ABB IRB 1600 - 6/1, IRB 1600 - 8/1, IRB 1600ID Product Manual

Product manual

Articulated Robot

IRB 1600 - 5/1,2 type A

IRB 1600 - 5/1,45 type A

IRB 1600 - 6/1,2 type A

IRB 1600 - 6/1,45 type A

IRB 1600 - 7/1,2 type A

IRB 1600 - 7/1,45 type A

IRB 1600 - 8/1,2 type A

IRB 1600 - 8/1,45 type A

IRB 1600ID

M2004

Product manual

IRB 1600 - 5/1.2 type A

IRB 1600 - 5/1.45 type A

IRB 1600 - 6/1.2 type A

IRB 1600 - 6/1.45 type A

IRB 1600 - 7/1.2 type A

IRB 1600 - 7/1.45 type A

IRB 1600 - 8/1.2 type A

IRB 1600 - 8/1.45 type A

IRB 1600ID

M2004

Document ID: 3HAC026660-001

Revision: C

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 2006-2008 ABB All rights reserved.

ABB AB

Robotics Products

SE-721 68 Västerås

Sweden

Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1 Safety 13

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.2.1 Safety in the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.2.2 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.2.2.1 Safety risks during installation and service work on robot . . . . . . . . . . . . . . . . . . . . . . . . 15

1.2.2.2 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.2.2.3 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.2.2.4 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.2.2.5 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.2.3 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.2.3.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.2.3.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.2.3.3 Emergency release of the robot’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.2.3.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.2.3.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.2.3.6 Safe use of the FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.2.3.7 Work inside the robot's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.2.3.8 Signal lamp (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.2.3.9 Translate the information on safety and information labels . . . . . . . . . . . . . . . . . . . . . . . 29

1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

1.3.2 DANGER - Moving robots are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1.3.3 DANGER - First test run may cause injury or damage! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

1.3.4 WARNING - The brake release buttons may be jammed after service work . . . . . . . . . . . . . . . . 34

1.3.5 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

1.3.6 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2 Installation and commissioning 37

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.2.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.2.2 Working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.3 On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2.3.1 Lifting robot with roundsling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2.3.2 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

2.3.3 Orienting and securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

2.3.4 Suspended mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

2.3.5 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2.3.6 Fitting equipment on the robot (robot dimensions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

2.3.7 Installation of signal lamp for 1600 (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

2.3.8 Installation of signal lamp for 1600 ID (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

2.4 Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

2.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

2.4.2 Installation of additional mechanical stops on axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

2.4.3 Installation of additional mechanical stop on axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

2.4.4 Installation of additional mechanical stops on axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

2.4.5 Installation of position switch, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

3HAC026660-001 Revision: C 3


2.5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

2.5.1 Connectors on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

2.5.2 Robot cabling and connection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

2.5.3 Customer connections on the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

2.6 Making robot ready for operation (Cleanroom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

2.6.1 Additional installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

3 Maintenance 89

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

3.2 Maintenance schedule and expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

3.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

3.2.3 Expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

3.3.1 Inspection, damper axes 2, 3 and 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

3.4 Replacement activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

3.4.1 Oil in gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

3.4.2 Oil change, gearbox axes 5 and 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

3.4.3 Oil change, gearbox axes 5- 6, IRB 1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

3.4.4 Replacement of measurement system battery pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

3.5 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

3.5.1 Cleaning, complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

4 Repair 107

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

4.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

4.2.2 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

4.2.3 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

4.3 Complete manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

4.3.1 Replacement of cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

4.3.2 Replacement of cable harness, IRB 1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

4.3.3 Replacement of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

4.4 Upper and lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

4.4.1 Replacement of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

4.4.2 Replacement of complete upper arm, IRB 1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

4.4.3 Replacement of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

4.4.4 Replacement of wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

4.4.5 Replacement of wrist unit, IRB1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

4.4.6 Replacement of damper, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151


4.4.8 Replacement of Mechanical damper, axis 3, IRB 1600ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155


4.4.10 Remove upper arm AW Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

4.4.11 Fitting equipment on the robot, IRB 1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

4.5 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

4.5.1 Replacement of base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

4.5.2 Replacement of serial measurement unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

4.5.3 Replacement of push button unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

4 3HAC026660-001 Revision: C


4.6 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

4.6.1 Replacement of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177



4.6.4 Replacement of motor, axis 3, IRB 1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189


4.6.6 Replacement of motor, axis 4, 1600ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

4.6.7 Replacement of motor and timing belt, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

4.6.8 Replacement of motor, axis 5, IRB 1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

4.6.9 Replacement of motor and timing belt, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

4.6.10 Replacement of motor, axis 6 IRB 1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

4.7 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

4.7.1 Replacement of gearbox, axes 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

4.7.2 Service work on gearboxes, axes 3, 4, 5 and 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

5 Calibration information 219

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

5.4 Calibration movement directions for all axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

5.6 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

6 Robot description 229

6.1 Type A of IRB 1600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

7 Reference information 231

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

7.2 Applicable safety standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

7.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

7.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

7.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

7.6 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

7.7 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

7.8 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

8 Spare parts and exploded views 241

8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

8.2 Spare parts - base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

8.3 Spare parts - base connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

8.4 Spare parts - frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

8.5 Spare parts - lower arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

8.6 Spare parts - upper arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

8.7 Spare parts - options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

8.8 Spare parts - upper arm 1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

9 Circuit diagram 261

9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

Index 263




Overview

Overview

About this manual

This manual contains instructions for:

• mechanical and electrical installation of the robot

• maintenance of the robot

• mechanical and electrical repair of the robot.

Usage

This manual should be used during:

• installation, from lifting the robot to its work site and securing it to the foundation, to making it ready for operation

• maintenance work

• repair work and calibration.

Who should read this manual?

This manual is intended for:

• installation personnel

• maintenance personnel

• repair personnel.

Prerequisites

A maintenance/repair/ installation craftsman working with an ABB Robot must:

• be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work.

Organization of chapters

The manual is organized in the following chapters:

Chapter Contents

Safety, service Safety information that must be read through before performing any installation or service work on robot. Contains general safety aspects as well as more specific information on how to avoid personal injuries and damage to the product.

Required information about lifting and installation of the robot.

Installation and commissioning

Maintenance Step-by-step procedures that describe how to perform maintenance of the robot. Based on a maintenance schedule that may be used to plan periodical maintenance.

Repair Step-by-step procedures that describe how to perform repair activities of the robot. Based on available spare parts.

Calibration information Procedures that do not require specific calibration equipment.

General information about calibration.

3HAC026660-001 Revision: C

Continues on next page

7

Overview

Continued

References

Revisions

Documentation referred to in the manual, is listed in the table below.

Document name Document Id

Product specification - IRB 1600

Product manual - IRC5

Operating manual - IRC5 with Flexpendant

Operating manual - Calibration pendulum

Operating manual - Service Information System

Application manual - Additional axes and stand alone controller

Technical reference manual - System parameter

3HAC023604-001

3HAC021313-001

3HAC16590-1

3HAC16578-1

3HAC025709-001

3HAC021395-001

3HAC17076-1

Note

Revision

-

A

B

C

Description

First edition. See also Type A of IRB 1600 on page 229

.

AW equipped upper arm 1600ID, IRB 1600-6/1.2, IRB 1600-6/1.45, IRB

1600-8/1.2 and IRB 1600-8/1.45 added.

Cleanroom added.

Changes made in:

• Prerequisites in section Overview .

• Oil change in section Maintenance .

Content updated in section:

• 2.6 Making robot ready for operation, Cleanroom / 2.6.1 Additional installation procedure


Product documentation, M2004

Product documentation, M2004

General

The robot documentation may be divided into a number of categories. This listing is based on the type of information contained within the documents, regardless of whether the products are standard or optional. This means that any given delivery of robot products will not contain all documents listed, only the ones pertaining to the equipment delivered.

However, all documents listed may be ordered from ABB. The documents listed are valid for

M2004 robot systems.

Product manuals

All hardware, robots and controllers, will be delivered with a Product manual that contain:

• Safety information

• Installation and commissioning (descriptions of mechanical installation, electrical connections)

• Maintenance (descriptions of all required preventive maintenance procedures including intervals)

• Repair (descriptions of all recommended repair procedures including spare parts)

• Additional procedures, if any (calibration, decommissioning)

• Reference information (article numbers for documentation referred to in Product manual, procedures, lists of tools, safety standards)

• Part list

• Foldouts or exploded views

• Circuit diagrams

Technical reference manuals

The following manuals describe the robot software in general and contain relevant reference information:

• RAPID Overview : An overview of the RAPID programming language.

• RAPID Instructions, Functions and Data types : Description and syntax for all

RAPID instructions, functions and data types.

• System parameters : Description of system parameters and configuration workflows.

Application manuals

Specific applications (for example software or hardware options) are described in

Application manuals . An application manual can describe one or several applications.

An application manual generally contains information about:

• The purpose of the application (what it does and when it is useful)

• What is included (for example cables, I/O boards, RAPID instructions, system parameters, CD with PC software)

• How to use the application

• Examples of how to use the application



9

Product documentation, M2004

Continued

Operating manuals

This group of manuals is aimed at those having first hand operational contact with the robot, that is production cell operators, programmers and trouble shooters. The group of manuals includes:

• Emergency safety information

• Getting started - IRC5 and RobotStudio

• IRC5 with FlexPendant

• RobotStudio

• Trouble shooting - IRC5 for the controller and robot


How to read the product manual

How to read the product manual

Reading the procedures

The procedures contain references to figures, tools, material etc. The references are read as described below.

References to figures

The procedures often include references to components or attachment points located on the robot/controller. The components or attachment points are marked with italic text in the procedures and completed with a reference to the figure where the current component or attachment point is shown.

The denomination in the procedure for the component or attachment point corresponds to the denomination in the referenced figure.

The table below shows an example of a reference to a figure from a step in a procedure.

Action Note/Illustration

8.

Remove the rear attachment screws, gearbox.

Shown in the figure Location of gearbox on page xx .

References to required equipment

The procedures often include references to equipment (spare parts, tools etc.) required for the different actions in the procedure. The equipment is marked with italic text in the procedures and completed with a reference to the section where the equipment is listed with further information, i.e. article number, dimension.

The denomination in the procedure for the component or attachment point corresponds to the denomination in the referenced list.

The table below shows an example of a reference to a list of required equipment, from a step in a procedure.

Action

3.

Fit a new sealing, axis 2 to the gearbox.

Note/Illustration

Art. no. is specified in Required equipment on page xx .

Safety information

The manual includes a separate safety chapter that must be read through before proceeding with any service or installation procedures. All procedures also include specific safety information when dangerous steps are to be performed.

Read more in chapter Safety .


How to read the product manual


1 Safety

1.1. Introduction

1 Safety

1.1. Introduction

Overview

The safety information in this manual is divided in two categories:

• general safety aspects, important to attend to before performing any service work on

the robot. These are applicable for all service work and are found in section General safety information on page 14

.

• specific safety information, pointed out in the procedure at the moment of the danger.

How to avoid and eliminate the danger is either detailed directly in the procedure, or further detailed in separate instructions, found in section Safety related instructions .


1 Safety

1.2.1. Safety in the robot system

1.2 General safety information

1.2.1. Safety in the robot system

Validity and responsibility

The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment, which can influence the safety of the total system. To protect personnel, the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed.

The users of ABB industrial robots are responsible for ensuring that the applicable safety laws and regulations in the country concerned are observed and that the safety devices necessary to protect people working with the robot system are designed and installed correctly.

Personnel working with robots must be familiar with the operation and handling of the industrial robot, described in the applicable documents, for example:

• Operating Manual - IRC5 with FlexPendant (M2004)

• Product Manual

Connection of external safety devices

Apart from the built-in safety functions, the robot is also supplied with an interface for the connection of external safety devices. Via this interface, an external safety function can interact with other machines and peripheral equipment. This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot.

Limitation of liability

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

Related information

Type of information Detailed in document

Installation of safety devices

Changing operating modes

Restricting the working space

Section

Product manual for the robot Installation and commissioning

Operating manual - IRC5 with

FlexPendant (RobotWare 5.0)

Operating modes

Product manual for the robot Installation and commissioning


1 Safety

1.2.2.1. Safety risks during installation and service work on robot

1.2.2. Safety risks

1.2.2.1. Safety risks during installation and service work on robot

Overview

This section includes information of general safety risks to be considered when performing installation and service work on the robot.

General risks during installation and service

• The instructions in the Product Manual, chapter Installation and Commissioning must always be followed.

• Emergency stop buttons must be positioned in easily accessible places so that the robot can be stopped quickly.

• Those in charge of operations must make sure that safety instructions are available for the installation in question.

• Those who install the robot must have the appropriate training for the robot system in question and in any safety matters associated with it.

Nation/region specific regulations

To prevent injuries and damage during the installation of the robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with.

Non-voltage related risks

• Safety zones, which have to be crossed before admittance, must be set up in front of the robot's working space. Light beams or sensitive mats are suitable devices.

• Turntables or the like should be used to keep the operator out of the robot's working space.

• The axes are affected by the force of gravity when the brakes are released. In addition to the risk of being hit by moving robot parts, you run the risk of being crushed by the parallel arm.

• Energy, stored in the robot for the purpose of counterbalancing certain axes, may be released if the robot, or parts thereof, are dismantled.

• When dismantling/assembling mechanical units, watch out for falling objects.

• Be aware of stored heat energy in the controller.

• Never use the robot as a ladder, that is do not climb on the robot motors or other part during service work. There is a serious risk of slipping because of the high temperature of the motors or oil spills that can occur on the robot.

To be observed by the supplier of the complete system

• The supplier of the complete system must ensure that all circuits used in the safety function are interlocked in accordance with the applicable standards for that function.

• The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner, in accordance with the applicable standards for the emergency stop function.



1 Safety

1.2.2.1. Safety risks during installation and service work on robot

Continued

Complete robot

Safety risk

Hot components!

Description

Removed parts may result in collapse of robot!

CAUTION!

Motors and gears are HOT after running the robot!

Touching the motors and gears may result in burns!

WARNING!

Take any necessary measures to ensure that the robot does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Cabling

Safety risk

Cable packs are sensitive to mechanical damage!

Description

CAUTION!

The cable packs are sensitive to mechanical damage!

They must be handled with care, especially the connectors, in order to avoid damaging them!

Gearboxes and motors

Safety risk

Gears may be damaged if excessive force is used!

Description

CAUTION!

Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used!


1 Safety

1.2.2.2. Safety risks related to tools/workpieces

1.2.2.2. Safety risks related to tools/workpieces

Safe handling

It must be possible to safely turn off tools, such as milling cutters, etc. Make sure that guards remain closed until the cutters stop rotating.

It should be possible to release parts by manual operation (valves).

Safe design

Grippers/end effectors must be designed so that they retain workpieces in the event of a power failure or a disturbance of the controller.

CAUTION!

Ensure that a gripper is prevented from dropping a workpiece, if such is used.


1 Safety

1.2.2.3. Safety risks related to pneumatic/hydraulic systems

1.2.2.3. Safety risks related to pneumatic/hydraulic systems

General

Special safety regulations apply to pneumatic and hydraulic systems.

Residual energy

• Residual energy may be present in these systems. After shutdown, particular care must be taken.

• The pressure in pneumatic and hydraulic systems must be released before starting to repair them.

Safe design

• Gravity may cause any parts or objects held by these systems to drop.

• Dump valves should be used in case of emergency.

• Shot bolts should be used to prevent tools etc. from falling due to gravity.


1 Safety

1.2.2.4. Safety risks during operational disturbances

1.2.2.4. Safety risks during operational disturbances

General

• The industrial robot is a flexible tool which can be used in many different industrial applications.

• All work must be carried out professionally and in accordance with the applicable safety regulations.

• Care must be taken at all times.

Qualified personnel

• Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts.

Extraordinary risks

If the working process is interrupted, extra care must be taken due to risks other than those associated with regular operation. Such an interruption may have to be rectified manually.


1 Safety

1.2.2.5. Risks associated with live electric parts

1.2.2.5. Risks associated with live electric parts

Voltage related risks, general

• Although troubleshooting may, on occasion, have to be carried out while the power supply is turned on, the robot must be turned off (by setting the mains switch to OFF) when repairing faults, disconnecting electric leads and disconnecting or connecting units.

• The mains supply to the robot must be connected in such a way that it can be turned off outside the robot’s working space.

Voltage related risks, IRC5 controller

A danger of high voltage is associated with for example the following parts:

• Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in the controller.

• Units such as I/O modules, can be supplied with power from an external source.

• The mains supply/mains switch

• The transformers

• The power unit

• The control power supply (230 VAC)

• The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)

• The drive unit (700 VDC)

• The drive system power supply (230 VAC)

• The service outlets (115/230 VAC)

• The customer power supply (230 VAC)

• The power supply unit for additional tools, or special power supply units for the machining process.

• The external voltage connected to the controller remains live even when the robot is disconnected from the mains.

• Additional connections.

Voltage related risks, robot

A danger of high voltage is associated with the robot in:

• The power supply for the motors (up to 800 VDC).

• The user connections for tools or other parts of the installation (max. 230 VAC, see chapter Installation and commissioning in the Product manual).

Voltage related risks, tools, material handling devices, etc

Tools, material handling devices, etc., may be live even if the robot system is in the

OFFposition. Power supply cables which are in motion during the working process may be damaged.


1 Safety

1.2.3.1. Safety fence dimensions

1.2.3. Safety actions

1.2.3.1. Safety fence dimensions

General

Install a safety cell around the robot to ensure safe robot installation and operation.

Dimensioning

Dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed. Determine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot is working in the work cell (see Product Specification - Description, Robot Motion ).

Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot.


1 Safety

1.2.3.2. Fire extinguishing

1.2.3.2. Fire extinguishing

NOTE!

Use a CARBON DIOXIDE (CO

2

) extinguisher in the event of a fire in the robot system (robot or controller)!


1 Safety

1.2.3.3. Emergency release of the robot’s arm

1.2.3.3. Emergency release of the robot’s arm

Description

In an emergency situation, any of the robot's axes may be released manually by pushing the brake release buttons on the robot.

How to release the brakes is detailed in section:

•

Manually releasing the brakes on page 47

.

The robot arm may be moved manually on smaller robot models, but larger models may require using an overhead crane or similar.

Increased injury

Before releasing the brakes, make sure that the weight of the arms does not increase the pressure on the trapped person, further increasing any injury!


1 Safety

1.2.3.4. Brake testing

1.2.3.4. Brake testing

When to test

During operation the holding brake of each axis motor wear normally. A test may be performed to determine whether the brake can still perform its function.

How to test

The function of the holding brake of each axis motor may be checked as detailed below:

1.

Run each robot axis to a position where the combined weight of the robot arm and any load is maximized (max. static load).

2.

Switch the motor to the MOTORS OFF position with the Operating mode selector on the controller.

3.

Check that the axis maintains its position.

If the robot does not change position as the motors are switched off, then the brake function is adequate.


1 Safety

1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s"

1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s"

NOTE!

Do not change "Transm gear ratio" or other kinematic system parameters from the

FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s".


1 Safety

1.2.3.6. Safe use of the FlexPendant

1.2.3.6. Safe use of the FlexPendant

NOTE!

The enabling device is a push button located on the side of the FlexPendant which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device is released or pushed all the way in, the robot is taken to the MOTORS OFF state.

To ensure safe use of the FlexPendant, the following must be implemented:

• The enabling device must never be rendered inoperative in any way.

• During programming and testing, the enabling device must be released as soon as there is no need for the robot to move.

• The programmer must always bring the FlexPendant with him/her, when entering the robot's working space. This is to prevent anyone else taking control of the robot without the programmer knowing.


1.2.3.7. Work inside the robot's working range

1 Safety

1.2.3.7. Work inside the robot's working range

WARNING!

If work must be carried out within the robot’s work envelope, the following points must be observed:

• The operating mode selector on the controller must be in the manual mode position to render the enabling device operative and to block operation from a computer link or remote control panel.

• The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in position "manual mode with reduced speed". This should be the normal position when entering the working space. The position "manual mode with full speed (100%)" may only be used by trained personnel who are aware of the risks that this entails.

• Pay attention to the rotating axes of the robot! Keep a distance to the axes in order not to get entangled with hair or clothing. Also be aware of any danger that may be caused by rotating tools or other devices mounted on the robot or inside the cell.

• Test the motor brake on each axis, according to section

Brake testing on page 24 .


1 Safety

1.2.3.8. Signal lamp (optional)

1.2.3.8. Signal lamp (optional)

Description

A signal lamp with an yellow fixed light can be mounted on the robot, as a safety device.

Function

The lamp is active in MOTORS ON mode.

Further information

Further information about the MOTORS ON/MOTORS OFF mode may be found in the controller documentation.


1 Safety

1.2.3.9. Translate the information on safety and information labels

1.2.3.9. Translate the information on safety and information labels

Labels on the product

Both the robot and the controller are marked with several safety and information labels, containing important information about the product. The information is useful for all personnel handling the robot system, eg. during installation, service or operation.

Translation possibilities

The labels fitted to the product contain space for adding a fourth language underneath the three standard languages (English, German and French).

Add a local language to the label by:

• Using a transparent sticker over the standard label with text added in a fourth language. Drawings detailing the design (text, figure, dimensions) of the standard labels can be ordered from ABB. Notice that each label is identified according to the article number located in the lower corner of the label.

Example of transparent sticker

The figure below shows the location of the free space on one of the labels on the robot, where the fourth language can be added. The figure also shows a transparent sticker, containing the text in Swedish.

xx0500002517

A Free space for adding a fourth language


1 Safety

1.3.1. Safety signals, general

1.3 Safety related instructions

1.3.1. Safety signals, general

General

This section specifies all dangers that may arise from performing the work detailed in the manual. Each danger is detailed in its own section consisting of:

• A caption specifying the danger level (DANGER, WARNING or CAUTION) and the type of danger.

• A brief description of what will happen if the operator/service personnel do not eliminate the danger.

• An instruction of how to eliminate the danger to facilitate performing the activity at hand.

Danger levels

The table below defines the captions specifying the danger levels used throughout this manual.

Symbol danger warning

Designation

DANGER

WARNING

ELECTRICAL

SHOCK

Signification

Warns that an accident will occur if the instructions are not followed, resulting in a serious or fatal injury and/or severe damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height etc.

Warns that an accident may occur if the instructions are not followed, that can lead to serious injury, possibly fatal, and/or great damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height etc.

The electrocution or electrical shock symbol indicates electrical hazards which could result in severe personal injury or death.

Electrical shock

CAUTION caution

Warns that an accident may occur if the instructions are not followed, that can result in injury and/or damage to the product. It also applies to warnings of risks that include burns, eye injury, skin injury, hearing damage, crushing or slipping, tripping, impact, fall from height etc. Furthermore, it applies to warnings that include function requirements when fitting and removing equipment, where there is a risk of damaging the product or causing a breakdown.

30



Symbol

1 Safety

1.3.1. Safety signals, general

Continued

Designation Signification

ELECTROSTATIC

DISCHARGE (ESD)

The electrostatic discharge (ESD) symbol indicates electrostatic hazards which could result in severe damage to the product.

Electrostatic discharge

(ESD)

NOTE Note symbols alert you to important facts and conditions.

Note

TIP Tip symbols direct you to specific instructions, where to find additional information or how to perform a certain operation in an easier way.

Tip


1 Safety

1.3.2. DANGER - Moving robots are potentially lethal!

1.3.2. DANGER - Moving robots are potentially lethal!

Description

Any moving robot is a potentially lethal machine.

When running the robot, it may perform unexpected and sometimes irrational movements.

However, all movements are performed with great force and may seriously injure any personnel and/or damage any piece of equipment located within the working range of the robot.

Elimination

Action Note

1. Before attempting to run the robot, make sure all emergency stop equipment is correctly installed and connected.

Emergency stop equipment such as gates, tread mats, light curtains, etc.

2. If possible, use the hold-to-run function whenever possible.

The hold-to-run function is used in manual mode, not in automatic mode.

How to use the hold-to-run function in

RobotWare 5.0 is detailed in section How to use the hold-to-run function in the

Operating manual - IRC5 with Flex-

Pendant .

3. Make sure no personnel are present within the working range of the robot before pressing the start button.


1 Safety

1.3.3. DANGER - First test run may cause injury or damage!

1.3.3. DANGER - First test run may cause injury or damage!

Description

Since performing a service activity often requires disassembly of the robot there are several safety risks to take into consideration before the first test run.

Elimination

Follow the procedure below when performing the first test run after a service activity (repair, installation or maintenance):

Action

1. Remove all service tools and foreign objects from the robot and its working area!

2. Install all safety equipment properly!

3. Make sure all personnel are standing at a safe distance from the robot, that is out of its reach behind safety fences, etc!

4. Pay special attention to the function of the part previously serviced!


1 Safety

1.3.4. WARNING - The brake release buttons may be jammed after service work

1.3.4. WARNING - The brake release buttons may be jammed after service work

Description

The brake release unit has push buttons for brake release of each axis motor. When service work is performed inside the SMB recess that includes removal and refitting of the brake release unit, the brake release buttons may be jammed after refitting.

In case the power is turned on while a brake release button is jammed in depressed position, the affected motor brake is released! This may cause serious personal injuries and damage to the robot.

Elimination

To eliminate the danger after service work has been performed inside the SMB recess, follow the procedure below.


1. Make sure the power is turned off.

2. Refit the push button guard, if removed.

3. Check the push buttons of the brake release unit by pressing them down, one by one.

Make sure none of the buttons are jammed by the push button guard!

4. If a button gets jammed in the depressed position, the alignment of the push button unit must be adjusted so that the buttons can move freely!

Remove the push button guard and:

• Make sure the centering piece (B) is properly fitted to the unit. (The piece aligns the unit vertically.)

• Adjust the unit sideways so that the measurements x1 and x2 in the figure to the right do not differ more than 1 mm from each other.

xx0600002776

Art. no. for the centering piece is specified in

Required equipment on page 173 .

5. Refit the push button guard and check the buttons again by pressing them down, one by one.


1 Safety

1.3.5. WARNING - The unit is sensitive to ESD!

1.3.5. WARNING - The unit is sensitive to ESD!

Description

ESD (electrostatic discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not grounded may potentially transfer high static charges. This discharge may destroy sensitive electronics.

Elimination

Action Note

1. Use a wrist strap Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly.

2. Use an ESD protective floor mat.

The mat must be grounded through a currentlimiting resistor.

3. Use a dissipative table mat.

The mat should provide a controlled discharge of static voltages and must be grounded.

Location of wrist strap button

The wrist strap button is located in the right corner as shown in the illustration below.

xx0500002171

A Wrist strap button


1 Safety

1.3.6. WARNING - Safety risks during work with gearbox oil

1.3.6. WARNING - Safety risks during work with gearbox oil

Description

When handling the gearbox oil, there are several dangers to both personal injuries and product damages! Following safety information must be regarded before performing any work with the oil in the gearboxes!

