommended position. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 248 Calibration is described in a separate calibration manual enclosed with the cal- ibration tools. General calibration information is included in section Calibration information on page 273. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 249 4 Repair 4.6.3 Replacing motor on axis 5 Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 250: Replacing The Axis 6 Motor
250. Location of the axis 6 motor The motors are located as shown in the figure. xx1100000282 Axis 1 motor Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 251 Releasing the brakes Connect the 24 VDC power supply for brake release to R1.MP. Connect to pins: Pin 12 Pin 13 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 252 Use this procedure to refit the axis 6 motor. Preparations Action Note Wipe clean all assembly surfaces. Make sure that the pinion is not damaged or scratched. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 253 General calibration information is included in section Calibration information on page 273. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 254: Gearboxes
M8 x 100 Always use guide pins in pairs! Lifting accessories Standard toolkit Content is defined in section Standard tools on page 297. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 255 • air pressure supply to the robot, before entering the robot work- ing area. CAUTION The IRB 1520 robot weighs 170 kg. All lifting accessories used must be sized accordingly! Remove the base. Replacing the base on page 207.
Page 256 254. holes. xx1100000450 Always use guide pins in pairs! Unscrew the remaining attachment screws securing the gearbox. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 257 Remove the gearbox carefully in order not to damage the motor pinion. xx1100000452 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 258 CAUTION Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 259 General calibration information is included in section Calibration information on page 273. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 260: Replacing The Axis 2 Gearbox
These procedures include may be required. See refer- references to the tools re- ences to these procedures in quired. the step-by-step instructions below. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 261 Replacing the cable harness - lower frame. end on page 142. Remove the complete arm system. Replacing the complete arm system on page 178. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 262 Unscrew the remaining attachment screws securing the gearbox. xx1100000456 If needed use the threaded holes on the gearbox and press out the gearbox. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 263 Use this procedure to refit the axis 2 gearbox. Action Note Wipe all contact surfaces clean on gearbox and robot. Check the cable protection. xx1100000459 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 264 Tightening torque: 17 Nm. screws. M6x40 (16 pcs) Remove the guide pins and fit the two remain- Tightening torque: 17 Nm. ing attachments screws. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 265 General calibration information is included in section Calibration information on page 273. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 266: Replacing The Axis 3 Gearbox
These procedures include may be required. See refer- references to the tools re- ences to these procedures in quired. the step-by-step instructions below. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 267 Remove two of the attachment screws and fit two guide pins in opposite holes. xx1100000463 Always use guide pins in pairs. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 268 Use this procedure to refit the axis 3 gearbox. Action Note Wipe clean all mating surfaces on lower arm and frame with isopropanol. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 269 Continued Action Note Check the protection ring. xx1100000459 Check the o-ring. Replace if damaged! xx1100000458 Put some grease on the o-ring. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 270 Place the gearbox on the guide pins and slide it in position. Secure the gearbox with its attachment screws. xx1100000464 Tightening torque: 14 Nm. M6x40 (16 pcs) Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 271 General calibration information is included in section Calibration information on page 273. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 272: Service Work On Axes 4, 5 And 6 Gearboxes
5 and 6: the complete wrist unit is to be replaced. This procedure is detailed in section Replacing the wrist unit, IRB 1600ID on page 195. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 273: Calibration Information
If the robot is not floor mounted, then the robot accuracy could be affected. The robot needs to be calibrated after it is mounted. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 274: Calibration Methods
Wrist optimization will update standard calib- ration data for axes 4 and 5. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 275 The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including the Operating manual - Calibration Pendulum, which describes the method and the different routines further. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 276: Synchronization Marks And Synchronization Position For Axes
Synchronization marks, IRB 1520ID xx1100000363 Figure 5.1: Calibration marks (from bottom left to top right): Axis 1, axis 4, axis 5 and axis 6. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 277 5 Calibration information 5.3 Synchronization marks and synchronization position for axes Continued xx1100000364 Figure 5.2: Calibration marks (from top to bottom): Axis 3 and axis 2. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 278: 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 279: Updating Revolution Counters
