Product specification IRB 1600

Product specification IRB 1600
ABB Robotics
Product specification
IRB 1600
Product specification
Articulated robot
IRB 1600-6/1.2
IRB 1600-6/1.45
IRB 1600-8/1.2
IRB 1600-8/1.45
IRB 1600ID-4/1.5
M2004
Document ID: 3HAC023604-001
© Copyright 2004-2010 ABB. All rights reserved.
Revision: M
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.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's written
permission, and contents thereof must not be imparted to a third party nor be used for
any unauthorized purpose. Contravention will be prosecuted.
©Copyright 2004-2010 ABB All right reserved.
ABB AB
Robotics Products
SE-721 68 Västerås
Sweden
© Copyright 2004-2010 ABB. All rights reserved.
Additional copies of this manual may be obtained from ABB at its then current charge.
Table of Contents
Overview of this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1 Description
7
1.1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1.2 Different robot versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2.1 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.2 Operating requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3.3 Mounting the manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4 Calibration and References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.4.1 Fine calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.4.2 Absolute Accuracy calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.5 Robot load and Load diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.5.2 Load diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.5.3 Maximum load and moment of inertia for full and limited axis 5 (center line down) movement . 30
1.5.4 Wrist torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.5.5 Mounting of equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.6 Robot Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.6.2 Performance according to ISO 9283 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.6.3 Velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.6.4 Stopping distance/time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.7 Typical cycle times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.8 Customer connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.9 Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
© Copyright 2004-2010 ABB. All rights reserved.
1.9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2 Specification of Variants and Options
51
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.1.2 Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.1.3 Positioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.1.4 Track Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.2 Floor cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.2.1 Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.2.2 Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.3 Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.3.1 DressPack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.3.2 Process equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.3.3 AW Safety options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.3.4 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3 Accessories
69
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Index
3HAC023604-001 Revision: M
71
3
© Copyright 2004-2010 ABB. All rights reserved.
Table of Contents
4
3HAC023604-001 Revision: M
Overview of this manual
Overview of this manual
About this Product specification
It describes the performance of the manipulator or a complete family of manipulators in terms
of:
•
The structure and dimensional prints
•
The fulfilment of standards, safety and operating requirements
•
The load diagrams, mounting of extra equipment, the motion and the robot reach
•
The integrated auxiliary equipments as that is: Customer Connections
•
The specification of variant and options available
Users
It is intended for:
•
Product managers and Product personnel
•
Sales and Marketing personnel
•
Order and Customer Service personnel
Contents
Please see Table of Contents.
© Copyright 2004-2010 ABB. All rights reserved.
References
Reference
Document ID
Product specification - Controller IRC5 with FlexPendant
3HAC021785-001
Product specification - Controller software IRC5
3HAC022349-001
Product specification - Robot user documentation
3HAC024534-001
Product manual - IRB 1600
3HAC023637-001
Revisions
Revision
Description
3
- Calibration positions and Absolute Accuracy information added in chapter
1.4
- New Inside address for ABB RobotLoad
- New wrist, Type A added in chapter 1.5.5
- Figures for customer connections added
D
- Option 287-5 Wash removed
E
- New versions IRB 1600ID-4/1.5, IRB 1600-6/x and
IRB 1600-8/x added
- Changes in Safety/Standards
- Directions of forces added
- Increased payloads for standard robots
- Arc welding options added
- Warranty information for load diagrams
F
- Old versions removed and AW offer changed.
Continues on next page
3HAC023604-001 Revision: M
5
Overview of this manual
Continued
Description
G
- Changes for Calibration data
- Work range
- Explanation of ISO values (new figure and table)
- Stopping distance
- Changes in chapter Specification of Variants and Options, Track Motion and
Process equipment
- User documentation on DVD
H
- Added information about mounting equipment on upper arm
J
- General update for 9.1 release
K
- Updated/Corrected Clean Room Class
- Option 17/6 removed in Variants and Options
L
- Foundry Plus 2
- Clean Room removed
M
- Text for Standards updated
© Copyright 2004-2010 ABB. All rights reserved.
Revision
6
3HAC023604-001 Revision: M
1 Description
1.1.1. Introduction
1 Description
1.1 Structure
1.1.1. Introduction
Robot family
A number of new possibilities open up with ABB’s IRB 1600 robot. It is available in five
versions, and the latest one is the dedicated AW robot, IRB 1600ID-4/1.5 with an compact
AW dressed process upper arm.
The IRB 1600 family is ideal for Arc Welding, Machine Tending, Material Handling, Gluing
and Deburring/Grinding applications.
Software product range
We have added a range of software products - all falling under the umbrella designation of
Active Safety - to protect not only personnel in the unlikely event of an accident, but also
robot tools, peripheral equipment and the robot itself.
Operating system
The robot is equipped with the IRC5 controller and robot control software, RobotWare.
RobotWare supports every aspect of the robot system, such as motion control, development
and execution of application programs, communication etc. See Product specification Controller IRC5 with FlexPendant.
Safety
Safety standards valid for complete robot, manipulator and controller.
© Copyright 2004-2010 ABB. All rights reserved.
Additional functionality
For additional functionality, the robot can be equipped with optional software for application
support - for example gluing and welding, communication features - network communication
- and advanced functions such as multitasking, sensor control etc. For a complete description
on optional software, see the Product specification - Controller software IRC5.
Foundry Plus 2
The Foundry Plus option is designed for harsh environments where the robot is exposed to
sprays of coolants, lubricants and metal spits that are typical for die casting applications or
other similar applications. Typical applications are spraying insertion and part extraction of
die-casting machines, cast cleaning, handling in sand casting and gravity casting, etc. (Please
refer to Foundry Prime for washing applications or other similar applications). Special care
must be taken in regard to operational and maintenance requirements for applications in
foundry are as well as in other applications areas. Please contact ABB Robotics Sales
organization if in doubt regarding specific application feasibility for the Foundry Plus
protected robot. The Foundry Plus robot is painted with two-component epoxy on top of a
primer for corrosion protection. To further improve the corrosion protection additional rust
preventive are applied to exposed and crucial areas, e.g. has the tool flange a special
preventive coating. Although, continuous splashing of water or other similar rust formation
Continues on next page
3HAC023604-001 Revision: M
7
1 Description
1.1.1. Introduction
Continued
fluids may case rust attach on the robots unpainted areas, joints, or other unprotected surfaces.
Under these circumstances it is recommended to add rust inhibitor to the fluid or take other
measures to prevent potential rust formation on the mentioned. The entire robot is IP67
compliant according to IEC 60529 - from base to wrist, which means that the electrical
compartments are sealed against liquid and solid contaminants. Among other things all
sensitive parts are better protected than the standard offer.