Warnings and elimination

Warning Description Elimination / Action

Changing and draining gearbox oil may require handling hot oil of up to 90 °C!

Make sure that protective gear like goggles and gloves are always worn during this activity.

-

Hot oil!

When opening the oil plug, there may be pressure present in the gearbox, causing oil to spray from the opening!

Open oil plug carefully and keep away from the opening. Do not overfill the gearbox when filling.

-

Possible pressure build up in gearbox!

-

Do not overfill!

-

Do not mix types of oil!

Overfilling of gearbox oil can lead to internal over-pressure inside the gearbox which in turn may:

• damage seals and gaskets

• completely press out seals and gaskets

• prevent the robot from moving freely.

Make sure not to overfill the gearbox when filling with oil!

After filling, check the correct oil level.

Mixing types of oil may cause severe damage to the gearbox!

When filling gearbox oil, do not mix different types of oil unless specified in the instruction.

Always use the type of oil specified by the manufacturer!

Warm oil drains quicker than cold oil.

When changing gearbox oil, first run the robot for a time to heat up the oil.

-

Heat up the oil!

-

Specified amount depends on drained volume!

The specified amount of oil is based on the total volume of the gearbox. When changing the oil, the amount of refilled oil may differ from the specified amount, depending on how much oil has previously been drained from the gearbox.

After refilling, check the oil level.


2 Installation and commissioning

2.1. Introduction



General

This chapter contains information for installing the robot to the working site.

More detailed technical data, such as load diagram, permitted extra loads (equipment) and location of extra loads (equipment), may be found in the Product Specification for the robot.



2.2.1. Pre-installation procedure

2.2 Unpacking

2.2.1. Pre-installation procedure

General

This instruction is primarily intended for use when unpacking and installing the robot for the first time. It also contains information useful during later re-installation of the robot.

Checking the pre-requisites for installation

The check-list below details what must be observed before proceeding with the actual installation of the robot:

Action Detailed in section:

1. Make sure only qualified installation personnel conforming to all national and local codes are allowed to perform the installation.

2. Make sure the robot has not been damaged, by visually inspecting its exterior.

3. Make sure the lifting device to be used is dimensioned to handle the weight of the robot.

Weight on page 38 .

4. If the robot is not to be installed directly, it must be stored.

5. Make sure the appointed operating environment of the robot conforms to the specifications.

Storage conditions on page 39

.

Operating conditions on page 39 and Protection classes on page

39

.

6. Before taking the robot to its installation site, make sure the site conforms to applicable requirements.

Loads on foundation on page 38

and Requirements, foundation on page 39 .

7. Before moving the robot, make sure it does not tip over!

8. When these prerequisites have been met, the robot may be taken to its installation site.

Lifting robot with roundsling on page 45 .

Weight

The table below shows the weight of the robot model.

Robot model Weight

IRB 1600 - x/1.2

IRB 1600 - x/1.45

247 kg

250 kg

Loads on foundation

The table below shows the various forces and torques working on the robot during different kinds of operation. Note!

These forces and torques are extreme values that are rarely encountered during operation. The values also never reach their maximum at the same time!

Force Mounting Endurance load

Max. load

(emergency stop)

Force XY Floor mounted

Suspended

Wall mounted

± 1650 N

± 1650 N

± 3900 N

± 31500 N

± 3150 N

± 5300 N

38




2.2.1. Pre-installation procedure

Continued

Force

Force Z

Torque XY

Torque Z

Mounting

Floor mounted

Suspended

Wall mounted

Floor mounted

Suspended

Wall mounted

Floor mounted

Suspended

Wall mounted

Endurance load

- 2500 ± 1150 N

+ 2500 ± 1150 N

± 1300 N

± 1700 Nm

± 1700 Nm

± 2310 Nm

± 855 Nm

± 855 Nm

± 855 Nm

Max. load

(emergency stop)

- 2500 ± 2200 N

+ 2500 ± 2200 N

± 2400 N

± 3750 Nm

± 3750 Nm

± 3850 Nm

± 1400 Nm

± 1400 Nm

± 1430 Nm

Requirements, foundation

The table below shows the requirements for the foundation where the weight of the installed robot is included.

Requirement Value Note

Levelness max. 0.5 mm The value for levelness aims at the circumstance of the three anchoring points in the robot base.

Storage conditions

The table below shows the allowed storage conditions for the robot.

Parameter Value

Min. ambient temperature -25º C

Max. ambient temperature +55º C

Max. ambient temperature (less than 24 hrs) +70º C

Max. ambient humidity Max. 95% at constant temperature

Operating conditions

The table below shows the allowed operating conditions for the robot.

Parameter Value

Min. ambient temperature

Max. ambient temperature

Max. ambient humidity

+5º C

+45º C

Max. 95% at constant temperature

Protection classes

The table below shows the protection class of the robot.

Equipment Protection class

Robot, standard

Robot, Foundry

Robot, Wash

IP 54

IP 67

IP 67



2.2.2. Working range

2.2.2. Working range

General

This section specifies the working ranges for the different robot models. The turning radius is also shown separately in the last figure.

Illustration, working range IRB 1600 - x/1.2

40

5

6

3

4

7

0

1

2 xx0400001260

Pos Positions at wrist center (mm)

X

750

150

494

1225

897

386

321

-808

Z

961.5

1561.5

470

486.5

-287

737

786

975

Angle (degrees) axis 2

0º

0º

0º

+90º

+136º

+136º

-63º

-63º axis 3

0º

-90º

+55º

-90º

-90º

-235º

+55º

-90º



Illustration, working range IRB 1600 - x/1.45



Continued

6

7

4

5

2

3

0

1 xx0400001261

Pos Positions at wrist center (mm)

X

750

150

404

1450

800

448

-6

-1150

Z

1186.5

1786.5

643

486.5

-639

478

740

486.5


0º

0º

0º

+90º

+150º

+150º

-90º

-90º axis 3

0º

-90º

+65º

-90º

-90º

-245º

+65º

-90º



41



Continued

Illustration, working range IRB 1600 ID

42

6

7

4

5

2

3

0

1 xx0700000136

Pos Positions at wrist center (mm)

X Z

790

150

1296,5

1836

380

1499,5

720,5

397,5

57,5

-1199,5

579

486,5

-736,5

499,5

716,5

486,5

0

0


0

+90

+150

+150

-90

-90 axis 3

0

-80

+79

-80

-80

-238

79

-80





Continued

Working ranges

Axis

Axis 1

Axis 2

Axis 3

Axis 4

Axis 5

Axis 6

IRB 1600 - x/1.2

IRB 1600- x/1.45

Note

+180º to -180º +180º to -180º Axis 1 working range has the following limitations:

• ±45º when tilting the robot up to 30º.

• ±20º for a wall mounted

IRB 1600-5/1.2

IRB 1600-6/1.2

IRB 1600-7/1.2

IRB 1600-5/1.45

IRB 1600-6/1.45

IRB 1600-7/1.45

• ±45º for a wall mounted

IRB 1600-8/1.2

IRB 1600-8/1.45

+110º to -63º +120º to -90º

+136º to -63º (with axis 1 limited to ±100º)

+150º to -90º (with axis 1 limited to ±95º)

+55º to -235º

+200º to -200º

+190 to -190 revolutions

+65º to -245º

+200º to -200º


Default value

Maximum value.

The default working range for axis

4 can be extended by changing parameter values in the software.

+115º to -115º

+400º to -400º


+115º to -115º

+400º to -400º


Default

Maximum value.

The default working range for axis

6 can be extended by changing parameter values in the software.



43



Continued

Turning radius

The turning radius for the robot is shown in the figure below. Notice the differences depending on the length of the lower arm.

xx0400001259

(A) Minimum turning radius axis 1 (all models)



2.3.1. Lifting robot with roundsling

2.3 On-site installation

2.3.1. Lifting robot with roundsling

Recommended lifting position

The figure below shows the recommended lifting positions. It is important that the roundsling has free space and does not wear against any part of the robot.

A - A

A

A

A

A

A

A

Required equipment xx0400001296

Equipment

Overhead crane

Roundsling -

-

Art. no.

Note

Lifting capacity: 500 kg.

Length: 2 m.

Lifting capacity: 500 kg.

Lifting the robot with roundsling

Action

1. Move the robot to an appropriate lifting position.

2. Secure the roundsling safely at the lifting eye and at the overhead crane.

Make sure the roundsling has free space and does not wear against any part of the robot.

Note

Shown in the figure

Recommended lifting position on page 45

.

Capacity for the roundsling is specified

in Required equipment on page 45 .

Attachment is shown in the figure

Recommended lifting position on page

45 .



45


2.3.1. Lifting robot with roundsling

Continued

3.

Action

4.

CAUTION!

The robot weighs 250 kg! All lifting equipment must be sized accordingly!

WARNING!

Personnel must not, under any circumstances, be present under the suspended load!

5. Raise the overhead crane to lift the robot.

Note



2.3.2. Manually releasing the brakes

2.3.2. Manually releasing the brakes

General

The section below details how to release the holding brakes of each axis' motor.

This may be done in one of three ways:

• using the brake release unit when the robot is connected to the controller.

• using the brake release unit when the robot is disconnected from the controller, but connected to an external power supply at the connector R1.MP.

• using an external voltage supply directly on the motor connector.

Using the brake release unit when the robot is connected to the controller

This section details how to release the holding brakes using the internal brake release unit.

Action

1. The internal brake release unit is located at the base of the robot and equipped with six buttons for controlling the axes brakes. The buttons are numbered according to the numbers of the axes.


2.

DANGER!

When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways!

Make sure no personnel is near the robot arm!

3. Release the holding brake on a particular robot axis by pressing the corresponding button on the internal brake release panel and keeping it depressed.

The brake will function again as soon as the button is released.

xx0400001255



47


2.3.2. Manually releasing the brakes

Continued

Using the brake release unit with an external power supply

This section details how to release the holding brakes with the internal brake release unit using an external voltage supply. This is done if the robot is not connected to the controller.


1.

DANGER!

Incorrect connections, such as supplying power to the wrong pin, may cause all brakes to be released simultaneously!

Also, be careful not to interchange the

24V and 0V pins. If they are mixed up, damage can be caused to a resistor diode and to the system board.

2. Connect an external power supply to connector R1.MP.

Supply:

• 0V on pin C10

• 24V on pin B8.

3. Push the brake release button to release the holding brakes, according to the previous procedure.

xx0400001302



2.3.3. Orienting and securing the robot

2.3.3. Orienting and securing the robot

General

This section details how to orient and secure the robot at a horizontal level at the installation site.

Hole configuration, base

The figure below shows the hole pattern and dimensions of the robot base.

xx0400001300

A Center of axis 1



49



Continued

Dimension, mounting surface and guiding sleeve

The figure below shows the dimension of the mounting surface and guiding sleeves, if used.

xx0400001306

Attachment bolts, specification

Attachment bolts, 3 pcs

50

Washers, 3 pcs

Quality

Tightening torque

M16 x 60 (installation directly on foundation of steel)

M16 x 70/80 (installation on foundation or base plate, using guiding sleeves)

17 x 30 x 3

Quality 8.8 (wall or angle mounted robot: Quality 12.9)

200 Nm



Guiding sleeves, 2 pcs



Continued

(needed if wall or angle mounted, or if the robot is calibrated with AbsAcc)

Orienting and securing the robot to installation site

Action Note

1. Make sure the installation site for the robot

conforms to the specifications in section Preinstallation procedure on page 38

.

2. Prepare the installation site with attachment holes.

If the robot is calibrated with AbsAcc, it must be installed using guiding sleeves.

3. Lift the robot to the installation site.

Hole configuration of the base is shown

in the figure Hole configuration, base on page 49 .

Dimension of mounting surface and the guiding sleeves are shown in the figure

Dimension, mounting surface and guiding sleeve on page 50

.

Detailed in section

Lifting robot with roundsling on page 45

.

4. Guide the robot gently using two of the M16 attachment bolts while lowering it into its mounting position.

5. Fit and tighten the bolts and washers in the base attachment holes.

Specified in section Attachment bolts, specification on page 50

.



2.3.4. Suspended mounting

2.3.4. Suspended mounting

General

Initially the system is configured for mounting on the floor, without leaning. The method for mounting the robot in a suspended position is basically the same as for floor mounting.

NOTE!

With suspended installation, make sure that the gantry or corresponding structure is rigid enough to prevent unacceptable vibrations and deflections, so that optimum performance can be achieved.

System parameters

If the robot is mounted at any other angle, the system parameter “gravity beta” must be updated. Gravity beta specifies the robot’s mounting angle expressed in radians.

NOTE!

It is very important to configure gravity beta correctly so that the robot system can control the movements in the best possible way. Incorrect definition of mounting angle (gravity beta) will result in:

• Overloading the mechanical structure.

• Lower path performance and path accuracy.

• Some functions will not work properly: for example Load Identification & Collision detection.

Mounting angles and values

The parameter “gravity beta” specifies the robot’s mounting angle in radians. It is calculated in the following way for a mounting angle of 45°.

Gravity beta = 45° x 3.141593/180 = 0.785398 radians.

Example of position Mounting angle

Floor (A)

Tilted (B)

Wall (C)

Suspended (D)

0°

30º

90°

180°

Gravity beta

0.000000 (Default)

0.523599

1.570796

3.141593

52





Continued xx0600002779

C

D

A

B

Floor mounted

Tilted mounting, mounting angle 30º

Wall mounted, mounting angle 90º

Suspended mounting, mounting angle 180º

Limitations in working area

If tilting a floor mounted robot or mounting the robot on a wall, the working range of axis 1 is limited. These limitations are specified in the table

Working ranges on page 43 .



53



Continued

Defining the parameter

The value of the system parameter Gravity beta must be redefined when changing the mounting angle of the robot. The parameter belongs to the type Robot , in the topic Motion .

How to calculate a new value is detailed in Mounting angles and values on page 52 .

The parameter is further detailed in the Technical reference manual - System parameters .

The parameter can be edited either with the FlexPendant or in RobotStudio. Read about how to change the parameter in the Operating manual - IRC5 with FlexPendant or in the

Operating manual - RobotStudio . Article numbers for the manuals are specified in

References on page 8 .



2.3.5. Loads

2.3.5. Loads

General

Any loads mounted on the manipulator must be defined correctly and carefully (with regard to the position of centre of gravity and inertia factor) in order to avoid jolting movements and overloading the motors. If this is not done correctly operation stops may result.

References

Load diagrams, permitted extra loads (equipment) and their positions as specified in the

Product Specification. The loads must also be defined in the software as detailed in Operating manual - IRC5 with FlexPendant .

Brake performance

Manipulator motor brake performance depends on any loads attached. For further information about brake performance, please contact ABB.



2.3.6. Fitting equipment on the robot (robot dimensions)

2.3.6. Fitting equipment on the robot (robot dimensions)

General

This section shows the robot dimensions and available mounting holes on the robot.

Main dimensions

The figures below show the main dimensions of the robot. The remaining dimensions and mounting holes on the upper arm, frame and turning disk are shown in the following figures.

56 xx0400001253

(A) Centerline of axis 1

(B) Smallest circumscribed radius, axis 1





Continued

Main dimension 1600 ID

The figure below shows the main dimensions for 1600 ID robot.

xx0700000118

(A)

(B)

Centerline of axis 1

Smallest circumscribed radius, axis 1



57



Continued

Mounting holes on the frame

The three available mounting holes for equipment on the frame must be threaded according to the figure below.

xx0400001252

1)

Prepared for threading M8 x max depth 20 mm

58





Continued

Dimensions of the upper arm and mounting holes

The figure below shows the dimensions of the upper arm and available mounting holes for equipment on the arm.

xx0600002859

(A)

(B)

(C)

(D)

(E)



Turning radius for axis 3

Smallest circumscribed radius for axis 4

Mounting holes for equipment (depth 10 mm)



59



Continued

Dimensions of the upper arm and mounting holes for 1600 ID

The figure below shows the dimensions of the upper arm and available mounting holes for equipment on the arm.

60 xx0700000119





Continued

Dimensions of the turning disk

The figure below shows the dimensions of the turning disk.

xx0200000063

Dimensions of the turning disk 1600ID

The figure below shows the dimensions of the turning disk on a IRB 1600ID

Fastener quality xx0700000090

When fitting tools on the turning disk, use only screws with quality 12.9. When fitting equipment on other places, standard screws with quality 8.8 can be used.



2.3.7. Installation of signal lamp for 1600 (option)

2.3.7. Installation of signal lamp for 1600 (option)

General

A signal lamp with an yellow fixed light can be mounted on the robot, as a safety device. The signal lamp is required on an UL/UR approved robot.


Location of signal lamp

The signal lamp is fitted to the upper arm housing of the robot, as shown in the figure below.

xx0400001265

A

C

D

E

F

Signal lamp

Cable gland

Cable bracket

Attachment holes for the signal lamp

Cover, upper arm housing

Required equipment

Equipment

Signal lamp

Art. no.

3HAC 022235-001

Note

62




2.3.7. Installation of signal lamp for 1600 (option)

Continued

Equipment

Gasket, customer connections

Gasket, upper arm cover

Art. no.

3HAC 022050-001

3HAC 022049-001

Note

Replace if damaged.

Replace if damaged.

Installation, signal lamp

The procedure below details how to install the signal lamp to the robot.


1.

Action

DANGER!

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

2. Remove the cover from the upper arm housing to get access to the connectors inside the housing.

Shown in the figure

Location of signal lamp on page 62

.

3. Remove the protection plug (A) from the insertion hole in the contact panel.

Run the cables of the lamp through the hole in the contact panel. Secure the cable gland in the hole.

xx0400001264

• A: Plug with o-ring, M10

4. Connect the lamp connectors, R3.H1 and

R3.H2 and place the cables safely inside the housing.

5. Take out the lamp unit through the hole in the upper arm housing cover and refit the cover.

Make sure the gaskets are not damaged.

6. Fit the cable bracket of the signal lamp to the two mounting holes in the upper arm housing

(B).

Shown in the figure


.

Shown in the figure


.

7. The signal lamp is now ready for use and is lit in MOTORS ON mode.

xx0400001263

• B: Mounting holes, M8 x 12



2.3.8. Installation of signal lamp for 1600 ID (option)

2.3.8. Installation of signal lamp for 1600 ID (option)

General

A signal lamp with an yellow fixed light can be mounted on the robot, as a safety device. The signal lamp is reqired on an UL/UR approved robot.


Location of signal lamp

The signal lamp is fitted to the upper arm housing of the robot, as shown in the figure below xx0700000100

A

B


Equipment

Signal lamp

Drill

Standard toolkit

Signal lamp


-

-

Art. no.

3HAC9258-1

64

Note

Spare part list, upper arm on page 254

Diameter 22,5 mm

The contents of the toolkit is defined in section,

Standard toolkit on page 237




2.3.8. Installation of signal lamp for 1600 ID (option)

Continued

1.


DANGER!


2. Remove the cover from the upper arm housing .

Shown in the figure Location of signal lamp on page 64

.

3. On the cover there is a mark where the lamp is to be installed. Find the mark and drill a hole with a diameter of 22.5mm.

4. Fit the lamp and tighten the nut.

5. In the upper arm housing find the two cables marked

R3.H1 and R3.H2 and connect them with the lamp

6. Refit the cover on the upper arm housing.

7. The signal lamp is now ready for use and is lit in

MOTORS ON mode.



2.4.1. Introduction

2.4 Restricting the working range

2.4.1. Introduction

General

When installing the robot, make sure that it can move freely within its entire working space.

If there is a risk that it may collide with other objects, its working space should be limited.

The working range of the following axes may be restricted:

• Axis 1, hardware (mechanical stop and position switch)

• Axis 2, hardware (mechanical stop)

• Axis 3, hardware (mechanical stop)

This section describes how to install hardware that restricts the working range.

Notice that adjustments must also be made in the software. References to software manuals are given in the following installation procedures.



2.4.2. Installation of additional mechanical stops on axis 1

2.4.2. Installation of additional mechanical stops on axis 1

General

This section details how to install additional mechanical stops on axis 1 in order to restrict the working range of the axis.

Restrictions in working range

The working range of axis 1 can be restricted by fitting one or two additional mechanical stops on the casted groove at the base.

The figure below shows both the minimum and maximum working range of the robot, when restricted by the additional mechanical stops. The working range can be restricted freely within the shown scope, depending on where the mechanical stop is installed along the casted groove.

+ 6

4 º

A

- 6 4

º

A

1

+

8

6

º -1

6

º

8

B

B xx0400001286

A

B

Mounting position of two additional stops for maximum working area (±168º)

Mounting position of two additional stops for minimum working area (±64º)



67



Continued

Illustration, mechanical stop, axis 1

The additional mechanical stop of axis 1 is fitted to the base of the robot, as shown in the figure below.

xx0400001287

C

E

A

B

F

G

Mechanical stop, axis 1 (additional)

Attachment bolts and washers, mechanical stop

Stop pin (standard)

Casted groove

Guiding pin

Hidden stiffening ribs


Equipment

Working range limit axis 1

Technical reference manual - System parameters (RobotWare 5.0)

Art. no.

Note

-

3HAC023110-001 Includes mechanical stops

(2 pcs), attachment bolts and washers.

Art. no. is specified in section


68





Continued

Installation of mechanical stop, axis 1

The procedure below details how to install the mechanical stop to axis 1.


1.

Action

DANGER!


2. Place the stop at the base, with the guiding pin in the casted groove. Turn the stop until the holes align with the groove.

The stop can be mounted in either direction, resulting in differences in the working range.

xx0400001288

Also see the figure

Illustration, mechanical stop, axis 1 on page

68

.

3. Drill two holes in the casted groove, with guidance from the circular and the elliptical hole.

Drill the holes through 10.2 mm.

If drilling in a stiffening rib, drill depth must be min.

30 mm.

4. Cut the threads M12.

If cutting in a stiffening rib, thread depth must be min. 23 mm.

5. Fit the stop to the base without tightening the bolts.

6. Turn axis 1 manually and check the working area between the stops.

7. Tighten the bolts.

How to release the holding brake of the axis motor is detailed in section

Manually releasing the brakes on page 47 .

2 pcs/stop: M12 x 40, tightening torque: 85 Nm.

8. The software working range limitations must be redefined to correspond to the changes in the mechanical limitations of the working range.

The system parameters that must be changed in RobotWare 5.0

(Upper joint bound and Lower joint bound) are further detailed in

Technical reference manual -

System parameters .

9.

WARNING!

If the mechanical stop is deformed after a hard collision, it must be replaced!



2.4.3. Installation of additional mechanical stop on axis 2

2.4.3. Installation of additional mechanical stop on axis 2

General

This section details how to install an additional mechanical stop on axis 2 in order to restrict the working range of the axis.


The working range of axis 2 can be restricted by fitting an additional mechanical stop at the frame. The working range can only be restricted backwards, as shown in the figures below.

Notice the different working ranges for the different models!

xx0400001289

70 xx0400001290





Continued


The additional mechanical stop for axis 2 is fitted together with a damper to the frame, as shown in the figure below.

xx0400001291

D

E

F

A

B

C

Mechanical stop, axis 2

Attachment bolts, mechanical stop (2 pcs)

Attachment holes, mechanical stop

Damper, axis 2

Washer

Attachment screw, damper


Equipment


Technical reference manual - System parameters (RobotWare 5.0)

-

Art. no.

3HAC023108-001

Note

Includes mechanical stop, damper and attachment bolts.






1.

Action

DANGER!


2. Fit the mechanical stop to the frame, without tightening the bolts.

Attachment holes are shown in the

figure Illustration, mechanical stop, axis 2 on page 71

.



71



Continued

Action

3. Make sure that the stop is in contact with the lower boss on the gearbox, as the arrow shows in the figure to the right.


72 xx0400001292

NOTE!

It is important that the mechanical stop is fitted in contact with the lower boss on the gearbox!

4. Tighten the attachment bolts.

2 pcs; M8 x 35, tightening torque: 25

Nm.

5. Fit the damper to the mechanical stop, with its attachment screw and washer. Tighten the screw.

Shown in the figure

Illustration, mechanical stop, axis 2 on page 71

.

6. The software working range limitations must be re-defined to correspond to the changes in the mechanical limitations of the working range.




System parameters .

7.

WARNING!





2.4.4. Installation of additional mechanical stops on axis 3

General

This section details how to install an additional mechanical stop on axis 3 in order to restrict the working range of the axis.


The working range of axis 3 can be restricted into two different working areas, as shown in the two figures below. Notice the differences between the different models.

xx0400001283

-

A

B

Robot models IRB 1600 - x/1.2

Working range A

Working range B



73




-

A

B

Robot models IRB 1600 - x/1.45

Working range A

Working range B


The mechanical stop is installed at the upper arm housing, as shown in the figure below.

74 xx0400001285

A

B

Mechanical stop, axis 3

Attachment screws and washers (2 pcs)





Continued


Equipment Art. no.

Note


Technical reference manual -

System parameters (RobotWare 5.0)

-

3HAC023109-001 Includes mechanical stop, attachment screws and washers.


References on page 8

.



Note

1.

Action

DANGER!


2. Fit the mechanical stop to the two mounting holes at the upper arm housing, with the two attachment screws and washers. Tighten the screws.

Shown in the figure Illustration, mechanical stop, axis 3 on page 74 .

2 pcs: M8 x 25, tightening torque: 25

Nm.





System parameters .

4.

WARNING!




2.4.5. Installation of position switch, axis 1

2.4.5. Installation of position switch, axis 1

General

This section details how to install the position switch to axis 1.

Location of position switch, axis 1

The position switch is installed between the frame and the base, as shown in the figure below.

xx0400001356

I

H

D

E

F

G

A

B

C

Position switch

Attachment screws, position switch, 2 pcs: M6 x 30

Holder ring (2 parts)

Attachment screws, holder ring, 6 pcs: M8 x 12

Cam

Bracket

Attachment screws, housing, 2 pcs: M6 x 8

Cable straps

Attachment screws, attachment plate, 2 pcs: M6 x 16


Equipment

Position switch, axis 1

Technical reference manual -

System parameters

(RobotWare 5.0)

Art. no.

3HAC023973-

001

Note

Includes 3 switches.

All parts are included in the delivery.

Instruction of how to cut the cams is enclosed in the kit.

Art. no. is specified in section References on page 8

.

76





Continued

Installation, position switch axis 1

The procedure below details how to install the position switch to the robot.

Note

1.

Action

DANGER!


2. Fit the two holder ring s underneath the frame with the six attachment screws.

Shown in the figure

Location of position switch, axis 1 on page 76 .

6 pcs, M8 x 12.

3. Cut the cams according to instructions, enclosed with the position switch kit.

4. Fit the cams to the holder ring with the attachment screws.

Shown in the figure


M6 x 12.

2 pcs, M6 x 30.

5. Attach the position switch to the bracket with two attachment screws.

6. Fit the complete bracket to the base of the robot with the two attachment screws.

Shown in the figure


2 pcs, M6 x 8.

7. Fit the attachment plate to the base of the robot with the two attachment screws.

Fit the switches to the attachment plate.

Adjust the height of the switches with shims until each roller aligns with corresponding cam.

