Product manual
Articulated Robot
IRB 1600 - 5/1,2 type A
IRB 1600 - 5/1,45 type A
IRB 1600 - 6/1,2 type A
IRB 1600 - 6/1,45 type A
IRB 1600 - 7/1,2 type A
IRB 1600 - 7/1,45 type A
IRB 1600 - 8/1,2 type A
IRB 1600 - 8/1,45 type A
IRB 1600ID
M2004
Product manual
IRB 1600 - 5/1.2 type A
IRB 1600 - 5/1.45 type A
IRB 1600 - 6/1.2 type A
IRB 1600 - 6/1.45 type A
IRB 1600 - 7/1.2 type A
IRB 1600 - 7/1.45 type A
IRB 1600 - 8/1.2 type A
IRB 1600 - 8/1.45 type A
IRB 1600ID
M2004
© Copyright 2006-2008 ABB. All rights reserved.
Document ID: 3HAC026660-001
Revision: C
The information in this manual is subject to change without notice and should not be
construed as a commitment by ABB. ABB assumes no responsibility for any errors that
may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to persons
or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's written
permission, and contents thereof must not be imparted to a third party nor be used for
any unauthorized purpose. Contravention will be prosecuted.
Copyright 2006-2008 ABB All rights reserved.
ABB AB
Robotics Products
SE-721 68 Västerås
Sweden
© Copyright 2006-2008 ABB. All rights reserved.
Additional copies of this manual may be obtained from ABB at its then current charge.
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Safety
13
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.1 Safety in the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.2 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2.1 Safety risks during installation and service work on robot . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2.2 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.2.3 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.2.4 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.2.2.5 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2.3 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.3.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.3.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.3.3 Emergency release of the robot’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.3.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.3.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.2.3.6 Safe use of the FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.3.7 Work inside the robot's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.3.8 Signal lamp (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.2.3.9 Translate the information on safety and information labels . . . . . . . . . . . . . . . . . . . . . . . 29
1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.3.2 DANGER - Moving robots are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.3.3 DANGER - First test run may cause injury or damage! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.3.4 WARNING - The brake release buttons may be jammed after service work . . . . . . . . . . . . . . . . 34
1.3.5 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.3.6 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2 Installation and commissioning
37
© Copyright 2006-2008 ABB. All rights reserved.
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.2.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.2.2 Working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.3 On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.3.1 Lifting robot with roundsling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.3.2 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.3.3 Orienting and securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.3.4 Suspended mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.3.5 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.3.6 Fitting equipment on the robot (robot dimensions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.3.7 Installation of signal lamp for 1600 (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.3.8 Installation of signal lamp for 1600 ID (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.4 Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.4.2 Installation of additional mechanical stops on axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.4.3 Installation of additional mechanical stop on axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.4.4 Installation of additional mechanical stops on axis 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.4.5 Installation of position switch, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3HAC026660-001 Revision: C
3
Table of Contents
2.5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.5.1 Connectors on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.5.2 Robot cabling and connection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.5.3 Customer connections on the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.6 Making robot ready for operation (Cleanroom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.6.1 Additional installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3 Maintenance
89
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.2 Maintenance schedule and expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.2.3 Expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.3.1 Inspection, damper axes 2, 3 and 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.4 Replacement activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.4.1 Oil in gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.4.2 Oil change, gearbox axes 5 and 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.4.3 Oil change, gearbox axes 5- 6, IRB 1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3.4.4 Replacement of measurement system battery pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.5 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.5.1 Cleaning, complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4 Repair
107
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.2.2 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.2.3 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.3 Complete manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.4 Upper and lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.4.1 Replacement of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.4.2 Replacement of complete upper arm, IRB 1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.4.3 Replacement of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.4.4 Replacement of wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.4.5 Replacement of wrist unit, IRB1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.4.6 Replacement of damper, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
4.4.7 Replacement of damper, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
4.4.8 Replacement of Mechanical damper, axis 3, IRB 1600ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4.4.9 Replacement of damper, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4.4.10 Remove upper arm AW Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
4.4.11 Fitting equipment on the robot, IRB 1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4.5 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.5.1 Replacement of base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.5.2 Replacement of serial measurement unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.5.3 Replacement of push button unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
4.3.1 Replacement of cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.3.2 Replacement of cable harness, IRB 1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.3.3 Replacement of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Table of Contents
4.6 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
4.6.1 Replacement of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
4.6.2 Replacement of motor, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
4.6.3 Replacement of motor, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
4.6.4 Replacement of motor, axis 3, IRB 1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
4.6.5 Replacement of motor, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
4.6.6 Replacement of motor, axis 4, 1600ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
4.6.7 Replacement of motor and timing belt, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4.6.8 Replacement of motor, axis 5, IRB 1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4.6.9 Replacement of motor and timing belt, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
4.6.10 Replacement of motor, axis 6 IRB 1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
4.7 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
4.7.1 Replacement of gearbox, axes 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
4.7.2 Service work on gearboxes, axes 3, 4, 5 and 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
5 Calibration information
219
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
5.4 Calibration movement directions for all axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
5.6 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
6 Robot description
229
6.1 Type A of IRB 1600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
7 Reference information
231
© Copyright 2006-2008 ABB. All rights reserved.
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
7.2 Applicable safety standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
7.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
7.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
7.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
7.6 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
7.7 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
7.8 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
8 Spare parts and exploded views
241
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
8.2 Spare parts - base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
8.3 Spare parts - base connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
8.4 Spare parts - frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
8.5 Spare parts - lower arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
8.6 Spare parts - upper arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
8.7 Spare parts - options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
8.8 Spare parts - upper arm 1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
9 Circuit diagram
261
9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Index
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263
5
© Copyright 2006-2008 ABB. All rights reserved.
Table of Contents
6
3HAC026660-001 Revision: C
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
© Copyright 2006-2008 ABB. All rights reserved.
The manual is organized in the following chapters:
Chapter
Contents
Safety, service
Safety information that must be read through before performing
any installation or service work on robot. Contains general safety
aspects as well as more specific information on how to avoid
personal injuries and damage to the product.
Installation and commissioning
Required information about lifting and installation of the robot.
Maintenance
Step-by-step procedures that describe how to perform
maintenance of the robot. Based on a maintenance schedule that
may be used to plan periodical maintenance.
Repair
Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.
Calibration information
Procedures that do not require specific calibration equipment.
General information about calibration.
Continues on next page
3HAC026660-001 Revision: C
7
Overview
Continued
References
Documentation referred to in the manual, is listed in the table below.
Document name
Document Id
Product specification - IRB 1600
3HAC023604-001
Product manual - IRC5
3HAC021313-001
Operating manual - IRC5 with Flexpendant
3HAC16590-1
Operating manual - Calibration pendulum
3HAC16578-1
Operating manual - Service Information System
3HAC025709-001
Application manual - Additional axes and stand alone
controller
3HAC021395-001
Technical reference manual - System parameter
3HAC17076-1
Note
Revisions
Description
-
First edition. See also Type A of IRB 1600 on page 229.
A
AW equipped upper arm 1600ID, IRB 1600-6/1.2, IRB 1600-6/1.45, IRB
1600-8/1.2 and IRB 1600-8/1.45 added.
B
Cleanroom added.
Changes made in:
• Prerequisites in section Overview.
• Oil change in section Maintenance.
C
Content updated in section:
• 2.6 Making robot ready for operation, Cleanroom / 2.6.1 Additional
installation procedure
© Copyright 2006-2008 ABB. All rights reserved.
Revision
8
3HAC026660-001 Revision: C
Product documentation, M2004
Product documentation, M2004
General
The robot documentation may be divided into a number of categories. This listing is based on
the type of information contained within the documents, regardless of whether the products
are standard or optional. This means that any given delivery of robot products will not contain
all documents listed, only the ones pertaining to the equipment delivered.
However, all documents listed may be ordered from ABB. The documents listed are valid for
M2004 robot systems.
Product manuals
All hardware, robots and controllers, will be delivered with a Product manual that contain:
•
Safety information
•
Installation and commissioning (descriptions of mechanical installation, electrical
connections)
•
Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
•
Repair (descriptions of all recommended repair procedures including spare parts)
•
Additional procedures, if any (calibration, decommissioning)
•
Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
•
Part list
•
Foldouts or exploded views
•
Circuit diagrams
Technical reference manuals
© Copyright 2006-2008 ABB. All rights reserved.
The following manuals describe the robot software in general and contain relevant reference
information:
•
RAPID Overview: An overview of the RAPID programming language.
•
RAPID Instructions, Functions and Data types: Description and syntax for all
RAPID instructions, functions and data types.
•
System parameters: Description of system parameters and configuration workflows.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several applications.
An application manual generally contains information about:
•
The purpose of the application (what it does and when it is useful)
•
What is included (for example cables, I/O boards, RAPID instructions, system
parameters, CD with PC software)
•
How to use the application
•
Examples of how to use the application
Continues on next page
3HAC026660-001 Revision: C
9
Product documentation, M2004
Continued
Operating manuals
This group of manuals is aimed at those having first hand operational contact with the robot,
that is production cell operators, programmers and trouble shooters. The group of manuals
includes:
Emergency safety information
•
Getting started - IRC5 and RobotStudio
•
IRC5 with FlexPendant
•
RobotStudio
•
Trouble shooting - IRC5 for the controller and robot
© Copyright 2006-2008 ABB. All rights reserved.
•
10
3HAC026660-001 Revision: C
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.
8.
Action
Note/Illustration
Remove the rear attachment screws, gearbox.
Shown in the figure Location of
gearbox on page xx.
References to required equipment
The procedures often include references to equipment (spare parts, tools etc.) required for the
different actions in the procedure. The equipment is marked with italic text in the procedures
and completed with a reference to the section where the equipment is listed with further
information, i.e. article number, dimension.
The denomination in the procedure for the component or attachment point corresponds to the
denomination in the referenced list.
© Copyright 2006-2008 ABB. All rights reserved.
The table below shows an example of a reference to a list of required equipment, from a step
in a procedure.
3.
Action
Note/Illustration
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.
3HAC026660-001 Revision: C
11
© Copyright 2006-2008 ABB. All rights reserved.
How to read the product manual
12
3HAC026660-001 Revision: C
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.
3HAC026660-001 Revision: C
13
© Copyright 2006-2008 ABB. All rights reserved.
•
1 Safety
1.2.1. Safety in the robot system
1.2 General safety information
1.2.1. Safety in the robot system
Validity and responsibility
The information does not cover how to design, install and operate a complete system, nor
does it cover all peripheral equipment, which can influence the safety of the total system. To
protect personnel, the complete system must be designed and installed in accordance with the
safety requirements set forth in the standards and regulations of the country where the robot
is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable safety laws
and regulations in the country concerned are observed and that the safety devices necessary
to protect people working with the robot system are designed and installed correctly.
Personnel working with robots must be familiar with the operation and handling of the
industrial robot, described in the applicable documents, for example:
•
Operating Manual - IRC5 with FlexPendant (M2004)
•
Product Manual
Connection of external safety devices
Apart from the built-in safety functions, the robot is also supplied with an interface for the
connection of external safety devices. Via this interface, an external safety function can
interact with other machines and peripheral equipment. This means that control signals can
act on safety signals received from the peripheral equipment as well as from the robot.
Limitation of liability
Related information
14
Type of information
Detailed in document
Section
Installation of safety
devices
Product manual for the robot
Installation and commissioning
Changing operating
modes
Operating manual - IRC5 with
FlexPendant (RobotWare 5.0)
Operating modes
Restricting the working
space
Product manual for the robot
Installation and commissioning
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
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.
1 Safety
1.2.2.1. Safety risks during installation and service work on robot
1.2.2. Safety risks
1.2.2.1. Safety risks during installation and service work on robot
Overview
This section includes information of general safety risks to be considered when performing
installation and service work on the robot.
General risks during installation and service
•
The instructions in the Product Manual, chapter Installation and Commissioning must
always be followed.
•
Emergency stop buttons must be positioned in easily accessible places so that the robot
can be stopped quickly.
•
Those in charge of operations must make sure that safety instructions are available for
the installation in question.
•
Those who install the robot must have the appropriate training for the robot system in
question and in any safety matters associated with it.
Nation/region specific regulations
To prevent injuries and damage during the installation of the robot system, the regulations
applicable in the country concerned and the instructions of ABB Robotics must be complied
with.
© Copyright 2006-2008 ABB. All rights reserved.
Non-voltage related risks
•
Safety zones, which have to be crossed before admittance, must be set up in front of
the robot's working space. Light beams or sensitive mats are suitable devices.
•
Turntables or the like should be used to keep the operator out of the robot's working
space.
•
The axes are affected by the force of gravity when the brakes are released. In addition
to the risk of being hit by moving robot parts, you run the risk of being crushed by the
parallel arm.
•
Energy, stored in the robot for the purpose of counterbalancing certain axes, may be
released if the robot, or parts thereof, are dismantled.
•
When dismantling/assembling mechanical units, watch out for falling objects.
•
Be aware of stored heat energy in the controller.
•
Never use the robot as a ladder, that is do not climb on the robot motors or other part
during service work. There is a serious risk of slipping because of the high temperature
of the motors or oil spills that can occur on the robot.
To be observed by the supplier of the complete system
•
The supplier of the complete system must ensure that all circuits used in the safety
function are interlocked in accordance with the applicable standards for that function.
•
The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance with the
applicable standards for the emergency stop function.
Continues on next page
3HAC026660-001 Revision: C
15
1 Safety
1.2.2.1. Safety risks during installation and service work on robot
Continued
Complete robot
Safety risk
Description
Hot components!
CAUTION!
Motors and gears are HOT after running the robot!
Touching the motors and gears may result in burns!
Removed parts may result in
collapse of robot!
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
Description
Cable packs are sensitive to
mechanical damage!
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
Description
CAUTION!
Whenever parting/mating motor and gearbox, the gears
may be damaged if excessive force is used!
16
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
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!
© Copyright 2006-2008 ABB. All rights reserved.
Ensure that a gripper is prevented from dropping a workpiece, if such is used.
3HAC026660-001 Revision: C
17
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.
•
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.
© Copyright 2006-2008 ABB. All rights reserved.
Safe design
18
3HAC026660-001 Revision: C
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.
•
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.
Qualified personnel
Extraordinary risks
© Copyright 2006-2008 ABB. All rights reserved.
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.
3HAC026660-001 Revision: C
19
1 Safety
1.2.2.5. Risks associated with live electric parts
1.2.2.5. Risks associated with live electric parts
Voltage related risks, general
•
Although troubleshooting may, on occasion, have to be carried out while the power
supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
•
The mains supply to the robot must be connected in such a way that it can be turned
off outside the robot’s working space.
Voltage related risks, IRC5 controller
•
Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in the
controller.
•
Units such as I/O modules, can be supplied with power from an external source.
•
The mains supply/mains switch
•
The transformers
•
The power unit
•
The control power supply (230 VAC)
•
The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
•
The drive unit (700 VDC)
•
The drive system power supply (230 VAC)
•
The service outlets (115/230 VAC)
•
The customer power supply (230 VAC)
•
The power supply unit for additional tools, or special power supply units for the
machining process.
•
The external voltage connected to the controller remains live even when the robot is
disconnected from the mains.
•
Additional connections.
Voltage related risks, robot
A danger of high voltage is associated with the robot in:
•
The power supply for the motors (up to 800 VDC).
•
The user connections for tools or other parts of the installation (max. 230 VAC, see
chapter Installation and commissioning in the Product manual).
Voltage related risks, tools, material handling devices, etc
Tools, material handling devices, etc., may be live even if the robot system is in the
OFFposition. Power supply cables which are in motion during the working process may be
damaged.
20
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
A danger of high voltage is associated with for example the following parts:
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).
© Copyright 2006-2008 ABB. All rights reserved.
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating
tool or other device fitted to the robot.
3HAC026660-001 Revision: C
21
1 Safety
1.2.3.2. Fire extinguishing
1.2.3.2. Fire extinguishing
NOTE!
© Copyright 2006-2008 ABB. All rights reserved.
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot system (robot
or controller)!
22
3HAC026660-001 Revision: C
1 Safety
1.2.3.3. Emergency release of the robot’s arm
1.2.3.3. Emergency release of the robot’s arm
Description
In an emergency situation, any of the robot's axes may be released manually by pushing the
brake release buttons on the robot.
How to release the brakes is detailed in section:
•
Manually releasing the brakes on page 47.
The robot arm may be moved manually on smaller robot models, but larger models may
require using an overhead crane or similar.
Increased injury
© Copyright 2006-2008 ABB. All rights reserved.
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!
3HAC026660-001 Revision: C
23
1 Safety
1.2.3.4. Brake testing
1.2.3.4. Brake testing
When to test
During operation the holding brake of each axis motor wear normally. A test may be
performed to determine whether the brake can still perform its function.
How to test
The function of the holding brake of each axis motor may be checked as detailed below:
1. Run each robot axis to a position where the combined weight of the robot arm and any
load is maximized (max. static load).
2. Switch the motor to the MOTORS OFF position with the Operating mode selector on the
controller.
3. Check that the axis maintains its position.
© Copyright 2006-2008 ABB. All rights reserved.
If the robot does not change position as the motors are switched off, then the brake
function is adequate.
24
3HAC026660-001 Revision: C
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!
© Copyright 2006-2008 ABB. All rights reserved.
Do not change "Transm gear ratio" or other kinematic system parameters from the
FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s".
3HAC026660-001 Revision: C
25
1 Safety
1.2.3.6. Safe use of the FlexPendant
1.2.3.6. Safe use of the FlexPendant
NOTE!
The enabling device is a push button located on the side of the FlexPendant which, when
pressed halfway in, takes the system to MOTORS ON. When the enabling device is released
or pushed all the way in, the robot is taken to the MOTORS OFF state.
To ensure safe use of the FlexPendant, the following must be implemented:
The enabling device must never be rendered inoperative in any way.
•
During programming and testing, the enabling device must be released as soon as
there is no need for the robot to move.
•
The programmer must always bring the FlexPendant with him/her, when entering the
robot's working space. This is to prevent anyone else taking control of the robot
without the programmer knowing.
© Copyright 2006-2008 ABB. All rights reserved.
•
26
3HAC026660-001 Revision: C
1 Safety
1.2.3.7. Work inside the robot's working range
1.2.3.7. Work inside the robot's working range
WARNING!
If work must be carried out within the robot’s work envelope, the following points must be
observed:
The operating mode selector on the controller must be in the manual mode position to
render the enabling device operative and to block operation from a computer link or
remote control panel.
•
The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in
position "manual mode with reduced speed". This should be the normal position when
entering the working space. The position "manual mode with full speed (100%)" may
only be used by trained personnel who are aware of the risks that this entails.
•
Pay attention to the rotating axes of the robot! Keep a distance to the axes in order not
to get entangled with hair or clothing. Also be aware of any danger that may be caused
by rotating tools or other devices mounted on the robot or inside the cell.
•
Test the motor brake on each axis, according to section Brake testing on page 24.
© Copyright 2006-2008 ABB. All rights reserved.
•
3HAC026660-001 Revision: C
27
1 Safety
1.2.3.8. Signal lamp (optional)
1.2.3.8. Signal lamp (optional)
Description
A signal lamp with an yellow fixed light can be mounted on the robot, as a safety device.
Function
The lamp is active in MOTORS ON mode.
Further information
© Copyright 2006-2008 ABB. All rights reserved.
Further information about the MOTORS ON/MOTORS OFF mode may be found in the
controller documentation.
28
3HAC026660-001 Revision: C
1 Safety
1.2.3.9. Translate the information on safety and information labels
1.2.3.9. Translate the information on safety and information labels
Labels on the product
Both the robot and the controller are marked with several safety and information labels,
containing important information about the product. The information is useful for all
personnel handling the robot system, eg. during installation, service or operation.
Translation possibilities
The labels fitted to the product contain space for adding a fourth language underneath the
three standard languages (English, German and French).
Add a local language to the label by:
•
Using a transparent sticker over the standard label with text added in a fourth
language. Drawings detailing the design (text, figure, dimensions) of the standard
labels can be ordered from ABB. Notice that each label is identified according to the
article number located in the lower corner of the label.
Example of transparent sticker
© Copyright 2006-2008 ABB. All rights reserved.
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
3HAC026660-001 Revision: C
Free space for adding a fourth language
29
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
Symbol
Designation
Signification
DANGER
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.
WARNING
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.
ELECTRICAL
SHOCK
The electrocution or electrical shock symbol
indicates electrical hazards which could result in
severe personal injury or death.
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.
danger
warning
Electrical shock
caution
Continues on next page
30
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
The table below defines the captions specifying the danger levels used throughout this
manual.
1 Safety
1.3.1. Safety signals, general
Continued
Symbol
Designation
Signification
ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates
DISCHARGE (ESD) electrostatic hazards which could result in severe
damage to the product.
Electrostatic discharge
(ESD)
NOTE
Note symbols alert you to important facts and
conditions.
TIP
Tip symbols direct you to specific instructions, where
to find additional information or how to perform a
certain operation in an easier way.
Note
© Copyright 2006-2008 ABB. All rights reserved.
Tip
3HAC026660-001 Revision: C
31
1 Safety
1.3.2. DANGER - Moving robots are potentially lethal!
1.3.2. DANGER - Moving robots are potentially lethal!
Description
Any moving robot is a potentially lethal machine.
When running the robot, it may perform unexpected and sometimes irrational movements.
However, all movements are performed with great force and may seriously injure any
personnel and/or damage any piece of equipment located within the working range of the
robot.
Elimination
Action
Note
1. Before attempting to run the robot, make
sure all emergency stop equipment is
correctly installed and connected.
Emergency stop equipment such as gates,
tread mats, light curtains, etc.
2. If possible, use the hold-to-run function
whenever possible.
The hold-to-run function is used in manual
mode, not in automatic mode.
How to use the hold-to-run function in
RobotWare 5.0 is detailed in section How
to use the hold-to-run function in the
Operating manual - IRC5 with FlexPendant.
© Copyright 2006-2008 ABB. All rights reserved.
3. Make sure no personnel are present within
the working range of the robot before
pressing the start button.
32
3HAC026660-001 Revision: C
1 Safety
1.3.3. DANGER - First test run may cause injury or damage!
1.3.3. DANGER - First test run may cause injury or damage!
Description
Since performing a service activity often requires disassembly of the robot there are several
safety risks to take into consideration before the first test run.
Elimination
Follow the procedure below when performing the first test run after a service activity (repair,
installation or maintenance):
Action
1. Remove all service tools and foreign objects from the robot and its working area!
2. Install all safety equipment properly!
3. Make sure all personnel are standing at a safe distance from the robot, that is out of its
reach behind safety fences, etc!
© Copyright 2006-2008 ABB. All rights reserved.
4. Pay special attention to the function of the part previously serviced!
3HAC026660-001 Revision: C
33
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.
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.)
xx0600002776
• Adjust the unit sideways so that the
measurements x1 and x2 in the figure Art. no. for the centering piece is
specified in Required equipment on
to the right do not differ more than 1
page 173.
mm from each other.
5. Refit the push button guard and check the
buttons again by pressing them down, one by
one.
34
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
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!
1 Safety
1.3.5. WARNING - The unit is sensitive to ESD!
1.3.5. WARNING - The unit is sensitive to ESD!
Description
ESD (electrostatic discharge) is the transfer of electrical static charge between two bodies at
different potentials, either through direct contact or through an induced electrical field. When
handling parts or their containers, personnel not grounded may potentially transfer high static
charges. This discharge may destroy sensitive electronics.
Elimination
Action
Note
1. Use a wrist strap
Wrist straps must be tested frequently to ensure
that they are not damaged and are operating
correctly.
2. Use an ESD protective floor mat.
The mat must be grounded through a currentlimiting resistor.
3. Use a dissipative table mat.
The mat should provide a controlled discharge of
static voltages and must be grounded.
Location of wrist strap button
© Copyright 2006-2008 ABB. All rights reserved.
The wrist strap button is located in the right corner as shown in the illustration below.
xx0500002171
A
3HAC026660-001 Revision: C
Wrist strap button
35
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
Make sure that protective gear
gearbox oil may require
like goggles and gloves are
handling hot oil of up to 90 °C! always worn during this activity.
-
Hot oil!
When opening the oil plug,
Open oil plug carefully and keep
there may be pressure present away from the opening. Do not
in the gearbox, causing oil to overfill the gearbox when filling.
spray from the opening!
-
-
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 robot from
moving freely.
Make sure not to overfill the
gearbox when filling with oil!
After filling, check the correct oil
level.
Mixing types of oil may cause
severe damage to the
gearbox!
When filling gearbox oil, do not
mix different types of oil unless
specified in the instruction.
Always use the type of oil
specified by the manufacturer!
Warm oil drains quicker than
cold oil.
When changing gearbox oil, first
run the robot for a time to heat
up the oil.
-
Do not mix types of oil!
-
Heat up the oil!
-
Specified amount
depends on drained
volume!
36
The specified amount of oil is After refilling, check the oil level.
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.
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
Possible pressure build
up in gearbox!
2 Installation and commissioning
2.1. Introduction
2 Installation and commissioning
2.1. Introduction
General
This chapter contains information for installing the robot to the working site.
© Copyright 2006-2008 ABB. All rights reserved.
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.
3HAC026660-001 Revision: C
37
2 Installation and commissioning
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.
Storage conditions on page 39.
5. Make sure the appointed operating environment of
the robot conforms to the specifications.
Operating conditions on page 39
and Protection classes on page
39.
6. Before taking the robot to its installation site, make
sure the site conforms to applicable requirements.
Loads on foundation on page 38
and Requirements, foundation
on page 39.
7. Before moving the robot, make sure it does not tip
over!
Lifting robot with roundsling on
page 45.
Weight
The table below shows the weight of the robot model.
Robot model
Weight
IRB 1600 - x/1.2
247 kg
IRB 1600 - x/1.45
250 kg
Loads on foundation
The table below shows the various forces and torques working on the robot during different
kinds of operation. Note! These forces and torques are extreme values that are rarely
encountered during operation. The values also never reach their maximum at the same time!
Force
Mounting
Endurance load
Max. load
(emergency stop)
Force XY
Floor mounted
Suspended
Wall mounted
± 1650 N
± 1650 N
± 3900 N
± 31500 N
± 3150 N
± 5300 N
Continues on next page
38
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
8. When these prerequisites have been met, the robot
may be taken to its installation site.
2 Installation and commissioning
2.2.1. Pre-installation procedure
Continued
Force
Mounting
Endurance load
Max. load
(emergency stop)
Force Z
Floor mounted
Suspended
Wall mounted
- 2500 ± 1150 N
+ 2500 ± 1150 N
± 1300 N
- 2500 ± 2200 N
+ 2500 ± 2200 N
± 2400 N
Torque XY
Floor mounted
Suspended
Wall mounted
± 1700 Nm
± 1700 Nm
± 2310 Nm
± 3750 Nm
± 3750 Nm
± 3850 Nm
Torque Z
Floor mounted
Suspended
Wall mounted
± 855 Nm
± 855 Nm
± 855 Nm
± 1400 Nm
± 1400 Nm
± 1430 Nm
Requirements, foundation
The table below shows the requirements for the foundation where the weight of the installed
robot is included.
Requirement
Value
Note
Levelness
max. 0.5 mm
The value for levelness aims at the circumstance of the three anchoring points in the
robot base.
Storage conditions
© Copyright 2006-2008 ABB. All rights reserved.
The table below shows the allowed storage conditions for the robot.
Parameter
Value
Min. ambient temperature
-25º C
Max. ambient temperature
+55º C
Max. ambient temperature (less than 24 hrs)
+70º C
Max. ambient humidity
Max. 95% at constant temperature
Operating conditions
The table below shows the allowed operating conditions for the robot.
Parameter
Value
Min. ambient temperature
+5º C
Max. ambient temperature
+45º C
Max. ambient humidity
Max. 95% at constant temperature
Protection classes
The table below shows the protection class of the robot.
Equipment
Protection class
Robot, standard
IP 54
Robot, Foundry
IP 67
Robot, Wash
IP 67
3HAC026660-001 Revision: C
39
2 Installation and commissioning
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.
xx0400001260
Pos
Positions at wrist center (mm)
Angle (degrees)
X
Z
axis 2
axis 3
0
750
961.5
0º
0º
1
150
1561.5
0º
-90º
2
494
470
0º
+55º
3
1225
486.5
+90º
-90º
4
897
-287
+136º
-90º
5
386
737
+136º
-235º
6
321
786
-63º
+55º
7
-808
975
-63º
-90º
Continues on next page
40
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
Illustration, working range IRB 1600 - x/1.2
2 Installation and commissioning
2.2.2. Working range
Continued
Illustration, working range IRB 1600 - x/1.45
xx0400001261
© Copyright 2006-2008 ABB. All rights reserved.