Selected Foundry Plus/Foundry Plus 2 features:
•
Improved sealing to prevent penetration into cavities to secure IP67
•
Additional protection of cabling and electronics
•
Special covers protecting cavities
•
Well-proven connectors
•
Nickel coated tool flange (Foundry Plus 2)
•
Rust preventives on screws, washers and unpainted/machined surfaces
The Foundry Plus robot can be cleaned with appropriate washing equipment according to
product manual. Appropriate cleaning and maintenance are required to maintain the Foundry
Plus 2 protection, for example can rust preventive be washed off with wrong cleaning
method.
xx1000000891
8
Pos
Description
Pos
Description
A
Axis 1
B
Axis 2
C
Axis 3
D
Axis 4
E
Axis 5
F
Axis 6
3HAC023604-001 Revision: M
© Copyright 2004-2010 ABB. All rights reserved.
Manipulator axes
1 Description
1.1.2. Different robot versions
1.1.2. Different robot versions
General
The IRB 1600 is available in five versions and four of them can be mounted on the floor, wall,
tilted (up to 60 degrees around the Y-axis) or inverted. See Robot Motion on page 38 for
limitations.
The IRB 1600ID-4/1.5 can only be mounted on the floor or inverted.
Robot type
Handling capacity (kg)
Reach (m)
IRB 1600
6 kg
1.2 m
IRB 1600
6 kg
1.45 m
IRB 1600
8 kg
1.2 m
IRB 1600
8 kg
1.45 m
IRB 1600ID
4 kg
1.5 m
Robot
Weight
IRB 1600-X/1.2
250 kg
IRB 1600-X/1.45
250 kg
IRB 1600ID-4/1.5
250 kg
Data
Description
Note
Airborne noise level
The sound pressure level
outside the working space
< 70 dB (A) Leq (acc. to
Machinery directive 89/392
EEC)
Manipulator weight
© Copyright 2004-2010 ABB. All rights reserved.
Other technical data
Power consumption
Path E1-E2-E3-E4 in the ISO Cube, max.load.
Power consumption (kW)
Speed (mm/s)
IRB 1600-x/1.2
IRB 1600(ID)-x/1.45(1.5)
Max.
0.58
0.57
1000
0.49
0.50
500
0.45
0.45
100
0.41
0.43
Continues on next page
3HAC023604-001 Revision: M
9
1 Description
1.1.2. Different robot versions
Continued
xx1000000101
Description
A
400
© Copyright 2004-2010 ABB. All rights reserved.
Pos
Continues on next page
10
3HAC023604-001 Revision: M
1 Description
1.1.2. Different robot versions
Continued
© Copyright 2004-2010 ABB. All rights reserved.
Dimensions IRB 1600-X/1.2 (1.45)
xx1000000972
Pos
Description
A
R335 Minimum turning radius
Continues on next page
3HAC023604-001 Revision: M
11
1 Description
1.1.2. Different robot versions
Continued
Dimensions IRB 1600ID-4/1.5
252.5
160
1022.5
AK
640
200
11 0
214.5
48
°
4 8 6 .5
19
)
1
1392
1 12 (3x Ø7
10
700
AK
242
(150)
242
278
CL Axi s
648
AI
AI
(63)
(A)
xx1000000893
12
Pos
Description
A
R335 Minimum turning radius
3HAC023604-001 Revision: M
© Copyright 2004-2010 ABB. All rights reserved.
3 3 .5
126
CL Axi s
1 Description
1.2.1. Standards
1.2 Standards
1.2.1. Standards
Standards, EN ISO
The manipulator system is designed in accordance with the requirements of:
Standard
Description
EN ISO 12100 -1
Safety of machinery - Basic concepts, general principles for
design - Part 1: Basic terminology, methodology
EN ISO 12100 -2
Safety of machinery - Basic concepts, general principles for
design - Part 2: Technical principles
EN ISO 13849-1
Safety of machinery, safety related parts of control systems Part 1: General principles for design
EN ISO 13850
Safety of machinery - Emergency stop - Principles for design
EN ISO 10218-1
1
EN ISO 9787
Manipulating industrial robots, Coordinate systems and motion
nomenclatures
EN ISO 9283
Manipulating industrial robots, Performance criteria and related
test methods
EN ISO 14644-12
Classification of air cleanliness
EN ISO 13732-1
Ergonomics of the thermal environment - Part 1
EN IEC 61000-6-4 (option
129-1)
EMC, Generic emission
EN IEC 61000-6-2
EMC, Generic immunity
EN IEC 60974-1
3
EN IEC 60974-10
© Copyright 2004-2010 ABB. All rights reserved.
Robots for industrial environments - Safety requirements -Part 1
Robot
Arc welding equipment - Part 1: Welding power sources
3
Arc welding equipment - Part 10: EMC requirements
EN IEC 60204-1
Safety of machinery - Electrical equipment of machines - Part 1
General requirements
IEC 60529
Degrees of protection provided by enclosures (IP code)
1. There is a deviation from paragraph 6.2 in that only worst case stop distances and stop
times are documented.
2. Only robots with Protection Clean Room.
3. Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.
European standards
Standard
Description
EN 614-1
Safety of machinery - Ergonomic design principles - Part 1:
Terminology and general principles
EN 574
Safety of machinery - Two-hand control devices - Functional
aspects - Principles for design
EN 953
Safety of machinery - General requirements for the design and
construction of fixed and movable guards
Continues on next page
3HAC023604-001 Revision: M
13
1 Description
1.2.1. Standards
Continued
Other standards
StandardStandard
DescriptionDescription
ANSI/RIA R15.06ANSI/
RIA R15.06
Safety Requirements for Industrial Robots and Robot SystemsSafety Requirements for Industrial Robots and Robot
Systems
ANSI/UL 1740(option 429- Safety Standard for Robots and Robotic Equipment
1)
© Copyright 2004-2010 ABB. All rights reserved.
CAN/CSA Z 434-03(option Industrial Robots and Robot Systems - General Safety Require429-1)
ments
14
3HAC023604-001 Revision: M
1 Description
1.3.1. Introduction
1.3 Installation
1.3.1. Introduction
General
IRB 1600 can be mounted on the floor, wall, tilted (up to 60 degrees around the Y-axis) or
inverted. See Robot Motion on page 38 for limitations.
IRB 1600ID-4/1.5 can only be mounted on the floor or inverted. An end effector with max.
weight of 6 kg or 8 kg including payload, can be mounted on the tool flange (axis 6), 4 kg
valid for the IRB 1600ID-4/1.5 robot. See Load diagrams on page 25.
Extra equipment can be mounted on to the hip and on the upper arm. See Mounting of
equipment on page 33.
Extra Loads
Extra load, which is included in the load diagrams, can be mounted on the upper arm. No
extra arm load is included in the load diagram for IRB 1600ID-4/1.5. An extra load of 15 kg
can also be mounted on the frame of axis 1. See Mounting hole for equipment on page 35.
Working Range
© Copyright 2004-2010 ABB. All rights reserved.
The working range of axes 1-3 can be limited by mechanical stops. Electronic Position
Switches can be used on all axes for position indication of the manipulator.
3HAC023604-001 Revision: M
15
1 Description
1.3.2. Operating requirements
1.3.2. Operating requirements
Protection Standards
Robot version
Protection Standard IEC60529
Standard manipulator
IP 54
Protection Foundry Plus 2
IP 67
IRB 1600ID-4/1.5
IP 40
Explosive Environments
The robot must not be located or operated in an explosive environment.