2 pcs, M6 x 16.

Shown in the figure


8. Secure the cabling inside the housing with cable straps .

xx0400001358

A. Attachment plate

B. Shims

C. Roller

D. Cam

Shown in the figure




77



Continued

Action Note

9. Connect the position switch cabling.


The cabling and connection points are specified in section

Position switch cables, robot base to controller (option) on page 82

.

The system parameters that must be changed in RobotWare 5.0 (Upper joint bound and Lower joint bound) are further detailed in Technical reference manual -

System parameters .



2.5.1. Connectors on robot

2.5 Electrical connections

2.5.1. Connectors on robot

Connectors on the robot

The figure below shows all connections of the robot cabling, including the customer connectors.

xx0400001262

A

B

Connection for air

Connection for signal lamp



79


2.5.1. Connectors on robot

Continued

Connectors on the robot upper arm IRB 1600ID

The figure below shows connections on the upper arm IRB 1600 ID

B

R4.FB5

R4.FB6

A

F

R4.MP5

R4.MP6

E xx0700000038

R3.FB3

R3.FB4

R3.FB5

R3.FB6

R3.MP3

R3.MP4

R3.MP5

R3.MP6



2.5.2. Robot cabling and connection points

2.5.2. Robot cabling and connection points

General

Connect the robot and controller to each other after securing them to the foundation. The lists below specify which cables to use for each respective application.

Main cable categories

All cables between the robot and controller are divided into the following categories:

Cable category Description

Robot cables

Position switch cables

(option)

Handles power supply to and control of the robot's motors as well as feedback from the serial measurement board.

Specified in the table

Robot cables on page 81

.

Handles supply to and feedback from any position switches on the robot.

Specified in the table

Position switch cables, robot base to controller (option) on page 82 .

Customer cables (option) Handles communication with equipment fitted on the robot by the customer, low voltage signals and high voltage power supply + protective ground.

See the product manual for the controller 1) .

Also specified in the table

Customer cables (option) on page

83 .

External axes cables (option) Handles power supply to and control of the external axes' motors as well as feedback from the servo system.

See the Application manual - Additional axes and stand alone controller (M2004) 1) .

1)

Art. no. is specified in section References on page 8 .

The cable categories are divided into sub-categories, specified below:

Robot cables

These cables are included in the standard delivery. They are completely pre-manufactured and ready to plug in.

Cable sub-category Description

Robot cable, power

Robot cable, signals

Connection point, cabinet

Connection point, robot

R1.MP Transfers drive power from the drive units in the control cabinet to the robot motors.

XS1

Transfers resolver data from and power supply to the serial measurement board.

XS2 R1.SMB

Robot cable, power, for robots with standard protection

Cable (standard)

Robot cable, power, 7 m




Art. no.

3HAC2492-1

3HAC2529-1

3HAC2539-1


81



Continued

Robot cable, power, for robots with foundry and wash protection

Cable (foundry)





Robot cable, signals



Cable

Robot cable, signal, shielded, 7 m




Art. no.

3HAC2564-1

Art. no.

3HAC9038-1

3HAC9038-2

3HAC9038-3

3HAC9038-4

Art. no.

3HAC2493-1

3HAC2530-1

3HAC2540-1

3HAC2566-1

Position switch cables, robot base to controller (option)

The cable is delivered in one length only and should be wound to suitable length.

Cabling between robot base and controller

Cable

Position switch cable, axis 1, 30 m

Art. no.


Connection point, cabinet

3HAC7997-4 R1.LS

XS8

82





Continued

Customer cables (option)

The customer cables specified below are connected between robot and controller.

The customer cables are ordered according to current protection class of the robot.

Customer cables for robots with standard protection


Customer cable, power-signal, 7 m




Art. no.

3HAC3353-1

3HAC3354-1

3HAC3355-1

3HAC3356-1


R1.CP/CS

R1.CP/CS

R1.CP/CS

R1.CP/CS

Customer cables for robots with foundry and wash protection

Cable (foundry and wash)





Art. no.

3HAC8183-1

3HAC8183-2

3HAC8183-3

3HAC8183-4


R1.CP/CS

R1.CP/CS

R1.CP/CS

R1.CP/CS



2.5.3. Customer connections on the robot

2.5.3. Customer connections on the robot

General

For connection of equipment on the robot, there are cables integrated into the robot cabling.

This section specifies recommendations for the customer connections.

The air and electrical connectors are shown in the figure Connectors on the robot on page 79 .

Air connection

Connection

Air inlet (at the base)

Air outlet (at the upper arm housing)

Dimension

1/4"

The integrated air hose is sized as specified in the table below.

Inner diameter Max. pressure

8 mm 0.8 MPa / 115 psi

Customer connectors R2.CS and R2.CP

The customer connectors R2.CS and R2.CP can be used with either:

• a connector set from ABB for standard connection

• specified connector components from Souriau, or

• connectors that meet Military standard MIL-C-26482 series 1.

These connectors are further detailed in following sections.

Connector set from ABB for standard connection

Equipment

Connection set R2.CP/R2.CS

ABB art. no.

3HAC025396-001

Note

Only for standard connection.

Specified connector components from Souriau

The components specified below are from connector manufacturer Souriau and can be used for connection to R2.CS and R2.CP.

84 xx0400001339

A

B

C

Pin connector

Pin

Backshell





Continued

Recommended pin connectors

Pin connector

Pin connector, standard connection, CS (Customer Signal)

Pin connector, standard connection, CP (Customer Power)

Pin connector, integrated wirefeeder cabling, CS

Pin connector, Integrated wirefeeder cabling, CP

Souriau art. no.

UT0W6 1626 P-H

UT0W6 1210 P-H

UT0W6 1626 P-H

UT06 1412 P-H04

Recommended pins (turned)

Turned pins for cable area...

Pin diameter Souriau art. no.

0.21 - 0.93 mm

2

(standard connection, CP/CS and integrated wirefeeder cabling, CS)

1 mm

0.13 - 0.25 mm

2

(integrated wirefeeder cabling, CP) 1.6 mm

0.25 - 0.5 mm 2 (integrated wirefeeder cabling, CP)

0.5 - 1.5 mm

2

(integrated wirefeeder cabling, CP)

1.6 mm

1.6 mm

RM18W3K

RM24M9K

RM20M12K

RM16M23K

Recommended backshell

Backshell

Backshell, standard connection, CS

Backshell, standard connection, CP

Backshell, integrated wirefeeder cabling, CS

Backshell, integrated wirefeeder cabling, CP

Souriau art. no.

UT0 16JC

UT0 12JC

UT0 16JC

UT0 14JC

Connectors that meet Military standard

The connectors specified below meet Millitary standard MIL-C-26482 series 1 and can be used for connection to R2.CS and R2.CP (only for standard customer connection).

The figure below shows a complete connector, including pin connector and backshell.

xx0400001340

Connector for crimping

The complete pin connectors for crimping include pin connector and backshell.

Connector for crimping Military standard MIL-C-26482

Complete pin connector, CS

Complete pin connector, CP

Turned pin 0.2 - 0.5 mm

2

MS3126*1626S

MS3126*1210S

M39029/31-240



85



Continued

Connector for crimping

Turned pin 0.5 - 1.5 mm

2

Military standard MIL-C-26482

M29029/31-228

Connector for soldering

The complete pin connectors for soldering include pin connector, backshell and pins.

Connector for soldering Military standard MIL-C-26482

Complete pin connector, CS

Complete pin connector, CP

MS3116*1626S

MS3116*1210S



2.6.1. Additional installation procedure.

2.6 Making robot ready for operation (Cleanroom)

2.6.1. Additional installation procedure.

General

Cleanroom robots are specially designed to work in a cleanroom environment.

Cleanroom robots are designed in order to prevent from particle emission from the robot. For example is maintenance work possible to perform without cracking the paint. The robot is painted with four layers of polyurethane paint. The last layer being a varnish over labels in order to simplify cleaning.

Parts being replaced on a Cleanroom robot must be replaced with other parts designed for use in Cleanroom environments.

Cleanroom class 5

Particle emission from the robot fulfill Cleanroom class 5 standard according to DIN EN ISO

14644-1.

Preparations before commissioning a Cleanroom robot

During transport and handling of a Cleanroom robot, it is likely that the robot has been contaminated with particles of different sorts. Therefore the Cleanroom robot must be minutely cleaned before commissioning.



2.6.1. Additional installation procedure.


3 Maintenance

3.1. Introduction

3 Maintenance


Structure of this chapter

This chapter details all maintenance activities recommended for the robot and any external units of the robot.

It is based on the maintenance schedule, located in the beginning of the chapter. The schedule contains information about required maintenance activities including intervals and refers to procedures for the activities.

Each procedure contains all information required to perform the activity, that is required tools and materials.

The procedures are gathered in different sections, divided according to the maintenance activity.


Before any service work is commenced, it is extremely important that all safety information is observed!

There are general safety aspects that must be read through, as well as more specific safety information that describe danger and safety risks when performing the procedures. Read the chapter Safety before performing any service work.


3 Maintenance

3.2.1. Specification of maintenance intervals

3.2 Maintenance schedule and expected component life

3.2.1. Specification of maintenance intervals

Description

The intervals may be specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the robot:

• Calendar time: specified in months regardless of whether the robot system is run or not

• Operating time: specified in operating hours. More frequent running of the robot means more frequent maintenance activities.


3 Maintenance

3.2.2. Maintenance schedule

3.2.2. Maintenance schedule

General

The robot must be maintained regularly to ensure proper function. The maintenance activities and intervals are specified in the table below.

Non-predictable situations also give rise to inspections of the robot. Any damages must be attended to immediately!

The inspection intervals do not specify the life of each component.

Maintenance schedule

The table below specifies the required maintenance activities and intervals:

Maintenance activity

Equipment Interval Detailed in section

Change

Change

Change

Cleaning

Gearbox oil, axes 5 and 6

IRB1600

Gearbox oil, axes 5-6

IRB1600ID

20,000 hrs

20,000 hrs

Battery, measurement system 12 - 36 mths 2)

Complete robot Regular 1)

Oil change, gearbox axes 5 and 6 on page

97

.

Oil change, gearbox axes 5- 6, IRB 1600ID on page 100

Replacement of measurement system battery pack on page

103 .

Cleaning, complete robot on page 105

.

1. A regular interval implies that the activity is to be performed regularly, but the actual interval may not be specified by the robot manufacturer. The interval depends on the operation cycle of the robot, its working environment and movement pattern.

Generally, the more contaminated environment, the closer the intervals. The more demanding movement pattern (sharper bending cable harness), the closer the intervals.

2. The battery is used as a back-up when the robot system is switched off. Therefore, the life of a lithium battery depends on how frequently the power to the system is switched off and also if the environment temperature is higher than recommended operating temperature. The life varies from 12 - 36 mths, depending on current conditions. An alert is given on the TPU or the FlexPendant when the battery is nearly discharged and it must then be replaced within a month.


3 Maintenance

3.2.3. Expected component life

3.2.3. Expected component life

General

The life of any component depends on how hard it is run, and it can vary greatly.

Expected life

Component

Robot cable harness IRB 1600

Robot cable harness IRB 1600ID

Cabling for position switch

Gearbox

Expected life

2,000,000 cycles

2,000,000 cycles

2,000,000 cycles

40,000 hrs

Note

See note 1)

See note 1)

See note 1)

1. The expected life can also be affected by grouping harnesses/cables other than standard options. The life expectancy is based on a test cycle that for every axis goes from the calibration position to minimum angle, to maximum angle and back to the calibration position. Deviations from this test cycle will result in differences in expected life!


3 Maintenance

3.3.1. Inspection, damper axes 2, 3 and 5

3.3 Inspection activities

3.3.1. Inspection, damper axes 2, 3 and 5

Location of dampers

The figure below shows the location of all the dampers to be inspected. xx0400001217

A

B

Damper, axis 2

Attachment screw xx0400001215

A

B

Damper, axis 3

Cast tab



93

3 Maintenance

3.3.1. Inspection, damper axes 2, 3 and 5


A

B


Equipment

Standard toolkit

Damper, axis 5

Recess

Art. no.

-

Note

The contents are defined in section Standard toolkit on page 237 .

Inspection, dampers

The procedure below details how to inspect the dampers.

1.

Action Note

DANGER!


2. Check all dampers for damage, such as cracks or existing impressions that are larger than 1 mm.

3. Check attachment screws for deformation.

Shown in the figure

Location of dampers on page 93

.

4. If any damage is detected, the damper must be replaced with a new one!

Replacement is detailed in sections:

•

Replacement of damper, axis 2 on page 151

•

Replacement of damper, axis 3 on page 153

•

Replacement of damper, axis 5 on page 157 .


3.4 Replacement activities

3.4.1. Oil in gearboxes

Location of gearboxes

3 Maintenance

3.4.1. Oil in gearboxes xx0500001427

C

D

A

B

E

Gearbox, axis 1

Gearbox, axis 2

Gearbox, axis 3

Gearbox, axis 4

Gearboxes, axes 5 and 6 IRB1600

Type and amount of oil in gearboxes 1600

Gearbox Type of oil

Axis 1

Axis 2

Axis 3, IRB1600

Axis 4, IRB1600

Axis 5-6 (wrist unit),

IRB1600.

Mobilgear 600 XP 320




Optimol BM 100

Art. no.

11712016-604

11712016-604

11712016-604

11712016-604

3HAC 0860-1

Amount

1200 ml

1000 ml

500 ml

350 ml

Total amount: 350 ml

(new wrist)

Amount at oil change:

300 ml



95

3 Maintenance

3.4.1. Oil in gearboxes

Continued

Type and amount of oil in gearboxes 1600ID

96 xx0700000285

Gearbox Type of oil Art. no.

Axis 3, IRB1600ID

Axis 4, IRB1600ID

Mobilgear 600 XP 320 11712016-604

Mobilgear 600 XP 320 11712016-604

Axis 5

Wrist Axis 5-6

IRB1600ID


Optimol BM 100

Wrist Axis 6, IRB1600ID Grease

11712016-604

3HAC 0860-1

Amount

500 ml

350 ml

15 ml

130 ml

20 ml


3 Maintenance

3.4.2. Oil change, gearbox axes 5 and 6

3.4.2. Oil change, gearbox axes 5 and 6

Location of oil plugs

The gearboxes for axes 5 and 6 are located in the wrist unit as shown in the figure below. xx0600002846

A

B

Oil plug, draining and filling

Oil plug, vent hole


Equipment, etc. Art. no. Amount Note

Lubricating oil

Oil collecting vessel

3HAC 0860-1 Total amount: 350 ml (new wrist)

Amount at oil change: 300 ml

Optimol BM 100

Capacity: 400 ml.

Standard toolkit

Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.

The contents are defined in

section Standard toolkit on page 237 .

These procedures include references to the tools required.



97

3 Maintenance


Continued

Draining, wrist unit

The procedure below details how to drain oil from the gearboxes in the wrist unit.

1.


2.

DANGER!


WARNING!

Handling gearbox oil involves several safety risks. Before proceeding, please observe the

safety information in section WARNING - Safety risks during work with gearbox oil on page 36 .

3. Position the robot as shown in the figure to the right:

• upper arm: upwards for a standing robot

• axis 4: 180º, to a position where the oil plug (A), faces downwards.

Vessel capacity is specified in section

Required equipment on page 97

!

NOTE!

The total amount of oil will not be drained. There will remain approximately 50 ml in the wrist unit.

xx0500001434

A. Oil plug, draining and filling

The position for an inverted robot is the opposite!

4. Remove the both oil plugs .

Both oil plugs must be removed in order to drain the wrist unit properly.

5. Refit the oil plug, vent hole.

Shown in the figure

Location of oil plugs on page 97 .

98



3 Maintenance


Continued

Filling oil, wrist unit

The procedure below details how to fill oil in the gearboxes in the wrist unit.


1.

Action

2.

DANGER!


WARNING!

Handling gearbox oil involves several safety risks. Before proceeding, please observe the

safety information in section WARNING -

Safety risks during work with gearbox oil on page 36 .

3. Remove the oil plug, draining and filling.

Shown in the figure

Location of oil plugs on page 97 !


• upper arm: downwards for a standing robot

• axis 4: 90º, to a position where the oil plug (A), faces upwards.

Fill oil in the wrist unit through the oil plug.

The oil quality and amount is specified

in section Required equipment on page 97 !

5. Refit the oil plug. xx0500001435

• A: Oil plug, draining and filling

The position for an inverted robot is the opposite.


3 Maintenance

3.4.3. Oil change, gearbox axes 5- 6, IRB 1600ID

3.4.3. Oil change, gearbox axes 5- 6, IRB 1600ID

Location of oil plugs

The oil plug for axes 5 are located in the wrist unit as shown in the figure below.

xx0700000030

A

B

Oil plug, draining and filling

Oil plug, draining ventilation plug.


Equipment, etc.

Art.no.

Lubricating oil 3HAC0860-1

Oil collecting vessel

Standard toolkit

Amount Note

Amount at oil change:

100 ml.

Optimol BM 100

Other tools and procedures may be required.

The contents are defined in section

Special tools on page

238 .

See references to these procedures in the step-by-step instructions below.

Draining, wrist unit

The procedure below details how to drain oil from the gearboxes in the wrist unit.


1.

Action

DANGER!


100



3 Maintenance


Continued


2.

Action

WARNING!

Handling gearbox oil involves several safety risks. Before proceeding, please observe the safety information in

section WARNING - Safety risks during work with gearbox oil on page 36

.


• upper arm: upwards for a standing robot.

• axis 4: - 90º, to a position where the oil plug (A), faces downwards.



NOTE!

The total amount of oil will not be drained. There will remain approximately 20 ml in the wrist unit.

4. Remove the oil plug (A) and the ventilation plug (B).

5. Tap the wrist of all oil.

xx0700000033

Shown in figure Location of oil plugs on page

100

.

About 100 ml



101

3 Maintenance


Continued

Filling oil, wrist unit

The procedure below details how to fill oil in the gearboxes in the wrist unit.



• upper arm: upwards for a standing robot.

• axis 4: + 90º, to a position where the oil plug (A), faces upwards.

Fill 180 ml new oil in the wrist.



2. Refit the oil plug and the ventilation plug.

xx0700000034

A. oil plugs, filling possition.


3 Maintenance

3.4.4. Replacement of measurement system battery pack

3.4.4. Replacement of measurement system battery pack

Location of battery pack

The battery pack for the measurement system is located inside the base of the robot, as shown in the figure below.

xx0500001390

A Base cover, including gasket. Battery pack is located beneath the cover.

Battery pack on serial measurement unit

The battery pack is attached to the serial measurement unit as shown in the figure below.

xx0500001393

A

B

C

Battery pack

Velcro strap

Connector X3



103

3 Maintenance

3.4.4. Replacement of measurement system battery pack

Continued


Equipment

Battery pack

Gasket, base cover

Standard toolkit

Circuit diagram

Spare part no.

3HAC 16831-1

3HAC 022047-001

-

Note

Replace if damaged.


Standard toolkit on page 237 .

See chapter Circuit diagram .

Replacement, battery pack

The procedure below details how to replace the battery pack.

Note

1.

Action

DANGER!


2. Remove the base cover from the robot by unscrewing its attachment screws.

3. Disconnect the battery from the serial measurement unit.

4. Remove the battery pack.

Shown in the figure

Location of battery pack on page 103 .

5. Fit the new battery pack and connect it to the serial measurement unit (X3).

Spare part no. is specified in


.

Shown in the figure Battery pack on serial measurement unit on page 103

.

6. Check the base cover gasket , replace if damaged.

7. Refit the base cover to the robot.

8. Update the revolution counters.



.

Shown in the figure

Location of battery pack on page 103 .

Detailed in section Updating revolution counters on page 225

.


3 Maintenance

3.5.1. Cleaning, complete robot

3.5 Cleaning activities

3.5.1. Cleaning, complete robot

General

The protection class of Foundry and Wash versions is IP 67, i.e. the robot is watertight.


Equipment, etc.

May be used on version

Foundry and Wash !

Steam cleaner

May be used on version

Foundry and Wash !

High pressure water cleaner

-

-

-

Art. no. Note

• Water pressure at nozzle: max. 2,500 kN/ m

2

(25 bar)

• Type of nozzle: fan jet, min. 45° spread

• Flow: max. 100 litres/min.

• Water temperature: max. 80° C

• Max. water pressure on enclosures: 50 kN/m 2 (0.5 bar)

• Fan jet nozzle should be used, min. 45° spread

• Flow: max. 100 liters/min.

• Cloth with mild detergent May be used on version

Cleanroom and Standard.

Vacuum cleaner

Do's and don'ts!

The section below specifies some special considerations when cleaning the robot.

Always!

• Always use cleaning equipment as specified above! Any other cleaning equipment may shorten the life of paintwork, rust inhibitors, signs, or labels!

• Always check that all protective covers are fitted to the robot before cleaning!

Never!

• Never point the water jet at bearing seals, contacts, and other seals!

• Never spray from a distance closer than 0.4 m!

• Never remove any covers or other protective devices before cleaning the robot!

• Never use any cleaning agents, e.g. compressed air or solvents, other than those specified above!

• Never spray connectors and similar items with a high pressure cleaner!


3 Maintenance

3.5.1. Cleaning, complete robot


4 Repair

4.1. Introduction

4 Repair


Structure of this chapter

This chapter details all repair activities recommended for the robot and any external units of the robot.

It is made up of separate procedures, each detailing a specific repair activity. Each procedure contains all information required to perform the activity, for example spare parts numbers, required special tools and materials.

The procedures are gathered in sections, divided according to the component location on the robot.


All equipment required to perform a specific repair activity is listed together with the current procedure.

The equipment is also gathered in different lists in the chapter .


Before any service work is commenced, it is extremely important that all safety information is observed!

There are general safety aspects that must be read through, as well as more specific safety information that describe danger and safety risks when performing specific steps in a procedure. Make sure to read through the chapter Safety before commencing any service work.


4 Repair

4.2.1. Performing a leak-down test

4.2 General procedures

4.2.1. Performing a leak-down test

General

After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test.


Equipment, etc.

Leakdown tester

Leak detection spray

Art. no.

3HAC0207-1

-

Note

Procedure

Action Note

1. Finish the refitting procedure of the motor or gear in question.

2. Remove the topmost oil plug on the gear in question, and replace it with the leakdown tester .

Adapters may be required, which are included in the leakdown tester kit.

Art. no. is specified above!

3. Apply compressed air, and raise the pressure with the knob until the correct value is shown on the manometer.

4. Disconnect the compressed air supply.

Recommended value:

0.2 - 0.25 bar (20 - 25 kPa)

5. Wait for approx. 8-10 minutes. No pressure loss must be detected.

If the compressed air is significantly colder or warmer than the gearbox to be tested, a slight pressure increase or decrease respectively may occur. This is quite normal.

6. Was any pressure drop evident?

Localize the leak as detailed below.

Remove the leakdown tester, and refit the oil plug.

The test is complete.

7. Spray suspected leak areas with leak detection spray .

Bubbles indicate a leak.

8. When the leak has been localized: take the necessary measures to correct the leak.


4 Repair

4.2.2. Mounting instructions for bearings

4.2.2. Mounting instructions for bearings

General

This section details how to mount and grease different types of bearings on the robot.

Equipment

Equipment, etc.

Grease

Art. no.

3HAB3537-1

Note

Used to grease the bearings, if not specified otherwise.

Assembly of all bearings

Follow the instructions below when mounting a bearing on the robot.

1.

To avoid contamination, let a new bearing remain in its wrapping until it is time for fitting.

2.

Ensure that all parts included in the bearing fitting are free from burrs, grinding waste and other contamination. Cast components must be free from foundry sand.

3.

Bearing rings, inner rings and roller elements must under no circumstances be subjected to direct impact. Furthermore, the roller elements must not be exposed to any stresses during the assembly work.

Assembly of tapered bearings

Follow the previous instructions for assembly of all bearings, when mounting a tapered bearing on the robot.

In addition to those instructions, the procedure below must be carried out to enable the roller elements to adjust to the correct position against the race flange.

1.

Tension the bearing gradually until the recommended pre-tension is achieved.

Note!

The roller elements must be rotated a specified number of turns before pretensioning is carried out and also rotated during the pre-tensioning sequence.

2.

Make sure the bearing is properly aligned, as this will directly affect the lifespan of the bearing.

Greasing of bearings

The bearings must be greased after assembly, according to instructions below:

• The bearings must not be completely filled with grease. However, if space is available beside the bearing fitting, the bearing may be totally filled with grease when mounted, as excessive grease will be pressed out from the bearing when the robot is started.

• During operation, the bearing should be filled to 70-80% of the available volume.

• Ensure that grease is handled and stored properly, to avoid contamination.

Grease the different types of bearings as detailed below:

• Grooved ball bearings must be filled with grease from both sides.

• Tapered roller bearings and axial needle bearings must be greased in the split condition.


4 Repair

4.2.3. Mounting instructions for seals

4.2.3. Mounting instructions for seals

General

This sections details how to mount different types of seals to the robot.

Equipment

Equipment, etc.

Grease

Art. no.

3HAB3537-1

Note

Used to lubricate the seals.

Rotating seals

The procedure below details how to fit rotating seals.

CAUTION!

Please observe the following before commencing any assembly of seals:

• Protect the sealing surfaces during transport and mounting.

• Keep the seal in its original wrappings or protect it well before actual mounting.

• The fitting of seals and gears must be carried out on clean workbenches.

• Use a protective sleeve for the sealing lip during mounting, when sliding over threads, keyways, etc.

Action Note

1. Check the seal to ensure that:

• the seal is of the correct type (provided with cutting edge).

• there is no damage to the sealing edge (feel with a fingernail).

2. Inspect the sealing surface before mounting. If scratches or damage are found, the seal must be replaced, as it may result in future leakage.

3. Lubricate the seal with grease just before fitting. (Not too early as there is a risk of dirt and foreign particles adhering to the seal.)

Fill the space between the dust tongue and sealing lip to 2/

3 with grease. The rubber coated external diameter must also be greased, unless otherwise specified.

Art. no. is specified in

Equipment on page 110 .

4. Mount the seal correctly with a mounting tool.

Never hammer directly on the seal as this may result in leakage.

110



4 Repair

4.2.3. Mounting instructions for seals

Continued

Flange seals and static seals

The procedure below details how to fit flange seals and static seals.

Action

1. Check the flange surfaces. They must be even and free from pores.

It is easy to check flatness using a gauge on the fastened joint (without sealing compound).

If the flange surfaces are defective, the parts may not be used because leakage could occur.

2. Clean the surfaces properly and in accordance with ABB recommendations.

3. Distribute the sealing compound evenly over the surface, preferably with a brush.

4. Tighten the screws evenly when fastening the flange joint.

O-rings

The procedure below details how to fit o-rings.

Action Note

1. Ensure that the correct o-ring size is used.

2. Check the o-ring for surface defects, burrs, shape accuracy, etc. Defective o-rings may not be used.

3. Check the o-ring grooves.

The grooves must be geometrically correct and free from pores and contamination.