When all axes are positioned, update the Step 2 - Updating the revolution counter revolution counter. with the FlexPendant on page 280. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 280 All mechanical units connected to the system are shown with their calibration status. Tap the mechanical unit in question. xx1500000943 Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 281 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 284. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 282: 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 283: Calibrating With Wrist Optimization Method
WARNING Robot moves automatically when pressing Calibrate. 6 Wrist optimization is finished. 7 Redefine / verify TCP for all tools. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 284: Checking The Synchronization Position
If they do not, up- ization position for axes on page 276 date the revolution counters. Updating revolution counters on page 279. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 285: Decommissioning
These parts must also be disposed of in accordance with the current legislation of the country in which the robot and control unit are installed. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 286: Environmental Information
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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 287: 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
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Page 289: Reference Information
7.1 Introduction 7 Reference information 7.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 290: Applicable Standards
Degrees of protection provided by enclosures (IP code) Only robots with protection Clean Room. Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 291 Safety of machinery - Ergonomic design principles - Part 1: Terminology and general principles EN 574:1996 + A1:2008 Safety of machinery - Two-hand control devices - Functional aspects - Principles for design Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 292: 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 293: Screw Joints
Any special torque specified overrides the standard torque! • Use the correct tightening torque for each type of screw joint. • Only use correctly calibrated torque keys. Continues on next page Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 294 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 295 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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 296: Weight Specifications
Following is an example of a weight specification in a procedure: Action Note CAUTION The arm weighs 25 kg. All lifting accessories used must be sized accord- ingly. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 297: Standard Tools
Socket head cap no: 12, socket 1/2" bit L 20 mm Socket head cap no: 14, socket 1/2" bit L 20 mm 100 mm extension, 1/2" square drive Small cutting plier T-handle with ball head Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 298: Special Tools
3HAC041422-001 Additional equipment to the Calibration Pendulum tool set, required for calibration of axis Includes calibration tool block, parallel pins and a pro- tection screw. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 299: Lifting Accessories And Lifting Instructions
This implies that the instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 300 This page is intentionally left blank...
Page 301: Spare Parts
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 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
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Page 303: Circuit Diagram
Circuit diagram - IRB 1200 3HAC046307-003 Circuit diagram - IRB 1410 3HAC2800-3 Circuit diagram - IRB 1600/1660 3HAC021351-003 Circuit diagram - IRB 1520 3HAC039498-007 Circuit diagram - IRB 2400 3HAC6670-3 Circuit diagram - IRB 2600 3HAC029570-007 Circuit diagram - IRB 4400/4450S...
Page 304 Circuit diagram - IRB 6700 / IRB 6790 3HAC043446-005 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 14000 3HAC050778-003 Circuit diagram - IRB 910SC 3HAC056159-002 Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 305: Index
55 jogging to, 284 HRA, 28 scales, 276 humidity calibration scales, 276 operation, 43 CalibWare, 274 storage, 43 carbon dioxide extinguisher, 29 Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 306 3, 117 hydraulic system, 30 operating conditions, 43 pneumatic system, 30 orienting, robot, 55 safety signals original spare parts, 17 in manual, 19 Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 307 276 Wrist Optimization system integrator requirements, 28 overview of method, 283 system parameter Gravity Alpha, 59 Gravity Beta, 58 zero position checking, 284 Product manual - IRB 1520 3HAC043435-001 Revision: L © Copyright 2012-2020 ABB. All rights reserved.
Page 310 ABB AB, Robotics Robotics and Motion S-721 68 VÄSTERÅS, Sweden Telephone +46 (0) 21 344 400 ABB AS, Robotics Robotics and Motion Nordlysvegen 7, N-4340 BRYNE, Norway Box 265, N-4349 BRYNE, Norway Telephone: +47 22 87 2000 ABB Engineering (Shanghai) Ltd. Robotics and Motion No.

ABB Robotics IRB 1520 Product Manual

1 Safety

2 Installation and Commissioning

3 Maintenance

4 Repair

5 Calibration Information

6 Decommissioning

7 Reference Information

8 Spare Parts

9 Circuit Diagram

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