Ambient Temprature
Description
Standard/Option
Temperature
Manipulator during
operation
Standard
+ 5°C (+ 41°F) to + 45°C (+ 113°F)
For the controller
Standard/Option
See Product specification - Controller
IRC5 with FlexPendant
Complete robot (incl.
controller) during transportation and storage
Standard
- 25°C (- 13°F) to + 55°C (+ 131°F)
For short periods not > 24 hours: +
70°C (+ 158°F)
Relative Humidity
Description
Relative humidity
© Copyright 2004-2010 ABB. All rights reserved.
Complete robot during operation, transportation and Max. 95% at constant temperature
storage
16
3HAC023604-001 Revision: M
1 Description
1.3.3. Mounting the manipulator
1.3.3. Mounting the manipulator
General
Maximum load in relation to the base coordination system. See Figure on next page.
Endurance load
in operation
Max. load at
Emergency stop
Force XY
Floor mounted
Suspended
Wall mounted
Tilted ± 30º
± 1650 N
± 1650 N
± 3900 N
± 2500 N
± 3150 N
± 3150 N
± 5300 N
± 6000 N
Force Z
Floor mounted
Suspended
Wall mounted
Tilted ± 30º
- 2500 ± 1150 N
+ 2500 ± 1150 N
± 1300 N
+ 2100 ± 1600 N
- 2500 ± 2200 N
+ 2500 ± 2200 N
± 2400 N
+ 2100 ± 3000 N
Torque XY
Floor, suspended
± 1700 Nm
± 3750 Nm
Torque Z
Floor, suspended
± 855 Nm
± 1400 Nm
Torque XY
Wall mounted
± 2310 Nm
± 3850 Nm
Torque Z
Wall mounted
± 855 Nm
± 1430 Nm
© Copyright 2004-2010 ABB. All rights reserved.
Mounting
xx1000000894
Continues on next page
3HAC023604-001 Revision: M
17
1 Description
1.3.3. Mounting the manipulator
Continued
Note regarding Mxy and Fxy
The bending torque (Mxy) can occur in any direction in the XY-plane of the base coordinate
system.
The same applies to the transverse force (Fxy).
xx1000000895
Attachment bolts, specification
The table below specifies required bolts and washers for securing the robot at installation site.
Specification
Description
Attachment bolts, 3 pcs
M16 x 60 (installation directly on foundation)
M16 x 70/80 (installation on foundation or
base plate, using guiding sleeves)
Continues on next page
18
3HAC023604-001 Revision: M
© Copyright 2004-2010 ABB. All rights reserved.
Fastening holes Robot base
1 Description
1.3.3. Mounting the manipulator
Continued
Specification
Description
Washers, 3 pcs
17 x 30 x 3
Quality
Quality 8.8, wall mounted quality 12.9
Tightening torque
200 Nm
NOTE!
Note: For wall mounted robot, two guide bushings according to Figure below are needed.
© Copyright 2004-2010 ABB. All rights reserved.
Regarding Abs.Acc. performance, the chosen guide holes according to Figure in the
beginning of this chapter are recommended.
Continues on next page
3HAC023604-001 Revision: M
19
1 Description
1.3.3. Mounting the manipulator
Continued
xx1000000896
20
Pos
Description
A
Surface treatment, ISO 2081 Fe/Zn 8 c2, Guide bushing
B
View D
C
3x common zone
3HAC023604-001 Revision: M
© Copyright 2004-2010 ABB. All rights reserved.
Mounting surface and bushings
1 Description
1.4.1. Fine calibration
1.4 Calibration and References
1.4.1. Fine calibration
General
Fine calibration is made using the Calibration Pendulum, please see Operating manual Calibration Pendulum
© Copyright 2004-2010 ABB. All rights reserved.
xx1000000891
Pos
Description
Pos
Description
A
Axis 1
B
Axis 2
C
Axis 3
D
Axis 4
E
Axis 5
F
Axis 6
Calibration
Calibration
Position
Calibration of all axes
All axes are in zero position
Calibration of axis 1 and 2
Axis 1 and 2 in zero position
Axis 3 to 6 in any position
Calibration of axis 1
Axis 1 in zero position
Axis 2 to 6 in any position
3HAC023604-001 Revision: M
21
1 Description
1.4.2. Absolute Accuracy calibration
1.4.2. Absolute Accuracy calibration
General
Requires RobotWare option Absolute Accuracy, please see Product specification - Controller
software IRC5/RobotWare Options for more details.
The calibration concept
Absolute Accuracy (AbsAcc) is a calibration concept, which ensures a TCP absolute
accuracy of better than ± 1 mm in the entire working range (working range of bending
backward robots, for example IRB 1600, are limited to only forward positions).
Absolute accuracy compensates for:
•
Mechanical tolerances in the robot structure
•
Deflection due to load
Absolute accuracy calibration is focusing on positioning accuracy in the cartesian coordinate
system for the robot. It also includes load compensation for deflection caused by the tool and
equipment. Tool data from robot program is used for this purpose. The positioning will be
within specified performance regardless of load.
Calibration data
The user is supplied with robot calibration data (compensation parameters saved on the
manipulator SMB) and a certificate that shows the performance (Birth certificate). The
difference between an ideal robot and a real robot without AbsAcc can typically be 8 mm,
resulting from mechanical tolerances and deflection in the robot structure.
© Copyright 2004-2010 ABB. All rights reserved.
If there is a difference, at first start-up, between calibration data in controller and the robot
SMB, correct by copying data from SMB to controller.
Continues on next page
22
3HAC023604-001 Revision: M
1 Description
1.4.2. Absolute Accuracy calibration
Continued
Absolute Accuracy option
Absolute Accuracy option is integrated in the controller algorithms for compensation of this
difference and does not need external equipment or calculation.
Absolute Accuracy is a RobotWare option and includes an individual calibration of the robot
(mechanical arm).
Absolute Accuracy is a TCP calibration in order to Reach (m) a good positioning in the
Cartesian coordinate system.
xx1000000897
Production data
Typical production data regarding calibration are:
Positioning accuracy (mm)
© Copyright 2004-2010 ABB. All rights reserved.
Robot
Average
Max
% Within 1 mm
IRB 1600-6/1.2
-6/1.45
-8/1.2
-8/1.45
0.30
0.65
100
IRB 1600ID-4/1.5
0.35
0.65
100
3HAC023604-001 Revision: M
23
1 Description
1.5.1. Introduction
1.5 Robot load and Load diagrams
1.5.1. Introduction
Information
WARNING!
It is very important to always define correct actual load data and correct payload of the robot.
Incorrect definitions of load data can result in overloading of the robot.
If incorrect load data and/or loads are outside load diagram is used the following parts can be
damaged due to overload:
•
motors
•
gearboxes
•
mechanical structure
WARNING!
In the robot system is the service routine LoadIdentify available, which allows the user to
make an automatic definition of the tool and load, to determine correct load parameters.
Please see Operating Manual - IRC5 with FlexPendant, art. No. 3HAC16590-1, for detailed
information.
WARNING!
Robots running with incorrect load data and/or with loads outside diagram, will not be
covered by robot warranty.
