ABB IRB 1600 - 7/1.2, IRB 1600 - 7/1.45 Product Manual

Product manual

Articulated robot

IRB 1600 - 5/1.2

IRB 1600 - 5/1.45

IRB 1600 - 7/1.2

IRB 1600 - 7/1.45

M2004

Product manual

IRB 1600 - 5/1.2

IRB 1600 - 5/1.45

IRB 1600 - 7/1.2

IRB 1600 - 7/1.45

M2004

Document ID: 3HAC023637-001

Revision: B

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 2005-2008 ABB All right reserved.

ABB Automation Technologies AB

Robotics

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 Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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

1.2.3.8 Translate the information on safety and information labels . . . . . . . . . . . . . . . . . . . . . . . 28

1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.3.2 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1.3.3 DANGER - First test run may cause injury or damage! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1.3.4 WARNING - The brake release buttons may be jammed after service work . . . . . . . . . . . . . . . . 33

1.3.5 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1.3.6 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

2.3.1 Lifting robot with roundsling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

2.3.2 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2.3.3 Orienting and securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2.3.4 Suspended mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2.3.5 Load diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

2.3.6 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

2.3.7 Fitting equipment on the robot (robot dimensions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

2.3.8 Installation of signal lamp (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

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

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


2.5.2 Robot cabling and connection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

2.5.3 Customer connections on the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

3 Maintenance 85

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

3.2 Maintenance schedule and expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

3.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

3.2.3 Expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

3.3.1 Inspection, damper axes 2, 3 and 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

3.4 Replacement activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

3.4.1 Oil in gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

3.4.2 Oil change, gearbox axes 5 and 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

3.4.3 Replacement of measurement system battery pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

3.5 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

3.5.1 Cleaning, complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

4 Repair 99

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

4.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

4.2.2 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

4.2.3 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

4.3 Complete manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

4.3.1 Replacement of cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

4.3.2 Replacement of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

4.4 Upper and lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

4.4.1 Replacement of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

4.4.2 Replacement of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

4.4.3 Replacement of wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

4.4.4 Replacement of damper, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128



4.5 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

4.5.1 Replacement of base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

4.5.2 Replacement of serial measurement unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

4.5.3 Replacement of push button unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

4.6 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

4.6.1 Replacement of motor, axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146




4.6.5 Replacement of motor and timing belt, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

4.6.6 Replacement of motor and timing belt, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

4.7 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

4.7.1 Replacement of gearbox, axes 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

4.7.2 Service work on gearboxes, axes 3, 4, 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

5 Calibration information 175

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176


5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

5.4 Calibration movement directions for all axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

5.6 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

6 Reference information 187

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

6.2 Applicable safety standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

6.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

6.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

6.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

6.6 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

6.7 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

6.8 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

7 Spare parts and exploded views 197

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

7.2 Spare parts - base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

7.3 Spare parts - base connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

7.4 Spare parts - frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

7.5 Spare parts - lower arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

7.6 Spare parts - upper arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

7.7 Spare parts - options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

8 Circuit diagram 211

8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

Index 213


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

Safety, service

Contents

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

Repair

Calibration information

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.

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

Procedures that do not require specific calibration equipment.

General information about calibration.

3HAC023637-001 Revision: B

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

3HAC023604-001

3HAC021313-001

3HAC16590-1

Operating manual - Calibration Pendulum

Operating manual - Service Information System

3HAC16578-1

3HAC025709-001

Application manual - Additional axes and stand alone controller

3HAC021395-001

Technical reference manual - System parameters 3HAC17076-1

Note

Revision

-

A

B

Description

First edition.

• Document references are moved from a separate section to the table

References on page 8

.

• Information about changing working range limitations in the software

is added to the sections in Restricting the working range on page 66

.

• Information about the alternative calibration method (Levelmeter

2000) is removed from the manual, since the method is not supported for the robot.

•

Safety information is added to the procedures Replacement of push button unit on page 142 ,

Replacement of serial measurement unit on page 138 and

Replacement of cable harness on page 104 . Also,

a new section is added to the chapter Safety,

WARNING - The brake release buttons may be jammed after service work on page 33 .

• Connector set for standard customer connection is added to section

Customer connections on the robot on page 82 . Incorrect article

number for Soriau pin is also corrected and information about pin diameter is added, in the same section.

•

New section: Suspended mounting on page 51

.

Changes made in:

Prerequisites in section Owerview

Oil change in section Maintenance

8 3HAC023637-001 Revision: B

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 controller cabinets, will be delivered with a Product manual which is divided into two parts:

Product manual, procedures

• Safety information

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

• 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)

Product manual, reference information

• 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

The product manual published as a PDF consists of only one file where the two parts are presented together, as one Product manual.

RobotWare manuals

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

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

• Technical reference manual - RAPID Instructions, functions and data types:

Description and syntax for all RAPID instructions, functions and data types.

• Technical reference manual - System parameters: Description of system parameters and configuration workflows.



9

Product documentation, M2004

Continued

Application manuals

Specific applications (e.g. 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 (e.g. cables, I/O boards, RAPID instructions, system parameters)

• How to use the application

• Examples of how to use the application

Operating manuals

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

• Getting started - IRC5 and RobotStudio Online

• Operating manual - IRC5 with FlexPendant

• Operating manual - RobotStudio Online

• Trouble shooting manual 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

8.

Remove the rear attachment screws, gearbox.

Note/Illustration

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.


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 on page 13

.

3HAC023637-001 Revision: B 11

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 on page 29

.


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, e.g. User’s guide - S4Cplus (M2000)

/ Operating manual - IRC5 with FlexPendant (M2004) and 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

Product manual for the robot

Operating manual - IRC5 with

FlexPendant (RobotWare 5.0)

Product manual for the robot

Section


Operating modes



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 - 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, i.e. 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, controller IRC5

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

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

• Units inside the controller, e.g. 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 tools, or special power supply units for the machining process.

• The external voltage connected to the control cabinet 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 OFF position. 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 manipulator.


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 (manipulator 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 46 .

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 manipulator axis to a position where the combined weight of the manipulator 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 manipulator 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 parameters from the Teach Pendant

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


1 Safety

1.2.3.6. Safe use of the Teach Pendant Unit

1.2.3.6. Safe use of the Teach Pendant Unit

NOTE!

The enabling device is a push button located on the side of the Teach Pendant Unit (TPU) 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 Teach Pendant Unit, 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 Teach Pendant Unit 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 Safety

1.2.3.7. Work inside the manipulator's working range

1.2.3.7. Work inside the manipulator'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 manipulator! 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 manipulator 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. Translate the information on safety and information labels

1.2.3.8. 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.



29

1 Safety

1.3.1. Safety signals, general

Continued

Symbol 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 manipulators are potentially lethal!

1.3.2. DANGER - Moving manipulators are potentially lethal!

Description

Any moving manipulator is a potentially lethal machine.

When running the manipulator, 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 manipulator working range.

Elimination

Action Note

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

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

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

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

How to use the hold-to-run control 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 manipulator working range 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, i.e. 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:

Action Note/Illustration

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 eachother.

xx0600002776

Art. no. for the centering piece is specified in

Required equipment on page 143 .

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 (electro static 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.


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!

-

Possible pressure build up in gearbox!

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.

Do not overfill!

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 manipulator 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!

Do not mix types of oil!

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.


1 Safety

1.3.6. WARNING - Safety risks during work with gearbox oil


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 39 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 44 .

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

38




2.2.1. Pre-installation procedure

Continued

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

Force Z

Torque XY

Torque Z

Floor mounted

Inverted

Tilted ± 30º

Floor mounted

Inverted

Tilted ± 30º

All

All

± 1600 N

± 1600 N

± 2500 N

- 2500 ± 1600 N

+ 2500 ± 1600 N

+ 2100 ± 1600 N

± 2000 Nm

± 350 Nm

± 5000 N

± 5000 N

± 6000 N

- 2500 ± 3000 N

+ 2500 ± 3000 N

+ 2100 ± 3000 N

± 5500 Nm

± 2000 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

Max. ambient temperature

Max. ambient temperature (less than 24 hrs)

Max. ambient humidity

-25º C

+55º C

+70º C

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 - 5/1.2 and IRB 1600 - 7/1.2

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





Continued

Illustration, working range IRB 1600 - 5/1.45 and IRB 1600 - 7/1.45

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

Angle (degrees) axis 2

0º

0º

0º

+90º

+150º

+150º

-90º

-90º axis 3

0º

-90º

+65º

-90º

-90º

-245º

+65º

-90º



41



Continued

Working ranges

Axis

Axis 1

Axis 2

Axis 3

Axis 4

Axis 5

Axis 6

IRB 1600 - 5/1.2 and - 7/1.2

IRB 1600- 5/1.45 and -7/1.45

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 robot.

+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.

42





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.

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 Note

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.

Shown in the figure

Recommended lifting position on page 44 .

Capacity for the roundsling is specified in

Required equipment on page 44

.

Attachment is shown in the figure

Recommended lifting position on page

44

.

44




2.3.1. Lifting robot with roundsling

Continued

Note

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.



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

46




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.

48 xx0400001300

A Center of axis 1





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

Washers, 3 pcs

Quality

Tightening torque

Guiding sleeves, 2 pcs


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

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


49



Continued

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 48

.

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

Dimension, mounting surface and guiding sleeve on page 49 .

Detailed in section Lifting robot with roundsling on page 44 .

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 49 .



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 inverted 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: e.g 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)

Inverted (D)

0°

30º

90°

180°

Gravity Beta

0.000000 (Default)

0.523599

1.570796

3.141593



51



Continued xx0600002779

C

D

A

B

Floor mounted

Tilted mounting, mounting angle 30º

Wall mounted, mounting angle 90º

Inverted 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 42

.

52





Continued

Defining the parameter in the software

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 51 .

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

The parameter can be edited either with the FlexPendant or in RobotStudio

Online

. Read about how to change the parameter in the Operating manual - IRC5 with FlexPendant or in the

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

References on page 8 .



2.3.5. Load diagrams

2.3.5. Load diagrams

General

The load diagrams include a nominal pay load inertia, J0 of 0.012 kgm

2

, and an extra load of

15 kg for the IRB 1600-5/x variants and 5 kg for the IRB 1600-7/x variants, at the upper arm housing.

At different arm load and moment of inertia the load diagram will be changed.

Accurate load diagram

For an accurate load diagram, please use the calculation program ABB RobotLoad IRB 1600,

Stand alone application on:

• Inside.abb.com/atma, click on Products ---> Robots ---> IRB 1600 or

• http://www.abb.com/roboticspartner, click on Product Range ---> Robots ---> IRB

1600

The application requires Microsoft.NET Framework and Microsoft Excel 9.0 software.

54



Load diagram - IRB 1600-5/1.2, IRB 1600-5/1.45




Maximum permitted load mounted on the robot tool flange at different positions

(center of gravity)



55



Continued

Load diagram - IRB 1600-5/1.2, IRB 1600-5/1.45, “Vertical Wrist” (±10º)

56 xx0500001450


(center of gravity) at “Vertical Wrist” (±10º)

Description Value

For wrist down (0º deviation from the vertical line) Max load = 6 kg

Z

Max

= 0.11 m

L

Max

= 0.04 m



Load diagram - IRB 1600-7/1.2, IRB 1600-7/1.45





(center of gravity)



57



Continued

Load diagram - IRB 1600-7/1.2, IRB 1600-7/1.45, “Vertical Wrist” (±10º)

L - Distance (m)

10 º 10 º

Z

L

58 xx0500001452


(center of gravity) at “Vertical Wrist” (±10º)

Description

For wrist down (0º deviation from the vertical line)

Value

Max load = 9 kg

Z

Max

= 0.075 m

L

Max

= 0.045 m



2.3.6. Loads

2.3.6. Loads

General

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

Permitted extra loads and their positions

The shaded areas indicate the permitted positions (center of gravity) for extra loads mounted on the wrist, upper arm housing and on the frame.

xx0500001448

The center of gravity of the extra load must be within the marked load areas.

Robot Max load

Load area A Load area B Load area A+B Load area C Load area D

IRB 1600 - 5/X 15 kg 5 kg 15 kg 0.5 kg 15 kg

IRB 1600 - 7/X 5 kg 5 kg 5 kg 0.5 kg 15 kg



2.3.7. Fitting equipment on the robot (robot dimensions)

2.3.7. Fitting equipment on the robot (robot dimensions)

General

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

Main dimensions

The two 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.

60 xx0400001253

(A) Centerline of axis 1

(B) Smallest circumscribed radius, axis 1





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



61



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.

62 xx0400001251

(A)

(B)

(C)

(D)

(E)

Centerline of axis 3

Centerline of axis 4

Turning radius for axis 3

Smallest circumscribed radius for axis 4

Mounting holes for equipment





Continued

Dimensions of the turning disk

The figure below shows the dimensions of the turning disk.

Fastener quality xx0200000063

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.



2.3.8. Installation of signal lamp (option)

2.3.8. Installation of signal lamp (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.

The lamp is active in MOTORS ON mode.

Location of signal lamp

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

xx0400001265

D

E

A

C

F

Signal lamp

Cable gland

Cable bracket

Attachment holes for the signal lamp

Cover, upper arm housing

Required equipment

Equipment

Signal lamp

Gasket, customer connections

Gasket, upper arm cover

Art. no.

3HAC 022235-001

3HAC 022050-001

3HAC 022049-001

64

Note

Replace if damaged.

Replace if damaged.




2.3.8. Installation of signal lamp (option)

Continued

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 64

.

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).


.


.

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

xx0400001263

• B: Mounting holes, M8 x 12



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.

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 46 .

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.

Note/Illustration 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.





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.





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.






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

F

G

D

E

I

H

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 rings 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 81

.

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 -




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



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)

Customer cables

(option)

External axes 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 80 .

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 81 .

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 81 .

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


.

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.

80

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.

3HAC 2492-1

3HAC 2529-1

3HAC 2539-1

3HAC 2564-1



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

Cable (foundry)





Robot cable, signals

Cable

Robot cable, signal, shielded, 7 m





2.5.2. Robot cabling and connection points

Continued

Art. no.

3HAC 9038-1

3HAC 9038-2

3HAC 9038-3

3HAC 9038-4

Art. no.

3HAC 2493-1

3HAC 2530-1

3HAC 2540-1

3HAC 2566-1

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 Art. no.


Position switch cable, axis 1, 30 m 3HAC 7997-4 R1.LS

Connection point, cabinet

XS8

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

Cable (standard)

Customer cable, power-signal, 7 m




Art. no.

3HAC 3353-1

3HAC 3354-1

3HAC 3355-1

3HAC 3356-1


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.

3HAC 8183-1

3HAC 8183-2

3HAC 8183-3

3HAC 8183-4


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.

xx0400001339

A

B

C

Pin connector

Pin

Backshell

82





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

Turned pin 0.5 - 1.5 mm

2

MS3126*1626S

MS3126*1210S

M39029/31-240

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





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, e.g. 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 on page 13 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

Cleaning

Gearbox oil, axes 5 and 6 20,000 hrs

Battery, measurement system

Complete robot

12 - 36 mths 2)

Regular

1)

Oil change, gearbox axes 5 and 6 on page 92 .

Replacement of measurement system battery pack on page 95

.

Cleaning, complete robot on page 97

.

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

Cabling for position switch

Gearbox

Expected life

2,000,000 cycles

2,000,000 cycles

40,000 hrs

Note

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



89

3 Maintenance

3.3.1. Inspection, damper axes 2, 3 and 5


A

B

Damper, axis 5

Recess


Equipment

Standard toolkit

Art. no. Note

- The contents are defined in section

Standard toolkit on page 194

, in part 2 of the Product manual.

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.

Shown in the figure

Location of dampers on page 89 .

3. Check attachment screws for deformation.

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 128

•

Replacement of damper, axis 3 on page 130

•

Replacement of damper, axis 5 on page 132 .


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

Type and amount of oil in gearboxes

Gearbox Type of oil

Axis 1

Axis 2

Axis 3

Axis 4

Axis 5-6

(wrist unit)

Art. no.

Mobilgear 600 XP320 11712016-604

Mobilgear 600 XP320 11712016-604

Mobilgear 600 XP320 11712016-604

Mobilgear 600 XP320 11712016-604

Optimol BM 100 3HAC 0860-1

Amount

3,400 ml

3,400 ml

500 ml

350 ml

Total amount: 350 ml (new wrist)

Amount at oil change: 300 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. xx0200000475

A

B

Oil plug, draining and filling

Oil plug, vent hole


Equipment, etc. Art. no. Amount Note

Lubricating oil

Oil collecting vessel

Standard toolkit

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

Amount at oil change: 300 ml

Optimol BM 100

Capacity: 400 ml.

The contents are defined in section


, in part 2 of the

Product manual.

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

These procedures include references to the tools required.

92



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 35 .

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.

Note! The total amount of oil will not be drained.

There will remain approximately 50 ml in the wrist unit.

Vessel capacity is specified in section


!

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 92 .



93

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 35

.

3. Remove the oil plug, draining and filling. Shown in the figure

Location of oil plugs on page 92

!

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

• 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


!

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. Replacement of measurement system battery pack

3.4.3. 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



95

3 Maintenance

3.4.3. 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 194 , in part 2 of

the Product manual.

See chapter Circuit diagram in the

Product manual, reference information .

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.

Shown in the figure Location of battery pack on page 95 .

4. Remove the battery pack.

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

Spare part no. is specified in Required equipment on page 96 .

Shown in the figure

Battery pack on serial measurement unit on page 95 .

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

7. Refit the base cover to the robot.

Spare part no. is specified in equipment on page 96

Shown in the figure pack on page 95 .

.

Required

Location of battery

8. Update the revolution counters.

Detailed in section Updating revolution counters on page 180 .


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 Foundry

versions only!

Steam cleaner

May be used on Foundry

versions only!

High pressure water cleaner

Vacuum cleaner

Cloth with mild detergent

-

-

-

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.

May be used on Standard version

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, e.g. 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 Product manual, reference information .


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 on page 13 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.

3HAC 0207-1

-

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.

Recommended value:

0.2 - 0.25 bar (20 - 25 kPa)

4. Disconnect the compressed air supply.

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.

3HAB 3537-1

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.

3HAB 3537-1

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 102 .

4. Mount the seal correctly with a mounting tool.

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

102



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 on page 197 .


Equipment

Cable harness IRB 1600/1.45


Cable harness IRB 1600/1.45,

Customer connections

Cable harness IRB 1600/1.2,

Customer connections

Cable harness IRB 1600/1.45, Wire feeder




Gasket, base cover

Gasket, gearbox axis 1-2

VK-cover

Spare part no.

Note

3HAC 021827-001 No application interface.

3HAC 021827-008 No application interface.

3HAC 021828-001

3HAC 021828-002

3HAC 021830-001

3HAC 021830-002

3HAC 022049-001 Replace if damaged.




3HAA 2166-23

3HAA 2166-21

Upper and lower covers.

2 pcs

Middle cover.

VK-cover

Cable ties

Centering piece

Standard toolkit

Circuit diagram

3HAC025815-001 Fitted to the push button unit in order to align it correctly.

Replace if damaged.



, in part 2 of the

Product manual.

See chapter Circuit diagram in the Product manual, reference information .

104



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



105

4 Repair


Continued

Removal, cable harness

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


1.

Action

DANGER!


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.

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!

All the covers are shown in the

figure Illustration, covers to remove on page 105 .

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 107 .

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 107 .

6. Disconnect all the connectors inside the frame.

Shown in the figure Illustration, cabling inside frame on page 109

.

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 109

.

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

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

Shown in the figure Illustration, cabling inside base on page 110

.

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

Shown in the figure Illustration, cabling inside base on page 110

.

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.

106



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



107

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

107

.


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.

Spare part no. is specified in


108

4. Fasten the cabling inside the upper arm housing by fitting the cable clamp unit to the distance

console with two attachment screws.

5. Fit the motor and signal cabling to the connector

plate with clamps.

xx0400001247

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


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.


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 107 .

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 105

.





4 Repair


Continued

Action

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

12. Continue refitting the cable harness according to procedure

Refitting, cable harness in frame and base on page 111 .




.

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



109

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.

110 xx0500001388

F

G

D

E

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 109

and

Illustration, cabling inside base on page 110

.

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.


.

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.


.

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 110 .

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 eachother!

Shown in the figure Illustration, cabling inside base on page 110 .

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 33

!



111

4 Repair


Continued

Action Note

11. Connect the:

• signal cable connectors to the SMB unit

• power cable connector to the housing in the base

• optional cabling, if any

• ground cable.

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

Replace the gaskets, if damaged.

Shown in the figure

Illustration, cabling inside base on page 110 .

13. Recalibrate the robot!

Shown in the figure Illustration, covers to remove on page 105

.


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

General calibration information is

included in section Calibration information on page 175 .


4 Repair

4.3.2. Replacement of complete arm system

4.3.2. 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







113

4 Repair


Continued

Removal, complete arm system

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

Note

1.

Action

DANGER!


2. Move the robot to its calibration position.

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:

•


•

Illustration, cabling inside frame on page 109

.

5. Push out the VK-cover from inside of the frame. Shown in the figure

Location of complete arm system on page 113

.

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.

114



4 Repair


Continued

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.

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

Art. no. is specified in Required equipment on page 113 .

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 111

.

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




115

4 Repair


Continued

Action


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 32 .




included in section Calibration information on page 175

.


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 208

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.

3HAC 023630-001

Art. no.

Note

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

VK-cover




Grease

3HAA 2166-23

3HAB 3732-19

3HAC 022049-001

3HAC 022050-001

Locking liquid


Replace if damaged.

Replace if damaged.

Replace if damaged.

-

3HAB 3537-1 To lubricate the sealing ring (V-ring).

Loctite 574


117

4 Repair


Continued

Equipment

Lifting slings

Standard toolkit

Spare part no.

-

Art. no.

Note




the Product manual.


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 117

.

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

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

Pull out the cabling from the arm housing.

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


Shown in the figure

Location of upper arm on page 117

.

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

7.

CAUTION!

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

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

118

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

xx0400001219



4 Repair


Continued

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.

xx0400001220

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


.

• B: Contact surface.

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

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.

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

xx0400001219



119

4 Repair


Continued


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 108

.

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 117 .

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 117 .

Spare part no. is specified in section


.


General calibration information is included in section

Calibration information on page 175

.

13.

DANGER!




4 Repair

4.4.2. Replacement of complete lower arm

4.4.2. 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 205


xx0400001246

A

B

C

Lower arm

VK-cover

VK-cover, middle


Equipment

Lower arm, spare

Lower arm, short, spare

VK-cover

VK-cover


Isopropanol


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

3HAB 3732-13

In the middle of the lower arm.

Replace if damaged.

Used to clean the mating surfaces.


121

4 Repair


Continued

Equipment

Locking liquid

Standard toolkit

Spare part no.

Note

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.

Detailed in section

Removal, complete upper arm on page 118

.

3. Remove the VK-covers.

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!

Shown in the figure

Location of lower arm on page 121

.

122

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

5.

xx0400001247

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!

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





4 Repair


Continued

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.


Required equipment on page

121 .

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.

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

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

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.


Required equipment on page

121 .

10. Refit the upper arm.

Detailed in section

Refitting, complete upper arm on page

119 .



123

4 Repair


Continued

Action


12.

DANGER!





General calibration information

is included in section Calibration information on page 175 .


4 Repair

4.4.3. Replacement of wrist unit

4.4.3. 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 207 in part 2 of the Product manual.

xx0200000438

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

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

3HAC 10475-1

3HAC 7191-1

Standard and Foundry versions.

O-ring sealingplate not included!

Must be replaced.

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

The contents are defined in

section Standard toolkit on page

194 , in part 2 of the Product

manual.




125

4 Repair


Continued

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


Shown in the figure in section

Location of wrist unit on page 125 .

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

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.

Use a new o-ring! Spare part no. is

specified in Required equipment on page 125 .

3 pcs, M8 x 25, tightening torque: 28

Nm.

6. Perform a leak-down test.

7. Refill the wrist unit with oil.

Detailed in section

Performing a leakdown test on page 100

.

Detailed in section


126



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 32

.

4 Repair


Continued

Note




.


4 Repair

4.4.4. Replacement of damper, axis 2

4.4.4. 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



, in part

2 of the Product manual.


128



4 Repair


Continued

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.

2.

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!

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 32 .

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 130 .

130

DANGER!


3. Remove the damper by gently prying it from the cast tab.



4 Repair


Continued



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 130 .

2.

DANGER!


3. Refit the damper by gently pressing it onto the cast tab on the upper arm.

4.

DANGER!


DANGER - First test run may cause injury or damage! on page 32

.


4 Repair




The damper, axis 5, is located as shown in the figure below!

xx0200000429

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 132 .

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.

132



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!


DANGER - First test run may cause injury or damage! on page 32 .


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 199


xx0500001453

A

B

Base

Attachment screws and washer, base-gearbox unit (VK-cover removed)


Equipment

Base, spare

V-ring (sealing ring)

VK-cover

Lifting slings

Locking liquid

Grease

Spare part no. Art. no.

3HAC 023552-001

3HAB 3732-21

3HAA 2166-26

Note

Replace if damaged.

-

Loctite 574

For sealing the base to the gearbox 1-2.

3HAB 3537-1 For lubricating the V-ring.

134



Equipment

Isopropanol

Standard toolkit



-

4 Repair


Continued

Note

For cleaning the mating surfaces.


section Standard toolkit on page 194

, in part 2 of the

Product manual.


Removal, base

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 139

.

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.

8.

CAUTION!

The base weighs 81 kg! All lifting equipment used must be sized accordingly!



135

4 Repair


Continued

Action Note

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 134

.

Refitting, base

The procedure below details how to refit the base to the robot.

Note

1.

Action

136

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 134

.

16 pcs, M10 x 40, tightening torque:

70 Nm.



10.

CAUTION!


11. Turn the robot to stand upright.

12. Secure the base to the foundation.

Attachment bolts and tightening torque are specified in section

Attachment bolts, specification on page 49 .

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 110 .



Action

14. Refit the serial measurement unit.

15. Recalibrate the robot.

16.

DANGER!



.

4 Repair


Continued

Note

Detailed in section Refitting, serial measurement unit on page 140 .





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 199 in part 2 of the Product manual.

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.

138 xx0500001391

C

D

A

B

E

Connector SMB

Connector SMB1-4

Connector SMB 3-6

Hexagon nuts (totally 4 pcs)

Battery pack



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.


Standard toolkit on page 194 , in part 2

of the Product manual.

See chapter Circuit diagram in the

Product manual, reference information .

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.

3. Remove the centering piece (B) from the push button unit.

xx0600002744

4. Remove the base cover from the robot.

5. Disconnect all the connectors from the serial measurement unit. xx0600002776

Shown in the figure Location of serial measurement unit on page 138 .



139

4 Repair


Continued


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 138 .

7. Lift and pull the serial measurement unit backwards, over the lip (A), and lift it away.

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).


140 xx0500001392

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 138

.



4 Repair


Continued

Action





6.

xx0600002777



WARNING!


WARNING - The brake release buttons may be jammed after service work on page 33 !

7. Check the gasket of the base cover. Replace it if damaged.

Spare part no. is specified in Required equipment on page 139

.

8. Refit the base cover.

9. Update the revolution counters!

Shown in the figure

Location of serial measurement unit on page 138

.

Detailed in section Updating revolution counters on page 180 .


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 199 in part 2 of the Product manual.

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.

142 xx0500001394

A

B

C

Push button unit

Hexagon nuts (2 pcs)

Hexagon nuts, SMB unit (4 pcs)



4 Repair


Continued


Equipment Spare part no.

Note

Push button unit 3HAC 020967-001 Includes brake release board and push buttons.

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 194 , in part 2 of the Product

manual.

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.

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 142

.

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 142

.



143

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 142 .

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.


Shown in the figure


3. Secure the unit with two hexagon nuts.

Shown in the figure


4. Push in and secure the SMB unit with the four

hexagon nuts.

Shown in the figure





xx0600002777

144



4 Repair


Continued

Note

7.

Action

WARNING!


WARNING - The brake release buttons may be jammed after service work on page 33 !

8. Reconnect all the connectors to the board.

9. Check the gasket of the base cover. Replace it if damaged.


10. Refit the base cover.

Shown in the figure

Location of push button unit on page 142 .


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 203 in part 2 of the Product manual.

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

O-ring 21522012-428

Gasket, gearbox axis 1-2 3HAC 022048-

001

Note

O-ring, motor.

Replace if damaged.

Replace if damaged.

146



4 Repair


Continued

Equipment

Power supply

Isopropanol

Grease

Rotation tool, motor

Standard toolkit

Circuit diagram

Spare part no.

Art. no.

-

-

Note

24 VDC, max 1.5 A

For releasing the brakes.

Used to clean mating surfaces.

-

-

3HAB 3537-1

3HAC022266-

003


Standard toolkit on page 194 , in part 2 of the

Product manual.


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 146 .

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.



147

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 146

.

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.

10. Tighten the motor attachment screws.

There should be a barely noticable gear play.


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.

Shown in the figure

Location of motor on page 146

.

The cable layout is shown in the

figure Illustration, cabling inside frame on page 109

.

15. Refit the cover, frame. Replace the gasket, if damaged.



.

148



Action


17.

DANGER!



.

4 Repair


Continued

Note



Calibration information on page 175 .


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 203 in part 2 of the Product manual.

xx0400001257

C

D

A

B

E

Motor, axis 2

Cover, frame

Connector plate for motor cabling

Bracket and cable tie

Motor cover


150



O-ring

Power supply

3HAC 023557-001


21522012-428 Must be replaced when replacing motor.

Replace if damaged.

Gasket, gearbox axis

1-2

3HAC 022048-001

Grease

Isopropanol

Standard toolkit -

-

3HAB 3537-1 For lubricating the o-ring.

For cleaning mating surfaces.



, in part 2 of the

Product manual.

For adjusting the gear play, motor/pinion

-

3HAC022266-

003

24 VDC, 1.5 A.




4 Repair


Continued

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


Circuit Diagram -

Note




The procedure below details how to remove the axis 2 motor.

Note

1.

Action

DANGER!


2. Remove the cover, frame.

Shown in the figure

Location of motor axis 2 on page 150 .

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




151

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 150

.




.

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 bracket underneath the frame.


Shown in the figure

motor axis 2 on page 150

Cable layout is shown in the figure

Illustration, cabling inside frame on page 109 .

Location of

.

Shown in the figure

Location of motor axis 2 on page 150

.

152



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 150 .

Art. no. for the gasket is specified in

section Required equipment on page 150 .

Detailed in section

Performing a leak-down test on page 100

.

Type of oil and amount is specified

in section Oil in gearboxes on page

91 .



included in section Calibration information on page 175

.

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 Upper arm, exploded view 1 on page 207 in part 2 of the Product manual.

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.

154



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.

4. Remove the upper arm housing cover.

5. Disconnect the motor connectors R3.MP3 and

R3.FB3.

3HAC023637-001 Revision: B xx0500001447

Shown in the figure Location of motor on page 154

.


.


155

4 Repair


Continued

6.

Action Note

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.



The procedure below details how to refit the axis 3 motor.

156

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


.



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.


Illustration, cabling inside upper arm housing on page 107

.

11. Refit the cover, upper arm housing. Check both the

gaskets and replace, if damaged.

Shown in the figure


.



.



Action

12. Refit any additional mechanical stops.


14.

DANGER!



.

4 Repair


Continued

Note

Detailed in section Installation of additional mechanical stops on axis 3 on page 73 .





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

Gasket, upper arm cover 3HAC 022049-001

3HAC 022050-001 Gasket, customer connections

Grease

Replace if damaged.

Replace if damaged.

Replace if damaged.

3HAB 3537-1 Used for lubricating the oring.

158



4 Repair


Continued

Equipment, etc.

Standard toolkit

Power supply



Circuit Diagram


-

Note


section Standard toolkit on page 194 , in part 2 of the

Product manual.

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.

Shown in the figure

Location of motor on page 158 .

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.

Shown in the figure


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!



159

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.







Detailed in section


.




.

14.

DANGER!



.


4 Repair

4.6.5. Replacement of motor and timing belt, axis 5

4.6.5. 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

G

H

E

F

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)



161

4 Repair


Continued



Art. no.


Timing belt 3HAC 021304-001



3HAC 022050-001

Belt tightener

Dynamometer

Standard toolkit


Circuit diagram

Note

Replace if damaged.

Replace if damaged.

-

3HAC 024044-001

Capacity: 100N



the Product manual.



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

162



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 159

.

Detailed in section Removal, motor and timing belt, axis 6 on page 166

.

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.

Shown in the figure


.

8. Remove the motor bracket from the motor.

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.



163

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 162 .

F (Force): 24 N.

Detailed in section

Refitting, motor and timing belt, axis 6 on page 167

.

Detailed in section Refitting, motor axis 4 on page 160

.

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 107

.

8. Refit the cover to the upper arm housing.

Check both the gaskets and replace, if damaged.


Art.no. is specified in





10.

DANGER!



.


4 Repair


4.6.6. 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

F

G

D

E

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.



165

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!


2. Remove the cover from the upper arm housing.

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.



166



4 Repair


Continued

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.

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.

Note/Illustration xx0400001282

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.


.

4. Refit the connector plate. Refit the cable tie. Shown in the figure Location of motor on page 165

.

5. Reconnect the motor cables: R3.MP6 and

R3.FB6.

6. Place all the cabling correctly inside the upper arm housing.

7. Refit the cover to the upper arm housing.

Check both the gaskets and replace, if damaged.

Cable layout is shown in the figure tion, cabling inside upper arm housing on page 107

.

Illustra-



.



167

4 Repair


Continued

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 32

.




Calibration information on page

175 .


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 203 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

-


For cleaning the mating surfaces before fitting.


169

4 Repair


Continued

Equipment

Grease

Locking liquid

Lifting slings

Standard toolkit



-

-

3HAB 3537-1

Note

For lubricating the V-ring.

Loctite 574


section Standard toolkit on page

194 , in part 2 of the Product

manual.


Removal, gearbox unit axes 1-2

The procedure below details how to remove the complete gearbox unit, axes 1-2.

Note

1.

Action

170

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 147 .

Detailed in section

Replacement of motor, axis 2 on page 150 .

Detailed in section

Removal, complete arm system on page 114

.

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.

9. Remove the VK-cover from the bottom of the robot base.

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.



4 Repair


Continued

Action

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.

Note

Shown in the figure Location of gearbox unit, axes 1-2 on page 169 .

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 169 .

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 169 .


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.



171

4 Repair


Continued

Action

11. Secure the base to the foundation.

12. Refit the complete arm system.

13. Refit the motors, axes 1 and 2.


15. Fill the two gearboxes with oil.

16. Recalibrate the robot.

17.

DANGER!



.

Note

Attachment bolts and the tightening torque are specified in section

Attachment bolts, specification on page

49 .

Detailed in section

Refitting, complete arm system on page 115

.

Detailed in sections:

•

Refitting, motor axis 1 on page 148

•

Refitting, motor axis 2 on page

152 .

Detailed in section


.

Type of oil and amount is specified in

section Oil in gearboxes on page 91 .





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 117 .

• axes 5 and 6: the complete wrist unit is to be replaced. This procedure is detailed in section

Replacement of wrist unit on page 125

.


4 Repair

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


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 176 , 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, e.g. 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 180

. 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, e.g. 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 Absolute 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, i.e. 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

176




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 - Absolute 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 detailed further in the manual CalibWare 2.0

Users Guide (M2000).

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 195 in part

2 of the Product manual. A calibration manual is enclosed with the calibration tools.

The article numbers for the operating manuals for calibration are also listed in section




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.

178 xx0500001423



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! 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, i.e. 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 178

.

Detailed in section:

Step 2 - Storing the revolution counter setting with the FlexPendant on page 181

(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).

180





Continued

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.

2. Tap the mechanical unit in question.

A screen is displayed: tap Rev. Counters.

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.



181



Continued

Action

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 183 .



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

Calibration scales and correct axis position on page 178 .

How to update the revolution counters is detailed in section


.

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

Calibration scales and correct axis position on page 178 .

How to update the counters is detailed in section


.


Overview

Overview

About this manual

This manual contains reference information for all procedures in part 1: Product manual,

procedures.

Usage

This manual should be used during:

• installation

• maintenance work

• repair work.

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

Reference information

Useful information when performing installation, maintenance or repair work. Includes lists of necessary tools, additional documents, safety standards, etc.

Spare parts and exploded views

Complete spare part list and complete list of robot components, shown in exploded views.

Circuit diagram Circuit diagram for the robot.



185

Overview

Continued

Revisions

Revision

-

A

B

Description

First edition.

• Document references are moved from a separate section to the table


.

• Information about changing working range limitations in the software

is added to the sections in Restricting the working range on page 66

.

• Information about the alternative calibration method (Levelmeter

2000) is removed from the manual, since the method is not supported for the robot.

•

Safety information is added to the procedures Replacement of push button unit on page 142 ,

Replacement of serial measurement unit on page 138 and

Replacement of cable harness on page 104 . Also,

a new section is added to the chapter Safety,

WARNING - The brake release buttons may be jammed after service work on page 33 .

• Connector set for standard customer connection is added to section

Customer connections on the robot on page 82 . Incorrect article

number for Soriau pin is also corrected and information about pin diameter is added, in the same section.

•

New section: Suspended mounting on page 51

.

Changes made in:

Prerequisites in section Owerview

Oil change in section Maintenance


6 Reference information

6.1. Introduction



General

This chapter includes general information, complementing the more specific information in the Product manual (part 1 of 2), procedures .



6.2. Applicable safety standards

6.2. 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

ISO EN 10218-1:2006

ISO EN 60204:2005

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 environment - 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).



6.3. Unit conversion

6.3. 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



6.4. Screw joints

6.4. 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 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) 1171 2016-618

190




6.4. Screw joints

Continued

Tightening torque

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, i.e. 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 Molycote-

lubricated 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



191


6.4. 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



6.5. Weight specifications

6.5. 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!



6.6. Standard toolkit

6.6. 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



6.7. Special tools

6.7. 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 194

, 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

Lifting tool, gearbox

Lifting tool, upper arm

Art. no.

Note

3HAC022266-003

-

3HAC024045-001

Capacity: 100N

Used to tighten the timing belt of axis 6, together with the dynamometer.

3HAC 024044-001 Used to tighten the timing belt of axis 5, together with the dynamometer.

3HAC 023364-001

3HAC 023386-001

Used to adjust the gear play on all motors.

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.



6.8. Lifting equipment and lifting instructions

6.8. 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 Spare parts and exploded views

7.1. 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.



7.2. Spare parts - base

7.2. Spare parts - base

Base, spare part list

The spare parts for the base are listed below and shown in the following figure.

11

12

13

14

100

101

102

Item no. Description

8

9

6

7

3

4

1

2

103

106

107

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



3HAC025815-001

3HAC 021827-001

3HAC 021827-008

Cable harness IRB 1600/1.45, Customer connections

3HAC 021828-001

Cable harness IRB 1600/1.2, Customer connections


3HAC 021828-002

3HAC 021830-001

Cable harness IRB 1600/1.2, Wire feeder 3HAC 021830-002

198



Base, exploded view


7.2. Spare parts - base




7.3. Spare parts - base connections

7.3. 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

200



Base connections, illustrations


7.3. Spare parts - base connections




7.4. Spare parts - frame

7.4. Spare parts - frame

Frame, spare part list

The spare parts are listed below and shown in the following figure.


13 Torx pan head screw

20

21

22

23

24

25

26

27

28

Gearbox axis 1-2, spare

Stop arm

Cover, gearbox axis 1-2

Gasket, gearbox axis 1-2

Damper, axis 2

V-ring (sealing ring)



O-ring

100-107 Cabling

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

21522012-428

See section Base, spare part list on page 198 .

Nitrile rubber

79.5x3

202



Frame, exploded view


7.4. Spare parts - frame




7.5. Spare parts - lower arm

7.5. 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

100-107 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 198

.

D=120, B=12

D=68, B=8

204



Lower arm, exploded view


7.5. Spare parts - lower arm




7.6. Spare parts - upper arm

7.6. 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

3HAC 023630-001

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 7191-1

3HAC 10475-1

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

100-107 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 198 .

D=11.4-13

206



Upper arm, exploded view 1






207



Continued

Upper arm, exploded view 2

208 xx0500001387



7.7. Spare parts - options

7.7. Spare parts - options

General

This section specifies available options for the robot.

Spare parts - options

Option no. Description

213-1

431-1

25-3

28-1

32-1

34-1

Spare part no.

Note

Lamp unit

Connection set R2.CP/

R2.CS

3HAC022235-001 Installed as detailed in section

Installation of signal lamp (option) on page 64

.

3HAC025396-001 Only for standard connection.

Position switch, axis 1 3HAC023973-001 Includes 3 switches.

Installed as detailed in section

Installation of position switch, axis 1 on page 76

.

Working range limit axis 1 3HAC023110-001 Installed as detailed in section

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 .



7.7. Spare parts - options


8 Circuit diagram


Overview

This chapter includes the circuit diagram for the robot.

8 Circuit diagram

8.1. Introduction


Circuit diagram 3HAC 021351-003/Rev. 00

Contents

Sheet

List of contents ............................................................................................................. 101

Connection point location............................................................................................. 102

Brake release unit, serial measuring board ................................................................... 103

Motor, axes 1-2............................................................................................................. 104

Feedback, axes 1-2 ....................................................................................................... 105

Motor, axes 3-4............................................................................................................. 106

Feedback, axes 3-4 ....................................................................................................... 107

Motor, axes 5-6............................................................................................................. 108

Feedback, axes 5-6 ....................................................................................................... 109

Cable harness, customer connection, options ............................................................... 110

Cable harness, customer connection, Wire Feeder, options ......................................... 112

Position indicator, axis 1, options................................................................................. 113

Circuit diagram IRB 1600

Circuit diagram

Contents

3HAC 021351-003/Rev. 00

Sheet

2 Circuit diagram IRB 1600

Circuit diagram 3HAC 021351-003












A

Absolute Accuracy, calibration

177

Absolute Accuracy, guiding sleeves

49

air connections, pressure

82

arm system replacing

113

attachment bolts, robot-foundation

49

B backshells, customer connection

82

base brake release buttons

46

hole configuration

48

replacing

134

screws, tightening torque

136

spare part number

134

battery pack replacing

95

replacing, interval

87

spare part number

96

belt tightener axis 5 article number

162

measure

162

brake release unit releasing the brakes

46

replacing

142

spare part number

143

brakes testing function

24

brakes, releasing external power supply to connector R1.MP

47

manually

46

power supply on motor axis 1

147

power supply to motor axis 2

151


156


159

C cable harness inside base, figure

110

inside frame, figure

109

inside upper arm, figure

107

replacing

104

spare part number

104

cabling inside base, figure

110

inside frame, figure

109

inside upper arm, figure

107

replacing

104

spare part number

104

cabling between robot and controller

80

cabling, robot

80

calibrating roughly

180

calibration

Absolute Accuracy type

176


177

marks/scales

178

rough

180

standard method

177

standard type

176

when to calibrate

175

calibration manuals

177


177

calibration position

180

checking

183

jogging to, FlexPendant

183

scales

178

calibration, Absolute Accuracy

177

CalibWare

176

check, installation site

38

cleaning robot, interval

87

cleaning, robot

97

complete arm system replacing

113

connecting the robot and controller, cabling

80

Connection of external safety devices

14

connectors air

82

customer

82

MIL-C-26482 series 1

83

on robot, figure

79

R2.CS and R2.CP

pins, customer connection 82

Souriau

82

cracks, damper

90

customer connections

79

D damage, damper

90

damper, axis 2

89

attachment screw

129

replacing

128

spare part number

128

damper, axis 3 inspection

89

replacing

130

spare part number

130

damper, axis 5 inspection

89

replacing

132

spare part number

132

dimensions guiding sleeves

49

mounting surface

49

robot

60

direction of axes

179

E environment

39

equipment, robot

60

ESD damage elimination

34

sensitive equipment

34

explanation, safety symbols

29

extra equipment

60

extra loads

59

F figures

Index

Index base, hole configuration

48

brake release buttons

46

cabling inside base

110

cabling inside frame

109

cabling inside upper arm housing

107

connectors on robot

79

gearboxes

91

mounting surface

49

power supply to connector R1.MP

47

fitting, equipment

60

FlexPendant jogging to calibration position

183

MoveAbsJ instruction

183

updating revolution counters

181

foundation loads

39

requirements

39

frame replacing

169

spare part number

169

G gaskets, spare part number base cover

143

gearbox axis 1-2

146

upper arm cover

165

upper arm customer connections

165

gearbox, axes 1-2 replacing

169

spare part number

169

gearboxes location on robot, figure

91

type of oil and amount

91

gearboxes, axes 3-6 replacing

173

service work

173

gearboxes, axes 5 and 6 amount and type of oil

92

oil change

92

Gravity Beta

51

H hole configuration base

48

I illustration base connections

201

illustrations base, exploded

199

base, hole configuration

48

brake release buttons

46

cabling inside base

110

cabling inside frame

109

cabling inside upper arm housing

107

connectors on robot

79

frame, exploded

203

gearboxes

91

lower arm, exploded

205

mounting surface

49

power supply to connector R1.MP

47

upper arm, exploded

207

,

208

inspection

89

installation checking site prior robot installation

38

equipment

60

mechanical stop axis 2

70

mechanical stops axis 3

73

mechanical stops, axis 1

67

position switch axis 1

76

robot, attachment bolts

49

signal lamp

64

intervals, maintenance

87

inverted mounting

51

L lamp unit article number

64

installation

64

lifting, robot

44

limitations in working range, tilted and wall mounted

42

load diagrams

54

loads

59

loads, foundation

39

location of connectors

79

lower arm removing together with upper arm

113

replacing

121


123

spare part number

121

M maintenance intervals

87

maintenance schedule

87

measurement system battery pack, replacing

95

measurement system battery pack, spare part number

96

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

147

replacing

146

spare part number

146

tightening torque

148


151

replacing

150

spare part number

150

tightening torque

152


156

replacing

154


156

spare part number

154


159

replace

158


160

spare part number

158

motor axis 5 replacing

161


164

spare part number

162

motor axis 6 replacing

165


167

spare part number

165

motor connectors

79

mounting, equipment

60

MoveAbsJ instruction

FlexPendant

183

N negative directions, axes

179

O oil change gearbox axes 5 and 6

92

gearboxes, axes 5 and 6, intervals

87

safety risks

35

wrist unit

92

wrist unit, intervals

87

oil in gearboxes amount

91

article numbers

91

type

91

operating, conditions

39

orienting, robot

48

P permitted extra loads

59

position switch axis 1

76

position switch axis 1 article number

76

position, robot

178

when draining wrist unit

93

when filling oil in wrist unit

94

positions at wrist center, 1.2 reach

40

positions at wrist center, 1.45 reach

41

positive directions, axes

179

protection classes, IP class

39

push button unit releasing the brakes

46

replacing

142

spare part number

143

R releasing brakes external power supply to connector R1.MP

47

manually

46

replacing together

113

requirements, foundation

39

restricting working range axis 1

67

axis 2

70

axis 3

73

revolution counters storing on FlexPendant

181

updating

180

robot cleaning

97

connectors

79

dimensions

60

equipment, fitting

60

lifting

44

orienting and securing

48

robot position

178

when draining wrist unit

93

when filling oil in wrist unit

94

RobotLoad

54

S safety equipment position switch axis 1

76

Safety, service

14

safety, symbols

29

scales on robot

178

schedule, maintenance

87

securing, robot

48

,

49

serial measurement unit battery pack, replacing

95

battery pack, spare part number

96

replacing

138

spare part number

139

signal connectors

79

signal lamp article number

64

installation

64

SMB unit battery pack, replacing

95

battery pack, spare part number

96

replacing

138

spare part number

139

Souriau, connector

82

spare parts base

198

,

199

base connections

200

,

201

frame

202

,

203

lower arm

204

,

205

optional equipment

209

upper arm

206

,

207

,

208

special tools

195

storage, conditions

39

suspended mounting

51

symbols, safety

29

sync marks

178

system parameter

Gravity Beta

51

T testing, brakes

24

tightening torques, attachment screws

Index

Index base-gearbox unit

136

lower arm-frame

123


69


72


75

motor axis 1

148

motor axis 2

152

motor axis 3

156

motor axis 4

160

motor axis 5

164

motor axis 6

167

robot to foundation, attachment bolts

49

upper arm

119

wrist unit

126

tilted mounting

51

timing belt axis 5 adjusting the tension

164

replacing

161

spare part number

162

timing belt axis 6 adjusting the tension

167

replacing

165

spare part number

165

tools belt tightener axis 5, article number

162

belt tightener axis 5, measure

162

Calibration Pendulum equipment

195

dynamometer axis 5 and 6

165

for service

195

hook axis 6, article number

165

rotational tool, article number

158

turning radius

43

U updating revolution counters

180

upper and lower arm

113

upper arm removing together with lower arm

113

replacing

117


119

spare part number

117

V

Validity and responsibility

14

VK-covers, spare part number at base

134

lower arm, lower

121

lower arm, middle

121

lower arm, upper

117

W wall mounting

51

weight base

135

,

136

complete arm system

114

,

115

gearbox unit

171

lower arm

122

,

123

robot

38

,

45

,

135

,

136

upper arm

118

,

119

working range

42

restricting axis 1

76

wrist unit amount and type of oil

92

oil change

92

replacing

125


126

spare part number

125

ABB Automation Technologies AB

Robotics

S-721 68 VÄSTERÅS

SWEDEN

Telephone: +46 (0) 21 344000

Telefax: +46 (0) 21 132592

ABB IRB 1600 - 7/1.2, IRB 1600 - 7/1.45 Product Manual

Product manual

Articulated robot

1 Safety

2 Installation and commissioning

3 Maintenance

4 Repair

5 Calibration information

6 Reference information

7 Spare parts and exploded views

8 Circuit diagram

Circuit diagram 3HAC 021351-003/Rev. 00

Contents

Circuit diagram

Contents

3HAC 021351-003/Rev. 00

Related manuals

Table of contents

ABB IRB 1600 - 7/1.2, IRB 1600 - 7/1.45 Product Manual

Product manual

Articulated robot

1 Safety

2 Installation and commissioning

3 Maintenance

4 Repair

5 Calibration information

6 Reference information

7 Spare parts and exploded views

8 Circuit diagram

Circuit diagram 3HAC 021351-003/Rev. 00

Contents

Circuit diagram

Contents

3HAC 021351-003/Rev. 00

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Table of contents