Pos
Positions at wrist center (mm)
Angle (degrees)
X
Z
axis 2
axis 3
0
750
1186.5
0º
0º
1
150
1786.5
0º
-90º
2
404
643
0º
+65º
3
1450
486.5
+90º
-90º
4
800
-639
+150º
-90º
5
448
478
+150º
-245º
6
-6
740
-90º
+65º
7
-1150
486.5
-90º
-90º
Continues on next page
3HAC026660-001 Revision: C
41
2 Installation and commissioning
2.2.2. Working range
Continued
Illustration, working range IRB 1600 ID
Pos
Positions at wrist center (mm)
Angle (degrees)
X
Z
axis 2
axis 3
0
790
1296,5
0
0
1
150
1836
0
-80
2
380
579
0
+79
3
1499,5
486,5
+90
-80
4
720,5
-736,5
+150
-80
5
397,5
499,5
+150
-238
6
57,5
716,5
-90
79
7
-1199,5
486,5
-90
-80
Continues on next page
42
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
xx0700000136
2 Installation and commissioning
2.2.2. Working range
Continued
Working ranges
Axis
IRB 1600 - x/1.2
IRB 1600- x/1.45
Note
Axis 1
+180º to -180º
+180º to -180º
Axis 1 working range has the
following limitations:
• ±45º when tilting the robot
up to 30º.
• ±20º for a wall mounted
IRB 1600-5/1.2
IRB 1600-6/1.2
IRB 1600-7/1.2
IRB 1600-5/1.45
IRB 1600-6/1.45
IRB 1600-7/1.45
• ±45º for a wall mounted
IRB 1600-8/1.2
IRB 1600-8/1.45
Axis 2
+110º to -63º
+120º to -90º
+136º to -63º (with
+150º to -90º (with
axis 1 limited to ±100º) axis 1 limited to ±95º)
+55º to -235º
+65º to -245º
Axis 4
+200º to -200º
+200º to -200º
Default value
+190 to -190
revolutions
+190 to -190
revolutions
Maximum value.
The default working range for axis
4 can be extended by changing
parameter values in the software.
Axis 5
+115º to -115º
+115º to -115º
Axis 6
+400º to -400º
+400º to -400º
Default
+288 to -288
revolutions
+288 to -288
revolutions
Maximum value.
The default working range for axis
6 can be extended by changing
parameter values in the software.
© Copyright 2006-2008 ABB. All rights reserved.
Axis 3
Continues on next page
3HAC026660-001 Revision: C
43
2 Installation and commissioning
2.2.2. Working range
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
Minimum turning radius axis 1 (all models)
© Copyright 2006-2008 ABB. All rights reserved.
(A)
44
3HAC026660-001 Revision: C
2 Installation and commissioning
2.3.1. Lifting robot with roundsling
2.3 On-site installation
2.3.1. Lifting robot with roundsling
Recommended lifting position
The figure below shows the recommended lifting positions. It is important that the roundsling
has free space and does not wear against any part of the robot.
A-A
A
A
A
A
A
A
© Copyright 2006-2008 ABB. All rights reserved.
xx0400001296
Required equipment
Equipment
Art. no.
Note
Overhead crane
-
Lifting capacity: 500 kg.
Roundsling
-
Length: 2 m.
Lifting capacity: 500 kg.
Lifting the robot with roundsling
Action
Note
1. Move the robot to an appropriate lifting
position.
Shown in the figure Recommended
lifting position on page 45.
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.
Capacity for the roundsling is specified
in Required equipment on page 45.
Attachment is shown in the figure
Recommended lifting position on page
45.
Continues on next page
3HAC026660-001 Revision: C
45
2 Installation and commissioning
2.3.1. Lifting robot with roundsling
Continued
Action
Note
3.
CAUTION!
The robot weighs 250 kg! All lifting equipment
must be sized accordingly!
4.
WARNING!
Personnel must not, under any circumstances,
be present under the suspended load!
© Copyright 2006-2008 ABB. All rights reserved.
5. Raise the overhead crane to lift the robot.
46
3HAC026660-001 Revision: C
2 Installation and commissioning
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
Note/Illustration
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.
xx0400001255
© Copyright 2006-2008 ABB. All rights reserved.
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.
Continues on next page
3HAC026660-001 Revision: C
47
2 Installation and commissioning
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.
Action
Note/Illustration
DANGER!
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.
1.
Incorrect connections, such as supplying
power to the wrong pin, may cause all brakes
to be released simultaneously!
xx0400001302
3. Push the brake release button to release the
holding brakes, according to the previous
procedure.
48
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
2. Connect an external power supply to
connector R1.MP.
Supply:
• 0V on pin C10
• 24V on pin B8.
2 Installation and commissioning
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
© Copyright 2006-2008 ABB. All rights reserved.
The figure below shows the hole pattern and dimensions of the robot base.
xx0400001300
A
Center of axis 1
Continues on next page
3HAC026660-001 Revision: C
49
2 Installation and commissioning
2.3.3. Orienting and securing the robot
Continued
Dimension, mounting surface and guiding sleeve
xx0400001306
Attachment bolts, specification
Attachment bolts, 3 pcs
M16 x 60 (installation directly on foundation of steel)
M16 x 70/80 (installation on foundation or base plate, using
guiding sleeves)
Washers, 3 pcs
17 x 30 x 3
Quality
Quality 8.8 (wall or angle mounted robot: Quality 12.9)
Tightening torque
200 Nm
Continues on next page
50
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
The figure below shows the dimension of the mounting surface and guiding sleeves, if used.
2 Installation and commissioning
2.3.3. Orienting and securing the robot
Continued
Guiding sleeves, 2 pcs
(needed if wall or angle mounted, or if the robot is calibrated
with AbsAcc)
Orienting and securing the robot to installation site
Action
Note
1. Make sure the installation site for the robot
conforms to the specifications in section Preinstallation procedure on page 38.
2. Prepare the installation site with attachment
holes.
If the robot is calibrated with AbsAcc, it must
be installed using guiding sleeves.
Hole configuration of the base is shown
in the figure Hole configuration, base on
page 49.
Dimension of mounting surface and the
guiding sleeves are shown in the figure
Dimension, mounting surface and
guiding sleeve on page 50.
3. Lift the robot to the installation site.
Detailed in section Lifting robot with
roundsling on page 45.
4. Guide the robot gently using two of the M16
attachment bolts while lowering it into its
mounting position.
Specified in section Attachment bolts,
specification on page 50.
© Copyright 2006-2008 ABB. All rights reserved.
5. Fit and tighten the bolts and washers in the
base attachment holes.
3HAC026660-001 Revision: C
51
2 Installation and commissioning
2.3.4. Suspended mounting
2.3.4. Suspended mounting
General
Initially the system is configured for mounting on the floor, without leaning. The method for
mounting the robot in a suspended position is basically the same as for floor mounting.
NOTE!
With suspended installation, make sure that the gantry or corresponding structure is rigid
enough to prevent unacceptable vibrations and deflections, so that optimum performance can
be achieved.
System parameters
If the robot is mounted at any other angle, the system parameter “gravity beta” must be
updated. Gravity beta specifies the robot’s mounting angle expressed in radians.
NOTE!
It is very important to configure gravity beta correctly so that the robot system can control the
movements in the best possible way. Incorrect definition of mounting angle (gravity beta) will
result in:
•
Overloading the mechanical structure.
•
Lower path performance and path accuracy.
•
Some functions will not work properly: for example Load Identification & Collision
detection.
Mounting angles and values
The parameter “gravity beta” specifies the robot’s mounting angle in radians. It is calculated
in the following way for a mounting angle of 45°.
Example of position
Mounting angle
Gravity beta
Floor (A)
0°
0.000000 (Default)
Tilted (B)
30º
0.523599
Wall (C)
90°
1.570796
Suspended (D)
180°
3.141593
Continues on next page
52
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
Gravity beta = 45° x 3.141593/180 = 0.785398 radians.
2 Installation and commissioning
2.3.4. Suspended mounting
Continued
© Copyright 2006-2008 ABB. All rights reserved.
xx0600002779
A
Floor mounted
B
Tilted mounting, mounting angle 30º
C
Wall mounted, mounting angle 90º
D
Suspended mounting, mounting angle 180º
Limitations in working area
If tilting a floor mounted robot or mounting the robot on a wall, the working range of axis 1
is limited. These limitations are specified in the table Working ranges on page 43.
Continues on next page
3HAC026660-001 Revision: C
53
2 Installation and commissioning
2.3.4. Suspended mounting
Continued
Defining the parameter
The value of the system parameter Gravity beta must be redefined when changing the
mounting angle of the robot. The parameter belongs to the type Robot, in the topic Motion.
How to calculate a new value is detailed in Mounting angles and values on page 52.
The parameter is further detailed in the Technical reference manual - System parameters.
© Copyright 2006-2008 ABB. All rights reserved.
The parameter can be edited either with the FlexPendant or in RobotStudio. Read about how
to change the parameter in the Operating manual - IRC5 with FlexPendant or in the
Operating manual - RobotStudio. Article numbers for the manuals are specified in References
on page 8.
54
3HAC026660-001 Revision: C
2 Installation and commissioning
2.3.5. Loads
2.3.5. Loads
General
Any loads mounted on the manipulator must be defined correctly and carefully (with regard
to the position of centre of gravity and inertia factor) in order to avoid jolting movements and
overloading the motors. If this is not done correctly operation stops may result.
References
Load diagrams, permitted extra loads (equipment) and their positions as specified in the
Product Specification. The loads must also be defined in the software as detailed in Operating
manual - IRC5 with FlexPendant.
Brake performance
© Copyright 2006-2008 ABB. All rights reserved.
Manipulator motor brake performance depends on any loads attached. For further
information about brake performance, please contact ABB.
3HAC026660-001 Revision: C
55
2 Installation and commissioning
2.3.6. Fitting equipment on the robot (robot dimensions)
2.3.6. Fitting equipment on the robot (robot dimensions)
General
This section shows the robot dimensions and available mounting holes on the robot.
Main dimensions
© Copyright 2006-2008 ABB. All rights reserved.
The figures below show the main dimensions of the robot. The remaining dimensions and
mounting holes on the upper arm, frame and turning disk are shown in the following figures.
xx0400001253
(A)
Centerline of axis 1
(B)
Smallest circumscribed radius, axis 1
Continues on next page
56
3HAC026660-001 Revision: C
2 Installation and commissioning
2.3.6. Fitting equipment on the robot (robot dimensions)
Continued
Main dimension 1600 ID
The figure below shows the main dimensions for 1600 ID robot.
xx0700000118
Centerline of axis 1
(B)
Smallest circumscribed radius, axis 1
© Copyright 2006-2008 ABB. All rights reserved.
(A)
Continues on next page
3HAC026660-001 Revision: C
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2 Installation and commissioning
2.3.6. Fitting equipment on the robot (robot dimensions)
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
Prepared for threading M8 x max depth 20 mm
© Copyright 2006-2008 ABB. All rights reserved.
1)
Continues on next page
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3HAC026660-001 Revision: C
2 Installation and commissioning
2.3.6. Fitting equipment on the robot (robot dimensions)
Continued
Dimensions of the upper arm and mounting holes
© Copyright 2006-2008 ABB. All rights reserved.
The figure below shows the dimensions of the upper arm and available mounting holes for
equipment on the arm.
xx0600002859
(A)
Centerline of axis 3
(B)
Centerline of axis 4
(C)
Turning radius for axis 3
(D)
Smallest circumscribed radius for axis 4
(E)
Mounting holes for equipment (depth 10 mm)
Continues on next page
3HAC026660-001 Revision: C
59
2 Installation and commissioning
2.3.6. Fitting equipment on the robot (robot dimensions)
Continued
Dimensions of the upper arm and mounting holes for 1600 ID
© Copyright 2006-2008 ABB. All rights reserved.
The figure below shows the dimensions of the upper arm and available mounting holes for
equipment on the arm.
xx0700000119
Continues on next page
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3HAC026660-001 Revision: C
2 Installation and commissioning
2.3.6. Fitting equipment on the robot (robot dimensions)
Continued
Dimensions of the turning disk
The figure below shows the dimensions of the turning disk.
xx0200000063
Dimensions of the turning disk 1600ID
© Copyright 2006-2008 ABB. All rights reserved.
The figure below shows the dimensions of the turning disk on a IRB 1600ID
xx0700000090
Fastener quality
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.
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2 Installation and commissioning
2.3.7. Installation of signal lamp for 1600 (option)
2.3.7. Installation of signal lamp for 1600 (option)
General
A signal lamp with an yellow fixed light can be mounted on the robot, as a safety device. The
signal lamp is required on an UL/UR approved robot.
The lamp is active in MOTORS ON mode.
Location of signal lamp
© Copyright 2006-2008 ABB. All rights reserved.
The signal lamp is fitted to the upper arm housing of the robot, as shown in the figure below.
xx0400001265
A
Signal lamp
C
Cable gland
D
Cable bracket
E
Attachment holes for the signal lamp
F
Cover, upper arm housing
Required equipment
Equipment
Art. no.
Signal lamp
3HAC 022235-001
Note
Continues on next page
62
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2 Installation and commissioning
2.3.7. Installation of signal lamp for 1600 (option)
Continued
Equipment
Art. no.
Note
Gasket, customer connections
3HAC 022050-001
Replace if damaged.
Gasket, upper arm cover
3HAC 022049-001
Replace if damaged.
Installation, signal lamp
The procedure below details how to install the signal lamp to the robot.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Remove the cover from the upper arm housing Shown in the figure Location of signal
to get access to the connectors inside the
lamp on page 62.
housing.
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
© Copyright 2006-2008 ABB. All rights reserved.
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.
Shown in the figure Location of signal
lamp on page 62.
6. Fit the cable bracket of the signal lamp to the
two mounting holes in the upper arm housing
(B).
Shown in the figure Location of signal
lamp on page 62.
xx0400001263
•
B: Mounting holes, M8 x 12
7. The signal lamp is now ready for use and is lit
in MOTORS ON mode.
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2 Installation and commissioning
2.3.8. Installation of signal lamp for 1600 ID (option)
2.3.8. Installation of signal lamp for 1600 ID (option)
General
A signal lamp with an yellow fixed light can be mounted on the robot, as a safety device. The
signal lamp is reqired on an UL/UR approved robot.
The lamp is active in MOTORS ON mode.
Location of signal lamp
xx0700000100
A
Signal lamp
B
Cover, upper arm housing
Required equipment
Equipment
Art. no.
Note
Signal lamp
3HAC9258-1
Spare part list, upper arm on
page 254
Drill
-
Diameter 22,5 mm
Standard toolkit
-
The contents of the toolkit is
defined in section, Standard
toolkit on page 237
Continues on next page
64
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
The signal lamp is fitted to the upper arm housing of the robot, as shown in the figure below
2 Installation and commissioning
2.3.8. Installation of signal lamp for 1600 ID (option)
Continued
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Remove the cover from the upper arm housing.
Shown in the figure Location of
signal lamp on page 64.
3. On the cover there is a mark where the lamp is to be
installed. Find the mark and drill a hole with a
diameter of 22.5mm.
4. Fit the lamp and tighten the nut.
5. In the upper arm housing find the two cables marked
R3.H1 and R3.H2 and connect them with the lamp
6. Refit the cover on the upper arm housing.
© Copyright 2006-2008 ABB. All rights reserved.
7. The signal lamp is now ready for use and is lit in
MOTORS ON mode.
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65
2 Installation and commissioning
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.
© Copyright 2006-2008 ABB. All rights reserved.
Notice that adjustments must also be made in the software. References to software manuals
are given in the following installation procedures.
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2 Installation and commissioning
2.4.2. Installation of additional mechanical stops on axis 1
2.4.2. Installation of additional mechanical stops on axis 1
General
This section details how to install additional mechanical stops on axis 1 in order to restrict the
working range of the axis.
Restrictions in working range
The working range of axis 1 can be restricted by fitting one or two additional mechanical
stops on the casted groove at the base.
The figure below shows both the minimum and maximum working range of the robot, when
restricted by the additional mechanical stops. The working range can be restricted freely
within the shown scope, depending on where the mechanical stop is installed along the casted
groove.
+6
-6
4º
A
º
+16
-1 6 8
8º
A
4º
B
© Copyright 2006-2008 ABB. All rights reserved.
B
xx0400001286
A
Mounting position of two additional stops for maximum working area (±168º)
B
Mounting position of two additional stops for minimum working area (±64º)
Continues on next page
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67
2 Installation and commissioning
2.4.2. Installation of additional mechanical stops on axis 1
Continued
Illustration, mechanical stop, axis 1
xx0400001287
A
Mechanical stop, axis 1 (additional)
B
Attachment bolts and washers, mechanical stop
C
Stop pin (standard)
E
Casted groove
F
Guiding pin
G
Hidden stiffening ribs
Required equipment
Equipment
Art. no.
Note
Working range limit axis 1
3HAC023110-001
Includes mechanical stops
(2 pcs), attachment bolts and
washers.
Technical reference manual - System
parameters (RobotWare 5.0)
-
Art. no. is specified in section
References on page 8.
Continues on next page
68
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
The additional mechanical stop of axis 1 is fitted to the base of the robot, as shown in the
figure below.
2 Installation and commissioning
2.4.2. Installation of additional mechanical stops on axis 1
Continued
Installation of mechanical stop, axis 1
The procedure below details how to install the mechanical stop to axis 1.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
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.
© Copyright 2006-2008 ABB. All rights reserved.
5. Fit the stop to the base without tightening the bolts.
6. Turn axis 1 manually and check the working area
between the stops.
How to release the holding brake
of the axis motor is detailed in
section Manually releasing the
brakes on page 47.
7. Tighten the bolts.
2 pcs/stop: M12 x 40, tightening
torque: 85 Nm.
8. The software working range limitations must be re- The system parameters that must
defined to correspond to the changes in the
be changed in RobotWare 5.0
mechanical limitations of the working range.
(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!
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2 Installation and commissioning
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.
Restrictions in working range
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!
© Copyright 2006-2008 ABB. All rights reserved.
xx0400001289
xx0400001290
Continues on next page
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2 Installation and commissioning
2.4.3. Installation of additional mechanical stop on axis 2
Continued
Illustration, mechanical stop, axis 2
The additional mechanical stop for axis 2 is fitted together with a damper to the frame, as
shown in the figure below.
xx0400001291
A
Mechanical stop, axis 2
B
Attachment bolts, mechanical stop (2 pcs)
C
Attachment holes, mechanical stop
D
Damper, axis 2
E
Washer
F
Attachment screw, damper
© Copyright 2006-2008 ABB. All rights reserved.
Required equipment
Equipment
Art. no.
Note
Working range limit axis 2
3HAC023108-001
Includes mechanical stop,
damper and attachment bolts.
Technical reference manual - System parameters (RobotWare 5.0)
Art. no. is specified in section
References on page 8.
Installation of mechanical stop, axis 2
The procedure below details how to install the mechanical stop to axis 2.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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.
Continues on next page
3HAC026660-001 Revision: C
71
2 Installation and commissioning
2.4.3. Installation of additional mechanical stop on axis 2
Continued
Action
Note/Illustration
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.
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.
6. The software working range limitations must be
re-defined 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.
7.
WARNING!
If the mechanical stop is deformed after a hard
collision, it must be replaced!
72
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
5. Fit the damper to the mechanical stop, with its
Shown in the figure Illustration,
attachment screw and washer. Tighten the screw. mechanical stop, axis 2 on page 71.
2 Installation and commissioning
2.4.4. Installation of additional mechanical stops on axis 3
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.
Restrictions in working range
© Copyright 2006-2008 ABB. All rights reserved.
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
-
Robot models IRB 1600 - x/1.2
A
Working range A
B
Working range B
Continues on next page
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73
2 Installation and commissioning
2.4.4. Installation of additional mechanical stops on axis 3
Continued
xx0400001284
-
Robot models IRB 1600 - x/1.45
A
Working range A
B
Working range B
Illustration, mechanical stop, axis 3
© Copyright 2006-2008 ABB. All rights reserved.
The mechanical stop is installed at the upper arm housing, as shown in the figure below.
xx0400001285
A
Mechanical stop, axis 3
B
Attachment screws and washers (2 pcs)
Continues on next page
74
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2 Installation and commissioning
2.4.4. Installation of additional mechanical stops on axis 3
Continued
Required equipment
Equipment
Art. no.
Note
Working range limit axis 3
3HAC023109-001
Includes mechanical stop,
attachment screws and
washers.
Technical reference manual System parameters (RobotWare 5.0)
Art. no. is specified in section
References on page 8.
Installation of mechanical stop, axis 3
The procedure below details how to install the mechanical stop to axis 3.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Fit the mechanical stop to the two mounting holes Shown in the figure Illustration,
at the upper arm housing, with the two attachment mechanical stop, axis 3 on page 74.
screws and washers. Tighten the screws.
2 pcs: M8 x 25, tightening torque: 25
Nm.
3. The software working range limitations must be
re-defined 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.
4.
© Copyright 2006-2008 ABB. All rights reserved.
WARNING!
If the mechanical stop is deformed after a hard
collision, it must be replaced!
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2 Installation and commissioning
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.
A
Position switch
B
Attachment screws, position switch, 2 pcs: M6 x 30
C
Holder ring (2 parts)
D
Attachment screws, holder ring, 6 pcs: M8 x 12
E
Cam
F
Bracket
G
Attachment screws, housing, 2 pcs: M6 x 8
H
Cable straps
I
Attachment screws, attachment plate, 2 pcs: M6 x 16
Required equipment
Equipment
Art. no.
Note
Position switch, axis 1
3HAC023973001
Includes 3 switches.
All parts are included in the delivery.
Instruction of how to cut the cams is
enclosed in the kit.
Technical reference manual System parameters
(RobotWare 5.0)
Art. no. is specified in section References
on page 8.
Continues on next page
76
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
xx0400001356
2 Installation and commissioning
2.4.5. Installation of position switch, axis 1
Continued
Installation, position switch axis 1
The procedure below details how to install the position switch to the robot.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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 Location of position
switch, axis 1 on page 76.
M6 x 12.
5. Attach the position switch to the bracket
with two attachment screws.
2 pcs, M6 x 30.
6. Fit the complete bracket to the base of the Shown in the figure Location of position
robot with the two attachment screws.
switch, axis 1 on page 76.
2 pcs, M6 x 8.
© Copyright 2006-2008 ABB. All rights reserved.
7. Fit the attachment plate to the base of the 2 pcs, M6 x 16.
robot with the two attachment screws.
Shown in the figure Location of position
Fit the switches to the attachment plate. switch, axis 1 on page 76.
Adjust the height of the switches with
shims until each roller aligns with corresponding cam.
xx0400001358
A. Attachment plate
B. Shims
C. Roller
D. Cam
8. Secure the cabling inside the housing
with cable straps.
Shown in the figure Location of position
switch, axis 1 on page 76.
Continues on next page
3HAC026660-001 Revision: C
77
2 Installation and commissioning
2.4.5. Installation of position switch, axis 1
Continued
Action
Note
The cabling and connection points are
specified in section Position switch cables,
robot base to controller (option) on page 82.
10. The software working range limitations
must be re-defined 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.
© Copyright 2006-2008 ABB. All rights reserved.
9. Connect the position switch cabling.
78
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2 Installation and commissioning
2.5.1. Connectors on robot
2.5 Electrical connections
2.5.1. Connectors on robot
Connectors on the robot
© Copyright 2006-2008 ABB. All rights reserved.
The figure below shows all connections of the robot cabling, including the customer
connectors.
xx0400001262
A
Connection for air
B
Connection for signal lamp
Continues on next page
3HAC026660-001 Revision: C
79
2 Installation and commissioning
2.5.1. Connectors on robot
Continued
Connectors on the robot upper arm IRB 1600ID
The figure below shows connections on the upper arm IRB 1600 ID
B
R4.FB5
R4.FB6
F
A
R4.MP5
R4.MP6
© Copyright 2006-2008 ABB. All rights reserved.
E
R3.FB3
R3.FB4
R3.FB5
R3.FB6
R3.MP3
R3.MP4
R3.MP5
R3.MP6
xx0700000038
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3HAC026660-001 Revision: C
2 Installation and commissioning
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
Handles power supply to and control of the robot's motors as
well as feedback from the serial measurement board.
Specified in the table Robot cables on page 81.
Position switch cables
(option)
Handles supply to and feedback from any position switches
on the robot.
Specified in the table Position switch cables, robot base to
controller (option) on page 82.
Customer cables (option)
Handles communication with equipment fitted on the robot
by the customer, low voltage signals and high voltage power
supply + protective ground.
See the product manual for the controller 1).
Also specified in the table Customer cables (option) on page
83.
External axes cables (option)
Handles power supply to and control of the external axes'
motors as well as feedback from the servo system.
See the Application manual - Additional axes and stand
alone controller (M2004)1).
1)
Art. no. is specified in section References on page 8.
The cable categories are divided into sub-categories, specified below:
© Copyright 2006-2008 ABB. All rights reserved.
Robot cables
These cables are included in the standard delivery. They are completely pre-manufactured
and ready to plug in.
Cable sub-category Description
Connection
Connection
point, cabinet point, robot
Robot cable, power
Transfers drive power from the
drive units in the control cabinet
to the robot motors.
XS1
R1.MP
Robot cable, signals
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)
Art. no.
Robot cable, power, 7 m
3HAC2492-1
Robot cable, power, 15 m
3HAC2529-1
Robot cable, power, 22 m
3HAC2539-1
Continues on next page
3HAC026660-001 Revision: C
81
2 Installation and commissioning
2.5.2. Robot cabling and connection points
Continued
Cable (standard)
Art. no.
Robot cable, power, 30 m
3HAC2564-1
Robot cable, power, for robots with foundry and wash protection
Cable (foundry)
Art. no.
Robot cable, power, 7 m
3HAC9038-1
Robot cable, power, 15 m
3HAC9038-2
Robot cable, power, 22 m
3HAC9038-3
Robot cable, power, 30 m
3HAC9038-4
Cable
Art. no.
Robot cable, signal, shielded, 7 m
3HAC2493-1
Robot cable, signal, shielded, 15 m
3HAC2530-1
Robot cable, signal, shielded, 22 m
3HAC2540-1
Robot cable, signal, shielded, 30 m
3HAC2566-1
Robot cable, signals
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.
Connection
Connection
point,
point, robot
cabinet
Position switch cable, axis 1, 30 m
3HAC7997-4
R1.LS
© Copyright 2006-2008 ABB. All rights reserved.
XS8
Continues on next page
82
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2 Installation and commissioning
2.5.2. Robot cabling and connection points
Continued
Customer cables (option)
The customer cables specified below are connected between robot and controller.
The customer cables are ordered according to current protection class of the robot.
Customer cables for robots with standard protection
Cable (standard)
Art. no.
Connection
point, robot
Customer cable, power-signal, 7 m
3HAC3353-1
R1.CP/CS
Customer cable, power-signal, 15 m
3HAC3354-1
R1.CP/CS
Customer cable, power-signal, 22 m
3HAC3355-1
R1.CP/CS
Customer cable, power-signal, 30 m
3HAC3356-1
R1.CP/CS
Cable (foundry and wash)
Art. no.
Connection
point, robot
Customer cable, power-signal, 7 m
3HAC8183-1
R1.CP/CS
Customer cable, power-signal, 15 m
3HAC8183-2
R1.CP/CS
Customer cable, power-signal, 22 m
3HAC8183-3
R1.CP/CS
Customer cable, power-signal, 30 m
3HAC8183-4
R1.CP/CS
© Copyright 2006-2008 ABB. All rights reserved.
Customer cables for robots with foundry and wash protection
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83
2 Installation and commissioning
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
Dimension
Air inlet (at the base)
Air outlet (at the upper arm housing)
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.
Equipment
ABB art. no.
Note
Connection set R2.CP/R2.CS
3HAC025396-001
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
Pin connector
B
Pin
C
Backshell
Continues on next page
84
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
Connector set from ABB for standard connection
2 Installation and commissioning
2.5.3. Customer connections on the robot
Continued
Recommended pin connectors
Pin connector
Souriau art. no.
Pin connector, standard connection, CS (Customer Signal)
UT0W6 1626 P-H
Pin connector, standard connection, CP (Customer Power)
UT0W6 1210 P-H
Pin connector, integrated wirefeeder cabling, CS
UT0W6 1626 P-H
Pin connector, Integrated wirefeeder cabling, CP
UT06 1412 P-H04
Recommended pins (turned)
Turned pins for cable area...
Pin diameter
Souriau art. no.
0.21 - 0.93 mm2 (standard connection, CP/CS and
integrated wirefeeder cabling, CS)
1 mm
RM18W3K
0.13 - 0.25 mm2 (integrated wirefeeder cabling, CP)
1.6 mm
RM24M9K
0.25 - 0.5 mm (integrated wirefeeder cabling, CP)
1.6 mm
RM20M12K
0.5 - 1.5 mm2 (integrated wirefeeder cabling, CP)
1.6 mm
RM16M23K
2
Recommended backshell
Backshell
Souriau art. no.
Backshell, standard connection, CS
UT0 16JC
Backshell, standard connection, CP
UT0 12JC
Backshell, integrated wirefeeder cabling, CS
UT0 16JC
Backshell, integrated wirefeeder cabling, CP
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).