General
At different arm load and moment of inertia the load diagram will be changed.
Control of load case by “RobotLoad”
For an easy check of a specific load case, use the calculation program ABB RobotLoad.
Please contact your local ABB organization.
24
3HAC023604-001 Revision: M
© Copyright 2004-2010 ABB. All rights reserved.
The load diagrams include a nominal pay load inertia, J0 of 0.012 kgm2, and an extra load of
15 kg for the IRB 1600-6/x variants and IRB 1600ID-4/1.5 (hose package included), 5 kg for
the IRB 1600-8/x variants , at the upper arm housing.
1 Description
1.5.2. Load diagrams
1.5.2. Load diagrams
© Copyright 2004-2010 ABB. All rights reserved.
IRB 1600-6/1.2, IRB 1600-6/1.45
xx1000000899
Extra load of 15 kg at the upper arm housing included in the load diagram.
Continues on next page
3HAC023604-001 Revision: M
25
1 Description
1.5.2. Load diagrams
Continued
xx1000000901
Extra load of 15 kg at the upper arm housing included in the load diagram.
Description
Values
For wrist down (0° deviation from the vertical line)
and no arm loads.
Max load = 13 kg
ZMax = 0.057 m
LMax = 0.031 m
Continues on next page
26
3HAC023604-001 Revision: M
© Copyright 2004-2010 ABB. All rights reserved.
IRB 1600-6/1.2, IRB 1600-6/1.45 “Vertical Wrist” (±10º)
1 Description
1.5.2. Load diagrams
Continued
IRB 1600-8/1.2, IRB 1600-8/1.45
xx1000000900
© Copyright 2004-2010 ABB. All rights reserved.
Extra load of 5 kg at the upper arm housing included in the load diagram.
Continues on next page
3HAC023604-001 Revision: M
27
1 Description
1.5.2. Load diagrams
Continued
xx1000000902
Extra load of 5 kg at the upper arm housing included in the load diagram.
Description
Values
For wrist down (0° deviation from the vertical line)
and no arm loads.
Max load = 12 kg
ZMax = 0.055 m
LMax = 0.017 m
Continues on next page
28
3HAC023604-001 Revision: M
© Copyright 2004-2010 ABB. All rights reserved.
IRB 1600-8/1.2, IRB 1600-8/1.45 “Vertical Wrist” (±10º)
1 Description
1.5.2. Load diagrams
Continued
© Copyright 2004-2010 ABB. All rights reserved.
IRB 1600ID-4/1.5
xx1000000898
Extra load of 15 kg (hose package included) at the upper arm housing included in the load
diagram.
3HAC023604-001 Revision: M
29
1 Description
1.5.3. Maximum load and moment of inertia for full and limited axis 5 (center line down) movement
1.5.3. Maximum load and moment of inertia for full and limited axis 5 (center line
down) movement
General
Total load given as: Mass in kg, center of gravity (Z and L) in m and moment of inertia (Jox,
Joy, Jox) in kgm2. L= ÷(X2 + Y2), see Figure below.
Full movement of Axis 5 (±115º)
Axis Robot Type
Max. value
5
IRB 1600-6/x
J5 = Mass x ((Z + 0.065)2 + L2) + max (Jox, Joy)  0.42 kgm2
6
IRB 1600-6/x
J6= Mass x L2 + J0Z  0.30 kgm2
Axis Robot Type
Max. value
5
IRB 1600-8/x
J5 = Mass x ((Z + 0.065)2 + L2) + max (Jox, Joy)  0.53 kgm2
6
IRB 1600-8/x
J6= Mass x L2 + J0Z  0.39 kgm2
Full movement of Axis 5 (+155º to -90º)
Max. value
5
IRB 1600ID-4/1.5 J5 = Mass x ((Z + 0.2002 + L2) + max (Jox, Joy)  0.58 kgm2
6
IRB 1600ID-4/1.5 J6= Mass x L2 + J0Z  0.24 kgm2
xx1000000903
Pos
Description
A
Center of gravity
Description
Jox, Joy, J0Z
Max. moment of inertia around the X, Y and Z axes at center of gravity.
Limited axis 5, Center line down
Axis Robot Type
Max. value
5
IRB 1600-6/x
J5 = Mass x ((Z + 0.065)2 + L2) + max (Jox, Joy)  0.55 kgm2
5
IRB 1600-8/x
J5 = Mass x ((Z + 0.065)2 + L2) + max (Jox, Joy)  0.65 kgm2
6
IRB 1600-6/x
J6= Mass x L2 + J0Z  0.40 kgm2
6
IRB 1600-8/x
J6= Mass x L2 + J0Z  0.48 kgm2
Continues on next page
30
3HAC023604-001 Revision: M
© Copyright 2004-2010 ABB. All rights reserved.
Axis Robot Type
1 Description
1.5.3. Maximum load and moment of inertia for full and limited axis 5 (center line down) movement
Continued
xx1000000904
Pos
Description
A
Center of gravity
Description
Max. moment of inertia around the X, Y and Z axes at center of gravity.
© Copyright 2004-2010 ABB. All rights reserved.
Jox, Joy, Joz
3HAC023604-001 Revision: M
31
1 Description
1.5.4. Wrist torque
1.5.4. Wrist torque
General
The table below shows the maximum permissible torque due to payload.
NOTE!
Note! The values are for reference only, and should not be used for calculating permitted load
offset (position of center of gravity) within the load diagram, since those also are limited by
main axes torques as well as dynamic loads. Also arm loads will influence the permitted load
diagram. For finding the absolute limits of the load diagram, please use the ABB RobotLoad.
Please contact your local ABB organization.
Max wrist torque Max wrist torque Max torque valid
axis 4 and 5
axis 6
at load
IRB 1600-6/1.2(1.45)
8.58 Nm
4.91 Nm
5 kg
IRB 1600-81.2(1.45)
11.25 Nm
6.43 Nm
6.5 kg
RB 1600ID-4/1.5
12.16 Nm
3.92 Nm
4 kg
© Copyright 2004-2010 ABB. All rights reserved.
Robot type
32
3HAC023604-001 Revision: M
1 Description
1.5.5. Mounting of equipment
1.5.5. Mounting of equipment
General
© Copyright 2004-2010 ABB. All rights reserved.
Extra loads can be mounted on the wrist, the upper arm housing and on the frame. Definitions
of load areas and permitted load are shown in Figure below. The center of gravity of the extra
load shall be within the marked load areas. The robot is supplied with holes for mounting of
extra equipment. (See Figure on next page).
xx1000000905
Max. load
Load areaRobot
A
B
A+B
C
D
E
IRB 1600-6/X
15 kg
5 kg
15 kg
0.5 kg
15 kg
-
IRB 1600-8/X
5 kg
5 kg
5 kg
0.5 kg
15 kg
-
IRB 1600ID-4/1.5
-
-
-
-
15 kg
15 kg
Continues on next page
3HAC023604-001 Revision: M
33
1 Description
1.5.5. Mounting of equipment
Continued
Holes for mounting of extra equipment
xx1000000906
© Copyright 2004-2010 ABB. All rights reserved.