Defective o-rings may not be used.

4. Lubricate the o-ring with grease.

5. Tighten the screws evenly when assembling.


4 Repair

4.3.1. Replacement of cable harness

4.3 Complete manipulator

4.3.1. Replacement of cable harness

Location of cable harness

The cable harness is run through the robot from the base to the upper arm housing. The location of the harness is shown in several figures, next to the procedures, later on in this section.

Views of the cable harness may also be found in the chapter Spare parts and exploded views .


Equipment

Cable harness IRB 1600/1.45

Cable harness IRB 1600/1.45,

Customer connections


Wire feeder


Customer connections



Gasket, base cover

Gasket, gearbox axis 1-2

VK-cover

VK-cover

Cable ties

Centering piece

Spare part no.

3HAC 021827-001

3HAC 021828-001

3HAC 021830-001

3HAC 021828-003

3HAC 022049-001

3HAC 022050-001

3HAC 022047-001

3HAC 022048-001

3HAA 2166-23

3HAA 2166-21

3HAC025815-001

Note

No application interface.

Replace if damaged.

Replace if damaged.

Replace if damaged.

Replace if damaged.

Upper and lower covers.

2 pcs

Middle cover.

Standard toolkit

Circuit diagram

Fitted to the push button unit in order to align it correctly.

Replace if damaged.


section Standard toolkit on page

237 .


112



4 Repair


Continued

Illustration, covers to remove

The figure below shows all the covers that must be removed from the robot in order to get access to the cable harness and all the brackets.

xx0400001248

A

B

C

D

E

Upper and lower VK-cover

Arm housing cover, with gaskets

VK-cover (also shown with the cover removed)

Cover, frame, with gasket

Base cover, with gasket

Removal, cable harness

The procedure below details how to remove the complete cable harness from the robot.


1.

Action

DANGER!




113

4 Repair


Continued

Action

2. Remove all the covers:

• Remove the covers of the upper arm housing, frame and base.

• Push out the upper and lower VK-cover from the inside.

• Remove the middle VK-cover from the lower arm.


All the covers are shown in the

figure Illustration, covers to remove on page 113 .

CAUTION!

Be careful not to damage the cabling and cable bracket inside the lower arm when removing the middle VK-cover!

The figure to the right shows the space underneath the cover. The gray areas are safe for insertion of a tool that may be inserted with a maximum depth of 20 mm!

xx0400001247

3. The cable bracket inside the lower arm is attached to the cable harness. Move the bracket to the new cabling.

4. Disconnect all the connectors inside the upper arm housing.

Shown in the figure Illustration, cabling inside upper arm housing on page 115 .

5. Remove all cable ties, clamps and brackets inside the upper arm housing.

Attachment points inside the upper arm housing are shown in the figure

Illustration, cabling inside upper arm housing on page 115 .

6. Disconnect all the connectors inside the frame.

Shown in the figure Illustration, cabling inside frame on page 117

.

7. Remove the fastening plate, all cable ties and brackets from inside the frame. Remove the cable clamp unit from the fastening plate.

Attachment points inside the frame are shown in the figure

Illustration, cabling inside frame on page 117

.

8. Disconnect all the connectors at the base and remove the SMB unit from the base.

Shown in the figure Illustration, cabling inside base on page 118

.

NOTE!

Do not lose the centering piece fitted to the push button unit!

9. Remove all cable ties and brackets at the base.

Shown in the figure Illustration, cabling inside base on page 118

.

10. Pull out the cabling from the upper arm housing and pull it down through the lower arm.

11. Continue pulling down the cable harness through the frame and pull it out at the rear of the base.

114



4 Repair


Continued

Illustration, cabling inside upper arm housing

The figure below shows how the cabling is run inside the upper arm housing.

I

H

F

G

C

D

E

J

K

L xx0400001250

A

B

Signal cabling; connectors for motors on axes 3, 4, 5 and 6: R3.FB3, R3.FB4,

R3.FB5 and R3.FB6

Power cabling; connectors for motors on axes 3, 4, 5 and 6: R3.MP3, R3.MP4,

R3.MP5 and R3.MP6

Optional connector: R2.CP

Optional connector: R2.CS

Distance console with contact panel

Cable clamp unit

Attachment screws, cable clamp unit (2 pcs, only one shown)

Clamp, signal cabling

Clamp, motor cabling

Connector plate

Connector holder

Cable tie, connector holder



115

4 Repair


Continued

Refitting, cable harness in upper arm housing and lower arm

The procedure below details how to refit the cabling inside the upper arm housing.

The cable layout is shown in the figure

Illustration, cabling inside upper arm housing on page

115

.


1.

Action

DANGER!


2. Insert the cabling to axes 3, 4, 5 and 6 up through the lower arm and into the upper arm housing.

3. Place the cable bracket correctly inside the lower arm and secure it by refitting the VK-cover .



.

116 xx0400001247

Cable bracket is attached to the cabling with 2 screws, M6x8.

4. Fasten the cabling inside the upper arm housing by fitting the cable clamp unit to the distance console with two attachment screws .

Shown in the figure


5. Fit the motor and signal cabling to the connector plate with clamps .

Hexagon nut: M5. 1 pc for each clamp.

6. Reconnect the signal cable connectors and slide them into the connector holder .

Notice that one of the cable ties in the connector holder plate must be removed in order to insert the cables into the holder. Refit it when the connectors are inserted.

Shown in the figure


7. Reconnect the motor cable connectors.

8. Reconnect optional connectors, if any, at the contact panel.

9. Place the cabling correctly inside the housing and secure it with cable ties.

The cable layout is shown in the figure

Illustration, cabling inside upper arm housing on page 115

.

10. Refit the arm housing cover with eight attachment screws. Check the two gaskets and replace, if damaged.

8 pcs, M6.

Shown in the figure

Illustration, covers to remove on page 113

.



.

11. Fit new VK-covers to the lower arm.



.



4 Repair


Continued

Action

12. Continue refitting the cable harness according to procedure

Refitting, cable harness in frame and base on page 119

.


Illustration, cabling inside frame

The figure below shows how the cabling is run inside the frame.

xx0400001249

C

D

A

B

E

Power cabling; connectors for motors on axes 1 and 2: R3.MP1 and R3.MP2

Signal cabling; connectors for motors on axes 1 and 2: R3.FB1 and R3.FB2

Cable clamp unit (attachment screws behind the fastening plate)

Fastening plate

Attachment screws and nuts



117

4 Repair


Continued

Illustration, cabling inside base

The figure below shows how the cabling is run inside the base. Optional cabling is also shown in the figure, but not further specified.

118 xx0500001388

D

E

F

G

H

A

B

C

Power cabling

Signal cabling

Clamp with hexagon nut

Attachment screws, cable clamp unit

Hexagon nut, SMB plate

Fastening plate

SMB unit

Cable clamp unit



4 Repair


Continued

Refitting, cable harness in frame and base

The procedure below details how to refit the cabling inside the frame and the base.

The cable layout is shown in the figures Illustration, cabling inside frame on page 117

and

Illustration, cabling inside base on page 118 .

Note

1.

Action

DANGER!


2. Run the cables from the lower arm into the frame.

3. Fit the cable clamp unit to the fastening plate with two attachment screws, but do not secure the plate to the frame yet.

Shown in the figure

Illustration, cabling inside frame on page 117 .

4. Run the cabling down to the base. Pull it out at the rear of the base.

5. Connect all the connectors inside the frame and secure all plates and cable brackets inside the frame with attachment screws and nuts .

Shown in the figure


6. In the base, secure the cabling to the bottom fastening plate :

• fit the cable clamp unit with two attachment screws (M6).

• fit the separate cables with clamps and hexagon nuts .

Shown in the figure

Illustration, cabling inside base on page 118

.

Shown in the figure


.

7. Refit the SMB unit to the fastening plate with hexagon nuts.

8. Refit the centering piece (B) to the push button unit in order to align it vertically.

Also make sure that the unit is correctly aligned sideways: the measurements x1 and x2 in the figure to the right should not differ more than 1 mm from each other!

9. Refit the push button guard to the robot base.

10.

xx0600002777



WARNING!

Before continuing any service work, please observe the safety information in section

WARNING - The brake release buttons may be jammed after service work on page 34

!



119

4 Repair


Continued

Action Note

11. Connect the:

• signal cable connectors to the SMB unit

• power cable connector to the housing in the base

Shown in the figure


.

• optional cabling, if any

• ground cable.

12. Refit the covers to the frame and to the base.

Replace the gaskets , if damaged.

13. Recalibrate the robot!

Shown in the figure

Illustration, covers to remove on page 113 .



Calibration is detailed in a separate calibration manual, enclosed with the calibration tools.

General calibration information is included in section Calibration information .


4 Repair

4.3.2. Replacement of cable harness, IRB 1600ID

4.3.2. Replacement of cable harness, IRB 1600ID

Location of the harness

The location of the harness is shown in several figures, next to the procedures, later on in this section.

B

R4.FB5

R4.FB6

A

F

R4.MP5

R4.MP6

E

R3.FB3

R3.FB4

R3.FB5

R3.FB6

xx0700000038

A

B

E

F

R4.FB6

R4.FB5

R4.MP6

R4.MP5

R3.MP3

R3.MP4

R3.MP5

R3.MP6


Equipment

Standard toolkit

Circuit diagram

Spare part no.


Note

Contents, standard toolkit.


121

4 Repair


Continued

Equipment

Cable ties

VK- cover

Spare part no.

3HAA 2166-23

Cable harness axis 5-6.

3HAC027523-002

Note

Upper and lower covers.

2 pcs

IRB 1600 AW

Removal, cable harness lower arm and upper arm back

The procedure below describes removal of the complete cable harness in upper arm back.

122

R3.FB3

R3.FB4

R3.FB5

R3.FB6

R3.MP3

R3.MP4

R3.MP5

R3.MP6

xx0700000105

Action

1.

DANGER!


2. Remove the cover to the upper arm.

Note



4 Repair


Continued

Action

3. Remove the hexagon nut with flange (A) holding the two (2) clamps.

Note xx0700000106

A. Hexagon nut with flange

4. Disconnect R3.FB3 - R3.FB6.

5. Disconnect R3.MP3 - R3.MP6.

6. Remove the cable harness from the lower arm.

Follow instructions in section Removal, cable harness .

Removal, cable harness upper arm tube 1600ID

The procedure below describes removal of the complete cable harness in upper arm tube.

xx0700000099

C

D

A

B

Cover plate

Clamp

R4.FB5

R4.FB6



123

4 Repair


Continued

I

J

E

F

G

H

R4.MP6

R4.MP5

R3.MP5

R3.MP6

R3.FB5

R3.FB6

1.

Action Note

DANGER!


2. Remove the upper arm tube.

Described in section Replacement of motor, axis 5,

IRB 1600ID .

3. Remove all the Torx pan head screw (A) holding the cover.

124

4. Remove the cover plate.

xx0700000113

A. Torx pan head screw M6x12

B. Hexagon nut with flange M5

TIP!

The spare part cable harness 3HAC027523-002 includes a galvanized coverplate without paint. If a painted cover is prefered, use the old cover plate.



4 Repair


Continued

Action

5. Remove the cable pulling it out through the passage (A).

Note

A xx0700000114

Refitting, cable harness

The procedure below describes refitting of the complete cable harness.

Action

1. Refit the cable harness.

2. Refit the upper arm tube.

3. Refit the connections in the upper arm.

Note

Described in section Refitting, cable harness in upper arm housing and lower arm on page 116

Described in section Refitting, motor axis 5 on page

207 .

Shown in figure Location of the harness on page 121 .


4 Repair

4.3.3. Replacement of complete arm system

4.3.3. Replacement of complete arm system

Location of complete arm system

The complete arm system includes complete upper and lower arm.

xx0500001443

A

B

C

VK-cover (attachment screws underneath cover)

Cover, frame

Cover, base


Equipment

Lifting slings

VK-cover

Sealing ring (V-ring)

Isopropanol

Locking liquid

Standard toolkit

Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.

Art. no.

-

-

-

-

3HAA 2166-23

3HAB 3732-13

Note

Replace if damaged.

Used to clean the mating surfaces.

Loctite 574



.


Removal, complete arm system

The procedure below details how to remove the complete arm system from the robot.

Action

1. Move the robot to its calibration position.

Note

126



4 Repair


Continued

Note

2.

Action

DANGER!


3. Remove the covers from the base and the frame.

4. Release the cable harness from below upwards to the lower arm by:

• disconnecting all the connectors inside the base and the frame.

• removing all cable ties and brackets inside the base and the frame.

The cable layouts inside the base and the frame are shown in the figures:

•


.

•


5. Push out the VK-cover

from inside of the frame. Shown in the figure Location of complete arm system on page 126 .

6.

CAUTION!

The complete arm system weighs 55 kg! All lifting equipment used must be sized accordingly!

7. Fit lifting slings to the upper arm to unload the weight of the complete arm system.

8. Unscrew the 12 attachment screws and remove the one washer.

Be careful when pulling the cabling through base, frame and lower arm. Use tape to bunch the connectors and protect them.

9. Gently pull out the cabling from the frame and base while lifting away the complete arm system.

10. Check the sealing ring . Replace if damaged.

Refitting, complete arm system

The procedure below details how to refit the complete arm system to the robot.


1.

Action

DANGER!


2. Clean the mating surfaces on both the lower arm and on the frame with isopropanol. Also clean the area where the sealing ring is fitted, if it has been removed.



127

4 Repair


Continued


3. Fit the sealing ring properly to the frame. Replace it if damaged.

Art. no. is specified in Required equipment on page 126 .

128

4. Lubricate the attachment holes at the mating surface on the frame with Loctite 574.

5.

xx0400001245

• A: Sealing ring

• B: Mating surface

CAUTION!

The complete arm system weighs 55 kg! All lifting equipment used must be sized accordingly!

6. Fit the lifting slings to the complete arm system and lift it into position while inserting the cabling into the frame.

7. Fit the lower arm against the frame, fit the one washer and secure with the 12 attachment screws.

8. Refit the cabling inside the frame and the base.

12 pcs; M10 x 40, tightening torque: 70 Nm.

Detailed in section Refitting, cable harness in frame and base on page 119

.

9. Fit a new VK-cover to the lower arm.





11.

DANGER!

Make sure all safety requirements are met when performing the first test run. These are further detailed in section

DANGER - First test run may cause injury or damage! on page 33 .


4 Repair

4.4.1. Replacement of complete upper arm

4.4 Upper and lower arm

4.4.1. Replacement of complete upper arm

General

The complete upper arm is considered a spare part, including wrist, gearboxes and motors.

Location of upper arm

The figure below shows the location of the upper arm on the robot and some of the upper arm components.

A more detailed view of the upper arm may be found in the spare part view

Upper arm, exploded view 2 on page 252

in part 2 of the Product manual.

xx0400001218

A

B

Arm housing cover, including gaskets for the cover and the contact panel

VK cover. Upper arm attachment screws inside


Equipment

Upper arm, spare

Spare part no.

3HAC026567-001

Art. no.

Note

Includes the wrist unit. All gearboxes are filled with oil at delivery.

Note ! This upper arm spare is interchangeable with upper arm spare with art. no.

3HAC 023630-001. But this change of upper arm requires software 5.07.01.

VK-cover


3HAA 2166-23

3HAB 3732-19

Gasket, upper arm cover 3HAC 022049-001


Replace if damaged.

Replace if damaged.


129

4 Repair


Continued

Equipment


Grease

Locking liquid

Lifting slings

Standard toolkit


Spare part no.

3HAC 022050-001

Art. no.

Note

Replace if damaged.

-

-

3HAB 3537-1 To lubricate the sealing ring

(V-ring).

Loctite 574



.


Removal, complete upper arm

The procedure below details how to remove the complete upper arm from the robot.

Action

1. Move the upper arm to a horizontal position.

2.


DANGER!


3. Remove the arm housing cover from the upper arm.

Shown in the figure Location of upper arm on page 129 .

4. Disconnect all connectors inside the arm housing and loosen the cabling from straps and brackets.

The cabling and all connectors inside the upper arm housing are shown in the figure


5. Remove the VK-cover from the lower arm by pushing it out from the inside.

Pull out the cabling from the arm housing.

6. Secure the weight of the arm with lifting slings.

Shown in the figure Location of upper arm on page 129 .

7.

CAUTION!

The complete upper arm weighs 34 kg without any additional equipment fitted! Use a suitable lifting device to avoid injury to personnel!

130



4 Repair


Continued

Action

8. Remove the 10 attachment screws (A) and the single washer (B).


9. Remove the upper arm, lift it away and place it securely.

xx0400001219

Refitting, complete upper arm

The procedure below details how to refit the complete upper arm to the robot.


1.

Action

DANGER!


2. Wipe the contact surfaces clean on both the upper and lower arm.

3.

CAUTION!

The complete upper arm weighs 34 kg without any additional equipment fitted! Use a suitable lifting device to avoid injury to personnel!

4. Attach lifting slings to the upper arm and lift it.

5. Lubricate the sealing ring (A) with grease and fit it to the upper arm.

Replace the sealing ring, if damaged.

6. Lubricate the the contact surface, upper arm, with Loctite 574.

xx0400001220

• A: Sealing ring, spare part no. is specified in


• B: Contact surface.



131

4 Repair


Continued

Action

7. Lift the upper arm to mounting position, fit the washer (B) and secure the upper arm with the

10 attachment screws (A).


10 pcs: M10 x 40.

Tightening torque: 70 Nm.

xx0400001219

8. Run the cabling through the lower arm and into the arm housing.

9. Connect all the connectors in the arm housing and secure the cabling with brackets and straps.

Refitting of the cabling in the upper arm housing is further detailed in section

Refitting, cable harness in upper arm housing and lower arm on page 116

.

10. Refit the arm housing cover to the upper arm.

Check the two gaskets in the cover and replace them, if damaged.

Shown in the figure Location of upper arm on page 129

.

Spare part no. is specified in section


.

11. Refit a new VK-cover to the lower arm.


Shown in the figure Location of upper arm on page 129

.

Spare part no. is specified in section


.



13.

DANGER!

Make sure all safety requirements are met when performing the first test run. These are further

detailed in section DANGER - First test run may cause injury or damage! on page 33 .


4 Repair

4.4.2. Replacement of complete upper arm, IRB 1600ID

4.4.2. Replacement of complete upper arm, IRB 1600ID

NOTE!

Recalibration of robot axis 3-6 is required after replacement of upper arm.

Location of upper arm

The complete upper arm is considered a spare part, including wrist, gearboxes and motors.

The figure below shows the location of the upper arm and connection to the lower arm.

xx0700000045

A

B

C

D

VK -Cover

Socket head cap screw M10x40

Cable harness

V-ring


Equipment

Upper arm, spare

Spare part no.

Art. no.


Note

Includes the wrist unit. All gearboxes are filled with oil at delivery.


133

4 Repair


Continued

Equipment

Standard tool kit

Spare part no.

VK-cover

V-ring axis 3


Pendulum calibration tool

3HAA 2166-23

3HAB3732-19

3HAC 022050-001

Art. no.

Note

Contents, standard toolkit

Replace if damaged

Remove, complete upper arm

The procedure below details how to remove the complete upper arm from the robot.

Note

1.

Action

DANGER!


2. Put the manipulator in synchronization position for Axis 3.

xx0700000075

A. Synchronization mark Axis 3

134



4 Repair


Continued

Action

3. Remove the cover arm housing from the upper arm, using standard tools.

Note

4. Disconnect all connectors inside the arm housing and loosen the cabling from straps and brackets.

5.

xx0700000077

A. Cover Arm Housing

B. Torx pan head screw

Described in section Removal, cable harness lower arm and upper arm back.

CAUTION!

The complete upper arm weighs

39 kg without any additional equipment fitted! Use a suitable lifting device to avoid injury to personnel!


3HAC026660-001 Revision: C xx0700000060


135

4 Repair


Continued

Action

7. Knock out the VK-cover from the motor side.

8. Remove the 10 attachment screws

(A) and the single washer, use standard tools.

Note

9. Carefully remove the upper arm.

xx0700000057

A. Socket head cap screw M10x40

Refitting, complete upper arm

The procedure below details how to refit the complete upper arm to the robot.

Action

1. Wipe the contact surfaces clean on both the upper and lower arm.

2. Attach lifting slings to the upper arm and lift it.

3. Clean the contact surface.

Note

136

A xx0700000076

A. Contact surface.



4 Repair


Continued

Action

4. Carefully refitting the upper arm to the lower arm, make sure that the new upper arm is mounted in the synchronization position.

Note

5. Refit the 10 attachment screws (A) and the single washer, use standard tools.

Tightening torque: 70 Nm xx0700000075

A. Synchronization mark Axis 3 xx0700000057

A. Socket head cap screw M10x40

6. Run the cabling through the lower arm and into the arm housing.

7. Connect all the connectors in the arm housing and secure the cabling with brackets and straps.

Refitting of the cabling in the upper arm housing is further detailed in section Refitting, cable harness..



137

4 Repair


Continued

Action

8. Refit the cover arm housing to the upper arm, using standard tools

Contents, standard toolkit .

Note

9. Refit a new VK-cover to the lower arm. replace it, if damaged.

10. Recalibrate the robot.

xx0700000077

A. Cover Arm Housing

B. Torx pan head screw

Spare part no. is specified in section Required equipment on page 129

.



11.

DANGER!




4 Repair

4.4.3. Replacement of complete lower arm

4.4.3. Replacement of complete lower arm

Location of lower arm

The lower arm is located on the robot as shown in the figure below.

A more detailed view of the lower arm may be found in the spare part view

Lower arm, exploded view on page 249


xx0400001246

A

B

C

Lower arm

VK-cover

VK-cover, middle


Equipment

Lower arm, spare

Lower arm, short, spare

VK-cover

VK-cover


Spare part no.

3HAC 023558-001

3HAC 023559-001

Note

IRB 1600 - 7/.12

IRB 1600 - 7/1.45

IRB 1600 - 5/1.2

IRB 1600 - 5/1.45

3HAA 2166-23

3HAA 2166-21 In the middle of the lower arm.


139

4 Repair


Continued

Equipment


Isopropanol

Locking liquid

Standard toolkit

Spare part no.

3HAB 3732-13

Note

Replace if damaged.

Used to clean the mating surfaces.

Loctite 574


Standard toolkit in the Product manual, reference information !



Removal, lower arm

The procedure below details how to remove the complete lower arm.


1.

Action

DANGER!


2. Remove the complete upper arm.

3. Remove the VK-cover s.

Detailed in section Removal, complete upper arm on page 130

.

Shown in the figure

Location of lower arm on page 139

.

140

CAUTION!

Be careful not to damage the cabling and cable bracket inside the lower arm when removing the middle VK-cover!

The figure to the right shows the space underneath the cover. The gray areas are safe for insertion of a tool that may be inserted with a maximum depth of

20 mm!

xx0400001247

4. Pull down the cabling through the lower arm and pull it out.

5.

CAUTION!

The lower arm weighs 20 kg! Use a suitable lifting device to avoid injury to personnel!

6. Fit the lifting device to the lower arm to secure the weight of the arm.

7. Unscrew the 12 attachment screws and remove the single washer.

8. Gently pull out the cabling while lifting away the lower arm. Be careful with the connectors, they are sensitive to damage!



4 Repair


Continued

Action

9. Check the sealing ring . Replace it if damaged.



Required equipment on page

139

.

Refitting, lower arm

The procedure below details how to refit the complete lower arm.


1. Clean the mating surfaces on both the lower arm and on the frame with isopropanol. Also clean the area where the sealing ring is fitted.

2. Fit the sealing ring properly to the frame. Replace it if damaged.



139 .

xx0400001245

• A: Sealing ring

• B: Mating surface

3. Lubricate the mating surface on the frame with

Loctite 574.

4.

CAUTION!

The lower arm weighs 20 kg! Use a suitable lifting device to avoid injury to personnel!

5. Fit the lifting device to the lower arm and lift it into position.

6. Insert the cabling into the lower arm.

7. Fit the lower arm against the frame, fit the washer and secure with the 12 attachment screws.

8. Push the cabling up through the lower arm and place the cable bracket inside the lower arm correctly.

12 pcs; M10 x 40, tightening torque: 70 Nm.

9. Fit new VK-covers to the lower arm.

Make sure that the cable bracket inside the lower arm is secured beneath the middle VK-cover.



139 .

10. Refit the upper arm.

Detailed in section

Refitting, complete upper arm on page

131 .



141

4 Repair


Continued

Action


12.

DANGER!







4 Repair

4.4.4. Replacement of wrist unit

4.4.4. Replacement of wrist unit

Location of wrist unit

The wrist unit is located in the frontmost part of the upper arm.

A more detailed view of the upper arm, including the wrist unit, is found in the spare part view

.

Upper arm, exploded view 1 on page 251 in part 2 of the Product manual.

xx0600002847

A

B

C

Attachment screws, wrist unit (3 pcs)

Oil plug (only one shown)

Wrist unit


Equipment, etc. Spare part no. Art. no. Note

Wrist, Standard/

Foundry

O-ring sealingplate

Grease

Standard toolkit

3HAC 026569-001

3HAC 025420-001

Standard and Foundry versions.

O-ring sealingplate not included!

Note ! The wrist, standard/

Foundry is not interchangeable with art. no. 3HAC 10475-1!

Must be replaced.

Note ! The o-ring sealingplate is not interchangeable with art.no.

3HAC 7191-1!

3HAC 3537-1 For lubricating the o-ring sealingplate.



237

.



143

4 Repair


Continued

Equipment, etc. Spare part no. Art. no.


Note


Removal, wrist unit

The procedure below details how to remove the complete wrist unit.

1.

Action Note

DANGER!


2. Drain the oil from the wrist unit.

3. Remove the wrist unit by unscrewing its three attachment screws.

Detailed in section Oil change, gearbox axes 5 and 6 on page 97 .

Shown in the figure in section Location of wrist unit on page 143

.

Refitting, wrist unit

The procedure below details how to refit the complete wrist unit.

Action

1. Move the robot to a position where the upper arm is vertical.

2.

Note

144

DANGER!


3. Lightly lubricate the o-ring sealingplate with grease .



4. In order to release the brake, connect the

24 VDC power supply to motors:

Connect to connector R3.MP5 or 6:

• +: pin 7

• -: pin 8

5. Fit the o-ring sealingplate to the upper arm. Fit the wrist unit to the upper arm with the three attachment screws, while making sure that the gears mate properly.

6. Perform a leak-down test.

Use a new o-ring! Spare part no. is specified

in Required equipment on page 143

.

3 pcs, M8 x 25, tightening torque: 28 Nm.

7. Refill the wrist unit with oil.

Detailed in section Performing a leak-down test on page 108

.

Detailed in section Oil change, gearbox axes

5 and 6 on page 97

.



Action


9.

DANGER!

Make sure all safety requirements are met when performing the first test run.

These are further detailed in section

DANGER - First test run may cause injury or damage! on page 33

.

4 Repair


Continued

Note




4 Repair

4.4.5. Replacement of wrist unit, IRB1600ID

4.4.5. Replacement of wrist unit, IRB1600ID

NOTE!

After replacement of motors/motor or gearbox in a manipulator, recalibration is required.

Location of wrist unit

The wrist unit is located in the frontmost part of the upper arm.

G

B

A

E

F

D

C xx0700000025

E

F

G

C

D

A

B

Upper arm

Wrist

Motor axis 6

Hexagon socket head screw M5x25

Hexagon socket head screw M5X16 (10.9) (Short head)




Equipment

Wrist, ID

O-ring

Grease

Standard toolkit

Spare part no. Art. No.

3HAC3537-1

Note

For lubricating the o-ring sealing plate.


146



4 Repair


Continued

Equipment

Arm

Other tools and procedures may be required.

Spare part no. Art. No.

3HAC9037-1

Loctite 542 12690014-412

Removal, wrist unit

The procedure below details how to remove the complete wrist unit.

Note

1.

Action

Note

For adjusting the gear play, motor/ pinion.

See references to these procedures in the step-by-step instructions below.

DANGER!

Turn of all electric power, hydraulic and pneumatic pressure supplies to the robot!.

2. Remove the AW equipment in the upper arm.

3. The plug (A) in figure covering the screw (C).

Remove the plug using standard tools (B).

Remove the screw for looking of motor axis 5,

(C) in figure

Location of wrist unit on page 146

.

Shown in

Remove AW Gun on page 160

3HAC026660-001 Revision: C xx0700000092

A. Plug.

B. Standard tool, Contents, standard toolkit .

C. Hexagon socket head screw M5X16 (Short head).


147

4 Repair


Continued

Action

4. Remove the VK-Cover

(A).

Note

5. Gently pull the cables out of the upper arm VK- cover hole.

6. Disconnect through the

VK-hole the cable harness contacts,

R4.FB6 and R4.MP6.

xx0700000054

A. VK-Cover

7. Remove the three attachment screws (A).

xx0700000053

A. Contact R4.FB6

B. Contact R4.MP6

148

8. Remove the wrist with motor 6 from the upper arm tube.

xx0700000052

A. Hex socket head cap screw M8x35



Action

9. Remove the three screws, hexagon socket head screw M5x25 (E).

Remove the axis 6 motor

(C).

Note

4 Repair



A. Contact R4.FB6

B. Contact R4.MP6

C. Motor axis 6

D. Hexagon socket head screw M8x35

E. Hexagon socket head screw M5x25

Refitting, wrist unit

The procedure below details how to refit the complete wrist unit.

Note

1.

Action

NOTE!

If the screws (A) for the Motor

Console (B) are removed, use

Loctite 542 12690014-412 on the screws when refitting.

Refit the Hex socket head cap screw M5x25

Tightening torque 4,1 Nm xx0700000353

A. Hex socket head cap screw M5x25

B. Motor Console

2. Refit the axis 6 motor using the three hexagon socket head screw M5x25, shown as

(D) in figure

Location of wrist unit on page 146

Tightening torque 4,1 Nm



149

4 Repair


Continued

Action

3. Carefully refit the wrist with motor to the upper arm tube.

Use a string to pull the cable harness back through the VK- hole in the upper arm tube.

Note xx0700000093

A. String

4. Use standard tools to refit the three hexagon socket head screw (M8x35).

Shown as (H) in figure

Location of wrist unit on page

146 .

Tightening torque 24 Nm

Make sure that all the cabling is placed correctly inside the upper arm tube.

5. Reconnect through the VKhole the cable harness contacts R4.FB6 and

R4.MP6.

6. Tightening the hexagon socket head screw M5X16

(Short head).

Shown as (E) in figure

146 .

Location of wrist unit on page


7. Tightening the plug (A).


150 xx0700000092

8. Refit the AW equipment in the upper arm.

Shown in

Refitting, wrist unit on page 149


Shown in Introduction , calibration information.


4 Repair

4.4.6. Replacement of damper, axis 2

4.4.6. Replacement of damper, axis 2

Location of damper, axis 2

The damper, axis 2, is located as shown in the figure below.

xx0400001217

A

B

Damper, axis 2

Attachment screw and washer


Equipment, etc.

Damper, axis 2

Standard toolkit


Spare part no. Note

3HAC 022013-001




Removal, damper axis 2

The procedure below details how to remove the damper, axis 2.

Action

1. Run the robot to a position that enables you to access the attachment screw of damper, axis 2.

Note



151

4 Repair


Continued

2.

Action Note

DANGER!


3. Remove the damper by unscrewing the single attachment screw and washer.

Refitting, damper axis 2

The procedure below details how to refit the damper, axis 2.

Action

1. Run the robot to a position that enables access to the attachment screw of the damper, axis 2.

2.

Note

DANGER!


3. Secure the damper with the attachment screw and washer.

4.

DANGER!



1 pc: M6 x 16.


4 Repair




The damper, axis 3, is shown in the figure below.

A more detailed view of the damper and its position may be found in the spare part view



xx0400001215

A

B

Damper, axis 3

Cast tab


Equipment, etc.

Damper, axis 3

Standard toolkit

Spare part no.

3HAC 022260-001

Note





Action

1. Run the robot to a position that enables access to damper, axis 3.

2.

Note

Shown in the figure Location of damper, axis 3 on page 153

.

DANGER!




153

4 Repair


Continued

Action

3. Remove the damper by gently prying it from the cast tab.

Note



Action Note

1. Run the robot to a position that enables access to the location where the damper, axis 3, is fitted.

Shown in the figure Location of damper, axis 3 on page 153

.

2.

DANGER!


3. Refit the damper by gently pressing it onto the cast tab on the upper arm.

4.

DANGER!




4 Repair

4.4.8. Replacement of Mechanical damper, axis 3, IRB 1600ID

4.4.8. Replacement of Mechanical damper, axis 3, IRB 1600ID


The location of damper, axis 3.

A

B xx0700000043

A

B

Torx counters. head screw

Mechanical damper


Equipment

Mechanical damper

Standard tools

Spare part no.

Art. no.

3HAC027626-001

Note

The contents are defined

in section Standard toolkit on page 237

.

Removal, Mechanical damper axis 3


Action

1. Run the robot to a position that enables access to damper, axis 3.

2.

Note

DANGER!




155

4 Repair

4.4.8. Replacement of Mechanical damper, axis 3, IRB 1600ID

Continued

Action

3. Remove the damper.

Note

Use standard tools, Contents, standard toolkit.

Refitting, Mechanical damper axis 3


Action

1. Refit the damper.

Note

Use standard tools, Contents, standard toolkit .

2.

DANGER!




4 Repair




The damper, axis 5, is located as shown in the figure below!

xx0600002806

A

B

Damper, axis 5

Recess


Equipment, etc.

Damper, axis 5

Standard toolkit

Spare part no. Note

3HAB 8964-1



.



Action Note

1. Run the robot to a position that enables the end of the damper to be pushed into the recess in the wrist unit.

Shown in the figure

Location of damper, axis 5 on page 157

.

2.

DANGER!


3. Unhook the end of the damper, and push it into the recess.

4. Manually move the wrist (robot axis 5) away from the damper to pull it out.



157

4 Repair


Continued



1.

Action Note

DANGER!


2. Push the end of the damper into the gap between the wrist unit and upper arm.

3. Manually move the wrist (robot axis 5) in order to pull the damper into position.

Make sure the damper is turned the correct way!

4. Fold out the damper hooks to secure it in position.

5.

DANGER!




4.4.10. Remove upper arm AW Gun

Location of AW Gun

The location of the AW equipment.

4 Repair

4.4.10. Remove upper arm AW Gun xx0700000153

A

B

C

D

Wire feeder (customer option)

Weld gun (BINZEL)

Welding cable (BINZEL)

Brace (BINZEL)


Equipment

Standard tools

Spare part no.

Art. no.

Note

Contents, standard toolkit .



159

4 Repair

4.4.10. Remove upper arm AW Gun

Continued

Remove AW Gun

The section below shows how to remove the AW. equipment from the upper arm of a IRB

1600 ID.

Note

1.

Action

DANGER!


2. Remove the welding cable (C) from the weld gun by twisting the locking sleeve (A) counter clockwise.

Loosen the locking screw (B) and pull out the welding cable.

160

3. Remove the two screws holding the brace.

xx0700000151

A. Locking sleeve

B. Locking screw

C. Welding cable xx0700000273

A. BINZEL Brace



Action

4. Remove the welding cable from the wire feeder and pull it out.

Note

4 Repair


Continued

5. The locking ring (A) has a thread, loosen it counter clockwise and remove it.

Remove the locking sleeve (B).

Remove all 6x M5 screw (C).

xx0700000142

A. Wire feeder

B. Welding cable

Refit AW Gun xx0700000150

A. Locking ring

B. Locking sleeve

C. Screw M5

The section below shows how to refit the AW. equipment to the upper arm of a IRB 1600 ID.

Note

1.

Action

DANGER!

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot.



161

4 Repair


Continued

Action

2. Refit the welding gun using the

6X Socket head cap screw M5

(C).

Refit the locking sleeve (B).

Lock the sleeve using the locking ring (A).

Note

3. Refit the welding cable (C).

Lock the cable using the screw

(B).

xx0700000150

A. Locking ring

B. Locking sleeve

C. Screw M5

162

4. Refit the brace (A).

xx0700000151

A. Locking sleeve

B. Locking screw

C. Welding cable xx0700000273


4 Repair

4.4.11. Fitting equipment on the robot, IRB 1600ID

4.4.11. Fitting equipment on the robot, IRB 1600ID

Location of shelf, wire feeder

F

C

A

B

E

D xx0700000311

D

E

F

A

B

C

Bracket ESAB wire feeder

Shelf, wire feeder

Hexagon nut with flange M5

Knob

Plain washer (8,4x16x1,6)

Hex socket head cap screw (M8x12)

Fitting the wire feeder shelf

Action Note

1. Fit the Shelf, wire feeder

(B) using the four (4) Hex socket head cap screw (F).

Shown in figure

Location of shelf, wire feeder on page 163



163

4 Repair

4.4.11. Fitting equipment on the robot, IRB 1600ID

Continued

Action

2. Fit the bracket on the wire feeder using the four (4)

Hexagon nut with flange

(A).

Note

3. Fit the wire feeder with the mounted bracket on the

Shelf, wire feeder and mount the two knobs.

xx0700000312

A. Hexagon nut with flange M5

B. Knob


4 Repair

4.5.1. Replacement of base

4.5 Frame and base

4.5.1. Replacement of base

Location of base

The base is located at the bottom of the robot as shown in the figure below.

A more detailed view of the base may be found in the spare part view

Base, exploded view on page 243


xx0500001453

A

B

Base

Attachment screws and washer, base-gearbox unit (VK-cover removed)


Equipment Spare part no. Art. no.

Base, spare 3HAC 023552-001

V-ring (sealing ring) 3HAB 3732-21

VK-cover

Lifting slings

3HAA 2166-26

Locking liquid

-

Note

Replace if damaged.

Grease 3HAB 3537-1

Loctite 574

For sealing the base to the gearbox 1-2.

For lubricating the V-ring.



165

4 Repair


Continued

Equipment

Isopropanol

Standard toolkit

Spare part no. Art. no.

-


Removal, base

Note

For cleaning the mating surfaces.



.


The procedure below details how to remove the base from the robot.

Note

1.

Action

DANGER!


2. Remove the cabling inside the base and pull it up to the gearbox unit.

3. Remove the serial measurement unit.

The cable layout in the base is shown in the figure


.

Detailed in section Removal, serial measurement unit on page 170

.

4. Unfasten the base from the installation site by removing the attachment bolts from the foundation.

5.

CAUTION!


6. Fit the lifting slings to the robot, lift it and place it with the side of the lower arm downwards on a work bench.

Be careful not to damage the motor connectors!



.

7. Remove the VK-cover from the base.

TIP!

Push out the cover from inside or drill a hole in the cover through which a tool can be inserted in order to bend out the cover.

166



4 Repair


Continued

8.

Action Note

CAUTION!

The base weighs 81 kg! All lifting equipment used must be sized accordingly!

9. Secure the weight of the base and remove the gearbox/base attachment screws and washer .

10. Separate the base from the gearbox unit.

Shown in the figure Location of base on page 165 .

Refitting, base

The procedure below details how to refit the base to the robot.

Note

1.

Action

DANGER!


2. Place the robot with the side of the lower arm downwards on a workbench.

Be careful not to damage the motor connectors.

3. Clean the mating surfaces between the base and the gearbox unit with isopropanol.

4. Check the V-ring on the gearbox unit. Lubricate with grease if needed. Replace it if damaged!



.

5. Lubricate the mating surface on the base with

Loctite 574.

6.

CAUTION!

The base weighs 81 kg! All lifting equipment used must be sized accordingly!

7. Lift the base to mounting position.

8. Secure the base to the gearbox unit with the gearbox/base attachment screws and washer.

9. Refit a new VK-cover to the base.

Shown in the figure

Location of base on page 165

.

16 pcs, M10 x 40, tightening torque:

70 Nm.



.

10.

CAUTION!


11. Turn the robot to stand upright.



167

4 Repair


Continued

Action Note

12. Secure the base to the foundation.

Attachment bolts and tightening torque are specified in section

Attachment bolts, specification on page 50 .

13. Pull down the cabling and refit it inside the base. The cable layout inside the base is

shown in the figure Illustration, cabling inside base on page 118

.

14. Refit the serial measurement unit.

Detailed in section Refitting, serial measurement unit on page 171 .

15. Recalibrate the robot. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools.


16.

DANGER!

Make sure all safety requirements are met when performing the first test run. These are

further detailed in section DANGER - First test run may cause injury or damage! on page 33

.


4 Repair

4.5.2. Replacement of serial measurement unit

4.5.2. Replacement of serial measurement unit

Location of serial measurement unit

The serial measurement unit is located inside the base of the robot, as shown in the figure below.

A more detailed view of the unit and its position may be found in the spare part view Base, exploded view on page 243


xx0500001390

A Base cover, including gasket. Serial measurement unit is located beneath the cover.

Serial measurement unit layout

The complete spare part of the serial measurement unit is shown in the figure below.

xx0500001391

C

D

A

B

E

Connector SMB

Connector SMB1-4

Connector SMB 3-6

Hexagon nuts (totally 4 pcs)

Battery pack



169

4 Repair


Continued


Equipment

Serial measurement unit

Gasket, base cover

Centering piece

Standard toolkit

Circuit diagram

-

Spare part no.

3HAC 023424-001

3HAC 022047-001

3HAC025815-001

Note

Fitted to the push button unit in order to align it correctly.

Replace if damaged.



.


Removal, serial measurement unit

The procedure below details how to remove the serial measurement unit from the robot.


1.

Action

DANGER!


2. Remove the push button guard (A) from the base.

The guard must be removed to ensure a correct refitting of the brake release buttons.

170

3. Remove the centering piece (B) from the push button unit.

xx0600002744

4. Remove the base cover from the robot.

xx0600002776

Shown in the figure Location of serial measurement unit on page 169

.

5. Disconnect all the connectors from the serial measurement unit.

6. Unscrew the four hexagon nuts on the serial measurement unit enough to enable lifting the unit.

Do not remove the nuts.

Shown in the figure Serial measurement unit layout on page 169

.



4 Repair


Continued

Action

7. Lift and pull the serial measurement unit backwards, over the lip (A), and lift it away.

Note/Illustration xx0500001455

Refitting, serial measurement unit

The procedure below details how to refit the serial measurement unit to the robot.

Action

1. Fit the serial measurement unit on to the four pins (A).


2. Slide the unit into position, within the lips, and secure with the four hexagon nuts.

Make sure the unit is positioned as straight as possible! The push buttons can otherwise get jammed.

3. Reconnect all the connectors to the unit.

Shown in the figure

Serial measurement unit layout on page 169 .



3HAC026660-001 Revision: C xx0600002777




171

4 Repair


Continued

Action


6.


WARNING!


WARNING - The brake release buttons may be jammed after service work on page 34 !

7. Check the gasket of the base cover. Replace it if damaged.

8. Refit the base cover .

9. Update the revolution counters!

Spare part no. is specified in Required equipment on page 170

.

Shown in the figure

Location of serial measurement unit on page 169 .

Detailed in section

Updating revolution counters on page 225 .


4 Repair

4.5.3. Replacement of push button unit

4.5.3. Replacement of push button unit

Location of push button unit

The push button unit for brake release is located inside the base of the robot, as shown in the figure below.

A more detailed view of the component and its location is shown in the spare part view

Base, exploded view on page 243


xx0500001390

A Base cover, including gasket. Push button unit is located beneath the cover.

Push button unit on serial measurement unit

The push button unit is attached to the serial measurement unit as shown in the figure below.

xx0500001394

A

B

C

Push button unit

Hexagon nuts (2 pcs)

Hexagon nuts, SMB unit (4 pcs)


Equipment

Push button unit


Spare part no.

Note

3HAC 020967-001 Includes brake release board and push buttons.


173

4 Repair


Continued

Equipment Spare part no.

Note

Gasket, base cover 3HAC 022047-001

Centering piece 3HAC025815-001 Fitted to the push button unit in order to align it correctly.

Replace if damaged.

Standard toolkit

The contents are defined in section Standard toolkit on page 237 .

Removal, push button unit

The procedure below details how to remove the push button unit from the robot.


1.

Action

DANGER!


2. Remove the push button guard (A) from the base.

The guard must be removed to ensure a correct refitting of the push button unit.

174

3. Remove the centering piece (B) from the push button unit.

xx0600002744

4. Remove the base cover from the robot.

xx0600002776

Shown in the figure

Location of push button unit on page 173

.

5. Disconnect all the connectors from the brake release board.

6. Unscrew the four hexagon nuts on the SMB unit enough to enable lifting the unit.

Do not remove the nuts.

Shown in the figure

Push button unit on serial measurement unit on page 173

.



4 Repair


Continued

Action

7. Lift and pull the serial measurement unit backwards, over the lip (A), and lift it away.


8. Remove the two hexagon nuts from the push button unit.

9. Remove the push button unit by lifting it up.

xx0500001455

Shown in the figure Push button unit on serial measurement unit on page 173

.

Refitting, push button unit

The procedure below details how to refit the push button unit to the robot.

Note

1.

Action

DANGER!


2. Fit the new push button unit to the serial measurement unit in the robot base.

3. Secure the unit with two hexagon nuts .



.


.


.

4. Push in and secure the SMB unit with the four hexagon nuts .


.




xx0600002777



175

4 Repair


Continued

7.

Action Note

WARNING!


WARNING - The brake release buttons may be jammed after service work on page 34 !

8. Reconnect all the connectors to the board.

9. Check the gasket of the base cover. Replace it if damaged.

Spare part no. is specified in Required equipment on page 173 .

10. Refit the base cover .

Shown in the figure

Location of push button unit on page 173 .


4 Repair

4.6.1. Replacement of motor, axis 1

4.6 Motors

4.6.1. Replacement of motor, axis 1

Location of motor

The axis 1 motor is located on the frame, as shown in the figure below.

A more detailed view of the motor and its position may be found in the spare part view Frame, exploded view on page 247


xx0400001256

C

D

A

B

E

Motor, axis 1

Connector plate for motor cabling

Cover, frame

Attachment screws, motor (4 pcs)

Motor cover



Art. no.

Rot. ac motor incl. pinion, spare

3HAC 023557-001

Cable harness, motor axes 1-2

O-ring

3HAC 023754-001

21522012-428


Note

Cable harness, motor axes 1-2 must be ordered separately.

O-ring, motor.

Replace if damaged.


177

4 Repair


Continued


Art. no.

Gasket, gearbox axis 1-2 3HAC 022048-001

Power supply -

Isopropanol

Grease

Rotation tool, motor

Standard toolkit

Circuit diagram

-

Note

Replace if damaged.

24 VDC, max 1.5 A

For releasing the brakes.

Used to clean mating surfaces.

-

-

3HAB 3537-1

3HAC022266-003



.


Removal, motor axis 1

The procedure below details how to remove the motor, axis 1.

1.

Action Note

DANGER!


2. Remove the cover, frame .

Shown in the figure Location of motor on page 177 .

3. Disconnect the connectors for the motor, axis 1.

4. Loosen the connector plate from the frame and pull out the motor cabling.

5. In order to release the brakes, connect the 24 VDC power supply to the motor.

Connect to connector

R3.MP1:

• +: pin 7

• -: pin 8

6. Unscrew the four attachment screws from the motor.


7. Remove the motor by gently lifting it straight up, making sure the motor pinion is not damaged against the gear.

8. Disconnect the brake release voltage from the motor connector.

178



4 Repair


Continued

Refitting, motor axis 1

The procedure below details how to refit the motor, axis 1.

Note

1.

Action

DANGER!


2. Clean the mating surface on the frame.

3. Make sure the o-ring on the circumference of the motor is seated properly. Lubricate the o-ring with grease .

4. Remove the motor cover from top of the motor.



.

Shown in the figure motor on page 177 .

Location of


Connect to connector R3.MP1:

• +: pin 7

• -: pin 8

6. Fit the rotation tool to the end of the motor shaft.



.

7. Fit the motor, making sure the motor pinion is properly mated to the gear of gearbox, axis 1.

Use the rotation tool to rotate the motor pinion, when mating it to the gear.

8. Secure the motor with four attachment screws and washers, but do not tighten yet.

4 pcs, M8 x 25.

9. Adjust the motor in relation to the gear in the gearbox:

• use the rotation tool to wiggle the motor shaft back and forth to feel the play. Tap with a plastic mallet.

• position the motor pinion at at least two other positions by turning axis 1 manually and check the gear play again.

There should be a barely noticable gear play.

10. Tighten the motor attachment screws.


11. Disconnect the brake release voltage.

12. Refit the motor cover to top of the motor.

13. Insert the motor cabling through the frame and secure the connector plate with attachment screws.

4 pcs.

14. Connect all the connectors inside the frame.


The cable layout is shown in the

figure Illustration, cabling inside frame on page 117 .

15. Refit the cover, frame. Replace the gasket , if damaged.





179

4 Repair


Continued

Action


17.

DANGER!



Note




4 Repair



Location of motor axis 2

The motor axis 2 is located on the front of the robot as shown in the figure below.

A more detailed view of the motor and its position may be found in the spare part view Frame, exploded view on page 247


xx0400001257

C

D

A

B

E

Motor, axis 2

Cover, frame

Connector plate for motor cabling

Bracket and cable tie

Motor cover




3HAC 023557-001

Cable harness, motor axes 1-2

3HAC 023754-001

O-ring 21522012-428

Cable harness, motor axes 1-2 must be ordered separately.

Must be replaced when replacing motor.

Replace if damaged.

Gasket, gearbox axis

1-2

3HAC 022048-001

Grease 3HAB 3537-1 For lubricating the o-ring.

Isopropanol

Standard toolkit


-

-

3HAC022266-

003

For cleaning mating surfaces.



For adjusting the gear play, motor/pinion



181

4 Repair


Continued


Power supply -


Circuit Diagram -

Note

24 VDC, 1.5 A.





The procedure below details how to remove the axis 2 motor.

Note

1.

Action

182

DANGER!


2. Remove the cover, frame .

Shown in the figure

Location of motor axis 2 on page 181

.

3. Disconnect the motor connectors inside the frame.

Connectors:

• R3.MP2

• R3.FB2

4. Cut any cable ties and remove any brackets or clamps securing the cables.

5. Remove the connector plate by removing its attachment screws, and pull the cables out from the frame.

Shown in the figure


.

6.

DANGER!

Secure the weight of the lower arm properly before releasing the brakes of motor, axis 2!

When releasing the holding brakes of the motor, the lower arm will be movable and may fall down!


Connect to connector R3.MP2

• +: pin 7

• -: pin 8

8.

WARNING!

Oil will be running out of the motor attachment hole when removing the motor! It may also be hot! Take any necessary measures to collect the oil.

9. Remove the motor by unscrewing its four attachment screws and plain washers.

Shown in the figure


.



4 Repair


Continued

Action

10. Remove the motor by gently pulling it out, making sure the motor pinion does not get damaged while moving it away from the gear.


12. Remove any remaining oil from the gearbox by siphoning it off.

Note


The procedure below details how to refit the axis 2 motor.

Action Note

1. Make sure the mating surfaces on the motor and the gearbox are clean and free from burrs.

If necessary, clean the surfaces with isopropanol.

2. Make sure the o-ring on the circumference of the motor is seated properly.

Lightly lubricate the o-ring with grease .



3. In order to release the brakes, connect the 24

VDC power supply to the motor.


• +: pin 7

• -: pin 8

4. Remove the motor cover from top of the motor.

Shown in the figure Location of motor axis 2 on page 181 .




6. Fit the motor, making sure the motor pinion is properly mated to gearbox 2.

Use the rotation tool to rotate the motor pinion, when mating it to the gear.

7. Secure the motor with four attachment screws and plain washers, but do not tighten yet.

8. Adjust the motor in relation to the gear in the gearbox.

Use the rotation tool to wiggle the motor shaft back and forth to feel the play. Tap with a plastic mallet.

Make sure the motor is turned the right way, i.e. connections upwards.

Make sure the motor pinion does not get damaged!

4 pcs, M8 x 25.

Tightening torque: approx 2 Nm.


9. Refit the motor cover to the top of the motor.

Be careful not to damage the cables!



12. Refit the connector plate with its attachment screws.

13. Reconnect the motor connectors inside the frame.

14. Refit all cable ties, and the the frame.

bracket underneath


Shown in the figure motor axis 2 on page 181

Cable layout is shown in the figure

Illustration, cabling inside frame on page 117

.

Location of

.

Shown in the figure Location of motor axis 2 on page 181 .



183

4 Repair


Continued

Action

15. Refit the cover, frame . Replace the gasket, if damaged.


17. Refill the gearbox with oil.


Note

Shown in the figure

Location of motor axis 2 on page 181 .

Art. no. for the gasket is specified in

section Required equipment on page 181 .

Detailed in section Performing a leak-down test on page 108

.

Type of oil and amount is specified in section Amount of oil .



19.

DANGER!




4 Repair




The motor of axis 3 is located inside the upper arm housing, as shown in the figure below.

A more detailed view of the motor and its position may be found in the spare part view



xx0400001258

E

F

G

C

D

A

B

Motor, axis 3

Attachment screws and washers of the motor (4 pcs)

Signal connector R3.FB3

Power connector R3.MP3

Connector holder

Upper arm housing cover

Cable tie


Equipment

Rot. ac motor incl pinion

O-ring



Spare part no.

Art. no.

3HAC 021798-001

21522012-426

3HAC 022049-001

3HAC 022050-001

Note

Replace if damaged.

Replace if damaged.

Replace if damaged.



185

4 Repair


Continued

Equipment

Isopropanol

Grease



Circuit diagram

Spare part no.

Art. no.

Note

-

3HAB 3537-1

Used for cleaning the mating surfaces.

Used for lubricating the oring.

3HAC022266-003 For adjusting the gear play.




The procedure below details how to remove the axis 3 motor.

Note

1.

Action

DANGER!


2. Remove any additional mechanical stops from axis 3.

3. Move:

• axis 2 to calibration position

• upper arm backwards against the mechanical stop.

This position enables removal of the motor without draining of the gearbox, axis 3.

186

4. Remove the upper arm housing cover .

5. Disconnect the motor connectors R3.MP3 and

R3.FB3.

xx0500001447

Shown in the figure Location of motor on page 185

.

Shown in the figure Location of motor on page 185

.



4 Repair


Continued

Note

6.

Action

DANGER!

Secure the weight of the upper arm properly before releasing the brakes of motor, axis 3.

When releasing the holding brakes of the motor, the upper arm will be movable and may fall down!



• +: pin 7

• -: pin 8

8. Remove the motor, axis 3, by unscrewing its attachment screws and washers.

Lift the motor gently straight out, making sure the motor pinion is not damaged.




Action Note

1. Clean the mating surfaces inside the upper arm housing and on the motor with isopropanol.

2. Make sure the o-ring on the circumference of the motor is seated properly. Ligthly lubricate it with grease.

Replace the o-ring if damaged. Art

.no. is specified in section




• +: pin 7

• -: pin 8.

4. Fit the motor to the upper arm housing, making sure the motor pinion is properly mated to the gear of axis 3.

5. Fit the attachment screws and washers but do not tighten them yet.

4 pcs, M6 x 20.

Shown in the figure

Location of motor on page 185 .




.

7. Adjust the motor in relation to the gear.

Use the rotation tool to wiggle the motor shaft back and forth to feel the play.





10. Reconnect the motor connectors, run and secure the cabling correctly inside the upper arm housing.



11. Refit the cover, upper arm housing . Check both the gaskets and replace, if damaged.

Shown in the figure






187

4 Repair


Continued

Action

12. Refit any additional mechanical stops.


14.

DANGER!



Note

Detailed in section Installation of additional mechanical stops on axis 3 on page 73 .




4 Repair

4.6.4. Replacement of motor, axis 3, IRB 1600ID

4.6.4. Replacement of motor, axis 3, IRB 1600ID

NOTE!

After replacement of motors/motor in a manipulator, recalibration is required.



xx0700000008

C

D

A

B

E

Motor, axis 3

Attachment screws and washers of the motor (4 pcs)

Signal connector R3.FB3

Power connector R3.MP3

Connector holder


Equipment


O-ring

Isopropanol

Spare part no.

3HAC 021798-001

3HAB3772-100

Art.no.

Grease

Standard tools

Circuit diagram

Pendulum Calibration tool

Note

Used for cleaning the mating surfaces.

Contents, standard toolkit



189

4 Repair


Continued


1.

Action Note

DANGER!




• +: pin 7

• -: pin 8

3. Remove any additional mechanical stops from axis 3.

4. Move:

• axis 2 to calibration position

• upper arm backwards against the mechanical stop

This position enables removal of the motor without draining oil of the gearbox, axis 3.

190

5. Remove the upper arm housing cover .

6. Disconnect the motor connectors R3.MP3 and

R3.FB3.

xx0700000010

Shown in the figure

Location of motor on page 189

Shown in the figure




7.

Action

DANGER!

Secure the weight of the upper arm properly before releasing the brakes of motor, axis 3.

When releasing the holding brakes of the motor, the upper arm will be movable and fall down!

8. Remove the motor, axis 3, by unscrewing its attachment screws and washers.

Lift the motor gently straight out, making sure the motor pinion is not damaged.

4 Repair


Continued

Note

B

C

9. Remove the resolver cover for refitting on the new motor.


A

E

D xx0700000050

A. Hex socket head cap screw

B. O-ring

C. Motor axis 3

D. Resolver cover

E. O-ring



Action

1. Clean the mating surfaces inside the upper arm housing and on the motor with Isopropanol.

2. Make sure the o-ring on the circumference of the motor is seated properly. Lubricate it with grease.

Note

Replace the o-ring if damaged.

Part number is specified in section


.



191

4 Repair


Continued

Action Note

3. Fit the new motor to the upper arm housing, making sure the motor pinion is properly mated to the gear of axis 3.


4 pcs, M6 x 20.

Shown in the figure



Part number is specified in


6. Adjust the motor in relation to the gear.

Use the rotation tool to wiggle the motor shaft back and forth to feel the play.


There should be a barely noticeable gear play.

Tightening torque: 10 Nm.

8. Refit the resolver cover on the new motor.

9. Reconnect the motor connectors, run and secure the cabling correctly inside the upper arm housing.

10. Refit the cover, upper arm housing .



.

Shown in the figure




11. Refit any additional mechanical stops.


Detailed in section Installation of additional mechanical stops on axis 3 on page 73 .



13.

DANGER!




4 Repair




The axis 4 motor is located inside the upper arm housing, as shown in the figure below.

A more detailed view of the component and its position may be found in the spare part view



xx0400001273

D

E

F

A

B

C

Motor, axis 4


Connector plate

Signal connector, R3.FB4

Power connector, R3.MP4

Attachment screw and washer, motor (4 pcs)



Rot. ac motor incl pinion 3HAC 021799-001

O-ring 3HAB 3772-81


3HAC 022050-001 Gasket, customer connections

Grease

Replace if damaged.

Replace if damaged.

Replace if damaged.

3HAB 3537-1 Used for lubricating the oring.



193

4 Repair


Continued

Equipment, etc.

Standard toolkit

Power supply



Circuit Diagram


-

Note



24 VDC, max. 1,5 A.


For adjusting the gear play.

3HAC022266-

003




The procedure below details how to remove the motor, axis 4.

Note

1.

Action

DANGER!


2. Manually move the robot to a position where the upper arm points straight down.

This will enable the motor 4 to be removed without draining the oil in the gearbox.

3. Remove the cover from the upper arm housing.

4. Remove the connector plate to get access to the axis 4 motor.


5. Disconnect the connectors R3.MP4 and R3.FB4 from the axis 4 motor.



• +: pin 7

• -: pin 8

7. Remove the motor, axis 4 by unscrewing the motor attachment screws .


8. Lift the motor to get the pinion away from the gear and disconnect the brake release voltage.

9. Remove the motor by gently lifting it out. Make sure the motor pinion is not damaged!

194



4 Repair


Continued


The procedure below details how to refit the motor, axis 4.

Action Note

1. Clean the mating surfaces on the motor and the gearbox.

Shown in the figure


.

2. Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate the o-ring with grease .

3. In order to release the brakes, connect the 24

VDC power supply to the motor.




• +: pin 7

• -: pin 8

4. Fit the motor with the attachment screws and washers.

Until the motor shaft is adjusted to the gear, as described in following steps, only tighten the screws lightly.

Shown in the figure


.

Tightening torque: approx. 2 Nm.

4 pcs, M6 x 20.

5. Fit the rotational tool to the end of the motor shaft.

6. Adjust the motor in relation to the gear in the gearbox.

Use the arm tool to wiggle the motor shaft back and forth to feel the play.

7. Tighten the motor attachment screws .




Shown in the figure


.


8. Reconnect the motor connectors R3.MP4 and

R3.FB4.

9. Refit the connector plate .

Shown in the figure


.

10. Make sure all the cabling is placed correctly inside the upper arm housing.

11. Refit the cover to the upper arm housing. Check both the gaskets and replace, if damaged.

Art. no. is specified in Required equipment on page 193

.




.


Detailed in section Performing a leakdown test on page 108 .



14.

DANGER!




4 Repair

4.6.6. Replacement of motor, axis 4, 1600ID

4.6.6. Replacement of motor, axis 4, 1600ID

NOTE!



196 xx0700000017

C

D

A

B

E

F

Motor, axis 4


Connector plate

Signal connector, R3.FB4

Power connector, R3.MP4

Attachment screw and washer, motor (4 pcs)



4 Repair


Continued




O-ring

Standard toolkit

3HAB 3772-81

Note

-


section Standard toolkit on page 237

, in part 2 of the

Product manual.

24 VDC, max. 1,5 A.


The contents are defined

in section Standard toolkit on page 237

, in part 2 of the Product manual.



Circuit Diagram

Pendulum Calibration tool


1.

Action

3HAC 4540-1

Note

For adjusting the gear play.


DANGER!



3. Remove the connector plate to get access to the axis 4 motor.


4. Disconnect the connectors R3.MP4 and R3.FB4 from the axis 4 motor.

5. Remove the motor, axis 4 by unscrewing the motor attachment screws .


6. Lift the motor to get the pinion away from the gear and disconnect the brake release voltage.

7. Remove the motor by gently lifting it out. Make sure the motor pinion is not damaged!


Action

1. Clean the mating surfaces on the motor and the gearbox.


Note



197

4 Repair


Continued

Action Note

2. Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate the o-ring with grease .

Art. no. is specified in section.

3. Fit the motor with the attachment screws and washers.

Until the motor shaft is adjusted to the gear, as described in following steps, only tighten the screws lightly.

Shown in the figure


Tightening torque: approx. 2

Nm .

4 pcs, M6 x 20.

4. Tighten the motor attachment screws .

Shown in the figure


Tightening torque: 10 Nm.

5. Reconnect the motor connectors R3.MP4 and

R3.FB4.

6. Refit the connector plate .

Shown in the figure

motor on page 196 .

Location of

7. Refit the cover to the upper arm housing.

8. Recalibrate the robot. General calibration information is included in section Introduction .


4 Repair

4.6.7. Replacement of motor and timing belt, axis 5

4.6.7. Replacement of motor and timing belt, axis 5


The motor and timing belt of axis 5 is located inside the upper arm housing, as shown in the figure below.




xx0400001279

E

F

G

H

C

D

A

B

Motor, axis 5


Connector plate

Signal cable, motor 5: R3.FB5

Power cable, motor 5: R3.MP5

Attachment screws and washers, motor bracket (2 pcs)

Motor bracket

Attachment screws and washers, motor (3 pcs)



199

4 Repair


Continued



Art. no.


Timing belt 3HAC 021304-001



3HAC 022050-001

Belt tightener

Dynamometer

Standard toolkit

-

3HAC024044-001


Circuit diagram

Note

Replace if damaged.

Replace if damaged.

Capacity: 100N





Belt tightener, 3HAC 024044-001

The belt tightener is a special tool that is used when adjusting the tension of the timing belt of axis 5. The length of the tool is important, since the tool is pulled with a given force.

xx0500001457

200



4 Repair


Continued

Removal, motor axis 5 and timing belt

The procedure below details how to remove the motor and the timing belt of axis 5.

Note

1.

Action

DANGER!


2. Remove the axis 4 motor.

3. Remove the motor and timing belt of axis 6.

Detailed in section Removal, motor axis 4 on page 194

.

Detailed in section Removal, motor and timing belt, axis 6 on page 210 .

4. Disconnect the axis 5 motor connectors: R3.MP5 and R3.FB5.

5. Move aside all cabling that is hindering access to the axis 5 motor.

6. Remove the motor bracket , including the motor, by unscrewing the two attachment screws and washers .

7. Remove the timing belt of axis 5.

8. Remove the motor bracket from the motor.

Shown in the figure


Refitting, motor and timing belt axis 5

The procedure below details how to refit the motor and timing belt of axis 5.


1.

Action

DANGER!


2. Clean the mating surfaces on the motor and in the upper arm housing.

3. Fit the new motor to the motor bracket, previously removed from the old motor.

3 pcs, M6 x 20.



201

4 Repair


Continued


4. Follow the steps below when fitting the motor:

• Place the timing belt (B) round the motor pinion and place the belt round the axis

5 as fitting the motor in the upper arm housing.

• Fasten the motor bracket with two attachment screws (C), but do not tighten the screws yet. Use correct attachment holes, shown in the figure to the right!

• Adjust the belt tension by pulling the motor bracket, using the belt tightener and dynamometer , as shown in the figure to the right.

• Tighten the two attachment screws of the bracket (C) with a torque of 10 Nm.



.

5. Refit the motor and timing belt of axis 6.

6. Refit the motor of axis 4.

xx0400001280

A. Motor axis 5

B. Timing belt, axis 5

C. Attachment screws and washers, motor bracket, 2 pcs,

M6 x 20

D. Belt tightener, the dimensions

are shown in the figure Belt tightener, 3HAC 024044-001 on page 200 .

F (Force): 24 N.

Detailed in section Refitting, motor and timing belt, axis 6 on page 210

.

Detailed in section Refitting, motor axis 4 on page 195

.

7. Reconnect all connectors and place the cabling correctly inside the upper arm housing.

Cable layout shown in the figure Illustration, cabling inside upper arm housing on page 115

.


Check both the gaskets and replace, if damaged.


Art.no. is specified in


.



10.

DANGER!


DANGER - First test run may cause injury or damage! on page 33

.


4 Repair


4.6.8. Replacement of motor, axis 5, IRB 1600ID

NOTE!


Location of motor, axis 5

The motor of axes 5 is located inside the upper arm as shown in the figure below.

xx0700000020

C

D

A

B

E

F

Arm Tube

Hex socket head cap screw M8X20

Cable harness IRB1600ID

Rotational ac motor Axis 5

Hex. socket head cap screw M6X20

O-ring

Cable harness bracket


Equipment, etc.

Rot. ac motor with pinion

VK cover

Standard toolkit

Spare part no. Art. no. Note

3HAA2166-19

Axis 5

3HAC020812-001 The contents are defined in section

Standard toolkit on page 237 , in part 2 of

the Product manual.



203

4 Repair


Continued

Equipment, etc.


Circuit Diagram


3HAC 6816-3

Note


See chapter Circuit diagram in the Product manual, reference information .

Nitrite O-ring

Cable grease

Isopropanol

3HAB3772-81


The procedure below details how to remove motor, axis 5.

WARNING!

Please observe the following before commencing any repair work on the manipulator:

• Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

• Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

NOTE!

Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used.

Action

1. Remove the cover (C) on the back of the upper arm tube (A). Rotate the upper arm to access all the screws (D).

Remove the screws (B) holding the cable harness.

Note

204

CAUTION!

After removal of the cover (mec stop), do not rotate axis 4 do to risk of cable harness damage.

xx0700000083

A. Arm Tube

B. Torx pan head screw M6X12

C. Cover

D. Torx pan head screw M6X12



4 Repair


Continued

Note

2.

Action

DANGER!

Turn of all electric power, hydraulic and pneumatic pressure supplies to the robot!.

3. Remove the AW equipment from the upper arm.

4. Disconnect connection R4.FB5 and

R4.MP5, from the backside.

Shown in section Remove AW Gun on page 160

5. Remove the VK- Cover to access the cable connections inside the arm.

xx0700000080

A. R4.FB5

6. Gently pull the cables out of the upper arm.

7. Disconnect through the hole connection R4.FB6 and R4.MP6. xx0700000054

A. VK-Cover

3HAC026660-001 Revision: C xx0700000053


205

4 Repair


Continued

8.

Action

CAUTION!

The upper arm tube weighs 12,3 kg without any additional equipment fitted. Use a suitable lifting device to avoid injury to personnel.


Note

10. Remove the seven (7) Hexagon socket head cap screw M8X20, holding the upper arm.

11. Remove the upper arm.

12. Remove the V-ring (A) and the support ring (B).

xx0700000088

Position (B) in figure

Location of motor, axis 5 on page 203

.

A

B

206

13. Remove the four (4) Hexagon socket head cap screw M6X20 holding motor 5.

xx0700000248

A. V-ring

B. Support ring

Position (E), (D) in figure

on page 203

Location of motor, axis 5

14. Remove the O-ring and change it if necessary.

Position (F) in figure Location of motor, axis 5 on page 203

.

15. Remove the resolver cover for reuse.



4 Repair


Continued


The procedure below details how to refit the motor of axis 5.

Action Note

1. Clean the mating surfaces inside the upper arm housing and on the motor with Isopropanol.

2. Make sure the o-ring on the circumference of the motor is seated properly. Lubricate it with grease.

Replace the o-ring if damaged. Part number is specified in section


203 .

3. Fit the motor to the upper arm housing, making sure the motor pinion is properly mated to the gear of axis 3.


5. Fit the rotation tool to the end of motor shaft.

7. Tighten the motors attachment scews.

8. Refit the V-ring and support ring.

4 pcs, M6 x 20. Shown in the figure

motor, axis 5 on page 203

.

Location of

Part number is specified in


6. Adjust the motor in relation to the gear. Use the rotation tool to wiggle the motor shaft back and forth to feel the play.

There should be a barely noticeable gear play.

Tightening torque: 10Nm

9. Refit the cable harness bracket (G)

in figure Location of motor, axis 5 on page 203

, inside the upper arm tube, use the two torx pan head screw M6X12 (B). Wind the cable harness (A), in a spiral with four free turns around the axis as in figure

Location of motor, axis 5 on page

203 Grease the cable harness with

cable grease .

A B

10. Refitt the upper arm using the 7 Hex socket head cap screw M8X20.

Shown in figure Location of motor, axis 5 on page

203 .

Tightening torque: 24 Nm

11. Reconnect through the VK-hole connection R4.FB6, and R4.MP6.

Make sure all the cabling is placed correctly inside the upper arm housing.

12. Reconnect connection R4.FB5 and

R4.MP5 from the backside.

xx0700000089

A. Cable harness

B. Torx pan head screw M6X12



207

4 Repair


Continued

13.

Action

DANGER!



14. Refit the cover (mec stop) on the back of the upper arm tube. Rotate the upper arm to access all tree screws.

Note

CAUTION!

Before refitting of the cover (mec stop), do not over rotate axis 4 do to risk of cable harness damage.

15. Recalibrate the robot. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools.

General calibration information is included in sections described in Introduction.


4 Repair


4.6.9. Replacement of motor and timing belt, axis 6


The motor and timing belt of axis 6 are located inside the upper arm housing, as shown in the figure below.




xx0400001281

D

E

F

G

H

A

B

C

Motor, axis 6


Connector plate

Signal cable, axis 6 motor: R3.FB6

Power cable, axis 6 motor: R3.MP6

Attachment screws and washers, motor (3 pcs)

Distance console with cable bracket and contact panel

Cable tie



Art. no.


Timing belt 3HAC 6779-1


Note

Replace if damaged.



209

4 Repair


Continued

Equipment


Hook

Dynamometer

Standard toolkit


Circuit diagram

Spare part no.

Art. no.

3HAC 022050-001

Note

Replace if damaged.

-

3HAC024045-001

Capacity: 100N



.



Removal, motor and timing belt, axis 6

The procedure below details how to remove the motor and timing belt of axis 6.

Note

1.

Action

DANGER!



3. Remove the connector plate .

4. Remove the complete distance console with cable brackets and contact panel.

5. Disconnect the motor cables for the axis 6 motor;

R3.MP6 and R3.FB6.

6. Remove the axis 6 motor by unscrewing its three attachment screws and washers.

7. Remove the timing belt.



Refitting, motor and timing belt, axis 6

The procedure below details how to refit the motor and timing belt of axis 6.

Action

1. Clean the mating surfaces on the motor and in the upper arm housing.


210



4 Repair


Continued

Action

2. Follow the steps below when fitting the motor:

• Place the timing belt (B) round the motor pinion and place the belt round the axis 6 as fitting the motor in the upper arm housing.

• Secure the motor with its tree attachment screws and washers

(C), but do not tighten them yet.

• Attach the hook round the motor pinion (underneath the motor) and adjust the belt tension with a force of

80 N, using a dynamometer . Shown in the figure to the right.

• Tighten the motor attachment screws with a torque of 10 Nm.


A. Motor, axis 6

B. Timing belt, axis 6

C. Attachment screws and washers, motor, 3 pcs, M6 x 20

D. Hook (motor pinion: Ø24.07 mm)

F (Force): 80 N.

3. Refit the complete distance console .

Shown in the figure


4. Refit the connector plate . Refit the cable tie . Shown in the figure


5. Reconnect the motor cables: R3.MP6 and

R3.FB6.

6. Place all the cabling correctly inside the upper arm housing.


Check both the gaskets and replace, if damaged.



tion, cabling inside upper arm housing on page 115 .

Illustra-

Art. no. is specified in Required equipment on page 209

.



9.

DANGER!


DANGER -

First test run may cause injury or damage! on page 33 .


4 Repair

4.6.10. Replacement of motor, axis 6 IRB 1600ID

4.6.10. Replacement of motor, axis 6 IRB 1600ID

NOTE!




G

B

A

E

C xx0700000025

D

E

F

G

A

B

C

Upper arm

Wrist

Motor, axis 6


Hexagon socket head screw M5x16 10.9 (Short head)



F

D



Art. no.


Standard toolkit


212

Note





4 Repair

4.6.10. Replacement of motor, axis 6 IRB 1600ID

Continued

Equipment

Circuit diagram

Spare part no.

Art. no.

Removal of motor axis 6

Action

1. Remove the motor according to description in

Removal, wrist unit on page 147

Note

Refitting of motor axis 6

Action

1. Refit the motor according to description in

Refitting of motor axis 6 on page 213

.

Note

Note


4 Repair

4.7.1. Replacement of gearbox, axes 1-2

4.7 Gearboxes

4.7.1. Replacement of gearbox, axes 1-2

Location of gearbox unit, axes 1-2

The gearboxes of axes 1 and 2 are located as shown in the figure below. Note that both gearboxes, 1 and 2, are a single unit!

A more detailed view of the gearbox and its position may be found in the spare part view

Frame, exploded view on page 247 in part 2 of the Product manual.

xx0500001400

A

B

Gearbox unit, axes 1-2

Attachment screws and washer, base-gearbox unit (VK-cover is removed)


Equipment

Gearbox axis 1-2, spare


3HAC 023555-001

Note

Includes:

• gearbox axis 1-2

• V-ring (sealing ring)

• lubricating oil in vessel

• stop arm.

VK-cover

Isopropanol

3HAA 2166-26

-

214

For cleaning the mating surfaces before fitting.



4 Repair


Continued

Equipment

Grease

Locking liquid

Lifting slings

Standard toolkit



-

-

3HAB 3537-1

Note

For lubricating the V-ring.

Loctite 574



237

.


Removal, gearbox unit axes 1-2

The procedure below details how to remove the complete gearbox unit, axes 1-2.

Note

1.

Action

DANGER!


2. Remove the motor, axis 1.

3. Remove the motor, axis 2.

4. Remove the complete arm system.

5. Drain the oil from gearbox, axis 1.

6. Unfasten the base from the installation site by removing the attachment bolts from the foundation.

7.

Detailed in section Removal, motor axis 1 on page 178 .

Detailed in section

Replacement of motor, axis 2 on page 181

.

Detailed in section

Removal, complete arm system on page 126 .

CAUTION!

The complete gearbox unit and base weighs 201 kg together! (Base: 81 kg, gearbox unit: 120 kg.)

All lifting equipment used must be sized accordingly!

8. Fit the lifting slings to the base/gearbox unit and place it with the lower arm side downwards, on top of a suitable workbench.



215

4 Repair


Continued

Action

9. Remove the VK-cover from the bottom of the robot base.

Note

TIP!

When the cabling is removed, it may be easier to drill a hole through the cover or to try and push it out from the inside.

10. Secure the weight of the base with lifting slings.

11. Remove the gearbox/base attachment screws and washer .

12. Separate the base from the gearbox unit.

Shown in the figure

Location of gearbox unit, axes 1-2 on page 214

.

Refitting, gearbox unit axes 1-2

The procedure below details how to refit the complete gearbox unit, axes 1-2.

Note

1.

Action

2.

DANGER!


CAUTION!

The complete gearbox unit weighs 120 kg

(without the base)! All lifting equipment used must be sized accordingly!

3. Place the gearbox unit with the lower arm side downwards on a suitable workbench.

4. Clean the mating surfaces of the base and of the gearbox unit with isopropanol.

5. Lubricate the V-ring with grease and fit it to the gearbox unit.


6. Fit a small amount of Loctite 574 on the mating surface in the gearbox unit.

7. Fit the base to the gearbox unit and secure it with the attachment screws and the washer.

Shown in the figure Location of gearbox unit, axes 1-2 on page 214 .

16 pcs, M10 x 40, tightening torque: 70

Nm.

8. Fit a new VK-cover

to the base of the robot. Shown in the figure Location of gearbox unit, axes 1-2 on page 214 .

Spare part no. is specified in Required equipment on page 214 .

216



4 Repair


Continued

Note Action

9.

CAUTION!

The complete gearbox unit and base weighs

201 kg together! (Base: 81 kg, gearbox unit:

120 kg.) All lifting equipment used must be sized accordingly!

10. Fit the lifting slings to the base/gearbox unit, turn it right side up and move it to the installation site.

11. Secure the base to the foundation.

Attachment bolts and the tightening torque are specified in section

Attachment bolts, specification on page

50

.

12. Refit the complete arm system.

13. Refit the motors, axes 1 and 2.

Detailed in section

Refitting, complete arm system on page 127 .

Detailed in sections:

•

Refitting, motor axis 1 on page 179

•

Refitting, motor axis 2 on page

183

.


15. Fill the two gearboxes with oil.

Detailed in section

Performing a leakdown test on page 108 .

Type of oil and amount is specified in section Type and amount of oil in gearboxes .

16. Fill the two gearboxes with oil.


Type of oil and amount is specified in section

Oil in gearboxes on page 95

.



18.

DANGER!




4 Repair

4.7.2. Service work on gearboxes, axes 3, 4, 5 and 6

4.7.2. Service work on gearboxes, axes 3, 4, 5 and 6

Gearboxes, replacement

The gearboxes of axes 3, 4, 5 and 6 are intended to run without requiring any repairs or maintenance work. This implies that they must under no circumstances be opened or serviced.

If the gearboxes require replacement:

• axes 3 and 4: the complete upper arm is to be replaced. This procedure is detailed in section

Replacement of complete upper arm on page 129 .

• axes 5 and 6: the complete wrist unit is to be replaced. This procedure is detailed in section

Replacement of wrist unit on page 143

.


5 Calibration information

5.1. Introduction



General

This chapter includes general information about different calibration methods and also details procedures that do not require specific calibration equipment.

When the robot system must be recalibrated, it is done according to documentation enclosed with the calibration tools.

When to calibrate

The system must be calibrated if any of the below occurs.

The resolver values are changed

If resolver values are changed, the robot must be recalibrated using the calibration methods supplied from ABB. Calibrate the robot carefully with standard calibration. The different

methods are briefly described in section Calibration methods on page 220 , and further

detailed in separate Calibration manuals.

If the robot has Absolute Accuracy calibration, it is also recommended but not always needed to be calibrated for new Absolute Accuracy.

The resolver values will change when parts affecting the calibration position are replaced on the robot, for example motors, wrist or part of transmission.

Contents of the revolution counter memory are lost

If the contents of the revolution counter memory are lost, the counters must be updated as detailed in section

Updating revolution counters on page 225 . This will occur when:

• the battery is discharged

• a resolver error occurs

• the signal between a resolver and measurement board is interrupted

• a robot axis is moved with the control system disconnected

The revolution counters must also be updated after the robot and controller are connected at the first installation.

The robot is rebuilt

If the robot has been rebuilt, for example after a crash or when the robot has been changed for other reachability, it needs to be recalibrated for new resolver values.

If the robot has Abslolute Accuracy calibration, it needs to be calibrated for new Absolute

Accuracy.



5.2. Calibration methods

5.2. Calibration methods

Overview

This section specifies the different types of calibration and the calibration methods that are supplied from ABB.

Types of calibration

Type of calibration

Description Calibration method

Standard calibration

Absolute Accuracy calibration

(optional)

The calibrated robot is positioned at home position, that is the axes positions (angles) are set to 0º.

Standard calibration data is found in the file calib.cfg, supplied with the robot at delivery.

The file identifies the correct resolver/motor position corresponding to the robot home position.

From deliveries together with RobotWare 5.0.5 and higher, the data will instead be found on the SMB (serial measurement board) in the robot, and not in a separate file.

Calibration Pendulum

(standard method)

Based on standard calibration, and besides positioning the robot at home position, the

Absolute Accuracy calibration also compensates for:

• mechanical tolerances in the robot structure

• deflection due to load.

Absolute Accuracy calibration focuses on positioning accuracy in the Cartesian coordinate system for the robot.

Absolute Accuracy data is found in the file absacc.cfg, supplied with the robot at delivery.

The file replaces the calib.cfg file and identifies motor positions as well as absacc-compensation parameters.

From deliveries together with RobotWare 5.0.6 and higher, the data will instead be found on the SMB (serial measurement board) in the robot, and not in a separate file.

A robot calibrated with AbsAcc has a sticker next to the identification plate of the robot.

To regain 100% Absolute Accuracy performance, the robot must be recalibrated for

Absolute Accuracy!

CalibWare xx0400001197

220




5.2. Calibration methods

Continued

Calibration methods

Each calibration method is detailed in a separate manual. Below is a brief description of the methods available.

Calibration Pendulum - standard method

Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB

6400R, IRB 640, IRB 1400H and IRB 4400S) and is also the most accurate method for the standard type of calibration. It is the recommended method in order to achieve proper performance.

Two different routines are available for the Calibration Pendulum method:

• Calibration Pendulum II

• Reference Calibration.

The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including the operating manual for Calibration Pendulum , which describes the method and the different routines further.

CalibWare - Absloute Accuracy calibration

In order to achieve a good positioning in the Cartesian coordinate system, Absolute Accuracy is used as a TCP calibration. The tool CalibWare guides through the calibration process and calculates new compensation parameters. This is further detailed in the application manual

Absolute Accuracy Calibware 2.0

.

If a service operation is done to a robot with Absolute Accuracy, a new absolute accuracy calibration is required in order to establish full performance. For most cases after motor and transmission replacements that do not include taking apart the robot structure, standard calibration is sufficient. Standard calibration also supports wrist exchange.

References

Article numbers for the calibration tools are listed in section Special tools on page 238 in part

2 of the Product manual.

The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including Operating manual - Calibration Pendulum , which describes the method and the different routines further.



5.3. Calibration scales and correct axis position

5.3. Calibration scales and correct axis position

Introduction

This section specifies the calibration scale positions and/or correct axis position for all robot models.

Calibration marks, IRB 1600

The illustration below shows the calibration marks and correct positions of the six axes of the robot. The marks shown in the figure are numbered according to the number of the axes.

222 xx0600002876




5.3. Calibration scales and correct axis position

Continued

Calibration scales, IRB 1600ID

The illustration below shows the calibration marks and correct positions of the six axes of the robot. The marks shown in the figure are numbered according to the number of the axes.

2

1

3

5

4

6 xx0700000095



5.4. Calibration movement directions for all axes

5.4. Calibration movement directions for all axes

Overview

When calibrating, the axis must consistently be run towards the calibration position in the same direction, in order to avoid position errors caused by backlash in gears etc. Positive directions are shown in the figure below.

This is normally handled by the robot calibration software.

Calibration movement directions, 6 axes

Note! The figure shows an IRB 7600, but the positive direction is the same for all 6-axis robots, except the positive direction of axis 3 for IRB 6400R which is in the opposite direction!

224 xx0200000089



5.5. Updating revolution counters

5.5. Updating revolution counters

General

This section details how to perform a rough calibration of each robot axis, that is updating the revolution counter value for each axis, using the pendant.

Step 1 - Manually running the robot to the calibration position

This procedure details the first step when updating the revolution counter; manually running the robot to the calibration position.

Action Note

1. Select axis-by-axis motion mode.

3. When all axes are positioned, store the revolution counter settings.

2. Jog the robot to place the calibration marks within the tolerance zone.

Shown in section

Calibration scales and correct axis position on page 222 .

Detailed in section:

Step 2 - Storing the revolution counter setting with the FlexPendant on page 225

(RobotWare 5.0).

Correct calibration position of axis 4 and 6

When running the robot to calibration position, it is extremely important to make sure that axes 4 and 6 of the below mentioned robots are positioned correctly. The axes can be calibrated at the wrong turn, resulting in wrong calibrated robot.

Make sure the axes are positioned according to the correct calibration values, not only according to the calibration marks. The correct values are found on a label, located either on the lower arm or underneath the flange plate on the base.

At delivery the robot is in the correct position, do NOT rotate axis 4 or 6 at power up before the revolution counters are updated.

If one of the below mentioned axes are rotated one or more turns from its calibration position before updating the revolution counter, the correct calibration position will be lost due to uneven gear ratio. This affects the following robots:

Robot variant

IRB 1600

Axis 4

No

Axis 6

Yes

If the calibration marks seem to be wrong (even if the motor calibration data is correct), try to rotate the axis one turn, update the revolution counter and check the calibration marks again (try both directions, if needed).

Step 2 - Storing the revolution counter setting with the FlexPendant

This procedure details the second step when updating the revolution counter; storing the revolution counter setting with the FlexPendant (RobotWare 5.0).

Action

1. On the ABB menu, tap Calibration .

All mechanical units connected to the system are shown along with their calibration status.



225


5.5. Updating revolution counters

Continued

Action

2. Tap the mechanical unit in question.

A screen is displayed: tap Rev. Counters .

226 en0400000771

3. Tap Update Revolution Counters...

.

A dialog box is displayed, warning that updating the revolution counters may change programmed robot positions:

• Tap Yes to update the revolution counters.

• Tap No to cancel updating the revolution counters.

Tapping Yes displays the axis selection window.

4. Select the axis to have its revolution counter updated by:

• Ticking in the box to the left

• Tapping Select all to update all axes.

Then tap Update .

5. A dialog box is displayed, warning that the updating operation cannot be undone:

• Tap Update to proceed with updating the revolution counters.

• Tap Cancel to cancel updating the revolution counters.

Tapping Update updates the ticked revolution counters and removes the tick from the list of axes.

6.

CAUTION!

If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, which in turn may cause damage or injury!

Check the calibration position very carefully after each update.

See section Checking the calibration position on page 227 .



5.6. Checking the calibration position

5.6. Checking the calibration position

General

Check the calibration position before beginning any programming of the robot system. This may be done in one of two ways:

• Using a MoveAbsJ instruction with argument zero on all axes.

• Using the Jogging window on the teach pendant.

Using a MoveAbsJ instruction on the FlexPendant, IRC5

This section describes how to create a program, which runs all the robot axes to their zero position.

Action Note

1. On ABB menu tap Program Editor.

2. Create a new program.

3. Use MoveAbsJ in the Motion&Proc menu.

4. Create the following program: MoveAbsJ

[[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,

9E9]]\NoEOffs, v1000, z50, Tool0

5. Run the program in manual mode.

6. Check that the calibration marks for the axes align correctly. If they do not, update the revolution counters!

The calibration marks are shown in section


How to update the revolution counters is detailed in section

Updating revolution counters on page 225

.

Using the Jogging window on the FlexPendant, IRC5

This section describes how to jog the robot to all axes zero position.

Action Note

1. Tap Jogging in the ABB menu.

2. Tap Motion mode to choose group of axes to jog.

3. Tap axes 1-3 to jog axes 1, 2 or 3.

4. Manually run the robots axes to a position where the axis position value read on the FlexPendant, is equal to zero.

5. Check that the calibration marks for the axes align correctly. If they do not, update the revolution counters!

The calibration marks are shown in section


How to update the counters is detailed in section

Updating revolution counters on page 225 .


6 Robot description

6.1. Type A of IRB 1600


6.1. Type A of IRB 1600

Type A - new upper arm and wrist

Type A of IRB 1600 have a new upper arm, complete and a new wrist unit. As a result of this, the following parts differ from earlier versions:

• Upper arm, complete

• Wrist unit

• O-ring sealingplate

How to know which type the robot is?

The identification plate on the cabinet and the lower arm of the robot tells if the robot has a new upper arm and wrist or not.

Those robots with a new upper arm and wrist are named IRB 1600, type A.

Those robots which are not equipped with a new upper arm and wrist are simply named IRB

1600 (no type specified).

Which parts are interchangeable and which are not?

The following parts are interchangeable .

• The upper arm, complete with spare part no. 3HAC026567-001 is interchangeable with spare part no. 3HAC023630-001. Note ! Software version 5.07.01 is needed!

The following parts are not interchangeable:

• The wrist unit with spare part no. 3HAC026569-001 is not interchangeable with spare part no. 3HAC10475-1.

• The o-ring sealingplate with spare part no. 3HAC025420-001 is not interchangeable with spare part no. 3HAC 7191-1.

Other changes in this product manual, compared to product manual IRB 1600, 3HAC023637-001

The content in this product manual is the same as in the product manual with art. no.

3HAC023637-001, except for the new upper arm complete and the new wrist unit for type A.

In order to distinguish IRB 1600 type A from earlier versions, a new art. no. has been created.

There has been a few other changes in the manual, not related to the IRB 1600 type A. These changes are described below:

• The cable harness for motors axes 1-2 has got a new spare part no. The motors axes 1-

2 (3HAC023557-001) and the cable harness, motors axes 1-2 (3HAC023754-001) now have two separate spare part no:s.

• Some cable harnesses have been replaced.

For details, see Base, spare part list on page 242

and Frame, spare part list on page 246

.



6.1. Type A of IRB 1600


7 Reference information

7.1. Introduction



General

This chapter includes general information, complementing the more specific information in the different procedures in the manual.

7.2. Applicable safety standards

Health and safety standards, robot

The robot, controlled by the IRC5, conforms to the following standards:

Standard Description

EN ISO 12100-1

EN ISO 12100-2

EN 954-1

EN ISO 10218-1:2006

EN ISO 60204-1:2005

EN 61000-6-4 (option)

EN 61000-6-2

Safety of machinery, terminology

Safety of machinery, technical specifications

Safety of machinery, safety related parts of control systems

Robots for industrial environments - Safety requirements - Part

1 Robot

Safety of machinery - Electrical equipment of machines - Part 1

General requirements

EMC, Generic emission

EMC, Generic immunity

Standard

IEC 204-1

IEC 529

Description

Electrical equipment of industrial machines

Degrees of protection provided by enclosures

Standard

ISO 9787

Standard

ANSI/RIA 15.06/1999

ANSI/UL 1740-1998

(option)

CAN/CSA Z 434-03

(option)

Description

Manipulating industrial robots, coordinate systems and motions

Description

Safety Requirements for Industrial Robots and Robot Systems

Safety Standard for Robots and Robotic Equipment (Max. payload 6 kg fulfilment).

Industrial Robots and Robot Systems - General Safety Requirements (Max. payload 6 kg fulfilment).



7.3. Unit conversion

7.3. Unit conversion

Converter table

Use the table below to convert units used in this manual.

Quantity

Length

Weight

Pressure

Force

Moment

Volume

Units

1 m

1 kg

1 bar

1 N

1 Nm

1 L

3.28 ft

2.21 lb

100 kPa

0.738 lbf

0.738 lbf-tn

0.264 US gal

39.37 in

14.5 psi



7.4. Screw joints

7.4. Screw joints

General

This section details how to tighten the various types of screw joints on the robot.

The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials.

UNBRAKO screws

UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below), and is extremely resistant to fatigue.

Whenever used, this is specified in the instructions, and in such cases, no other type of replacement screw is allowed! Using other types of screws will void any warranty and may potentially cause serious damage or injury!

Gleitmo treated screws

Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.

Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this the screw must be discarded and replaced with a new one.

When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should be used.

Screws lubricated in other ways

Screws lubricated with Molycote 1000 should only be used when specified in the repair, maintenance or installation procedure descriptions.

In such cases, proceed as follows:

1. Apply lubricant to the screw thread.

2. Apply lubricant between the plain washer and screw head.

3. Tighten to the torque specified in section

Tightening torque on page 234

below. Screw dimensions of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or smaller may be tightened without a torque wrench if this is done by trained and qualified personnel.

Lubricant Art. no.

Molycote 1000 (molybdenum disulphide grease) 11712016-618



233


7.4. Screw joints

Continued

Tightening torque

234

Before tightening any screw, note the following:

• Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure description. Any special torque specified overrides the standard value.

• Use the correct tightening torque for each type of screw joint.

• Only use correctly calibrated torque keys.

• Always tighten the joint by hand, and never use pneumatical tools.

• Use the correct tightening technique , that is do not jerk. Tighten the screw in a slow, flowing motion.

• Maximum allowed total deviation from the specified value is 10% !

The table below specifies the recommended standard tightening torque for oil-lubricated screws with slotted or cross-recess head screws.

Dimension

M2.5

M3

M4

M5

M6

Tightening torque (Nm)

Class 4.8, oil-lubricated

0.25

0.5

1.2

2.5

5.0

The table below specifies the recommended standard tightening torque for oil-lubricated screws with Allen head screws.

M5

M6

M8

M10

M12

M16

Dimension


(Nm)


6

10

24

47

82

200


(Nm)



(Nm)


-

-

34

67

115

290

-

-

40

80

140

340

The table below specifies the recommended standard tightening torque for Molycotelubricated screws with Allen head screws.

Dimension


Class 10.9, Molycote-lubricated


Class 12.9, Molycote-lubricated

M8

M10

M12

M16

28

55

96

235

34

66

115

280




7.4. Screw joints

Continued

The table below specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass .

Dimension


Nm - Nominal

1/8

1/4

3/8

1/2

3/4

12

15

20

40

70


Nm - Min.

8

10

15

30

55


Nm - Max.

15

20

25

50

90



7.5. Weight specifications

7.5. Weight specifications

Definition

In installation, repair and maintenance procedures, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.

To avoid injury, ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each manipulator model.

Example

Below is an example of how a weight specification is presented, inside a procedure table:

Action Note

CAUTION!

The motor weighs 32 kg! All lifting equipment used must be sized accordingly!



7.6. Standard toolkit

7.6. Standard toolkit

General

Contents, standard toolkit

Qty

1

1

1

1

1

1

1

1

1

1

1

All service (repairs, maintenance and installation) procedures contain lists of tools required to perform the specified activity.

All special tools required are listed directly in the procedures while all the tools that are considered standard are gathered in the Standard toolkit and defined in the table below.

This way, the tools required are the sum of the Standard Toolkit and any tools listed in the instruction.

Tool

Ring-open-end spanner 8-19 mm

Socket head cap 2.5-17 mm

Torx socket no: 20-60

Torque wrench 10-100 Nm

Small screwdriver

Plastic mallet

Ratchet head for torque wrench 1/2

Socket head cap no: 5, socket 1/2" bit L 20 mm



Small cutting plier



7.7. Special tools

7.7. Special tools

General

All service instructions contain lists of tools required to perform the specified activity. The

required tools are a sum of standard tools, defined in section Standard toolkit on page 237

, and of special tools, listed directly in the instructions and also gathered in this section.

Special tools

The table below specifies all the tools, not considered standard, used when performing service activities on the robot The special tools are also listed directly in the instructions.

Description


Dynamometer

Hook

Belt tightener

Art. no.

3HAC022266-003

-

3HAC024045-001

3HAC024044-001

Note

Used to adjust the gear play on all motors.

Capacity: 100N

Used to tighten the timing belt of axis 6, together with the dynamometer.

Used to tighten the timing belt of axis 5, together with the dynamometer.

Lifting tool, gearbox

Lifting tool, upper arm

3HAC023364-001

3HAC023386-001

Calibration equipment, Calibration Pendulum

The table below specifies the calibration equipment needed when calibrating the robot with the Calibration Pendulum method.

Description Art. no.

Note

Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes operating manual.



7.8. Lifting equipment and lifting instructions

7.8. Lifting equipment and lifting instructions

General

Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each procedure.

The use of each piece of lifting equipment is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting equipment.

This implies that the instructions delivered with the lifting equipment should be stored for later reference.



7.8. Lifting equipment and lifting instructions


8 Spare parts and exploded views

8.1. Introduction



Overview

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



8.2. Spare parts - base

8.2. Spare parts - base

Base, spare part list

The spare parts for the base are listed below and shown in the following figure.

Item no. Description

11

12

13

8

9

6

7

3

4

1

2

14

100

102

106

108

109

Base, spare

Stop pin

Cover base, spare

Gasket, base cover

VK-cover

Serial measurement unit

Push button unit

Battery pack

Push button guard

Signal cable SMB

Torx pan head screw

Spare part no.

3HAC 023552-001

3HAB 3258-1

3HAC 023554-001

3HAC 022047-001

3HAA 2166-26

3HAC 023424-001

3HAC 020967-001

3HAC 16831-1

Dimension

D=180, B=12

Lithium

34x102x63

3HAC 6499-1

3HAC 4050-1

9ADA 618-56 Steel 8.8-A2F

M6 x 16

Centering piece

Cable harness IRB 1600/1.2, Customer connections

3HAC025815-001

Cable harness IRB 1600/1.45

3HAC 021827-001

Cable harness IRB 1600/1.45, Customer connections

3HAC 021828-001

3HAC 021830-001 Cable harness IRB 1600/1.45, Wire feeder

Cable harness, Motor 1-2 3HAC 023754-001

3HAC 021828-003

242



Base, exploded view


8.2. Spare parts - base




8.3. Spare parts - base connections

8.3. Spare parts - base connections

Base connections, spare part list

The spare parts for connections at the base are listed below and shown in the following figure.


85

86

87

88

80

81

82

84

89

90

92

93

Spare part no.

Gasket

Housing 40P

3HAB 9040-1

3HAB 6411-1

Surface mounted housing HIP. 16/40 AG 3HAC 022964-001

Cover, cable harness wire feeder 3HAC 022918-002

Cover

Key pin

Plug

Protective hood

3HAC 6823-1

5217687-9

3HAC 11719-1

25222101-8

Dust cap

Environmental dust cap

Dust cap

Protection cover 40-p

5217649-9

3HAA 1001-727

3HAA 1001-630

3HAC 7816-1

Dimension

115x46 T=3

D=11.4-13

244



Base connections, illustrations


8.3. Spare parts - base connections




8.4. Spare parts - frame

8.4. Spare parts - frame

Frame, spare part list

The spare parts are listed below and shown in the following figure.


13 Torx pan head screw

27

27

28

20

21

22

23

24

25

26

Gearbox axis 1-2, spare

Stop arm

Cover, gearbox axis 1-2

Gasket, gearbox axis 1-2

Damper, axis 2

V-ring (sealing ring)


Rot. ac motor incl. pinion,

Cleanroom

O-ring

100-109 Cabling

108


Cable harness motor 1 - 2

Spare part no.

9ADA 618-56

Dimension

Steel 8.8-A2F

M6 x 16

3HAC 023555-001

3HAC 022001-001

3HAC 023556-001

3HAC 022048-001

3HAC 022013-001

3HAB 3732-21

3HAB 3732-13

V-150A

135x12.8

V-110-L

99x10.5

3HAC 023557-001

3HAC031018-001

21522012-428

See section Base, spare part list on page 242Base, spare part list on page

242 .

3HAC 023754-001

Nitrile rubber

79.5x3

246



Frame, exploded view


8.4. Spare parts - frame




8.5. Spare parts - lower arm

8.5. Spare parts - lower arm

Lower arm, spare part list

The spare parts are listed below and shown in the following figure.

Item no.

Description

40

41

42

43

Lower arm, spare

Lower arm, short, spare

VK-cover

VK-cover

100-109 Cabling

Spare part no.

Dimension

3HAC 023558-001

3HAC 023559-001

3HAA 2166-23

3HAA 2166-21

See section

Base, spare part list on page 242

.

D=120, B=12

D=68, B=8

248



Lower arm, exploded view


8.5. Spare parts - lower arm




8.6. Spare parts - upper arm

8.6. Spare parts - upper arm

Spare part list, upper arm

The spare parts listed below are shown in the exploded views, located on the next two pages.

Item no. Description Spare part no.

Dimension

13 Torx pan head screw 9ADA 618-56 Steel 8.8-A2F

M6 x 16

60

61

62

Upper arm, spare


O-ring

3HAC026567-001

3HAC 021799-001

3HAB 3772-81 Nitrile rubber

D1=41, D2=3

67

68

69

63

64

65

66


Timing belt

Timing belt

O-ring sealingplate

Wrist, Standard/Foundry


O-ring

3HAC 021800-001

3HAC 6779-1

3HAC 021304-001

3HAC 025420-001

3HAC 026569-001

3HAC 021798-001

21522012-426 Nitrile rubber

74.5x3

70

71

Damper, axis 3


3HAC 022260-001

3HAB 3732-19 Flourinated rubber/

V-95A

85x11

73

77

79

88

72

73

74

75

Damper, axis 5

Arm housing cover, spare

3HAB 8964-1

3HAC 023560-001


Gasket, customer connections 3HAC 022050-001

Contact panel

Connector panel

Contact pane, Wire feeder

Protective hood

3HAC 022173-001

3HAC 022173-002

3HAC 022173-006

25222101-8

89

90

91

94

Dust cap

Environmental dust cap

Dust cap

Plug with o-ring M10

95

96

Coupling

Lamp unit

100-109 Cabling

5217649-9

3HAA 1001-727

5217649-82

3HAC 022881-003

3HAB 3333-20

3HAC 022235-001

See section Base, spare part list on page 242

.

D=11.4-13

250



Upper arm, exploded view 1






251



Continued

Upper arm, exploded view 2

252 xx0600002856



8.7. Spare parts - options

8.7. Spare parts - options

General

This section specifies available options for the robot.

Spare parts - options

Option no.

213-1

431-1

25-3

28-1

32-1

34-1

Description

Lamp unit

Connection set R2.CP/

R2.CS

Position switch, axis 1

Spare part no.

3HAC022235-001

3HAC025396-001

3HAC023973-001

Working range limit axis 1 3HAC023110-001



Note

Installed as detailed in section

Installation of signal lamp for 1600

(option) on page 62

.

Only for standard connection.

Includes 3 switches.


Installation of position switch, axis 1 on page 76 .


Installation of additional mechanical stops on axis 1 on page

67

.


Installation of additional mechanical stop on axis 2 on page

70

.


Installation of additional mechanical stops on axis 3 on page

73

.



8.8. Spare parts - upper arm 1600ID

8.8. Spare parts - upper arm 1600ID

Location of upper arm 1600ID

The location of upper arm 1600ID.

Spare part list, upper arm

The spare parts listed below are shown in the exploded views, located on the next pages.

7

8

Item no.

Description

1 Wrist.

2

3

4

5

6

9

10

11

12

13

Spare part no.

3HAC027716-001

Part no.

Cable harness IRB

1600ID on page

255

Motor axis 3

( Motors and Orings on page 256

O-ring motor axis 3

( Motors and Orings on page 256 )

Motor axis 4 and 5

( Motors and Orings on page 256 )

O-ring motor 4 and

5 (

Motors and Orings on page 256 )

Motor axis 6

Cover arm housing

Covers and mechanical stops on page 257 )

3HAC027874-001

Mecanical stop

( Covers and mechanical stops on page 257

Cover upper arm

tube ( Covers and mechanical stops on page 257

Indicator lamp

( Indicator lamp on page 258 )

3HAC027877-001

Sealing ring(V-ring)

axis 3 ( Exploaded view on page 259

)

V-ring(V 130A) axis

4 (

Exploaded view on page 259 )

3HAC027523-001

3HAC021798-001

2152 2012-426

3HAC021799-001

3HAB3772-81

3HAC17342-1

3HAC027626-001

3HAC9258-1

3HAB3732-19

3HAB3732-25

Dimension without motor, plates and screws.

plate, no colour plate, no colour

254



Cable harness IRB 1600ID






255



Continued

Motors and O-rings

256 xx0700000157



Covers and mechanical stops






257



Continued

Indicator lamp xx0700000159

258



Exploaded view



Continued

13 xx0700000160


12

259




9 Circuit diagram


Overview

This chapter includes the circuit diagram for the robot.


9.1. Introduction



261


9.1. Introduction

Continued


Latest revision:

Prepared by, date: Approved by, date:

The information in this document 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 document.

Except as may be expressly stated anywhere in this document, 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 document.

This document and parts thereof must not be reproduced or copied without ABB's written permission, and contents therof must not be imparted to a third party nor be used for any unauthorized purpose.

Contravention will be prosecuted.

Additional copies of this document may be obtained from ABB at its then current charge.

© Copyright 2007 ABB ALL right reserved.

ABB Automation Technologies AB

Robotics

SE-721 68 Västerås

Sweden

Lab/Office:

COPYRIGHT page

Title page/cover sheet

Status:

2007-03-19

Approved

Document no.

Plant:

Location:

Sublocation:

3HAC021351-003

=

+

+

IRB1600

Manipulator

Rev. Ind

01

Page

Next

Total

1

2

15

Customer

Robot serial number(s)

Drawing number

Drawing version

Manufacture

Type

Type of installation

Control cabinet

Mains voltage

Supply

Control voltage

Year of construction

Project start

Project manager

Last revision

Designed by

Designed date

Number of pages

:

:

:

:

Manipulator

:

:

:

:

:

:

:

:

2007-03-22

:

:

:

:

:

:

:

sestper

2007-03-22

15

Latest revision:


Lab/Office:

TITLE PAGE

Title page/cover sheet

Status:

2007-03-19

Approved

Document no.

Plant:

Location:

Sublocation:

3HAC021351-003

=

+

+

IRB1600

Manipulator

Rev. Ind

01

Page

Next

Total

2

11

15

1

Latest revision:

Prepared by, date:

2

Approved by, date:

3 4

IRB 1600 ID

5 6 7

R4.MP6

R4.FB6

R3.MP3

R3.MP4

R3.MP5

R3.MP6

R3.H1

R3.H2

R4.MP5

R4.FB5

R3.FB3

R3.FB4

R3.FB5

R3.FB6

R2.CS

Air R2.CP

R2.CBUS

8

R3.FB3

R3.FB4

R3.FB5

R3.FB6

R3.MP3

R3.MP4

R3.MP5

R3.MP6

R3.H1

R3.H2

R3.MP1

R3.MP2

R3.FB1

R3.FB2

R4.FB1

R4.MP1

R1.CP/CS

R1.CBUS

R1.CP

R1.CS

R1.LS

R4.MP2

R4.FB2

R1.MP

Air

R1.SMB

R1.FB1-2 R2.G

R1.FB3-6 R2.BU

R2.SMB R2.BU1-6

Lab/Office:

Manipulator Connection Points

Status:

Document no.

Plant:

Location:

Sublocation:

3HAC021351-003

=

+

+

Connection Points

Manipulator

Rev. Ind

01

Page 11

Next 20

Total 15

-

PE

1

-R1.MP

C8

C9

B8

C10

B7

BRAKE REL

BRAKE REL

BRAKE PB

BU

BU

BU

0V BRAKE

0V BRAKE

BU

BU

B4

B3

C2

C1

EXT LIM 2

EXT LIM 1

LIM 2

LIM 1

BU

BU

BU

BU

2

GNYE

Latest revision:


3

-

PE

4 5

R2.BU

2

3

-BU Brake Release (Simplified)1

2

3

1

1

6 7

A K

Brake Bleed Circuit

A K

Brake Bleed Circuit

A K

2

-

R2.BU1-6

-2

-BRAKE REL 1 / +AXIS 1/22.1

1

-

4

-

-1

-4

-0V BRAKE 1 / +AXIS 1/22.1


3

-

-

5

-

6

8

-

-3

-5

-6

-8

-0V BRAKE 2 / +AXIS 2/23.2

-PTC2 / +AXIS 2/23.2

-PTC6 / +AXIS 6/27.2

+AXIS 6 IRB1600ID/29.2


Brake Bleed Circuit

A K

7

-

10

-

-7

-10


Brake Bleed Circuit

A K

9

11

12

-

-

-

-

14

-9

-11

-12

-14

Brake Bleed Circuit

A K

Brake Bleed Circuit

13

16

15

-

-

-

-13

-16

-15



-0V BRAKE 5 / +AXIS 5/26.2




-0V BRAKE 6 / +AXIS 6/27.2

8

Lab/Office:

Brake Release Unit

Status: 2007-03-19

Approved

Document no.

Plant:

Location:

Sublocation:

3HAC021351-003

=

+

+

IRB1600

BU

Rev. Ind

01

Page 20

Next 21

Total 15

1 2 3 4 5 6 7 8

R1.SMB

A

L

J

F

K

KEYPIN

M

D

E

B

C

SMB

SDI

SDI-N

SDO

SDO-N

0V

+24V

+BATSUP

0V BATLD

WH

BU

WH

OG

WH

GN

GY

RD

7

6

2

4

3

5

8

R2.SMB

9

R2.SMB

9

7

6

2

4

3

5

8

G

+ - + - + -

0V

+

R2.G(X3)

2

1

R2.G(X3)

2

1

R1.SMB1.7

5

12

4

11

2

9

R1.SMB1.7

5

11

2

12

4

9

SIGNAL CABLE AXIS 7 (OPTION)

X7

BU

0V X7

WH

Y7

WH

0V Y7

OG

0V EXC 2

WH

EXC 2

GN

R2.FB7

A

D

E

B

C

F

Latest revision:


Lab/Office:

Serial Measuring Board

Status: 2007-03-19

Approved

Document no.

Plant:

Location:

Sublocation:

3HAC021351-003

=

+

+

IRB1600

SMB

Rev. Ind

01

Page 21

Next 22

Total 15

+AXIS 2/23.1

+AXIS 3/24.1

+AXIS 4/25.1

+AXIS 5/26.1

+AXIS 6/27.1



-SMB

1

-R1.MP

A1

A2

A3

-PE

B2

+BU/20.7 / +BU-BRAKE REL 1

+BU/20.7 / +BU-0V BRAKE 1

A5

2

M1R

M1R

M1S

M1S

M1T

M1T

PE

1.1

1.10

1.2

1.11

1.3

1.12

1.8

PTC1 1.6

BRAKE REL.1

0V BRAKE.1

1.4

1.5

3 4

-R3.MP1

1

1

2

2

3

3

9

9

-PE12 / +AXIS 2/23.4

5

5

6

6

-PTC12 / +AXIS 2/23.4

7

7

8

8

5

M1R

M1S

M1T

PE

1

2

3

GNYE

BRAKE REL.1

4

0V BRAKE.1

5

3

15

2

14

6

18

-R2.FB1-2

2

14

6

18

3

15

X1

0V X1

Y1

0V Y1

0V EXC

EXC

GY

WH

VT

WH

WH

BU

-R3.FB1

6 6

1 1

7

2

7

2

8

3

8

3

6

-R4.MP1

1

-MU1

1

2

3

PE

2

7

8

7

8

X1

0V X1

Y1

0V Y1

0V EXC

EXC

WHBU

BU

WHOG

OG

GN

WHGN

6

3

5

2

-FB1

-R4.FB1-

4

1

4

1

6

3

5

2

7

3

PE GNYE

R (U) PE

S (V)

3

M

~

T (W)

Brake

Resolver

8

Latest revision:


Lab/Office:

Axis 1

Status: 2007-03-19

Approved

Document no.

Plant:

Location:

Sublocation:

3HAC021351-003

=

+

+

IRB1600

AXIS 1

Rev. Ind

01

Page 22

Next 23

Total 15

1

-PE

-R1.MP

A4

D1

D2

+BU/20.7 / -PTC2

A6



2 3

M2R

M2R

M2S

M2S

M2T

M2T

1.13

1.18

1.14

1.19

1.15

1.20

-R3.MP2

1

1

2

2

3

3

9

9

+AXIS 1/22.3 / -PE12

1.22

+AXIS 1/22.3 / -PTC12 5

6

5

6 PTC 2

BRAKE REL.2

0V BRAKE.2

1.16

1.17

7

8

7

8

4 5

M2R

M2S

M2T

PE

1

2

3

GNYE

BRAKE REL.2

0V BRAKE.2

4

5

+AXIS 1/22.1

-SMB

7

19

5

17

4

16

-R2.FB1-2

4

16

7

19

5

17

Latest revision:


X2

0V X2

GN

WH

Y2

0V Y2

YE

WH

0V EXC

EXC

WH

OG

-R3.FB2

6 6

1 1

7

2

7

2

8

3

8

3

Lab/Office:

Axis 2

X2

0V X2

WHBU

BU

Y2

0V Y2

WHOG

OG

0V EXC

EXC

GN

WHGN

6 7

2

3

PE

-R4.MP2

1

-MU2

1

2

3

PE GNYE

R (U) PE

S (V)

3

M

~

T (W)

8

7

8

7

8

6

3

5

2

4

-

1

-FB2

4

1

6

3

5

2

Brake

Resolver

Status: 2007-03-19

Approved

Document no.

Plant:

Location:

Sublocation:

3HAC021351-003

=

+

+

IRB1600

AXIS 2

Rev. Ind

01

Page 23

Next 24

Total 15

1

-R1.MP

D3

D4

B1

2

M3R

M3S

M3T

2.10

2.11

2.12

3


B5

BRAKE REL.3

2.13

C7

+AXIS 1/22.1

-SMB

11

-

23

-

12

-

24

-

-

13

25

-

-R3.FB3-6

-

11

-

23

-

-

-

-

12

24

13

25

Latest revision:


MONLMP 2.6

X3

0V X3

Y3

0V Y3

0V EXC

EXC

RDBN

RDGN

RDYE

RDGY

BKGY

BKYE

4 5

Lab/Office:

Axis 3

6 7

3

+AXIS 4/25.5 / -PE43

PE

+AXIS 4/25.5 / -PTC34

5

6

-PTC35 / +AXIS 5/26.6


7

8

-R3.MP3

1

-MP3

1

2

2

7

8

3

PE

5

6

GNYE

R (U) PE

S (V)

3

M

~

T (W)

Brake

8

-0V BRAKE 3 / +AXIS 6/27.6


1

1

SIGNAL LAMP (OPTION)

1

R3.H1

A K

1

R3.H2

8

3

7

2

-R3.FB3

-

6

-FB3

6

1 1

8

3

7

2

Resolver

Status: 2007-03-19

Approved

Document no.

Plant:

Location:

Sublocation:

3HAC021351-003

=

+

+

IRB1600

AXIS 3

Rev. Ind

01

Page 24

Next 25

Total 15

1

Latest revision:

Prepared by, date:

-PE

-R1.MP

A10

A9

A8


B6

+AXIS 1/22.1

-SMB

2

-

-

14

3

-

-

15

7

-

-

19

-R2.FB3-6

-

2

-

14

-

3

-

15

-

7

-

19

2

Approved by, date:

3

M4R

M4S

M4T

PE

2.14

2.15

2.16

2.9

BRAKE REL.4

2.17

X4

0V X4

Y4

0V Y4

0V EXC

EXC

RDBU

RD

BKBN

BKGN

BU

BUPK

4 5 6 7 8

-R3.MP4

1

-MU4

1

2

2

R (U) PE

S (V)

3

M

~

T (W)

Lab/Office:

Axis 4

3

3

9

-PE43 / +AXIS 3/24.6

+AXIS 6/27.5

+AXIS 6 IRB1600ID/29.4 / -PTC46

5

6

-PTC34 / +AXIS 3/24.6

7

8

9

-0V BRAKE4 / +AXIS 5/26.6


-R3.FB4

-

6

1

-FB4

6

1

7

8

5

6

7

2

7

2

Brake

Resolver

8

3

-0V EXC45 / +AXIS 5/26.6


-EXC45 / +AXIS 5/26.6


8

3

Status: 2007-03-19

Approved

Document no.

Plant:

Location:

Sublocation:

3HAC021351-003

=

+

+

IRB1600

AXIS 4

Rev. Ind

01

Page 25

Next 26

Total 15

1

-R1.MP

A7

D10

D9

2

M5R

M5S

M5T

2.18

2.19

2.20

3



B9

C5

+AXIS 1/22.1

-SMB

4

-

-

16

-R2.FB3-6

-

4

-

16

5

-

-

17

-

-

5

17

0V PTC 2.22

BRAKE REL.5

0V BRAKE 5

2.21

2.23

X5

0V X5

Y5

0V Y5

BKPK

BKBU

BKRD

BK

Latest revision:


4 5 6 7

-R3.MP5


1

-MU5

1

2

3

+AXIS 6/27.6 / -PE65

9

2

3

9 GNYE

R (U) PE

S (V)

3

M

~

T (W)

8

+AXIS 3/24.5 / +AXIS 3-PTC35 5

6

7

8

+AXIS 4/25.5 / +AXIS 4-0V BRAKE4

7

8

5

6

Brake

+AXIS 4/25.6 / +AXIS 4-0V EXC45

+AXIS 4/25.6 / +AXIS 4-EXC45

Lab/Office:

Axis 5

-R3.FB5

6

1

-FB5

6

1

7

2

7

2

Resolver

8

3

8

3

-0V EXC56 / +AXIS 6/27.6

-EXC56 / +AXIS 6/27.6

Status: 2007-03-19

Approved

Document no.

Plant:

Location:

Sublocation:

3HAC021351-003

=

+

+

IRB1600

AXIS 5

Rev. Ind

01

Page 26

Next 27

Total 15

1 2 3

-PE

-R1.MP

D8

D7

B10

+BU/20.7 / +BU-PTC6



C6

+AXIS 1/22.1

-SMB

9

-

21

-

10

-

22

-

-

-R2.FB3-6

9

-

21

-

10

-

22

M6R

M6S

M6T

PE

2.1

2.2

2.3

2.8

PTC 2.5

BRAKE REL.6

0V BRAKE 6

2.4

2.7

BUBN

BUGN

BUYE

BUGY

X6

0V X6

Y6

0V Y6

Latest revision:


4 5 6 7 8

-R3.MP6


1

-MU6

1

2

3

9

-PE65 / +AXIS 5/26.6

5

6

+AXIS 4-PTC46 / +AXIS 4/25.6

7

8

7

8

5

6

2

3

9 GNYE

R (U) PE

S (V)

3

M

~

T (W)

Brake

+AXIS 3/24.5 / +AXIS 3-0V BRAKE 3

R3.FB6


-

6

-FB6

6

1 1

+AXIS 5/26.6 / +AXIS 5-0V EXC56

+AXIS 5/26.6 / +AXIS 5-EXC56

8

3

7

2

8

3

7

2

Resolver

Lab/Office:

Axis 6

Status: 2007-03-19

Approved

Document no.

Plant:

Location:

Sublocation:

3HAC021351-003

=

+

+

IRB1600

AXIS 6

Rev. Ind

01

Page 27

Next 28

Total 15

1 2 3 4 5 6 7 8

-R1.MP

A7

D10

D9

M5R

M5S

2.18

2.19

-R3.MP5

1

1

2

2

M5T 2.20

3

3

+AXIS 6 IRB1600ID/29.4 / -PE65 9

9

M5R

M5S

M5T

PE

17

18

19

24



B9

C5

+AXIS 1/22.1

-SMB

4

-

-

16

-R2.FB3-6

-

4

-

16

5

-

-

17

-

5

-

17

Latest revision:


0V PTC

+AXIS 3/24.5 / +AXIS 3-PTC35

2.22

5

6

5

6

BRAKE REL.5

0V BRAKE.2

2.21

2.23

7

8

7

8

+AXIS 4/25.5 / +AXIS 4-0V BRAKE4

X5

0V X5

BKPK

BKBU

Y5

0V Y5

BKRD

BK

+AXIS 4/25.6 / +AXIS 4-0V EXC45

+AXIS 4/25.6 / +AXIS 4-EXC45

PTC

PTC

20

21

BRAKE REL.5

22

0V BRAKE.5

23

-R3.FB5

6

6

1

1

X5

0V X5

GN

WH

7

2

7

2

8

3

8

3

Y5

0V Y5

YE

WH

0V EXC

EXC

WH

OG

-0V EXC56 / +AXIS 6 IRB1600ID/29.4

-EXC56 / +AXIS 6 IRB1600ID/29.4

Lab/Office:

Axis 5 IRB1600ID

-R4.MP5

+AXIS 5/26.7

1

-MU5

1

2

3

9

2

3

9 GNYE

R (U) PE

S (V)

3

M

~

T (W)

5

6

7

8

7

8

5

6

Brake

8

3

7

2

-R4.FB5

-FB5

6

6

1

1

8

3

7

2

Status: 2007-03-19

Approved

Document no.

Plant:

Location:

Sublocation:

3HAC021351-003

Resolver

=

+

+

IRB1600

AXIS 5 IRB1600ID

Rev. Ind

01

Page 28

Next 29

Total 15

1 2 3 4 5

+AXIS 1/22.1

-SMB

-PE

-R1.MP

D8

D7

+BU/20.7 / +BU-PTC6


/ +BU-0V BRAKE 6

B10

C6

M6R

M6S

M6T

PE

PTC

2.1

2.2

2.3

2.8

2.5

BRAKE REL.6

2.4

0V BRAKE.6

2.7

+AXIS 3/24.5 / +AXIS 3-0V BRAKE 3

-R3.MP6

1

1

M6R 1

2

2 M6S

M6T

2

3

3

3

9

9

-PE65 / +AXIS 5 IRB1600ID/28.4

PE

5

5

6

6

+AXIS 4-PTC46 / +AXIS 4/25.6

7

7

8

8

PTC

PTC

BRAKE REL.6

0V BRAKE.6

8

4

5

6

7

9

-

21

-

-R2.SMB3-6

-

9

-

21

10

-

22

-

-

10

-

22

BUBN

BUGN

BUYE

BUGY

X6

0V X6

Y6

0V Y6

6

R3.FB6

6

1 1

7

2

7

2

+AXIS 5 IRB1600ID/28.4 / +AXIS 5 IRB1600ID-0V EXC56

+AXIS 5 IRB1600ID/28.4 / +AXIS 5 IRB1600ID-EXC56

8

3

8

3

GY

WH

VT

WH

X6

0V X6

Y6

0V Y6

WH

BU

0V EXC

EXC

6 7

5

6

7

8

-R4.MP6

+AXIS 6/27.7

1

-MU6

1

2

2

3

9

3

9 GNYE

R (U) PE

S (V)

3

M

~

T (W)

5

6

7

8

Brake

8

8

3

7

2

R4.FB6

+AXIS 6/27.7

-

6

-FB6

6

1 1

8

3

7

2

Resolver

Latest revision:


Lab/Office:

Axis 6 IRB1600ID

Status: 2007-03-19

Approved

Document no.

Plant:

Location:

Sublocation:

3HAC021351-003

=

+

+

IRB1600

AXIS 6 IRB1600ID

Rev. Ind

01

Page 29

Next 30

Total 15

1

-R1.CP/CS-

A1

B1

B2

C2

D2

A3

C1

D1

A2

-

B8

C8

D8

A9

B7

C7

D7

A8

B6

C6

D6

A7

B5

C5

D5

A6

B10

C10

D10

B9

C9

D9

A10

Latest revision:


2

CPA

CPB

CPC

CPD

CPE

CPF

CPJ

CPK

CPH

BK

BN

RD

OG

YE

GN

BU

VT

GY

CPG GNYE

GYBN

GYRD

GYOG

GYYE

GYGN

GYBU

GYVT

GYWH

WHBN

WHRD

WHOG

WHYE

WHGN

WHBU

WHVT

WHGY

GYBK

GNBK

GNBN

GNRD

GNOG

GNBU

GNVT

CSK

CSL

CSM

CSN

CSP

CSR

CSS

CST

CSA

CSB

CSC

CSD

CSE

CSF

CSG

CSH

CSJ

CSU

CSV

CSW

CSX

CSY

CSZ

3 4 5

E

F

J

K

H

-R2.CP

A

CUSTOMER CONNECTION

B

POWER (OPTION)

C

KUNDANSLUTNING

KRAFT (OPTION)

D

G

-R1.CP/CS-

A

D

E

B

C

F

G

H

X

Y

V

W

Z

T

U

R

S

N

P

L

M

J

K

G

H

-R2.CS

A

B

C

D

CUSTOMER CONNECTION

SIGNAL (OPTION)

KUNDANSLUTNING

SIGNAL (OPTION)

E

F

CBUS1

CBUS2

CP1

CP2

CP3

CP4

CP5

CP6

6

Lab/Office:

Customer Connections

7 8

F

G

H

-R2.CP

A

CUSTOMER CONNECTION

B

CANBUS (OPTION)

C

KUNDANSLUTNING

CANBUS (OPTION)

D

E

Status: 2007-03-19

Approved

Document no.

Plant:

Location:

Sublocation:

3HAC021351-003

=

+

+

IRB1600

CC

Rev. Ind

01

Page 30

Next 31

Total 15

1 2 3 4 5 6 7 8

Latest revision:


-PE

-PE

-PE

D

C

A

B

R1.LS

GNYE

BK

BN

BU

BK

H

G

E

F

GNYE

BK

BN

BU

BK

M

L

J

K

GNYE

BK

BN

BU

BK

Z KEY PIN / STIFT

R2.LS1-1

R2.LS1-2

R2.LS1-3

One switch

En brytare

Two switches

Två brytare

Three switches

Tre brytare

Lab/Office:

Position Indicator Axis 1; Option

Status: 2007-03-19

Approved

Document no.

Plant:

Location:

Sublocation:

3HAC021351-003

=

+

+

IRB1600

LS

Rev. Ind

01

Page 31

Next

Total 15

A

Absolute Accuracy, calibration

221

Absolute Accuracy, guiding sleeves

51

air connections, pressure

84

arm system replacing

126

attachment bolts, robot-foundation

50

B backshells, customer connection

84

base brake release buttons

47

hole configuration

49

replacing

165

screws, tightening torque

167

spare part number

165

battery pack replacing

103

replacing, interval

91

spare part number

104

belt tightener axis 5 article number

200

measure

200

brake release unit releasing the brakes

47

replacing

173

spare part number

173

brakes testing function

24

brakes, releasing external power supply to connector R1.MP

48

manually

47

power supply on motor axis 1

178

power supply to motor axis 2

182


187


194

C cable harness inside base, figure

118

inside frame, figure

117

inside upper arm, figure

115

replacing

112

spare part number

112

cabling inside base, figure

118

inside frame, figure

117

inside upper arm, figure

115

replacing

112

spare part number

112

cabling between robot and controller

81

cabling, robot

81

calibrating roughly

225

calibration

Absolute Accuracy type

220

marks/scales

222

rough

225

standard type

220

when to calibrate

219


Index calibration manuals

221

calibration position

225

checking

227

jogging to, FlexPendant

227

scales

222

calibration, Absolute Accuracy

221

CalibWare

220

check, installation site

38

cleaning robot, interval

91

cleaning, robot

105

complete arm system replacing

126

connecting the robot and controller, cabling

81

Connection of external safety devices

14

connectors air

84

customer

84

MIL-C-26482 series 1

85

on robot, figure

79

R2.CS and R2.CP

pins, customer connection

84

Souriau

84

cracks, damper

94

customer connections

79

D damage, damper

94

damper, axis 2

93

attachment screw

152

replacing

151

spare part number

151

damper, axis 3 inspection

93

replacing

153

spare part number

153

damper, axis 5 inspection

93

replacing

157

spare part number

157

dimensions guiding sleeves

50

mounting surface

50

robot

56

direction of axes

224

E environment

39

equipment, robot

56

ESD damage elimination

35

sensitive equipment

35

wrist strap connection point

35

explanation, safety symbols

30

extra equipment

56

extra loads

55

F figures base, hole configuration

49

brake release buttons

47

263

Index cabling inside base

118

cabling inside frame

117

cabling inside upper arm housing

115

connectors on robot

79

gearboxes

95

mounting surface

50

power supply to connector R1.MP

48

fitting, equipment

56

FlexPendant jogging to calibration position

227

MoveAbsJ instruction

227

updating revolution counters

225

foundation loads

38

requirements

39

frame replacing

214

spare part number

214

G gaskets, spare part number base cover

173

gearbox axis 1-2

177

upper arm cover

209

upper arm customer connections

209

gearbox, axes 1-2 replacing

214

spare part number

214

gearboxes location on robot, figure

95

type of oil and amount

95

gearboxes, axes 3-6 replacing

218

service work

218

gearboxes, axes 5 and 6 amount and type of oil

97

oil change

97

Gravity Beta

52

H hole configuration base

49

I illustration base connections

245

illustrations base, exploded

243

base, hole configuration

49

brake release buttons

47

cabling inside base

118

cabling inside frame

117

cabling inside upper arm housing

115

connectors on robot

79

frame, exploded

247

gearboxes

95

lower arm, exploded

249

mounting surface

50

power supply to connector R1.MP

48

upper arm, exploded

251

,

252

inspection

93

264 installation checking site prior robot installation

38

equipment

56

mechanical stop axis 2

70

mechanical stops axis 3

73

mechanical stops, axis 1

67

position switch axis 1

76

robot, attachment bolts

50

signal lamp

62

intervals, maintenance

91

inverted mounting

52

L lamp unit article number

62

installation

62

lifting, robot

45

limitations in working range, tilted and wall mounted

43

loads

55

loads, foundation

38

location of connectors

79

lower arm removing together with upper arm

126

replacing

139


141

spare part number

139

M maintenance intervals

91

maintenance schedule

91

measurement system battery pack, replacing

103

measurement system battery pack, spare part number

104

mechanical stop axis 2 article number

71

installation

70

mechanical stop axis 3 article number

75


75

mechanical stops axis 1 article number

68

installation

67


69

mechanical stops axis 2 screws, tightening torque

72

mechanical stops axis 3 installation

73

motor axis 1 brake release with power supply

178

replacing

177

spare part number

177

tightening torque

179


182

replacing

181

spare part number

181

tightening torque

183


187

replacing

185


187

,

192

spare part number

185


Index motor axis 4 brake release with power supply

194

replace

193


195

,

198

spare part number

193

motor axis 5 replacing

199


202

spare part number

200

motor axis 6 replacing

209


211

spare part number

209

motor connectors

79

mounting, equipment

56

MoveAbsJ instruction

FlexPendant

227

N negative directions, axes

224

O oil change gearbox axes 5 and 6

97

gearboxes, axes 5 and 6, intervals

91

safety risks

36

wrist unit

97

wrist unit, intervals

91

oil in gearboxes amount

95

article numbers

95

type

95

operating, conditions

39

orienting, robot

49

P permitted extra loads

55

position switch axis 1

76

position switch axis 1 article number

76

position, robot

222

when draining wrist unit

98

,

101

,

102

when filling oil in wrist unit

99

positions at wrist center, 1.2 reach

40

positions at wrist center, 1.45 reach

41

positive directions, axes

224

protection classes, IP class

39

push button unit releasing the brakes

47

replacing

173

spare part number

173

R releasing brakes external power supply to connector R1.MP

48

manually

47

replacing together

126

requirements, foundation

39

restricting working range axis 1

67

,

76

3HAC026660-001 Revision: C axis 2

70

axis 3

73

revolution counters storing on FlexPendant

225

updating

225

robot cleaning

105

connectors

79

dimensions

56

equipment, fitting

56

lifting

45

orienting and securing

49

robot position

222

when draining wrist unit

98

,

101

,

102

when filling oil in wrist unit

99

S safety equipment position switch axis 1

76

Safety, service

14

safety, symbols

30

scales on robot

222

schedule, maintenance

91

securing, robot

49

,

50

serial measurement unit battery pack, replacing

103

battery pack, spare part number

104

replacing

169

spare part number

170

signal connectors

79

signal lamp article number

62

installation

62

SMB unit battery pack, replacing

103

battery pack, spare part number

104

replacing

169

spare part number

170

Souriau, connector

84

spare parts base

242

,

243

base connections

244

,

245

frame

246

,

247

lower arm

248

,

249

optional equipment

253

upper arm

250

,

251

,

252

special tools

238

storage, conditions

39

suspended mounting

52

symbols, safety

30

sync marks

222

system parameter

Gravity Beta

52

T testing, brakes

24

tightening torques, attachment screws base-gearbox unit

167

lower arm-frame

141


69


72

265

Index mechanical stop axis 3

75

motor axis 1

179

motor axis 2

183

motor axis 3

187

,

192

motor axis 4

195

,

198

motor axis 5

202

motor axis 6

211

robot to foundation, attachment bolts

50

upper arm

132

wrist unit

144

tilted mounting

52

timing belt axis 5 adjusting the tension

202

replacing

199

spare part number

200

timing belt axis 6 adjusting the tension

211

replacing

209

spare part number

209

tools belt tightener axis 5, article number

200

belt tightener axis 5, measure

200

Calibration Pendulum equipment

238

dynamometer axis 5 and 6

209

for service

238

hook axis 6, article number

209

rotational tool, article number

193

turning radius

44

U updating revolution counters

225

upper and lower arm

126

upper arm removing together with lower arm

126

replacing

129


132

spare part number

129

V

Validity and responsibility

14

VK-covers, spare part number at base

165

lower arm, lower

139

lower arm, middle

139

lower arm, upper

129

W wall mounting

52

weight base

167

complete arm system

127

,

128

gearbox unit

216

lower arm

140

,

141

robot

38

,

46

,

166

,

167

upper arm

130

,

131

working range

43

restricting axis 1

76

wrist unit amount and type of oil

97

oil change

97

replacing

143

266 screws, tightening torque

144

spare part number

143


ABB AB

Robotics Products

S-721 68 VÄSTERÅS

S WEDEN

T e l e phone : +46 (0) 21 344000

Fax : +46 (0) 21 132592

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