© Copyright 2006-2008 ABB. All rights reserved.
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
MS3126*1626S
Complete pin connector, CP
MS3126*1210S
Turned pin 0.2 - 0.5 mm
2
M39029/31-240
Continues on next page
3HAC026660-001 Revision: C
85
2 Installation and commissioning
2.5.3. Customer connections on the robot
Continued
Connector for crimping
Turned pin 0.5 - 1.5 mm
2
Military standard MIL-C-26482
M29029/31-228
Connector for soldering
The complete pin connectors for soldering include pin connector, backshell and pins.
Military standard MIL-C-26482
Complete pin connector, CS
MS3116*1626S
Complete pin connector, CP
MS3116*1210S
© Copyright 2006-2008 ABB. All rights reserved.
Connector for soldering
86
3HAC026660-001 Revision: C
2 Installation and commissioning
2.6.1. Additional installation procedure.
2.6 Making robot ready for operation (Cleanroom)
2.6.1. Additional installation procedure.
General
Cleanroom robots are specially designed to work in a cleanroom environment.
Cleanroom robots are designed in order to prevent from particle emission from the robot. For
example is maintenance work possible to perform without cracking the paint. The robot is
painted with four layers of polyurethane paint. The last layer being a varnish over labels in
order to simplify cleaning.
Parts being replaced on a Cleanroom robot must be replaced with other parts designed for use
in Cleanroom environments.
Cleanroom class 5
Particle emission from the robot fulfill Cleanroom class 5 standard according to DIN EN ISO
14644-1.
Preparations before commissioning a Cleanroom robot
© Copyright 2006-2008 ABB. All rights reserved.
During transport and handling of a Cleanroom robot, it is likely that the robot has been
contaminated with particles of different sorts. Therefore the Cleanroom robot must be
minutely cleaned before commissioning.
3HAC026660-001 Revision: C
87
2 Installation and commissioning
© Copyright 2006-2008 ABB. All rights reserved.
2.6.1. Additional installation procedure.
88
3HAC026660-001 Revision: C
3 Maintenance
3.1. Introduction
3 Maintenance
3.1. Introduction
Structure of this chapter
This chapter details all maintenance activities recommended for the robot and any external
units of the robot.
It is based on the maintenance schedule, located in the beginning of the chapter. The schedule
contains information about required maintenance activities including intervals and refers to
procedures for the activities.
Each procedure contains all information required to perform the activity, that is required tools
and materials.
The procedures are gathered in different sections, divided according to the maintenance
activity.
Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed!
© Copyright 2006-2008 ABB. All rights reserved.
There are general safety aspects that must be read through, as well as more specific safety
information that describe danger and safety risks when performing the procedures. Read the
chapter Safety before performing any service work.
3HAC026660-001 Revision: C
89
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.
© Copyright 2006-2008 ABB. All rights reserved.
•
90
3HAC026660-001 Revision: C
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
Equipment
activity
Interval
Detailed in section
Change
Gearbox oil, axes 5 and 6
IRB1600
20,000 hrs
Oil change, gearbox
axes 5 and 6 on page
97.
Change
Gearbox oil, axes 5-6
IRB1600ID
20,000 hrs
Oil change, gearbox
axes 5- 6, IRB 1600ID
on page 100
Change
Battery, measurement system 12 - 36 mths 2)
Cleaning
Complete robot
Regular 1)
Replacement of
measurement system
battery pack on page
103.
Cleaning, complete
robot on page 105.
© Copyright 2006-2008 ABB. All rights reserved.
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.
3HAC026660-001 Revision: C
91
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
Expected life
Note
Robot cable harness IRB 1600
2,000,000 cycles
See note 1)
Robot cable harness IRB 1600ID
2,000,000 cycles
See note 1)
Cabling for position switch
2,000,000 cycles
See note 1)
Gearbox
40,000 hrs
© Copyright 2006-2008 ABB. All rights reserved.
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!
92
3HAC026660-001 Revision: C
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.
© Copyright 2006-2008 ABB. All rights reserved.
xx0400001217
A
Damper, axis 2
B
Attachment screw
xx0400001215
A
Damper, axis 3
B
Cast tab
Continues on next page
3HAC026660-001 Revision: C
93
3 Maintenance
3.3.1. Inspection, damper axes 2, 3 and 5
Continued
xx0600002806
A
Damper, axis 5
B
Recess
Required equipment
Equipment
Art. no.
Note
Standard toolkit
-
The contents are defined in section Standard toolkit
on page 237.
Inspection, dampers
The procedure below details how to inspect the dampers.
Action
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Check all dampers for damage, such as cracks or Shown in the figure Location of
existing impressions that are larger than 1 mm.
dampers on page 93.
3. Check attachment screws for deformation.
4. If any damage is detected, the damper must be
replaced with a new one!
94
Replacement is detailed in
sections:
• Replacement of damper,
axis 2 on page 151
• Replacement of damper,
axis 3 on page 153
• Replacement of damper,
axis 5 on page 157.
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
1.
3 Maintenance
3.4.1. Oil in gearboxes
3.4 Replacement activities
3.4.1. Oil in gearboxes
Location of gearboxes
© Copyright 2006-2008 ABB. All rights reserved.
xx0500001427
A
Gearbox, axis 1
B
Gearbox, axis 2
C
Gearbox, axis 3
D
Gearbox, axis 4
E
Gearboxes, axes 5 and 6 IRB1600
Type and amount of oil in gearboxes 1600
Gearbox
Type of oil
Art. no.
Amount
Axis 1
Mobilgear 600 XP 320
11712016-604
1200 ml
Axis 2
Mobilgear 600 XP 320
11712016-604
1000 ml
Axis 3, IRB1600
Mobilgear 600 XP 320
11712016-604
500 ml
Axis 4, IRB1600
Mobilgear 600 XP 320
11712016-604
350 ml
Axis 5-6 (wrist unit),
IRB1600.
Optimol BM 100
3HAC 0860-1
Total amount: 350 ml
(new wrist)
Amount at oil change:
300 ml
Continues on next page
3HAC026660-001 Revision: C
95
3 Maintenance
3.4.1. Oil in gearboxes
Continued
Type and amount of oil in gearboxes 1600ID
Gearbox
Type of oil
Art. no.
Amount
Axis 3, IRB1600ID
Mobilgear 600 XP 320
11712016-604
500 ml
Axis 4, IRB1600ID
Mobilgear 600 XP 320
11712016-604
350 ml
Axis 5
Mobilgear 600 XP 320
11712016-604
15 ml
Wrist Axis 5-6
IRB1600ID
Optimol BM 100
3HAC 0860-1
130 ml
Wrist Axis 6, IRB1600ID Grease
96
20 ml
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
xx0700000285
3 Maintenance
3.4.2. Oil change, gearbox axes 5 and 6
3.4.2. Oil change, gearbox axes 5 and 6
Location of oil plugs
The gearboxes for axes 5 and 6 are located in the wrist unit as shown in the figure below.
xx0600002846
A
Oil plug, draining and filling
B
Oil plug, vent hole
© Copyright 2006-2008 ABB. All rights reserved.
Required equipment
Equipment, etc.
Art. no.
Amount
Note
Lubricating oil
3HAC 0860-1
Total amount: 350 Optimol BM 100
ml (new wrist)
Amount at oil
change: 300 ml
Oil collecting vessel
Capacity: 400 ml.
Standard toolkit
The contents are defined in
section Standard toolkit on
page 237.
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.
Continues on next page
3HAC026660-001 Revision: C
97
3 Maintenance
3.4.2. Oil change, gearbox axes 5 and 6
Continued
Draining, wrist unit
The procedure below details how to drain oil from the gearboxes in the wrist unit.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
WARNING!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING - Safety
risks during work with gearbox oil on page 36.
3. Position the robot as shown in the figure to the Vessel capacity is specified in section
right:
Required equipment on page 97!
• upper arm: upwards for a standing robot
• axis 4: 180º, to a position where the oil
plug (A), faces downwards.
NOTE!
xx0500001434
A. Oil plug, draining and filling
The position for an inverted robot is
the opposite!
4. Remove the both oil plugs.
Shown in the figure Location of oil
Both oil plugs must be removed in order to drain plugs on page 97.
the wrist unit properly.
5. Refit the oil plug, vent hole.
Continues on next page
98
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
The total amount of oil will not be drained. There
will remain approximately 50 ml in the wrist unit.
3 Maintenance
3.4.2. Oil change, gearbox axes 5 and 6
Continued
Filling oil, wrist unit
The procedure below details how to fill oil in the gearboxes in the wrist unit.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
WARNING!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING Safety risks during work with gearbox oil on
page 36.
3. Remove the oil plug, draining and filling.
Shown in the figure Location of oil
plugs on page 97!
© Copyright 2006-2008 ABB. All rights reserved.
4. Position the robot as shown in the figure to the The oil quality and amount is specified
right:
in section Required equipment on
page 97!
• upper arm: downwards for a standing
robot
• axis 4: 90º, to a position where the oil
plug (A), faces upwards.
Fill oil in the wrist unit through the oil plug.
xx0500001435
• A: Oil plug, draining and filling
The position for an inverted robot is the
opposite.
5. Refit the oil plug.
3HAC026660-001 Revision: C
99
3 Maintenance
3.4.3. Oil change, gearbox axes 5- 6, IRB 1600ID
3.4.3. Oil change, gearbox axes 5- 6, IRB 1600ID
Location of oil plugs
The oil plug for axes 5 are located in the wrist unit as shown in the figure below.
xx0700000030
A
Oil plug, draining and filling
B
Oil plug, draining ventilation plug.
Required equipment
Equipment, etc.
Art.no.
Amount
Note
Lubricating oil
3HAC0860-1
Amount at oil change: Optimol BM 100
100 ml.
Standard toolkit
The contents are
defined in section
Special tools on page
238.
Other tools and
procedures may be
required.
See references to
these procedures in
the step-by-step
instructions below.
Draining, wrist unit
The procedure below details how to drain oil from the gearboxes in the wrist unit.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the
robot!
Continues on next page
100
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
Oil collecting vessel
3 Maintenance
3.4.3. Oil change, gearbox axes 5- 6, IRB 1600ID
Continued
Action
Note/Illustration
2.
WARNING!
Handling gearbox oil involves several
safety risks. Before proceeding, please
observe the safety information in
section WARNING - Safety risks during
work with gearbox oil on page 36.
3. Position the robot as shown in the
Vessel capacity is specified in section
figure to the right:
Required equipment on page 100.
• upper arm: upwards for a
standing robot.
• axis 4: - 90º, to a position where
the oil plug (A), faces
downwards.
NOTE!
The total amount of oil will not be
drained. There will remain approximately 20 ml in the wrist unit.
xx0700000033
Shown in figure Location of oil plugs on page
100.
5. Tap the wrist of all oil.
About 100 ml
© Copyright 2006-2008 ABB. All rights reserved.
4. Remove the oil plug (A) and the
ventilation plug (B).
Continues on next page
3HAC026660-001 Revision: C
101
3 Maintenance
3.4.3. Oil change, gearbox axes 5- 6, IRB 1600ID
Continued
Filling oil, wrist unit
The procedure below details how to fill oil in the gearboxes in the wrist unit.
Action
Note/Illustration
1. Position the robot as shown in the figure to Vessel capacity is specified in section
the right:
Required equipment on page 100.
• upper arm: upwards for a standing
robot.
• axis 4: + 90º, to a position where the
oil plug (A), faces upwards.
Fill 180 ml new oil in the wrist.
xx0700000034
A. oil plugs, filling possition.
© Copyright 2006-2008 ABB. All rights reserved.
2. Refit the oil plug and the ventilation plug.
102
3HAC026660-001 Revision: C
3 Maintenance
3.4.4. Replacement of measurement system battery pack
3.4.4. Replacement of measurement system battery pack
Location of battery pack
The battery pack for the measurement system is located inside the base of the robot, as shown
in the figure below.
xx0500001390
A
Base cover, including gasket. Battery pack is located beneath the cover.
Battery pack on serial measurement unit
© Copyright 2006-2008 ABB. All rights reserved.
The battery pack is attached to the serial measurement unit as shown in the figure below.
xx0500001393
A
Battery pack
B
Velcro strap
C
Connector X3
Continues on next page
3HAC026660-001 Revision: C
103
3 Maintenance
3.4.4. Replacement of measurement system battery pack
Continued
Required equipment
Equipment
Spare part no.
Battery pack
3HAC 16831-1
Gasket, base cover
3HAC 022047-001
Replace if damaged.
Standard toolkit
-
The contents are defined in section
Standard toolkit on page 237.
Circuit diagram
Note
See chapter Circuit diagram.
Replacement, battery pack
The procedure below details how to replace the battery pack.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Remove the base cover from the robot by
unscrewing its attachment screws.
Shown in the figure Location of battery
pack on page 103.
3. Disconnect the battery from the serial
measurement unit.
4. Remove the battery pack.
104
6. Check the base cover gasket, replace if
damaged.
Spare part no. is specified in Required
equipment on page 104.
7. Refit the base cover to the robot.
Shown in the figure Location of battery
pack on page 103.
8. Update the revolution counters.
Detailed in section Updating revolution
counters on page 225.
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
5. Fit the new battery pack and connect it to the Spare part no. is specified in Required
serial measurement unit (X3).
equipment on page 104.
Shown in the figure Battery pack on
serial measurement unit on page 103.
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.
Required equipment
Equipment, etc.
Art. no. Note
May be used on version
Foundry and Wash!
Steam cleaner
-
May be used on version
Foundry and Wash!
High pressure water cleaner
-
May be used on version
Cleanroom and Standard.
Vacuum cleaner
•
•
•
•
•
•
Max. water pressure on enclosures: 50
kN/m 2 (0.5 bar)
Fan jet nozzle should be used, min. 45°
spread
Flow: max. 100 liters/min.
•
Cloth with mild detergent
•
-
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
Do's and don'ts!
The section below specifies some special considerations when cleaning the robot.
© Copyright 2006-2008 ABB. All rights reserved.
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 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!
Never!
3HAC026660-001 Revision: C
105
3 Maintenance
© Copyright 2006-2008 ABB. All rights reserved.
3.5.1. Cleaning, complete robot
106
3HAC026660-001 Revision: C
4 Repair
4.1. Introduction
4 Repair
4.1. Introduction
Structure of this chapter
This chapter details all repair activities recommended for the robot and any external units of
the robot.
It is made up of separate procedures, each detailing a specific repair activity. Each procedure
contains all information required to perform the activity, for example spare parts numbers,
required special tools and materials.
The procedures are gathered in sections, divided according to the component location on the
robot.
Required equipment
All equipment required to perform a specific repair activity is listed together with the current
procedure.
The equipment is also gathered in different lists in the chapter .
Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed!
© Copyright 2006-2008 ABB. All rights reserved.
There are general safety aspects that must be read through, as well as more specific safety
information that describe danger and safety risks when performing specific steps in a
procedure. Make sure to read through the chapter Safety before commencing any service
work.
3HAC026660-001 Revision: C
107
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.
Required equipment
Equipment, etc.
Art. no.
Leakdown tester
3HAC0207-1
Leak detection spray
-
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, Art. no. is specified above!
and replace it with the leakdown tester.
Adapters may be required, which are included in the
leakdown tester kit.
3. Apply compressed air, and raise the pressure with the Recommended value:
knob until the correct value is shown on the
0.2 - 0.25 bar (20 - 25 kPa)
manometer.
5. Wait for approx. 8-10 minutes. No pressure loss must If the compressed air is signifibe detected.
cantly 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.
108
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
4. Disconnect the compressed air supply.
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.
Art. no.
Note
Grease
3HAB3537-1
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.
© Copyright 2006-2008 ABB. All rights reserved.
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.
3HAC026660-001 Revision: C
109
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.
Art. no.
Note
Grease
3HAB3537-1
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).
3. Lubricate the seal with grease just before fitting. (Not too
Art. no. is specified in
early as there is a risk of dirt and foreign particles adhering Equipment on page 110.
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.
4. Mount the seal correctly with a mounting tool.
Never hammer directly on the seal as this may result in
leakage.
Continues on next page
110
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
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.
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.
Defective o-rings may
The grooves must be geometrically correct and free from pores not be used.
and contamination.
4. Lubricate the o-ring with grease.
© Copyright 2006-2008 ABB. All rights reserved.
5. Tighten the screws evenly when assembling.
3HAC026660-001 Revision: C
111
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.
Required equipment
Equipment
Spare part no.
Note
Cable harness IRB 1600/1.45
3HAC 021827-001
No application interface.
Cable harness IRB 1600/1.45,
Customer connections
3HAC 021828-001
Cable harness IRB 1600/1.45,
Wire feeder
3HAC 021830-001
Cable harness IRB 1600/1.2,
Customer connections
3HAC 021828-003
Gasket, upper arm cover
3HAC 022049-001
Replace if damaged.
Gasket, customer connections
3HAC 022050-001
Replace if damaged.
Gasket, base cover
3HAC 022047-001
Replace if damaged.
Gasket, gearbox axis 1-2
3HAC 022048-001
Replace if damaged.
VK-cover
3HAA 2166-23
Upper and lower covers.
2 pcs
VK-cover
3HAA 2166-21
Middle cover.
3HAC025815-001
Fitted to the push button unit in
order to align it correctly.
Replace if damaged.
Centering piece
Standard toolkit
The contents are defined in
section Standard toolkit on page
237.
Circuit diagram
See chapter Circuit diagram.
Continues on next page
112
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
Cable ties
4 Repair
4.3.1. Replacement of cable harness
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.
© Copyright 2006-2008 ABB. All rights reserved.
xx0400001248
A
Upper and lower VK-cover
B
Arm housing cover, with gaskets
C
VK-cover (also shown with the cover removed)
D
Cover, frame, with gasket
E
Base cover, with gasket
Removal, cable harness
The procedure below details how to remove the complete cable harness from the robot.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
Continues on next page
3HAC026660-001 Revision: C
113
4 Repair
4.3.1. Replacement of cable harness
Continued
Action
2. Remove all the covers:
• Remove the covers of the upper arm
housing, frame and base.
• Push out the upper and lower VK-cover
from the inside.
• Remove the middle VK-cover from the
lower arm.
Note/Illustration
All the covers are shown in the
figure Illustration, covers to remove
on page 113.
CAUTION!
Be careful not to damage the cabling and cable
bracket inside the lower arm when removing the
middle VK-cover!
The figure to the right shows the space underneath
the cover. The gray areas are safe for insertion of
a tool that may be inserted with a maximum depth
of 20 mm!
xx0400001247
3. The cable bracket inside the lower arm is attached
to the cable harness. Move the bracket to the new
cabling.
4. Disconnect all the connectors inside the upper arm Shown in the figure Illustration,
housing.
cabling inside upper arm housing
on page 115.
5. Remove all cable ties, clamps and brackets inside Attachment points inside the upper
the upper arm housing.
arm housing are shown in the
figure Illustration, cabling inside
upper arm housing on page 115.
6. Disconnect all the connectors inside the frame.
Shown in the figure Illustration,
cabling inside frame on page 117.
8. Disconnect all the connectors at the base and
remove the SMB unit from the base.
Shown in the figure Illustration,
cabling inside base on page 118.
NOTE!
Do not lose the centering piece fitted to the push
button unit!
9. Remove all cable ties and brackets at the base.
Shown in the figure Illustration,
cabling inside base on page 118.
10. Pull out the cabling from the upper arm housing
and pull it down through the lower arm.
11. Continue pulling down the cable harness through
the frame and pull it out at the rear of the base.
Continues on next page
114
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
7. Remove the fastening plate, all cable ties and
Attachment points inside the frame
brackets from inside the frame. Remove the cable are shown in the figure Illustration,
clamp unit from the fastening plate.
cabling inside frame on page 117.
4 Repair
4.3.1. Replacement of cable harness
Continued
Illustration, cabling inside upper arm housing
The figure below shows how the cabling is run inside the upper arm housing.
© Copyright 2006-2008 ABB. All rights reserved.
xx0400001250
A
Signal cabling; connectors for motors on axes 3, 4, 5 and 6: R3.FB3, R3.FB4,
R3.FB5 and R3.FB6
B
Power cabling; connectors for motors on axes 3, 4, 5 and 6: R3.MP3, R3.MP4,
R3.MP5 and R3.MP6
C
Optional connector: R2.CP
D
Optional connector: R2.CS
E
Distance console with contact panel
F
Cable clamp unit
G
Attachment screws, cable clamp unit (2 pcs, only one shown)
H
Clamp, signal cabling
I
Clamp, motor cabling
J
Connector plate
K
Connector holder
L
Cable tie, connector holder
Continues on next page
3HAC026660-001 Revision: C
115
4 Repair
4.3.1. Replacement of cable harness
Continued
Refitting, cable harness in upper arm housing and lower arm
The procedure below details how to refit the cabling inside the upper arm housing.
The cable layout is shown in the figure Illustration, cabling inside upper arm housing on page
115.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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 Spare part no. is specified in
arm and secure it by refitting the VK-cover.
Required equipment on page 112.
xx0400001247
Cable bracket is attached to the
cabling with 2 screws, M6x8.
4. Fasten the cabling inside the upper arm housing Shown in the figure Illustration,
by fitting the cable clamp unit to the distance
cabling inside upper arm housing on
console with two attachment screws.
page 115.
6. Reconnect the signal cable connectors and slide Shown in the figure Illustration,
them into the connector holder.
cabling inside upper arm housing on
Notice that one of the cable ties in the connector page 115.
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 115.
10. Refit the arm housing cover with eight attachment 8 pcs, M6.
screws. Check the two gaskets and replace, if
Shown in the figure Illustration,
damaged.
covers to remove on page 113.
Spare part no. is specified in
Required equipment on page 112.
11. Fit new VK-covers to the lower arm.
Spare part no. is specified in
Required equipment on page 112.
Continues on next page
116
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
5. Fit the motor and signal cabling to the connector Hexagon nut: M5. 1 pc for each
plate with clamps.
clamp.
4 Repair
4.3.1. Replacement of cable harness
Continued
Action
Note/Illustration
12. Continue refitting the cable harness according to
procedure Refitting, cable harness in frame and
base on page 119.
Illustration, cabling inside frame
The figure below shows how the cabling is run inside the frame.
© Copyright 2006-2008 ABB. All rights reserved.
xx0400001249
A
Power cabling; connectors for motors on axes 1 and 2: R3.MP1 and R3.MP2
B
Signal cabling; connectors for motors on axes 1 and 2: R3.FB1 and R3.FB2
C
Cable clamp unit (attachment screws behind the fastening plate)
D
Fastening plate
E
Attachment screws and nuts
Continues on next page
3HAC026660-001 Revision: C
117
4 Repair
4.3.1. Replacement of cable harness
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.
A
Power cabling
B
Signal cabling
C
Clamp with hexagon nut
D
Attachment screws, cable clamp unit
E
Hexagon nut, SMB plate
F
Fastening plate
G
SMB unit
H
Cable clamp unit
© Copyright 2006-2008 ABB. All rights reserved.
xx0500001388
Continues on next page
118
3HAC026660-001 Revision: C
4 Repair
4.3.1. Replacement of cable harness
Continued
Refitting, cable harness in frame and base
The procedure below details how to refit the cabling inside the frame and the base.
The cable layout is shown in the figures Illustration, cabling inside frame on page 117 and
Illustration, cabling inside base on page 118.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Run the cables from the lower arm into the
frame.
3. Fit the cable clamp unit to the fastening plate Shown in the figure Illustration, cabling
with two attachment screws, but do not secure inside frame on page 117.
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
Shown in the figure Illustration, cabling
and secure all plates and cable brackets inside inside frame on page 117.
the frame with attachment screws and nuts.
6. In the base, secure the cabling to the bottom Shown in the figure Illustration, cabling
fastening plate:
inside base on page 118.
• fit the cable clamp unit with two
attachment screws (M6).
• fit the separate cables with clamps and
hexagon nuts.
© Copyright 2006-2008 ABB. All rights reserved.
7. Refit the SMB unit to the fastening plate with
hexagon nuts.
Shown in the figure Illustration, cabling
inside base on page 118.
8. Refit the centering piece (B) to the push button
unit in order to align it vertically.
Also make sure that the unit is correctly aligned
sideways: the measurements x1 and x2 in the
figure to the right should not differ more than 1
mm from each other!
xx0600002777
Art. no. for the centering piece is
specified in Required equipment on
page 112.
9. Refit the push button guard to the robot base.
10.
WARNING!
Before continuing any service work, please
observe the safety information in section
WARNING - The brake release buttons may be
jammed after service work on page 34!
Continues on next page
3HAC026660-001 Revision: C
119
4 Repair
4.3.1. Replacement of cable harness
Continued
Action
Note
11. Connect the:
Shown in the figure Illustration, cabling
• signal cable connectors to the SMB unit inside base on page 118.
• power cable connector to the housing in
the base
• optional cabling, if any
• ground cable.
Shown in the figure Illustration, covers
to remove on page 113.
Spare part no. is specified in Required
equipment on page 112.
13. Recalibrate the robot!
Calibration is detailed in a separate
calibration manual, enclosed with the
calibration tools.
General calibration information is
included in section Calibration information.
© Copyright 2006-2008 ABB. All rights reserved.
12. Refit the covers to the frame and to the base.
Replace the gaskets, if damaged.
120
3HAC026660-001 Revision: C
4 Repair
4.3.2. Replacement of cable harness, IRB 1600ID
4.3.2. Replacement of cable harness, IRB 1600ID
Location of the harness
The location of the harness is shown in several figures, next to the procedures, later on in this
section.
B
R4.FB5
R4.FB6
R4.MP5
F
A
R4.MP6
E
© Copyright 2006-2008 ABB. All rights reserved.
R3.FB3
R3.FB4
R3.FB5
R3.FB6
R3.MP3
R3.MP4
R3.MP5
R3.MP6
xx0700000038
A
R4.FB6
B
R4.FB5
E
R4.MP6
F
R4.MP5
Required equipment
Equipment
Standard toolkit
Spare part no.
Note
Contents, standard toolkit.
Circuit diagram
Continues on next page
3HAC026660-001 Revision: C
121
4 Repair
4.3.2. Replacement of cable harness, IRB 1600ID
Continued
Equipment
Spare part no.
Note
VK- cover
3HAA 2166-23
Upper and lower covers.
2 pcs
Cable harness axis 5-6.
3HAC027523-002
IRB 1600 AW
Cable ties
Removal, cable harness lower arm and upper arm back
The procedure below describes removal of the complete cable harness in upper arm back.
R3.FB3
R3.FB4
R3.FB5
R3.FB6
© Copyright 2006-2008 ABB. All rights reserved.
R3.MP3
R3.MP4
R3.MP5
R3.MP6
xx0700000105
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Remove the cover to the upper arm.
Continues on next page
122
3HAC026660-001 Revision: C
4 Repair
4.3.2. Replacement of cable harness, IRB 1600ID
Continued
Action
Note
3. Remove the hexagon nut with flange (A)
holding the two (2) clamps.
xx0700000106
A. Hexagon nut with flange
4. Disconnect R3.FB3 - R3.FB6.
5. Disconnect R3.MP3 - R3.MP6.
6. Remove the cable harness from the lower Follow instructions in section Removal,
arm.
cable harness.
Removal, cable harness upper arm tube 1600ID
© Copyright 2006-2008 ABB. All rights reserved.
The procedure below describes removal of the complete cable harness in upper arm tube.
xx0700000099
A
Cover plate
B
Clamp
C
R4.FB5
D
R4.FB6
Continues on next page
3HAC026660-001 Revision: C
123
4 Repair
4.3.2. Replacement of cable harness, IRB 1600ID
Continued
E
R4.MP6
F
R4.MP5
G
R3.MP5
H
R3.MP6
I
R3.FB5
J
R3.FB6
Action
Note
1.
DANGER!
Turn off all electric power,
hydraulic and pneumatic
pressure supplies to the robot!
2. Remove the upper arm tube.
Described in section Replacement of motor, axis 5,
IRB 1600ID.
xx0700000113
A. Torx pan head screw M6x12
B. Hexagon nut with flange M5
4. Remove the cover plate.
TIP!
The spare part cable harness 3HAC027523-002
includes a galvanized coverplate without paint. If a
painted cover is prefered, use the old cover plate.
Continues on next page
124
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
3. Remove all the Torx pan head
screw (A) holding the cover.
4 Repair
4.3.2. Replacement of cable harness, IRB 1600ID
Continued
Action
Note
5. Remove the cable pulling it out
through the passage (A).
A
xx0700000114
Refitting, cable harness
The procedure below describes refitting of the complete cable harness.
Action
Note
Described in section Refitting, cable harness in upper
arm housing and lower arm on page 116
2. Refit the upper arm tube.
Described in section Refitting, motor axis 5 on page
207.
3. Refit the connections in the
upper arm.
Shown in figure Location of the harness on page 121.
© Copyright 2006-2008 ABB. All rights reserved.
1. Refit the cable harness.
3HAC026660-001 Revision: C
125
4 Repair
4.3.3. Replacement of complete arm system
4.3.3. Replacement of complete arm system
Location of complete arm system
The complete arm system includes complete upper and lower arm.
xx0500001443
A
VK-cover (attachment screws underneath cover)
B
Cover, frame
C
Cover, base
Required equipment
Art. no.
Lifting slings
-
VK-cover
3HAA 2166-23
Sealing ring (V-ring)
3HAB 3732-13
Replace if damaged.
Isopropanol
-
Used to clean the mating surfaces.
Locking liquid
-
Loctite 574
Standard toolkit
-
The contents are defined in section
Standard toolkit on page 237.
Other tools and procedures may
be required. See references to
these procedures in the step-bystep instructions below.
Note
These procedures include
references to the tools required.
Removal, complete arm system
The procedure below details how to remove the complete arm system from the robot.
Action
Note
1. Move the robot to its calibration position.
Continues on next page
126
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
Equipment
4 Repair
4.3.3. Replacement of complete arm system
Continued
Action
Note
2.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3. Remove the covers from the base and the
frame.
4. Release the cable harness from below upwards The cable layouts inside the base and
to the lower arm by:
the frame are shown in the figures:
• disconnecting all the connectors inside
• Illustration, cabling inside
the base and the frame.
base on page 118.
• removing all cable ties and brackets
• Illustration, cabling inside
inside the base and the frame.
frame on page 117.
5. Push out the VK-cover from inside of the frame. Shown in the figure Location of
complete arm system on page 126.
6.
CAUTION!
The complete arm system weighs 55 kg! All
lifting equipment used must be sized accordingly!
7. Fit lifting slings to the upper arm to unload the
weight of the complete arm system.
8. Unscrew the 12 attachment screws and remove
the one washer.
Be careful when pulling the cabling through
base, frame and lower arm. Use tape to bunch
the connectors and protect them.
© Copyright 2006-2008 ABB. All rights reserved.
9. Gently pull out the cabling from the frame and
base while lifting away the complete arm
system.
10. Check the sealing ring. Replace if damaged.
Refitting, complete arm system
The procedure below details how to refit the complete arm system to the robot.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
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.
Continues on next page
3HAC026660-001 Revision: C
127
4 Repair
4.3.3. Replacement of complete arm system
Continued
Action
Note/Illustration
3. Fit the sealing ring properly to the frame. Replace it Art. no. is specified in Required
if damaged.
equipment on page 126.
xx0400001245
•
•
A: Sealing ring
B: Mating surface
4. Lubricate the attachment holes at the mating surface
on the frame with Loctite 574.
5.
CAUTION!
The complete arm system weighs 55 kg! All lifting
equipment used must be sized accordingly!
7. Fit the lower arm against the frame, fit the one
washer and secure with the 12 attachment screws.
12 pcs; M10 x 40, tightening
torque: 70 Nm.
8. Refit the cabling inside the frame and the base.
Detailed in section Refitting,
cable harness in frame and base
on page 119.
9. Fit a new VK-cover to the lower arm.
Art. no. is specified in Required
equipment on page 126.
10. Recalibrate the robot!
Calibration is detailed in a
separate calibration manual,
enclosed with the calibration
tools.
General calibration information is
included in section Calibration
information.
11.
DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in section DANGER - First test run may
cause injury or damage! on page 33.
128
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
6. Fit the lifting slings to the complete arm system and
lift it into position while inserting the cabling into the
frame.
4 Repair
4.4.1. Replacement of complete upper arm
4.4 Upper and lower arm
4.4.1. Replacement of complete upper arm
General
The complete upper arm is considered a spare part, including wrist, gearboxes and motors.
Location of upper arm
The figure below shows the location of the upper arm on the robot and some of the upper arm
components.
A more detailed view of the upper arm may be found in the spare part view Upper arm,
exploded view 2 on page 252 in part 2 of the Product manual.
© Copyright 2006-2008 ABB. All rights reserved.
xx0400001218
A
Arm housing cover, including gaskets for the cover and the contact panel
B
VK cover. Upper arm attachment screws inside
Required equipment
Equipment
Spare part no.
Upper arm, spare
3HAC026567-001
VK-cover
3HAA 2166-23
Sealing ring (V-ring)
3HAB 3732-19
Gasket, upper arm cover 3HAC 022049-001
Art. no.
Note
Includes the wrist unit. All
gearboxes are filled with oil
at delivery.
Note! This upper arm spare
is interchangeable with
upper arm spare with art. no.
3HAC 023630-001. But this
change of upper arm
requires software 5.07.01.
Replace if damaged.
Replace if damaged.
Continues on next page
3HAC026660-001 Revision: C
129
4 Repair
4.4.1. Replacement of complete upper arm
Continued
Equipment
Spare part no.
Gasket, customer
connections
3HAC 022050-001
Art. no.
Note
Replace if damaged.
Grease
3HAB 3537-1 To lubricate the sealing ring
(V-ring).
Locking liquid
-
Lifting slings
-
Loctite 574
Standard toolkit
The contents are defined in
section Standard toolkit on
page 237.
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.
Removal, complete upper arm
The procedure below details how to remove the complete upper arm from the robot.
Action
Note/Illustration
1. Move the upper arm to a horizontal position.
2.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
4. Disconnect all connectors inside the arm
housing and loosen the cabling from straps
and brackets.
The cabling and all connectors inside
the upper arm housing are shown in
the figure Illustration, cabling inside
upper arm housing on page 115.
5. Remove the VK-cover from the lower arm by
pushing it out from the inside.
Pull out the cabling from the arm housing.
Shown in the figure Location of upper
arm on page 129.
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!
Continues on next page
130
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
3. Remove the arm housing cover from the upper Shown in the figure Location of upper
arm.
arm on page 129.
4 Repair
4.4.1. Replacement of complete upper arm
Continued
Action
Note/Illustration
8. Remove the 10 attachment screws (A) and the
single washer (B).
xx0400001219
9. Remove the upper arm, lift it away and place it
securely.
Refitting, complete upper arm
The procedure below details how to refit the complete upper arm to the robot.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Wipe the contact surfaces clean on both the
upper and lower arm.
3.
CAUTION!
© Copyright 2006-2008 ABB. All rights reserved.
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 Required
equipment on page 129.
B: Contact surface.
6. Lubricate the the contact surface, upper arm,
with Loctite 574.
Continues on next page
3HAC026660-001 Revision: C
131
4 Repair
4.4.1. Replacement of complete upper arm
Continued
Action
7. Lift the upper arm to mounting position, fit the
washer (B) and secure the upper arm with the
10 attachment screws (A).
Note/Illustration
10 pcs: M10 x 40.
Tightening torque: 70 Nm.
xx0400001219
8. Run the cabling through the lower arm and into
the arm housing.
9. Connect all the connectors in the arm housing Refitting of the cabling in the upper
and secure the cabling with brackets and straps. arm housing is further detailed in
section Refitting, cable harness in
upper arm housing and lower arm on
page 116.
10. Refit the arm housing cover to the upper arm. Shown in the figure Location of upper
Check the two gaskets in the cover and replace arm on page 129.
them, if damaged.
Spare part no. is specified in section
Required equipment on page 129.
11. Refit a new VK-cover to the lower arm.
Shown in the figure Location of upper
arm on page 129.
Spare part no. is specified in section
Required equipment on page 129.
12. Recalibrate the robot!
Calibration is detailed in a separate
calibration manual, enclosed with the
calibration tools.
General calibration information is
included in section Calibration information.
© Copyright 2006-2008 ABB. All rights reserved.
13.
DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in section DANGER - First test run may
cause injury or damage! on page 33.
132
3HAC026660-001 Revision: C
4 Repair
4.4.2. Replacement of complete upper arm, IRB 1600ID
4.4.2. Replacement of complete upper arm, IRB 1600ID
NOTE!
Recalibration of robot axis 3-6 is required after replacement of upper arm.
Location of upper arm
© Copyright 2006-2008 ABB. All rights reserved.
The complete upper arm is considered a spare part, including wrist, gearboxes and motors.
The figure below shows the location of the upper arm and connection to the lower arm.
xx0700000045
A
VK -Cover
B
Socket head cap screw M10x40
C
Cable harness
D
V-ring
Required equipment
Equipment
Upper arm, spare
Spare part no.
Art. no.
Note
Includes the wrist
unit. All gearboxes
are filled with oil at
delivery.
Continues on next page
3HAC026660-001 Revision: C
133
4 Repair
4.4.2. Replacement of complete upper arm, IRB 1600ID
Continued
Equipment
Spare part no.
Art. no.
Standard tool kit
Note
Contents, standard
toolkit
VK-cover
3HAA 2166-23
V-ring axis 3
3HAB3732-19
Gasket, customer
connections
3HAC 022050-001
Replace if
damaged
Pendulum calibration tool
Remove, complete upper arm
The procedure below details how to remove the complete upper arm from the robot.
Action
Note
1.
DANGER!
Turn off all electric power,
hydraulic and pneumatic pressure
supplies to the robot!
xx0700000075
A. Synchronization mark Axis 3
Continues on next page
134
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
2. Put the manipulator in synchronization position for Axis 3.
4 Repair
4.4.2. Replacement of complete upper arm, IRB 1600ID
Continued
Action
Note
3. Remove the cover arm housing
from the upper arm, using
standard tools.
xx0700000077
A. Cover Arm Housing
B. Torx pan head screw
4. Disconnect all connectors inside
the arm housing and loosen the
cabling from straps and brackets.
Described in section Removal, cable harness
lower arm and upper arm back.
5.
CAUTION!
The complete upper arm weighs
39 kg without any additional
equipment fitted! Use a suitable
lifting device to avoid injury to
personnel!
© Copyright 2006-2008 ABB. All rights reserved.
6. Secure the weight of the arm with
lifting slings.
xx0700000060
Continues on next page
3HAC026660-001 Revision: C
135
4 Repair
4.4.2. Replacement of complete upper arm, IRB 1600ID
Continued
Action
Note
7. Knock out the VK-cover from the
motor side.
8. Remove the 10 attachment screws
(A) and the single washer, use
standard tools.
xx0700000057
A. Socket head cap screw M10x40
9. Carefully remove the upper arm.
Refitting, complete upper arm
The procedure below details how to refit the complete upper arm to the robot.
Action
Note
1. Wipe the contact surfaces clean on
both the upper and lower arm.
2. Attach lifting slings to the upper
arm and lift it.
© Copyright 2006-2008 ABB. All rights reserved.
3. Clean the contact surface.
A
xx0700000076
A. Contact surface.
Continues on next page
136
3HAC026660-001 Revision: C
4 Repair
4.4.2. Replacement of complete upper arm, IRB 1600ID
Continued
Action
Note
4. Carefully refitting the upper arm to
the lower arm, make sure that the
new upper arm is mounted in the
synchronization position.
xx0700000075
A. Synchronization mark Axis 3
© Copyright 2006-2008 ABB. All rights reserved.
5. Refit the 10 attachment screws (A)
and the single washer, use
standard tools.
Tightening torque: 70 Nm
xx0700000057
A. Socket head cap screw M10x40
6. Run the cabling through the lower
arm and into the arm housing.
7. Connect all the connectors in the
arm housing and secure the
cabling with brackets and straps.
Refitting of the cabling in the upper arm housing is
further detailed in section Refitting, cable harness..
Continues on next page
3HAC026660-001 Revision: C
137
4 Repair
4.4.2. Replacement of complete upper arm, IRB 1600ID
Continued
Action
Note
8. Refit the cover arm housing to the
upper arm, using standard tools
Contents, standard toolkit.
xx0700000077
A. Cover Arm Housing
B. Torx pan head screw
9. Refit a new VK-cover to the lower
arm. replace it, if damaged.
Spare part no. is specified in section Required
equipment on page 129.
10. Recalibrate the robot.
Calibration is detailed in a separate calibration
manual, enclosed with the calibration tools.
General calibration information is included in
section Calibration information.
11.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
Make sure all safety requirements
are met when performing the first
test run. These are further detailed
in section DANGER - First test run
may cause injury or damage! on
page 33.
138
3HAC026660-001 Revision: C
4 Repair
4.4.3. Replacement of complete lower arm
4.4.3. Replacement of complete lower arm
Location of lower arm
The lower arm is located on the robot as shown in the figure below.
© Copyright 2006-2008 ABB. All rights reserved.
A more detailed view of the lower arm may be found in the spare part view Lower arm,
exploded view on page 249 in part 2 of the Product manual.
xx0400001246
A
Lower arm
B
VK-cover
C
VK-cover, middle
Required equipment
Equipment
Spare part no.
Note
Lower arm, spare
3HAC 023558-001
IRB 1600 - 7/.12
IRB 1600 - 7/1.45
Lower arm, short, spare
3HAC 023559-001
IRB 1600 - 5/1.2
IRB 1600 - 5/1.45
VK-cover
3HAA 2166-23
VK-cover
3HAA 2166-21
In the middle of the lower arm.
Continues on next page
3HAC026660-001 Revision: C
139
4 Repair
4.4.3. Replacement of complete lower arm
Continued
Equipment
Spare part no.
Note
Sealing ring (V-ring)
3HAB 3732-13
Replace if damaged.
Isopropanol
Used to clean the mating surfaces.
Locking liquid
Loctite 574
Standard toolkit
The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Other tools and procedures
may be required. See
references to these
procedures in the step-bystep instructions below.
These procedures include references
to the tools required.
Removal, lower arm
The procedure below details how to remove the complete lower arm.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Remove the complete upper arm.
Detailed in section Removal,
complete upper arm on page 130.
3. Remove the VK-covers.
Shown in the figure Location of
lower arm on page 139.
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!
© Copyright 2006-2008 ABB. All rights reserved.
CAUTION!
xx0400001247
4. Pull down the cabling through the lower arm and pull
it out.
5.
CAUTION!
The lower arm weighs 20 kg! Use a suitable lifting
device to avoid injury to personnel!
6. Fit the lifting device to the lower arm to secure the
weight of the arm.
7. Unscrew the 12 attachment screws and remove the
single washer.
8. Gently pull out the cabling while lifting away the
lower arm. Be careful with the connectors, they are
sensitive to damage!
Continues on next page
140
3HAC026660-001 Revision: C
4 Repair
4.4.3. Replacement of complete lower arm
Continued
Action
9. Check the sealing ring. Replace it if damaged.
Note/Illustration
Spare part no. is specified in
Required equipment on page
139.
Refitting, lower arm
The procedure below details how to refit the complete lower arm.
Action
Note/Illustration
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 Spare part no. is specified in
damaged.
Required equipment on page
139.
xx0400001245
•
•
A: Sealing ring
B: Mating surface
© Copyright 2006-2008 ABB. All rights reserved.
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.
Spare part no. is specified in
Make sure that the cable bracket inside the lower arm Required equipment on page
139.
is secured beneath the middle VK-cover.
10. Refit the upper arm.
Detailed in section Refitting,
complete upper arm on page
131.
Continues on next page
3HAC026660-001 Revision: C
141
4 Repair
4.4.3. Replacement of complete lower arm
Continued
Action
11. Recalibrate the robot!
Note/Illustration
Calibration is detailed in a
separate calibration manual,
enclosed with the calibration
tools.
General calibration information
is included in section Calibration
information.
12.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in section DANGER - First test run may
cause injury or damage! on page 33.
142
3HAC026660-001 Revision: C
4 Repair
4.4.4. Replacement of wrist unit
4.4.4. Replacement of wrist unit
Location of wrist unit
The wrist unit is located in the frontmost part of the upper arm.
A more detailed view of the upper arm, including the wrist unit, is found in the spare part view
.Upper arm, exploded view 1 on page 251 in part 2 of the Product manual.
xx0600002847
A
Attachment screws, wrist unit (3 pcs)
B
Oil plug (only one shown)
C
Wrist unit
© Copyright 2006-2008 ABB. All rights reserved.
Required equipment
Equipment, etc.
Spare part no.
Wrist, Standard/
Foundry
3HAC 026569-001
Standard and Foundry versions.
O-ring sealingplate not included!
Note! The wrist, standard/
Foundry is not interchangeable
with art. no. 3HAC 10475-1!
O-ring sealingplate
3HAC 025420-001
Must be replaced.
Note! The o-ring sealingplate is
not interchangeable with art.no.
3HAC 7191-1!
Grease
Standard toolkit
Art. no.
Note
3HAC 3537-1 For lubricating the o-ring sealingplate.
The contents are defined in
section Standard toolkit on page
237.
Continues on next page
3HAC026660-001 Revision: C
143
4 Repair
4.4.4. Replacement of wrist unit
Continued
Equipment, etc.
Spare part no.
Art. no.
Other tools and
procedures may be
required. See
references to these
procedures in the
step-by-step instructions below.
Note
These procedures include
references to the tools required.
Removal, wrist unit
The procedure below details how to remove the complete wrist unit.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Drain the oil from the wrist unit.
Detailed in section Oil change, gearbox
axes 5 and 6 on page 97.
3. Remove the wrist unit by unscrewing its
three attachment screws.
Shown in the figure in section Location of
wrist unit on page 143.
Refitting, wrist unit
The procedure below details how to refit the complete wrist unit.
Action
Note
1. Move the robot to a position where the
upper arm is vertical.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the
robot!
3. Lightly lubricate the o-ring sealingplate
with grease.
Art. no. is specified in section Required
equipment on page 143.
4. In order to release the brake, connect the Connect to connector R3.MP5 or 6:
24 VDC power supply to motors:
•
+: 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 143.
3 pcs, M8 x 25, tightening torque: 28 Nm.
6. Perform a leak-down test.
Detailed in section Performing a leak-down
test on page 108.
7. Refill the wrist unit with oil.
Detailed in section Oil change, gearbox axes
5 and 6 on page 97.
Continues on next page
144
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
2.
4 Repair
4.4.4. Replacement of wrist unit
Continued
Action
8. Recalibrate the robot!
Note
Calibration is detailed in a separate
calibration manual, enclosed with the
calibration tools.
General calibration information is included in
section Calibration information.
9.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
Make sure all safety requirements are
met when performing the first test run.
These are further detailed in section
DANGER - First test run may cause
injury or damage! on page 33.
3HAC026660-001 Revision: C
145
4 Repair
4.4.5. Replacement of wrist unit, IRB1600ID
4.4.5. Replacement of wrist unit, IRB1600ID
NOTE!
After replacement of motors/motor or gearbox in a manipulator, recalibration is required.
Location of wrist unit
The wrist unit is located in the frontmost part of the upper arm.
G
B
A
E
F
D
C
A
Upper arm
B
Wrist
C
Motor axis 6
D
Hexagon socket head screw M5x25
E
Hexagon socket head screw M5X16 (10.9) (Short head)
F
Hexagon socket head screw M5x25
G
Hexagon socket head screw M8x35
Required equipment
Equipment
Spare part no. Art. No.
Note
Wrist, ID
O-ring
Grease
Standard toolkit
3HAC3537-1
For lubricating the
o-ring sealing plate.
Contents, standard
toolkit.
Continues on next page
146
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
xx0700000025
4 Repair
4.4.5. Replacement of wrist unit, IRB1600ID
Continued
Equipment
Spare part no. Art. No.
Arm
3HAC9037-1
Other tools and procedures
may be required.
Note
For adjusting the
gear play, motor/
pinion.
See references to
these procedures in
the step-by-step
instructions below.
Loctite 542
12690014-412
Removal, wrist unit
The procedure below details how to remove the complete wrist unit.
Action
Note
1.
DANGER!
Turn of all electric power,
hydraulic and pneumatic
pressure supplies to the
robot!.
2. Remove the AW
equipment in the upper
arm.
Shown in Remove AW Gun on page 160
© Copyright 2006-2008 ABB. All rights reserved.
3. The plug (A) in figure
covering the screw (C).
Remove the plug using
standard tools (B).
Remove the screw for
looking of motor axis 5,
(C) in figure Location of
wrist unit on page 146.
xx0700000092
A. Plug.
B. Standard tool, Contents, standard toolkit.
C. Hexagon socket head screw M5X16 (Short head).
Continues on next page
3HAC026660-001 Revision: C
147
4 Repair
4.4.5. Replacement of wrist unit, IRB1600ID
Continued
Action
Note
4. Remove the VK-Cover
(A).
xx0700000054
A. VK-Cover
5. Gently pull the cables out
of the upper arm VKcover hole.
6. Disconnect through the
VK-hole the cable
harness contacts,
R4.FB6 and R4.MP6.
xx0700000053
© Copyright 2006-2008 ABB. All rights reserved.
A. Contact R4.FB6
B. Contact R4.MP6
7. Remove the three
attachment screws (A).
xx0700000052
A. Hex socket head cap screw M8x35
8. Remove the wrist with
motor 6 from the upper
arm tube.
Continues on next page
148
3HAC026660-001 Revision: C
4 Repair
4.4.5. Replacement of wrist unit, IRB1600ID
Continued
Action
Note
9. Remove the three
screws, hexagon socket
head screw M5x25 (E).
Remove the axis 6 motor
(C).
xx0700000091
A. Contact R4.FB6
B. Contact R4.MP6
C. Motor axis 6
D. Hexagon socket head screw M8x35
E. Hexagon socket head screw M5x25
Refitting, wrist unit
The procedure below details how to refit the complete wrist unit.
Action
Note
1.
© Copyright 2006-2008 ABB. All rights reserved.
NOTE!
If the screws (A) for the Motor
Console (B) are removed, use
Loctite 542 12690014-412 on
the screws when refitting.
Refit the Hex socket head cap
screw M5x25
Tightening torque 4,1 Nm
xx0700000353
A. Hex socket head cap screw M5x25
B. Motor Console
2. Refit the axis 6 motor using
Tightening torque 4,1 Nm
the three hexagon socket
head screw M5x25, shown as
(D) in figure Location of wrist
unit on page 146
Continues on next page
3HAC026660-001 Revision: C
149
4 Repair
4.4.5. Replacement of wrist unit, IRB1600ID
Continued
Action
Note
3. Carefully refit the wrist with
motor to the upper arm tube.
Use a string to pull the cable
harness back through the VKhole in the upper arm tube.
xx0700000093
A. String
4. Use standard tools to refit the Shown as (H) in figure Location of wrist unit on page
three hexagon socket head
146.
screw (M8x35).
Tightening torque 24 Nm
5. Reconnect through the VKhole the cable harness
contacts R4.FB6 and
R4.MP6.
Make sure that all the cabling is placed correctly inside
the upper arm tube.
6. Tightening the hexagon
socket head screw M5X16
(Short head).
Shown as (E) in figure Location of wrist unit on page
146.
Tightening torque 6 Nm
xx0700000092
8. Refit the AW equipment in the Shown in Refitting, wrist unit on page 149
upper arm.
9. Recalibrate the robot.
150
Shown in Introduction, calibration information.
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
7. Tightening the plug (A).
Tightening torque 6 Nm
4 Repair
4.4.6. Replacement of damper, axis 2
4.4.6. Replacement of damper, axis 2
Location of damper, axis 2
The damper, axis 2, is located as shown in the figure below.
xx0400001217
A
Damper, axis 2
B
Attachment screw and washer
© Copyright 2006-2008 ABB. All rights reserved.
Required equipment
Equipment, etc.
Spare part no.
Damper, axis 2
3HAC 022013-001
Note
Standard toolkit
The contents are defined in section
Standard toolkit on page 237.
Other tools and procedures may
be required. See references to
these procedures in the step-bystep instructions below.
These procedures include
references to the tools required.
Removal, damper axis 2
The procedure below details how to remove the damper, axis 2.
Action
Note
1. Run the robot to a position that enables you to access the
attachment screw of damper, axis 2.
Continues on next page
3HAC026660-001 Revision: C
151
4 Repair
4.4.6. Replacement of damper, axis 2
Continued
Action
Note
2.
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure
supplies to the robot!
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
Note
1. Run the robot to a position that enables access to the
attachment screw of the damper, axis 2.
2.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
3. Secure the damper with the attachment screw and
washer.
1 pc: M6 x 16.
4.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
Make sure all safety requirements are met when
performing the first test run. These are further detailed in
section DANGER - First test run may cause injury or
damage! on page 33.
152
3HAC026660-001 Revision: C
4 Repair
4.4.7. Replacement of damper, axis 3
4.4.7. Replacement of damper, axis 3
Location of damper, axis 3
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
Upper arm, exploded view 2 on page 252 in part 2 of the Product manual.
xx0400001215
A
Damper, axis 3
B
Cast tab
© Copyright 2006-2008 ABB. All rights reserved.
Required equipment
Equipment, etc.
Spare part no.
Damper, axis 3
3HAC 022260-001
Standard toolkit
Note
The contents are defined in section
Standard toolkit on page 237.
Removal, damper axis 3
The procedure below details how to remove the damper, axis 3.
Action
1. Run the robot to a position that enables access to
damper, axis 3.
Note
Shown in the figure Location of
damper, axis 3 on page 153.
2.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
Continues on next page
3HAC026660-001 Revision: C
153
4 Repair
4.4.7. Replacement of damper, axis 3
Continued
Action
Note
3. Remove the damper by gently prying it from the cast
tab.
Refitting, damper axis 3
The procedure below details how to refit the damper, axis 3.
Action
Note
1. Run the robot to a position that enables access to the Shown in the figure Location of
location where the damper, axis 3, is fitted.
damper, axis 3 on page 153.
2.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
3. Refit the damper by gently pressing it onto the cast
tab on the upper arm.
4.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in section DANGER - First test run may
cause injury or damage! on page 33.
154
3HAC026660-001 Revision: C
4 Repair
4.4.8. Replacement of Mechanical damper, axis 3, IRB 1600ID
4.4.8. Replacement of Mechanical damper, axis 3, IRB 1600ID
Location of damper, axis 3
The location of damper, axis 3.
A
B
xx0700000043
A
Torx counters. head screw
B
Mechanical damper
Required equipment
© Copyright 2006-2008 ABB. All rights reserved.
Equipment
Mechanical damper
Spare part no.
Art. no.
Note
3HAC027626-001
Standard tools
The contents are defined
in section Standard toolkit
on page 237.
Removal, Mechanical damper axis 3
The procedure below details how to remove the damper, axis 3.
Action
Note
1. Run the robot to a position that enables access to
damper, axis 3.
2.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
Continues on next page
3HAC026660-001 Revision: C
155
4 Repair
4.4.8. Replacement of Mechanical damper, axis 3, IRB 1600ID
Continued
Action
3. Remove the damper.
Note
Use standard tools, Contents,
standard toolkit.
Refitting, Mechanical damper axis 3
The procedure below details how to refit the damper, axis 3.
Action
1. Refit the damper.
Note
Use standard tools, Contents,
standard toolkit.
2.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in section DANGER - First test run may
cause injury or damage! on page 33.
156
3HAC026660-001 Revision: C
4 Repair
4.4.9. Replacement of damper, axis 5
4.4.9. Replacement of damper, axis 5
Location of damper, axis 5
The damper, axis 5, is located as shown in the figure below!
xx0600002806
A
Damper, axis 5
B
Recess
Required equipment
Equipment, etc.
Spare part no.
Damper, axis 5
3HAB 8964-1
Standard toolkit
Note
The contents are defined in section
Standard toolkit on page 237.
Removal, damper axis 5
© Copyright 2006-2008 ABB. All rights reserved.
The procedure below details how to remove the damper, axis 5.
Action
Note
1. Run the robot to a position that enables the end of the Shown in the figure Location of
damper to be pushed into the recess in the wrist unit. damper, axis 5 on page 157.
2.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
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.
Continues on next page
3HAC026660-001 Revision: C
157
4 Repair
4.4.9. Replacement of damper, axis 5
Continued
Refitting, damper axis 5
The procedure below details how to refit the damper, axis 5.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Push the end of the damper into the gap between the
wrist unit and upper arm.
Make sure the damper is
turned the correct way!
3. Manually move the wrist (robot axis 5) in order to pull the
damper into position.
4. Fold out the damper hooks to secure it in position.
5.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
Make sure all safety requirements are met when
performing the first test run. These are further detailed in
section DANGER - First test run may cause injury or
damage! on page 33.
158
3HAC026660-001 Revision: C
4 Repair
4.4.10. Remove upper arm AW Gun
4.4.10. Remove upper arm AW Gun
Location of AW Gun
The location of the AW equipment.
© Copyright 2006-2008 ABB. All rights reserved.
xx0700000153
A
Wire feeder (customer option)
B
Weld gun (BINZEL)
C
Welding cable (BINZEL)
D
Brace (BINZEL)
Required equipment
Equipment
Standard tools
Spare part no.
Art. no.
Note
Contents, standard toolkit.
Continues on next page
3HAC026660-001 Revision: C
159
4 Repair
4.4.10. Remove upper arm AW Gun
Continued
Remove AW Gun
The section below shows how to remove the AW. equipment from the upper arm of a IRB
1600 ID.
Action
Note
1.
DANGER!
Turn off all electric power,
hydraulic and pneumatic
pressure supplies to the robot!
2. Remove the welding cable (C)
from the weld gun by twisting
the locking sleeve (A) counter
clockwise.
Loosen the locking screw (B)
and pull out the welding cable.
xx0700000151
A. Locking sleeve
B. Locking screw
C. Welding cable
© Copyright 2006-2008 ABB. All rights reserved.
3. Remove the two screws
holding the brace.
xx0700000273
A. BINZEL Brace
Continues on next page
160
3HAC026660-001 Revision: C
4 Repair
4.4.10. Remove upper arm AW Gun
Continued
Action
Note
4. Remove the welding cable from
the wire feeder and pull it out.
xx0700000142
A. Wire feeder
B. Welding cable
© Copyright 2006-2008 ABB. All rights reserved.
5. The locking ring (A) has a
thread, loosen it counter
clockwise and remove it.
Remove the locking sleeve (B).
Remove all 6x M5 screw (C).
xx0700000150
A. Locking ring
B. Locking sleeve
C. Screw M5
Refit AW Gun
The section below shows how to refit the AW. equipment to the upper arm of a IRB 1600 ID.
Action
Note
1.
DANGER!
Turn off all electric power,
hydraulic and pneumatic
pressure supplies to the robot.
Continues on next page
3HAC026660-001 Revision: C
161
4 Repair
4.4.10. Remove upper arm AW Gun
Continued
Action
Note
2. Refit the welding gun using the
6X Socket head cap screw M5
(C).
Refit the locking sleeve (B).
Lock the sleeve using the
locking ring (A).
xx0700000150
A. Locking ring
B. Locking sleeve
C. Screw M5
© Copyright 2006-2008 ABB. All rights reserved.
3. Refit the welding cable (C).
Lock the cable using the screw
(B).
xx0700000151
A. Locking sleeve
B. Locking screw
C. Welding cable
4. Refit the brace (A).
xx0700000273
162
3HAC026660-001 Revision: C
4 Repair
4.4.11. Fitting equipment on the robot, IRB 1600ID
4.4.11. Fitting equipment on the robot, IRB 1600ID
Location of shelf, wire feeder
F
C
A
B
E
D
© Copyright 2006-2008 ABB. All rights reserved.
xx0700000311
A
Bracket ESAB wire feeder
B
Shelf, wire feeder
C
Hexagon nut with flange M5
D
Knob
E
Plain washer (8,4x16x1,6)
F
Hex socket head cap screw (M8x12)
Fitting the wire feeder shelf
Action
Note
1. Fit the Shelf, wire feeder
Shown in figure Location of shelf, wire feeder on page 163
(B) using the four (4) Hex
socket head cap screw (F).
Continues on next page
3HAC026660-001 Revision: C
163
4 Repair
4.4.11. Fitting equipment on the robot, IRB 1600ID
Continued
Action
Note
2. Fit the bracket on the wire
feeder using the four (4)
Hexagon nut with flange
(A).
xx0700000312
A. Hexagon nut with flange M5
B. Knob
© Copyright 2006-2008 ABB. All rights reserved.
3. Fit the wire feeder with the
mounted bracket on the
Shelf, wire feeder and
mount the two knobs.
164
3HAC026660-001 Revision: C
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.
© Copyright 2006-2008 ABB. All rights reserved.
A more detailed view of the base may be found in the spare part view Base, exploded view on
page 243 in part 2 of the Product manual.
xx0500001453
A
Base
B
Attachment screws and washer, base-gearbox unit (VK-cover removed)
Required equipment
Equipment
Spare part no.
Base, spare
3HAC 023552-001
V-ring (sealing ring)
3HAB 3732-21
VK-cover
3HAA 2166-26
Lifting slings
Art. no.
Replace if damaged.
-
Locking liquid
Grease
Note
Loctite 574
For sealing the base to the
gearbox 1-2.
3HAB 3537-1
For lubricating the V-ring.
Continues on next page
3HAC026660-001 Revision: C
165
4 Repair
4.5.1. Replacement of base
Continued
Equipment
Spare part no.
Art. no.
Note
Isopropanol
Standard toolkit
For cleaning the mating
surfaces.
-
The contents are defined
in section Standard toolkit
on page 237.
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.
Removal, base
The procedure below details how to remove the base from the robot.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Remove the cabling inside the base and pull it
up to the gearbox unit.
The cable layout in the base is shown
in the figure Illustration, cabling inside
base on page 118.
3. Remove the serial measurement unit.
Detailed in section Removal, serial
measurement unit on page 170.
4. Unfasten the base from the installation site by
removing the attachment bolts from the
foundation.
CAUTION!
The robot weighs 250 kg! All lifting equipment
must be sized accordingly!
6. Fit the lifting slings to the robot, lift it and place it Art. no. is specified in Required
with the side of the lower arm downwards on a equipment on page 165.
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.
Continues on next page
166
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
5.
4 Repair
4.5.1. Replacement of base
Continued
Action
Note
8.
CAUTION!
The base weighs 81 kg! All lifting equipment
used must be sized accordingly!
9. Secure the weight of the base and remove the
gearbox/base attachment screws and washer.
Shown in the figure Location of base
on page 165.
10. Separate the base from the gearbox unit.
Refitting, base
The procedure below details how to refit the base to the robot.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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 Spare part no. is specified in Required
with grease if needed. Replace it if damaged! equipment on page 165.
5. Lubricate the mating surface on the base with
Loctite 574.
© Copyright 2006-2008 ABB. All rights reserved.
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.
Shown in the figure Location of base
on page 165.
16 pcs, M10 x 40, tightening torque:
70 Nm.
9. Refit a new VK-cover to the base.
Spare part no. is specified in Required
equipment on page 165.
10.
CAUTION!
The robot weighs 250 kg! All lifting equipment
must be sized accordingly!
11. Turn the robot to stand upright.
Continues on next page
3HAC026660-001 Revision: C
167
4 Repair
4.5.1. Replacement of base
Continued
Action
12. Secure the base to the foundation.
Note
Attachment bolts and tightening
torque are specified in section
Attachment bolts, specification on
page 50.
13. Pull down the cabling and refit it inside the base. The cable layout inside the base is
shown in the figure Illustration, cabling
inside base on page 118.
14. Refit the serial measurement unit.
Detailed in section Refitting, serial
measurement unit on page 171.
15. Recalibrate the robot.
Calibration is detailed in a separate
calibration manual, enclosed with the
calibration tools.
General calibration information is
included in section Calibration information.
16.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in section DANGER - First test
run may cause injury or damage! on page 33.
168
3HAC026660-001 Revision: C
4 Repair
4.5.2. Replacement of serial measurement unit
4.5.2. Replacement of serial measurement unit
Location of serial measurement unit
The serial measurement unit is located inside the base of the robot, as shown in the figure
below.
A more detailed view of the unit and its position may be found in the spare part view Base,
exploded view on page 243 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
© Copyright 2006-2008 ABB. All rights reserved.
The complete spare part of the serial measurement unit is shown in the figure below.
xx0500001391
A
Connector SMB
B
Connector SMB1-4
C
Connector SMB 3-6
D
Hexagon nuts (totally 4 pcs)
E
Battery pack
Continues on next page
3HAC026660-001 Revision: C
169
4 Repair
4.5.2. Replacement of serial measurement unit
Continued
Required equipment
Equipment
Spare part no.
Serial measurement unit
3HAC 023424-001
Gasket, base cover
3HAC 022047-001
Centering piece
3HAC025815-001
Fitted to the push button unit in order to
align it correctly.
Replace if damaged.
Standard toolkit
-
The contents are defined in section
Standard toolkit on page 237.
Circuit diagram
Note
See chapter Circuit diagram.
Removal, serial measurement unit
The procedure below details how to remove the serial measurement unit from the robot.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
xx0600002744
3. Remove the centering piece (B) from the
push button unit.
xx0600002776
4. Remove the base cover from the robot.
Shown in the figure Location of serial
measurement unit on page 169.
5. Disconnect all the connectors from the
serial measurement unit.
6. Unscrew the four hexagon nuts on the
Shown in the figure Serial measurement
serial measurement unit enough to enable unit layout on page 169.
lifting the unit.
Do not remove the nuts.
Continues on next page
170
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
2. Remove the push button guard (A) from the The guard must be removed to ensure a
base.
correct refitting of the brake release
buttons.
4 Repair
4.5.2. Replacement of serial measurement unit
Continued
Action
Note/Illustration
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
Note/Illustration
1. Fit the serial measurement unit on to the four
pins (A).
© Copyright 2006-2008 ABB. All rights reserved.
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 169.
4. Refit the centering piece (B) to the push button
unit in order to align it vertically.
Also make sure that the unit is correctly
aligned sideways: the measurements x1 and
x2 in the figure to the right should not differ
more than 1 mm from each other!
xx0600002777
Art. no. for the centering piece is
specified in Required equipment on
page 170.
Continues on next page
3HAC026660-001 Revision: C
171
4 Repair
4.5.2. Replacement of serial measurement unit
Continued
Action
Note/Illustration
5. Refit the push button guard to the robot base.
6.
WARNING!
Before continuing any service work, please
observe the safety information in section
WARNING - The brake release buttons may
be jammed after service work on page 34!
7. Check the gasket of the base cover. Replace it Spare part no. is specified in Required
if damaged.
equipment on page 170.
Shown in the figure Location of serial
measurement unit on page 169.
9. Update the revolution counters!
Detailed in section Updating revolution
counters on page 225.
© Copyright 2006-2008 ABB. All rights reserved.
8. Refit the base cover.
172
3HAC026660-001 Revision: C
4 Repair
4.5.3. Replacement of push button unit
4.5.3. Replacement of push button unit
Location of push button unit
The push button unit for brake release is located inside the base of the robot, as shown in the
figure below.
A more detailed view of the component and its location is shown in the spare part view Base,
exploded view on page 243 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
© Copyright 2006-2008 ABB. All rights reserved.
The push button unit is attached to the serial measurement unit as shown in the figure below.
xx0500001394
A
Push button unit
B
Hexagon nuts (2 pcs)
C
Hexagon nuts, SMB unit (4 pcs)
Required equipment
Equipment
Spare part no.
Note
Push button unit
3HAC 020967-001
Includes brake release board and push buttons.
Continues on next page
3HAC026660-001 Revision: C
173
4 Repair
4.5.3. Replacement of push button unit
Continued
Equipment
Spare part no.
Gasket, base cover
3HAC 022047-001
Centering piece
3HAC025815-001
Standard toolkit
Note
Fitted to the push button unit in order to align it
correctly.
Replace if damaged.
The contents are defined in section Standard
toolkit on page 237.
Removal, push button unit
The procedure below details how to remove the push button unit from the robot.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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.
xx0600002744
xx0600002776
4. Remove the base cover from the robot.
Shown in the figure Location of push
button unit on page 173.
5. Disconnect all the connectors from the brake
release board.
6. Unscrew the four hexagon nuts on the SMB
unit enough to enable lifting the unit.
Do not remove the nuts.
Shown in the figure Push button unit on
serial measurement unit on page 173.
Continues on next page
174
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
3. Remove the centering piece (B) from the push
button unit.
4 Repair
4.5.3. Replacement of push button unit
Continued
Action
Note/Illustration
7. Lift and pull the serial measurement unit
backwards, over the lip (A), and lift it away.
xx0500001455
8. Remove the two hexagon nuts from the push
button unit.
Shown in the figure Push button unit on
serial measurement unit on page 173.
9. Remove the push button unit by lifting it up.
Refitting, push button unit
The procedure below details how to refit the push button unit to the robot.
Action
Note
1.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Fit the new push button unit to the serial
measurement unit in the robot base.
Spare part no. is specified in Required
equipment on page 173.
Shown in the figure Push button unit on
serial measurement unit on page 173.
3. Secure the unit with two hexagon nuts.
Shown in the figure Push button unit on
serial measurement unit on page 173.
4. Push in and secure the SMB unit with the four Shown in the figure Push button unit on
hexagon nuts.
serial measurement unit on page 173.
5. Refit the centering piece (B) to the push button
unit in order to align it vertically.
Also make sure that the unit is correctly
aligned sideways: the measurements x1 and
x2 in the figure to the right should not differ
more than 1 mm from each other!
xx0600002777
6. Refit the push button guard to the robot base.
Continues on next page
3HAC026660-001 Revision: C
175
4 Repair
4.5.3. Replacement of push button unit
Continued
Action
Note
7.
WARNING!
Before continuing any service work, please
observe the safety information in section
WARNING - The brake release buttons may
be jammed after service work on page 34!
8. Reconnect all the connectors to the board.
9. Check the gasket of the base cover. Replace Spare part no. is specified in Required
it if damaged.
equipment on page 173.
Shown in the figure Location of push
button unit on page 173.
© Copyright 2006-2008 ABB. All rights reserved.
10. Refit the base cover.
176
3HAC026660-001 Revision: C
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.
© Copyright 2006-2008 ABB. All rights reserved.
A more detailed view of the motor and its position may be found in the spare part view Frame,
exploded view on page 247 in part 2 of the Product manual.
xx0400001256
A
Motor, axis 1
B
Connector plate for motor cabling
C
Cover, frame
D
Attachment screws, motor (4 pcs)
E
Motor cover
Required equipment
Equipment
Spare part no.
Rot. ac motor incl. pinion, 3HAC 023557-001
spare
Cable harness, motor
axes 1-2
3HAC 023754-001
O-ring
21522012-428
Art. no.
Note
Cable harness, motor
axes 1-2 must be
ordered separately.
O-ring, motor.
Replace if damaged.
Continues on next page
3HAC026660-001 Revision: C
177
4 Repair
4.6.1. Replacement of motor, axis 1
Continued
Equipment
Spare part no.
Art. no.
Note
Gasket, gearbox axis 1-2 3HAC 022048-001
Replace if damaged.
Power supply
-
24 VDC, max 1.5 A
For releasing the
brakes.
Isopropanol
-
Used to clean mating
surfaces.
Grease
3HAB 3537-1
Rotation tool, motor
3HAC022266-003
Standard toolkit
-
The contents are
defined in section
Standard toolkit on
page 237.
Circuit diagram
-
See chapter Circuit
diagram.
Removal, motor axis 1
The procedure below details how to remove the motor, axis 1.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Remove the cover, frame.
Shown in the figure Location
of motor on page 177.
3. Disconnect the connectors for the motor, axis 1.
5. In order to release the brakes, connect the 24 VDC power Connect to connector
supply to the motor.
R3.MP1:
• +: pin 7
• -: pin 8
6. Unscrew the four attachment screws from the motor.
Shown in the figure Location
of motor on page 177.
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.
Continues on next page
178
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
4. Loosen the connector plate from the frame and pull out
the motor cabling.
4 Repair
4.6.1. Replacement of motor, axis 1
Continued
Refitting, motor axis 1
The procedure below details how to refit the motor, axis 1.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
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.
Art. no. is specified in Required
equipment on page 177.
4. Remove the motor cover from top of the motor.
Shown in the figure Location of
motor on page 177.
5. In order to release the brakes, connect the 24 VDC Connect to connector R3.MP1:
power supply to the motor.
• +: pin 7
• -: pin 8
6. Fit the rotation tool to the end of the motor shaft.
Art. no. is specified in Required
equipment on page 177.
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.
© Copyright 2006-2008 ABB. All rights reserved.
8. Secure the motor with four attachment screws and 4 pcs, M8 x 25.
washers, but do not tighten yet.
9. Adjust the motor in relation to the gear in the
There should be a barely noticable
gearbox:
gear play.
• 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.
Tightening torque: 35 Nm.
11. Disconnect the brake release voltage.
12. Refit the motor cover to top of the motor.
Shown in the figure Location of
motor on page 177.
13. Insert the motor cabling through the frame and
4 pcs.
secure the connector plate with attachment screws.
14. Connect all the connectors inside the frame.
The cable layout is shown in the
figure Illustration, cabling inside
frame on page 117.
15. Refit the cover, frame. Replace the gasket, if
damaged.
Spare part no. is specified in
Required equipment on page 177.
Continues on next page
3HAC026660-001 Revision: C
179
4 Repair
4.6.1. Replacement of motor, axis 1
Continued
Action
16. Recalibrate the robot!
Note
Calibration is detailed in a
separate calibration manual,
enclosed with the calibration tools.
General calibration information is
included in section Calibration
information.
17.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in section DANGER - First test run may
cause injury or damage! on page 33.
180
3HAC026660-001 Revision: C
4 Repair
4.6.2. Replacement of motor, axis 2
4.6.2. Replacement of motor, axis 2
Location of motor axis 2
The motor axis 2 is located on the front of the robot as shown in the figure below.
A more detailed view of the motor and its position may be found in the spare part view Frame,
exploded view on page 247 in part 2 of the Product manual.
© Copyright 2006-2008 ABB. All rights reserved.
xx0400001257
A
Motor, axis 2
B
Cover, frame
C
Connector plate for motor cabling
D
Bracket and cable tie
E
Motor cover
Required equipment
Equipment, etc.
Spare part no.
Rot. ac motor incl.
pinion, spare
3HAC 023557-001
Art. no.
Note
Cable harness, motor axes 1-2
must be ordered separately.
Cable harness, motor 3HAC 023754-001
axes 1-2
O-ring
21522012-428
Must be replaced when
replacing motor.
Gasket, gearbox axis 3HAC 022048-001
1-2
Replace if damaged.
Grease
3HAB 3537-1
For lubricating the o-ring.
Isopropanol
-
For cleaning mating surfaces.
Standard toolkit
-
The contents are defined in
section Standard toolkit on
page 237.
Rotation tool, motor
3HAC022266003
For adjusting the gear play,
motor/pinion
Continues on next page
3HAC026660-001 Revision: C
181
4 Repair
4.6.2. Replacement of motor, axis 2
Continued
Equipment, etc.
Spare part no.
Power supply
Art. no.
Note
-
24 VDC, 1.5 A.
For releasing the brakes.
Other tools and
procedures may be
required. See
references to these
procedures in the
step-by-step instructions below.
Circuit Diagram
These procedures include
references to the tools
required.
-
See chapter Circuit diagram.
Removal, motor axis 2
The procedure below details how to remove the axis 2 motor.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Remove the cover, frame.
Shown in the figure Location
of motor axis 2 on page 181.
3. Disconnect the motor connectors inside the frame.
Connectors:
• R3.MP2
• R3.FB2
4. Cut any cable ties and remove any brackets or clamps
securing the cables.
5. Remove the connector plate by removing its attachment Shown in the figure Location
screws, and pull the cables out from the frame.
of motor axis 2 on page 181.
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!
7. In order to release the brakes, connect the 24 VDC
power supply to the motor.
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 Location
of motor axis 2 on page 181.
Continues on next page
182
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
6.
4 Repair
4.6.2. Replacement of motor, axis 2
Continued
Action
Note
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.
11. Disconnect the brake release voltage.
12. Remove any remaining oil from the gearbox by
siphoning it off.
Refitting, motor axis 2
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 Art. no. is specified in section
motor is seated properly.
Required equipment on page 181.
Lightly lubricate the o-ring with grease.
3. In order to release the brakes, connect the 24
VDC power supply to the motor.
Connect to connector R3.MP2:
•
+: pin 7
•
-: pin 8
4. Remove the motor cover from top of the motor.
Shown in the figure Location of
motor axis 2 on page 181.
© Copyright 2006-2008 ABB. All rights reserved.
5. Fit the rotation tool to the end of the motor shaft. Art. no. is specified in section
Required equipment on page 181.
6. Fit the motor, making sure the motor pinion is
properly mated to gearbox 2.
Use the rotation tool to rotate the motor pinion,
when mating it to the gear.
Make sure the motor is turned the
right way, i.e. connections upwards.
Make sure the motor pinion does
not get damaged!
7. Secure the motor with four attachment screws
and plain washers, but do not tighten yet.
4 pcs, M8 x 25.
Tightening torque: approx 2 Nm.
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.
There should be a barely noticable
gear play.
9. Refit the motor cover to the top of the motor.
Be careful not to damage the cables!
10. Tighten the motor attachment screws.
Tightening torque: 35 Nm.
11. Disconnect the brake release voltage.
12. Refit the connector plate with its attachment
screws.
Shown in the figure Location of
motor axis 2 on page 181.
13. Reconnect the motor connectors inside the
frame.
Cable layout is shown in the figure
Illustration, cabling inside frame on
page 117.
14. Refit all cable ties, and the bracket underneath
the frame.
Shown in the figure Location of
motor axis 2 on page 181.
Continues on next page
3HAC026660-001 Revision: C
183
4 Repair
4.6.2. Replacement of motor, axis 2
Continued
Action
Note
15. Refit the cover, frame. Replace the gasket, if
damaged.
Shown in the figure Location of
motor axis 2 on page 181.
Art. no. for the gasket is specified in
section Required equipment on
page 181.
16. Perform a leak-down test.
Detailed in section Performing a
leak-down test on page 108.
17. Refill the gearbox with oil.
Type of oil and amount is specified
in section Amount of oil.
18. Recalibrate the robot!
Calibration is detailed in a separate
calibration manual, enclosed with
the calibration tools.
General calibration information is
included in section Calibration information.
19.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in section DANGER - First test run may
cause injury or damage! on page 33.
184
3HAC026660-001 Revision: C
4 Repair
4.6.3. Replacement of motor, axis 3
4.6.3. Replacement of motor, axis 3
Location of motor
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 251 in part 2 of the Product manual.
© Copyright 2006-2008 ABB. All rights reserved.
xx0400001258
A
Motor, axis 3
B
Attachment screws and washers of the motor (4 pcs)
C
Signal connector R3.FB3
D
Power connector R3.MP3
E
Connector holder
F
Upper arm housing cover
G
Cable tie
Required equipment
Equipment
Spare part no.
Art. no.
Note
Rot. ac motor incl
pinion
3HAC 021798-001
O-ring
21522012-426
Replace if damaged.
Gasket, upper arm
cover
3HAC 022049-001
Replace if damaged.
Gasket, customer
connections
3HAC 022050-001
Replace if damaged.
Continues on next page
3HAC026660-001 Revision: C
185
4 Repair
4.6.3. Replacement of motor, axis 3
Continued
Equipment
Spare part no.
Art. no.
Note
Isopropanol
-
Used for cleaning the
mating surfaces.
Grease
3HAB 3537-1
Used for lubricating the oring.
Rotation tool, motor
3HAC022266-003
For adjusting the gear
play.
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.
Circuit diagram
See chapter Circuit
diagram.
Removal, motor axis 3
The procedure below details how to remove the axis 3 motor.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
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.
xx0500001447
4. Remove the upper arm housing cover.
Shown in the figure Location of
motor on page 185.
5. Disconnect the motor connectors R3.MP3 and
R3.FB3.
Shown in the figure Location of
motor on page 185.
Continues on next page
186
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
2. Remove any additional mechanical stops from axis 3.
4 Repair
4.6.3. Replacement of motor, axis 3
Continued
Action
Note
6.
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!
7. In order to release the brakes, connect the 24 VDC
power supply to the motor.
Connect to connector R3.MP3:
• +: 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.
9. Disconnect the brake release voltage.
Refitting, motor axis 3
The procedure below details how to refit the axis 3 motor.
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
Required equipment on page 185.
© Copyright 2006-2008 ABB. All rights reserved.
3. In order to release the brakes, connect the 24 VDC Connect to connector R3.MP3:
power supply to the motor.
• +: 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 4 pcs, M6 x 20.
tighten them yet.
Shown in the figure Location of
motor on page 185.
6. Fit the rotation tool to the end of the motor shaft.
Art. no. is specified in Required
equipment on page 185.
7. Adjust the motor in relation to the gear.
There should be a barely noticable
Use the rotation tool to wiggle the motor shaft back gear play.
and forth to feel the play.
8. Tighten the motor attachment screws.
Tightening torque: 10 Nm.
9. Disconnect the brake release voltage.
10. Reconnect the motor connectors, run and secure Cable layout is shown in the figure
the cabling correctly inside the upper arm housing. Illustration, cabling inside upper
arm housing on page 115.
11. Refit the cover, upper arm housing. Check both the Shown in the figure Location of
gaskets and replace, if damaged.
motor on page 185.
Art. no. is specified in section
Required equipment on page 185.
Continues on next page
3HAC026660-001 Revision: C
187
4 Repair
4.6.3. Replacement of motor, axis 3
Continued
Action
Note
12. Refit any additional mechanical stops.
Detailed in section Installation of
additional mechanical stops on
axis 3 on page 73.
13. Recalibrate the robot!
Calibration is detailed in a separate
calibration manual, enclosed with
the calibration tools.
General calibration information is
included in section Calibration
information.
14.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in section DANGER - First test run may
cause injury or damage! on page 33.
188
3HAC026660-001 Revision: C
4 Repair
4.6.4. Replacement of motor, axis 3, IRB 1600ID
4.6.4. Replacement of motor, axis 3, IRB 1600ID
NOTE!
After replacement of motors/motor in a manipulator, recalibration is required.
Location of motor
The motor of axis 3 is located inside the upper arm housing, as shown in the figure below.
xx0700000008
A
Motor, axis 3
B
Attachment screws and washers of the motor (4 pcs)
C
Signal connector R3.FB3
D
Power connector R3.MP3
E
Connector holder
© Copyright 2006-2008 ABB. All rights reserved.
Required equipment
Equipment
Spare part no.
Rot. ac motor incl
pinion
3HAC 021798-001
O-ring
3HAB3772-100
Isopropanol
Art.no.
Note
Used for cleaning
the mating
surfaces.
Grease
Standard tools
Contents,
standard toolkit
Circuit diagram
Pendulum Calibration
tool
Continues on next page
3HAC026660-001 Revision: C
189
4 Repair
4.6.4. Replacement of motor, axis 3, IRB 1600ID
Continued
Removal, motor axis 3
Action
Note
1.
DANGER!
Turn off all electric power,
hydraulic and pneumatic
pressure supplies to the robot!
2. In order to release the brakes, Connect to connector R3.MP3:
connect the 24 VDC power
• +: pin 7
supply to the motor.
• -: pin 8
3. Remove any additional
mechanical stops from axis 3.
xx0700000010
5. Remove the upper arm
housing cover.
Shown in the figure Location of motor on page 189
6. Disconnect the motor
connectors R3.MP3 and
R3.FB3.
Shown in the figure Location of motor on page 189
Continues on next page
190
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
4. Move:
• axis 2 to calibration
position
• upper arm backwards
against the mechanical
stop
This position enables removal
of the motor without draining
oil of the gearbox, axis 3.
4 Repair
4.6.4. Replacement of motor, axis 3, IRB 1600ID
Continued
Action
Note
7.
DANGER!
Secure the weight of the upper
arm properly before releasing
the brakes of motor, axis 3.
When releasing the holding
brakes of the motor, the upper
arm will be movable and fall
down!
8. Remove the motor, axis 3, by
unscrewing its attachment
screws and washers.
Lift the motor gently straight
out, making sure the motor
pinion is not damaged.
B
C
A
E
D
© Copyright 2006-2008 ABB. All rights reserved.
xx0700000050
A. Hex socket head cap screw
B. O-ring
C. Motor axis 3
D. Resolver cover
E. O-ring
9. Remove the resolver cover for
refitting on the new motor.
10. Disconnect the brake release
voltage.
Refitting, motor axis 3
The procedure below details how to refit the axis 3 motor.
Action
Note
1. Clean the mating surfaces inside the upper arm
housing and on the motor with Isopropanol.
2. Make sure the o-ring on the circumference of the
motor is seated properly. Lubricate it with grease.
Replace the o-ring if damaged.
Part number is specified in section
Required equipment on page 185.
Continues on next page
3HAC026660-001 Revision: C
191
4 Repair
4.6.4. Replacement of motor, axis 3, IRB 1600ID
Continued
Action
Note
3. Fit the new motor to the upper arm housing, making
sure the motor pinion is properly mated to the gear
of axis 3.
4. Fit the attachment screws and washers but do not
tighten them yet.
4 pcs, M6 x 20.
Shown in the figure Location of
motor on page 189.
5. Fit the rotation tool to the end of the motor shaft.
Part number is specified in
Required equipment on page 185.
6. Adjust the motor in relation to the gear.
There should be a barely
Use the rotation tool to wiggle the motor shaft back noticeable gear play.
and forth to feel the play.
7. Tighten the motor attachment screws.
Tightening torque: 10 Nm.
8. Refit the resolver cover on the new motor.
9. Reconnect the motor connectors, run and secure
the cabling correctly inside the upper arm housing.
Cable layout is shown in the figure
Illustration, cabling inside upper
arm housing on page 115.
10. Refit the cover, upper arm housing.
Shown in the figure Location of
motor on page 189.
Art. no. is specified in section
Required equipment on page 185.
11. Refit any additional mechanical stops.
Detailed in section Installation of
additional mechanical stops on
axis 3 on page 73.
12. Recalibrate the robot.
Calibration is detailed in a
separate calibration manual,
enclosed with the calibration
tools.
General calibration information is
included in section Calibration
information.
© Copyright 2006-2008 ABB. All rights reserved.
13.
DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in section DANGER - First test run may
cause injury or damage! on page 33.
192
3HAC026660-001 Revision: C
4 Repair
4.6.5. Replacement of motor, axis 4
4.6.5. Replacement of motor, axis 4
Location of motor
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
Upper arm, exploded view 1 on page 251 in part 2 of the Product manual.
© Copyright 2006-2008 ABB. All rights reserved.
xx0400001273
A
Motor, axis 4
B
Cover, upper arm housing
C
Connector plate
D
Signal connector, R3.FB4
E
Power connector, R3.MP4
F
Attachment screw and washer, motor (4 pcs)
Required equipment
Equipment, etc.
Spare part no.
Art. no.
Note
Rot. ac motor incl pinion 3HAC 021799-001
O-ring
3HAB 3772-81
Replace if damaged.
Gasket, upper arm cover 3HAC 022049-001
Replace if damaged.
Gasket, customer
connections
Replace if damaged.
Grease
3HAC 022050-001
3HAB 3537-1
Used for lubricating the oring.
Continues on next page
3HAC026660-001 Revision: C
193
4 Repair
4.6.5. Replacement of motor, axis 4
Continued
Equipment, etc.
Spare part no.
Art. no.
Note
Standard toolkit
The contents are defined in
section Standard toolkit on
page 237.
Power supply
-
24 VDC, max. 1,5 A.
For releasing the brakes.
Rotation tool, motor
3HAC022266003
For adjusting the gear play.
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.
Circuit Diagram
See chapter Circuit
diagram.
Removal, motor axis 4
The procedure below details how to remove the motor, axis 4.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
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.
4. Remove the connector plate to get access to the
axis 4 motor.
Shown in the figure Location of
motor on page 193.
5. Disconnect the connectors R3.MP4 and R3.FB4
from the axis 4 motor.
6. In order to release the brakes, connect the 24 VDC Connect to connector R3.MP4
power supply to the motor.
• +: pin 7
• -: pin 8
7. Remove the motor, axis 4 by unscrewing the motor Shown in the figure Location of
attachment screws.
motor on page 193.
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!
Continues on next page
194
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
3. Remove the cover from the upper arm housing.
4 Repair
4.6.5. Replacement of motor, axis 4
Continued
Refitting, motor axis 4
The procedure below details how to refit the motor, axis 4.
Action
Note
1. Clean the mating surfaces on the motor and the Shown in the figure Location of motor
gearbox.
on page 193.
2. Make sure the o-ring on the circumference of Art. no. is specified in section
the motor is seated properly. Lightly lubricate
Required equipment on page 193.
the o-ring with grease .
3. In order to release the brakes, connect the 24
VDC power supply to the motor.
Connect to connector R3.MP4
•
+: 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 Location of motor
on page 193.
Tightening torque: approx. 2 Nm.
4 pcs, M6 x 20.
5. Fit the rotational tool to the end of the motor
shaft.
Art. no. is specified in section
Required equipment on page 193.
6. Adjust the motor in relation to the gear in the
There should be a barely noticable
gearbox.
gear play.
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 Location of motor
on page 193.
Tightening torque: 10 Nm.
© Copyright 2006-2008 ABB. All rights reserved.
8. Reconnect the motor connectors R3.MP4 and
R3.FB4.
9. Refit the connector plate.
Shown in the figure Location of motor
on page 193.
10. Make sure all the cabling is placed correctly
inside the upper arm housing.
Cable layout is shown in the figure
Illustration, cabling inside upper arm
housing on page 115.
11. Refit the cover to the upper arm housing. Check Art. no. is specified in Required
both the gaskets and replace, if damaged.
equipment on page 193.
12. Perform a leak-down test.
Detailed in section Performing a leakdown test on page 108.
13. Recalibrate the robot!
Calibration is detailed in a separate
calibration manual, enclosed with the
calibration tools.
General calibration information is
included in section Calibration information.
14.
DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in section DANGER - First test
run may cause injury or damage! on page 33.
3HAC026660-001 Revision: C
195
4 Repair
4.6.6. Replacement of motor, axis 4, 1600ID
4.6.6. Replacement of motor, axis 4, 1600ID
NOTE!
After replacement of motors/motor in a manipulator, recalibration is required.
© Copyright 2006-2008 ABB. All rights reserved.
Location of motor
xx0700000017
A
Motor, axis 4
B
Cover, upper arm housing
C
Connector plate
D
Signal connector, R3.FB4
E
Power connector, R3.MP4
F
Attachment screw and washer, motor (4 pcs)
Continues on next page
196
3HAC026660-001 Revision: C
4 Repair
4.6.6. Replacement of motor, axis 4, 1600ID
Continued
Required equipment
Equipment, etc.
Spare part no.
Art. no.
Note
Rot. ac motor incl pinion 3HAC 021799-001
O-ring
3HAB 3772-81
Standard toolkit
The contents are defined
in section Standard
toolkit on page 237, in
part 2 of the Product
manual.
The contents are defined in
section Standard toolkit on
page 237, in part 2 of the
Product manual.
-
24 VDC, max. 1,5 A.
For releasing the brakes.
Rotation tool, motor
For adjusting the gear play.
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.
Circuit Diagram
Pendulum Calibration
tool
3HAC 4540-1
Removal, motor axis 4
Action
Note
1.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Remove the cover from the upper arm housing.
3. Remove the connector plate to get access to the
axis 4 motor.
Shown in the figure Location of
motor on page 196.
4. Disconnect the connectors R3.MP4 and R3.FB4
from the axis 4 motor.
5. Remove the motor, axis 4 by unscrewing the motor Shown in the figure Location of
attachment screws.
motor on page 196.
6. Lift the motor to get the pinion away from the gear
and disconnect the brake release voltage.
7. Remove the motor by gently lifting it out.
Make sure the motor pinion is not
damaged!
Refitting, motor axis 4
Action
1. Clean the mating surfaces on the motor and the
gearbox.
Note
Shown in the figure Location of
motor on page 196.
Continues on next page
3HAC026660-001 Revision: C
197
4 Repair
4.6.6. Replacement of motor, axis 4, 1600ID
Continued
Action
Note
2. Make sure the o-ring on the circumference of the
Art. no. is specified in section.
motor is seated properly. Lightly lubricate the o-ring
with grease.
3. Fit the motor with the attachment screws and
washers.
Until the motor shaft is adjusted to the gear, as
described in following steps, only tighten the screws
lightly.
Shown in the figure Location of
motor on page 196.
Tightening torque: approx. 2
Nm.
4 pcs, M6 x 20.
4. Tighten the motor attachment screws.
Shown in the figure Location of
motor on page 196.
Tightening torque: 10 Nm.
5. Reconnect the motor connectors R3.MP4 and
R3.FB4.
6. Refit the connector plate.
Shown in the figure Location of
motor on page 196.
7. Refit the cover to the upper arm housing.
General calibration information is
included in section Introduction.
© Copyright 2006-2008 ABB. All rights reserved.
8. Recalibrate the robot.
198
3HAC026660-001 Revision: C
4 Repair
4.6.7. Replacement of motor and timing belt, axis 5
4.6.7. Replacement of motor and timing belt, axis 5
Location of motor
The motor and timing belt of axis 5 is located inside the upper arm housing, as shown in the
figure below.
© Copyright 2006-2008 ABB. All rights reserved.
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 251 in part 2 of the Product manual.
xx0400001279
A
Motor, axis 5
B
Cover, upper arm housing
C
Connector plate
D
Signal cable, motor 5: R3.FB5
E
Power cable, motor 5: R3.MP5
F
Attachment screws and washers, motor bracket (2 pcs)
G
Motor bracket
H
Attachment screws and washers, motor (3 pcs)
Continues on next page
3HAC026660-001 Revision: C
199
4 Repair
4.6.7. Replacement of motor and timing belt, axis 5
Continued
Required equipment
Equipment
Spare part no.
Rot. ac motor incl pinion
3HAC 021800-001
Timing belt
3HAC 021304-001
Art. no.
Note
Gasket, upper arm cover 3HAC 022049-001
Replace if damaged.
Gasket, customer
connections
Replace if damaged.
3HAC 022050-001
Belt tightener
3HAC024044-001
Dynamometer
-
Capacity: 100N
Standard toolkit
The contents are
defined in section
Standard toolkit on
page 237.
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.
Circuit diagram
See chapter Circuit
diagram.
Belt tightener, 3HAC 024044-001
© Copyright 2006-2008 ABB. All rights reserved.
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
Continues on next page
200
3HAC026660-001 Revision: C
4 Repair
4.6.7. Replacement of motor and timing belt, axis 5
Continued
Removal, motor axis 5 and timing belt
The procedure below details how to remove the motor and the timing belt of axis 5.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Remove the axis 4 motor.
Detailed in section Removal, motor
axis 4 on page 194.
3. Remove the motor and timing belt of axis 6.
Detailed in section Removal, motor
and timing belt, axis 6 on page 210.
4. Disconnect the axis 5 motor connectors: R3.MP5
and R3.FB5.
5. Move aside all cabling that is hindering access to
the axis 5 motor.
6. Remove the motor bracket, including the motor,
by unscrewing the two attachment screws and
washers.
Shown in the figure Location of
motor on page 199.
7. Remove the timing belt of axis 5.
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.
Action
Note/Illustration
1.
© Copyright 2006-2008 ABB. All rights reserved.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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.
Continues on next page
3HAC026660-001 Revision: C
201
4 Repair
4.6.7. Replacement of motor and timing belt, axis 5
Continued
Action
Note/Illustration
4. Follow the steps below when fitting the motor: Art. no. is specified in Required
• Place the timing belt (B) round the motor equipment on page 200.
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.
xx0400001280
5. Refit the motor and timing belt of axis 6.
Detailed in section Refitting, motor and
timing belt, axis 6 on page 210.
6. Refit the motor of axis 4.
Detailed in section Refitting, motor
axis 4 on page 195.
7. Reconnect all connectors and place the cabling Cable layout shown in the figure Illuscorrectly inside the upper arm housing.
tration, cabling inside upper arm
housing on page 115.
8. Refit the cover to the upper arm housing.
Check both the gaskets and replace, if
damaged.
Art.no. is specified in Required
equipment on page 200.
9. Recalibrate the robot!
Calibration is detailed in a separate
calibration manual, enclosed with the
calibration tools.
General calibration information is
included in section Calibration information.
10.
DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in section DANGER - First test
run may cause injury or damage! on page 33.
202
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
A. Motor axis 5
B. Timing belt, axis 5
C. Attachment screws and
washers, motor bracket, 2 pcs,
M6 x 20
D. Belt tightener, the dimensions
are shown in the figure Belt
tightener, 3HAC 024044-001
on page 200.
F (Force): 24 N.
4 Repair
4.6.8. Replacement of motor, axis 5, IRB 1600ID
4.6.8. Replacement of motor, axis 5, IRB 1600ID
NOTE!
After replacement of motors/motor in a manipulator, recalibration is required.
Location of motor, axis 5
The motor of axes 5 is located inside the upper arm as shown in the figure below.
© Copyright 2006-2008 ABB. All rights reserved.
xx0700000020
A
Arm Tube
B
Hex socket head cap screw M8X20
C
Cable harness IRB1600ID
D
Rotational ac motor Axis 5
E
Hex. socket head cap screw M6X20
F
O-ring
Cable harness bracket
Required equipment
Equipment, etc.
Spare part no. Art. no.
Rot. ac motor with pinion
Note
Axis 5
VK cover
3HAA2166-19
Standard toolkit
3HAC020812-001
The contents are
defined in section
Standard toolkit on
page 237, in part 2 of
the Product manual.
Continues on next page
3HAC026660-001 Revision: C
203
4 Repair
4.6.8. Replacement of motor, axis 5, IRB 1600ID
Continued
Equipment, etc.
Spare part no. Art. no.
Note
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.
Circuit Diagram
3HAC 6816-3
See chapter Circuit
diagram in the Product
manual, reference
information.
O-ring
3HAB3772-81
Nitrite
Cable grease
Isopropanol
Removal, motor axis 5
The procedure below details how to remove motor, axis 5.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
•
Motors and gears are HOT after running the robot! Touching the motors and gears
may result in burns!
•
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
•
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used.
Action
Note
© Copyright 2006-2008 ABB. All rights reserved.
1. Remove the cover (C) on the back
of the upper arm tube (A). Rotate
the upper arm to access all the
screws (D).
Remove the screws (B) holding the
cable harness.
CAUTION!
After removal of the cover (mec
stop), do not rotate axis 4 do to risk
of cable harness damage.
xx0700000083
A. Arm Tube
B. Torx pan head screw M6X12
C. Cover
D. Torx pan head screw M6X12
Continues on next page
204
3HAC026660-001 Revision: C
4 Repair
4.6.8. Replacement of motor, axis 5, IRB 1600ID
Continued
Action
Note
2.
DANGER!
Turn of all electric power, hydraulic
and pneumatic pressure supplies to
the robot!.
3. Remove the AW equipment from
the upper arm.
Shown in section Remove AW Gun on page 160
4. Disconnect connection R4.FB5 and
R4.MP5, from the backside.
xx0700000080
A. R4.FB5
5. Remove the VK- Cover to access
the cable connections inside the
arm.
xx0700000054
A. VK-Cover
© Copyright 2006-2008 ABB. All rights reserved.
6. Gently pull the cables out of the
upper arm.
7. Disconnect through the hole
connection R4.FB6 and R4.MP6.
xx0700000053
Continues on next page
3HAC026660-001 Revision: C
205
4 Repair
4.6.8. Replacement of motor, axis 5, IRB 1600ID
Continued
Action
Note
8.
CAUTION!
The upper arm tube weighs 12,3 kg
without any additional equipment
fitted. Use a suitable lifting device to
avoid injury to personnel.
9. Secure the weight of the arm with
lifting slings.
xx0700000088
10. Remove the seven (7) Hexagon
socket head cap screw M8X20,
holding the upper arm.
Position (B) in figure Location of motor, axis 5 on
page 203.
11. Remove the upper arm.
A
B
xx0700000248
A. V-ring
B. Support ring
13. Remove the four (4) Hexagon
socket head cap screw M6X20
holding motor 5.
Position (E), (D) in figure Location of motor, axis 5
on page 203
14. Remove the O-ring and change it if Position (F) in figure Location of motor, axis 5 on
necessary.
page 203.
15. Remove the resolver cover for
reuse.
Continues on next page
206
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
12. Remove the V-ring (A) and the
support ring (B).
4 Repair
4.6.8. Replacement of motor, axis 5, IRB 1600ID
Continued
Refitting, motor axis 5
The procedure below details how to refit the motor of axis 5.
Action
Note
1. Clean the mating surfaces inside
the upper arm housing and on the
motor with Isopropanol.
2. Make sure the o-ring on the circum- Replace the o-ring if damaged. Part number is
ference of the motor is seated
specified in section Required equipment on page
properly. Lubricate it with grease.
203.
3. Fit the motor to the upper arm
housing, making sure the motor
pinion is properly mated to the gear
of axis 3.
4. Fit the attachment screws and
washers but do not tighten them
yet.
4 pcs, M6 x 20. Shown in the figure Location of
motor, axis 5 on page 203.
5. Fit the rotation tool to the end of
motor shaft.
Part number is specified in Required equipment on
page 203
6. Adjust the motor in relation to the
There should be a barely noticeable gear play.
gear. Use the rotation tool to wiggle
the motor shaft back and forth to
feel the play.
7. Tighten the motors attachment
scews.
Tightening torque: 10Nm
© Copyright 2006-2008 ABB. All rights reserved.
8. Refit the V-ring and support ring.
9. Refit the cable harness bracket (G)
in figure Location of motor, axis 5 on
page 203, inside the upper arm
tube, use the two torx pan head
screw M6X12 (B). Wind the cable
harness (A), in a spiral with four free
turns around the axis as in figure
Location of motor, axis 5 on page
203 Grease the cable harness with
cable grease.
A
B
xx0700000089
A. Cable harness
B. Torx pan head screw M6X12
10. Refitt the upper arm using the 7 Hex Shown in figure Location of motor, axis 5 on page
socket head cap screw M8X20.
203.
Tightening torque: 24 Nm
11. Reconnect through the VK-hole
connection R4.FB6, and R4.MP6.
Make sure all the cabling is placed
correctly inside the upper arm
housing.
12. Reconnect connection R4.FB5 and
R4.MP5 from the backside.
Continues on next page
3HAC026660-001 Revision: C
207
4 Repair
4.6.8. Replacement of motor, axis 5, IRB 1600ID
Continued
Action
Note
13.
DANGER!
Make sure all safety requirements
are met when performing the first
test run. These are further detailed
in section DANGER - First test run
may cause injury or damage! on
page 33.
14. Refit the cover (mec stop) on the
back of the upper arm tube. Rotate
the upper arm to access all tree
screws.
CAUTION!
Before refitting of the cover (mec
stop), do not over rotate axis 4 do to
risk of cable harness damage.
Calibration is detailed in a separate calibration
manual, enclosed with the calibration tools.
General calibration information is included in
sections described in Introduction.
© Copyright 2006-2008 ABB. All rights reserved.
15. Recalibrate the robot.
208
3HAC026660-001 Revision: C
4 Repair
4.6.9. Replacement of motor and timing belt, axis 6
4.6.9. Replacement of motor and timing belt, axis 6
Location of motor
The motor and timing belt of axis 6 are 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 251 in part 2 of the Product manual.
© Copyright 2006-2008 ABB. All rights reserved.
xx0400001281
A
Motor, axis 6
B
Cover, upper arm housing
C
Connector plate
D
Signal cable, axis 6 motor: R3.FB6
E
Power cable, axis 6 motor: R3.MP6
F
Attachment screws and washers, motor (3 pcs)
G
Distance console with cable bracket and contact panel
H
Cable tie
Required equipment
Equipment
Spare part no.
Rot. ac motor incl pinion
3HAC 021800-001
Timing belt
3HAC 6779-1
Gasket, upper arm cover 3HAC 022049-001
Art. no.
Note
Replace if damaged.
Continues on next page
3HAC026660-001 Revision: C
209
4 Repair
4.6.9. Replacement of motor and timing belt, axis 6
Continued
Equipment
Spare part no.
Gasket, customer
connections
3HAC 022050-001
Art. no.
Note
Replace if damaged.
Hook
3HAC024045-001
Dynamometer
-
Capacity: 100N
Standard toolkit
The contents are
defined in section
Standard toolkit on
page 237.
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.
Circuit diagram
See chapter Circuit
diagram.
Removal, motor and timing belt, axis 6
The procedure below details how to remove the motor and timing belt of axis 6.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
3. Remove the connector plate.
Shown in the figure Location
of motor on page 209.
4. Remove the complete distance console with cable
brackets and contact panel.
Shown in the figure Location
of motor on page 209.
5. Disconnect the motor cables for the axis 6 motor;
R3.MP6 and R3.FB6.
6. Remove the axis 6 motor by unscrewing its three
attachment screws and washers.
7. Remove the timing belt.
Refitting, motor and timing belt, axis 6
The procedure below details how to refit the motor and timing belt of axis 6.
Action
Note/Illustration
1. Clean the mating surfaces on the motor and
in the upper arm housing.
Continues on next page
210
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
2. Remove the cover from the upper arm housing.
4 Repair
4.6.9. Replacement of motor and timing belt, axis 6
Continued
Action
Note/Illustration
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.
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.
Shown in the figure Location of motor on
page 209.
4. Refit the connector plate. Refit the cable tie. Shown in the figure Location of motor on
page 209.
© Copyright 2006-2008 ABB. All rights reserved.
5. Reconnect the motor cables: R3.MP6 and
R3.FB6.
6. Place all the cabling correctly inside the
upper arm housing.
Cable layout is shown in the figure Illustration, cabling inside upper arm housing on
page 115.
7. Refit the cover to the upper arm housing.
Check both the gaskets and replace, if
damaged.
Art. no. is specified in Required equipment
on page 209.
8. Recalibrate the robot!
Calibration is detailed in a separate
calibration manual, enclosed with the
calibration tools.
General calibration information is included
in section Calibration information.
9.
DANGER!
Make sure all safety requirements are met
when performing the first test run. These
are further detailed in section DANGER First test run may cause injury or damage!
on page 33.
3HAC026660-001 Revision: C
211
4 Repair
4.6.10. Replacement of motor, axis 6 IRB 1600ID
4.6.10. Replacement of motor, axis 6 IRB 1600ID
NOTE!
After replacement of motors/motor in a manipulator, recalibration is required.
Location of motor
The motor of axis 6 is located inside the upper arm housing, as shown in the figure below.
G
B
A
E
F
D
C
A
Upper arm
B
Wrist
C
Motor, axis 6
D
Hexagon socket head screw M5x25
E
Hexagon socket head screw M5x16 10.9 (Short head)
F
Hexagon socket head screw M5x25
G
Hexagon socket head screw M8x35
Required equipment
Equipment
Spare part no.
Rot. ac motor incl pinion
3HAC 021800-001
Art. no.
Note
Standard toolkit
Contents, standard
toolkit.
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.
Continues on next page
212
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
xx0700000025
4 Repair
4.6.10. Replacement of motor, axis 6 IRB 1600ID
Continued
Equipment
Spare part no.
Art. no.
Note
Circuit diagram
Removal of motor axis 6
Action
Note
1. Remove the motor according to description in
Removal, wrist unit on page 147
Refitting of motor axis 6
Action
Note
© Copyright 2006-2008 ABB. All rights reserved.
1. Refit the motor according to description in Refitting
of motor axis 6 on page 213.
3HAC026660-001 Revision: C
213
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!
xx0500001400
A
Gearbox unit, axes 1-2
B
Attachment screws and washer, base-gearbox unit (VK-cover is removed)
Required equipment
Equipment
Spare part no.
Gearbox axis 1-2,
spare
3HAC 023555-001
VK-cover
3HAA 2166-26
Isopropanol
Art. no.
Note
Includes:
• gearbox axis 1-2
• V-ring (sealing ring)
• lubricating oil in vessel
• stop arm.
-
For cleaning the mating
surfaces before fitting.
Continues on next page
214
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
A more detailed view of the gearbox and its position may be found in the spare part view
Frame, exploded view on page 247 in part 2 of the Product manual.
4 Repair
4.7.1. Replacement of gearbox, axes 1-2
Continued
Equipment
Spare part no.
Art. no.
Note
Grease
3HAB 3537-1
For lubricating the V-ring.
Locking liquid
-
Loctite 574
Lifting slings
-
Standard toolkit
The contents are defined in
section Standard toolkit on page
237.
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.
Removal, gearbox unit axes 1-2
The procedure below details how to remove the complete gearbox unit, axes 1-2.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Remove the motor, axis 1.
Detailed in section Removal, motor
axis 1 on page 178.
3. Remove the motor, axis 2.
Detailed in section Replacement of
motor, axis 2 on page 181.
4. Remove the complete arm system.
Detailed in section Removal,
complete arm system on page 126.
© Copyright 2006-2008 ABB. All rights reserved.
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.
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.
Continues on next page
3HAC026660-001 Revision: C
215
4 Repair
4.7.1. Replacement of gearbox, axes 1-2
Continued
Action
Note
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.
10. Secure the weight of the base with lifting slings.
11. Remove the gearbox/base attachment screws
and washer.
Shown in the figure Location of
gearbox unit, axes 1-2 on page 214.
12. Separate the base from the gearbox unit.
Refitting, gearbox unit axes 1-2
The procedure below details how to refit the complete gearbox unit, axes 1-2.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
CAUTION!
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 Art. no. is specified in Required
the gearbox unit.
equipment on page 214.
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 Shown in the figure Location of gearbox
it with the attachment screws and the
unit, axes 1-2 on page 214.
washer.
16 pcs, M10 x 40, tightening torque: 70
Nm.
8. Fit a new VK-cover to the base of the robot. Shown in the figure Location of gearbox
unit, axes 1-2 on page 214.
Spare part no. is specified in Required
equipment on page 214.
Continues on next page
216
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
The complete gearbox unit weighs 120 kg
(without the base)! All lifting equipment used
must be sized accordingly!
4 Repair
4.7.1. Replacement of gearbox, axes 1-2
Continued
Action
Note
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!
© Copyright 2006-2008 ABB. All rights reserved.
10. Fit the lifting slings to the base/gearbox unit,
turn it right side up and move it to the installation site.
11. Secure the base to the foundation.
Attachment bolts and the tightening
torque are specified in section
Attachment bolts, specification on page
50.
12. Refit the complete arm system.
Detailed in section Refitting, complete
arm system on page 127.
13. Refit the motors, axes 1 and 2.
Detailed in sections:
• Refitting, motor axis 1 on page 179
• Refitting, motor axis 2 on page
183.
14. Perform a leak-down test.
Detailed in section Performing a leakdown test on page 108.
15. Fill the two gearboxes with oil.
Type of oil and amount is specified in
section Type and amount of oil in
gearboxes.
16. Fill the two gearboxes with oil.
Type of oil and amount is specified in
section Oil in gearboxes on page 95.
17. Recalibrate the robot.
Calibration is detailed in a separate
calibration manual, enclosed with the
calibration tools.
General calibration information is
included in section Calibration information.
18.
DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in section DANGER - First
test run may cause injury or damage! on
page 33.
3HAC026660-001 Revision: C
217
4 Repair
4.7.2. Service work on gearboxes, axes 3, 4, 5 and 6
4.7.2. Service work on gearboxes, axes 3, 4, 5 and 6
Gearboxes, replacement
The gearboxes of axes 3, 4, 5 and 6 are intended to run without requiring any repairs or
maintenance work. This implies that they must under no circumstances be opened or
serviced.
If the gearboxes require replacement:
axes 3 and 4: the complete upper arm is to be replaced. This procedure is detailed in
section Replacement of complete upper arm on page 129.
•
axes 5 and 6: the complete wrist unit is to be replaced. This procedure is detailed in
section Replacement of wrist unit on page 143.
© Copyright 2006-2008 ABB. All rights reserved.
•
218
3HAC026660-001 Revision: C
5 Calibration information
5.1. Introduction
5 Calibration information
5.1. Introduction
General
This chapter includes general information about different calibration methods and also details
procedures that do not require specific calibration equipment.
When the robot system must be recalibrated, it is done according to documentation enclosed
with the calibration tools.
When to calibrate
The system must be calibrated if any of the below occurs.
The resolver values are changed
If resolver values are changed, the robot must be recalibrated using the calibration methods
supplied from ABB. Calibrate the robot carefully with standard calibration. The different
methods are briefly described in section Calibration methods on page 220, and further
detailed in separate Calibration manuals.
If the robot has Absolute Accuracy calibration, it is also recommended but not always needed
to be calibrated for new Absolute Accuracy.
The resolver values will change when parts affecting the calibration position are replaced on
the robot, for example motors, wrist or part of transmission.
Contents of the revolution counter memory are lost
© Copyright 2006-2008 ABB. All rights reserved.
If the contents of the revolution counter memory are lost, the counters must be updated as
detailed in section Updating revolution counters on page 225. This will occur when:
•
the battery is discharged
•
a resolver error occurs
•
the signal between a resolver and measurement board is interrupted
•
a robot axis is moved with the control system disconnected
The revolution counters must also be updated after the robot and controller are connected at
the first installation.
The robot is rebuilt
If the robot has been rebuilt, for example after a crash or when the robot has been changed for
other reachability, it needs to be recalibrated for new resolver values.
If the robot has Abslolute Accuracy calibration, it needs to be calibrated for new Absolute
Accuracy.
3HAC026660-001 Revision: C
219
5 Calibration information
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
Description
Calibration method
Standard
calibration
The calibrated robot is positioned at home
Calibration Pendulum
position, that is the axes positions (angles) are (standard method)
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.
Absolute Accuracy
calibration
(optional)
Based on standard calibration, and besides
CalibWare
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!
xx0400001197
Continues on next page
220
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
Type of
calibration
5 Calibration information
5.2. Calibration methods
Continued
Calibration methods
Each calibration method is detailed in a separate manual. Below is a brief description of the
methods available.
Calibration Pendulum - standard method
Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB
6400R, IRB 640, IRB 1400H and IRB 4400S) and is also the most accurate method for the
standard type of calibration. It is the recommended method in order to achieve proper
performance.
Two different routines are available for the Calibration Pendulum method:
•
Calibration Pendulum II
•
Reference Calibration.
The calibration equipment for Calibration Pendulum is delivered as a complete toolkit,
including the operating manual for Calibration Pendulum, which describes the method and
the different routines further.
CalibWare - Absloute Accuracy calibration
In order to achieve a good positioning in the Cartesian coordinate system, Absolute Accuracy
is used as a TCP calibration. The tool CalibWare guides through the calibration process and
calculates new compensation parameters. This is further detailed in the application manual
Absolute Accuracy Calibware 2.0.
If a service operation is done to a robot with Absolute Accuracy, a new absolute accuracy
calibration is required in order to establish full performance. For most cases after motor and
transmission replacements that do not include taking apart the robot structure, standard
calibration is sufficient. Standard calibration also supports wrist exchange.
References
© Copyright 2006-2008 ABB. All rights reserved.
Article numbers for the calibration tools are listed in section Special tools on page 238 in part
2 of the Product manual.
The calibration equipment for Calibration Pendulum is delivered as a complete toolkit,
including Operating manual - Calibration Pendulum, which describes the method and the
different routines further.
3HAC026660-001 Revision: C
221
5 Calibration information
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
© Copyright 2006-2008 ABB. All rights reserved.
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.
xx0600002876
Continues on next page
222
3HAC026660-001 Revision: C
5 Calibration information
5.3. Calibration scales and correct axis position
Continued
Calibration scales, IRB 1600ID
The illustration below shows the calibration marks and correct positions of the six axes of the
robot. The marks shown in the figure are numbered according to the number of the axes.
2
1
3
© Copyright 2006-2008 ABB. All rights reserved.
4
5
6
xx0700000095
3HAC026660-001 Revision: C
223
5 Calibration information
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
© Copyright 2006-2008 ABB. All rights reserved.
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
224
3HAC026660-001 Revision: C
5 Calibration information
5.5. Updating revolution counters
5.5. Updating revolution counters
General
This section details how to perform a rough calibration of each robot axis, that is updating the
revolution counter value for each axis, using the pendant.
Step 1 - Manually running the robot to the calibration position
This procedure details the first step when updating the revolution counter; manually running
the robot to the calibration position.
Action
Note
1. Select axis-by-axis motion mode.
2. Jog the robot to place the calibration marks
within the tolerance zone.
Shown in section Calibration scales and
correct axis position on page 222.
3. When all axes are positioned, store the
revolution counter settings.
Detailed in section:
Step 2 - Storing the revolution counter
setting with the FlexPendant on page 225
(RobotWare 5.0).
Correct calibration position of axis 4 and 6
When running the robot to calibration position, it is extremely important to make sure that
axes 4 and 6 of the below mentioned robots are positioned correctly. The axes can be
calibrated at the wrong turn, resulting in wrong calibrated robot.
Make sure the axes are positioned according to the correct calibration values, not only
according to the calibration marks. The correct values are found on a label, located either on
the lower arm or underneath the flange plate on the base.
© Copyright 2006-2008 ABB. All rights reserved.
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
Axis 4
Axis 6
IRB 1600
No
Yes
If the calibration marks seem to be wrong (even if the motor calibration data is correct), try
to rotate the axis one turn, update the revolution counter and check the calibration marks
again (try both directions, if needed).
Step 2 - Storing the revolution counter setting with the FlexPendant
This procedure details the second step when updating the revolution counter; storing the
revolution counter setting with the FlexPendant (RobotWare 5.0).
Action
1. On the ABB menu, tap Calibration.
All mechanical units connected to the system are shown along with their calibration
status.
Continues on next page
3HAC026660-001 Revision: C
225
5 Calibration information
5.5. Updating revolution counters
Continued
Action
2. Tap the mechanical unit in question.
A screen is displayed: tap Rev. Counters.
en0400000771
4. Select the axis to have its revolution counter updated by:
• Ticking in the box to the left
• Tapping Select all to update all axes.
Then tap Update.
5. A dialog box is displayed, warning that the updating operation cannot be undone:
• Tap Update to proceed with updating the revolution counters.
• Tap Cancel to cancel updating the revolution counters.
Tapping Update updates the ticked revolution counters and removes the tick from the
list of axes.
6.
CAUTION!
If a revolution counter is incorrectly updated, it will cause incorrect robot positioning,
which in turn may cause damage or injury!
Check the calibration position very carefully after each update.
See section Checking the calibration position on page 227.
226
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
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.
5 Calibration information
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 The calibration marks are shown in
correctly. If they do not, update the revolution
section Calibration scales and
counters!
correct axis position on page 222.
How to update the revolution
counters is detailed in section
Updating revolution counters on
page 225.
Using the Jogging window on the FlexPendant, IRC5
© Copyright 2006-2008 ABB. All rights reserved.
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!
3HAC026660-001 Revision: C
The calibration marks are
shown in section Calibration
scales and correct axis
position on page 222.
How to update the counters
is detailed in section
Updating revolution counters
on page 225.
227
6 Robot description
6.1. Type A of IRB 1600
6 Robot description
6.1. Type A of IRB 1600
Type A - new upper arm and wrist
Type A of IRB 1600 have a new upper arm, complete and a new wrist unit. As a result of this,
the following parts differ from earlier versions:
•
Upper arm, complete
•
Wrist unit
•
O-ring sealingplate
How to know which type the robot is?
The identification plate on the cabinet and the lower arm of the robot tells if the robot has a
new upper arm and wrist or not.
Those robots with a new upper arm and wrist are named IRB 1600, type A.
Those robots which are not equipped with a new upper arm and wrist are simply named IRB
1600 (no type specified).
Which parts are interchangeable and which are not?
The following parts are interchangeable.
•
The upper arm, complete with spare part no. 3HAC026567-001 is interchangeable
with spare part no. 3HAC023630-001. Note! Software version 5.07.01 is needed!
© Copyright 2006-2008 ABB. All rights reserved.
The following parts are not interchangeable:
•
The wrist unit with spare part no. 3HAC026569-001 is not interchangeable with spare
part no. 3HAC10475-1.
•
The o-ring sealingplate with spare part no. 3HAC025420-001 is not interchangeable
with spare part no. 3HAC 7191-1.
Other changes in this product manual, compared to product manual IRB 1600, 3HAC023637-001
The content in this product manual is the same as in the product manual with art. no.
3HAC023637-001, except for the new upper arm complete and the new wrist unit for type A.
In order to distinguish IRB 1600 type A from earlier versions, a new art. no. has been created.
There has been a few other changes in the manual, not related to the IRB 1600 type A. These
changes are described below:
•
The cable harness for motors axes 1-2 has got a new spare part no. The motors axes 12 (3HAC023557-001) and the cable harness, motors axes 1-2 (3HAC023754-001)
now have two separate spare part no:s.
•
Some cable harnesses have been replaced.
For details, see Base, spare part list on page 242 and Frame, spare part list on page 246.
3HAC026660-001 Revision: C
229
6 Robot description
© Copyright 2006-2008 ABB. All rights reserved.
6.1. Type A of IRB 1600
230
3HAC026660-001 Revision: C
7 Reference information
7.1. Introduction
7 Reference information
7.1. Introduction
General
This chapter includes general information, complementing the more specific information in
the different procedures in the manual.
7.2. Applicable safety standards
© Copyright 2006-2008 ABB. All rights reserved.
Health and safety standards, robot
The robot, controlled by the IRC5, conforms to the following standards:
Standard
Description
EN ISO 12100-1
Safety of machinery, terminology
EN ISO 12100-2
Safety of machinery, technical specifications
EN 954-1
Safety of machinery, safety related parts of control systems
EN ISO 10218-1:2006
Robots for industrial environments - Safety requirements - Part
1 Robot
EN ISO 60204-1:2005
Safety of machinery - Electrical equipment of machines - Part 1
General requirements
EN 61000-6-4 (option)
EMC, Generic emission
EN 61000-6-2
EMC, Generic immunity
Standard
Description
IEC 204-1
Electrical equipment of industrial machines
IEC 529
Degrees of protection provided by enclosures
Standard
Description
ISO 9787
Manipulating industrial robots, coordinate systems and motions
Standard
Description
ANSI/RIA 15.06/1999
Safety Requirements for Industrial Robots and Robot Systems
ANSI/UL 1740-1998
(option)
Safety Standard for Robots and Robotic Equipment (Max.
payload 6 kg fulfilment).
CAN/CSA Z 434-03
(option)
Industrial Robots and Robot Systems - General Safety Requirements (Max. payload 6 kg fulfilment).
3HAC026660-001 Revision: C
231
7 Reference information
7.3. Unit conversion
7.3. Unit conversion
Converter table
Use the table below to convert units used in this manual.
Quantity
Units
Length
1m
3.28 ft
Weight
1 kg
2.21 lb
Pressure
1 bar
100 kPa
Force
1N
0.738 lbf
Moment
1 Nm
0.738 lbf-tn
Volume
1L
0.264 US gal
39.37 in
© Copyright 2006-2008 ABB. All rights reserved.
14.5 psi
232
3HAC026660-001 Revision: C
7 Reference information
7.4. Screw joints
7.4. Screw joints
General
This section details how to tighten the various types of screw joints on the robot.
The instructions and torque values are valid for screw joints comprised of metallic materials
and do not apply to soft or brittle materials.
UNBRAKO screws
UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It
features special surface treatment (Gleitmo as described below), and is extremely resistant to
fatigue.
Whenever used, this is specified in the instructions, and in such cases, no other type of
replacement screw is allowed! Using other types of screws will void any warranty and may
potentially cause serious damage or injury!
Gleitmo treated screws
Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.
Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this
the screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should
be used.
Screws lubricated in other ways
Screws lubricated with Molycote 1000 should only be used when specified in the repair,
maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1. Apply lubricant to the screw thread.
© Copyright 2006-2008 ABB. All rights reserved.
2. Apply lubricant between the plain washer and screw head.
3. Tighten to the torque specified in section Tightening torque on page 234 below. Screw
dimensions of M8 or larger must be tightened with a torque wrench. Screw dimensions
of M6 or smaller may be tightened without a torque wrench if this is done by trained
and qualified personnel.
Lubricant
Art. no.
Molycote 1000 (molybdenum disulphide grease)
11712016-618
Continues on next page
3HAC026660-001 Revision: C
233
7 Reference information
7.4. 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, that is do not jerk. Tighten the screw in a slow,
flowing motion.
•
Maximum allowed total deviation from the specified value is 10%!
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with slotted or cross-recess head screws.
Dimension
Tightening torque (Nm)
Class 4.8, oil-lubricated
M2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
Dimension
Tightening torque
(Nm)
Class 8.8, oil-lubricated
Tightening torque
(Nm)
Class 10.9, oil-lubricated
Tightening torque
(Nm)
Class 12.9, oil-lubricated
M5
6
-
-
M6
10
-
-
M8
24
34
40
M10
47
67
80
M12
82
115
140
M16
200
290
340
The table below specifies the recommended standard tightening torque for Molycotelubricated screws with Allen head screws.
Dimension
Tightening torque (Nm)
Tightening torque (Nm)
Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M8
28
34
M10
55
66
M12
96
115
M16
235
280
Continues on next page
234
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with Allen head screws.
7 Reference information
7.4. Screw joints
Continued
The table below specifies the recommended standard tightening torque for water and air
connectors when one or both connectors are made of brass.
Tightening torque
Nm - Nominal
Tightening torque
Nm - Min.
Tightening torque
Nm - Max.
1/8
12
8
15
1/4
15
10
20
3/8
20
15
25
1/2
40
30
50
3/4
70
55
90
© Copyright 2006-2008 ABB. All rights reserved.
Dimension
3HAC026660-001 Revision: C
235
7 Reference information
7.5. Weight specifications
7.5. Weight specifications
Definition
In installation, repair and maintenance procedures, weights of the components handled are
sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.
To avoid injury, ABB recommends the use of lifting equipment when handling components
with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each
manipulator model.
Example
Below is an example of how a weight specification is presented, inside a procedure table:
Action
Note
CAUTION!
© Copyright 2006-2008 ABB. All rights reserved.
The motor weighs 32 kg! All lifting equipment used
must be sized accordingly!
236
3HAC026660-001 Revision: C
7 Reference information
7.6. Standard toolkit
7.6. Standard toolkit
General
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.
Contents, standard toolkit
Tool
1
Ring-open-end spanner 8-19 mm
1
Socket head cap 2.5-17 mm
1
Torx socket no: 20-60
1
Torque wrench 10-100 Nm
1
Small screwdriver
1
Plastic mallet
1
Ratchet head for torque wrench 1/2
1
Socket head cap no: 5, socket 1/2" bit L 20 mm
1
Socket head cap no: 6, socket 1/2" bit L 20 mm
1
Socket head cap no: 8, socket 1/2" bit L 20 mm
1
Small cutting plier
© Copyright 2006-2008 ABB. All rights reserved.
Qty
3HAC026660-001 Revision: C
237
7 Reference information
7.7. Special tools
7.7. Special tools
General
All service instructions contain lists of tools required to perform the specified activity. The
required tools are a sum of standard tools, defined in section Standard toolkit on page 237,
and of special tools, listed directly in the instructions and also gathered in this section.
Special tools
The table below specifies all the tools, not considered standard, used when performing
service activities on the robot The special tools are also listed directly in the instructions.
Description
Art. no.
Note
Rotation tool, motor
3HAC022266-003
Used to adjust the gear play on all
motors.
Dynamometer
-
Capacity: 100N
Hook
3HAC024045-001
Used to tighten the timing belt of axis 6,
together with the dynamometer.
Belt tightener
3HAC024044-001
Used to tighten the timing belt of axis 5,
together with the dynamometer.
Lifting tool, gearbox
3HAC023364-001
Lifting tool, upper arm
3HAC023386-001
Calibration equipment, Calibration Pendulum
The table below specifies the calibration equipment needed when calibrating the robot with
the Calibration Pendulum method.
Art. no.
Note
Calibration Pendulum toolkit
3HAC15716-1
Complete kit that also includes operating
manual.
© Copyright 2006-2008 ABB. All rights reserved.
Description
238
3HAC026660-001 Revision: C
7 Reference information
7.8. Lifting equipment and lifting instructions
7.8. Lifting equipment and lifting instructions
General
Many repair and maintenance activities require different pieces of lifting equipment, which
are specified in each procedure.
The use of each piece of lifting equipment is not detailed in the activity procedure, but in the
instruction delivered with each piece of lifting equipment.
© Copyright 2006-2008 ABB. All rights reserved.
This implies that the instructions delivered with the lifting equipment should be stored for
later reference.
3HAC026660-001 Revision: C
239
7 Reference information
© Copyright 2006-2008 ABB. All rights reserved.
7.8. Lifting equipment and lifting instructions
240
3HAC026660-001 Revision: C
8 Spare parts and exploded views
8.1. Introduction
8 Spare parts and exploded views
8.1. Introduction
Overview
© Copyright 2006-2008 ABB. All rights reserved.
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.
3HAC026660-001 Revision: C
241
8 Spare parts and exploded views
8.2. Spare parts - base
8.2. Spare parts - base
Base, spare part list
The spare parts for the base are listed below and shown in the following figure.
Item no. Description
Spare part no.
1
Base, spare
3HAC 023552-001
2
Stop pin
3HAB 3258-1
3
Cover base, spare
3HAC 023554-001
4
Gasket, base cover
3HAC 022047-001
6
VK-cover
3HAA 2166-26
7
Serial measurement unit
3HAC 023424-001
8
Push button unit
3HAC 020967-001
9
Battery pack
3HAC 16831-1
11
Push button guard
3HAC 6499-1
12
Signal cable SMB
3HAC 4050-1
13
Torx pan head screw
9ADA 618-56
14
Centering piece
3HAC025815-001
100
Cable harness IRB 1600/1.45
3HAC 021827-001
102
Cable harness IRB 1600/1.45, Customer 3HAC 021828-001
connections
106
Cable harness IRB 1600/1.45, Wire
feeder
3HAC 021830-001
108
Cable harness, Motor 1-2
3HAC 023754-001
109
Cable harness IRB 1600/1.2, Customer
connections
3HAC 021828-003
Dimension
D=180, B=12
Lithium
34x102x63
© Copyright 2006-2008 ABB. All rights reserved.
Steel 8.8-A2F
M6 x 16
Continues on next page
242
3HAC026660-001 Revision: C
8 Spare parts and exploded views
8.2. Spare parts - base
Continued
© Copyright 2006-2008 ABB. All rights reserved.
Base, exploded view
xx0500001382
3HAC026660-001 Revision: C
243
8 Spare parts and exploded views
8.3. Spare parts - base connections
8.3. Spare parts - base connections
Base connections, spare part list
The spare parts for connections at the base are listed below and shown in the following figure.
Item no. Description
Spare part no.
Dimension
80
Gasket
3HAB 9040-1
115x46 T=3
81
Housing 40P
3HAB 6411-1
82
Surface mounted housing HIP. 16/40 AG
3HAC 022964-001
84
Cover, cable harness wire feeder
3HAC 022918-002
85
Cover
3HAC 6823-1
86
Key pin
5217687-9
87
Plug
3HAC 11719-1
88
Protective hood
25222101-8
89
Dust cap
5217649-9
90
Environmental dust cap
3HAA 1001-727
92
Dust cap
3HAA 1001-630
93
Protection cover 40-p
3HAC 7816-1
© Copyright 2006-2008 ABB. All rights reserved.
D=11.4-13
Continues on next page
244
3HAC026660-001 Revision: C
8 Spare parts and exploded views
8.3. Spare parts - base connections
Continued
© Copyright 2006-2008 ABB. All rights reserved.
Base connections, illustrations
xx0500001383
3HAC026660-001 Revision: C
245
8 Spare parts and exploded views
8.4. Spare parts - frame
8.4. Spare parts - frame
Frame, spare part list
The spare parts are listed below and shown in the following figure.
Item no. Description
Spare part no.
Dimension
13
Torx pan head screw
9ADA 618-56
Steel 8.8-A2F
M6 x 16
20
Gearbox axis 1-2, spare
3HAC 023555-001
21
Stop arm
3HAC 022001-001
22
Cover, gearbox axis 1-2
3HAC 023556-001
23
Gasket, gearbox axis 1-2
3HAC 022048-001
24
Damper, axis 2
3HAC 022013-001
25
V-ring (sealing ring)
3HAB 3732-21
V-150A
135x12.8
26
Sealing ring (V-ring)
3HAB 3732-13
V-110-L
99x10.5
27
Rot. ac motor incl. pinion, spare
3HAC 023557-001
27
Rot. ac motor incl. pinion,
Cleanroom
3HAC031018-001
28
O-ring
21522012-428
100-109
Cabling
See section Base, spare
part list on page 242Base,
spare part list on page
242.
108
Cable harness motor 1 - 2
3HAC 023754-001
© Copyright 2006-2008 ABB. All rights reserved.
Nitrile rubber
79.5x3
Continues on next page
246
3HAC026660-001 Revision: C
8 Spare parts and exploded views
8.4. Spare parts - frame
Continued
© Copyright 2006-2008 ABB. All rights reserved.
Frame, exploded view
xx0600002845
3HAC026660-001 Revision: C
247
8 Spare parts and exploded views
8.5. Spare parts - lower arm
8.5. Spare parts - lower arm
Lower arm, spare part list
The spare parts are listed below and shown in the following figure.
Spare part no.
Dimension
40
Lower arm, spare
3HAC 023558-001
41
Lower arm, short, spare
3HAC 023559-001
42
VK-cover
3HAA 2166-23
D=120, B=12
43
VK-cover
3HAA 2166-21
D=68, B=8
100-109
Cabling
See section Base, spare part
list on page 242.
© Copyright 2006-2008 ABB. All rights reserved.
Item no. Description
Continues on next page
248
3HAC026660-001 Revision: C
8 Spare parts and exploded views
8.5. Spare parts - lower arm
Continued
© Copyright 2006-2008 ABB. All rights reserved.
Lower arm, exploded view
xx0500001385
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249
8 Spare parts and exploded views
8.6. Spare parts - upper arm
8.6. Spare parts - upper arm
Spare part list, upper arm
The spare parts listed below are shown in the exploded views, located on the next two pages.
Item no. Description
Spare part no.
Dimension
13
Torx pan head screw
9ADA 618-56
Steel 8.8-A2F
M6 x 16
60
Upper arm, spare
3HAC026567-001
61
Rot. ac motor incl pinion
3HAC 021799-001
62
O-ring
3HAB 3772-81
63
Rot. ac motor incl pinion
3HAC 021800-001
64
Timing belt
3HAC 6779-1
65
Timing belt
3HAC 021304-001
66
O-ring sealingplate
3HAC 025420-001
67
Wrist, Standard/Foundry
3HAC 026569-001
68
Rot. ac motor incl pinion
3HAC 021798-001
69
O-ring
21522012-426
70
Damper, axis 3
3HAC 022260-001
71
Sealing ring (V-ring)
3HAB 3732-19
72
Damper, axis 5
3HAB 8964-1
73
Arm housing cover, spare
3HAC 023560-001
74
Gasket, upper arm cover
3HAC 022049-001
75
Gasket, customer connections
3HAC 022050-001
73
Contact panel
3HAC 022173-001
77
Connector panel
3HAC 022173-002
79
Contact pane, Wire feeder
3HAC 022173-006
88
Protective hood
25222101-8
89
Dust cap
5217649-9
90
Environmental dust cap
3HAA 1001-727
91
Dust cap
5217649-82
94
Plug with o-ring M10
3HAC 022881-003
95
Coupling
3HAB 3333-20
96
Lamp unit
3HAC 022235-001
100-109
Cabling
See section Base, spare
part list on page 242.
Nitrile rubber
D1=41, D2=3
Nitrile rubber
74.5x3
D=11.4-13
Continues on next page
250
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
Flourinated rubber/
V-95A
85x11
8 Spare parts and exploded views
8.6. Spare parts - upper arm
Continued
© Copyright 2006-2008 ABB. All rights reserved.
Upper arm, exploded view 1
xx0600002854
Continues on next page
3HAC026660-001 Revision: C
251
8 Spare parts and exploded views
8.6. Spare parts - upper arm
Continued
© Copyright 2006-2008 ABB. All rights reserved.
Upper arm, exploded view 2
xx0600002856
252
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8 Spare parts and exploded views
8.7. Spare parts - options
8.7. Spare parts - options
General
This section specifies available options for the robot.
Spare parts - options
Description
Spare part no.
Note
213-1
Lamp unit
3HAC022235-001
Installed as detailed in
section Installation of
signal lamp for 1600
(option) on page 62.
431-1
Connection set R2.CP/
R2.CS
3HAC025396-001
Only for standard
connection.
25-3
Position switch, axis 1
3HAC023973-001
Includes 3 switches.
Installed as detailed in
section Installation of
position switch, axis 1 on
page 76.
28-1
Working range limit axis 1
3HAC023110-001
Installed as detailed in
section Installation of
additional mechanical
stops on axis 1 on page
67.
32-1
Working range limit axis 2
3HAC023108-001
Installed as detailed in
section Installation of
additional mechanical
stop on axis 2 on page
70.
34-1
Working range limit axis 3
3HAC023109-001
Installed as detailed in
section Installation of
additional mechanical
stops on axis 3 on page
73.
© Copyright 2006-2008 ABB. All rights reserved.
Option no.
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8 Spare parts and exploded views
8.8. Spare parts - upper arm 1600ID
8.8. Spare parts - upper arm 1600ID
Location of upper arm 1600ID
The location of upper arm 1600ID.
Spare part list, upper arm
The spare parts listed below are shown in the exploded views, located on the next pages.
Item no.
Description
Spare part no.
Part no.
Dimension
1
Wrist.
3HAC027716-001
2
Cable harness IRB
1600ID on page
255
3HAC027523-001
3
Motor axis 3
(Motors and Orings on page 256
3HAC021798-001
4
O-ring motor axis 3
(Motors and Orings on page 256)
2152 2012-426
5
Motor axis 4 and 5
(Motors and Orings on page 256)
3HAC021799-001
6
O-ring motor 4 and
5 (Motors and Orings on page 256)
3HAB3772-81
7
Motor axis 6
3HAC17342-1
8
Cover arm housing 3HAC027874-001
Covers and
mechanical stops
on page 257)
9
Mecanical stop
(Covers and
mechanical stops
on page 257
10
Cover upper arm
tube (Covers and
mechanical stops
on page 257
11
Indicator lamp
(Indicator lamp on
page 258)
3HAC9258-1
12
Sealing ring(V-ring)
axis 3 (Exploaded
view on page 259)
3HAB3732-19
13
V-ring(V 130A) axis
4 (Exploaded view
on page 259)
3HAB3732-25
without motor,
plates and
screws.
plate, no
colour
3HAC027877-001
Continues on next page
254
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
3HAC027626-001
plate, no
colour
8 Spare parts and exploded views
8.8. Spare parts - upper arm 1600ID
Continued
© Copyright 2006-2008 ABB. All rights reserved.
Cable harness IRB 1600ID
xx0700000156
Continues on next page
3HAC026660-001 Revision: C
255
8 Spare parts and exploded views
8.8. Spare parts - upper arm 1600ID
Continued
© Copyright 2006-2008 ABB. All rights reserved.
Motors and O-rings
xx0700000157
Continues on next page
256
3HAC026660-001 Revision: C
8 Spare parts and exploded views
8.8. Spare parts - upper arm 1600ID
Continued
© Copyright 2006-2008 ABB. All rights reserved.
Covers and mechanical stops
xx0700000158
Continues on next page
3HAC026660-001 Revision: C
257
8 Spare parts and exploded views
8.8. Spare parts - upper arm 1600ID
Continued
Indicator lamp
© Copyright 2006-2008 ABB. All rights reserved.
xx0700000159
Continues on next page
258
3HAC026660-001 Revision: C
8 Spare parts and exploded views
8.8. Spare parts - upper arm 1600ID
Continued
Exploaded view
© Copyright 2006-2008 ABB. All rights reserved.
13
12
xx0700000160
3HAC026660-001 Revision: C
259
8 Spare parts and exploded views
© Copyright 2006-2008 ABB. All rights reserved.
8.8. Spare parts - upper arm 1600ID
260
3HAC026660-001 Revision: C
9 Circuit diagram
9.1. Introduction
9 Circuit diagram
9.1. Introduction
Overview
© Copyright 2006-2008 ABB. All rights reserved.
This chapter includes the circuit diagram for the robot.
Continues on next page
3HAC026660-001 Revision: C
261
9 Circuit diagram
9.1. Introduction
© Copyright 2006-2008 ABB. All rights reserved.
Continued
262
3HAC026660-001 Revision: C
The information in this document is subject to change without notice and should not be construed as a
commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document.
Except as may be expressly stated anywhere in this document, nothing herein shall be construed as any
kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a
specific purpose or the like.
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
In no event shall ABB be liable for incidental or consequential damages arising from use of this document.
This document and parts thereof must not be reproduced or copied without ABB's written permission,
and contents therof must not be imparted to a third party nor be used for any unauthorized purpose.
Contravention will be prosecuted.
Additional copies of this document may be obtained from ABB at its then current charge.
© Copyright 2007 ABB ALL right reserved.
ABB Automation Technologies AB
Robotics
SE-721 68 Västerås
Sweden
Lab/Office:
Latest revision:
Status:
2007-03-19
Approved
Prepared by, date:
Approved by, date:
COPYRIGHT page
Title page/cover sheet
Document no.
= IRB1600
Plant:
+ Manipulator
Location:
Sublocation: +
Rev. Ind Page 1
Next 2
Total 15
3HAC021351-003
01
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Customer
:
Robot serial number(s)
:
Drawing number
: Manipulator
Drawing version
:
Manufacture
:
Type
:
Type of installation
:
Control cabinet
:
Mains voltage
:
Supply
:
Control voltage
:
Year of construction
:
Project start
:
Project manager
:
Last revision
:
Designed by
:
sestper
Designed date
:
2007-03-22
Number of pages
:
15
2007-03-22
:
Lab/Office:
Latest revision:
Status:
2007-03-19
Approved
Prepared by, date:
Approved by, date:
TITLE PAGE
Title page/cover sheet
Document no.
= IRB1600
Plant:
+ Manipulator
Location:
Sublocation: +
Rev. Ind Page 2
Next 11
Total 15
3HAC021351-003
01
1
2
3
4
5
6
7
8
R4.MP5
R4.FB5
R3.FB3
R3.FB4
R3.FB5
R3.FB6
IRB 1600 ID
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
R4.MP6
R4.FB6
R3.MP3
R3.MP4
R3.MP5
R3.MP6
R3.H1
R3.H2
R3.FB3
R3.FB4
R3.FB5
R3.FB6
R2.CS
Air R2.CP
R2.CBUS
R3.MP3
R3.MP4
R3.MP5
R3.MP6
R3.H1
R3.H2
R3.MP1
R3.MP2
R3.FB1
R3.FB2
R4.FB1
R1.CP/CS
R1.CBUS
R1.CP
R1.CS
R4.MP1
R4.MP2
R4.FB2
R1.LS
Air
R1.MP R1.SMB
R1.FB1-2
R1.FB3-6
R2.SMB
R2.G
R2.BU
R2.BU1-6
Lab/Office:
Latest revision:
Status:
Manipulator Connection Points
Prepared by, date:
Approved by, date:
Document no.
= Connection Points
Plant:
+ Manipulator
Location:
Sublocation: +
Rev. Ind Page 11
Next 20
Total 15
3HAC021351-003
01
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
2
3
4
5
6
7
8
-BU Brake Release (Simplified)1
-R1.MP
C8
BRAKE REL
BU
C9
BRAKE REL
BU
R2.BU
R2.BU1-6
2
2
A
B8
BRAKE PB
BU
3
3
C10
0V BRAKE
BU
1
1
B7
0V BRAKE
BU
K
Brake Bleed Circuit
EXT LIM 2
BU
B3
EXT LIM 1
BU
C2
LIM 2
BU
C1
LIM 1
BU
K
-1
-
-4
-
-3
-
-5
-
-6
-
-8
-
-7
-
-10
-
-9
-
-11
-
-12
-
-14
-
-13
-
-16
-
-15
3
5
6
K
8
Brake Bleed Circuit
-
-
4
Brake Bleed Circuit
A
GNYE
-2
1
A
B4
2
-BRAKE REL 1 / +AXIS 1/22.1
-0V BRAKE 1 / +AXIS 1/22.1
-BRAKE REL 2 / +AXIS 2/23.2
-0V BRAKE 2 / +AXIS 2/23.2
-PTC2 / +AXIS 2/23.2
-PTC6 / +AXIS 6/27.2
+AXIS 6 IRB1600ID/29.2
-BRAKE REL 3 / +AXIS 3/24.2
7
PE
PE
A
K
10
Brake Bleed Circuit
-BRAKE REL 4 / +AXIS 4/25.2
9
11
12
A
K
14
Brake Bleed Circuit
13
A
K
16
Brake Bleed Circuit
15
Lab/Office:
Latest revision:
Status:
Brake Release Unit
-BRAKE REL 5 / +AXIS 5/26.2
+AXIS 5 IRB1600ID/28.2
-0V BRAKE 5 / +AXIS 5/26.2
+AXIS 5 IRB1600ID/28.2
-BRAKE REL 6 / +AXIS 6/27.2
+AXIS 6 IRB1600ID/29.2
-0V BRAKE 6 / +AXIS 6/27.2
2007-03-19
Approved
Document no.
Prepared by, date:
Approved by, date:
= IRB1600
Plant:
+ BU
Location:
Sublocation: +
Rev. Ind Page 20
Next 21
Total 15
3HAC021351-003
01
1
2
3
4
5
6
7
8
SMB
R2.SMB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
R1.SMB
R2.SMB
A
SDI
WH
9
9
B
SDI-N
BU
5
5
C
SDO
WH
8
8
D
SDO-N
OG
4
4
E
0V
WH
3
3
F
+24V
GN
7
7
K
+BATSUP
GY
6
6
L
0V BATLD
RD
2
2
SIGNAL CABLE AXIS 7 (OPTION)
R1.SMB1.7
R2.FB7
R1.SMB1.7
5
5
X7
BU
A
12
12
0V X7
WH
B
4
4
Y7
WH
C
11
11
0V Y7
OG
D
2
2
0V EXC 2
WH
E
9
9
EXC 2
GN
F
J
M
KEYPIN
G
R2.G(X3)
+
-+
-+
-
R2.G(X3)
0V
2
2
+
1
1
Lab/Office:
Latest revision:
Status:
Serial Measuring Board
2007-03-19
Approved
Document no.
Prepared by, date:
Approved by, date:
= IRB1600
Plant:
+ SMB
Location:
Sublocation: +
Rev. Ind Page 21
Next 22
Total 15
3HAC021351-003
01
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
2
3
4
5
6
7
8
-MU1
-R3.MP1
-R1.MP
A1
A2
A3
-PE
M1R
1.1
M1R
1.10
M1S
1.2
M1S
1.11
M1T
1.3
M1T
1.12
PE
1.8
1
-R4.MP1
M1R
1
1
1
1
R (U)
PE
M
T (W)
3 ~
2
2
M1S
2
2
2
3
3
M1T
3
3
3
9
9
PE
GNYE
PE
PE
S (V)
GNYE
-PE12 / +AXIS 2/23.4
PTC1
B2
1.6
A5
5
5
6
6
-PTC12 / +AXIS 2/23.4
+BU/20.7 / +BU-BRAKE REL 1
BRAKE REL.1
1.4
7
7
BRAKE REL.1 4
7
7
+BU/20.7 / +BU-0V BRAKE 1
0V BRAKE.1
1.5
8
8
0V BRAKE.1
8
8
Brake
5
-FB1
-SMB
-R2.FB1-2
IS 2/23.1
IS 3/24.1
IS 4/25.1
IS 5/26.1
IS 6/27.1
00ID/28.1
00ID/29.1
-R3.FB1
2
2
X1
GY
6
6
X1
14
14
0V X1
WH
1
1
0V X1
WHBU
BU
-R4.FB14
4
1
1
Resolver
3
3
Y1
VT
7
7
Y1
WHOG
5
5
15
15
0V Y1
WH
2
2
0V Y1
OG
2
2
6
6
0V EXC
WH
8
8
0V EXC
GN
6
6
18
18
EXC
BU
3
3
EXC
WHGN
3
3
Lab/Office:
Latest revision:
Status:
Axis 1
2007-03-19
Approved
Document no.
Prepared by, date:
Approved by, date:
= IRB1600
Plant:
+ AXIS 1
Location:
Sublocation: +
Rev. Ind Page 22
Next 23
Total 15
3HAC021351-003
01
1
2
3
4
5
6
7
8
-MU2
-R1.MP
-R3.MP2
A4
D1
D2
M2R
1.13
M2R
1.18
M2S
1.14
M2S
1.19
M2T
1.15
M2T
1.20
1
-R4.MP2
1
M2R
1
1
1
R (U)
PE
M
-PE
2
2
M2S
3
3
M2T
9
9
PE
5
5
T (W)
3 ~
2
2
2
3
3
GNYE
PE
PE
3
S (V)
GNYE
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
+AXIS 1/22.3 / -PE12
+AXIS 1/22.3 / -PTC12
+BU/20.7 / -PTC2
PTC 2
1.22
6
6
+BU/20.7 / +BU-BRAKE REL 2
BRAKE REL.2
1.16
7
7
BRAKE REL.2
4
7
7
+BU/20.7 / +BU-0V BRAKE 2
0V BRAKE.2
1.17
8
8
0V BRAKE.2
5
8
8
A6
Brake
-SMB
-FB2
-R2.FB1-2
+AXIS 1/22.1
-R3.FB2
4
4
X2
GN
6
6
X2
16
16
0V X2
WH
1
1
0V X2
-
WHBU
4
4
BU
1
1
Resolver
5
5
Y2
YE
7
7
Y2
WHOG
5
5
17
17
0V Y2
WH
2
2
0V Y2
OG
2
2
7
7
0V EXC
WH
8
8
0V EXC
GN
6
6
19
19
EXC
OG
3
3
EXC
WHGN
3
3
Lab/Office:
Latest revision:
Status:
Axis 2
2007-03-19
Approved
Document no.
Prepared by, date:
Approved by, date:
= IRB1600
Plant:
+ AXIS 2
Location:
Sublocation: +
Rev. Ind Page 23
Next 24
Total 15
3HAC021351-003
01
1
2
3
4
5
6
7
8
-MP3
-R1.MP
-R3.MP3
M3R
D3
2.10
1
1
R (U)
PE
M
T (W)
3 ~
D4
M3S
2.11
2
2
B1
M3T
2.12
3
3
+AXIS 4/25.5 / -PE43
PE
PE
+AXIS 4/25.5 / -PTC34
5
5
6
6
7
7
8
8
GNYE
-PTC35 / +AXIS 5/26.6
+AXIS 5 IRB1600ID/28.4
B5
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
S (V)
+BU/20.7 / +BU-BRAKE REL 3
BRAKE REL.3
2.13
Brake
-0V BRAKE 3 / +AXIS 6/27.6
+AXIS 6 IRB1600ID/29.3
SIGNAL LAMP (OPTION)
R3.H1
MONLMP
C7
2.6
1
1
1
1
A
K
R3.H2
-SMB
-R3.FB3-6
+AXIS 1/22.1
-
-
11
-
11
X3
RDBN
23
0V X3
RDGN
-
23
-R3.FB3
-
-FB3
6
6
1
1
Resolver
-
-
12
-
25
RDYE
7
7
24
0V Y3
RDGY
2
2
13
0V EXC
BKGY
8
8
25
EXC
BKYE
3
3
-
13
-
Y3
-
24
-
12
-
Lab/Office:
Latest revision:
Status:
Axis 3
2007-03-19
Approved
Document no.
Prepared by, date:
Approved by, date:
= IRB1600
Plant:
+ AXIS 3
Location:
Sublocation: +
Rev. Ind Page 24
Next 25
Total 15
3HAC021351-003
01
1
2
3
4
5
6
7
8
-MU4
-R1.MP
-R3.MP4
M4R
A10
2.14
1
1
R (U)
PE
M
T (W)
3 ~
A9
M4S
2.15
2
2
A8
M4T
2.16
3
3
PE
2.9
9
9
5
5
6
6
7
7
8
8
-PE
S (V)
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-PE43 / +AXIS 3/24.6
+AXIS 6/27.5
+AXIS 6 IRB1600ID/29.4 / -PTC46
B6
-PTC34 / +AXIS 3/24.6
+BU/20.7 / +BU-BRAKE REL 4
BRAKE REL.4
2.17
Brake
-0V BRAKE4 / +AXIS 5/26.6
+AXIS 5 IRB1600ID/28.3
-SMB
-FB4
+AXIS 1/22.1
-
-R2.FB3-6
-
2
-
2
X4
14
0V X4
-
14
-R3.FB4
-
RDBU
RD
6
6
1
1
Resolver
-
-
3
-
19
BKBN
7
7
15
0V Y4
BKGN
2
2
7
0V EXC
BU
8
8
19
EXC
BUPK
3
3
-
7
-
Y4
-
15
-
3
-
-0V EXC45 / +AXIS 5/26.6
+AXIS 5 IRB1600ID/28.3
-EXC45 / +AXIS 5/26.6
+AXIS 5 IRB1600ID/28.3
Lab/Office:
Latest revision:
Status:
Axis 4
2007-03-19
Approved
Document no.
Prepared by, date:
Approved by, date:
= IRB1600
Plant:
+ AXIS 4
Location:
Sublocation: +
Rev. Ind Page 25
Next 26
Total 15
3HAC021351-003
01
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
2
3
4
5
6
7
8
-MU5
-R1.MP
-R3.MP5
M5R
A7
+AXIS 5 IRB1600ID/28.7
1
2.18
1
R (U)
PE
M
T (W)
3 ~
D10
M5S
2.19
2
2
D9
M5T
2.20
3
3
+AXIS 6/27.6 / -PE65
9
9
+AXIS 3/24.5 / +AXIS 3-PTC35
5
5
6
0V PTC
2.22
6
+BU/20.7 / +BU-BRAKE REL 5
BRAKE REL.5
2.21
7
7
+BU/20.7 / +BU-0V BRAKE 5
0V BRAKE 5
2.23
8
8
B9
S (V)
GNYE
C5
Brake
+AXIS 4/25.5 / +AXIS 4-0V BRAKE4
-SMB
+AXIS 1/22.1
-
-R2.FB3-6
-
4
-
-FB5
4
X5
BKPK
+AXIS 5 IRB1600ID/28.7
6
6
16
0V X5
BKBU
1
1
-
16
-R3.FB5
Resolver
-
-
-
-
5
17
5
Y5
17
0V Y5
BKRD
7
7
BK
2
2
+AXIS 4/25.6 / +AXIS 4-0V EXC45
8
8
+AXIS 4/25.6 / +AXIS 4-EXC45
3
3
-0V EXC56 / +AXIS 6/27.6
-EXC56 / +AXIS 6/27.6
Lab/Office:
Latest revision:
Status:
Axis 5
2007-03-19
Approved
Document no.
Prepared by, date:
Approved by, date:
= IRB1600
Plant:
+ AXIS 5
Location:
Sublocation: +
Rev. Ind Page 26
Next 27
Total 15
3HAC021351-003
01
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
2
3
4
5
6
7
-R3.MP6
-R1.MP
M6R
D8
-MU6
+AXIS 6 IRB1600ID/29.7
1
2.1
8
1
R (U)
PE
M
T (W)
3 ~
D7
M6S
2.2
2
2
B10
M6T
2.3
3
3
PE
2.8
9
9
5
5
6
6
-PE
S (V)
GNYE
-PE65 / +AXIS 5/26.6
PTC
+BU/20.7 / +BU-PTC6
2.5
C6
+AXIS 4-PTC46 / +AXIS 4/25.6
+BU/20.7 / +BU-BRAKE REL 6
BRAKE REL.6
2.4
+BU/20.7 / +BU-0V BRAKE 6
0V BRAKE 6
2.7
7
7
8
8
Brake
+AXIS 3/24.5 / +AXIS 3-0V BRAKE 3
-SMB
-FB6
-R2.FB3-6
+AXIS 1/22.1
-
-
9
-
9
BUBN
X6
21
BUGN
0V X6
-
21
R3.FB6
-
+AXIS 6 IRB1600ID/29.7
6
6
1
1
Resolver
-
-
10
22
10
BUYE
Y6
7
7
22
BUGY
0V Y6
2
2
+AXIS 5/26.6 / +AXIS 5-0V EXC56
8
8
+AXIS 5/26.6 / +AXIS 5-EXC56
3
3
-
Lab/Office:
Latest revision:
Status:
Axis 6
2007-03-19
Approved
Document no.
Prepared by, date:
Approved by, date:
= IRB1600
Plant:
+ AXIS 6
Location:
Sublocation: +
Rev. Ind Page 27
Next 28
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3HAC021351-003
01
1
2
3
4
5
6
7
8
-MU5
-R3.MP5
-R1.MP
M5R
A7
2.18
1
-R4.MP5
M5R
1
+AXIS 5/26.7
1
17
1
R (U)
PE
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
M
D10
M5S
2.19
2
2
M5S
18
2
2
D9
M5T
2.20
3
3
M5T
19
3
3
+AXIS 6 IRB1600ID/29.4 / -PE65
9
9
PE
24
9
9
+AXIS 3/24.5 / +AXIS 3-PTC35
5
5
PTC
20
5
5
6
0V PTC
2.22
6
6
PTC
21
6
+BU/20.7 / +BU-BRAKE REL 5
BRAKE REL.5
2.21
7
7
BRAKE REL.5 22
7
7
+BU/20.7 / +BU-0V BRAKE 5
0V BRAKE.2
2.23
8
8
0V BRAKE.5
8
8
B9
T (W)
3 ~
S (V)
GNYE
C5
Brake
23
+AXIS 4/25.5 / +AXIS 4-0V BRAKE4
-SMB
+AXIS 1/22.1
-
-R2.FB3-6
-
4
-
4
X5
BKPK
6
6
X5
GN
16
0V X5
BKBU
1
1
0V X5
WH
-
16
-R3.FB5
-FB5
-R4.FB5
+AXIS
- 5/26.7
6
6
1
1
Resolver
-
-
5
17
BKRD
7
7
Y5
YE
7
7
BK
2
2
0V Y5
WH
2
2
+AXIS 4/25.6 / +AXIS 4-0V EXC45
8
8
0V EXC
WH
8
8
+AXIS 4/25.6 / +AXIS 4-EXC45
3
3
EXC
OG
3
3
5
Y5
17
0V Y5
-
-0V EXC56 / +AXIS 6 IRB1600ID/29.4
-EXC56 / +AXIS 6 IRB1600ID/29.4
Lab/Office:
Latest revision:
Status:
Axis 5 IRB1600ID
2007-03-19
Approved
Document no.
Prepared by, date:
Approved by, date:
= IRB1600
Plant:
+ AXIS 5 IRB1600ID
Location:
Sublocation: +
Rev. Ind Page 28
Next 29
Total 15
3HAC021351-003
01
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
2
3
4
5
6
7
8
-MU6
-R1.MP
-R3.MP6
M6R
D8
2.1
1
-R4.MP6
M6R
1
1
+AXIS 6/27.7
1
1
PE
M
3 ~
D7
M6S
2.2
2
2
M6S
2
2
2
B10
M6T
2.3
3
3
M6T
3
3
3
PE
2.8
9
9
PE
8
9
9
-PE
R (U)
T (W)
S (V)
GNYE
-PE65 / +AXIS 5 IRB1600ID/28.4
PTC
+BU/20.7 / +BU-PTC6
2.5
C6
5
5
PTC
4
5
5
6
6
PTC
5
6
6
+AXIS 4-PTC46 / +AXIS 4/25.6
+BU/20.7 / +BU-BRAKE REL 6
/ +BU-0V BRAKE 6
BRAKE REL.6
2.4
7
7
BRAKE REL.6
6
7
7
0V BRAKE.6
2.7
8
8
0V BRAKE.6
7
8
8
Brake
+AXIS 3/24.5 / +AXIS 3-0V BRAKE 3
-SMB
-FB6
+AXIS 1/22.1
-
-R2.SMB3-6
-
9
-
R3.FB6
9
BUBN
21
BUGN
-
21
R4.FB6
+AXIS 6/27.7
-
X6
6
6
GY
X6
6
6
0V X6
1
1
WH
0V X6
1
1
Resolver
-
-
10
22
10
BUYE
Y6
7
7
VT
Y6
7
7
22
BUGY
0V Y6
2
2
WH
0V Y6
2
2
+AXIS 5 IRB1600ID/28.4 / +AXIS 5 IRB1600ID-0V EXC56
8
8
WH
0V EXC
8
8
+AXIS 5 IRB1600ID/28.4 / +AXIS 5 IRB1600ID-EXC56
3
3
BU
EXC
3
3
-
Lab/Office:
Latest revision:
Status:
Axis 6 IRB1600ID
2007-03-19
Approved
Document no.
Prepared by, date:
Approved by, date:
= IRB1600
Plant:
+ AXIS 6 IRB1600ID
Location:
Sublocation: +
Rev. Ind Page 29
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3HAC021351-003
01
1
2
-R1.CP/CSA1
4
5
-R1.CP/CS-
-R2.CP
CPA
BK
A
B1
CPB
BN
B
C1
CPC
RD
C
D1
CPD
OG
D
A2
CPE
YE
E
B2
CPF
GN
F
C2
CPJ
BU
J
D2
CPK
VT
K
A3
CPH
GY
H
CPG
GNYE
G
B5
CSA
WHBN
C5
CSB
WHRD
B
D5
CSC
WHOG
C
A6
CSD
WHYE
D
B6
CSE
WHGN
E
C6
CSF
WHBU
F
D6
CSG
WHVT
G
A7
CSH
WHGY
H
B7
CSJ
GYBK
J
C7
CSK
GYBN
K
D7
CSL
GYRD
L
A8
CSM
GYOG
M
B8
CSN
GYYE
N
C8
CSP
GYGN
P
D8
CSR
GYBU
R
A9
CSS
GYVT
S
B9
CST
GYWH
T
C9
CSU
GNBK
U
D9
CSV
GNBN
V
A10
CSW
GNRD
W
B10
CSX
GNOG
X
C10
CSY
GNBU
Y
D10
CSZ
GNVT
Z
-
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
3
CUSTOMER CONNECTION
POWER (OPTION)
KUNDANSLUTNING
KRAFT (OPTION)
6
8
-R2.CP
A
CBUS1
A
B
CBUS2
B
C
CP1
C
D
CP2
D
E
CP3
E
F
CP4
F
G
CP5
G
H
CP6
H
A
CUSTOMER CONNECTION
SIGNAL (OPTION)
KUNDANSLUTNING
SIGNAL (OPTION)
Status:
Customer Connections
2007-03-19
Approved
Document no.
Prepared by, date:
Approved by, date:
CUSTOMER CONNECTION
CANBUS (OPTION)
KUNDANSLUTNING
CANBUS (OPTION)
-R2.CS
Lab/Office:
Latest revision:
7
= IRB1600
Plant:
+ CC
Location:
Sublocation: +
Rev. Ind Page 30
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3HAC021351-003
01
1
2
3
4
5
R1.LS
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-PE
6
8
R2.LS1-1
GNYE
A
BK
B
BN
D
BU
C
BK
One
switch
En
brytare
Two
switches
R2.LS1-2
-PE
7
Två
brytare
GNYE
E
BK
F
BN
H
BU
G
BK
Three
switches
Tre
brytare
R2.LS1-3
-PE
GNYE
J
BK
K
BN
M
BU
L
BK
Z
KEY PIN / STIFT
Lab/Office:
Latest revision:
Status:
Position Indicator Axis 1; Option
2007-03-19
Approved
Document no.
Prepared by, date:
Approved by, date:
= IRB1600
Plant:
+ LS
Location:
Sublocation: +
Rev. Ind Page 31
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Total 15
3HAC021351-003
01
Index
A
Absolute Accuracy, calibration 221
Absolute Accuracy, guiding sleeves 51
air connections, pressure 84
arm system
replacing 126
attachment bolts, robot-foundation 50
B
backshells, customer connection 84
base
brake release buttons 47
hole configuration 49
replacing 165
screws, tightening torque 167
spare part number 165
battery pack
replacing 103
replacing, interval 91
spare part number 104
belt tightener axis 5
article number 200
measure 200
brake release unit
releasing the brakes 47
replacing 173
spare part number 173
brakes
testing function 24
brakes, releasing
external power supply to connector R1.MP 48
manually 47
power supply on motor axis 1 178
power supply to motor axis 2 182
power supply to motor axis 3 187
power supply to motor axis 4 194
© Copyright 2006-2008 ABB. All rights reserved.
C
cable harness
inside base, figure 118
inside frame, figure 117
inside upper arm, figure 115
replacing 112
spare part number 112
cabling
inside base, figure 118
inside frame, figure 117
inside upper arm, figure 115
replacing 112
spare part number 112
cabling between robot and controller 81
cabling, robot 81
calibrating
roughly 225
calibration
Absolute Accuracy type 220
marks/scales 222
rough 225
standard type 220
when to calibrate 219
3HAC026660-001 Revision: C
calibration manuals 221
calibration position 225
checking 227
jogging to, FlexPendant 227
scales 222
calibration, Absolute Accuracy 221
CalibWare 220
check, installation site 38
cleaning
robot, interval 91
cleaning, robot 105
complete arm system
replacing 126
connecting the robot and controller, cabling 81
Connection of external safety devices 14
connectors
air 84
customer 84
MIL-C-26482 series 1 85
on robot, figure 79
R2.CS and R2.CP
pins, customer connection 84
Souriau 84
cracks, damper 94
customer connections 79
D
damage, damper 94
damper, axis 2 93
attachment screw 152
replacing 151
spare part number 151
damper, axis 3
inspection 93
replacing 153
spare part number 153
damper, axis 5
inspection 93
replacing 157
spare part number 157
dimensions
guiding sleeves 50
mounting surface 50
robot 56
direction of axes 224
E
environment 39
equipment, robot 56
ESD
damage elimination 35
sensitive equipment 35
wrist strap connection point 35
explanation, safety symbols 30
extra equipment 56
extra loads 55
F
figures
base, hole configuration 49
brake release buttons 47
263
Index
G
gaskets, spare part number
base cover 173
gearbox axis 1-2 177
upper arm cover 209
upper arm customer connections 209
gearbox, axes 1-2
replacing 214
spare part number 214
gearboxes
location on robot, figure 95
type of oil and amount 95
gearboxes, axes 3-6
replacing 218
service work 218
gearboxes, axes 5 and 6
amount and type of oil 97
oil change 97
Gravity Beta 52
H
hole configuration
base 49
I
illustration
base connections 245
illustrations
base, exploded 243
base, hole configuration 49
brake release buttons 47
cabling inside base 118
cabling inside frame 117
cabling inside upper arm housing 115
connectors on robot 79
frame, exploded 247
gearboxes 95
lower arm, exploded 249
mounting surface 50
power supply to connector R1.MP 48
upper arm, exploded 251, 252
inspection 93
264
installation
checking site prior robot installation 38
equipment 56
mechanical stop axis 2 70
mechanical stops axis 3 73
mechanical stops, axis 1 67
position switch axis 1 76
robot, attachment bolts 50
signal lamp 62
intervals, maintenance 91
inverted mounting 52
L
lamp unit
article number 62
installation 62
lifting, robot 45
limitations in working range, tilted and wall mounted 43
loads 55
loads, foundation 38
location of connectors 79
lower arm
removing together with upper arm 126
replacing 139
screws, tightening torque 141
spare part number 139
M
maintenance intervals 91
maintenance schedule 91
measurement system battery pack, replacing 103
measurement system battery pack, spare part number 104
mechanical stop axis 2
article number 71
installation 70
mechanical stop axis 3
article number 75
screws, tightening torque 75
mechanical stops axis 1
article number 68
installation 67
screws, tightening torque 69
mechanical stops axis 2
screws, tightening torque 72
mechanical stops axis 3
installation 73
motor axis 1
brake release with power supply 178
replacing 177
spare part number 177
tightening torque 179
motor axis 2
brake release with power supply 182
replacing 181
spare part number 181
tightening torque 183
motor axis 3
brake release with power supply 187
replacing 185
screws, tightening torque 187, 192
spare part number 185
3HAC026660-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
cabling inside base 118
cabling inside frame 117
cabling inside upper arm housing 115
connectors on robot 79
gearboxes 95
mounting surface 50
power supply to connector R1.MP 48
fitting, equipment 56
FlexPendant
jogging to calibration position 227
MoveAbsJ instruction 227
updating revolution counters 225
foundation
loads 38
requirements 39
frame
replacing 214
spare part number 214
Index
motor axis 4
brake release with power supply 194
replace 193
screws, tightening torque 195, 198
spare part number 193
motor axis 5
replacing 199
screws, tightening torque 202
spare part number 200
motor axis 6
replacing 209
screws, tightening torque 211
spare part number 209
motor connectors 79
mounting, equipment 56
MoveAbsJ instruction
FlexPendant 227
N
negative directions, axes 224
O
oil change
gearbox axes 5 and 6 97
gearboxes, axes 5 and 6, intervals 91
safety risks 36
wrist unit 97
wrist unit, intervals 91
oil in gearboxes
amount 95
article numbers 95
type 95
operating, conditions 39
orienting, robot 49
© Copyright 2006-2008 ABB. All rights reserved.
P
permitted extra loads 55
position switch
axis 1 76
position switch axis 1
article number 76
position, robot 222
when draining wrist unit 98, 101, 102
when filling oil in wrist unit 99
positions at wrist center, 1.2 reach 40
positions at wrist center, 1.45 reach 41
positive directions, axes 224
protection classes, IP class 39
push button unit
releasing the brakes 47
replacing 173
spare part number 173
R
releasing brakes
external power supply to connector R1.MP 48
manually 47
replacing together 126
requirements, foundation 39
restricting working range
axis 1 67, 76
3HAC026660-001 Revision: C
axis 2 70
axis 3 73
revolution counters
storing on FlexPendant 225
updating 225
robot
cleaning 105
connectors 79
dimensions 56
equipment, fitting 56
lifting 45
orienting and securing 49
robot position 222
when draining wrist unit 98, 101, 102
when filling oil in wrist unit 99
S
safety equipment
position switch axis 1 76
Safety, service 14
safety, symbols 30
scales on robot 222
schedule, maintenance 91
securing, robot 49, 50
serial measurement unit
battery pack, replacing 103
battery pack, spare part number 104
replacing 169
spare part number 170
signal connectors 79
signal lamp
article number 62
installation 62
SMB unit
battery pack, replacing 103
battery pack, spare part number 104
replacing 169
spare part number 170
Souriau, connector 84
spare parts
base 242, 243
base connections 244, 245
frame 246, 247
lower arm 248, 249
optional equipment 253
upper arm 250, 251, 252
special tools 238
storage, conditions 39
suspended mounting 52
symbols, safety 30
sync marks 222
system parameter
Gravity Beta 52
T
testing, brakes 24
tightening torques, attachment screws
base-gearbox unit 167
lower arm-frame 141
mechanical stop axis 1 69
mechanical stop axis 2 72
265
Index
mechanical stop axis 3 75
motor axis 1 179
motor axis 2 183
motor axis 3 187, 192
motor axis 4 195, 198
motor axis 5 202
motor axis 6 211
robot to foundation, attachment bolts 50
upper arm 132
wrist unit 144
tilted mounting 52
timing belt axis 5
adjusting the tension 202
replacing 199
spare part number 200
timing belt axis 6
adjusting the tension 211
replacing 209
spare part number 209
tools
belt tightener axis 5, article number 200
belt tightener axis 5, measure 200
Calibration Pendulum equipment 238
dynamometer axis 5 and 6 209
for service 238
hook axis 6, article number 209
rotational tool, article number 193
turning radius 44
screws, tightening torque 144
spare part number 143
U
updating revolution counters 225
upper and lower arm 126
upper arm
removing together with lower arm 126
replacing 129
screws, tightening torque 132
spare part number 129
V
© Copyright 2006-2008 ABB. All rights reserved.
Validity and responsibility 14
VK-covers, spare part number
at base 165
lower arm, lower 139
lower arm, middle 139
lower arm, upper 129
W
wall mounting 52
weight
base 167
complete arm system 127, 128
gearbox unit 216
lower arm 140, 141
robot 38, 46, 166, 167
upper arm 130, 131
working range 43
restricting axis 1 76
wrist unit
amount and type of oil 97
oil change 97
replacing 143
266
3HAC026660-001 Revision: C
3HAC026660-001, Revision C, en
ABB AB
Robotics Products
S-721 68 VÄSTERÅS
SWEDEN
Telephone : +46 (0) 21 344000
Fax : +46 (0) 21 132592