Design until June 2006
xx1000000907
Design after June 2006, Type A
xx1000000908
Continues on next page
34
3HAC023604-001 Revision: M
1 Description
1.5.5. Mounting of equipment
Continued
Design IRB 1600ID-4/1.5
xx1000000909
Mounting hole for equipment
© Copyright 2004-2010 ABB. All rights reserved.
xx1000000910
Pos
Description
A
View E
B
Design until June 2006: 2x M5 depth 7.5, Mounting holes for equipment
Design after June 2006, Type A: 2x M6 depth 10, Mounting holes for
equipment
C
3x M8 depth 12, Mounting holes for equipment
D
R175, Axis 3 turning radius
E
3 x M8 depth 16, Mounting hole for equipment
F
From center line axis 2
G
From center line axis 4
NOTE!
Note! When mounting heavier equipment, e.g. wire feeders, in holes (C) must the bracket be
support in the opposite holes (E).
Continues on next page
3HAC023604-001 Revision: M
35
1 Description
1.5.5. Mounting of equipment
Continued
© Copyright 2004-2010 ABB. All rights reserved.
Holes for mounting of extra equipment for IRB 1600ID-4/1.5
xx1000000911
Pos
Description
A
R198, Axis 3 turning radius
B
2x M8 depth 16, Mounting holes for equipment
C
2x M8, Mounting holes for equipment
Continues on next page
36
3HAC023604-001 Revision: M
1 Description
1.5.5. Mounting of equipment
Continued
Robot tool flange
xx1000000912
Robot tool flange for IRB 1600ID-4/1.5
© Copyright 2004-2010 ABB. All rights reserved.
xx1000000913
3HAC023604-001 Revision: M
37
1 Description
1.6.1. Introduction
1.6 Robot Motion
1.6.1. Introduction
IRB 1600-X/1.2 and 1.45
Axis
Type of motion
Range of movement 1.2 Range of movement
m reach
1.45 m reach
1
Rotation motion
+180° to -180° a
+180° to -180° a
2
Arm motion
+110° to -63°
+136° to -63°
with Axis 1 limited to ±100°
+120° to -90°
+150° to -90°
with Axis 1 limited to ±95°
3
Arm motion
+55° to -235°
+65° to -245°
4
Rotation motion
+200° to -200° Default
+200° to -200° Default
+190 rev.b to -190 rev. Max.c +190 rev.b to -190 rev. Max.c
5
Bend motion
+115° to -115°
6
Turn motion
+400° to -400° default
+400° to -400° default
+288 rev.b to -288 rev. Max.c +288 rev.b to -288 rev. Max.c
+115° to -115°
a. In wall mounted position the axis 1 working range has the following limitations:
IRB 1600-6/X the axis 1 limit is ± 20°
IRB 1600-8/X the limit axis 1 is ± 60°
The following axis 1 and tilt angle combinations are allowed:
IRB 1600-6/x axis 1 ± 45° with tilt angles up to 30°
IRB 1600-8/x axis 1 ± 180° with tilt angles up to 60°
b. rev. = Revolutions
Option 610-1 “Independent axis” can be used for resetting the revolution counter after the
axis has been rotated (no need for “rewinding” the axis).
IRB 1600ID-4/1.5
Axis
Type of motion
Range of movement
1
Rotation motion
+180° to -180°
2
Arm motion
+150° to -90°
3
Arm motion
+79° to -238°
4
Rotation motion
+155° to -155°
5
Bend motion
+135° to -90°
6
Turn motion
+200° to -200°
Continues on next page
38
3HAC023604-001 Revision: M
© Copyright 2004-2010 ABB. All rights reserved.
c. The default working range for axis 4 and axis 6 can be extended by changing parameter
values in the software.
1 Description
1.6.1. Introduction
Continued
xx1000000914
© Copyright 2004-2010 ABB. All rights reserved.
Positions at wrist center 1.2 m reach
Pos No. see X Position
Figure above (mm)
Z Position
(mm)
Axis 2 Angle
(degrees)
Axis 3 Angle
(degrees)
0
750
962
0
0
1
150
1562
0
-90
2
494
470
0
+55
3
1225
487
+90
-90
4
897
-287
+136
-90
5
386
737
+136
-235
6
321
786
-63
+55
7
-808
975
-63
-90
Continues on next page
3HAC023604-001 Revision: M
39
1 Description
1.6.1. Introduction
Continued
xx1000000915
Pos No. see X Position
Figure above (mm)
Z Position
(mm)
Axis 2 Angle
(degrees)
Axis 3 Angle
(degrees)
0
750
1187
0
0
1
150
1787
0
-90
2
404
643
0
+65
3
1450
487
+90
-90
4
800
-639
+150
-90
5
448
478
+150
-245
6
-6
740
-90
+65
7
-1150
487
-90
-90
Continues on next page
40
3HAC023604-001 Revision: M
© Copyright 2004-2010 ABB. All rights reserved.
Positions at wrist center 1.45 m reach
1 Description
1.6.1. Introduction
Continued
xx1000000916
© Copyright 2004-2010 ABB. All rights reserved.
Positions at wrist center IRB 1600ID-4/1.5
Pos No. see X Position
Figure above (mm)
Z Position
(mm)
Axis 2 Angle
(degrees)
Axis 3 Angle
(degrees)
0
790
1297
0
0
1
150
1836
0
-80
2
380
579
0
+79
3
1500
487
+90
-80
4
721
-737
+150
-80
5
398
500
+150
-238
6
58
717
-90
+79
7
-1200
487
-90
-80
3HAC023604-001 Revision: M
41
1 Description
1.6.2. Performance according to ISO 9283
1.6.2. Performance according to ISO 9283
General
At rated maximum load, maximum offset and 1.6 m/s velocity on the inclined ISO test plane,
with all six axes in motion
The figures for AP, RP, AT and RT are measured according to figure below.
xx0800000424
Pos
Description
Pos
Description
A
Programmed position
E
Programmed path
B
Mean position at program
execution
D
Actual path at program execution
AP
Mean distance from
programmed position
AT
Max deviation from E
RP
Tolerance of position B at
repeated positioning
RT
Tolerance of the path at repeated
program execution
IRB
1600ID
IRB 1600
-6/1.2
-6/1.45
-8/1.2
-8/1.45
ID-4/1.5
0.02
0.02
0.04
0.05
0.02
Pose accuracy, AP (mm)
0.04
0.04
0.04
0.05
0.04
Linear path repeatability, RT
(mm)
0.13
0.19
0.14
0.12
0.48b
Linear path accuracy, AT
(mm)
0.97
1.03
0.96
0.42
1.98
Pose stabilization time, (PSt) 0.11
to within 0.2 mm of the
position (s)
0.11
0.20
0.04
0.35
Pose repeatability, RP (mm)
a
a. AP according to the ISO test above, is the difference between the teached position (position
manually modified in the cell) and the average position obtained during program execution.
b. Measured at a velocity of 100 mm/s.
The above values are the range of average test results from a number of robots.
42
3HAC023604-001 Revision: M
© Copyright 2004-2010 ABB. All rights reserved.
