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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
Product specification
Articulated robot
3HAC023604-001
Rev.H
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
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.
Additional copies of this manual may be obtained from ABB at its then current charge.
©Copyright 2004 ABB All right reserved.
ABB AB
Robotics Products
SE-721 68 Västerås
Sweden
Table of Contents
Overview
5
1 Description
7
1.1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.1.2 Different robot versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.2 Safety/Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2.1 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1.3.2 Operating requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1.3.3 Mounting the manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
1.4 Calibration and References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.4.1 Fine calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
1.4.2 Absolute Accuracy calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
1.5 Robot load and Load diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
1.5.2 Load diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
1.5.3 Maximum load and moment of inertia for full and limited axis
5 (center line down) movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
1.5.4 Wrist torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
1.5.5 Mounting of equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
1.6 Robot Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
1.6.2 Performance according to ISO 9283 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
1.6.3 Velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
1.6.4 Stopping distance/time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
1.7 Typical cycle times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
1.8 Customer connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
1.9 Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
2.1.3 Positioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
2.1.4 Track Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
2.2 Floor cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.2.1 Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
2.2.2 Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
2.3 Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
2.3.1 DressPack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
2.3.2 Process equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
2.3.3 AW Safety options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
2.3.4 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
3 Accessories
3HAC023604-001
65
Rev.H
3
Table of Contents
4
Rev.H
3HAC023604-001
Overview
Overview
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 on page 3
Revisions
3HAC023604-001
Revision
Description
Revision 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
Revision D
- Option 287-5 Wash removed
Revision 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
Revision F
- Old versions removed and AW offer changed.
Revision 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
Revision H
- Added information about moutin equipment on upper arm
Rev.H
5
Overview
Complementary documentation
Product specification
Description
Controller
IRC5 with FlexPendant, 3HAC021785-001
Controller Software IRC5
RobotWare 5.11, 3HAC022349-001
Robot User Documentation IRC5 and M2004, 3HAC024534-001
6
Product Manual
Description
Manipulator
IRB 1600, 3HAC026660-001
Rev.H
3HAC023604-001
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 operating system RobotWare RW. RobotWare RW
controls every aspect of the robot, like motion control, development and execution
of application programs, communication etc. see Product specification - Controller
IRC5 with FlexPendant.
Additional functionality
For additional functionality, the robot can be equipped with optional software for
application support - for example spot welding, communication features - network
communication - and advanced functions such as multi-tasking, sensor control, etc.
For a complete description on optional software, see Product specification - Controller software IRC5.
3HAC023604-001
Rev.H
7
1 Description
1.1.1 Introduction
Protection Foundry
With Protection Foundry, the robot is suitable to operate in harsh environments and
has special surface treatment and paint for excellent corrosion protection. The connectors are designed for severe environments and bearings, gears and other sensitive
parts are carefully protected. The robot has Foundry Plus protection, which means
that the whole manipulator is IP 67 classified and steam washable.
Clean room robots
The Clean room robots are classified for room class 10 according to US Federal
Standard 209 or class 4 according to ISO 14644-1.
The performed clean room test has classify the air cleanliness exclusively in terms of
concentration of airborne particles generated by the robot. Other aspects of the clean
room test or other clean room requirements are not considered.
Manipulator axes
Figure 1 The IRB 1600 manipulator has 6 axes.
8
Rev.H
3HAC023604-001
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 or inverted. Tilting of 30º of the robot base is allowed for the floor
mounted with a rotation of axis 1 within ± 60º. For wall mounted robot with 6 kg
payload the rotation of axis 1 is limited within ± 20º. For wall mounted robot with 8
kg payload the rotation of axis 1 is limited within ± 60°.
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
Other technical data
Power consumption
Path E1-E2-E3-E4 in the ISO Cube, max.load.
Power consumption (kW)
Speed (mm/s)
3HAC023604-001
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
Rev.H
9
1 Description
1.1.2 Different robot versions
Figure 2 Path E-E2-E3-E4 in the ISO Cube, maximum load.
10
Rev.H
3HAC023604-001
1 Description
1.1.2 Different robot versions
Dimensions IRB 1600-X/1.2 (1.45)
Figure 3 View of the manipulator from the back, side and above (dimensions in mm).
3HAC023604-001
Pos
Description
A
R335 Minimum turning radius
Rev.H
11
1 Description
1.1.2 Different robot versions
Dimensions IRB 1600ID-4/1.5
Figure 4 View of the manipulator from the back, side and above (dimensions in mm).
12
Pos
Description
A
R335 Minimum turning radius
Rev.H
3HAC023604-001
1 Description
1.2.1 Standards
1.2 Safety/Standards
1.2.1 Standards
The robot conforms to the following standards:
Standard
Description
EN ISO 12100 -1
Safety of machinery, terminology
EN ISO 12100 -2
Safety of machinery, technical specifications
EN 954-1
Safety of machinery, safety related parts of control Systems
EN 60204
Electrical equipment of industrial machines
EN ISO 60204-1:2006
EN ISO 10218-1:2006
Safety of machinery - Electrical equipment of machines
a
Robots for industrial environments - Safety requirements
EN 609074-10: 2003
Arc welding equipment - part 10: electro magnetic capability
(EMC) requirements
EN 61000-6-4: 2001b
EMC, Generic emission
EN 61000-6-2: 2005
EMC, Generic immunity
a. There is a deviation from paragraph 6.2 in that only worst case stop distances and
stop times are documented.
b. Not valid for IRB 1600ID-4/1.5
3HAC023604-001
Standard
Description
IEC 60529
Degrees of protection provided by enclosures
Standard
Description
ISO 9787
Manipulating industrial robots, coordinate Systems and
motions
Standard
Description
ANSI/RIA 15.06/1999
Safety Requirements for Industrial Robots and Robot
Systems.
ANSI/UL 1740-1998 (option)
Safety Standard for Robots and Robotic Equipment
CAN/CSA Z 434-03 (option)
Industrial Robots and Robot Systems - General Safety
Requirements
US Federal Standard 209
Clean room classification
Rev.H
13
1 Description
1.2.1 Standards
The robot complies fully with the health and safety standards specified in the EEC’s
Machinery Directives.
Safety function
Description
The Service
Information System
(SIS)
The service information system gathers information about the
robot’s usage and determines how hard the robot is used. The
usage is characterized by the speed, the rotation angles and the
load of every axis.
With this data collection, the service interval of every individual
robot of this generation can be predicted, optimized and service
activities planned ahead. The collection data is available via the
FlexPendant or the network link to the robot.
The Process Robot Generation is designed with absolute safety in
mind. It is dedicated to actively or passively avoid collisions and
offers the highest level of safety to the operators and the machines
as well as the surrounding and attached equipment. These features
are presented in the active and passive safety system.
The time the robot is in operation (brakes released) is indicated on
the FlexPendant. Data can also be monitored over network, using
for example WebWare.
The Active Safety
System
Description
General
The active safety system includes those software features that
maintain the accuracy of the robot’s path and those that actively
avoid collisions which can occur if the robot leaves the programmed
path accidentally or if an obstacle is put into the robot’s path.
The Active Brake System (ABS)
All robots are delivered with an active brake system that supports
the robots to maintain the programmed path in General Stop (GS),
Auto Stop (AS) and Superior Stop (SS).
The ABS is active during all stop modes, braking the robot to a stop
with the power of the servo drive system along the programmed
path. After a specific time the mechanical brakes are activated
ensuring a safe stop.
The stopping process is in accordance with a class 1 stop. The
maximum applicable torque on the most loaded axis determines the
stopping distance.
In case of a failure of the drive system or a power interruption, a
class 0 stop turns out. Emergency Stop (ES) is a class 0 stop. All
stops (GS, AS, SS and ES) are reconfigurable.
While programming the robot in manual mode, the enabling device
has a class 0 stop.
The Self Tuning Perfor- The Process Robot Generation is designed to run at different load
mance (STP)
configurations, many of which occur within the same program and
cycle.
The robot’s installed electrical power can thus be exploited to lift
heavy loads, create a high axis force or accelerate quickly without
changing the configuration of the robot.
Consequently the robot can run in a “power mode” or a “speed
mode” which can be measured in the respective cycle time of one
and the same program but with different tool loads. This feature is
based on QuickMoveTM.
The respective change in cycle time can be measured by running
the robot in NoMotionExecution with different loads or with simulation tools like RobotStudio.
14
Rev.H
3HAC023604-001
1 Description
1.2.1 Standards
The Active Safety
System
Description
The Electronically Stabilised Path (ESP)
The load and inertia of the tool have a significant effect on the path
performance of a robot. The Process Robot Generation is equipped
with a system to electronically stabilize the robot’s path in order to
achieve the best path performance.
This has an influence while accelerating and braking and consequently stabilizes the path during all motion operations with a compromise of the best cycle time. This feature is secured through
TrueMoveTM.
Over-speed protection
The speed of the robot is monitored by two independent computers.
Restricting the working The movement of each axis can be restricted using software limits.
space
As options there are safeguarded space stops for connection of
position switches to restrict the working space for the axes 1-3.
Axes 1-3 can also be restricted by means of mechanical stops.
Collision detection
(option)
In case of an unexpected mechanical disturbance, such as a collision, electrode sticking, etc., the robot will detect the collision, stop
on the path and slightly back off from its stop position, releasing
tension in the tool.
The Passive Safety
Description
System
3HAC023604-001
General
The Process Robot Generation has a dedicated passive safety system that by hardware construction and dedicated solutions is
designed to avoid collisions with surrounding equipment. It integrates the robot system into the surrounding equipment safely.
Compact robot arm
design
The shape of the lower and upper arm system is compact, avoiding
interference into the working envelope of the robot.
The lower arm is shaped inward, giving more space under the upper
arm to re-orientate large parts and leaving more working space
while reaching over equipment in front of the robot.
The rear side of the upper arm is compact, with no components
projecting over the edge of the robot base even when the robot is
moved into the home position.
Moveable mechanical
limitation of main axes
(option)
All main axes can be equipped with moveable mechanical stops,
limiting the working range of every axis individually. The mechanical
stops are designed to withstand a collision even under full load.
Electronic Position
Switches (EPS) on up
to 7 axes (option)
EPS offers axes position status signals, fulfilling applicable regulations for personnel safety. Five outputs can each be configured to
reflect the position of a single axis or a combination of axes. For
each output, the range for each included axis can be set arbitrarily.
Rev.H
15
1 Description
1.2.1 Standards
The Internal Safety
Description
Concept
General
The internal safety concept of the Process Robot Generation is
based on a two-channel circuit that is monitored continuously. If any
component fails, the electrical power supplied to the motors shuts
off and the brakes engage.
Safety category 3
Malfunction of a single component, such as a sticking relay, will be
detected at the next MOTOR OFF/MOTOR ON operation. MOTOR
ON is then prevented and the faulty section is indicated. This complies with category 3 of EN 954-1, Safety of machinery - safety
related parts of control Systems - Part 1.
Selecting the operating The robot can be operated either manually or automatically. In manmode
ual mode, the robot can only be operated via the FlexPendant, that
is not by any external equipment.
Reduced speed
In manual mode, the speed is limited to a maximum of 250 mm/s
(600 inch/min.). The speed limitation applies not only to the TCP
(Tool Center Point), but to all parts of the robot. It is also possible to
monitor the speed of equipment mounted on the robot.
Three position enabling The enabling device on the FlexPendant must be used to move the
device
robot when in manual mode. The enabling device consists of a
switch with three positions, meaning that all robot movements stop
when either the enabling device is pushed fully in, or when it is
released completely. This makes the robot safer to operate.
16
Safe manual movement
The robot is moved using a joystick instead of the operator having
to look at the FlexPendant to find the right key.
Emergency stop
There is one emergency stop push button on the controller and
another on the FlexPendant. Additional emergency stop buttons
can be connected to the robot’s safety chain circuit.
Safeguarded space
stop
The robot has a number of electrical inputs which can be used to
connect external safety equipment, such as safety gates and light
curtains. This allows the robot’s safety functions to be activated
both by peripheral equipment and by the robot itself.
Delayed safeguarded
space stop
A delayed stop gives a smooth stop. The robot stops the same way
as at a normal program stop with no deviation from the programmed
path. After approx. 1 second the power supplied to the motors is
shut off.
Hold-to-run control
“Hold-to-run” means that you must depress the start button in order
to move the robot. When the button is released the robot will stop.
The hold-to-run function makes program testing safer.
Fire safety
Both the manipulator and control system comply with UL’s (Underwriters Laboratories Inc.) tough requirements for fire safety.
Safety lamp (option)
As an option, the robot can be equipped with a safety lamp mounted
on the manipulator. This is activated when the motors are in the
MOTORS ON state.
Rev.H
3HAC023604-001
1 Description
1.3.1 Introduction
1.3 Installation
1.3.1 Introduction
General
IRB 1600 can be mounted on the floor, wall or inverted. A tilting of 30º of the robot
base is allowed with a rotation of axis 1 within ± 45º. For wall mounted robot with 6
kg payload the rotation of axis 1 is limited to within ± 20º. For wall mounted robot
with 8 kg payload the rotation of axis 1 is limited within ± 60º. 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 chapter Robot load and 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 Holes for mounting
extra equipment on IRB 1600 page 33.
Working Range
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.
1.3.2 Operating requirements
Protection Standards
Robot version
Protection Standard IEC60529
Standard manipulator
IP 54
Protection Foundry
IP 67
Protection Wash
IP 67
IRB 1600ID-4/1.5
IP 40
Clean room standards
Clean room manipulator US Federal Standard 209, class 10 or ISO 14644-1 class 4.
Explosive Environments
The robot must not be located or operated in an explosive environment.
3HAC023604-001
Rev.H
17
1 Description
1.3.3 Mounting the manipulator
Ambient Temprature
Description
Standard/Option
Temperature
Manipulator during oper- Standard
ation
+ 5°C (+ 41°F) to + 45°C (+ 113°F)
For the controller
Standard/Option
See Product specification - 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
Complete robot during operation, transportation and Max. 95% at constant temperature
storage
1.3.3 Mounting the manipulator
Maximum load in relation to the base coordination system. See Figure 6.
18
Mounting
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
Rev.H
3HAC023604-001
1 Description
1.3.3 Mounting the manipulator
Figure 5 Directions of forces.
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).
3HAC023604-001
Rev.H
19
1 Description
1.3.3 Mounting the manipulator
Fastening holes Robot base
Figure 6 Hole configuration for robot base (dimensions in mm). View from the bottom of the base.
Attachment bolts, specification
The table below specifies required bolts and washers for securing the robot at installation site.
20
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)
Washers, 3 pcs
17 x 30 x 3
Quality
Quality 8.8, wall mounted quality 12.9
Tightening torque
200 Nm
Rev.H
3HAC023604-001
1 Description
1.3.3 Mounting the manipulator
Note: For wall mounted robot, two guide bushings according to Figure 7 are needed.
Regarding Abs.Acc. performance, the chosen guide holes according to Figure 5 are
recommended.
Mounting surface and bushings
Figure 7 Mounting surface and bushings.
3HAC023604-001
Pos
Description
A
Surface treatment, ISO 2081 Fe/Zn 8 c2, Guide bushing
B
View D
C
3x common zone
Rev.H
21
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.
Figure 8 All axes in zero position.
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
22
Rev.H
3HAC023604-001
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.
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.
3HAC023604-001
Rev.H
23
1 Description
1.4.2 Absolute Accuracy calibration
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.
Figure 9 The Cartesian coordinate system.
Production data
Typical production data regarding calibration are:
Positioning accuracy (mm)
Robot
Average
Max
% Within 1 mm
0.30
0.65
100
0.35
0.65
100
IRB 1600-6/1.2
-6/1.45
-8/1.2
-8/1.45
IRB 1600ID-4/1.5
24
Rev.H
3HAC023604-001
1 Description
1.5.1 Introduction
1.5 Robot load and Load diagrams
1.5.1 Introduction
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 outside load diagram is used the following parts
can be damaged due to overload:
•
motors
•
gearboxes
•
mechanical structure
Robots running with incorrect load data and/or with loads outside load
diagram will not be covered by the robot warranty.
General
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.
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.
3HAC023604-001
Rev.H
25
1 Description
1.5.2 Load diagrams
1.5.2 Load diagrams
IRB 1600-6/1.2, IRB 1600-6/1.45
Figure 10 Maximum permitted load mounted on the robot tool flange at different positions (center of
gravity).
26
Rev.H
3HAC023604-001
1 Description
1.5.2 Load diagrams
IRB 1600-6/1.2, IRB 1600-6/1.45 “Vertical Wrist” (±10º)
Figure 11 Maximum permitted load mounted on the robot tool flange at different positions (center of
gravity) at “Vertical Wrist” (±10º).
3HAC023604-001
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
Rev.H
27
1 Description
1.5.2 Load diagrams
IRB 1600-8/1.2, IRB 1600-8/1.45
Figure 12 Maximum permitted load mounted on the robot tool flange at different positions (center of
gravity).
28
Rev.H
3HAC023604-001
1 Description
1.5.2 Load diagrams
IRB 1600-8/1.2, IRB 1600-8/1.45 “Vertical Wrist” (±10º)
Figure 13 Maximum permitted load mounted on the robot tool flange at different positions (center of
gravity) at “Vertical Wrist” (±10º).
3HAC023604-001
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
Rev.H
29
1 Description
1.5.2 Load diagrams
IRB 1600ID-4/1.5
Figure 14 Maximum permitted load mounted on the robot tool flange at different positions (center of
gravity)
30
Rev.H
3HAC023604-001
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 15.
Full movement of Axis 5 (±115º)
Axis Robot Type
Max. value
5
IRB 1600-6/x
6
IRB 1600-6/x
J5 = Mass x ((Z + 0.065)2 + L2) + max (Jox, Joy) ≤ 0.42 kgm2
J6= Mass x L2 + J0Z ≤ 0.30 kgm2
Axis Robot Type
Max. value
5
IRB 1600-8/x
6
IRB 1600-8/x
J5 = Mass x ((Z + 0.065)2 + L2) + max (Jox, Joy) ≤ 0.53 kgm2
J6= Mass x L2 + J0Z ≤ 0.39 kgm2
Full movement of Axis 5 (+155º to -90º)
5
Axis Robot Type
5
6
Max. value
IRB 1600ID-4/1.5 J5 = Mass x ((Z + 0.2002 + L2) + max (Jox, Joy) ≤ 0.58 kgm2
IRB 1600ID-4/1.5 J6= Mass x L2 + J0Z ≤ 0.24 kgm2
Figure 15 Moment of inertia when full movement of axis 5.
Pos
Description
A
Center of gravity
Description
Jox, Joy, Joz
3HAC023604-001
Max. moment of inertia around the X, Y and Z axes at center of gravity.
Rev.H
31
1 Description
1.5.4 Wrist torque
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
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
5
Figure 16 Moment of inertia when axis 5 center line down.
Pos
Description
A
Center of gravity
Description
Jox, Joy, Joz Max. moment of inertia around the X, Y and Z axes at center of gravity.
1.5.4 Wrist torque
The table below shows the maximum permissible torque due to payload.
.
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.
Robot type
Max wrist torque Max wrist torque Max torque valid
axis 4 and 5
axis 6
at load
IRB 1600-6/1.2(1.45)
32
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
Rev.H
3HAC023604-001
1 Description
1.5.5 Mounting of equipment
1.5.5 Mounting of equipment
General
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 17. 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 18).
Figure 17 The shaded area indicates the permitted positions (center of gravity) for extra load mounted on
the robot (dimensions in mm).
3HAC023604-001
Rev.H
33
1 Description
1.5.5 Mounting of equipment
Load area
Max. load
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
-
-
-
-
-
15 kg
15 kg
Robot
IRB 1600ID-4/1.5
Holes for mounting of extra equipment
Figure 18 Holes for mounting extra equipment on the wrist, the upper arm housing and on the frame.
34
Rev.H
3HAC023604-001
1 Description
1.5.5 Mounting of equipment
Design until June 2006
Design after June 2006, Type A
Design IRB 1600ID-4/1.5
3HAC023604-001
Rev.H
35
1 Description
1.5.5 Mounting of equipment
Mounting hole for equipment
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! When mounting heavier equipment, e.g. wire feeders, in holes (C) must the bracket
be support in the opposite holes (E).
36
Rev.H
3HAC023604-001
1 Description
1.5.5 Mounting of equipment
Holes for mounting of extra equipment for IRB 1600ID-4/1.5
Figure 19 Holes for mounting extra equipment on the wrist, the upper arm housing and on the frame of
IRB 1600ID-4/1.5.
3HAC023604-001
Pos
Description
A
R198, Axis 3 turning radius
B
2x M8 depth 16, Mounting holes for equipment
C
2x M8, Mounting holes for equipment
Rev.H
37
1 Description
1.5.5 Mounting of equipment
Robot tool flange
Figure 20 Robot tool flange (dimensions in mm).
Robot tool flange for IRB 1600ID-4/1.5
Figure 21 Robot tool flange for IRB 1600ID-4/1.5 (dimensions in mm).
38
Rev.H
3HAC023604-001
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 m reach
Range of movement
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. Axis 1 working range has the following limitations:
+45° to -45° when tilting the robot up to 30º
+20° to -20° for wall mounted IRB 1600-6/X
+60° to -60° for wall mounted IRB 1600-8/X
b. rev. = Revolutions
c. The default working range for axis 4 and axis 6 can be extended by changing
parameter values in the software.
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
3HAC023604-001
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°
Rev.H
39
1 Description
1.6.1 Introduction
Figure 22 The extreme positions of the robot arm with 1.2 m reach.
Positions at wrist center 1.2 m reach
40
Pos No. see
Figure 22
X Position
(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
Rev.H
3HAC023604-001
1 Description
1.6.1 Introduction
Figure 23 The extreme positions of the robot arm with 1.45 m reach.
Positions at wrist center 1.45 m reach
3HAC023604-001
Pos No. see
Figure 23
X Position
(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
Rev.H
41
1 Description
1.6.1 Introduction
Figure 24 The extreme positions of the robot IRB 1600ID arm with 1.5 m reach.
Positions at wrist center IRB 1600ID-4/1.5
42
Pos No. see
Figure 24
X Position
(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
Rev.H
3HAC023604-001
1 Description
1.6.2 Performance according to ISO 9283
1.6.2 Performance according to ISO 9283
General
At rated load and 1 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 25.
Figure 25 Explanation of ISO values.
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
Description
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.
3HAC023604-001
Rev.H
43
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 1600-8/1.45
IRB 1600ID-4/1.5
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
Approx. 0.01º on each axis.
1.6.4 Stopping distance/time
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
Robot Type
Axis
IRB 1600-6/1.2 (1.45)
IRB 1600-8/1.2 (1.45)
A
B
A
B
A
B
1
25
0.2
45
0.4
31
n.a.
2
23.
0.2
32
0.3
30
n.a.
3
14
0.2
25
0.2
18
n.a.
Category 0
Category 1
Main power failure
Robot Type
Axis
IRB 1600ID-4/1.5
A
B
A
B
A
B
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.
Description
44
A
Distance in degrees
B
Stop time (s)
Rev.H
3HAC023604-001
1 Description
1.7.1 Introduction
1.7 Typical cycle times
1.7.1 Introduction
Figure 26 Packer cycle (dimensions in mm).
Approx. cycle times
Pay load at wrist down
IRB 1600-6/x
IRB 1600-8/x
7 kg
10 kg
Cycle time Packer cycle 0.95 s
1.01 s
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 2 Specification of Variants and Options, Application interface Connection type.
Note: No customer/application connections available for IRB 1600ID-4/1.5.
3HAC023604-001
Rev.H
45
1 Description
1.8.1 Introduction
Connections at robot base
Figure 27 to Figure 30 show the customer connections at the robot base. For description of all connection types see table below Figure 30.
Figure 27 No application interface.
Figure 28 Standard application interface.
Figure 29 Integrated wirefeed interface.
46
Rev.H
3HAC023604-001
1 Description
1.8.1 Introduction
Figure 30 Axis 7 connection.
3HAC023604-001
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
Rev.H
47
1 Description
1.8.1 Introduction
Connections at upper arm
Figure 31 shows the Customer connections at the upper arm.
Figure 31 Customer connections at the 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
Rev.H
3HAC023604-001
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
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 Maintenance section in the Product Manual.
3HAC023604-001
Rev.H
49
1 Description
1.9.1 Introduction
50
Rev.H
3HAC023604-001
2 Specification of Variants and Options
2.1.1 General
2 Specification of Variants and Options
2.1 Introduction
2.1.1 General
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 IRC5 with FlexPendant
and for software options, see Product specification - Controller software IRC5/
RobotWare Options.
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.
Manipulator color
3HAC023604-001
Rev.H
51
2 Specification of Variants and Options
2.1.2 Manipulator
Protection
Option
Name
Description
287-4
Standard
IP 54, IP 40 for IRB 1600ID-4/1.5
287-3
Foundry Plus
The robot has the Foundry Plus protection which means that
the whole manipulator is IP 67 classified and steam washable.
An excellent corrosion protection is obtained by a special
coating. The connectors are designed for severe environments, and bearings, gears and other sensitive parts are
highly protected.
Not valid for IRB 1600ID-4/1.5.
287-1
Clean room
Robot with clean room class 10 according to US Federal Standard 209 and with the same protection as in option 287-4.
The robot is labeled with “Clean Room”.
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.
52
Rev.H
3HAC023604-001
2 Specification of Variants and Options
2.1.2 Manipulator
Application interface Connection type
Option
17-5
a
17-6a
Name
Description
Standard
One Souriau UTOW6 1210 P-H
One Souriau UTOW6 1626 P-H
50 V, 250 mA
Signals 23
250 V, 2 A
Power 10
Max. 8 bar, hose inner diameter
Air 1
8 mm. R 1/4 “ at base and upper
arm.
Integrated Signals 16
wire feed
cable
Power 12
17-7
49 V, 500 mA
Connector on upper arm housing:
-Souriau UT0W7 1626 S-H.
Connector on robot base:
- FCI 23-pin socket
UT 001823SHT
300 V, 4 A
- Souriau UT07 1412 S-H.
Connector on robot base:
-FCI 12-pin UT 001412PHT
No application
interface
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
3HAC023604-001
Rev.H
53
2 Specification of Variants and Options
2.1.2 Manipulator
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.
For more detailed information, see Product specification - Controller IRC5 with
FlexPendant and Application Manual Electronic Position Switches, art. No.
3HAC0277709-001.
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 32.
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)
Figure 32 Mounting area of the additional stops for Axis 1.
54
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).
Rev.H
3HAC023604-001
2 Specification of Variants and Options
2.1.2 Manipulator
3
2
1
Figure 33 Material included in the option 28-1.
Pos
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 34. Notice the different working range for the different
models.
Figure 34 Mounting area of additional stop Axis 2.
3HAC023604-001
Rev.H
55
2 Specification of Variants and Options
2.1.2 Manipulator
Option
a
34-1
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 35. Notice the different working range
for the different models.
a. Not valid for IRB 1600ID-4/1.5.
Figure 35 Mounting area of additional stop Axis 3.
56
Rev.H
3HAC023604-001
2 Specification of Variants and Options
2.1.3 Positioners
2.1.3 Positioners
General
Regarding positioners, see Product specification - 3HAC028283-001.
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
6 1001-1 Add travel length
In this case, option 1000-5 specify a track motion with a travel length of 1.7 m,
option 1001-1 adds 6 meters to that, ending up with a total travel length of 7.7 m.
Warranty
3HAC023604-001
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)
438-8
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).
Rev.H
57
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
58
Option
Lengths
94-1
7m
94-2
15 m
94-3
22 m
94-4
30 m
Rev.H
3HAC023604-001
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
Weld return cable
Return cable
3HAC023604-001
Rev.H
59
2 Specification of Variants and Options
2.3.1 DressPack
2.3 Process
2.3.1 DressPack
Welding torch package
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
Side impact protection (SIP)
Option
Description
883-1
Upper arm process cable protection, see Figure 36.
Figure 36 Process cable protection to be mounted on the upper arm.
Process module
60
Option
Type
Description
768-1
Empty cabinet
small
See Product specification - Controller IRC5 with FlexPendant, 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.
Rev.H
3HAC023604-001
2 Specification of Variants and Options
2.3.2 Process equipment
Installation kit
Option
Type
Description
715-1
Installation kit
See Product specification - Controller IRC5 with FlexPendant, chapter 2.2.1
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.
2.3.2 Process equipment
Power source
Current/Hose set
Feed kit
Torch service
3HAC023604-001
Rev.H
61
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”.
Operator panel
AW Safety interface
Gate switch
Lightbeam
62
Rev.H
3HAC023604-001
2 Specification of Variants and Options
2.3.4 Documentation
Home position switch
Option
Type
Description
1061-1
Home position
switch
Home position switch for IRB 1600/2400, one working area.
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).
Option
Type
Description
808-1
Documentation
on DVD
See Product Specification - Robot User
Documentation
Station indication
Pre-reset unit
Activation unit
Extended EM stop
2.3.4 Documentation
DVD User Documentation
3HAC023604-001
Rev.H
63
2 Specification of Variants and Options
2.3.4 Documentation
64
Rev.H
3HAC023604-001
3 Accessories
3 Accessories
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
3HAC023604-001
•
Track Motion
•
Motor Units
Rev.H
65
3 Accessories
66
Rev.H
3HAC023604-001
Index
A
P
Active Brake System, 14
active safety system, 14
advanced functions, 7
application support, 7
Arc Welding, 7
Passive Safety System, 15
Performance, 43
position switches, 17
Protection Foundry, 8, 17
Protection Wash, 17
C
R
Clean room, 8, 17
Collision detection, 15
compact robot arm, 15
cooling device, 9
Customer connections, 45
Cycle time, 45
reduced speed, 16
D
design, 15
E
eburring/Grinding applications, 7
Electronic Position Switches, 15
Electronically Stabilised Path, 15
emergency stop, 16
enabling device, 16
extra, 17
F
forklift, 44
Foundry Plus protection, 8
G
S
safeguarded space stop, 16
delayed, 16
safety, 13
Safety category 3, 16
safety lamp, 16
Self Tuning Performance, 14
Service Information System, 14
service information system, 14
space requirements, 9
spot welding, communication features, 7
standards, 13
strucure, 7
V
Velocity, 44
W
working space
restricting, 15, 17
Gluing, 7
H
hold-to-run control, 16
I
Internal Safety Concept, 16
L
limit switches, 17
limitation, 15
loads, 17
M
Machine Tending, 7
Material Handling, 7
motion control, development and execution of application programs, communication, 7
moveable, mechanical, main axes, 15
multi-tasking, sensor control, 7
N
noise level, 9
O
operating system, 7
3HAC023604-001
Rev.H
67
Index
68
Rev.H
3HAC023604-001
3HAC 023604-001, Revision H, en
ABB AB
Robotics Products
S-721 68 VÄSTERÅS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax:
+46 (0) 21 132592

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