Description
1 Description
1.6.3. Velocity
1.6.3. Velocity
Maximum axis speeds
Axis No.
IRB 1600-6/1.2 IRB
1600-6/1.45
IRB 1600-8/1.2 IRB
IRB 1600ID-4/1.5
1600-8/1.45
1
150°/s
180°/s
180°/s
2
160°/s
180°/s
180°/s
3
170°/s
200°/s
180°/s
4
320°/s
400°/s
320°/s
5
400°/s
400°/s
380°/s
6
460°/s
460°/s
460°/s
Axis Resolution
© Copyright 2004-2010 ABB. All rights reserved.
Approx. 0.01º on each axis.
3HAC023604-001 Revision: M
43
1 Description
1.6.4. Stopping distance/time
1.6.4. Stopping distance/time
General
Stopping distance/time for emergency stop (category 0), program stop (category 1) and at
mains power supply failure at max speed, max stretched out and max load, categories
according to EN 60204-1. All results are from tests on one moving axis. All stop distances
are valid for floor mounted robot, without any tilting.
Category 0
Category 1
Main power failure
A
B
A
B
A
B
IRB 1600-6/1.2 (1.45) 1
IRB 1600-8/1.2 (1.45) 2
25
0.2
45
0.4
31
n.a.
23.
0.2
32
0.3
30
n.a.
3
14
0.2
25
0.2
18
n.a.
1
23
0.2
47
0.5
29
n.a.
2
24
0.3
34
0.4
27
n.a.
3
17
0.2
32
0.3
24
n.a.
Robot Type
Axis
IRB 1600ID-4/1.5
Description
Distance in degrees
B
Stop time (s)
© Copyright 2004-2010 ABB. All rights reserved.
A
44
3HAC023604-001 Revision: M
1 Description
1.7.1. Introduction
1.7 Typical cycle times
1.7.1. Introduction
General
xx1000000917
Approx. cycle times
Pay load at wrist down
IRB 1600-6/x
IRB 1600-8/x
7 kg
10 kg
1.01 s
© Copyright 2004-2010 ABB. All rights reserved.
Cycle time Packer cycle 0.95 s
3HAC023604-001 Revision: M
45
1 Description
1.8.1. Introduction
1.8 Customer connections
1.8.1. Introduction
General
Customer connections are options, the cables for them are integrated in the robot and the
connectors are placed on the upper arm housing.
The customer connections are:
•
The Standard connections for Signals, Power and Air.
•
The Integrated wire feed cabling for Signals and Power.
•
The 7-Axis connection.
For the specification of the customer connection, see chapter 1 Specification of Variants and
Options, Application interface Connection type.
NOTE!
Note: No customer/application connections available for IRB 1600ID-4/1.5.
Connections at robot base
© Copyright 2004-2010 ABB. All rights reserved.
Figures below show the customer connections at the robot base. For description of all
connection types see table below Figure on next page.
xx1000000918
xx1000000919
Continues on next page
46
3HAC023604-001 Revision: M
1 Description
1.8.1. Introduction
Continued
xx1000000920
© Copyright 2004-2010 ABB. All rights reserved.
xx1000000921
Pos
Connection type Description
A
R1.MP
Motor power
B
R1.SMB
Serial measurement board signal
C
-
Robot axes brake release buttons
D
R.1 CP/CS
Standard Customer Power and Customer Signal
E
R.1Air
Standard Air
F
R1.CS
Customer Signal for Integrated wirefeed interface
G
R1.CP
Customer Power for Integrated wirefeed interface
H
R1.FB7
Axis 7 connection, 1.5 m cable
Continues on next page
3HAC023604-001 Revision: M
47
1 Description
1.8.1. Introduction
Continued
Connections at upper arm
48
Pos
Connection type Description
A
R3.CP
Standard Customer Power
B
R3.CS
Standard Customer Signal
C
R3.Air
Standard Air
D
R3.CP
Customer Power for Integrated wirefeed interface
E
R3.CS
Customer Signal for Integrated wirefeed interface
3HAC023604-001 Revision: M
© Copyright 2004-2010 ABB. All rights reserved.
xx1000000922
1 Description
1.9.1. Introduction
1.9 Maintenance and Troubleshooting
1.9.1. Introduction
General
The robot requires only a minimum maintenance during operation. It is designed to make it
as easy to service as possible:
•
Maintenance-free AC motors are used.
•
Oil and grease are used for the gear boxes.
•
The cabling is routed for longevity, and in the unlikely event of a failure, its modular
design makes it easy to change.
•
It has a progam memory “battery low” alarm.
Maintenance
© Copyright 2004-2010 ABB. All rights reserved.
The maintenance intervals depend on the use of the robot, the required maintenance activities
also depends on selected options. For detailed information on maintenance procedures, see
Product manual - IRB 1600.
3HAC023604-001 Revision: M
49
1 Description
© Copyright 2004-2010 ABB. All rights reserved.
1.9.1. Introduction
50
3HAC023604-001 Revision: M
2 Specification of Variants and Options
2.1.1. General
2 Specification of Variants and Options
2.1 Introduction
2.1.1. General
Introduction
The different variants and options for the IRB 1600 are described below. The same numbers
are used here as in the Specification Form.
For controller options, see Product specification - Controller software IRC5 and
© Copyright 2004-2010 ABB. All rights reserved.
Product specification - Controller IRC5 with FlexPendant
3HAC023604-001 Revision: M
51
2 Specification of Variants and Options
2.1.2. Manipulator
2.1.2. Manipulator
Variants
Option
IRB Type
Handling capacity (kg)/Reach (m)
435-79
1600ID
4/1.5
435-89
1600
8/1.2
435-90
1600
8/1.45
435-91
1600
6/1.2
435-92
1600
6/1.45
Option
Name
Description
209-1
ABB Standard
The robot is painted in color ABB Orange.
209-2
ABB White
The robot is painted in white color.
209-4--192
RAL code
The manipulator is painted with the chosen RAL-color.
Option
Name
Description
287-4
Standard
IP 54, IP 40 for IRB 1600ID-4/1.5
Manipulator color
© Copyright 2004-2010 ABB. All rights reserved.
Protection
Continues on next page
52
3HAC023604-001 Revision: M
2 Specification of Variants and Options
2.1.2. Manipulator
© Copyright 2004-2010 ABB. All rights reserved.
Continued
Option
Name
Description
287-3
Foundry Plus
The Foundry Plus option is designed for harsh environments
where the robot is exposed to sprays of coolants, lubricants
and metal spits that are typical for die casting applications or
other similar applications. Typical applications are spraying
insertion and part extraction of die-casting machines, cast
cleaning, handling in sand casting and gravity casting, etc.
(Please refer to Foundry Prime for washing applications or
other similar applications). Special care must be taken in
regard to operational and maintenance requirements for
applications in foundry are as well as in other applications
areas. Please contact ABB Robotics Sales organization if in
doubt regarding specific application feasibility for the
Foundry Plus robot. The Foundry Plus robot is painted with
two-component epoxy on top of a primer for corrosion
protection. To further improve the corrosion protection
additional rust preventive are applied to exposed and crucial
areas, e.g. has the tool flange a special preventive coating.
Although, continuous splashing of water or other similar rust
formation fluids may case rust attach on the robots
unpainted areas, joints, or other unprotected surfaces.
Under these circumstances it is recommended to add rust
inhibitor to the fluid or take other measures to prevent
potential rust formation on the mentioned.The entire robot is
IP67 compliant according to IEC 60529 - from base to wrist,
which means that the electrical compartments are sealed
against liquid and solid contaminants. Among other things
all sensitive parts are better protected than the standard
offer.
Selected Foundry Plus/Foundry Plus 2 features:
• Improved sealing to prevent penetration into cavities
to secure IP67
• Additional protection of cabling and electronics
• Special covers protecting cavities
• Well-proven connectors
• Rust preventives on screws, washers and unpainted/
machined surfaces
• Extended service and maintenance program
Selected Foundry Plus/Foundry Plus 2 features:The
Foundry Plus 2 robot can be cleaned with appropriate
washing equipment.Not valid for IRB 1600ID-4/1.5.
Application interface Connected to
Option
Name
Description
16-1
Cabineta
The signals are connected to 12-pole screw terminals,
Phoenix MSTB 2.5/12-ST-5.08, to the Control Module. Not
together with option 17-6 Integrated wire feed cabling.
Not valid for IRB 1600ID-4/1.5.
a. Note! In a MultiMove application, additional robots have no Control Module. The screw
terminal with internal cabling are then delivered separately to be mounted in the main robot
Control Module or in another encapsulation, for example a PLC cabinet.
Continues on next page
3HAC023604-001 Revision: M
53
2 Specification of Variants and Options
2.1.2. Manipulator
Continued
Application interface Connection type
Option
Name
Description
17-5a
Standard
One Souriau UTOW6 1210 P-H
One Souriau UTOW6 1626 P-H
Signals 23
Power 10
Air 1
17-7
No
application
interface
50 V, 250 mA
250 V, 2 A
Max. 8 bar, hose inner diameter
8 mm. R 1/4“ at base and upper
arm.
a. Not valid for IRB 1600ID-4/1.5.
Connector kit upper arm
The kit consists of connetor, pins and sockets, fitting connectors in option 17-5.
Option
Name
Description
431-1
Upper arm
Customer Power (CP) and Customer Signals (CS).
Option
Name
Description
213-1
Safety lamp
It has an orange fixed light, is active in MOTORS ON mode
and is std. on an UL/UR approved robot.
Safety lamp
Electronic Position Switches (EPS)
The mechanical position switches indicating the position of the three main axes are replaced
with electronic position switches for up to 7 axes, for increased flexibility and robustness.
© Copyright 2004-2010 ABB. All rights reserved.
For more detailed information, see Product specification - Controller IRC5 with FlexPendant
and Application manual - Electronic Position Switches, art. No. 3HAC027709-001.
Continues on next page
54
3HAC023604-001 Revision: M
2 Specification of Variants and Options
2.1.2. Manipulator
Continued
Working range limit
To increase the safety of the robot, the working range of axis 1, 2 and 3 can be restricted.
Option
Name
Description
28-1
Axis 1
Working range
limit
One or two mechanical stops for restricting the working
range of axis 1. The option includes two stops.
See Figure below.
The working range can be restricted freely within the shown scope, depending on where the
mechanical stop is installed along the casted groove.
+64
(A)
°
-6 4
°
(A)
+168°
-1 6 8 °
(B)
(B)
© Copyright 2004-2010 ABB. All rights reserved.
xx1000000958
Pos
Description
A
Mounting position of two additional stops for maximum working area (+/- 160o).
B
Mounting position of two additional stops for maximum working area (+/- 64o).
Continues on next page
3HAC023604-001 Revision: M
55
2 Specification of Variants and Options
2.1.2. Manipulator
Continued
3
2
1
xx1000000957
Description
1
Mechanical stop (x2)
2
Washers (x4)
3
Screws (x4)
Option
Name
Description
32-1
Axis 2
working range
limit
An additional mechanical stop for restricting the working
range of axis 2 can be mounted on the frame. The working
range can only be restricted backwards as shown in
Figure below. Notice the different working range for the
different models.
© Copyright 2004-2010 ABB. All rights reserved.
Pos
xx0400001290
Continues on next page
56
3HAC023604-001 Revision: M
2 Specification of Variants and Options
2.1.2. Manipulator
Continued
xx0400001290
Option
Name
Description
Axis 3
working range
limit
The mechanical stop to restrict the working range within
zone A and B for axis 3 can be mounted at the upper arm
housing. See Figure 4. Notice the different working range for
the different models.
© Copyright 2004-2010 ABB. All rights reserved.
34-1
a
Continues on next page
3HAC023604-001 Revision: M
57
2 Specification of Variants and Options
2.1.2. Manipulator
Continued
a. Not valid for IRB 1600ID-4/1.5.
© Copyright 2004-2010 ABB. All rights reserved.
xx0400001283
xx0400001284
58
3HAC023604-001 Revision: M
2 Specification of Variants and Options
2.1.3. Positioners
2.1.3. Positioners
General
© Copyright 2004-2010 ABB. All rights reserved.
Regarding positioners, see Product specification - 3HAC028283-001.
3HAC023604-001 Revision: M
59
2 Specification of Variants and Options
2.1.4. Track Motion
2.1.4. Track Motion
Track Motion type
Option
Type
Description
1000-5
no AW
For IRB 1600/2400 robot, with a travel length of 1.7 m
For for example material handling robot.
1000-6
for AW
For IRB 1600/2400 robot, with a travel length of 1.7 m
For AW robot with Marthon-pac or Bobbin holder.
Option
Description
Note
1001-1
(1-18) Add
travel length
Chose additional travel length in meter, above the min.
length under Track Motion Type.
The selection 1 adds 1m travel length, 2 adds 2m travel
length and so on...
Additional travel length
Example of ordering a track motion RTT, with a requested travel length of 7.5 m:
Track Motion Type
•
1000-5 RTT with Bobbin
•
1001-1 Add travel length
In this case, option 1000-5 specify a track motion with a travel length of 1.7 m, option 10011 adds 6 meters to that, ending up with a total travel length of 7.7 m.
Option
Type
Description
935-1
RoboCare II
2 years. REQUIRES: Remote Service [890-1]
935-2
RoboCare III
3 years. REQUIRES: Remote Service [890-1]
Warranty
60
Option Type
Description
438-1
Standard Warranty
Standard warranty is 18 months (1 1/2 years)
438-2
Standard + 12 months
18 + 12 months (2 1/2 years)
438-4
Standard + 18 months
18 + 18 months (3 years)
438-5
Standard + 24 months
18 + 24 months (3 1/2 years)
438-6
Standard + 6 months
18 + 6 months (2 years)
438-7
Standard + 30 months
Warranty extension 30 months
438-8
Stock Warranty
Maximum 6 months postponed warranty starting from
shipment date ABB Robotics Production unit (PRU) +
Option 438-1. Warranty commences automatically after
6 months or from activation date of standard warranty.
(See ABB Robotics BA Warranty Rules).
3HAC023604-001 Revision: M
© Copyright 2004-2010 ABB. All rights reserved.
RoboCare
2 Specification of Variants and Options
2.2.1. Manipulator
2.2 Floor cables
2.2.1. Manipulator
Manipulator cable length
Option
Lengths
210-2
7m
210-3
15 m
210-4
22 m
210-5
30 m
Connection of Parallel communication
Lengths
94-1
7m
94-2
15 m
94-3
22 m
94-4
30 m
© Copyright 2004-2010 ABB. All rights reserved.
Option
3HAC023604-001 Revision: M
61
2 Specification of Variants and Options
2.2.2. Positioner
2.2.2. Positioner
Positioner cable 1
Option
Lengths
1067-1
7m
1067-2
10 m (Standard length)
1067-3
15 m
Option
Lengths
1068-1
7m
1068-2
10 m (Standard length)
1068-3
15 m
Option
Type
Description
1048-1
Flexible
Only available with one or two MTC 250/500/750/2000/5000
Option
Lengths
1056-1
7m
1056-2
7mx2
1056-3
10 m
1056-4
10 m x 2
1056-5
15 m
1056-6
15 m x 2
Option
Type
Description
1057-1
OKC
T-connection
Choose quantity, 1-2
Positioner cable 2
Positioner cable type
© Copyright 2004-2010 ABB. All rights reserved.
Weld return cable
Return cable
62
3HAC023604-001 Revision: M
2 Specification of Variants and Options
2.3.1. DressPack
2.3 Process
2.3.1. DressPack
Welding torch package
NOTE!
The robot can either be ordered without AW equipment (option 878-1) or fully dressed with
torch including hose package (option 878-2 or 878-3) and AristoMig 4000i
(option 1029-13) or 5000i (option 1029-14). Only torch and hose package without AristoMig
is not possible to order from SEROP but can be ordered from supplier locally.
Option
Description
878-1
None, upper arm without any AW process equipment
878-2
Self cooled torch, iSTM-ABIROB A 22 degrees
878-3
Water cooled torch, iSTM-ABIROB W 22 degrees
© Copyright 2004-2010 ABB. All rights reserved.
Side impact protection (SIP)
Option
Description
883-1
Upper arm process cable protection, see Figure below.
xx1000000959
Process module
Option
Type
Description
768-1
Empty cabinet
small
See Product specification - Controller IRC5 with FlexPendant, see chapter 2.2.1
768-2
Empty cabinet
large
See Product specification - Controller IRC5 with FlexPendant, chapter 2.2.1
768-5
AWC /
WeldGuide
Only together with AristoMig 4000i/5000i, MigRob and TPS
power sources.
Continues on next page
3HAC023604-001 Revision: M
63
2 Specification of Variants and Options
2.3.1. DressPack
Continued
Installation kit
Type
Description
715-1
Installation kit
See Product specification - Controller IRC5 with FlexPendant, chapter 2.2.1
© Copyright 2004-2010 ABB. All rights reserved.
Option
64
3HAC023604-001 Revision: M
2 Specification of Variants and Options
2.3.2. Process equipment
2.3.2. Process equipment
Power source
Option
Type
Description
1029-13
AristoMig 4000i 400V (requires option 650-10)
Only together with option 878-2 or 878-3.
1029-14
AristoMig 5000i 400V (requires option 650-10)
Only together with option 878-2 or 878-3.
Option
Type
Description
1030-4
7.5 m
For external suspension mounting, not included. Only
together with option 1029-13 or 1029-14.
1030-5
10 m
Internal suspension mounting, hose package attatched to
the robot base. Protective hose included.
Only together with option 1029-13 or 1029-14.
Option
Type
Description
1033-2
Marathon Pac
Octagon
Liner for 250 kg Marathon Pac.Plastic hood for round
Maraton-Pac included.
1033-3
Bobin
A 15 kg bobin holder on the robot.
Option
Type
Description
1037-1
ABB TSC
ABB Torch Service Center.
1037-2
ABB TC96
ABB Torch cleaner.
1037-5
BullsEye
BullsEye stand alone.
Current/Hose set
Feed kit
© Copyright 2004-2010 ABB. All rights reserved.
Torch service
3HAC023604-001 Revision: M
65
2 Specification of Variants and Options
2.3.3. AW Safety options
2.3.3. AW Safety options
Working area
Option
Type
Description
1072-1
One working
area
1072-2
Two working
areas
Option
Type
Description
1054-1
Operator panel
1 area
For one working area
1054-2
Operator panel
2 areas
For two working areas.
1054-3
2 x operators
panel 2 areas
Two operator panels, one for each working area.
Option
Type
Description
1058-1
Safety interface SIB
1058-2
Active relay
Active relay supervision (open relay).
Option
Type
Description
1060-1
Gate switch
1060-2
Gate switch/
ext. reset
Option
Type
Description
1059-1
Lightbeam
Qty 1 or 2, one working area requires one PC of ”two level
light beams”.
Two working areas rerquire two PCs of “two level light
beams”.
Option
Type
Description
1061-1
Home position
switch
Home position switch for IRB 1600/2400, one working area.
Operator panel
AW Safety interface
Lightbeam
Home position switch
Continues on next page
66
3HAC023604-001 Revision: M
© Copyright 2004-2010 ABB. All rights reserved.
Gate switch
2 Specification of Variants and Options
2.3.3. AW Safety options
Continued
Station indication
Option
Type
Description
1062-1
Station
indication
Station indication for IRB 1600/2400, two working areas.
Option
Type
Description
1063-1
Pre-reset unit
Qty 1 or 2, one working area requires one PC of “Pre-reset”.
Two working areas require two PCs of “Pre-reset”.
Option
Type
Description
1064-1
Activation unit
Qty 1 or 2, one requires one PC of “Activation unit”. Two
working areas require two PCs of “Activation unit”.
Option
Type
Description
1065-1
Extended EM
stop
Required when using external EM-stop push buttons and
when ordering a dual arc system (two welding packages).
Pre-reset unit
Activation unit
© Copyright 2004-2010 ABB. All rights reserved.
Extended EM stop
3HAC023604-001 Revision: M
67
2 Specification of Variants and Options
2.3.4. Documentation
2.3.4. Documentation
DVD User Documentation
Type
Description
808-1
Documentation on DVD See Product specification - Robot user documentation
© Copyright 2004-2010 ABB. All rights reserved.
Option
68
3HAC023604-001 Revision: M
3 Accessories
3.1. Introduction
3 Accessories
3.1. Introduction
General
There is a range of tools and equipment available, especially designed for the robot.
Robot software options for robot and PC
For more information, see Product specification - Controller IRC5 with FlexPendant and
Product specification - Controller software IRC5/RobotWare Options.
Robot Peripherals
Track Motion
•
Motor Units
© Copyright 2004-2010 ABB. All rights reserved.
•
3HAC023604-001 Revision: M
69
ABB AB
Discrete Automation and Motion
Robotics
S-721 68 VÄSTERÅS
SWEDEN
Telephone +46 (0) 21 344 400
www.abb.com
3HAC023604-001 Rev M, en
Contact us
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement