ABB IRB 1200 Product Manual Download Page 6

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Introduction ......................................................................................................

116

3.2

Maintenance schedule .......................................................................................

116

3.2.1

Specification of maintenance intervals ........................................................

117

3.2.2

Maintenance schedule .............................................................................

119

3.3

Inspection activities ...........................................................................................

119

3.3.1

Inspecting the robot paint .........................................................................

120

3.3.2

Inspecting the robot cabling .....................................................................

121

3.3.3

Inspecting the information labels ................................................................

126

3.3.4

Inspecting mechanical stops ....................................................................

129

3.3.5

Inspecting timing belts ............................................................................

132

3.3.6

Inspecting the signal lamp (option) .............................................................

134

3.4

Replacement/changing activities ..........................................................................

134

3.4.1

Replacing the battery pack .......................................................................

144

3.4.2

Replacing the sealing set on tool flange of Hygienic robots .............................

149

3.5

Cleaning activities .............................................................................................

149

3.5.1

Cleaning the IRB 1200 ..............................................................................

152

3.5.2

Cleaning the IRB 1200 with protection type Hygienic ......................................

Introduction ......................................................................................................

158

4.2

General procedures ...........................................................................................

158

4.2.1

Cut the paint or surface on the robot before replacing parts ............................

161

4.2.2

Mounting instructions for sealings ..............................................................

164

4.2.3

Sealing differences depending on protection class ........................................

165

4.2.4

Swing sealing plug for Clean Room, food grade lubrication and Hygienic robots ..

169

4.3

Cable harness ..................................................................................................

169

4.3.1

Replacing the main cable package .............................................................

245

4.3.2

Replacing the axis-4 FPC unit, housing extender unit and housing extender sealings
.............................................................................................................

277

4.3.3

Replacing the axis-5 FPC unit ...................................................................

291

4.3.4

Replacing the EIB/SMB unit ......................................................................

308

4.4

Upper and lower arms ........................................................................................

308

4.4.1

Replacing the lower arm ..........................................................................

377

4.4.2

Replacing the signal lamp ........................................................................

380

4.4.3

Replacing the tubular spare parts ..............................................................

418

4.4.4

Replacing the axis-3 radial sealing and sealing ring ......................................

454

4.4.5

Replacing the axis-2 mechanical stop .........................................................

457

4.4.6

Replacing the axis-3 mechanical stop .........................................................

460

4.4.7

Replacing the axis-4 mechanical stop .........................................................

492

4.5

Swing and base ................................................................................................

492

4.5.1

Replacing the base spare parts (base, axis-1 radial sealing, protection sleeve) ...

572

4.5.2

Replacing the swing spare parts (swing, axis-2 radial sealing) ........................

638

4.5.3

Replacing the axis-1 mechanical stop .........................................................

641

4.6

Motors and gearboxes .......................................................................................

641

4.6.1

Replacing the axis-1 gear unit ....................................................................

642

4.6.2

Replacing the axis-2 drive unit ..................................................................

664

4.6.3

Replacing the axis-3 drive unit ..................................................................

686

4.6.4

Replacing the axis-4 gearbox, drive shaft and pulley .....................................

728

4.6.5

Replacing the axis-4 motor with pulley .......................................................

740

4.6.6

Replacing the axis-4 timing belt .................................................................

758

4.6.7

Replacing the axis-5 motor with pulley .......................................................

771

4.6.8

Replacing the axis-5 timing belt .................................................................

778

4.6.9

Replacing the axis-5 and axis-6 drive unit ...................................................

Introduction to calibration ...................................................................................

805

5.1.1

Introduction and calibration terminology ......................................................

Product manual - IRB 1200

3HAC046983-001 Revision: S

Table of contents

Summary of Contents for IRB 1200

Page 1: ...ROBOTICS Product manual IRB 1200 ...

Page 2: ...Trace back information Workspace 21D version a15 Checked in 2021 12 16 Skribenta version 5 4 005 ...

Page 3: ...0 5 0 9 type A IRB 1200 5 0 9 type B IRB 1200 7 0 7 IRB 1200 7 0 7 type A IRB 1200 7 0 7 type B IRC5 OmniCore Document ID 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved Specifications subject to change without notice ...

Page 4: ...ty by ABB for losses damage 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 Keep for future reference Additional copies of this manual may be obtained f...

Page 5: ...e installation 65 2 3 1 Lifting robot with roundslings 70 2 3 2 Lifting and turning a suspended mounted robot 71 2 3 3 Manually releasing the brakes 74 2 3 4 Orienting and securing the robot 78 2 3 5 Setting the system parameters for a suspended or tilted robot 83 2 3 6 Loads fitted to the robot stopping time and braking distances 84 2 3 7 Fitting of equipment on the robot 84 2 3 7 1 Introduction ...

Page 6: ...ing extender sealings 277 4 3 3 Replacing the axis 5 FPC unit 291 4 3 4 Replacing the EIB SMB unit 308 4 4 Upper and lower arms 308 4 4 1 Replacing the lower arm 377 4 4 2 Replacing the signal lamp 380 4 4 3 Replacing the tubular spare parts 418 4 4 4 Replacing the axis 3 radial sealing and sealing ring 454 4 4 5 Replacing the axis 2 mechanical stop 457 4 4 6 Replacing the axis 3 mechanical stop 4...

Page 7: ...libration method calibrating axis 4 860 5 6 7 Manual calibration method calibrating axis 5 and axis 6 864 5 7 Verifying the calibration 865 5 8 Checking the synchronization position 867 6 Decommissioning 867 6 1 Introduction 868 6 2 Environmental information 870 6 3 Scrapping of robot 871 7 Robot description 871 7 1 Introduction 872 7 2 Type A of IRB 1200 873 7 3 Type B of IRB 1200 874 7 4 Descrip...

Page 9: ...of the IRB 1200 Some variants and designs may have been removed from the business offer and are no longer available for purchase Organization of chapters The manual is organized in the following chapters Contents Chapter 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 ho...

Page 10: ...ety manual for robot Manipulator and IRC5 or OmniCore con troller i 3HAC046307 003 Circuit diagram IRB 1200 3HAC042927 001 Technical reference manual Lubrication in gearboxes 3HAC050948 001 Technical reference manual System parameters i This manual contains all safety instructions from the product manuals for the manipulators and the controllers IRC5 Document ID Document name 3HAC021313 001 Produc...

Page 11: ...t see Creating space for separation of upper and lower arm on page 669 Information also added about refitting the same screws throughout complete manual Information added about releasing the holding brakes prior to ro tating axes manually in calibration procedures chapter Calibration on page 805 Working range of axis 6 corrected from 360 to 400 see Working range on page 59 Information added about ...

Page 12: ...nit on page 642 Replacing the axis 3 drive unit on page 664 and Replacing the axis 4 timing belt on page 740 No need to remove and refit cable bracket when removing and refitting the cable package to the axis 1 sealing ring see Replacing the main cable package on page 169 No need to remove and refit connector plate when removing and refitting the axis 5 motor with pulley see Replacing the axis 4 F...

Page 13: ...f axis 6 corrected to 242 see Working range on page 61 Clean Room option added Food grade lubrication option added Spare part numbers for several gaskets IP67 updated The base the swing and the axis 1 sealing ring are updated due to IP67 improvements C Published in release R16 2 The following updates are done in this revi sion New standard calibration method introduced Axis Calibration See Calibra...

Page 14: ... force control package Updated extra o ring fitting information for robots with protection type Clean Room and robots with food grade lubrication Note added to calibration chapter to emphasize the requirement of equally dressed robot when using previously created reference calibration values Information about myABB Business Portal added Spare part number of axis 4 gearbox shaft changed from 3HAC04...

Page 15: ...Published in release 20C The following updates are made in this revision Flange sealing changed from 12340011 116 Loctite 574 to 3HAC026759 003 Sikaflex 521FC for tubular covers for robots with protection class IP67 and protection type Clean Room Updated the figure of customer connection information N Published in release 20D The following updates are made in this revision Added information about ...

Page 16: ...sioning Reference information safety standards unit conversions screw joints lists of tools Spare parts list with corresponding figures or references to separate spare parts lists References to circuit diagrams Technical reference manuals The technical reference manuals describe reference information for robotics products for example lubrication the RAPID language and system parameters Application...

Page 17: ...s The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters Product manual IRB 1200 17 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved Product documentation Continued ...

Page 18: ... include specific safety information when dangerous steps are to be performed Read more in the chapter Safety on page 19 Illustrations The product is illustrated with general figures that does not take painting or protection type in consideration Likewise certain work methods or general information that is valid for several product models can be illustrated with illustrations that show a different...

Page 19: ...ration of the robot when the safety devices are defective not in their intended location or in any other way not working When instructions for operation and maintenance are not followed Non authorized design modifications of the robot Repairs on the robot and its spare parts carried out by in experienced or non qualified personnel Foreign objects Force majeure Spare parts and equipment ABB supplie...

Page 20: ...uence of alcohol drugs or any other intoxicating substances are not allowed to install maintain service repair or use the robot The plant liable must make sure that the personnel is trained on the robot and on responding to emergency or abnormal situations Personal protective equipment Use personal protective equipment as stated in the instructions 20 Product manual IRB 1200 3HAC046983 001 Revisio...

Page 21: ...d will result in ser ious injury DANGER Signal word used to indicate a potentially hazardous situation which if not avoided could result in serious injury WARNING Signal word used to indicate a potentially hazardous situation related to electrical hazards which if not avoided could result in serious injury ELECTRICAL SHOCK Signal word used to indicate a potentially hazardous situation which if not...

Page 22: ...d to indicate where to find additional information or how to do an operation in an easier way TIP 22 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 1 Safety 1 2 1 Safety signals in the manual Continued ...

Page 23: ...ription Symbol Warning xx0900000812 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 Caution xx090000...

Page 24: ...o not disassemble xx0900000815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the robot arm can fall down Continues on next page 24 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights rese...

Page 25: ... over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page Product manual IRB 1200 25 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 26: ...1 06 xx1300001087 Moving robot 1 2 3 4 5 6 xx0900000819 The robot can move unexpectedly xx1000001141 1 2 3 4 xx1500002616 Continues on next page 26 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 27: ...01242 Lifting of robot xx0900000822 Oil xx0900000823 Can be used in combination with prohibition if oil is not allowed Mechanical stop xx0900000824 Continues on next page Product manual IRB 1200 27 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 28: ...t this part is pressurized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller Do not step xx1400002648 Warns that stepping on these parts can cause damage to the parts 28 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Cont...

Page 29: ...product manual for the controller For more information see Product manual OmniCore C30 Product manual OmniCore C90XT Product manual OmniCore E10 Product manual IRC5 Product manual IRC5 Compact Product manual IRB 1200 29 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 1 Safety 1 3 Robot stopping functions ...

Page 30: ...impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot The maximum TCP speed and the maximum velocity of the robot axes are detailed in the section Robot motion in the product specification for the respective manipulator Consider exposure to hazards such as slipping tripping and falling Hazards due to the working position and posture for a person working wi...

Page 31: ...ry to protect people working with the robot system are designed and installed correctly When integrating the robot with external devices to a robot system The integrator of the robot system must ensure that emergency stop functions are interlocked in accordance with applicable standards The integrator of the robot system must ensure that safety functions are interlocked in accordance with applicab...

Page 32: ...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 All pipes hoses and connections have to be inspected regularly for leaks and damage Damage must be repaired immediately Verify the safety functions Before the robot system is put into operation verify that the safety functions are working as intended and that any remai...

Page 33: ...t of robot arm WARNING Hazards due to the use of brake release devices and or gravity beneath the manipulator shall be considered A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment Product manual IRB 1200 33 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 1 Safety 1 5 Operation ...

Page 34: ...king as intended Hot surfaces Surfaces can be hot after running the robot and touching these may result in burns Allow the surfaces to cool down before maintenance or repair Allergic reaction Elimination Action Description Warning Make sure that protective gear like goggles and gloves are al ways worn When working with lubricants there is a risk of an allergic reac tion Allergic reaction Gearbox l...

Page 35: ...usly been drained from the gearbox Specified amount de pends on drained volume For lifetime reasons always drain as much oil as possible from the gearbox The magnetic oil plugs will gather residual metal chips Contaminated oil in gearboxes Hazards related to batteries Under rated conditions the electrode materials and liquid electrolyte in the batteries are sealed and not exposed to the outside Th...

Page 36: ...perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment Related information See also the safety information related to installation and operation 36 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 1 Safety 1 6 1 Maintenance and repair Continued ...

Page 37: ...ire using an overhead crane or similar equipment Increased injury Before releasing the brakes make sure that the weight of the manipulator does not result in additional hazards for example even more severe injuries on a trapped person DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unexpected ways Make sure no personnel is near or beneath the robot Pr...

Page 38: ... Switch the motor to the MOTORS OFF 3 Inspect and verify that the axis maintains its position If the manipulator does not change position as the motors are switched off then the brake function is adequate Note It is recommended to run the service routine BrakeCheck as part of the regular maintenance see the operating manual for the robot controller For robots with the option SafeMove the Cyclic Br...

Page 39: ...engineers A risk assessment must be done to address both robot and robot system specific hazards WARNING Hazards due to the use of brake release devices and or gravity beneath the manipulator shall be considered A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment Related information See also the safety informati...

Page 40: ...e release devices and or gravity beneath the manipulator shall be considered A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment 40 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 1 Safety 1 8 Decommissioning ...

Page 41: ... are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page19 before performing any installation work Note Always connect the IRB 1200 and the robot to protective earth and residual current device RCD before connecting to power and starting any installatio...

Page 42: ...robots with protection class IP67 3HAB3772 19 O ring For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Used to seal between the main power cable and the connector Robots with manipulator cables routed from the rear of the base xx1500000243 Robots with manipulator cables routed from...

Page 43: ...ain cable is fitted Label for IP67 Foundry Plus Clean Room and food grade lubrication robots 3HAC063211 001 Extra O ring 3HAB3772 19 delivered in Accessories for protection class IP67 protection type Foundry Plus and Clean Room must be fitted xx1700001298 Label for Hygienic robots 3HAC079172 001 Extra O ring 3HAB3772 19 delivered in Accessories must be fitted xx2100001272 Further information For i...

Page 44: ... RJ 45 protector Used to cover unused connectors for water and dust proofing Replace if damaged Protection covers for Foundry Plus robots For robots with protection type Foundry Plus Extra protection covers sealing and plugs are delivered together with Foundry Plus robots and must be fitted to the robot during installation Note Art no Equipment Used with protection type Foundry Plus 3HAC058350 001...

Page 45: ...installed on the force sensor IRB 1200 5 0 9 IRB 1200 7 0 7 With force control package Without force control package With force control package Without force control package xx1800000002 xx1800000003 xx1800000004 xx1500001605 3HAC064318 001 3HAC051897 001 3HAC064317 001 3HAC051896 001 Removing the transportation bracket Use this procedure to remove the bracket Note The bracket must be kept for reu...

Page 46: ...t is likely to be mechanically unstable if not secured to the foundation 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic It is important not to rub against the paint of the robot while performing any service work on the robot 2 Continues on next page 46 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2...

Page 47: ...n robots not in protection type Hygienic which are M5x12 3 For robots delivered with force control package xx1800000005 xx1500001400 Remove the bracket For robots with protection type Foundry Plus Remove the two M10 rubber washers as circled in the figure together with the bracket and reserve them for further use xx1600001178 4 Continues on next page Product manual IRB 1200 47 3HAC046983 001 Revis...

Page 48: ... the swing sealing plug and seal the joint See Swing sealing plug for Clean Room food grade lubrication and Hygienic robots on page 165 After the replacement wipe clean 5 Protection plug for lifting holes For robots with protection type Foundry Plus 6 3HAC4836 24 xx1600001147 Fit protection plugs to the lifting holes 48 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All ...

Page 49: ...rming a risk assessment according to EN ISO 14159 it shall be assumed that the robot conforms to Level 1 as defined in EN ISO 14159 Annex A Following risks but not limited to should be assessed Leakage of oil and grease Wearing of gaskets and sealings Loss of plugs and screws Tiny clearances and hard to reach areas of the robot Flakes of paint Uncoated areas on the robot Residuals of products and ...

Page 50: ...Requirements foundation on page 52 8 Before moving the robot please observe the stability of the robot Risk of tipping sta bility on page 62 9 When these prerequisites are met the robot can be taken to its installation site as described in section On site installation on page 65 10 Install required equipment if any Installing the signal lamp on IRC5 robots on page 94 11 Weight robot The table show...

Page 51: ...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 WARNING The robot installation is restricted to the mounting options given in following load table s Floor mounted Max load emergency stop Endurance load in operation Force 1620 N 910 N Force xy 550 1610 N 550 980 N Force z 1550...

Page 52: ...uency than recommended Minimum resonance frequency Due to foundation stiffness consider robot mass including equipment i For information about compensating for founda tion flexibility see the application manual of the controller software section Motion Process Mode i The minimum resonance frequency given should be interpreted as the frequency of the robot mass inertia robot assumed stiff when a fo...

Page 53: ...ne a warm up phase recommended to be run with the robot Otherwise there is a risk that the robot stops or run with lower performance due to temperature dependent oil and grease viscosity ii For robots with food grade lubrication For robots with protection type Hygienic If environment temperature 35ºC contact ABB for further information Protection classes robot The table shows the available protect...

Page 54: ...anipulator protection type Hygienic IP69K max 30bar on axis 6 flange 54 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 2 4 Pre installation procedure Continued ...

Page 55: ...7 105 190 185 D 115 C xx1300000366 Description Position Minimum turning radius axis 4 R 79 mm A Minimum turning radius axis 3 R 139 mm B Minimum turning radius axis 1 R 138 mm C Valid for option Robot cabling routing 966 1 From below D Continues on next page Product manual IRB 1200 55 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 2 5 Dimen...

Page 56: ...n Minimum turning radius axis 4 R 79 mm A Minimum turning radius axis 3 R 139 mm B Minimum turning radius axis 1 R 138 mm C Valid for option Robot cabling routing 966 1 From below D Continues on next page 56 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 2 5 Dimensions Continued ...

Page 57: ...85 D 115 C xx1400000339 Description Pos Minimum turning radius axis 4 R 79 mm A Minimum turning radius axis 3 R 111 mm B Minimum turning radius axis 1 R 138 mm C Valid for option Robot cabling routing 966 1 From below D Continues on next page Product manual IRB 1200 57 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 2 5 Dimensions Continued ...

Page 58: ...tion Position Minimum turning radius axis 4 R 79 mm A Minimum turning radius axis 3 R 139 mm B Minimum turning radius axis 1 R 138 mm C Valid for option Robot cabling routing 966 1 From below D 58 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 2 5 Dimensions Continued ...

Page 59: ...9 Pos 7 xx1300000386 Angle degrees Positions at wrist center mm Position in the figure Axis 3 Axis 2 Z X 0º 0º 791 351 Pos0 83º 0º 1102 0 Pos1 70º 0º 434 160 Pos2 83º 90º 398 703 Pos3 83º 135º 99 497 Pos4 200º 100º 55 133 Pos5 70º 100º 550 62 Pos6 83º 90º 400 703 Pos7 83º 100º 278 693 Pos8 200 135 488 358 Pos9 Continues on next page Product manual IRB 1200 59 3HAC046983 001 Revision S Copyright 20...

Page 60: ...00387 Angle degrees Positions at wrist center mm Position in the figure Axis 3 Axis 2 Z X 0º 0º 889 451 Pos0 85º 0º 1300 0 Pos1 70º 0º 438 194 Pos2 85º 90º 402 901 Pos3 85º 130º 178 692 Pos4 200º 100º 48 179 Pos5 70º 100º 583 72 Pos6 85º 90º 397 901 Pos7 85º 100º 240 887 Pos8 200 130 549 458 Pos9 Continues on next page 60 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB Al...

Page 61: ... 270 to 270 Wrist motion Axis 4 130 not Hygienic robots 128 Hygienic robots 130 not Hygienic robots 128 Hygienic robots Bend motion Axis 5 Default 400 to 400 Maximum revolution 242i Default 400 to 400 Maximum revolution 242i Turn motion Axis 6 i The default working range for axis 6 can be extended by changing parameter values in the software Option Independent axis can be used for resetting the re...

Page 62: ...on position This figure shows the robot in its shipping position and transportation position Taking IRB 1200 5 0 9 as an example B A xx1500001399 B A 25 10 IRB 1200 all variants not in protection type Hygienic Continues on next page 62 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 2 7 Risk of tipping stability ...

Page 63: ...portation The transportation bracket must be removed before fitting the lifting accessory to the robot during the lifting of the robot to the installation site For details see Transportation bracket on page 45 WARNING The robot will be mechanically unstable if not properly secured to the foundation Product manual IRB 1200 63 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 I...

Page 64: ... sensitive electronics Safe handling Use one of the following alternatives Use a wrist strap Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly Use an ESD protective floor mat The mat must be grounded through a current limiting resistor Use a dissipative table mat The mat should provide a controlled discharge of static voltages and must be ground...

Page 65: ...bracket must be removed before fitting the lifting accessory to the robot during the lifting of the robot to the installation site For details see Transportation bracket on page 45 xx1400000501 Required equipment Note Article number Equipment etc Overhead crane Continues on next page Product manual IRB 1200 65 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and...

Page 66: ... IRB 1200 5 0 9 as an example B A xx1500001399 B A 25 10 IRB 1200 all variants not in protection type Hygienic 25 66 11 95 IRB 1200 7 0 7 in protection type Hy gienic 25 48 11 77 IRB 1200 5 0 9 in protection type Hy gienic Move the robot to an appropriate lifting posi tion WARNING The robot is likely to be mechanically unstable if not secured to the foundation 1 Continues on next page 66 Product m...

Page 67: ...t the paint of the robot while performing any service work on the robot 2 xx1600001147 For robots with protection type Foundry Plus Remove the protection plugs in lifting holes 3 Continues on next page Product manual IRB 1200 67 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 3 1 Lifting robot with roundslings Continued ...

Page 68: ...ing the joint when fitting the lifting tools xx1600000205 4 Tightening torque 15 Nm For robots with protection type Foundry Plus xx1600001177 Replace the swing sealing plug if damaged and seal the joint See Swing sealing plug for Clean Room food grade lubrication and Hygienic robots on page 165 After the replacement wipe clean Make sure the roundsling has free space and does not wear against any p...

Page 69: ...RNING Personnel must not under any circumstances be present under the suspended load 8 Raise the overhead crane to lift the robot 9 xx1600000005 If the manipulator should be mounted on a wall or in an suspended position the manipulator can now be tilted slowly by hand 10 Product manual IRB 1200 69 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissionin...

Page 70: ...n page 891 Any additional equipment required is specified in the instruction for the lifting accessory Contact ABB for more information How to lift and turn the robot into position for wall position Contact ABB for more information How to lift and turn the robot into position for tilted position Contact ABB for more information 70 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 20...

Page 71: ...brakes for the motors of each axis Location of brake release unit The internal brake release unit is located as shown in the figure xx1400000030 Continues on next page Product manual IRB 1200 71 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 3 3 Manually releasing the brakes ...

Page 72: ...ke sure no personnel is near or beneath the robot arm 2 Release the holding brake on all robot axes by pressing the button on the internal brake release unit 3 The brake will function again as soon as the button is released Supplying power to connector R1 MP If the robot is not connected to the controller power must be supplied to connector R1 MP on the robot in order to enable the brake release b...

Page 73: ...the 24V and 0V pins If they are mixed up damage can be caused to the brake release unit and to the system board 2 Product manual IRB 1200 73 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 3 3 Manually releasing the brakes Continued ...

Page 74: ...ads on foundation robot on page 51 Requirements foundation on page 52 Hole configuration base The illustration shows the hole configuration used when securing the robot 180 95 70 180 2 x 6 H8 0 018 0 70 95 F F 0 03 4 x 13 5 16 0 3 F F xx1300000368 Continues on next page 74 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning...

Page 75: ...th protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Manipulator cables routed from below The O ring specified below is delivered together with the robot and must be installed to the bottom of the base during installation Note Art no Equipment For robots with protection class IP67 3HAB3772 141 O ring For robots with protection type Foundry P...

Page 76: ...ots with protection class IP67 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Cabling routed from below Fit the O ring 3HAB3772 141 to underneath the robot base 6 2 pcs D6x20 ISO 2338 6m6x20 A1 Fit two pins to the holes in the base 7 Make sure the robot base is cor rectly fitted...

Page 77: ...connector on the robot base 11 Robots with manipulator cables routed from below option 996 1 xx1500000242 Securing robot on a mounting plate When bolting a mounting plate or frame to a concrete floor follow the general instructions for expansion shell bolts Screw joints must be able to withstand the stress loads defined in section Loads on foundation robot on page 51 Product manual IRB 1200 77 3HA...

Page 78: ...l the movements in the best possible way An incorrect definition of the mounting angle will result in Overloading the mechanical structure Lower path performance and path accuracy Some functions will not work properly for example Load Identification and Collision detection Gravity Beta If the robot is mounted upside down or on a wall rotated around the y axis then the robot base frame and the syst...

Page 79: ... performance motion is set see Technical reference manual System parameters Gamma Rotation Gamma Rotation defines the orientation of the robot foot on the travel carriage track motion Mounting angles and values The parameter Gravity Beta or Gravity Alpha specifies the mounting angle of the robot in radians It is calculated in the following way Gravity Beta A x 3 141593 180 B radians where A is the...

Page 80: ...le 45 Tilted Pos 2 Mounting angle 90 Wall Pos 3 Mounting angle 180 Suspended Pos 4 Continues on next page 80 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 3 5 Setting the system parameters for a suspended or tilted robot Continued ...

Page 81: ...s 0 0 Floor mounted 1 0 785398 45 Tilted 2 1 570796 90 Wall 3 1 570796 90 Wall 4 Note For suspended robots 180 it is recommended to use Gravity Beta instead of Gravity Alpha Continues on next page Product manual IRB 1200 81 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 3 5 Setting the system parameters for a suspended or tilted robot Conti...

Page 82: ...lculate a new value is detailed in Mounting angles and values on page79 The system parameters are described in Technical reference manual System parameters The system parameters are configured in RobotStudio or on the FlexPendant 82 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 3 5 Setting the system parameters for ...

Page 83: ...nces Load diagrams permitted extra loads equipment and their positions are specified in the product specification The loads must be defined in the software Operating manual IRC5 with FlexPendant Operating manual OmniCore Stopping time and braking distances The performance of the motor brake depends on if there are any loads attached to the robot For more information see product specification for t...

Page 84: ... the marked load areas The robot is supplied with holes for fitting of extra equipment See Holes for fitting extra equipment on page 85 216 68 68 216 34 108 34 68 216 108 A 216 A A A IRB 1200 7 0 7 IRB 1200 5 0 9 150 250 xx1300000384 Max load Load area A 0 3 kg IRB 1200 5 0 9 IRB 1200 7 0 7 84 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installat...

Page 85: ... 0 125 xx1300000381 Description Pos IRB 1200 5 0 9 451 mm IRB 1200 7 0 7 351 mm A IRB 1200 5 0 9 216 mm IRB 1200 7 0 7 116 mm B Continues on next page Product manual IRB 1200 85 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 3 7 2 Holes for fitting extra equipment ...

Page 86: ...rness or air hoses of the tools rather than fitting extra equipment 2 x M4 8 xx1700002331 Continues on next page 86 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 3 7 2 Holes for fitting extra equipment Continued ...

Page 87: ...tion Pos IRB 1200 5 0 9 451 mm IRB 1200 7 0 7 351 mm A IRB 1200 5 0 9 216 mm IRB 1200 7 0 7 116 mm B Continues on next page Product manual IRB 1200 87 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 3 7 2 Holes for fitting extra equipment Continued ...

Page 88: ...a equipment 2xM4 10 xx2100001280 Lower arm 568 1 666 1 30 0 15 2 x M5 7 5 A A IRB 1200 7 0 7 IRB 1200 5 0 9 122 5 122 5 122 5 122 5 xx1300000382 Continues on next page 88 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 3 7 2 Holes for fitting extra equipment Continued ...

Page 89: ...e 4xM5 6 5 H7 0 012 0 6 4x 90 J J 0 25 0 04 4 6 5 5 20 H7 0 021 0 40 h7 0 0 025 J J 45 31 5 xx1300000383 Continues on next page Product manual IRB 1200 89 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 3 7 2 Holes for fitting extra equipment Continued ...

Page 90: ...25 40 h7 6 5 0 25 0 04 45 6 4xM5 6 0 0 012 5 H7 4x 90 E E xx1600001322 Continues on next page 90 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 3 7 2 Holes for fitting extra equipment Continued ...

Page 91: ...001281 Fastener quality When fitting tools on the tool flange only use screws with quality 12 9 For other equipment use suitable screws and tightening torque for your application Product manual IRB 1200 91 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 3 7 2 Holes for fitting extra equipment Continued ...

Page 92: ...1 with the robot at delivery xx2100002211 Note Qty Description Item 1 Gasket A 1 Guide pin B 4 FDA washers C Tightening torque 6 Nm 4 Stainless flange bolts D Always apply a little grease Molykote P1900 to the bolt thread before fitting the tool using the bolts Continues on next page 92 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and...

Page 93: ...e dimension of the robot tool flange specified in Robot tool flange on page 89 0 2 X 45 A 44 0 40 h11 0 160 Min 5 6 1 1 0 1 0 Greater than 3 xx2100002644 Product manual IRB 1200 93 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 3 7 3 Fitting tools on Hygienic robots Continued ...

Page 94: ...pproved robot The lamp is active in MOTORS ON mode Location of signal lamp The signal lamp is located as shown in the figure xx1300000455 Required spare parts Note Article number Spare part 3HAC16738 1 Signal lamp Continues on next page 94 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 4 1 Installing the signal lamp ...

Page 95: ...t with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before repla cing parts on page 158 2 xx1300000464 Remove the cover from the upper arm housing 3 xx1300000465 Drill a hole with a diameter of 22 5 mm in the center of the raised platform 4 Fit the lamp and tighten the nut 5 Connect the two lamp cables connectors R3 H1 and R3 H2 t...

Page 96: ...n type Hygienic Clean seal and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 158 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth The signal lamp is now ready for use and is lit in MOTORS ON mode 9 96 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights re...

Page 97: ...p cable connector to the I O connector on the controller Note The I O connectors provides 8 digital output signals for use Configure the lamp by adding a System Output type signal with status set to Motors On State 4 The lamp is now ready for use and is lit in MOTORS ON mode 5 Installation of signal lamp from MON_LAMP signal Action DANGER Make sure that all supplies for electrical power hydraulic ...

Page 98: ...ready for use and is lit in MOTORS ON mode 4 Further information Further information about the MOTORS ON MOTORS OFF mode may be found in the product manual for the controller Further information about how to set up I O system may be found in Technical reference manual System parameters 98 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation a...

Page 99: ... during operation of robot Axis 3 hardware mechanical stop and software Note The axis 3 stop is a fixed stop that must be installed during operation of robot Axis 4 hardware mechanical stop and software Note The axis 4 stop is a fixed stop that must be installed during operation of robot Axis 5 hardware mechanical stop and software Axis 6 software This section describes how to install hardware tha...

Page 100: ...nical stops are placed on the robot xx1700001293 Mechanical stop axis 1 swing A Mechanical stop axis 1 base B Continues on next page 100 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 5 2 Mechanically restricting the working range ...

Page 101: ... A Mechanical stop axis 2 swing B Continues on next page Product manual IRB 1200 101 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 5 2 Mechanically restricting the working range Continued ...

Page 102: ...A Mechanical stop axis 3 tubular B Continues on next page 102 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 5 2 Mechanically restricting the working range Continued ...

Page 103: ...0001297 Continues on next page Product manual IRB 1200 103 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 5 2 Mechanically restricting the working range Continued ...

Page 104: ...xis 1 mechanical stop on page 638 Replacing the axis 2 mechanical stop on page 454 Replacing the axis 3 mechanical stop on page 457 Replacing the axis 4 mechanical stop on page 460 104 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 5 2 Mechanically restricting the working range Continued ...

Page 105: ... to IPA test result the robot IRB 1200 is suitable for use in Clean Room environment Classification of airborne molecular contamination Outgassing amount Parameter Classifica tion in ac cordance to ISO 14644 8 Norm based on 1m2and 1s g Total detec ted ng Performed test Temp C Test dura tion s Area m2 6 8 1 7E 07 2848 TVOC 23 3600 4 5E 03 3 8 1 7E 04 46524 TVOC 90 60 4 5E 03 Preparations before com...

Page 106: ...es These cables are included in the standard delivery They are completely pre manufactured and ready to plug in Connection point robot Connection point cabinet Description Cable sub category R1 MP XS1 IRC5 con trollers Transfers drive power from the drive units in the control cabinet to the robot motors Robot cable power X1 OmniCore controllers R1 EIB XS2 IRC5 con trollers Transfers encoder data f...

Page 107: ...19 001 22 m IRC5 3HAC068920 001 30 m IRC5 The following table lists the signal cables for connecting OmniCore controller Article number Power cable length 3HAC080671 001 3 m OmniCore 3HAC080671 002 7 m OmniCore 3HAC080671 003 15 m OmniCore Bending radius for static floor cables The minimum bending radius is 10 times the cable diameter for static floor cables A B xx1600002016 Diameter A Diameter x1...

Page 108: ... Installation of extra O ring For robots with protection class IP67 For robots with protection type FoundryPlus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Continues on next page 108 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 7 1 Robot...

Page 109: ...bles routed from the rear of the base xx1500000243 Robots with manipulator cables routed from below option 996 1 xx1500000242 Customer cables CP CS cable option The following table lists the CP CS cables for connecting IRC5 IRC5C controller Article number CP CS cable length 3HAC049089 001 3 m IRC5 3HAC049089 004 7 m IRC5 3HAC049089 005 15 m IRC5 3HAC049089 006 22 m IRC5 3HAC049089 007 30 m IRC5 3H...

Page 110: ...ing IRC5 IRC5C controller Article number Ethernet floor cable length 3HAC055518 001 3 m IRC5 IRC5C 3HAC055518 002 7 m IRC5 IRC5C 3HAC055518 003 15 m IRC5 IRC5C 3HAC055518 004 22 m IRC5 IRC5C 3HAC055518 005 30 m IRC5 IRC5C The following table lists the Ethernet cables for connecting OmniCore controller Article number Ethernet floor cable length 3HAC055518 002 7 m OmniCore 3HAC055518 003 15 m OmniCo...

Page 111: ...rotector for customer connection otherwise application overload will burn out the CP CS cables in the robot Detailed information about the CP CS connection is provided in a warning label on the tubular housing xx1600001687 There is also connections for Ethernet one connector R4 Ethernet at the tubular housing and the corresponding connector R1 Ethernet located at the base Continues on next page Pr...

Page 112: ... tables describes the connectors on base and tubular housing upper arm Connectors base Art no Description Position 3HAC022117 002 Pin connector 10p bulkhead Robot 3HAC037038 001 Connector set R1 CP CS Customer connector Connectors tubular housing Art no Description Position 3HAC023624 002 Socket connector 10p flange mounted Robot 3HAC037070 001 Connector set R3 CP CS Customer connector Continues o...

Page 113: ...n Position 4xM5 Robot 3HAC032049 001 Air connector Customer cable Product manual IRB 1200 113 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 2 Installation and commissioning 2 7 2 Customer connections Continued ...

Page 114: ...regulated with the RAPID instruction VelSet Start the robot with its normal program but with reduced speed 1 Adjusting the speed and acceleration during warm up Depending on how cold the environment is and what program is being used the speed might need to be ramped up until reached maximum The table shows examples of how to adjust the speed Speed velocity AccSet Work cycles v100 100 mm s 20 20 3 ...

Page 115: ...ust be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page 19 before performing any service work The maintenance must be done by qualified personnel in accordance with the safety requirements set forth in the applicable national and regional standards and regulations Note If the IRB 1200 ...

Page 116: ...onality Service Information System activated can show active counters in the device browser in RobotStudio or on the FlexPendant Overhaul Depending on application and operational environment a complete overhaul may be necessary in average around 30000 hours ABB Connected Services and its Assessment tools can help you to identify the real stress level of your robot and define the optimal ABB suppor...

Page 117: ...pection activities Check for abnormal wear or contam ination x Inspecting the robot For robots with protection type Clean Room Inspect daily Inspecting the robot paint on page 119 x Inspecting the paint Inspecting the robot cabling on page 120 x iii Inspecting the robot cabling ii Inspecting the information labels on page 121 x Inspecting the information labels Inspecting mechanical stops on page ...

Page 118: ... in order to get access to and inspect the mechanical stop vi The battery low alert 38213 Battery charge low is displayed when remaining backup capacity robot powered off is less than 2 months Typical life of a new battery is 36 months if the robot is powered off 2 days week or 18 months if the robot is powered off 16 hours day The life can be extended approximately 3 times for longer production b...

Page 119: ...001 Touch up paint Clean Room Hy gienic Inspection robot paint Description Action Visually inspect the robot surface paint for any paint breaking 1 Use a lint free cloth If there is paint breaking clean the surface so that it is free from oil and grease 2 3HAC036639 001 Use Touch up paint Clean Room Hygienic white to paint any damaged surfaces Note Always read the instruction in the product data s...

Page 120: ...cedures may be required if the spare part needs to be replaced These are specified in the replacement procedure Inspection robot cabling Use this procedure to inspect the robot cabling Note Action DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot air pressure supply to the robot Before entering the robot working area 1 Visually inspect the control cablin...

Page 121: ...e23 Illustration 1 of 2 ABB Robotics Products AB Axis Resolver values Absolute Accuracy TYPE LABEL Barcodes Streckkod IRB 1200 7 0 7 FOOD GRADE LUBRICATION CP CS connection IRB 1200 5 0 9 CP CS connection B B B B B B B B B B D D B A J H G K Continues on next page Product manual IRB 1200 121 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 3 Maintenance 3 3 3 Inspecting the inf...

Page 122: ...A IRB 1200 0 5 9 D E F D B B B B B C B Illustration Description Calibration label A xx1300001091 Warning label Flash B Continues on next page 122 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 3 Maintenance 3 3 3 Inspecting the information labels Continued ...

Page 123: ...00000984 3HAC 2577 1 04 xx1400000519 Instruction label Brake release Moving robot Brake release buttons E UL label F Rating label G Continues on next page Product manual IRB 1200 123 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 3 Maintenance 3 3 3 Inspecting the information labels Continued ...

Page 124: ...ening bolts H xx1600001074 Clean Room label J xx1600001075 Foundry Plus label Continues on next page 124 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 3 Maintenance 3 3 3 Inspecting the information labels Continued ...

Page 125: ... 1R RI VK 5HY LQG LDQJ 052 1 50 Q UHYLHZ 7 SH DEHO UDZLQJ 6 HVFULSWLRQ RFXPHQW RF W SH 6XSSOHPHQWDU GRFXPHQW 0DWHULDO 7 SH LPHQVLRQ 2 1XPEHU xx1600002137 Type B label Required spare parts Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the IRB 1200 via myABB Business Portal www abb com myABB Note Article number Spare part Not valid for prot...

Page 126: ...nical stops on axes 1 2 and 3 are located as shown in the figures Axis 1 xx1400000391 Axis 2 xx1400000389 Continues on next page 126 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 3 Maintenance 3 3 4 Inspecting mechanical stops ...

Page 127: ...chanical stop pin 1 pc and screws 3HAC049637 001 Mechanical stop set axis 2 Includes mechanical stop pin 1 pc and screws 3HAC049644 001 Mechanical stop set axis 3 Required tools and equipment Visual inspection no tools are required Other tools and procedures may be required if the spare part needs to be replaced These are specified in the replacement procedure Continues on next page Product manual...

Page 128: ... the robot working area 1 See the figures in Location of mechanical stops on page 126 Inspect the mechanical stops 2 Replace if the mechanical stop is bent loose damaged Note The expected life of gearboxes can be reduced as a result of collisions with the mechanical stop 3 128 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 3 Maintenance 3 3 4 Inspecti...

Page 129: ...he paint or surface on the robot before replacing parts on page 158 Location of timing belts The timing belts are located as shown in the figures Axis 4 xx1400000036 Continues on next page Product manual IRB 1200 129 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 3 Maintenance 3 3 5 Inspecting timing belts ...

Page 130: ...lts Information Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Gain access to each timing belt by removing the cover 2 Check the timing belts for damage or wear 3 Check the timing belt pulleys for damage 4 If any damage or wear is detected the part must be replaced 5 Continues on next page 130 Pro...

Page 131: ...ether timing belts are slack manually 6 If the belt has no tension adjust it Product manual IRB 1200 131 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 3 Maintenance 3 3 5 Inspecting timing belts Continued ...

Page 132: ...e 897 Signal lamp kit Content is defined in section Stand ard toolkit on page 890 Standard toolkit Inspecting signal lamp Use this procedure to inspect the function of the signal lamp Note Action Inspect that signal lamp is lit when motors are put in operation MOTORS ON 1 Continues on next page 132 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 3 Main...

Page 133: ... tools and equipment on page 132 If the lamp is not lit trace the fault by inspecting whether the signal lamp is broken If so replace it inspecting cable connections inspecting the cabling Replace the cabling if a fault is detected 3 Product manual IRB 1200 133 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 3 Maintenance 3 3 6 Inspecting the signal lamp option Continued ...

Page 134: ...ys week or 18 months if the robot is powered off 16 hours day The life can be extended approximately 3 times for longer production breaks by a battery shutdown service routine See the operating manual for the robot controller Location of battery pack The battery pack is located as shown in the figure xx1300002574 Continues on next page 134 Product manual IRB 1200 3HAC046983 001 Revision S Copyrigh...

Page 135: ...AC056728 001 3HAC080706 001 Gasket on EIB SMB cover Required tools and equipment Note Article number Equipment etc Used to release the motor brakes 24 VDC power supply Content is defined in section Standard toolkit on page 890 Standard toolkit CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts...

Page 136: ... pack Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 64 2 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robot...

Page 137: ...lures CAUTION Be aware of the cabling that is attached to the cover 4 xx1400000812 Valid for IRB 1200 no type specified and IRB 1200 Type A Disconnect the connectors on the EIB unit R1 ME1 3 R1 ME4 6 R2 EIB 5 xx1700000004 Valid for IRB 1200 Type B Loose the connector screws 6 Continues on next page Product manual IRB 1200 137 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 3 ...

Page 138: ...B 7 Valid for IRB 1200 no type spe cified and IRB 1200 Type A xx1300002571 Disconnect the battery cable 8 Valid for IRB 1200 Type B xx1700000006 Continues on next page 138 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 3 Maintenance 3 4 1 Replacing the battery pack Continued ...

Page 139: ...200 Type B xx1700000007 Refitting the battery pack Use these procedures to refit the battery pack Refitting the battery pack Note Action ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 64 1 Continues on next page Product manual IRB 1200 139 3HAC046983 001 Revision S Copyright 20...

Page 140: ... IRB 1200 no type spe cified and IRB 1200 Type A xx1300002579 Fit the battery and and secure it with a cable strap Note Battery includes protection circuits Only replace with a specified spare part or with an ABB ap proved equivalent 3 Valid for IRB 1200 Type B xx1700000007 Continues on next page 140 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 3 Ma...

Page 141: ... and IRB 1200 Type A Connect the connectors to the EIB unit R1 ME1 3 R1 ME4 6 R2 EIB WARNING Make sure not to mix the R2 EIB and R2 ME2 Axis 2 may be severely damaged See the labels on the connectors for correct connection 5 Continues on next page Product manual IRB 1200 141 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 3 Maintenance 3 4 1 Replacing the battery pack Continu...

Page 142: ...ning torque 0 3 Nm xx1700000004 Valid for IRB 1200 Type B Tighten the connector screws 7 Screws 3HAB3409 207 M3x8 Refit the EIB SMB cover to the lower arm with the attachment screws 8 Tightening torque 1 5 Nm xx1300002427 Note Only use specified screws never replace them with other screws Continues on next page 142 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All right...

Page 143: ... paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 158 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth DANGER Make sure all safety requirements are met when performing the first test run 3 Product manual IRB 1200 143 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 3 Ma...

Page 144: ...interval Gasket axis 6 Hygienic A Recommended to replace at a 12 month interval Seal ring unit B Replace if damaged Stainless shaft C Recommended to replace at a 12 month interval Sealing washer D Replace if damaged Stainless screws E Required spare parts Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the IRB 1200 via myABB Business Portal...

Page 145: ...ol Used with robots in protection type Hygienic 3HAC079684 001 Guide pin for stainless shaft on tool flange Required consumables Note Art no Consumable Molykote P1900 3HAC070875 001 Grease For robots with protection type Hygienic CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page158 Re...

Page 146: ...6 001 xx2100001452 Place the flange tightening tool together with a 3 8 10 mm socket spanner on the seal ring unit and loosen the unit 4 xx2100001453 Remove the gasket and seal ring unit 5 Continues on next page 146 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 3 Maintenance 3 4 2 Replacing the sealing set on tool flange of Hygienic robots Continued ...

Page 147: ...1455 Flange tightening tool 3HAC079686 001 Place the flange tightening tool together with a 3 8 10 mm socket spanner on the seal ring unit and tighten the unit 9 Tightening torque 8 Nm xx2100001456 Continues on next page Product manual IRB 1200 147 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 3 Maintenance 3 4 2 Replacing the sealing set on tool flange of Hygienic robots C...

Page 148: ... of the two guide pins Make sure the pin hole on the shaft aligned with the pin on the tool flange 11 Tightening torque 1 5 Nm xx2100001459 Secure with screws and washers 12 xx2100001460 Remove the guide pins 13 148 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 3 Maintenance 3 4 2 Replacing the sealing set on tool flange of Hygienic robots Continued ...

Page 149: ...eaning equipment may shorten the life of the robot Always check that all protective covers are fitted to the robot before cleaning Never point the water jet at connectors joints sealings or gaskets Do not use compressed air to clean the robot Never use solvents that are not approved by ABB to clean the robot Do not spray from a distance closer than 0 4 m Do not remove any covers or other protectiv...

Page 150: ...IRB 1200 with protection type Hygienic on page 152 Wiping with cloth Additional cleaning instructions for robots with food grade lubrication Make sure that no liquid flows into the robot or stagnates in any gap or surface after cleaning Cleaning with water and steam Instructions for rinsing with water IRB 1200 with protection class IP67 option and with protection type Foundry Plus can be cleaned b...

Page 151: ...rs Maximum water temperature 80 C Cables Movable cables need to be able to move freely Remove waste material such as sand dust and chips if it prevents cable movement Clean the cables if they have a crusty surface for example from dry release agents Product manual IRB 1200 151 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 3 Maintenance 3 5 1 Cleaning the IRB 1200 Continued ...

Page 152: ...roper cleaning method according to the actual applications and strictly follow the cleaning procedure xx2100001401 User tools A The robot body without any protection should use the wipe down method for cleaning If the robot body is properly covered by protective device or equipment the wash down method is also applic able Wipe down area B In most cases the tool flange surface should use the wash d...

Page 153: ... cleaning activities The following list defines the prerequisites Read the material safety data sheet MSDS before using any chemicals Always use proper protective equipment like gloves goggles safety boots face shields and apron when using chemicals Cleaning instructions DANGER Turn off all electrical power hydraulic and pneumatic pressure supplies before entering the workspace of the manipulator ...

Page 154: ...5 minutes 4 Let the detergent work for approx 15 minutes to retain effective cleaning properties Ensure that the cleaning agent does not dry on the surface Recommended water temperature 40 60 C Rinse thoroughly with water to remove the deter gent 5 Detergent Topaz AC3 concentra tion v v 2 Foam the surface with detergent Topaz AC3 Use a sprinkling can so that the to be cleaned areas can be covered ...

Page 155: ... no spraying or ejecting of any detergents disinfectants and water to the robot surfaces during the cleaning 1 Use the lint free cloth to remove soils or any other contaminant from the to be cleaned surfaces 2 Make sure no visible residues left Disinfectant DRYSANTMDUO concentration v v 100 Spray disinfectant DRYSANTMDUO on robot surfaces 3 Wait 2 3 minutes for disinfectant volatilization and then...

Page 156: ...This page is intentionally left blank ...

Page 157: ... unit and the replacement unit This is particularly important for safety equipment to maintain the safety integrity of the installation Safety information Make sure to read through the chapter Safety on page 19 before commencing any service work Note If the IRB 1200 is connected to power always make sure that the IRB 1200 is connected to protective earth and a residual current device RCD before st...

Page 158: ...ipment Sikaflex 521 FC Color white 3HAC026759 001 Sealing compound Trans clear 3HAC073510 001 Sealing compound for Hygienic robots Width 6 9 mm made of wood Tooling pin Ethanol Cleaning agent Knife Lint free cloth White 3HAC036639 001 Touch up paint Clean Room Hy gienic Graphite White 3HAC067974 001 Touch up paint Standard Foundry Plus Removing Description Action xx0900000121 Cut the paint with a ...

Page 159: ... robots with protection type Clean Room For robots with food grade lubrication 5 For robots with food grade lubrication Wait 10 minutes Sikaflex 521FC skin dry time 10 minutes For robots with protection type Hygienic For robots with protection type Hygienic Wait 40 minutes Trans Clear skin dry time 40 minutes 3HAC036639 001 Use Touch up paint Clean Room Hygienic white to paint any damaged surfaces...

Page 160: ...bot free from particles with spirit on a lint free cloth 160 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 2 1 Cut the paint or surface on the robot before replacing parts Continued ...

Page 161: ...he sealing in its original wrappings or protect it well before actual mounting The fitting of sealings and gears must be carried out on clean workbenches Use a protective sleeve for the main lip during mounting when sliding over threads keyways or other sharp edges Note Action Check the sealing to ensure that The sealing is of the correct type There is no damage on the main lip 1 Inspect the shaft...

Page 162: ...and the main lip with grease If the sealing is without dust lip just lubricate the main lip with a thin layer of grease 3 A xx2000000072 A Gap Mount the sealing correctly with a mounting tool Never hammer directly on the sealing as this may result in leakage 4 Make sure that no grease is left on the robot surface 5 Continues on next page 162 Product manual IRB 1200 3HAC046983 001 Revision S Copyri...

Page 163: ...tening the flange joint 4 O rings The following procedure describes how to fit o rings Note Action Ensure that the correct o ring size is used 1 Defective o rings including damaged or deformed o rings may not be used Check the o ring for surface defects burrs shape accuracy or deformation 2 Check the o ring grooves 3 The grooves must be geometrically correct and should be free of pores and contami...

Page 164: ... equipped with gaskets several components has been applied with locking liquid etc This means that there are differences in the repair procedures depending on the robot protection class These are clearly stated in the step by step procedures 164 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 2 3 Sealing differences depending on protection c...

Page 165: ... com myABB Note Article number Spare part Used with protection type Clean Room Used for robots with food grade lubrication Used with protection type Hy gienic Replace if damaged 3HAC053687 001 Swing sealing plug Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 890 Standard toolkit Continues on next page Product manual IRB 1200 16...

Page 166: ...moving the swing sealing plug Note Action xx1600000206 Cut the swing sealing plug through with a sharp object to get access to the screws 1 xx1600000207 Remove the cable housing cover of the swing by removing the screws 2 Continues on next page 166 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 2 4 Swing sealing plug for Clean Room food gra...

Page 167: ...nt Sikaflex 521FC For robots with protection type Hygienic Sealant Trans Clear xx1600000210 Smooth out the sealant string using a finger tip Use washing up on finger tips to get a smooth joint If necessary add extra sealant to get a full cover joint Make sure the sealant fully covers the gap but is not applied to the screw cavities 3 Continues on next page Product manual IRB 1200 167 3HAC046983 00...

Page 168: ...obots with protection type Hygienic Sealant Trans Clear xx1600000211 xx1600000261 xx1600000212 Refit the swing sealing plug 6 xx1600000213 If there is any overflowing sealant remove and clean it Make sure no space exists between the swing sealing plug and the robot casting and the sealant string is fully jointed with the plug 7 168 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2...

Page 169: ...tional Ethernet cabling can also be included The air hoses and optional Ethernet must be disconnected inside the wrist unit before the cable package can be removed As standard feature the connector interface is located at the rear of the base The interface can also be bottom mounted as an option This section describes both configurations Connector interface at the rear of the base standard xx13000...

Page 170: ...terface With connector interface at rear of the base 3HAC059674 001 Manipulator cable harness without Ethernet rear interface Used with protection type Clean Room 3HAC056219 001 Manipulator cable harness with Ethernet rear interface Clean Room Used for robots with food grade lubrication Manipulator cable harness with Ethernet rear interface food grade lubrication With connector interface at rear o...

Page 171: ... robots with food grade lubrication Used with protection type Hy gienic Manipulator cable harness with Ethernet rear interface Hygien ic With connector interface at rear of the base Used for IRB 1200 Type B See Type B of IRB 1200 on page873 3HAC061287 001 Manipulator cable harness without Ethernet rear interface Clean Room and SafeMove 2 supported Used with protection type Clean Room Manipulator c...

Page 172: ...9675 001 Base rear cover without connect or interface Used with protection type Clean Room 3HAC056147 001 Base rear cover without connect or interface Clean Room Used for robots with food grade lubrication Base rear cover without connect or interface food grade lubrica tion Used with protection type Hy gienic Base rear cover without connect or interface Hygienic Replace if damaged Not used with pr...

Page 173: ...Clean Room Used for robots with food grade lubrication Cover on top of swing food grade lubrication Used with protection type Hy gienic Cover on top of swing Hygienic Replace if damaged Not used with protection class IP40 3HAC056696 001 3HAC080698 001 Gasket on top swing cover Replace if damaged Used with protection class IP67 3HAC044641 004 M2 variseal sealing Used with protection type Foundry Pl...

Page 174: ...ged Not used with protection class IP40 3HAC056724 001 3HAC080702 001 Gasket on cable housing cover Replace if damaged Not used with protection class IP40 3HAC058822 001 3HAC080709 001 Gasket for tubular cover Replace if damaged Not used with protection class IP40 3HAC056707 001 3HAC080701 001 Gasket for tubular cable housing cover Replace if damaged Not used with protection class IP40 3HAC056698 ...

Page 175: ...e straps Used for lubrication of cable con tact areas 3HAC042536 001 Grease Used for lubrication of cable con tact areas for robots with food grade lubrication and robots in protection type Hygienic 3HAC029132 001 Grease Loctite 243 3HAB7116 1 Locking liquid Loctite 7063 Cleaning agent Loctite 574 12340011 116 Flange sealing For robots with protection type Clean Room For robots with food grade lub...

Page 176: ...revious reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 819 If no previous reference values exist and no new reference values ca...

Page 177: ... 158 4 Getting access to inside of the wrist unit Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot S...

Page 178: ...ication The tubular cover left hand side cover has two extra screws and washers as encircled in the figure For robots with protection type Hygienic xx2100001406 Note For robots with protection type Hygienic The tubular cover right hand side cover has two extra screws as encircled in the figure Do not remove the two screws when removing the cover The screws are used for blocking the screw holes rat...

Page 179: ... them to have as a reference when reconnecting 3 Disconnecting the axis 5 FPC connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge ...

Page 180: ...with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1400000738 Disconnect the air hoses 3 xx1500000252 If equipped disconnect the CP CS connector 4 Continues on next page 180 Product manual IRB 1200 3HAC04...

Page 181: ... with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300002400 Remove the cable housing cover 3 xx1300002413 Remove the plate 4 Continues on next page Product manual IRB 1200 181 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights res...

Page 182: ...ng and disconnect them 5 Cable layout in IRB 1200 5 0 9 xx1400001471 xx1300002398 Remove the small cover of the housing 6 Continues on next page 182 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 1 Replacing the main cable package Continued ...

Page 183: ...ife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300000456 Remove the cover from the upper arm housing CAUTION For robots with safety lamp option Be aware of the signal lamp cables that are at tached inside the housing Disconnect the lamp cable connectors R3 H1 and R3 H2 and then lift away the cover...

Page 184: ...er hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Continues on next page 184 Product ma...

Page 185: ...an Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300002422 Remove the screw that fastens the air hose hold er 3 Continues on next page Product manual IRB 1200 185 3HAC046983 001 Revi...

Page 186: ... the cable clamp screw There is a risk of rearrangement of the cable layout which would result in shortened lifetime of the cable harness 6 Valid for IRB 1200 5 0 9 7 Cut the cable straps at the bottom of the housing Disconnecting the cabling in the lower arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next p...

Page 187: ...r CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures CAUTION Be aware of the cabling that is attached to the cover The cover can not be removed completely until the connectors and lugs are disconnected as shown in following step 4 xx1300002428 Valid for IRB 1200 no type specified and IRB 1200 Type A Disconne...

Page 188: ...e and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Pull the cable package out from the upper arm housing 3 C...

Page 189: ...ifetime of the cable harness 5 xx1400001130 Cut the cable strap that holds the cabling together inside the EIB SMB cavity 6 xx1600000205 For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Remove the swing sealing plug Follow the procedure specified in Removing the swing sealing plug on page 166 7 Continues on next page Product...

Page 190: ... screws 8 xx1400001528 Cut the cable straps 9 xx1300002432 Remove the axis 2 motor bracket screws 10 Continues on next page 190 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 1 Replacing the main cable package Continued ...

Page 191: ...yout which would result in shortened lifetime of the cable harness 11 xx1300002434 Disconnect the motor connectors R2 ME2 R2 MP2 12 xx1300002435 Loosen the cable housing from the swing by re moving the screws Leave it hanging on the cable package 13 Continues on next page Product manual IRB 1200 191 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 1 Replacing the ...

Page 192: ...side Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot befo...

Page 193: ...side and not on the cable arm side which would damage the robot 4 WARNING The robot is likely to be mechanically un stable if not secured to the foundation 5 CAUTION The robot weighs IRB 1200 5 0 9 54 kg IRB 1200 7 0 7 52 kg All lifting accessories used must be sized accordingly 6 Continues on next page Product manual IRB 1200 193 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserv...

Page 194: ...ed off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Continues on next page 194 Product manual IRB 1200 3HAC046983 001 Revision S Copyrig...

Page 195: ...469 Remove the bottom cover 3 Bottom connector interface xx1400000403 Continues on next page Product manual IRB 1200 195 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 1 Replacing the main cable package Continued ...

Page 196: ...face xx1400000404 xx1300002496 Loosen the connectors from the bracket by cutting the cable straps and disconnect the connectors 5 Continues on next page 196 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 1 Replacing the main cable package Continued ...

Page 197: ...ge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300000467 Remove the swing top cover by removing the screws Tip Fit M4 screws in the cover holes to pull out the cover more easily Only tighten the screws lightly in order not to damage the threads 3 xx1300000471 Remove the screws and washers 4 Continues on next page Product m...

Page 198: ...ood grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300002438 Remove the axis 1 sealing ring from the swing and carefully run the cable package out from the swing 3 Remove the swing including arm system com ple...

Page 199: ...ure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158...

Page 200: ...ON For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1400000405 Open the base cover 3 Remove the brake release button from the base cover 4 Disconnec...

Page 201: ...the cable package Adjusting the air hose length for IRB 1200 7 0 7 Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page Product manual IRB 1200 201 3HAC046983 001 Revision S Copyright 2014...

Page 202: ...r robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Gasket for rear base cover 3HAC058566 001 not Hygienic robots 3HAC080710 001 Hygien ic robots xx1400000741 For robots with protection class IP67 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food gr...

Page 203: ...rocedure if the cable connector interface is located at the bottom of the base and the cabling is routed from below Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Insert the cable package in and up through...

Page 204: ...h protection class IP67 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the gasket of the base cover Replace if damaged 5 Reconnect the earth cable 6 Refit the brake release button to the base cover 7 Continues on next page 204 Product manual IRB 1200 3HAC046983 001 Revisio...

Page 205: ... robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Axis 1 sealing ring 3HAC044676 001 3HAC068107 001 i Check the axis 1 sealing ring Replace if damaged 2 Sealant Sikaflex 521FC xx1600001125 For robots with protection class IP67 On axis 1 sealing ring version 3HAC056658 001 Add sealant to the axis 1 sealing ...

Page 206: ...See Spare part versions for the axis 1 sealing ring on IP40 IP67 robots on page 878 Replace if damaged On axis 1 sealing ring version 3HAC058568 001 Axis 1 sealing ring gasket 3HAC058349 001 not Hygienic robots 3HAC080707 001 Hygien ic robots xx1600001149 On axis 1 sealing ring version 3HAC068107 001 Axis 1 sealing ring gasket 3HAC058349 001 not Hygienic robots 3HAC080707 001 Hygien ic robots xx19...

Page 207: ...aling ring version 3HAC058568 001 xx1600001150 On axis 1 sealing ring version 3HAC068107 001 xx1900001736 Cable protection 3HAC044691 001 Check the cable protection on the axis 1 sealing ring 6 Torx countersunk head screw M3x5 3HAC14286 4 Replace if damaged Tightening torque 0 3 Nm xx1400000456 If replacing the cable protection use locking liquid Loctite 243 on the screws Tightening torque 1 Nm xx...

Page 208: ...Replace if damaged Note For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Apply a little grease to the sealing when replacing the radial sealing and wipe clean after the replacement For robots with protection class IP67 Check the M2 variseal sealing in the base Replacement is detailed in Replacing the base spare parts base ax...

Page 209: ... use three guide pins together Refit the swing to the base with guidance from the guide pins while running the cabling up through the swing 5 Position and angle the cabling inside the base as it was positioned during removal CAUTION Be careful not to squeeze any cabling dur ing the refitting procedure Continues on next page Product manual IRB 1200 209 3HAC046983 001 Revision S Copyright 2014 2021 ...

Page 210: ...never replace them with other screws xx1300000523 Remove the guide pins and refit the remain ing attachment screws and washers 7 Tightening torque 40 Nm Tighten all screws 8 Continues on next page 210 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 1 Replacing the main cable package Continued ...

Page 211: ...e if damaged Cover on top of swing 3HAC059679 001 Refit the swing top cover with the screws 10 Cover on top of swing Clean Room Replace if damaged Cover on top of swing food grade lubrica tion Cover on top of swing Hygienic 3HAC056133 001 Screws 3HAB3409 209 M3x20 Tightening torque 1 5 Nm xx1300000467 Note Only use specified screws never replace them with other screws Continues on next page Produc...

Page 212: ...ean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002496 Reconnect the connectors and secure the connectors to the bracket with cable straps 2 Continues on next page 212 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 1 Replacing the main cable package Continued ...

Page 213: ...ection class IP67 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the O ring Replace if damaged 4 Continues on next page Product manual IRB 1200 213 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 1 Replacing the main cable package Continu...

Page 214: ... robot to the foundation Note Action For robots with protection type Clean Room 1 For robots with food grade lubrica tion For robots with protection type Hy gienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 214 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4...

Page 215: ...Check the gasket at the bottom of the base Replace if damaged Attachment screws M12x35 robot installation directly on foundation quality 8 8 Raise the robot to standing and secure to the foundation with the attachment screws and washers 4 Washers 13 x 20 x 2 steel hardness class 300HV Pin 2 pcs D6x20 ISO 2338 6m6x20 A1 Tightening Torque 55 Nm 5 Nm Refitting the cable package in the lower arm Note ...

Page 216: ...Check the gasket Replace if damaged Gasket of plastic plate 3HAC044894 001 not Hygienic robots 3HAC080695 001 Hygien ic robots xx1400000457 For robots with protection class IP67 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the gasket of the cable housing plastic plate Re...

Page 217: ... plastic plate is included in Cable harness material set 3HAC049663 001 xx1400000023 Fasten the plastic plate to the cable housing if removed Replace if damaged 5 Continues on next page Product manual IRB 1200 217 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 1 Replacing the main cable package Continued ...

Page 218: ...pe Foundry Plus Check the sealing Replace if damaged CAUTION Do not fit M2 variseal sealing on robots in other protection class or protection types 6 Continues on next page 218 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 1 Replacing the main cable package Continued ...

Page 219: ...pply a little grease to the sealing when replacing the radial sealing and wipe clean after the replace ment 7 Replacement is detailed in Repla cing the swing spare parts swing axis 2 radial sealing on page 572 Guide the cable package into the lower arm Tip There is a groove on the lower arm casting that simplifies cable passage if needed Its position can easily be felt by hand 8 Tightening torque ...

Page 220: ...ly use specified screws never replace them with other screws xx1400000481 Apply grease to the cable package cover all moving area of the package 11 Continues on next page 220 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 1 Replacing the main cable package Continued ...

Page 221: ... Do not loosen the cable clamp screw There is a risk of rearrangement of the cable layout which would result in shortened lifetime of the cable harness 13 xx1300002432 Refit the axis 2 motor bracket to the motor 14 Continues on next page Product manual IRB 1200 221 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 1 Replacing the main cable package Continued ...

Page 222: ...ble package must be secured accordingly inside the EIB SMB cavity 1 The cable package is strapped with tape by the supplier at two locations Put a cable strap around the cable package at each location 2 Insert a third cable strap through the top strap and the bottom strap and close the strap to secure the cable package and keep it in place See the figure 17 Continues on next page 222 Product manua...

Page 223: ...brication For robots with protection type Hygienic Check the gasket of the cable housing cover Replace if damaged 18 PTFE film on cable housing cover 3HAC044660 001 Check the PTFE film Replace if damaged 19 Apply grease to the inner surface of the cable housing cover and to the PTFE film surface 20 Continues on next page Product manual IRB 1200 223 3HAC046983 001 Revision S Copyright 2014 2021 ABB...

Page 224: ...ng Hygienic 3HAC056214 001 Screws 3HAB3409 207 M3x8 Tightening torque 1 5 Nm xx1300002431 Note Only use specified screws never replace them with other screws Protection plug for lifting holes 3HAC4836 24 xx1600001151 For robots with protection type Foundry Plus Check the protection plugs for lifting holes Replace if damaged 22 Continues on next page 224 Product manual IRB 1200 3HAC046983 001 Revis...

Page 225: ...d result in shortened lifetime of the cable harness 24 Connecting the cabling in the lower arm Note Action ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 64 1 For robots with protection type Clean Room 2 For robots with food grade lubrication For robots with protection type Hyg...

Page 226: ...1 ME1 3 R1 ME4 6 R2 EIB WARNING Make sure not to mix the R2 EIB and R2 ME2 Axis 2 may be severely damaged See the labels on the connectors for correct connection 4 Valid for IRB 1200 no type specified and IRB 1200 Type A 5 Connect the lugs to the EIB SMB cover xx1700000005 Valid for IRB 1200 Type B Connect the connectors to the SMB unit R1 ME1 2 4 5 R1 ME3 6 R2 SMB WARNING Make sure not to mix the...

Page 227: ...EIB SMB cover to the lower arm with the attachment screws 8 Tightening torque 1 5 Nm xx1300002427 Note Only use specified screws never replace them with other screws Continues on next page Product manual IRB 1200 227 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 1 Replacing the main cable package Continued ...

Page 228: ... and wipe the parts free from particles with spirit on a lint free Area to be lubricated shown in cable package already fitted to the housing xx1400000483 Before guiding the cable package into the housing and upper arm apply grease to the cable package to the area going into the upper arm shown in the figure Cover all moving area of the package 2 Continues on next page 228 Product manual IRB 1200 ...

Page 229: ...ed in an optimized way It is necessary to keep the air hose holder vertically and firmly against the left side of the axis 3 motor 3 Tightening torque 1 5 Nm xx1300002424 Refit the bracket to the sheet with two screws CAUTION Do not loosen the cable clamp screw There is a risk of rearrangement of the cable layout which would result in shortened lifetime of the cable harness 4 Tightening torque 1 5...

Page 230: ...rstly remove the bracket from the fix sheet by removing the two M3 screws Fit the holder to the bracket and then refit the complete assembly to the fix sheet again Tightening torque for the two M3 screws 1 5 Nm xx1400001133 7 Tightening torque 4 Nm xx1300002422 xx1300002420 Reconnect the axis 3 motor connectors 8 Continues on next page 230 Product manual IRB 1200 3HAC046983 001 Revision S Copyrigh...

Page 231: ...r robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002371 Reconnect the motor connectors 2 Continues on next page Product manual IRB 1200 231 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Rep...

Page 232: ...tion type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002399 Reconnect the FPC connectors Tip See the number markings on the connectors for help to find the corresponding connector 2 Continues on next page 232 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 1 Repla...

Page 233: ...onnectors for help to find the corresponding connector 3 Cable layout in IRB 1200 5 0 9 xx1400001471 Remove residual locking liquid and other pollut ants with cleaning agent Loctite 7063 4 Continues on next page Product manual IRB 1200 233 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 1 Replacing the main cable package Continued ...

Page 234: ...type Clean Room For robots with protection type Clean Room For robots with food grade lubrication 7 For robots with food grade lubric ation For robots with protection type Hygienic Apply a string of the sealant to the joint of the small cover on the housing Sealant SikaFlex 521FC For robots with protection type Hygienic Smooth out the sealant string using a finger tip Use washing up on finger tips...

Page 235: ... arm cable housing 3HAC044710 001 xx1400000740 Check the PTFE film on the cable housing Replace if damaged 9 Continues on next page Product manual IRB 1200 235 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 1 Replacing the main cable package Continued ...

Page 236: ... cable housing cover 3HAC044660 001 xx1400000048 For robots with protection type Hygienic Check the gasket of the cable housing cover Replace if damaged Check the PTFE film on the cable housing cover 11 Replace if damaged Apply grease to the inner surface of the cable housing cover and the PTFE film surface 12 Continues on next page 236 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2...

Page 237: ... class and protection type Connecting the air hoses and CP CS cabling on robots not in protection type Hygienic Use this procedure if the robot is not in protection type Hygienic Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Air connector set wi...

Page 238: ...otection class IP67 On robots with protection type Foundry Plus Gasket 3HAC058567 001 xx1500000251 Protection bracket for CP CS con nectors 3HAC058350 001 xx1600001152 For robots with protection type Foundry Plus If required fit the protection bracket for CP CS connectors 4 Connecting the air hoses and CP CS cabling on robots in protection type Hygienic Use this procedure if the robot is with prot...

Page 239: ...aged xx1400000738 Reconnect the air hoses 3 xx1500000252 Reconnect the CP CS cabling 4 Plate with connector set 3HAC079691 001 Check the connectors on the plate with connector set and the attached gasket 5 Gasket 3HAC078804 001 xx2100001434 Replace if damaged Continues on next page Product manual IRB 1200 239 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 1 Repl...

Page 240: ...th food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002360 Reconnect the motor cables R3 MP5 R3 ME5 2 Refitting the wrist covers Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean th...

Page 241: ...d 2 Gasket for tubular cable housing cover 3HAC056707 001 not Hygienic robots 3HAC080701 001 Hygienic robots xx1400000345 For robots with protection class IP67 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cable housing cover gasket Replace if damaged 3 Contin...

Page 242: ... Clean Room For robots with food grade lubrication xx1600001153 For robots with protection type Clean Room For robots with food grade lubrication Remember to refit the extra two screws and washers to the tubular cover Note Only use specified screws never replace them with other screws For robots with protection type Hygienic xx2100001406 Note For robots with protection type Hygienic Check the two ...

Page 243: ...s with food grade lubrication For robots with protection type Hygienic Check the gasket Replace if damaged Screws 3HAB3409 207 M3x8 Refit the upper arm housing cover with the screws CAUTION For robots with safety lamp option Reconnect the lamp cable connectors R3 H1 and R3 H2 and then secure the cover 2 Tightening torque 1 5 Nm xx1300000456 Note Only use specified screws never replace them with ot...

Page 244: ...ra sealant to get a full cover joint For robots with protection type Clean Room 4 For robots with food grade lubrication For robots with protection type Hygienic Clean seal and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 158 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth Calibration ...

Page 245: ...yABB Business Portal www abb com myABB Note Article number Spare part 3HAC055517 001 FPC unit axis 4 Not used with protection class IP40 Replace if damaged 3HAB3701 48 Radial sealing with dust lip Used with protection class IP67 Used with protection type Foundry Plus Replace if damaged 3HAC044641 007 M2 variseal sealing Replace if damaged 3HAC059686 001 Housing extender unit Continues on next page...

Page 246: ...cover Hygienic Not used with protection class IP40 Replace if damaged 3HAC058822 001 3HAC080709 001 Gasket for tubular cover Not used with protection class IP40 Replace if damaged 3HAC056707 001 3HAC080701 001 Gasket for tubular cable housing cover Required tools and equipment Note Article number Equipment etc Used to refit the radial sealing if re placement is needed 3HAC049699 001 Axis 4 sealing...

Page 247: ...ne on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibrati...

Page 248: ...inside of the wrist unit Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surfa...

Page 249: ...r left hand side cover has two extra screws and washers as encircled in the figure For robots with protection type Hygienic xx2100001406 Note For robots with protection type Hygienic The tubular cover right hand side cover has two extra screws as encircled in the figure Do not remove the two screws when removing the cover The screws are used for blocking the screw holes rather than fixing the cove...

Page 250: ...e axis 5 motor with pulley Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or sur...

Page 251: ...r 6 Removing the wrist Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1200 251 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 2 Replacing the axis 4 FPC unit housing extender unit and housing extender sealings Continued ...

Page 252: ...aint or surface on the robot before replacing parts on page 158 2 xx1300002353 Disconnect the connectors shown in the figure 3 xx1300002355 Disconnect the air hoses 4 xx1300002356 Remove the connector plate attachment screws 5 Continues on next page 252 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 2 Replacing the axis 4 FPC unit housing...

Page 253: ...the air hoses out of the wrist Be careful not to damage the FPC cabling and the connectors CAUTION Pay special attention to the plastic block on the FPC unit It is easily pulled off make sure it stays fitted to the FPC unit xx1300002611 8 Continues on next page Product manual IRB 1200 253 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 2 Replacing the axis 4 FPC ...

Page 254: ...ienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300002400 Remove the cable housing cover 3 xx1300002413 Remove the plate 4 Continues on next page 254 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 2 Repl...

Page 255: ...Cable layout in IRB 1200 5 0 9 xx1400001471 xx1300002398 Remove the small cover of the housing 6 Continues on next page Product manual IRB 1200 255 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 2 Replacing the axis 4 FPC unit housing extender unit and housing extender sealings Continued ...

Page 256: ...parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300002373 Remove the axis 4 FPC unit screws 3 xx1600000262 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Remove the plugs covering the extender unit screws with a needle nose pl...

Page 257: ...ood grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300002415 Remove the mechanical stop assembly from the housing extender unit by removing the screws 3 Continues on next page Product manual IRB 1200 257 3HAC0...

Page 258: ...g in the figure is very closely located to the cabling Be careful not to damage the cabling with the screwdriver when remov ing refitting the screw 3 Refitting the FPC unit and the housing extender sealings Use these procedures to refit the FPC unit and the housing extender sealings Checking the housing extender sealings Note Action For robots with protection type Clean Room 1 For robots with food...

Page 259: ...ade lubrication For robots with protection type Hygienic Check the radial sealing Replace if damaged as described below In order to replace the radial sealing both the axis 4 mechanical stop and the axis 4 FPC unit must be removed from the hous ing extender unit if not already removed 3 Apply a little grease to the sealing when replacing the radial sealing and wipe clean after the replacement 4 Fi...

Page 260: ...erly fitted 10 Refit both the axis 4 mechanical stop and the axis 4 FPC unit to the housing extender unit 11 Refitting the axis 4 FPC unit Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next p...

Page 261: ...bots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002613 For robots with protection class IP67 For robots with protection type Foundry Plus Remove residual locking liquid and other pollut ants with cleaning agent Loctite...

Page 262: ...its zero position when refitting the housing extender unit Note Mate the unit to the two locating pins attached to the housing 4 Screws M4x30 Secure with screws and washers using locking liquid Loctite 243 5 Tightening torque 2 7 Nm xx1300002372 Screw sealing plug 3HAC053685 001 xx1600000263 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with foo...

Page 263: ... Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002399 Reconnect the FPC connectors Tip See the number markings on the connectors for help to find the corresponding connector 2 Continues on next page Product manual IRB 1200 263 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 2 Replacing the axis 4 FP...

Page 264: ...d the corresponding connector 3 Cable layout in IRB 1200 5 0 9 xx1400001471 Remove residual locking liquid and other pollut ants with cleaning agent Loctite 7063 4 Continues on next page 264 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 2 Replacing the axis 4 FPC unit housing extender unit and housing extender sealings Continued ...

Page 265: ...ts with protection type Clean Room For robots with food grade lubrication 7 For robots with food grade lubric ation For robots with protection type Hygienic Apply a string of the sealant to the joint of the small cover on the housing Sealant SikaFlex 521FC For robots with protection type Hygienic Smooth out the sealant string using a finger tip Use washing up on finger tips to get a smooth joint S...

Page 266: ...44710 001 xx1400000740 Check the PTFE film on the cable housing Replace if damaged 9 Continues on next page 266 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 2 Replacing the axis 4 FPC unit housing extender unit and housing extender sealings Continued ...

Page 267: ...C044660 001 xx1400000048 For robots with protection type Hygienic Check the gasket of the cable housing cover Replace if damaged Check the PTFE film on the cable housing cover 11 Replace if damaged Apply grease to the inner surface of the cable housing cover and the PTFE film surface 12 Continues on next page Product manual IRB 1200 267 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights ...

Page 268: ...ing the cover Note Only use specified screws never replace them with other screws Refitting the wrist Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 268 Product manual IRB 1200 3HAC0...

Page 269: ... on the FPC unit It is easily pulled off make sure it stays fitted to the FPC unit xx1300002611 2 Washer 3HAC044869 001 xx1400000001 Refit the washer while at the same time putting the cables through its center Replace washer if damaged 3 Continues on next page Product manual IRB 1200 269 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 2 Replacing the axis 4 FPC ...

Page 270: ...35 7 pcs 5 Note Only use specified screws never replace them with other screws Tightening torque 8 Nm Tighten all screws 6 Tightening torque 0 3 Nm xx1300002356 Put the cables through the plate hole and refit the plate 7 Continues on next page 270 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 2 Replacing the axis 4 FPC unit housing exten...

Page 271: ...and wipe the parts free from particles with spirit on a lint free Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 2 Screws 3HAB3409 212 M4x16 xx1300002463 Place the motor at its mounting position and fasten the attachment screws and washers just enough to still be able to move the motor 3 Note Only use specified screws never replace them with other s...

Page 272: ...belt tension is reached F 26 N 3 xx1300002350 Secure the motor with its attachment screws 4 Tightening torque 3 5 Nm Connecting the axis 5 motor FPC connectors Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint fre...

Page 273: ... lint free xx1300002360 Reconnect the motor cables R3 MP5 R3 ME5 2 Refitting the wrist covers Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page Product manual IRB 1200 273 3HAC046983 00...

Page 274: ...ble housing cover 3HAC056707 001 not Hygienic robots 3HAC080701 001 Hygienic robots xx1400000345 For robots with protection class IP67 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cable housing cover gasket Replace if damaged 3 Continues on next page 274 Prod...

Page 275: ...ith food grade lubrication xx1600001153 For robots with protection type Clean Room For robots with food grade lubrication Remember to refit the extra two screws and washers to the tubular cover Note Only use specified screws never replace them with other screws For robots with protection type Hygienic xx2100001406 Note For robots with protection type Hygienic Check the two extra screws on the tubu...

Page 276: ... 158 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth Calibration information is included in sec tion Calibration on page 805 Recalibrate the robot 2 DANGER Make sure all safety requirements are met when performing the first test run 3 276 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 2 Repla...

Page 277: ...l sealing Not used with protection class IP40 and protection type Hy gienic 3HAB3701 42 Radial sealing Replace if damaged Not used with protection class IP40 3HAC056707 001 3HAC080701 001 Gasket for tubular cable housing cover Replace if damaged 3HAC059695 001 Tubular cable housing Used with protection type Clean Room 3HAC056143 001 Tubular cable housing Clean Room Used for robots with food grade ...

Page 278: ...Clear 3HAC073510 001 Sealant For robots with protection type Hygienic Deciding calibration routine Decide which calibration routine to be used based on the information in the table Depending on which routine is chosen action might be required prior to beginning the repair work of the robot see the table Note Action Note Calibrating axis 6 always requires tools to be removed from the mounting flang...

Page 279: ...lues can be created then reference calibration is not possible If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the FPC unit Use these procedures to remove the FPC unit Preparations before removing the axis 5 FPC unit Note Action Decide which calibration routine to use and take actions accordingly prior to beginni...

Page 280: ...at all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1...

Page 281: ...l supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx130000...

Page 282: ... motor connectors and re move the FPC unit completely 6 Refitting the FPC unit Use these procedures to refit the FPC unit Refitting the axis 5 FPC unit Note Action WARNING It is important that axis 5 is in zero position when fitting the FPC unit Make sure that the FPC is in zero position and does not get twisted during refitting 1 Continues on next page 282 Product manual IRB 1200 3HAC046983 001 R...

Page 283: ...it on a lint free xx1300002395 Reconnect the axis 6 motor connectors to the FPC unit 3 Tightening torque 0 3 Nm xx1300002394 Carefully refit the FPC unit and secure with screws Note Check that the FPC unit is at the zero pos ition when refitting it 4 Continues on next page Product manual IRB 1200 283 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 3 Replacing the...

Page 284: ...eeve Note For Hygienic robots wipe clean the over flowing flange sealing if there is any Sleeve 3HAC044661 001 Refit the sleeve and secure with screws 6 Tightening torque 1 5 Nm xx1300002393 Replace if damaged Checking the tubular cable housing sealings Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the...

Page 285: ... below If undamaged and properly seated skip to the next procedure table 3 Apply a little grease to the sealing when replacing the radial sealing and wipe clean after the replacement 4 Fit the radial sealing into the tubular cable housing 5 Axis 5 sealing assembly tool set 3HAC049701 001 xx1400000485 Fit the circular part of the radial sealing assembly tool against the radial sealing 6 Fit the too...

Page 286: ...r robots with protection class IP67 For robots with protection type Foundry Plus 2 For robots with protection type Foundry Plus For robots with protection type Hygienic Remove residual locking liquid and other pollut ants with cleaning agent Loctite 7063 Flange sealant SikaFlex 521FC For robots with protection type Hygienic Apply flange sealing on the mounting surfaces of the tubular cable housing...

Page 287: ...e Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Tightening torque 0 3 Nm xx1400001401 Refit the connector plate and secure with the M3 screws 2 Continues on next page Product manual IRB 1200 287 3HAC046983 001...

Page 288: ...n a lint free xx1300002390 Connect the axis 5 FPC connectors and snap them to their holders 2 Refitting the tubular cable housing cover Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page...

Page 289: ...ood grade lubrication For robots with protection type Hygienic Check the tubular cable housing cover gasket Replace if damaged 2 Screws 3HAB3409 207 M3x8 Refit the cover to the cable housing 3 Tightening torque 1 5 Nm xx1300002389 Note Only use specified screws never replace them with other screws Continues on next page Product manual IRB 1200 289 3HAC046983 001 Revision S Copyright 2014 2021 ABB ...

Page 290: ...re replacing parts on page 158 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth Calibration information is included in sec tion Calibration on page 805 Recalibrate the robot 2 DANGER Make sure all safety requirements are met when performing the first test run 3 290 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights res...

Page 291: ...e figure Note The EIB unit is used for IRB 1200 no type specified and IRB 1200 Type A The SMB unit is used for IRB 1200 Type B xx1300002574 Continues on next page Product manual IRB 1200 291 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 4 Replacing the EIB SMB unit ...

Page 292: ...onsumables Note Article number Equipment Loctite 243 3HAB7116 1 Locking liquid Deciding calibration routine Decide which calibration routine to be used based on the information in the table Depending on which routine is chosen action might be required prior to beginning the repair work of the robot see the table Note Action Note Calibrating axis 6 always requires tools to be removed from the mount...

Page 293: ...es can be created then reference calibration is not possible If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the EIB SMB unit Use these procedures to remove the EIB SMB unit Preparations before removing the EIB SMB unit Note Action Decide which calibration routine to use and take actions accordingly prior to begi...

Page 294: ... lower arm cable housing cov er 5 Disconnecting the cabling in the lower arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 64 2 Continues on next page 294 P...

Page 295: ...ortage on the boards which can result in hazardous failures CAUTION Be aware of the cabling that is attached to the cover The cover can not be removed completely until the connectors and lugs are disconnected as shown in following step 4 xx1300002428 Valid for IRB 1200 no type specified and IRB 1200 Type A Disconnect the connectors on the EIB unit R1 ME1 3 R1 ME4 6 R2 EIB Remove the EIB SMB cover ...

Page 296: ...fied and IRB 1200 Type A Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 64 2 Continues on next page 296 Product manual IRB 1200 3HAC046983 001 Revision S Cop...

Page 297: ... when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 3 xx1300002571 Disconnect the battery cable 4 xx1300002572 Remove the battery pack plate by removing the screws 5 Continues on next page Product manual IRB 1200 297 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 4 Replacing the EIB SMB unit Continu...

Page 298: ...formation in the section The unit is sensitive to ESD on page 64 2 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 3 Continues on next page 298...

Page 299: ...attery pack plate by removing the screws 5 xx1700000009 Remove the SMB unit by removing the distance screws 6 Continues on next page Product manual IRB 1200 299 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 4 Replacing the EIB SMB unit Continued ...

Page 300: ...t is sensitive to ESD on page 64 1 For robots with protection type Clean Room 2 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002573 Refit the EIB unit with the distance screws 3 Continues on next page 300 Product manual IRB 1200 3HAC046983 001 Revision S...

Page 301: ...d the safety information in the section The unit is sensitive to ESD on page 64 1 For robots with protection type Clean Room 2 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page Product manual IRB 1200 301 3HAC046983 001 Revision S Copyright 2...

Page 302: ...que 1 5 Nm xx1700000008 Refit the battery pack plate with the screws 4 xx1700000006 Reconnect the battery cable 5 Continues on next page 302 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 4 Replacing the EIB SMB unit Continued ...

Page 303: ...wipe the parts free from particles with spirit on a lint free Gasket on EIB SMB cover 3HAC056728 001 not Hygienic robots 3HAC080706 001 Hygien ic robots xx1400000475 For robots with protection class IP67 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the EIB SMB cover gask...

Page 304: ...nect the lugs to the EIB SMB cover xx1700000005 Valid for IRB 1200 Type B Connect the connectors to the SMB unit R1 ME1 2 4 5 R1 ME3 6 R2 SMB WARNING Make sure not to mix the R2 SMB and R2 ME2 Axis 2 may be severely damaged See the labels on the connectors for correct connection 6 Tightening torque 0 3 Nm xx1700000004 Valid for IRB 1200 Type B Tighten the connector screws 7 Continues on next page ...

Page 305: ...02427 Note Only use specified screws never replace them with other screws Tightening torque 1 5 Nm xx1300002426 Refit the fix sheet attachment screws in the lower arm 9 Continues on next page Product manual IRB 1200 305 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 3 4 Replacing the EIB SMB unit Continued ...

Page 306: ... lubrication For robots with protection type Hygienic Check the gasket of the cable housing cover Replace if damaged 1 PTFE film on cable housing cover 3HAC044660 001 Check the PTFE film on the cable housing cover 2 Replace if damaged Apply grease to the inner surface of the cable housing cover and the PTFE film surface 3 Continues on next page 306 Product manual IRB 1200 3HAC046983 001 Revision S...

Page 307: ... protection type Clean Room 5 For robots with food grade lubrication For robots with protection type Hygienic Clean seal and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 158 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth Calibration information is included in sec tion Calibration on p...

Page 308: ...ers that are listed in the table can be out of date See the latest spare parts of the IRB 1200 via myABB Business Portal www abb com myABB Note Article number Spare part Includes guide pin 3HAC059687 001 Lower arm IRB 1200 7 0 7 Continues on next page 308 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 1 Replacing the lower arm ...

Page 309: ...robots with food grade lubrication Used with protection type Hy gienic Replace if damaged 3HAC056135 001 Cable housing of the lower arm Clean Room Cable housing of the lower arm food grade lubrication Cable housing of the lower arm Hygienic Not used with protection class IP40 Replace if damaged 3HAC044895 001 3HAC080696 001 Gasket on lower arm cable housing Used with protection class IP67 Used wit...

Page 310: ...ged 3HAC056214 001 Cable housing cover of the swing Clean Room Cable housing cover of the swing food grade lubrication Cable housing cover of the swing Hygienic Not used for robots with protec tion class IP40 Replace if damaged 3HAC056726 001 3HAC080704 001 Gasket on cable housing cover Used with protection class IP67 Used with protection type Foundry Plus Replace if damaged 3HAC044641 003 M2 vari...

Page 311: ...Replace if damaged 3HAC056707 001 3HAC080701 001 Gasket for tubular cable housing cover Not used with protection class IP40 Replace if damaged 3HAC056698 001 3HAC080700 001 Housing cover gasket IRB 1200 7 0 7 Not used with protection class IP40 Replace if damaged 3HAC056697 001 3HAC080699 001 Housing cover gasket IRB 1200 5 0 9 Includes tubular flange air con nectors and seal bolts Replace if dama...

Page 312: ... menu on the FlexPendant If no data is found related to standard calibration manual calibration is used as default Required consumables Note Art no Consumable Cable straps Loctite 7063 Cleaning agent Loctite 243 3HAB7116 1 Locking liquid Loctite 574 12340011 116 Flange sealing Used for lubrication of cable con tact areas 3HAC042536 001 Grease Used for lubrication of cable con tact areas for robots...

Page 313: ...er ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 819 If no previous reference values exist and ...

Page 314: ...page 158 4 Getting access to inside of the wrist unit Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the rob...

Page 315: ... lubrication The tubular cover left hand side cover has two extra screws and washers as encircled in the figure For robots with protection type Hygienic xx2100001406 Note For robots with protection type Hygienic The tubular cover right hand side cover has two extra screws as encircled in the figure Do not remove the two screws when removing the cover The screws are used for blocking the screw hole...

Page 316: ...cting them to have as a reference when reconnecting 3 Disconnecting the axis 5 FPC connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint ...

Page 317: ...bots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1400000738 Disconnect the air hoses 3 xx1500000252 If equipped disconnect the CP CS connector 4 Continues on next page Product manual IRB 1200 317 3...

Page 318: ...bots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300002400 Remove the cable housing cover 3 xx1300002413 Remove the plate 4 Continues on next page 318 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights...

Page 319: ...ousing and disconnect them 5 Cable layout in IRB 1200 5 0 9 xx1400001471 xx1300002398 Remove the small cover of the housing 6 Continues on next page Product manual IRB 1200 319 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 1 Replacing the lower arm Continued ...

Page 320: ... a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300000456 Remove the cover from the upper arm housing CAUTION For robots with safety lamp option Be aware of the signal lamp cables that are at tached inside the housing Disconnect the lamp cable connectors R3 H1 and R3 H2 and then lift away the ...

Page 321: ...l power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Continues on next page Product m...

Page 322: ...e Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300002422 Remove the screw that fastens the air hose hold er 3 Continues on next page 322 Product manual IRB 1200 3HAC046983 001...

Page 323: ...oosen the cable clamp screw There is a risk of rearrangement of the cable layout which would result in shortened lifetime of the cable harness 6 Valid for IRB 1200 5 0 9 7 Cut the cable straps at the bottom of the housing Disconnecting the cabling in the lower arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on n...

Page 324: ... cover CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures CAUTION Be aware of the cabling that is attached to the cover The cover can not be removed completely until the connectors and lugs are disconnected as shown in following step 4 xx1300002428 Valid for IRB 1200 no type specified and IRB 1200 Type A Dis...

Page 325: ...essure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Pull the cable package out from the upper arm housin...

Page 326: ...ned lifetime of the cable harness 5 xx1400001130 Cut the cable strap that holds the cabling together inside the EIB SMB cavity 6 xx1600000205 For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Remove the swing sealing plug Follow the procedure specified in Removing the swing sealing plug on page 166 7 Continues on next page 32...

Page 327: ...g the screws 8 xx1400001528 Cut the cable straps 9 xx1300002432 Remove the axis 2 motor bracket screws 10 Continues on next page Product manual IRB 1200 327 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 1 Replacing the lower arm Continued ...

Page 328: ...e layout which would result in shortened lifetime of the cable harness 11 xx1300002434 Disconnect the motor connectors R2 ME2 R2 MP2 12 xx1300002435 Loosen the cable housing from the swing by re moving the screws Leave it hanging on the cable package 13 Continues on next page 328 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 1 Replacing ...

Page 329: ...able housing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the ro...

Page 330: ...with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Continues on next page 330 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights ...

Page 331: ...upport the weight of the arm no force 5 xx1300002531 Remove the upper arm screws WARNING This releases the upper arm from the lower arm Make sure the weight of the upper arm is properly secured by the lifting slings 6 Continues on next page Product manual IRB 1200 331 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 1 Replacing the lower arm Continued ...

Page 332: ...er and lower arm with guidance from the guide pins 8 Removing the lower arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 332 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 1 Replacing the lower arm Continued ...

Page 333: ...on page 158 2 xx1300002551 Remove the swing cover 3 xx1300002552 Remove the lower arm screws and wash ers WARNING This releases the lower arm from the swing Make sure the weight of the arm is properly secured The lower arm weighs 13 kg If the upper arm is also attached to the lower arm it adds an additional 17 kg to the total weight 4 Continues on next page Product manual IRB 1200 333 3HAC046983 0...

Page 334: ... evenly 6 Removing the axis 2 drive unit Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut th...

Page 335: ...it is best performed by two persons working together Person 1 Hold the lower arm still Person 2 Remove the drive unit screws according to step below 4 Remove the grey screws from the drive unit WARNING Keep the eight black screws fitted They hold the gearbox together Removing them can damage the gearbox severely 5 xx1400000008 Insert two M4 screws to the press out holes and press out the drive uni...

Page 336: ...nt amount of grease on the gear Apply more grease if needed 2 For robots with food grade lubrication For robots with protection type Hygienic LUBRIPLATE SYNXTREME FG 0 3HAC043771 001 xx1400000006 For robots with protection class IP67 For robots with protection type Foundry Plus Remove residual locking liquid and other pollutants with cleaning agent Loctite 7063 Apply flange sealing Loctite 574 on ...

Page 337: ...s refitted in a hanging lower arm this step requires two persons Person 1 Hold the lower arm still Person 2 Refit the drive unit screws Secure the screws but do not tighten yet 5 Note Only use specified screws never replace them with other screws Tightening torque 5 Nm If the drive unit is refitted in a hanging lower arm this step requires two persons Person 1 Hold the lower arm still Person 2 Tig...

Page 338: ...aged 2 xx1400001403 Remove residual locking liquid and other pollutants with cleaning agent Loctite 7063 Apply flange sealing Loctite 574 to the cyl indrical surface in the swing Note For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Wipe clean the overflowing Loctite 574 if there is any 3 Continues on next page 338 Product m...

Page 339: ...or robots with protection type Foundry Plus Check the sealing Replace if damaged CAUTION Do not fit M2 variseal sealing on robots in other protection class or protection types 5 xx1300002563 Fit the lower arm to the swing with guid ance from the guide pins 6 Continues on next page Product manual IRB 1200 339 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 1 Repla...

Page 340: ...pecified screws never replace them with other screws xx1300002565 Remove the guide pins and refit the remain ing screws and washers using locking li quid Loctite 243 8 Tightening torque 45 Nm Tighten all screws 9 Continues on next page 340 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 1 Replacing the lower arm Continued ...

Page 341: ...obots with protection type Hygienic Check the swing cover gasket Replace if damaged 10 Screws 3HAB3409 207 M3x8 Refit the swing cover 11 Tightening torque 1 5 Nm Replace if damaged Swing cover 3HAC059676 001 Swing cover Clean Room Swing cover food grade lubrication Swing cover Hygienic 3HAC056215 001 xx1300002551 Continues on next page Product manual IRB 1200 341 3HAC046983 001 Revision S Copyrigh...

Page 342: ...protection type Hygienic For robots with protection type Hygienic Apply a string of the sealant to the joint of the swing cover Sealant Trans Clear xx1600000217 Smooth out the sealant string using a finger tip Use washing up on finger tips to get a smooth joint If necessary add extra sealant to get a full cover joint xx1600001154 For robots with protection type Foundry Plus If required fit two scr...

Page 343: ... pins to the axis 3 gear unit 2 Always use three guide pins together xx1400000027 M2 variseal sealing 3HAC044641 005 xx1400000474 For robots with protection class IP67 For robots with protection type Foundry Plus Check the sealing Replace if damaged CAUTION Do not fit M2 variseal sealing on robots in other protection class or protection types 3 Continues on next page Product manual IRB 1200 343 3H...

Page 344: ...te Only use specified screws never replace them with other screws xx1400000029 Remove the guide pins and refit the remain ing screws and washers 5 Tightening torque 4 5 Nm Tighten all screws 6 Continues on next page 344 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 1 Replacing the lower arm Continued ...

Page 345: ...s with food grade lubrication For robots with protection type Hygienic Check the lower arm cover gasket Replace if damaged 7 Screws 3HAB3409 207 M3x8 Refit the lower arm cover 8 Tightening torque 1 5 Nm xx1300002528 Note Only use specified screws never replace them with other screws Continues on next page Product manual IRB 1200 345 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights rese...

Page 346: ...ean Room For robots with food grade lubrication For robots with protection type Hygienic Check the axis 3 radial sealing and the M2 variseal sealing in the cable housing Replace if damaged CAUTION Do not fit M2 variseal sealing on Clean Room food grade lubrication and Hygienic robots Note For robots with protection type Clean Room For robots with food grade lubrication For robots with protection t...

Page 347: ...of the cable housing of the lower arm Sealant Trans Clear xx1600000218 Smooth out the sealant string using a finger tip Use washing up on finger tips to get a smooth joint If necessary add extra sealant to get a full cover joint Note No sealing is required in the cavities of the three lower screws highlighted with a ring in the figure xx1600001155 For robots with protection type Foundry Plus If re...

Page 348: ... type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the gasket Replace if damaged Gasket of plastic plate 3HAC044894 001 not Hygienic robots 3HAC080695 001 Hygien ic robots xx1400000457 For robots with protection class IP67 For robots with protection type Foundry Plus For robots with protection type Cle...

Page 349: ... The plastic plate is included in Cable harness material set 3HAC049663 001 xx1400000023 Fasten the plastic plate to the cable housing if removed Replace if damaged 5 Continues on next page Product manual IRB 1200 349 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 1 Replacing the lower arm Continued ...

Page 350: ...on type Foundry Plus Check the sealing Replace if damaged CAUTION Do not fit M2 variseal sealing on robots in other protection class or protection types 6 Continues on next page 350 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 1 Replacing the lower arm Continued ...

Page 351: ...nic Apply a little grease to the sealing when replacing the radial sealing and wipe clean after the replace ment 7 Replacement is detailed in Repla cing the swing spare parts swing axis 2 radial sealing on page 572 Guide the cable package into the lower arm Tip There is a groove on the lower arm casting that simplifies cable passage if needed Its position can easily be felt by hand 8 Tightening to...

Page 352: ...e Only use specified screws never replace them with other screws xx1400000481 Apply grease to the cable package cover all moving area of the package 11 Continues on next page 352 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 1 Replacing the lower arm Continued ...

Page 353: ...TION Do not loosen the cable clamp screw There is a risk of rearrangement of the cable layout which would result in shortened lifetime of the cable harness 13 xx1300002432 Refit the axis 2 motor bracket to the motor 14 Continues on next page Product manual IRB 1200 353 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 1 Replacing the lower arm Continued ...

Page 354: ...e cable package must be secured accordingly inside the EIB SMB cavity 1 The cable package is strapped with tape by the supplier at two locations Put a cable strap around the cable package at each location 2 Insert a third cable strap through the top strap and the bottom strap and close the strap to secure the cable package and keep it in place See the figure 17 Continues on next page 354 Product m...

Page 355: ...de lubrication For robots with protection type Hygienic Check the gasket of the cable housing cover Replace if damaged 18 PTFE film on cable housing cover 3HAC044660 001 Check the PTFE film Replace if damaged 19 Apply grease to the inner surface of the cable housing cover and to the PTFE film surface 20 Continues on next page Product manual IRB 1200 355 3HAC046983 001 Revision S Copyright 2014 202...

Page 356: ...e swing Hygienic 3HAC056214 001 Screws 3HAB3409 207 M3x8 Tightening torque 1 5 Nm xx1300002431 Note Only use specified screws never replace them with other screws Protection plug for lifting holes 3HAC4836 24 xx1600001151 For robots with protection type Foundry Plus Check the protection plugs for lifting holes Replace if damaged 22 Continues on next page 356 Product manual IRB 1200 3HAC046983 001 ...

Page 357: ...would result in shortened lifetime of the cable harness 24 Connecting the cabling in the lower arm Note Action ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 64 1 For robots with protection type Clean Room 2 For robots with food grade lubrication For robots with protection type...

Page 358: ...it R1 ME1 3 R1 ME4 6 R2 EIB WARNING Make sure not to mix the R2 EIB and R2 ME2 Axis 2 may be severely damaged See the labels on the connectors for correct connection 4 Valid for IRB 1200 no type specified and IRB 1200 Type A 5 Connect the lugs to the EIB SMB cover xx1700000005 Valid for IRB 1200 Type B Connect the connectors to the SMB unit R1 ME1 2 4 5 R1 ME3 6 R2 SMB WARNING Make sure not to mix...

Page 359: ...the EIB SMB cover to the lower arm with the attachment screws 8 Tightening torque 1 5 Nm xx1300002427 Note Only use specified screws never replace them with other screws Continues on next page Product manual IRB 1200 359 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 1 Replacing the lower arm Continued ...

Page 360: ...ened and wipe the parts free from particles with spirit on a lint free Area to be lubricated shown in cable package already fitted to the housing xx1400000483 Before guiding the cable package into the housing and upper arm apply grease to the cable package to the area going into the upper arm shown in the figure Cover all moving area of the package 2 Continues on next page 360 Product manual IRB 1...

Page 361: ...rranged in an optimized way It is necessary to keep the air hose holder vertically and firmly against the left side of the axis 3 motor 3 Tightening torque 1 5 Nm xx1300002424 Refit the bracket to the sheet with two screws CAUTION Do not loosen the cable clamp screw There is a risk of rearrangement of the cable layout which would result in shortened lifetime of the cable harness 4 Tightening torqu...

Page 362: ...it firstly remove the bracket from the fix sheet by removing the two M3 screws Fit the holder to the bracket and then refit the complete assembly to the fix sheet again Tightening torque for the two M3 screws 1 5 Nm xx1400001133 7 Tightening torque 4 Nm xx1300002422 xx1300002420 Reconnect the axis 3 motor connectors 8 Continues on next page 362 Product manual IRB 1200 3HAC046983 001 Revision S Cop...

Page 363: ...on For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002371 Reconnect the motor connectors 2 Continues on next page Product manual IRB 1200 363 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved ...

Page 364: ...rotection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002399 Reconnect the FPC connectors Tip See the number markings on the connectors for help to find the corresponding connector 2 Continues on next page 364 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 1 ...

Page 365: ...he connectors for help to find the corresponding connector 3 Cable layout in IRB 1200 5 0 9 xx1400001471 Remove residual locking liquid and other pollut ants with cleaning agent Loctite 7063 4 Continues on next page Product manual IRB 1200 365 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 1 Replacing the lower arm Continued ...

Page 366: ...tion type Clean Room For robots with protection type Clean Room For robots with food grade lubrication 7 For robots with food grade lubric ation For robots with protection type Hygienic Apply a string of the sealant to the joint of the small cover on the housing Sealant SikaFlex 521FC For robots with protection type Hygienic Smooth out the sealant string using a finger tip Use washing up on finger...

Page 367: ...lower arm cable housing 3HAC044710 001 xx1400000740 Check the PTFE film on the cable housing Replace if damaged 9 Continues on next page Product manual IRB 1200 367 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 1 Replacing the lower arm Continued ...

Page 368: ...lm on cable housing cover 3HAC044660 001 xx1400000048 For robots with protection type Hygienic Check the gasket of the cable housing cover Replace if damaged Check the PTFE film on the cable housing cover 11 Replace if damaged Apply grease to the inner surface of the cable housing cover and the PTFE film surface 12 Continues on next page 368 Product manual IRB 1200 3HAC046983 001 Revision S Copyri...

Page 369: ...tion class and protection type Connecting the air hoses and CP CS cabling on robots not in protection type Hygienic Use this procedure if the robot is not in protection type Hygienic Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Air connector se...

Page 370: ...h protection class IP67 On robots with protection type Foundry Plus Gasket 3HAC058567 001 xx1500000251 Protection bracket for CP CS con nectors 3HAC058350 001 xx1600001152 For robots with protection type Foundry Plus If required fit the protection bracket for CP CS connectors 4 Connecting the air hoses and CP CS cabling on robots in protection type Hygienic Use this procedure if the robot is with ...

Page 371: ...f damaged xx1400000738 Reconnect the air hoses 3 xx1500000252 Reconnect the CP CS cabling 4 Plate with connector set 3HAC079691 001 Check the connectors on the plate with connector set and the attached gasket 5 Gasket 3HAC078804 001 xx2100001434 Replace if damaged Continues on next page Product manual IRB 1200 371 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 1...

Page 372: ...ts with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002360 Reconnect the motor cables R3 MP5 R3 ME5 2 Refitting the wrist covers Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Cle...

Page 373: ...maged 2 Gasket for tubular cable housing cover 3HAC056707 001 not Hygienic robots 3HAC080701 001 Hygienic robots xx1400000345 For robots with protection class IP67 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cable housing cover gasket Replace if damaged 3 Co...

Page 374: ... type Clean Room For robots with food grade lubrication xx1600001153 For robots with protection type Clean Room For robots with food grade lubrication Remember to refit the extra two screws and washers to the tubular cover Note Only use specified screws never replace them with other screws For robots with protection type Hygienic xx2100001406 Note For robots with protection type Hygienic Check the...

Page 375: ...obots with food grade lubrication For robots with protection type Hygienic Check the gasket Replace if damaged Screws 3HAB3409 207 M3x8 Refit the upper arm housing cover with the screws CAUTION For robots with safety lamp option Reconnect the lamp cable connectors R3 H1 and R3 H2 and then secure the cover 2 Tightening torque 1 5 Nm xx1300000456 Note Only use specified screws never replace them wit...

Page 376: ...d extra sealant to get a full cover joint For robots with protection type Clean Room 4 For robots with food grade lubrication For robots with protection type Hygienic Clean seal and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 158 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth Calibra...

Page 377: ...rtal www abb com myABB Note Article number Spare part 3HAC16738 1 Signal lamp Not used with protection class IP40 Replace if damaged 3HAC056698 001 3HAC080700 001 Housing cover gasket IRB 1200 7 0 7 Not used with protection class IP40 Replace if damaged 3HAC056697 001 3HAC080699 001 Housing cover gasket IRB 1200 5 0 9 Continues on next page Product manual IRB 1200 377 3HAC046983 001 Revision S Cop...

Page 378: ...obot See Cut the paint or surface on the robot before repla cing parts on page 158 2 xx1300000456 Remove the attachment screws of the upper arm housing cover and lift the cover carefully until the connectors of the signal lamp can be reached 3 Disconnect the connectors and remove the cover from the robot 4 Remove the nut from the lamp and pull out the lamp from the cover 5 Fit the new lamp to the ...

Page 379: ...k the gasket Replace if damaged Screws 3HAB3409 207 M3x8 Refit the cover on the upper arm housing 10 Tightening torque 1 5 Nm Note Only use specified screws never replace them with other screws The signal lamp is now ready for use and is lit in MOTORS ON mode 11 For robots with protection type Clean Room 12 For robots with food grade lubrication For robots with protection type Hygienic Clean seal ...

Page 380: ...rotection type Hygienic 3HAC079693 001 Used with protection type Hygienic Used with protection type Hygienic Replace if damaged Replace if damaged i For information on which tubular to be ordered see Spare part versions for the tubular on Type A robots on page 881 ii For information on which tubular cover for Clean Room robots to be ordered see Spare part versions for the tubular cover on Clean Ro...

Page 381: ...l sealing Replace if damaged 3HAC059694 001 Tubular cable housing cover Used with protection type Clean Room Used for robots with food grade lubrication Replace if damaged 3HAC056145 001 Tubular cable housing cover Clean Room Tubular cable housing cover food grade lubrication Used with protection type Hy gienic Replace if damaged 3HAC079690 001 Tubular cable housing cover Hygienic Not used with pr...

Page 382: ...de pin for stainless shaft on tool flange i The robot is calibrated by either manual calibration or Axis Calibration at factory Always use the same calibration method as used at the factory Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant If no data is found related to standard calibration manual calibration is used as defau...

Page 383: ... be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 819 If no previous refe...

Page 384: ...hese procedures to replace the tubular cable housing Getting access to inside of the wrist unit Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the pain...

Page 385: ...ubrication The tubular cover left hand side cover has two extra screws and washers as encircled in the figure For robots with protection type Hygienic xx2100001406 Note For robots with protection type Hygienic The tubular cover right hand side cover has two extra screws as encircled in the figure Do not remove the two screws when removing the cover The screws are used for blocking the screw holes ...

Page 386: ...using of the tubular by first removing the screws Note For robots with protection class IP67 For robots with protection type Foundry Plus For robots with protection type Hygienic The frame is glued and needs to be pried off 5 Checking the tubular cable housing sealings Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hy...

Page 387: ...elow If undamaged and properly seated skip to the next procedure table 3 Apply a little grease to the sealing when replacing the radial sealing and wipe clean after the replacement 4 Fit the radial sealing into the tubular cable housing 5 Axis 5 sealing assembly tool set 3HAC049701 001 xx1400000485 Fit the circular part of the radial sealing assembly tool against the radial sealing 6 Fit the tool ...

Page 388: ...robots with protection class IP67 For robots with protection type Foundry Plus 2 For robots with protection type Foundry Plus For robots with protection type Hygienic Remove residual locking liquid and other pollut ants with cleaning agent Loctite 7063 Flange sealant SikaFlex 521FC For robots with protection type Hygienic Apply flange sealing on the mounting surfaces of the tubular cable housing N...

Page 389: ...Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Tightening torque 0 3 Nm xx1400001401 Refit the connector plate and secure with the M3 screws 2 Continues on next page Product manual IRB 1200 389 3HAC046983 001 R...

Page 390: ...irit on a lint free xx1300002390 Connect the axis 5 FPC connectors and snap them to their holders 2 Refitting the wrist covers Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 390 Prod...

Page 391: ... 2 Gasket for tubular cable housing cover 3HAC056707 001 not Hygienic robots 3HAC080701 001 Hygienic robots xx1400000345 For robots with protection class IP67 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cable housing cover gasket Replace if damaged 3 Continu...

Page 392: ... Clean Room For robots with food grade lubrication xx1600001153 For robots with protection type Clean Room For robots with food grade lubrication Remember to refit the extra two screws and washers to the tubular cover Note Only use specified screws never replace them with other screws For robots with protection type Hygienic xx2100001406 Note For robots with protection type Hygienic Check the two ...

Page 393: ...ection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Continues on next page Product manual IRB 1200 393 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved ...

Page 394: ...ication The tubular cover left hand side cover has two extra screws and washers as encircled in the figure For robots with protection type Hygienic xx2100001406 Note For robots with protection type Hygienic The tubular cover right hand side cover has two extra screws as encircled in the figure Do not remove the two screws when removing the cover The screws are used for blocking the screw holes rat...

Page 395: ...connecting 3 Removing the axis 5 motor with pulley Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot ...

Page 396: ...ws and pull out the motor 6 Removing the wrist Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 396 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 3 Replacing the tubular spare parts Continued ...

Page 397: ... the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300002353 Disconnect the connectors shown in the figure 3 xx1300002355 Disconnect the air hoses 4 xx1300002356 Remove the connector plate attachment screws 5 Continues on next page Product manual IRB 1200 397 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 3 Replacing the...

Page 398: ...ling all connectors and the air hoses out of the wrist Be careful not to damage the FPC cabling and the connectors CAUTION Pay special attention to the plastic block on the FPC unit It is easily pulled off make sure it stays fitted to the FPC unit xx1300002611 8 Continues on next page 398 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 3 R...

Page 399: ...s on page 158 2 xx1400000774 Remove the cable housing of the tubular by first removing the screws Note For robots with protection class IP67 For robots with protection type Foundry Plus For robots with protection type Hygienic The frame is glued and needs to be pried off 3 xx1300002469 Support the weight of the tilt unit and remove the screws 4 Guide pin for tilt unit axis 5 3HAC049706 001 Fit gui...

Page 400: ...ticles with spirit on a lint free 1 xx2100001448 Check the gasket A seal ring unit B and stainless shaft C on the tool flange Replace if damaged as described below If undamaged and properly seated skip to the next procedure table 2 xx2100001449 Remove the screws and washers 3 Continues on next page 400 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 ...

Page 401: ... flange tightening tool together with a 3 8 10 mm socket spanner on the seal ring unit and loosen the unit 5 xx2100001453 Remove the gasket and seal ring unit 6 Replace the damaged parts with new ones 7 Continues on next page Product manual IRB 1200 401 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 3 Replacing the tubular spare parts Continued ...

Page 402: ...55 Flange tightening tool 3HAC079686 001 Place the flange tightening tool together with a 3 8 10 mm socket spanner on the seal ring unit and tighten the unit 10 Tightening torque 6 Nm xx2100001456 Continues on next page 402 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 3 Replacing the tubular spare parts Continued ...

Page 403: ... Secure with screws and washers 13 xx2100001460 Remove the guide pins 14 Refitting the axis 5 and axis 6 drive unit Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page Product manual IRB ...

Page 404: ...lass or protection types 3 For robots not in protection type Hygienic Remove residual locking liquid and other pollut ants with cleaning agent Loctite 7063 4 Flange sealant SikaFlex 521FC Apply flange sealing on the mounting surfaces of the drive unit Note For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Wipe clean the overf...

Page 405: ...s with food grade lubrication Make sure the sealing to the tilt covers is intact before the refitting For robots with protection type Hygienic Hygienic robots do not have tilt covers 6 xx1600000220 Continues on next page Product manual IRB 1200 405 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 3 Replacing the tubular spare parts Continued ...

Page 406: ...nd washers 8 Cross tighten all the screws with torque 1 Nm first then with 2 Nm with 4 Nm and finally with 4 5 Nm 9 Checking the tubular cable housing sealings Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint fre...

Page 407: ...elow If undamaged and properly seated skip to the next procedure table 3 Apply a little grease to the sealing when replacing the radial sealing and wipe clean after the replacement 4 Fit the radial sealing into the tubular cable housing 5 Axis 5 sealing assembly tool set 3HAC049701 001 xx1400000485 Fit the circular part of the radial sealing assembly tool against the radial sealing 6 Fit the tool ...

Page 408: ...robots with protection class IP67 For robots with protection type Foundry Plus 2 For robots with protection type Foundry Plus For robots with protection type Hygienic Remove residual locking liquid and other pollut ants with cleaning agent Loctite 7063 Flange sealant SikaFlex 521FC For robots with protection type Hygienic Apply flange sealing on the mounting surfaces of the tubular cable housing N...

Page 409: ...Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002359 Put the connectors and air hoses into the wrist carefully while at the same time refitting the wrist to the housing extender unit Be careful not to damage the FPC cabling and the connectors CAUTION Pay special attention to the plastic block on the FPC unit It is easily pulled off m...

Page 410: ...Note Only use specified screws never replace them with other screws Screw 3HAB3409 237 M5x35 7 pcs xx1400000003 Refit the rest of the screws M5x35 7 pcs 5 Note Only use specified screws never replace them with other screws Tightening torque 8 Nm Tighten all screws 6 Continues on next page 410 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4...

Page 411: ... the axis 5 motor Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 2 Continues on next page Product manual IRB ...

Page 412: ...Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002351 Refit the timing belt on the pulley 2 Note Do not strech the timing belt too much Move the motor to a position where a good timing belt tension is reached F 26 N 3 Continues on next page 412 Prod...

Page 413: ...ygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Tightening torque 0 3 Nm xx1400001401 Refit the connector plate and secure with the M3 screws 2 Tightening torque 0 3 Nm xx1400001402 Secure the three M2 5 screws 3 Continues on next page Product manual IRB 1200 413 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4...

Page 414: ...th food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002360 Reconnect the motor cables R3 MP5 R3 ME5 2 Refitting the wrist covers Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean th...

Page 415: ... 2 Gasket for tubular cable housing cover 3HAC056707 001 not Hygienic robots 3HAC080701 001 Hygienic robots xx1400000345 For robots with protection class IP67 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cable housing cover gasket Replace if damaged 3 Continu...

Page 416: ... Clean Room For robots with food grade lubrication xx1600001153 For robots with protection type Clean Room For robots with food grade lubrication Remember to refit the extra two screws and washers to the tubular cover Note Only use specified screws never replace them with other screws For robots with protection type Hygienic xx2100001406 Note For robots with protection type Hygienic Check the two ...

Page 417: ... replacing parts on page 158 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth Calibration information is included in sec tion Calibration on page 805 Recalibrate the robot 2 DANGER Make sure all safety requirements are met when performing the first test run 3 Product manual IRB 1200 417 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reser...

Page 418: ...parts of the IRB 1200 via myABB Business Portal www abb com myABB Note Article number Spare part Not used with protection class IP40 Replace if damaged 3HAC024865 001 Radial sealing Used with protection class IP67 Used with protection type Foundry Plus Replace if damaged 3HAC044641 006 M2 variseal sealing Continues on next page 418 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2...

Page 419: ...9665 001 Air connector set without Ether net hole in flange Used with protection type Hy gienic Includes Ethernet connector air connectors CP CS connector and gasket 3HAC078804 001 3HAC079691 001 Plate with connector set Used with protection type Hy gienic Includes gasket 3HAC078804 001 3HAC078810 001 Plate without connector set Used with protection type Hy gienic Replace if damage 3HAC078804 001 ...

Page 420: ...e for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find...

Page 421: ...ply air pressure supply to the robot before entering the robot working area 3 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 4 Continues on ne...

Page 422: ...e paint or surface on the robot before replacing parts on page 158 2 xx1300002360 Snap loose the motor connectors from their holders and then disconnect them R3 MP5 R3 ME5 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 3 Disconnecting the axis 5 FPC connectors Note Action DANGER Make sure that all supplies for electrical power...

Page 423: ...n DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing pa...

Page 424: ...ts with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300002400 Remove the cable housing cover 3 Continues on next page 424 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All r...

Page 425: ...he FPC connectors from the housing and disconnect them 5 Cable layout in IRB 1200 5 0 9 xx1400001471 Continues on next page Product manual IRB 1200 425 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 4 Replacing the axis 3 radial sealing and sealing ring Continued ...

Page 426: ...r robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Continues on next page 426 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB Al...

Page 427: ...rs 4 xx1300002495 Disconnect the motor connectors Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 5 Disconnecting the axis 3 motor connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1200 427 3HAC046983 001 ...

Page 428: ... the housing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the ro...

Page 429: ... access the screws that fasten the cable bracket to the sheet Loosen the bracket from the sheet by removing the two screws CAUTION Do not loosen the cable clamp screw There is a risk of rearrangement of the cable layout which would result in shortened lifetime of the cable harness 6 Continues on next page Product manual IRB 1200 429 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights rese...

Page 430: ...bots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Pull the cable harness out from the upper arm housing 3 xx1300002529 Remove the cable housing of the lower arm by removing the screws 4 Continues on next page 430 Product manual IRB 1200 3H...

Page 431: ...protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1400000473 For robots with protection class IP67 For robots with protection type Foundry Plus Remove the M2 variseal sealing 3 Continues on next page Product manual IRB 1200 431 3HAC046983 001 Revi...

Page 432: ...obots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Continues on next page 432 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All r...

Page 433: ...if the axis 3 sealing ring needs to be refitted Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page Product manual IRB 1200 433 3HAC046983 001 Revision S Copyright 2014 2021 ABB All right...

Page 434: ...e this procedure if the axis 3 radial sealing needs to be refitted Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free For robots with protection type Clean Room 2 For robots with food grade lubrication For rob...

Page 435: ...ng the six screws M6X50 into the plate little by little Fit the circular part of the radial sealing fitting tool against the radial sealing 4 Fit the tool plate to the other side of the cable housing with the six screws M6X50 5 Screw the screws little by little to press the sealing into place 6 Remove the assembly tool 7 Continues on next page Product manual IRB 1200 435 3HAC046983 001 Revision S ...

Page 436: ... opened and wipe the parts free from particles with spirit on a lint free Gasket on lower arm cable housing 3HAC044895 001 not Hygienic robots 3HAC080696 001 Hygienic robots xx1400000414 For robots with protection class IP67 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check t...

Page 437: ... food grade lubrication and Hygienic robots Note For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Apply a little grease to the sealing when replacing the radial sealing and wipe clean after the replacement Replacement of the radial sealing is de tailed in previous section Tightening torque 4 Nm xx1300002529 Refit the cable h...

Page 438: ...ower screws highlighted with a ring in the figure Refitting the cable package in the housing Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Area to be lubricated shown in cable package already fitted to th...

Page 439: ...ptimized way It is necessary to keep the air hose holder vertically and firmly against the left side of the axis 3 motor 3 Tightening torque 1 5 Nm xx1300002424 Refit the bracket to the sheet with two screws CAUTION Do not loosen the cable clamp screw There is a risk of rearrangement of the cable layout which would result in shortened lifetime of the cable harness 4 Tightening torque 1 5 Nm xx1300...

Page 440: ...ve the bracket from the fix sheet by removing the two M3 screws Fit the holder to the bracket and then refit the complete assembly to the fix sheet again Tightening torque for the two M3 screws 1 5 Nm xx1400001133 7 Tightening torque 4 Nm xx1300002422 xx1300002420 Reconnect the axis 3 motor connectors 8 Continues on next page 440 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 202...

Page 441: ...ith protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002371 Reconnect the motor connectors 2 Continues on next page Product manual IRB 1200 441 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 4 ...

Page 442: ...Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002399 Reconnect the FPC connectors Tip See the number markings on the connectors for help to find the corresponding connector 2 Continues on next page 442 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 4 Replacing the a...

Page 443: ...for help to find the corresponding connector 3 Cable layout in IRB 1200 5 0 9 xx1400001471 Remove residual locking liquid and other pollut ants with cleaning agent Loctite 7063 4 Continues on next page Product manual IRB 1200 443 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 4 Replacing the axis 3 radial sealing and sealing ring Continued ...

Page 444: ... Room For robots with protection type Clean Room For robots with food grade lubrication 7 For robots with food grade lubric ation For robots with protection type Hygienic Apply a string of the sealant to the joint of the small cover on the housing Sealant SikaFlex 521FC For robots with protection type Hygienic Smooth out the sealant string using a finger tip Use washing up on finger tips to get a ...

Page 445: ... housing 3HAC044710 001 xx1400000740 Check the PTFE film on the cable housing Replace if damaged 9 Continues on next page Product manual IRB 1200 445 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 4 Replacing the axis 3 radial sealing and sealing ring Continued ...

Page 446: ...sing cover 3HAC044660 001 xx1400000048 For robots with protection type Hygienic Check the gasket of the cable housing cover Replace if damaged Check the PTFE film on the cable housing cover 11 Replace if damaged Apply grease to the inner surface of the cable housing cover and the PTFE film surface 12 Continues on next page 446 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 A...

Page 447: ... protection type Connecting the air hoses and CP CS cabling on robots not in protection type Hygienic Use this procedure if the robot is not in protection type Hygienic Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Air connector set with Etherne...

Page 448: ...lass IP67 On robots with protection type Foundry Plus Gasket 3HAC058567 001 xx1500000251 Protection bracket for CP CS con nectors 3HAC058350 001 xx1600001152 For robots with protection type Foundry Plus If required fit the protection bracket for CP CS connectors 4 Connecting the air hoses and CP CS cabling on robots in protection type Hygienic Use this procedure if the robot is with protection typ...

Page 449: ...0000738 Reconnect the air hoses 3 xx1500000252 Reconnect the CP CS cabling 4 Plate with connector set 3HAC079691 001 Check the connectors on the plate with connector set and the attached gasket 5 Gasket 3HAC078804 001 xx2100001434 Replace if damaged Continues on next page Product manual IRB 1200 449 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 4 Replacing the ...

Page 450: ...rication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002360 Reconnect the motor cables R3 MP5 R3 ME5 2 Refitting the tubular cable housing cover Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the ...

Page 451: ...ubrication For robots with protection type Hygienic Check the tubular cable housing cover gasket Replace if damaged 2 Screws 3HAB3409 207 M3x8 Refit the cover to the cable housing 3 Tightening torque 1 5 Nm xx1300002389 Note Only use specified screws never replace them with other screws Continues on next page Product manual IRB 1200 451 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights ...

Page 452: ... For robots with food grade lubrication Check the gasket Replace if damaged Screws 3HAB3409 207 M3x8 Refit the upper arm housing cover with the screws CAUTION For robots with safety lamp option Reconnect the lamp cable connectors R3 H1 and R3 H2 and then secure the cover 2 Tightening torque 1 5 Nm xx1300000456 Note Only use specified screws never replace them with other screws Continues on next pa...

Page 453: ...t a full cover joint For robots with protection type Clean Room 4 For robots with food grade lubrication For robots with protection type Hygienic Clean seal and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 158 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth Calibration information is i...

Page 454: ...ed in the table can be out of date See the latest spare parts of the IRB 1200 via myABB Business Portal www abb com myABB Note Article number Spare part Includes mechanical stop pin 1 pc and screws 3HAC049637 001 Mechanical stop set axis 2 Continues on next page 454 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 5 Replacing the axis 2 mec...

Page 455: ...pply to the robot before entering the robot working area 2 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 3 Replacing the axis 2 mechanical st...

Page 456: ...16 Tightening torque 4 Nm Note Only use specified screws never replace them with other screws For robots with protection type Clean Room 6 For robots with food grade lubrication For robots with protection type Hygienic Clean seal and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 158 Note After all repair work wipe the robot free fro...

Page 457: ... Portal www abb com myABB Note Article number Spare part Includes mechanical stop pin 1 pc and screws 3HAC049644 001 Mechanical stop set axis 3 Required tools and equipment Note Article number Equipment etc Used to release the motor brakes 24 VDC power supply Content is defined in section Standard toolkit on page 890 Standard toolkit Continues on next page Product manual IRB 1200 457 3HAC046983 00...

Page 458: ... when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 3 Replacing the axis 3 mechanical stop Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hy...

Page 459: ...ots with food grade lubrication For robots with protection type Hygienic Clean seal and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 158 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth DANGER Make sure all safety requirements are met when performing the first test run 7 Product manual ...

Page 460: ...ide the housing extender unit as shown in the figure xx1300002416 Required spare parts Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the IRB 1200 via myABB Business Portal www abb com myABB Note Article number Spare part Includes mechanical stop pin guide slider and screws 3HAC049652 001 Mechanical stop set Continues on next page 460 Prod...

Page 461: ... 001 PTFE film on cable housing cover Replace if damaged 3HAC044869 001 Washer Not used with protection class IP40 Replace if damaged 3HAC058822 001 3HAC080709 001 Gasket for tubular cover Not used with protection class IP40 Replace if damaged 3HAC056707 001 3HAC080701 001 Gasket for tubular cable housing cover Required tools and equipment Note Article number Equipment etc Used to refit the radial...

Page 462: ...ons given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more a...

Page 463: ...enic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 4 Getting access to inside of the wrist unit Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1200 463 3HAC...

Page 464: ...he tubular cover left hand side cover has two extra screws and washers as encircled in the figure For robots with protection type Clean Room xx1600001148 Note For robots with protection type Clean Room For robots with food grade lubrication The tubular cover left hand side cover has two extra screws and washers as encircled in the figure For robots with protection type Hygienic xx2100001406 Note F...

Page 465: ...E5 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 3 Removing the axis 5 motor with pulley Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection ...

Page 466: ...ng belt 4 xx1300002390 Snap loose and disconnect the axis 5 FPC connectors 5 xx1300002352 Remove the screws and pull out the motor 6 Continues on next page 466 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 7 Replacing the axis 4 mechanical stop Continued ...

Page 467: ...th a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300002353 Disconnect the connectors shown in the figure 3 xx1300002355 Disconnect the air hoses 4 xx1300002356 Remove the connector plate attachment screws 5 Continues on next page Product manual IRB 1200 467 3HAC046983 001 Revision S Copyright...

Page 468: ...ng all connectors and the air hoses out of the wrist Be careful not to damage the FPC cabling and the connectors CAUTION Pay special attention to the plastic block on the FPC unit It is easily pulled off make sure it stays fitted to the FPC unit xx1300002611 8 Continues on next page 468 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 7 Rep...

Page 469: ...ith protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300002400 Remove the cable housing cover 3 xx1300002413 Remove the plate 4 Continues on next page Product manual IRB 1200 469 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reser...

Page 470: ... and disconnect them 5 Cable layout in IRB 1200 5 0 9 xx1400001471 xx1300002398 Remove the small cover of the housing 6 Continues on next page 470 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 7 Replacing the axis 4 mechanical stop Continued ...

Page 471: ...dge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300002373 Remove the axis 4 FPC unit screws 3 xx1600000262 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Remove the plugs covering the extender unit screw...

Page 472: ...Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300002415 Remove the mechanical stop assembly from the housing extender unit by removing the screws 3 Continues on next page 472 Product...

Page 473: ...2 variseal sealing on robots in other protection class or protection types 2 Radial sealing with dust lip 3HAB3701 48 xx1400000438 For robots with protection class IP67 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the radial sealing Replace if damaged as described below ...

Page 474: ...the tool plate to the other side of the housing extender unit with the six screws M6X50 7 xx1400000437 Screw the screws little by little to press the sealing into place 8 Remove the assembly tool 9 Check that the sealing is undamaged and properly fitted 10 Refit both the axis 4 mechanical stop and the axis 4 FPC unit to the housing extender unit 11 Continues on next page 474 Product manual IRB 120...

Page 475: ...231 M4x8 Fit the mechanical stop screw to the axis 4 shaft 2 Tightening torque 4 Nm xx1400000393 Screws 3HAB3409 216 M5x12 Fit the mechanical stop assembly to the housing extender unit and secure with screws 3 Tightening torque 4 Nm xx1300002415 Note Only use specified screws never replace them with other screws Continues on next page Product manual IRB 1200 475 3HAC046983 001 Revision S Copyright...

Page 476: ...e Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Make sure the four cavities are fully filled with glue If not fill glue again before the refitting 3 xx1300002374 Refit the housing extender unit to the housing while putting the FPC cables into the housing and the air hoses through the housing extender unit Be ...

Page 477: ...lugs to cover the screws 6 Tightening torque 0 3 Nm xx1300002373 Fit and secure the axis 4 FPC unit screws 7 Connecting the axis 4 FPC connectors Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on...

Page 478: ...nto place inside the housing Tip See the number markings on the connectors for help to find the corresponding connector 3 Cable layout in IRB 1200 5 0 9 xx1400001471 Remove residual locking liquid and other pollut ants with cleaning agent Loctite 7063 4 Continues on next page 478 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 7 Replacing ...

Page 479: ...pe Clean Room For robots with protection type Clean Room For robots with food grade lubrication 7 For robots with food grade lubric ation For robots with protection type Hygienic Apply a string of the sealant to the joint of the small cover on the housing Sealant SikaFlex 521FC For robots with protection type Hygienic Smooth out the sealant string using a finger tip Use washing up on finger tips t...

Page 480: ...rm cable housing 3HAC044710 001 xx1400000740 Check the PTFE film on the cable housing Replace if damaged 9 Continues on next page 480 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 7 Replacing the axis 4 mechanical stop Continued ...

Page 481: ...able housing cover 3HAC044660 001 xx1400000048 For robots with protection type Hygienic Check the gasket of the cable housing cover Replace if damaged Check the PTFE film on the cable housing cover 11 Replace if damaged Apply grease to the inner surface of the cable housing cover and the PTFE film surface 12 Continues on next page Product manual IRB 1200 481 3HAC046983 001 Revision S Copyright 201...

Page 482: ...to all the screws securing the cover Note Only use specified screws never replace them with other screws Refitting the wrist Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 482 Produc...

Page 483: ...on to the plastic block on the FPC unit It is easily pulled off make sure it stays fitted to the FPC unit xx1300002611 2 Washer 3HAC044869 001 xx1400000001 Refit the washer while at the same time putting the cables through its center Replace washer if damaged 3 Continues on next page Product manual IRB 1200 483 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 7 Re...

Page 484: ... rest of the screws M5x35 7 pcs 5 Note Only use specified screws never replace them with other screws Tightening torque 8 Nm Tighten all screws 6 Tightening torque 0 3 Nm xx1300002356 Put the cables through the plate hole and refit the plate 7 Continues on next page 484 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 7 Replacing the axis 4...

Page 485: ...that have been opened and wipe the parts free from particles with spirit on a lint free Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 2 Screws 3HAB3409 212 M4x16 xx1300002463 Place the motor at its mounting position and fasten the attachment screws and washers just enough to still be able to move the motor 3 Note Only use specified screws never rep...

Page 486: ...position where a good timing belt tension is reached F 26 N 3 xx1300002350 Secure the motor with its attachment screws 4 Tightening torque 3 5 Nm Refitting the connector plate Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spir...

Page 487: ...pe Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002390 Connect the axis 5 FPC connectors and snap them to their holders 2 Continues on next page Product manual IRB 1200 487 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserve...

Page 488: ...h protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Gasket for tubular cover 3HAC058822 001 not Hygienic robots 3HAC080709 001 Hygienic robots xx1400000034 For robots with protection class IP67 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication...

Page 489: ...ion type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cable housing cover gasket Replace if damaged 3 Continues on next page Product manual IRB 1200 489 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 4 7 Replacing the axis 4 mechanical stop Continued ...

Page 490: ...lean Room For robots with food grade lubrication xx1600001153 For robots with protection type Clean Room For robots with food grade lubrication Remember to refit the extra two screws and washers to the tubular cover Note Only use specified screws never replace them with other screws For robots with protection type Hygienic xx2100001406 Note For robots with protection type Hygienic Check the two ex...

Page 491: ...efore replacing parts on page 158 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth Calibration is detailed in section Calibration on page 805 Recalibrate the robot 2 DANGER Make sure all safety requirements are met when performing the first test run 3 Product manual IRB 1200 491 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Re...

Page 492: ... in terface Replace if dam aged Includes base machining axis 1 gear unit and axis 1 AC motor with resolver in terface Incompatible with swing 3HAC049632 001 See Spare part versions for the base on IP40 IP67 robots on page 874 3HAC061271 001 3HAC059699 001 Used for IRB 1200 Type B See Type B of IRB 1200 on page 873 Used with protection type Clean Room Used with protection type Clean Room 3HAC061272...

Page 493: ... Note Article number Spare part Includes base machining axis 1 gear unit and axis 1 AC motor with encoder interface Incompatible with swing 3HAC049632 001 See Spare part versions for the base on IP40 IP67 robots on page 874 3HAC059553 001 Base Used with protection type Clean Room Includes base machining axis 1 gear unit and axis 1 AC motor with encoder interface 3HAC059699 001 Base Clean Room Used...

Page 494: ...xis 1 sealing ring ver sion 3HAC044676 001 See Spare part versions for the axis 1 sealing ring on IP40 IP67 ro bots on page 878 Replace if damaged 3HAC045685 001 Axis 1 sealing ring gasket Not used with protection class IP40 Only on axis 1 sealing ring ver sion 3HAC058568 001 or 3HAC068107 001 See Spare part versions for the axis 1 sealing ring on IP40 IP67 robots on page878 Replace if damaged 3HA...

Page 495: ...41 004 M2 variseal sealing Includes brackets sheets dis tance screws plastics cable clamp seal bolts and air protec tion in tubular 3HAC049663 001 Cable harness material set Not used with protection class IP40 Replace if damaged 3HAC056724 001 3HAC080702 001 Gasket on cable housing cover Not used with protection class IP40 Replace if damaged 3HAC056707 001 3HAC080701 001 Gasket for tubular cable h...

Page 496: ...me calibration method as used at the factory Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant If no data is found related to standard calibration manual calibration is used as default Required consumables Note Art no Equipment Cable straps Used for lubrication of cable con tact areas 3HAC042536 001 Grease Loctite 243 3HAB711...

Page 497: ...t to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference cali...

Page 498: ...cation For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 4 xx1300002389 Remove the wrist cover 5 Continues on next page 498 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 1 Re...

Page 499: ... the connector and cable position before disconnecting them to have as a reference when reconnecting 3 Disconnecting the axis 5 FPC connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Alway...

Page 500: ...cation For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1400000738 Disconnect the air hoses 3 xx1500000252 If equipped disconnect the CP CS connector 4 Continues on next page 500 Product manual IRB 1200 3HAC046983 001 Revision S C...

Page 501: ...Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300002400 Remove the cable housing cover 3 xx1300002413 Remove the plate 4 Continues on next page Product manual IRB 1200 501 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 1 R...

Page 502: ... 5 Cable layout in IRB 1200 5 0 9 xx1400001471 xx1300002398 Remove the small cover of the housing 6 Continues on next page 502 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 1 Replacing the base spare parts base axis 1 radial sealing protection sleeve Continued ...

Page 503: ...nt edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300000456 Remove the cover from the upper arm housing CAUTION For robots with safety lamp option Be aware of the signal lamp cables that are at tached inside the housing Disconnect the lamp cable connectors R3 H1 and R3 H2 and then lift away the cover completely 3 Continu...

Page 504: ... and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Continues on next page 504 Product manual IRB 1200 3HAC046...

Page 505: ...th food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300002422 Remove the screw that fastens the air hose hold er 3 Continues on next page Product manual IRB 1200 505 3HAC046983 001 Revision S Copyright 2014...

Page 506: ...w There is a risk of rearrangement of the cable layout which would result in shortened lifetime of the cable harness 6 Valid for IRB 1200 5 0 9 7 Cut the cable straps at the bottom of the housing Disconnecting the cabling in the lower arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 506 Product manua...

Page 507: ... from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures CAUTION Be aware of the cabling that is attached to the cover The cover can not be removed completely until the connectors and lugs are disconnected as shown in following step 4 xx1300002428 Valid for IRB 1200 no type specified and IRB 1200 Type A Disconnect the connectors on ...

Page 508: ...e turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Pull the cable package out from the upper arm housing 3 Continues on next page...

Page 509: ...harness 5 xx1400001130 Cut the cable strap that holds the cabling together inside the EIB SMB cavity 6 xx1600000205 For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Remove the swing sealing plug Follow the procedure specified in Removing the swing sealing plug on page 166 7 Continues on next page Product manual IRB 1200 509 ...

Page 510: ...8 Cut the cable straps 9 xx1300002432 Remove the axis 2 motor bracket screws 10 Continues on next page 510 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 1 Replacing the base spare parts base axis 1 radial sealing protection sleeve Continued ...

Page 511: ...t in shortened lifetime of the cable harness 11 xx1300002434 Disconnect the motor connectors R2 ME2 R2 MP2 12 xx1300002435 Loosen the cable housing from the swing by re moving the screws Leave it hanging on the cable package 13 Continues on next page Product manual IRB 1200 511 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 1 Replacing the base spare parts base ...

Page 512: ...R Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on ...

Page 513: ...ble arm side which would damage the robot 4 WARNING The robot is likely to be mechanically un stable if not secured to the foundation 5 CAUTION The robot weighs IRB 1200 5 0 9 54 kg IRB 1200 7 0 7 52 kg All lifting accessories used must be sized accordingly 6 Continues on next page Product manual IRB 1200 513 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 1 Repl...

Page 514: ...type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300000467 Remove the swing top cover by removing the screws Tip Fit M4 screws in the cover holes to pull out the cover more easily Only tighten the screws lightly in order not to damage the threads 3 Continu...

Page 515: ...ressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Continues on next page Product manual IRB 1200 515 ...

Page 516: ...dure to replace the axis 1 radial sealing The sealing is only used for robots with protection class IP67 and protection type Foundry Plus Removing the axis 1 radial sealing and M2 variseal sealing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Raise the base into standing and put most of the cable harness including the seali...

Page 517: ...ve the radial sealing 4 Refitting the axis 1 radial sealing and M2 variseal sealing Note Action Radial sealing with dust lip 3HAB3701 47 xx1400000270 Fit the new sealing in its groove in the base 1 Continues on next page Product manual IRB 1200 517 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 1 Replacing the base spare parts base axis 1 radial sealing protecti...

Page 518: ...or the base on IP40 IP67 ro bots on page 874 CAUTION Do not fit M2 variseal sealing on robots in other protection class or protection types 4 M2 variseal sealing 3HAC044641 002 Check that the sealings are undamaged and properly fitted 5 Replacing the M2 variseal sealing IP67 The M2 variseal sealing is only installed on base version 3HAC049628 001 See Spare part versions for the base on IP40 IP67 r...

Page 519: ...g in its groove in the base CAUTION Do not fit M2 variseal sealing on robots in other protection class or protection types 3 M2 variseal sealing 3HAC044641 002 Replacing the cable protection sleeve First remove the cabling according to Removing the cabling on page 497 then use this procedure to replace the protection sleeve Replacing the cable protection sleeve Note Action DANGER Make sure that al...

Page 520: ...ews 4 xx1400000777 Pull up the protection sleeve 5 For robots with protection type Clean Room 6 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Tightening torque 0 3 Nm Fit the new protection sleeve and secure with screws 7 Continues on next page 520 Product manu...

Page 521: ...ff 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Continues on next page Product manual IRB 1200 521 3HAC046983 001 Revision S Copyright 2...

Page 522: ...cover 3 Bottom connector interface xx1400000403 Continues on next page 522 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 1 Replacing the base spare parts base axis 1 radial sealing protection sleeve Continued ...

Page 523: ...00002496 Loosen the connectors from the bracket by cutting the cable straps and disconnect the connectors 5 Continues on next page Product manual IRB 1200 523 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 1 Replacing the base spare parts base axis 1 radial sealing protection sleeve Continued ...

Page 524: ...tection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300002448 Open the base cover 3 Disconnect the earth cable 4 xx1300002456 Pull the cable package out from the base th...

Page 525: ... with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1400000405 Open the base cover 3 Remove the brake release button from the base cover 4 Disconnect the earth cable 5 xx1400000406 Remove the cable bracket by removing the screws 6 Continues on...

Page 526: ...od grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Raise the base into standing and put most of the cable harness including the sealing ring bracket into the base in the space of the protection sleeve 3 Continues ...

Page 527: ...r pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Continues on next page Product manual IRB 1200 527 3HAC046983 001...

Page 528: ...obots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free For robots with protection type Clean Room 2 Apply a little grease to the sealing when replacing the radial sealing and wipe clean after the replacement Continues on next page 528 Product manual IRB 1200 3HAC046983 001 R...

Page 529: ... against the axis 1 gear and slowly press the sealing into the base by screwing the five screws M10X35 into the axis 1 gear screws little by little 4 Remove the assembly tool 5 Continues on next page Product manual IRB 1200 529 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 1 Replacing the base spare parts base axis 1 radial sealing protection sleeve Continued ...

Page 530: ...e is located at the rear of the base Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Gasket for rear base cover 3HAC058566 001 not Hygienic robots 3HAC080710 001 Hygien ic robots xx1400000741 For robots wit...

Page 531: ...routed from below Use this procedure if the cable connector interface is located at the bottom of the base and the cabling is routed from below Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Insert the cab...

Page 532: ...7 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the gasket of the base cover Replace if damaged 5 Reconnect the earth cable 6 Refit the brake release button to the base cover 7 Continues on next page 532 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 202...

Page 533: ...ced Refitting the cable package to the axis 1 sealing ring Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Axis 1 sealing ring 3HAC044676 001 3HAC068107 001 i Check the axis 1 sealing ring Replace if damage...

Page 534: ... 1 sealing ring version 3HAC058568 001 or 3HAC068107 001 Check the gasket on the axis 1 sealing ring See Spare part versions for the axis 1 sealing ring on IP40 IP67 robots on page 878 Replace if damaged On axis 1 sealing ring version 3HAC058568 001 Axis 1 sealing ring gasket 3HAC058349 001 not Hygienic robots 3HAC080707 001 Hygien ic robots xx1600001149 On axis 1 sealing ring version 3HAC068107 0...

Page 535: ...AC058568 001 xx1600001150 On axis 1 sealing ring version 3HAC068107 001 xx1900001736 Cable protection 3HAC044691 001 Check the cable protection on the axis 1 sealing ring 6 Torx countersunk head screw M3x5 3HAC14286 4 Replace if damaged Tightening torque 0 3 Nm xx1400000456 If replacing the cable protection use locking liquid Loctite 243 on the screws Tightening torque 1 Nm xx1300002446 Refit the ...

Page 536: ...te For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Apply a little grease to the sealing when replacing the radial sealing and wipe clean after the replacement For robots with protection class IP67 Check the M2 variseal sealing in the base Replacement is detailed in Replacing the base spare parts base axis 1 radial seal ing ...

Page 537: ...together Refit the swing to the base with guidance from the guide pins while running the cabling up through the swing 5 Position and angle the cabling inside the base as it was positioned during removal CAUTION Be careful not to squeeze any cabling dur ing the refitting procedure Continues on next page Product manual IRB 1200 537 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserve...

Page 538: ...h other screws xx1300000523 Remove the guide pins and refit the remain ing attachment screws and washers 7 Tightening torque 40 Nm Tighten all screws 8 Continues on next page 538 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 1 Replacing the base spare parts base axis 1 radial sealing protection sleeve Continued ...

Page 539: ... top of swing 3HAC059679 001 Refit the swing top cover with the screws 10 Cover on top of swing Clean Room Replace if damaged Cover on top of swing food grade lubrica tion Cover on top of swing Hygienic 3HAC056133 001 Screws 3HAB3409 209 M3x20 Tightening torque 1 5 Nm xx1300000467 Note Only use specified screws never replace them with other screws Continues on next page Product manual IRB 1200 539...

Page 540: ...ve been opened and wipe the parts free from particles with spirit on a lint free xx1300002496 Reconnect the connectors and secure the connectors to the bracket with cable straps 2 Continues on next page 540 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 1 Replacing the base spare parts base axis 1 radial sealing protection sleeve Continue...

Page 541: ...robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the O ring Replace if damaged 4 Continues on next page Product manual IRB 1200 541 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 1 Replacing the base spare parts base axis 1 radial sealing prot...

Page 542: ...on Note Action For robots with protection type Clean Room 1 For robots with food grade lubrica tion For robots with protection type Hy gienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 542 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 1 Replacing the bas...

Page 543: ...e bottom of the base Replace if damaged Attachment screws M12x35 robot installation directly on foundation quality 8 8 Raise the robot to standing and secure to the foundation with the attachment screws and washers 4 Washers 13 x 20 x 2 steel hardness class 300HV Pin 2 pcs D6x20 ISO 2338 6m6x20 A1 Tightening Torque 55 Nm 5 Nm Refitting the cable package in the lower arm Note Action For robots with...

Page 544: ...ce if damaged Gasket of plastic plate 3HAC044894 001 not Hygienic robots 3HAC080695 001 Hygien ic robots xx1400000457 For robots with protection class IP67 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the gasket of the cable housing plastic plate Replace if damaged 3 Con...

Page 545: ...uded in Cable harness material set 3HAC049663 001 xx1400000023 Fasten the plastic plate to the cable housing if removed Replace if damaged 5 Continues on next page Product manual IRB 1200 545 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 1 Replacing the base spare parts base axis 1 radial sealing protection sleeve Continued ...

Page 546: ... the sealing Replace if damaged CAUTION Do not fit M2 variseal sealing on robots in other protection class or protection types 6 Continues on next page 546 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 1 Replacing the base spare parts base axis 1 radial sealing protection sleeve Continued ...

Page 547: ...to the sealing when replacing the radial sealing and wipe clean after the replace ment 7 Replacement is detailed in Repla cing the swing spare parts swing axis 2 radial sealing on page 572 Guide the cable package into the lower arm Tip There is a groove on the lower arm casting that simplifies cable passage if needed Its position can easily be felt by hand 8 Tightening torque 1 5 Nm xx1400000020 R...

Page 548: ...s never replace them with other screws xx1400000481 Apply grease to the cable package cover all moving area of the package 11 Continues on next page 548 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 1 Replacing the base spare parts base axis 1 radial sealing protection sleeve Continued ...

Page 549: ...le clamp screw There is a risk of rearrangement of the cable layout which would result in shortened lifetime of the cable harness 13 xx1300002432 Refit the axis 2 motor bracket to the motor 14 Continues on next page Product manual IRB 1200 549 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 1 Replacing the base spare parts base axis 1 radial sealing protection sl...

Page 550: ...cured accordingly inside the EIB SMB cavity 1 The cable package is strapped with tape by the supplier at two locations Put a cable strap around the cable package at each location 2 Insert a third cable strap through the top strap and the bottom strap and close the strap to secure the cable package and keep it in place See the figure 17 Continues on next page 550 Product manual IRB 1200 3HAC046983 ...

Page 551: ...with protection type Hygienic Check the gasket of the cable housing cover Replace if damaged 18 PTFE film on cable housing cover 3HAC044660 001 Check the PTFE film Replace if damaged 19 Apply grease to the inner surface of the cable housing cover and to the PTFE film surface 20 Continues on next page Product manual IRB 1200 551 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved ...

Page 552: ...4 001 Screws 3HAB3409 207 M3x8 Tightening torque 1 5 Nm xx1300002431 Note Only use specified screws never replace them with other screws Protection plug for lifting holes 3HAC4836 24 xx1600001151 For robots with protection type Foundry Plus Check the protection plugs for lifting holes Replace if damaged 22 Continues on next page 552 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 ...

Page 553: ...lifetime of the cable harness 24 Connecting the cabling in the lower arm Note Action ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 64 1 For robots with protection type Clean Room 2 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints...

Page 554: ...B WARNING Make sure not to mix the R2 EIB and R2 ME2 Axis 2 may be severely damaged See the labels on the connectors for correct connection 4 Valid for IRB 1200 no type specified and IRB 1200 Type A 5 Connect the lugs to the EIB SMB cover xx1700000005 Valid for IRB 1200 Type B Connect the connectors to the SMB unit R1 ME1 2 4 5 R1 ME3 6 R2 SMB WARNING Make sure not to mix the R2 SMB and R2 ME2 Axi...

Page 555: ...ower arm with the attachment screws 8 Tightening torque 1 5 Nm xx1300002427 Note Only use specified screws never replace them with other screws Continues on next page Product manual IRB 1200 555 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 1 Replacing the base spare parts base axis 1 radial sealing protection sleeve Continued ...

Page 556: ...ee from particles with spirit on a lint free Area to be lubricated shown in cable package already fitted to the housing xx1400000483 Before guiding the cable package into the housing and upper arm apply grease to the cable package to the area going into the upper arm shown in the figure Cover all moving area of the package 2 Continues on next page 556 Product manual IRB 1200 3HAC046983 001 Revisio...

Page 557: ...y It is necessary to keep the air hose holder vertically and firmly against the left side of the axis 3 motor 3 Tightening torque 1 5 Nm xx1300002424 Refit the bracket to the sheet with two screws CAUTION Do not loosen the cable clamp screw There is a risk of rearrangement of the cable layout which would result in shortened lifetime of the cable harness 4 Tightening torque 1 5 Nm xx1300002423 Refi...

Page 558: ...ket from the fix sheet by removing the two M3 screws Fit the holder to the bracket and then refit the complete assembly to the fix sheet again Tightening torque for the two M3 screws 1 5 Nm xx1400001133 7 Tightening torque 4 Nm xx1300002422 xx1300002420 Reconnect the axis 3 motor connectors 8 Continues on next page 558 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All r...

Page 559: ...ion type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002371 Reconnect the motor connectors 2 Continues on next page Product manual IRB 1200 559 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 1 Replacing t...

Page 560: ...ean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002399 Reconnect the FPC connectors Tip See the number markings on the connectors for help to find the corresponding connector 2 Continues on next page 560 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 1 Replacing the base spare p...

Page 561: ...find the corresponding connector 3 Cable layout in IRB 1200 5 0 9 xx1400001471 Remove residual locking liquid and other pollut ants with cleaning agent Loctite 7063 4 Continues on next page Product manual IRB 1200 561 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 1 Replacing the base spare parts base axis 1 radial sealing protection sleeve Continued ...

Page 562: ...obots with protection type Clean Room For robots with food grade lubrication 7 For robots with food grade lubric ation For robots with protection type Hygienic Apply a string of the sealant to the joint of the small cover on the housing Sealant SikaFlex 521FC For robots with protection type Hygienic Smooth out the sealant string using a finger tip Use washing up on finger tips to get a smooth join...

Page 563: ...AC044710 001 xx1400000740 Check the PTFE film on the cable housing Replace if damaged 9 Continues on next page Product manual IRB 1200 563 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 1 Replacing the base spare parts base axis 1 radial sealing protection sleeve Continued ...

Page 564: ...3HAC044660 001 xx1400000048 For robots with protection type Hygienic Check the gasket of the cable housing cover Replace if damaged Check the PTFE film on the cable housing cover 11 Replace if damaged Apply grease to the inner surface of the cable housing cover and the PTFE film surface 12 Continues on next page 564 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All righ...

Page 565: ...type Connecting the air hoses and CP CS cabling on robots not in protection type Hygienic Use this procedure if the robot is not in protection type Hygienic Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Air connector set with Ethernet hole in fl...

Page 566: ... robots with protection type Foundry Plus Gasket 3HAC058567 001 xx1500000251 Protection bracket for CP CS con nectors 3HAC058350 001 xx1600001152 For robots with protection type Foundry Plus If required fit the protection bracket for CP CS connectors 4 Connecting the air hoses and CP CS cabling on robots in protection type Hygienic Use this procedure if the robot is with protection type Hygienic N...

Page 567: ...onnect the air hoses 3 xx1500000252 Reconnect the CP CS cabling 4 Plate with connector set 3HAC079691 001 Check the connectors on the plate with connector set and the attached gasket 5 Gasket 3HAC078804 001 xx2100001434 Replace if damaged Continues on next page Product manual IRB 1200 567 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 1 Replacing the base spare ...

Page 568: ... robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002360 Reconnect the motor cables R3 MP5 R3 ME5 2 Refitting the tubular cable housing cover Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that ...

Page 569: ...or robots with protection type Hygienic Check the tubular cable housing cover gasket Replace if damaged 2 Screws 3HAB3409 207 M3x8 Refit the cover to the cable housing 3 Tightening torque 1 5 Nm xx1300002389 Note Only use specified screws never replace them with other screws Continues on next page Product manual IRB 1200 569 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 R...

Page 570: ... with food grade lubrication Check the gasket Replace if damaged Screws 3HAB3409 207 M3x8 Refit the upper arm housing cover with the screws CAUTION For robots with safety lamp option Reconnect the lamp cable connectors R3 H1 and R3 H2 and then secure the cover 2 Tightening torque 1 5 Nm xx1300000456 Note Only use specified screws never replace them with other screws Continues on next page 570 Prod...

Page 571: ...er joint For robots with protection type Clean Room 4 For robots with food grade lubrication For robots with protection type Hygienic Clean seal and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 158 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth Calibration information is included in s...

Page 572: ...with protection type Clean Room Used for robots with food grade lubrication Used for robots with food grade lubrication Used with protection type Hygienic Used with protection type Hygienic Replace if damaged Radial sealing with dust lip Cable housing cover of the swing Cable housing of the swing xx1400000444 xx1400000445 xx1400000446 Continues on next page 572 Product manual IRB 1200 3HAC046983 0...

Page 573: ...on IP40 IP67 robots on page 876 3HAC059554 001 Swing Used with protection type Clean Room Used for robots with food grade lubrication Used with protection type Hy gienic 3HAC059700 001 Swing Clean Room Swing food grade lubrication Swing Hygienic Replace if damaged 3HAC044676 001 3HAC068107 001 i Axis 1 sealing ring Used with protection class IP67 Only on axis 1 sealing ring ver sion 3HAC044676 001...

Page 574: ...cover Used with protection type Clean Room Used for robots with food grade lubrication Used with protection type Hy gienic Replace if damaged 3HAC056215 001 Swing cover Clean Room Swing cover food grade lubrica tion Swing cover Hygienic Not used with protection class IP40 Replace if damaged 3HAC056727 001 3HAC080705 001 Gasket on swing cover Not used with protection class IP40 Replace if damaged 3...

Page 575: ...terial set Not used with protection class IP40 Replace if damaged 3HAC056724 001 3HAC080702 001 Gasket on cable housing cover Not used with protection class IP40 Replace if damaged 3HAC056707 001 3HAC080701 001 Gasket for tubular cable housing cover Not used with protection class IP40 Replace if damaged 3HAC056698 001 3HAC080700 001 Housing cover gasket IRB 1200 7 0 7 Not used with protection clas...

Page 576: ...oolkit manual calibration Content is defined in section Standard toolkit on page 890 Standard toolkit i The robot is calibrated by either manual calibration or Axis Calibration at factory Always use the same calibration method as used at the factory Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant If no data is found related...

Page 577: ...vious reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 819 If no previous reference values exist and no new reference values can ...

Page 578: ...paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 4 xx1300002389 Remove the wrist cover 5 Disconnecting the axis 5 motor connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 578 Product manual IRB 1200 3HAC046983 001 Revis...

Page 579: ... as a reference when reconnecting 3 Disconnecting the axis 5 FPC connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassem...

Page 580: ...de lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1400000738 Disconnect the air hoses 3 xx1500000252 If equipped disconnect the CP CS connector 4 Continues on next page 580 Product manual IRB 1200 3HAC046983 001 Revi...

Page 581: ...on type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300002400 Remove the cable housing cover 3 xx1300002413 Remove the plate 4 Continues on next page Product manual IRB 1200 581 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair...

Page 582: ...ect them 5 Cable layout in IRB 1200 5 0 9 xx1400001471 xx1300002398 Remove the small cover of the housing 6 Continues on next page 582 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 2 Replacing the swing spare parts swing axis 2 radial sealing Continued ...

Page 583: ... the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300000456 Remove the cover from the upper arm housing CAUTION For robots with safety lamp option Be aware of the signal lamp cables that are at tached inside the housing Disconnect the lamp cable connectors R3 H1 and R3 H2 and then lift away the cover completely 3...

Page 584: ...pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Continues on next page 584 Product manual IRB 1200...

Page 585: ...obots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300002422 Remove the screw that fastens the air hose hold er 3 Continues on next page Product manual IRB 1200 585 3HAC046983 001 Revision S Copyri...

Page 586: ...amp screw There is a risk of rearrangement of the cable layout which would result in shortened lifetime of the cable harness 6 Valid for IRB 1200 5 0 9 7 Cut the cable straps at the bottom of the housing Disconnecting the cabling in the lower arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 586 Produ...

Page 587: ...an cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures CAUTION Be aware of the cabling that is attached to the cover The cover can not be removed completely until the connectors and lugs are disconnected as shown in following step 4 xx1300002428 Valid for IRB 1200 no type specified and IRB 1200 Type A Disconnect the connec...

Page 588: ...ssure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Pull the cable package out from the upper arm housing 3 Continues on n...

Page 589: ...e cable harness 5 xx1400001130 Cut the cable strap that holds the cabling together inside the EIB SMB cavity 6 xx1600000205 For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Remove the swing sealing plug Follow the procedure specified in Removing the swing sealing plug on page 166 7 Continues on next page Product manual IRB 1...

Page 590: ...400001528 Cut the cable straps 9 xx1300002432 Remove the axis 2 motor bracket screws 10 Continues on next page 590 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 2 Replacing the swing spare parts swing axis 2 radial sealing Continued ...

Page 591: ...ld result in shortened lifetime of the cable harness 11 xx1300002434 Disconnect the motor connectors R2 ME2 R2 MP2 12 xx1300002435 Loosen the cable housing from the swing by re moving the screws Leave it hanging on the cable package 13 Continues on next page Product manual IRB 1200 591 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 2 Replacing the swing spare pa...

Page 592: ...tting lifting equipment to the upper and lower arm Note Action CAUTION The lower and upper arms together weigh 30 kg All lifting accessories used must be sized accord ingly 1 Roundsling 2 m Fit lifting slings to the upper and lower arm 2 Removing the lower arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next ...

Page 593: ...00002551 Remove the swing cover 3 xx1300002552 Remove the lower arm screws and wash ers WARNING This releases the lower arm from the swing Make sure the weight of the arm is properly secured The lower arm weighs 13 kg If the upper arm is also attached to the lower arm it adds an additional 17 kg to the total weight 4 Continues on next page Product manual IRB 1200 593 3HAC046983 001 Revision S Copy...

Page 594: ...this procedure if replacing the swing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the p...

Page 595: ...4 xx1400000449 Lift the swing upwards to access the axis 1 seal ing ring CAUTION Be aware of the cabling that is attached to the sealing ring fitted to the swing The swing can not be removed completely until the axis 1 sealing ring is removed as shown in following step 5 Continues on next page Product manual IRB 1200 595 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repai...

Page 596: ...obots with protection class IP67 and with protection type Foundry Plus Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1400000450 Remove the axis 2 radial sealing from the cable housing 2 Continues on next page 596 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 2 R...

Page 597: ...600000053 For robots with protection class IP67 For robots with protection type Foundry Plus On swing version 3HAC058000 001 Add sealant to the swing groove 2 Sealant Sikaflex 521FC xx1600001125 For robots with protection class IP67 On axis 1 sealing ring version 3HAC056658 001 Add sealant to the axis 1 sealing ring See Spare part versions for the axis 1 sealing ring on IP40 IP67 robots on page 87...

Page 598: ...aged See Spare part versions for the axis 1 sealing ring on IP40 IP67 robots on page 878 On axis 1 sealing ring version 3HAC058568 001 Axis 1 sealing ring gasket 3HAC058349 001 not Hygienic robots 3HAC080707 001 Hygien ic robots xx1600001149 On axis 1 sealing ring version 3HAC068107 001 Axis 1 sealing ring gasket 3HAC058349 001 not Hygienic robots 3HAC080707 001 Hygien ic robots xx1900001735 Conti...

Page 599: ...obots on page 878 Replace if damaged On axis 1 sealing ring version 3HAC058568 001 xx1600001150 On axis 1 sealing ring version 3HAC068107 001 xx1900001736 Cable protection 3HAC044691 001 Check the cable protection on the axis 1 sealing ring 6 Torx countersunk head screw M3x5 3HAC14286 4 Replace if damaged Tightening torque 0 3 Nm xx1400000456 If replacing the cable protection use locking liquid Lo...

Page 600: ...the swing 7 Tightening torque 1 5 Nm xx1400000455 xx1400000449 Lower the swing down into place while at the same time guiding the cabling through the cable hole 8 Continues on next page 600 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 2 Replacing the swing spare parts swing axis 2 radial sealing Continued ...

Page 601: ... ic robots xx1400000425 For robots with protection class IP67 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the gasket Replace if damaged 10 Continues on next page Product manual IRB 1200 601 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4...

Page 602: ...2 radial sealing The sealing is only used for robots with protection class IP67 with protection type Foundry Plus with protection type Clean Room with food grade lubrication and protection type Hygienic Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts fr...

Page 603: ...51 Fit the circular part of the radial sealing fitting tool against the radial sealing 4 Fit the tool plate to the other side of the cable housing with the six screws M6X50 5 Continues on next page Product manual IRB 1200 603 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 2 Replacing the swing spare parts swing axis 2 radial sealing Continued ...

Page 604: ...rd ingly 1 Roundsling 2 m Fit lifting slings to the upper and lower arm 2 Refitting the lower arm Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 604 Product manual IRB 1200 3HAC04698...

Page 605: ...n type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Wipe clean the overflowing Loctite 574 if there is any 3 Guide pin for axis 2 gear unit 3HAC049704 001 xx1300002562 Fit guide pins to the gearbox 4 Always use three guide pins together Continues on next page Product manual IRB 1200 605 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reser...

Page 606: ...AUTION Do not fit M2 variseal sealing on robots in other protection class or protection types 5 xx1300002563 Fit the lower arm to the swing with guid ance from the guide pins 6 Continues on next page 606 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 2 Replacing the swing spare parts swing axis 2 radial sealing Continued ...

Page 607: ...ver replace them with other screws xx1300002565 Remove the guide pins and refit the remain ing screws and washers using locking li quid Loctite 243 8 Tightening torque 45 Nm Tighten all screws 9 Continues on next page Product manual IRB 1200 607 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 2 Replacing the swing spare parts swing axis 2 radial sealing Continued...

Page 608: ...ion type Hygienic Check the swing cover gasket Replace if damaged 10 Screws 3HAB3409 207 M3x8 Refit the swing cover 11 Tightening torque 1 5 Nm Replace if damaged Swing cover 3HAC059676 001 Swing cover Clean Room Swing cover food grade lubrication Swing cover Hygienic 3HAC056215 001 xx1300002551 Continues on next page 608 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB Al...

Page 609: ...gienic For robots with protection type Hygienic Apply a string of the sealant to the joint of the swing cover Sealant Trans Clear xx1600000217 Smooth out the sealant string using a finger tip Use washing up on finger tips to get a smooth joint If necessary add extra sealant to get a full cover joint xx1600001154 For robots with protection type Foundry Plus If required fit two screws for protection...

Page 610: ... For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the gasket Replace if damaged Gasket of plastic plate 3HAC044894 001 not Hygienic robots 3HAC080695 001 Hygien ic robots xx1400000457 For robots with protection class IP67 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots...

Page 611: ... is included in Cable harness material set 3HAC049663 001 xx1400000023 Fasten the plastic plate to the cable housing if removed Replace if damaged 5 Continues on next page Product manual IRB 1200 611 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 2 Replacing the swing spare parts swing axis 2 radial sealing Continued ...

Page 612: ...us Check the sealing Replace if damaged CAUTION Do not fit M2 variseal sealing on robots in other protection class or protection types 6 Continues on next page 612 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 2 Replacing the swing spare parts swing axis 2 radial sealing Continued ...

Page 613: ... grease to the sealing when replacing the radial sealing and wipe clean after the replace ment 7 Replacement is detailed in Repla cing the swing spare parts swing axis 2 radial sealing on page 572 Guide the cable package into the lower arm Tip There is a groove on the lower arm casting that simplifies cable passage if needed Its position can easily be felt by hand 8 Tightening torque 1 5 Nm xx1400...

Page 614: ...ed screws never replace them with other screws xx1400000481 Apply grease to the cable package cover all moving area of the package 11 Continues on next page 614 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 2 Replacing the swing spare parts swing axis 2 radial sealing Continued ...

Page 615: ... the cable clamp screw There is a risk of rearrangement of the cable layout which would result in shortened lifetime of the cable harness 13 xx1300002432 Refit the axis 2 motor bracket to the motor 14 Continues on next page Product manual IRB 1200 615 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 2 Replacing the swing spare parts swing axis 2 radial sealing Con...

Page 616: ...st be secured accordingly inside the EIB SMB cavity 1 The cable package is strapped with tape by the supplier at two locations Put a cable strap around the cable package at each location 2 Insert a third cable strap through the top strap and the bottom strap and close the strap to secure the cable package and keep it in place See the figure 17 Continues on next page 616 Product manual IRB 1200 3HA...

Page 617: ... robots with protection type Hygienic Check the gasket of the cable housing cover Replace if damaged 18 PTFE film on cable housing cover 3HAC044660 001 Check the PTFE film Replace if damaged 19 Apply grease to the inner surface of the cable housing cover and to the PTFE film surface 20 Continues on next page Product manual IRB 1200 617 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights r...

Page 618: ...HAC056214 001 Screws 3HAB3409 207 M3x8 Tightening torque 1 5 Nm xx1300002431 Note Only use specified screws never replace them with other screws Protection plug for lifting holes 3HAC4836 24 xx1600001151 For robots with protection type Foundry Plus Check the protection plugs for lifting holes Replace if damaged 22 Continues on next page 618 Product manual IRB 1200 3HAC046983 001 Revision S Copyrig...

Page 619: ...ortened lifetime of the cable harness 24 Connecting the cabling in the lower arm Note Action ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 64 1 For robots with protection type Clean Room 2 For robots with food grade lubrication For robots with protection type Hygienic Clean th...

Page 620: ... 6 R2 EIB WARNING Make sure not to mix the R2 EIB and R2 ME2 Axis 2 may be severely damaged See the labels on the connectors for correct connection 4 Valid for IRB 1200 no type specified and IRB 1200 Type A 5 Connect the lugs to the EIB SMB cover xx1700000005 Valid for IRB 1200 Type B Connect the connectors to the SMB unit R1 ME1 2 4 5 R1 ME3 6 R2 SMB WARNING Make sure not to mix the R2 SMB and R2...

Page 621: ...to the lower arm with the attachment screws 8 Tightening torque 1 5 Nm xx1300002427 Note Only use specified screws never replace them with other screws Continues on next page Product manual IRB 1200 621 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 2 Replacing the swing spare parts swing axis 2 radial sealing Continued ...

Page 622: ...parts free from particles with spirit on a lint free Area to be lubricated shown in cable package already fitted to the housing xx1400000483 Before guiding the cable package into the housing and upper arm apply grease to the cable package to the area going into the upper arm shown in the figure Cover all moving area of the package 2 Continues on next page 622 Product manual IRB 1200 3HAC046983 001...

Page 623: ...mized way It is necessary to keep the air hose holder vertically and firmly against the left side of the axis 3 motor 3 Tightening torque 1 5 Nm xx1300002424 Refit the bracket to the sheet with two screws CAUTION Do not loosen the cable clamp screw There is a risk of rearrangement of the cable layout which would result in shortened lifetime of the cable harness 4 Tightening torque 1 5 Nm xx1300002...

Page 624: ...the bracket from the fix sheet by removing the two M3 screws Fit the holder to the bracket and then refit the complete assembly to the fix sheet again Tightening torque for the two M3 screws 1 5 Nm xx1400001133 7 Tightening torque 4 Nm xx1300002422 xx1300002420 Reconnect the axis 3 motor connectors 8 Continues on next page 624 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 A...

Page 625: ... protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002371 Reconnect the motor connectors 2 Continues on next page Product manual IRB 1200 625 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 2 Rep...

Page 626: ...ienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002399 Reconnect the FPC connectors Tip See the number markings on the connectors for help to find the corresponding connector 2 Continues on next page 626 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 2 Replacing the swin...

Page 627: ...help to find the corresponding connector 3 Cable layout in IRB 1200 5 0 9 xx1400001471 Remove residual locking liquid and other pollut ants with cleaning agent Loctite 7063 4 Continues on next page Product manual IRB 1200 627 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 2 Replacing the swing spare parts swing axis 2 radial sealing Continued ...

Page 628: ...om For robots with protection type Clean Room For robots with food grade lubrication 7 For robots with food grade lubric ation For robots with protection type Hygienic Apply a string of the sealant to the joint of the small cover on the housing Sealant SikaFlex 521FC For robots with protection type Hygienic Smooth out the sealant string using a finger tip Use washing up on finger tips to get a smo...

Page 629: ...using 3HAC044710 001 xx1400000740 Check the PTFE film on the cable housing Replace if damaged 9 Continues on next page Product manual IRB 1200 629 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 2 Replacing the swing spare parts swing axis 2 radial sealing Continued ...

Page 630: ...g cover 3HAC044660 001 xx1400000048 For robots with protection type Hygienic Check the gasket of the cable housing cover Replace if damaged Check the PTFE film on the cable housing cover 11 Replace if damaged Apply grease to the inner surface of the cable housing cover and the PTFE film surface 12 Continues on next page 630 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB ...

Page 631: ...tection type Connecting the air hoses and CP CS cabling on robots not in protection type Hygienic Use this procedure if the robot is not in protection type Hygienic Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Air connector set with Ethernet ho...

Page 632: ... IP67 On robots with protection type Foundry Plus Gasket 3HAC058567 001 xx1500000251 Protection bracket for CP CS con nectors 3HAC058350 001 xx1600001152 For robots with protection type Foundry Plus If required fit the protection bracket for CP CS connectors 4 Connecting the air hoses and CP CS cabling on robots in protection type Hygienic Use this procedure if the robot is with protection type Hy...

Page 633: ...0738 Reconnect the air hoses 3 xx1500000252 Reconnect the CP CS cabling 4 Plate with connector set 3HAC079691 001 Check the connectors on the plate with connector set and the attached gasket 5 Gasket 3HAC078804 001 xx2100001434 Replace if damaged Continues on next page Product manual IRB 1200 633 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 5 2 Replacing the swi...

Page 634: ...tion For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002360 Reconnect the motor cables R3 MP5 R3 ME5 2 Refitting the tubular cable housing cover Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the join...

Page 635: ...cation For robots with protection type Hygienic Check the tubular cable housing cover gasket Replace if damaged 2 Screws 3HAB3409 207 M3x8 Refit the cover to the cable housing 3 Tightening torque 1 5 Nm xx1300002389 Note Only use specified screws never replace them with other screws Continues on next page Product manual IRB 1200 635 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights rese...

Page 636: ...r robots with food grade lubrication Check the gasket Replace if damaged Screws 3HAB3409 207 M3x8 Refit the upper arm housing cover with the screws CAUTION For robots with safety lamp option Reconnect the lamp cable connectors R3 H1 and R3 H2 and then secure the cover 2 Tightening torque 1 5 Nm xx1300000456 Note Only use specified screws never replace them with other screws Continues on next page ...

Page 637: ... get a full cover joint For robots with protection type Clean Room 4 For robots with food grade lubrication For robots with protection type Hygienic Clean seal and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 158 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth Calibration is detailed i...

Page 638: ... 1200 via myABB Business Portal www abb com myABB Note Article number Spare part Includes mechanical stop pin 1 pc washer and screw 3HAC049630 001 Mechanical stop set axis 1 Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 890 Standard toolkit Continues on next page 638 Product manual IRB 1200 3HAC046983 001 Revision S Copyright ...

Page 639: ...hen disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 3 Replacing the axis 1 mechanical stop Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygi...

Page 640: ...obots with food grade lubrication For robots with protection type Hygienic Clean seal and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 158 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth DANGER Make sure all safety requirements are met when performing the first test run 7 640 Product m...

Page 641: ...it and axis 1 motor is part of the complete base spare part assembly see Replacing the base spare parts base axis 1 radial sealing protection sleeve on page 492 Product manual IRB 1200 641 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 1 Replacing the axis 1 gear unit ...

Page 642: ... spare parts Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the IRB 1200 via myABB Business Portal www abb com myABB Continues on next page 642 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 2 Replacing the axis 2 drive unit ...

Page 643: ...tion class IP67 Used with protection type Foundry Plus Replace if damaged 3HAC044641 003 M2 variseal sealing Not used with protection class IP40 Replace if damaged 3HAC056727 001 3HAC080705 001 Gasket on swing cover Not used for robots with protec tion class IP40 Replace if damaged 3HAC056726 001 3HAC080704 001 Gasket on cable housing cover Required tools and equipment Note Article number Equipmen...

Page 644: ...C026759 001 Sealant For robots with protection type Clean Room For robots with food grade lubric ation Trans Clear 3HAC073510 001 Sealant For robots with protection type Hygienic Deciding calibration routine Decide which calibration routine to be used based on the information in the table Depending on which routine is chosen action might be required prior to beginning the repair work of the robot ...

Page 645: ... be created then reference calibration is not possible If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the drive unit Use these procedures to remove the axis 2 drive unit Preparations before removing the axis 2 drive unit Note Action Decide which calibration routine to use and take actions accordingly prior to be...

Page 646: ...ight of the upper and lower arm no force 6 Loosening the cabling in the swing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disass...

Page 647: ...g Follow the procedure specified in Remov ing the swing sealing plug on page 166 3 xx1300002431 Remove the cable housing cover of the swing by removing the screws 4 xx1400001528 Cut the cable straps 5 Continues on next page Product manual IRB 1200 647 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 2 Replacing the axis 2 drive unit Continued ...

Page 648: ...548 Pull out the cable harness slightly from the lower arm housing Note The cabling is still connected inside the robot so be careful not to strain the cables 8 Continues on next page 648 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 2 Replacing the axis 2 drive unit Continued ...

Page 649: ...lic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Continues on next page Product manual IRB 1200...

Page 650: ...Make sure the weight of the arm is properly secured The lower arm weighs 13 kg If the upper arm is also attached to the lower arm it adds an additional 17 kg to the total weight 4 Continues on next page 650 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 2 Replacing the axis 2 drive unit Continued ...

Page 651: ...nly 6 Removing the axis 2 drive unit Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the pa...

Page 652: ...s best performed by two persons working together Person 1 Hold the lower arm still Person 2 Remove the drive unit screws according to step below 4 Remove the grey screws from the drive unit WARNING Keep the eight black screws fitted They hold the gearbox together Removing them can damage the gearbox severely 5 xx1400000008 Insert two M4 screws to the press out holes and press out the drive unit 6 ...

Page 653: ...ent amount of grease on the gear Apply more grease if needed 2 For robots with food grade lubrication For robots with protection type Hygienic LUBRIPLATE SYNXTREME FG 0 3HAC043771 001 xx1400000006 For robots with protection class IP67 For robots with protection type Foundry Plus Remove residual locking liquid and other pollutants with cleaning agent Loctite 7063 Apply flange sealing Loctite 574 on...

Page 654: ...fitted in a hanging lower arm this step requires two persons Person 1 Hold the lower arm still Person 2 Refit the drive unit screws Secure the screws but do not tighten yet 5 Note Only use specified screws never replace them with other screws Tightening torque 5 Nm If the drive unit is refitted in a hanging lower arm this step requires two persons Person 1 Hold the lower arm still Person 2 Tighten...

Page 655: ... 2 xx1400001403 Remove residual locking liquid and other pollutants with cleaning agent Loctite 7063 Apply flange sealing Loctite 574 to the cyl indrical surface in the swing Note For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Wipe clean the overflowing Loctite 574 if there is any 3 Continues on next page Product manual IR...

Page 656: ...obots with protection type Foundry Plus Check the sealing Replace if damaged CAUTION Do not fit M2 variseal sealing on robots in other protection class or protection types 5 xx1300002563 Fit the lower arm to the swing with guid ance from the guide pins 6 Continues on next page 656 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 2 Replacing...

Page 657: ...fied screws never replace them with other screws xx1300002565 Remove the guide pins and refit the remain ing screws and washers using locking li quid Loctite 243 8 Tightening torque 45 Nm Tighten all screws 9 Continues on next page Product manual IRB 1200 657 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 2 Replacing the axis 2 drive unit Continued ...

Page 658: ...s with protection type Hygienic Check the swing cover gasket Replace if damaged 10 Screws 3HAB3409 207 M3x8 Refit the swing cover 11 Tightening torque 1 5 Nm Replace if damaged Swing cover 3HAC059676 001 Swing cover Clean Room Swing cover food grade lubrication Swing cover Hygienic 3HAC056215 001 xx1300002551 Continues on next page 658 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 20...

Page 659: ...ection type Hygienic For robots with protection type Hygienic Apply a string of the sealant to the joint of the swing cover Sealant Trans Clear xx1600000217 Smooth out the sealant string using a finger tip Use washing up on finger tips to get a smooth joint If necessary add extra sealant to get a full cover joint xx1600001154 For robots with protection type Foundry Plus If required fit two screws ...

Page 660: ...n opened and wipe the parts free from particles with spirit on a lint free Tightening torque 3 Nm xx1300002549 Refit the cable housing to the swing with the screws 2 xx1300002548 Insert the cable harness into the lower arm 3 Continues on next page 660 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 2 Replacing the axis 2 drive unit Continu...

Page 661: ... xx1400001529 Secure the connector R2 MP2 and its cable with cable straps onto the motor bracket Make sure the connector is fixed by its tab to the bracket 6 Continues on next page Product manual IRB 1200 661 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 2 Replacing the axis 2 drive unit Continued ...

Page 662: ...er surface of the cable housing cover and the PTFE film surface 9 Cable housing cover of the swing 3HAC059678 001 Refit the cable housing cover with the screws Note Remember to refit the two lower screws shown in the figure 10 Cable housing cover of the swing Clean Room Cable housing cover of the swing food grade lubrication Cable housing cover of the swing Hygienic 3HAC056214 001 Screws 3HAB3409 ...

Page 663: ...ots with food grade lubrication For robots with protection type Hygienic Clean seal and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 158 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth Calibration is detailed in section Calibration on page 805 Recalibrate the robot 3 DANGER Make sure a...

Page 664: ...ut of date See the latest spare parts of the IRB 1200 via myABB Business Portal www abb com myABB Note Article number Spare part Includes axis 3 gearbox AC motor with encoder interface motor adapter and O ring 3HAC048939 002 3HAC061403 001 Drive unit Continues on next page 664 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 3 Replacing the...

Page 665: ...n type Foundry Plus Replace if damaged 3HAC044641 005 M2 variseal sealing Used with protection class IP67 Used with protection type Foundry Plus Replace if damaged 3HAC044641 006 M2 variseal sealing Not used with protection class IP40 Replace if damaged 3HAC024865 001 Radial sealing Not used with protection class IP40 Replace if damaged 3HAC056725 001 3HAC080703 001 Gasket on lower arm cover Not u...

Page 666: ...011 116 Flange sealing For robots with protection class IP67 For robots with protection type Foundry Plus Sikaflex 521FC 3HAC026759 001 Sealant For robots with protection type Clean Room For robots with food grade lubric ation Trans Clear 3HAC073510 001 Sealant For robots with protection type Hygienic Total amount 32 g 3HAC037302 001 Harmonic grease 4B No 2 Used to lubricate the gearbox The gear i...

Page 667: ...ration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 819 If no previous reference values exist and no new refere...

Page 668: ...th protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 4 xx1300002400 Remove the cable housing cover 5 xx1300002413 Remove the plate 6 Continues on next page 668 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserv...

Page 669: ... connectors from the housing and disconnect them 3 Creating space for separation of upper and lower arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind ...

Page 670: ... xx1300002530 Pull out the cable harness slightly from the upper arm housing and from the lower arm Note The cabling is still connected inside the robot so be careful not to strain the cables 5 Continues on next page 670 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 3 Replacing the axis 3 drive unit Continued ...

Page 671: ...robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Continues on next page Product manual IRB 1200 671 3HAC046983 001 Revision S Copyright 2014 2021 ABB All ...

Page 672: ...rt the weight of the arm no force 5 xx1300002531 Remove the upper arm screws WARNING This releases the upper arm from the lower arm Make sure the weight of the upper arm is properly secured by the lifting slings 6 Continues on next page 672 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 3 Replacing the axis 3 drive unit Continued ...

Page 673: ...pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Continues on next page Product manual IRB 1200 673...

Page 674: ...r robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Harmonic grease 4B No 2 3HAC037302 001 Check if there is a sufficient amount of grease on the gear Apply more grease if needed 2 For robots with food grade lubrication For robots with protection type Hygienic LUBRIPLA...

Page 675: ...g liquid and other pollutants with cleaning agent Loctite 7063 Apply flange sealing Loctite 574 on the mounting surfaces of the motor adapter 5 xx1300002534 Refit the drive unit into the upper arm Note Make sure to refit the drive unit correctly oriented When the upper arm is in its zero position horizontal the motor connectors should point downwards 6 Continues on next page Product manual IRB 120...

Page 676: ...r work wipe the robot free from particles with spirit on a lint free cloth 8 Refitting the upper arm Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 676 Product manual IRB 1200 3HAC04...

Page 677: ...or robots with protection class IP67 For robots with protection type Foundry Plus Check the sealing Replace if damaged CAUTION Do not fit M2 variseal sealing on robots in other protection class or protection types 3 Continues on next page Product manual IRB 1200 677 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 3 Replacing the axis 3 drive unit Continued ...

Page 678: ...nly use specified screws never replace them with other screws xx1400000029 Remove the guide pins and refit the remain ing screws and washers 5 Tightening torque 4 5 Nm Tighten all screws 6 Continues on next page 678 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 3 Replacing the axis 3 drive unit Continued ...

Page 679: ...th food grade lubrication For robots with protection type Hygienic Check the lower arm cover gasket Replace if damaged 7 Screws 3HAB3409 207 M3x8 Refit the lower arm cover 8 Tightening torque 1 5 Nm xx1300002528 Note Only use specified screws never replace them with other screws Continues on next page Product manual IRB 1200 679 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved...

Page 680: ...Room For robots with food grade lubrication For robots with protection type Hygienic Check the axis 3 radial sealing and the M2 variseal sealing in the cable housing Replace if damaged CAUTION Do not fit M2 variseal sealing on Clean Room food grade lubrication and Hygienic robots Note For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type ...

Page 681: ...he cable housing of the lower arm Sealant Trans Clear xx1600000218 Smooth out the sealant string using a finger tip Use washing up on finger tips to get a smooth joint If necessary add extra sealant to get a full cover joint Note No sealing is required in the cavities of the three lower screws highlighted with a ring in the figure xx1600001155 For robots with protection type Foundry Plus If requir...

Page 682: ...ening torque 1 5 Nm xx1300002421 Refit the fix sheet to the inner plastic guide 2 xx1300002420 Reconnect the axis 3 motor connectors 3 Continues on next page 682 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 3 Replacing the axis 3 drive unit Continued ...

Page 683: ...67 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the gasket of the cable housing cover Replace if damaged 5 Continues on next page Product manual IRB 1200 683 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 3 Replacing the axis 3 drive u...

Page 684: ...iquid Loctite 243 to all the screws securing the cover Note Only use specified screws never replace them with other screws For robots with protection type Clean Room 9 For robots with food grade lubrication For robots with protection type Hygienic Clean seal and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 158 Note After all repair...

Page 685: ...re all safety requirements are met when performing the first test run 11 Product manual IRB 1200 685 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 3 Replacing the axis 3 drive unit Continued ...

Page 686: ...myABB Business Portal www abb com myABB Note Article number Spare part 3HAC049629 001 Gearbox Used for robots with food grade lubrication Used with protection type Hy gienic 3HAC057904 001 Gearbox food grade lubrication Gearbox Hygienic 3HAC044692 001 Shaft 3HAC044687 001 Pulley Replace if damaged 3HAC044689 001 Motor bracket 3HAC044685 001 Gearbox sleeve Continues on next page 686 Product manual ...

Page 687: ...gasket IRB 1200 5 0 9 Required tools and equipment Note Article number Equipment etc Used to refit the radial sealing if re placement is needed 3HAC049699 001 Axis 4 sealing assembly tool set Used to release the motor brakes 24 VDC power supply Includes calibration tools pins and at tachment screws for manual calibration method i 3HAC051256 001 Calibration toolkit manual calibration Content is def...

Page 688: ...he robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference...

Page 689: ...ean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 4 Getting access to inside of the wrist unit Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and a...

Page 690: ...lar cover left hand side cover has two extra screws and washers as encircled in the figure For robots with protection type Clean Room xx1600001148 Note For robots with protection type Clean Room For robots with food grade lubrication The tubular cover left hand side cover has two extra screws and washers as encircled in the figure For robots with protection type Hygienic xx2100001406 Note For robo...

Page 691: ...ake photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 3 Removing the axis 5 motor with pulley Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hyg...

Page 692: ...4 xx1300002390 Snap loose and disconnect the axis 5 FPC connectors 5 xx1300002352 Remove the screws and pull out the motor 6 Continues on next page 692 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 4 Replacing the axis 4 gearbox drive shaft and pulley Continued ...

Page 693: ...fe and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300002353 Disconnect the connectors shown in the figure 3 xx1300002355 Disconnect the air hoses 4 xx1300002356 Remove the connector plate attachment screws 5 Continues on next page Product manual IRB 1200 693 3HAC046983 001 Revision S Copyright 2014 20...

Page 694: ...connectors and the air hoses out of the wrist Be careful not to damage the FPC cabling and the connectors CAUTION Pay special attention to the plastic block on the FPC unit It is easily pulled off make sure it stays fitted to the FPC unit xx1300002611 8 Continues on next page 694 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 4 Replacing ...

Page 695: ... Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300000456 Remove the cover from the upper arm housing CAUTION For robots with safety lamp option Be aware of the signal lamp cables that are at tached inside the housing Disconnect the lamp cable connectors R3 H1 and R3 H2 and then lift away the cover completely 3 xx1300002494 Cut the strap that holds the connectors 4 C...

Page 696: ...ON For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300002400 Remove the cable housing cover 3 Continues on next page 696 Product manual IRB 1200 3...

Page 697: ...the FPC connectors from the housing and disconnect them 5 Cable layout in IRB 1200 5 0 9 xx1400001471 Continues on next page Product manual IRB 1200 697 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 4 Replacing the axis 4 gearbox drive shaft and pulley Continued ...

Page 698: ... with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Continues on next page 698 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights...

Page 699: ... pul ley 4 Remove the timing belt from its groove on the motor 5 Removing the air hoses Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1200 699 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 4 Replacing the axis 4 gearbox drive shaft and pulley Con...

Page 700: ...nit 4 Removing the housing extender unit Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut th...

Page 701: ...needle nose plier 4 xx1300002372 Remove the extender unit screws 5 xx1300002374 Remove the housing extender unit Be careful not to damage the cabling 6 Removing the axis 4 drive shaft Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1200 701 3HAC046983 001 Revision S Copyright 2014 202...

Page 702: ...r surface on the robot before replacing parts on page 158 2 xx1300002376 Remove the screws and washers 3 xx1400002400 Remove the shaft 4 xx1300002387 If replacing the drive shaft with a new spare part remove the sleeve from the shaft and fit it to the new shaft 5 Continues on next page 702 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 4 ...

Page 703: ...ction type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300002378 Remove the gear attachment screws 3 xx1300002379 Pull out the gear 4 Continues on next page Product manual IRB 1200 703 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4...

Page 704: ...ean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Screws 3HAB3409 209 M3x20 Refit the pulley to the gear and secure with its attachment screws 2 Tightening torque 1 1 Nm xx1300002380 Note Only use specified screws never replace them with other screws Continues on next page 704 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021...

Page 705: ...ive shaft Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page Product manual IRB 1200 705 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 4 Replacing th...

Page 706: ...ft xx1300002377 Position the shaft so that the encircled screw is on top then refit the shaft 3 Screws 3HAB3409 210 M3x25 Secure with screws and washers 4 Tightening torque 1 8 Nm xx1300002376 Note Only use specified screws never replace them with other screws Continues on next page 706 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 4 Rep...

Page 707: ...lip 3HAB3701 48 xx1400000438 For robots with protection class IP67 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the radial sealing Replace if damaged as described below In order to replace the radial sealing both the axis 4 mechanical stop and the axis 4 FPC unit must be...

Page 708: ...k that the sealing is undamaged and properly fitted 10 Refit both the axis 4 mechanical stop and the axis 4 FPC unit to the housing extender unit 11 Refitting the housing extender unit Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles ...

Page 709: ... fill glue again before the refitting 3 xx1300002374 Refit the housing extender unit to the housing while putting the FPC cables into the housing and the air hoses through the housing extender unit Be careful not to damage the cabling CAUTION Make sure that the axis 4 FPC unit is in its zero position when refitting the housing extender unit Note Mate the unit to the two locating pins attached to t...

Page 710: ...he air hoses Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Place the timing belt at the gear pulley and run the air hoses through the belt 2 Install the air hoses in and through the housing extender unit ...

Page 711: ...ic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Check that all assembly surfaces are clean and undamaged the motor is clean and undamaged 2 Fit the timing belt to the motor pulley 3 Continues on next page Product manual IRB 1200 711 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 4 Replacing the axis 4 g...

Page 712: ...s parallel with the mounting flange surface on the housing shown in the figure when moving the motor 4 Note Only use specified screws never replace them with other screws xx1300002612 xx1300002525 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pulleys 5 Continues on next page 712 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 ...

Page 713: ...nect the FPC connectors Tip See the number markings on the connectors for help to find the corresponding connector 2 Cable layout in IRB 1200 7 0 7 xx1300002412 Reconnect the FPC connectors and push them into place inside the housing Tip See the number markings on the connectors for help to find the corresponding connector 3 Cable layout in IRB 1200 5 0 9 xx1400001471 Remove residual locking liqui...

Page 714: ...n Room For robots with protection type Clean Room For robots with food grade lubrication 7 For robots with food grade lubric ation For robots with protection type Hygienic Apply a string of the sealant to the joint of the small cover on the housing Sealant SikaFlex 521FC For robots with protection type Hygienic Smooth out the sealant string using a finger tip Use washing up on finger tips to get a...

Page 715: ...e housing 3HAC044710 001 xx1400000740 Check the PTFE film on the cable housing Replace if damaged 9 Continues on next page Product manual IRB 1200 715 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 4 Replacing the axis 4 gearbox drive shaft and pulley Continued ...

Page 716: ...using cover 3HAC044660 001 xx1400000048 For robots with protection type Hygienic Check the gasket of the cable housing cover Replace if damaged Check the PTFE film on the cable housing cover 11 Replace if damaged Apply grease to the inner surface of the cable housing cover and the PTFE film surface 12 Continues on next page 716 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ...

Page 717: ...e Only use specified screws never replace them with other screws Connecting the axis 4 motor connectors Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002371 Reconnect the motor connectors 2 Continue...

Page 718: ...1300002359 Put the connectors and air hoses into the wrist carefully while at the same time refitting the wrist to the housing extender unit Be careful not to damage the FPC cabling and the connectors CAUTION Pay special attention to the plastic block on the FPC unit It is easily pulled off make sure it stays fitted to the FPC unit xx1300002611 2 Continues on next page 718 Product manual IRB 1200 ...

Page 719: ... use specified screws never replace them with other screws Screw 3HAB3409 237 M5x35 7 pcs xx1400000003 Refit the rest of the screws M5x35 7 pcs 5 Note Only use specified screws never replace them with other screws Tightening torque 8 Nm Tighten all screws 6 Continues on next page Product manual IRB 1200 719 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 4 Replac...

Page 720: ... 5 motor Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 2 Continues on next page 720 Product manual IRB 1200 ...

Page 721: ...r robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002351 Refit the timing belt on the pulley 2 Note Do not strech the timing belt too much Move the motor to a position where a good timing belt tension is reached F 26 N 3 Continues on next page Product manual IR...

Page 722: ...a lint free xx1300002390 Connect the axis 5 FPC connectors and snap them to their holders 2 Connecting the axis 5 motor connectors Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 722 ...

Page 723: ... tubular cover 3HAC058822 001 not Hygienic robots 3HAC080709 001 Hygienic robots xx1400000034 For robots with protection class IP67 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cover gasket Replace if damaged 2 Continues on next page Product manual IRB 1200 7...

Page 724: ... Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cable housing cover gasket Replace if damaged 3 Continues on next page 724 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 4 Replacing the axis 4 gearbox drive shaft and pulley Continued...

Page 725: ...om For robots with food grade lubrication xx1600001153 For robots with protection type Clean Room For robots with food grade lubrication Remember to refit the extra two screws and washers to the tubular cover Note Only use specified screws never replace them with other screws For robots with protection type Hygienic xx2100001406 Note For robots with protection type Hygienic Check the two extra scr...

Page 726: ...0456 Note Only use specified screws never replace them with other screws For robots with protection type Clean Room For robots with protection type Clean Room For robots with food grade lubrication 3 For robots with food grade lubric ation For robots with protection type Hygienic Apply a string of the sealant to the joint of the upper arm housing cover Sealant SikaFlex 521FC For robots with protec...

Page 727: ...rts on page 158 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth Calibration is detailed in section Calibration on page 805 Recalibrate the robot 5 DANGER Make sure all safety requirements are met when performing the first test run 6 Product manual IRB 1200 727 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 4 Replaci...

Page 728: ... Portal www abb com myABB Note Article number Spare part 3HAC045827 001 Motor with pulley Used for IRB 1200 Type B See Type B of IRB 1200 on page873 Used with protection type Hy gienic 3HAC061277 001 Motor with pulley SafeMove 2 supported Motor with pulley Hygienic Replace if damaged 3HAC047479 001 Motor flange Continues on next page 728 Product manual IRB 1200 3HAC046983 001 Revision S Copyright ...

Page 729: ...bration is used as default Required consumables Note Art no Consumable Isopropanol Cleaning agent Cable straps Sikaflex 521FC 3HAC026759 001 Sealant For robots with protection type Clean Room For robots with food grade lubric ation Trans Clear 3HAC073510 001 Sealant For robots with protection type Hygienic Deciding calibration routine Decide which calibration routine to be used based on the inform...

Page 730: ...an be created then reference calibration is not possible If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the motor with pulley Use these procedures to remove the motor Preparations before removing the axis 4 motor Note Action Decide which calibration routine to use and take actions accordingly prior to beginning ...

Page 731: ...e Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300000456 Remove the cover from the upper arm housing CAUTION For robots with safety lamp option Be aware of the signal lamp cab...

Page 732: ...c pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Continues on next page 732 Product manual IRB 12...

Page 733: ...y 4 Remove the timing belt from its groove on the motor 5 Separating the axis 4 motor from the motor flange Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1200 733 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 5 Replacing the axis 4 motor with pul...

Page 734: ...e motor by removing the screws 3 Refitting the motor with pulley Use these procedures to refit the motor Fitting the axis 4 motor to the motor flange Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continue...

Page 735: ...tion type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Check that all assembly surfaces are clean and undamaged the motor is clean and undamaged 2 Fit the timing belt to the motor pulley 3 Continues on next page Product manual IRB 1200 735 3HAC046...

Page 736: ...motor is parallel with the mounting flange surface on the housing shown in the figure when moving the motor 4 Note Only use specified screws never replace them with other screws xx1300002612 xx1300002525 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pulleys 5 Continues on next page 736 Product manual IRB 1200 3HAC046983 001 Revision S Copyrigh...

Page 737: ... food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002371 Reconnect the motor connectors 2 xx1300002494 Secure the connectors to the motor with a cable strap 3 Continues on next page Product manual IRB 1200 737 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights res...

Page 738: ...0477 For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the gasket Replace if damaged Screws 3HAB3409 207 M3x8 Refit the upper arm housing cover with the screws 2 Tightening torque 1 5 Nm xx1300000456 Note Only use specified screws never replace them with other screws Continues on next page 738 Product manual IRB 1200 3H...

Page 739: ...t to get a full cover joint For robots with protection type Clean Room 4 For robots with food grade lubrication For robots with protection type Hygienic Clean seal and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 158 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth Calibration informati...

Page 740: ...HAC044694 001 Timing belt Not used with protection class IP40 Replace if damaged 3HAC056724 001 3HAC080702 001 Gasket on cable housing cover Not used with protection class IP40 Replace if damaged 3HAC056698 001 3HAC080700 001 Housing cover gasket IRB 1200 7 0 7 Not used with protection class IP40 Replace if damaged 3HAC056697 001 3HAC080699 001 Housing cover gasket IRB 1200 5 0 9 Continues on next...

Page 741: ...ith protection type Hy gienic Replace if damage 3HAC078804 001 Gasket Required tools and equipment Note Article number Equipment etc Used to release the motor brakes 24 VDC power supply Content is defined in section Standard toolkit on page 890 Standard toolkit Required consumables Note Art no Consumable Isopropanol Cleaning agent Cable straps Loctite 7063 Cleaning agent Loctite 574 12340011 116 F...

Page 742: ...tion Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 819 If no previous reference values exist and no new referenc...

Page 743: ...e Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 4 xx1300002400 Remove the lower arm cable housing cover 5 xx1300002389 Remove the tubular cable housing cover 6 Continues on next page Product manual IRB 1200 743 3HAC046983 001 Revision S Copyright 2014 2021 ABB Al...

Page 744: ... grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300000456 Remove the cover from the upper arm housing CAUTION For robots with safety lamp option Be aware of the signal lamp cables that are at tached inside the housing Disconnect the lamp cable connectors R3 H1 and R3 H2 and then lift away the cover comple...

Page 745: ...ulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Continues on next page Product manual IRB 120...

Page 746: ...or and the pul ley 4 Remove the timing belt from its groove on the motor 5 Removing the air hoses Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 746 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 6 Replacing the axis 4 timing belt Continued ...

Page 747: ... Removing the axis 4 timing belt Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint ...

Page 748: ... through the housing extender unit 3 xx1400000797 Refit the plastic protection plate with its screws 4 Securing the axis 4 motor Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Check that all assembly surfa...

Page 749: ... 4 motor is parallel with the mounting flange surface on the housing shown in the figure when moving the motor 4 Note Only use specified screws never replace them with other screws xx1300002612 xx1300002525 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pulleys 5 Continues on next page Product manual IRB 1200 749 3HAC046983 001 Revision S Copyr...

Page 750: ...ith food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002371 Reconnect the motor connectors 2 xx1300002494 Secure the connectors to the motor with a cable strap 3 Continues on next page 750 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights ...

Page 751: ...set without Ethernet hole in flange 3HAC049665 001 xx1400000738 xx1500000252 If equipped reconnect the CP CS connector For robots with protection class IP67 For robots with protection type Foundry Plus 1 Check the gasket 2 Replace if damaged For robots with protection type Clean Room For robots with food grade lubrication 1 Remove residual locking liquid and other pollutants with cleaning agent Lo...

Page 752: ...e been opened and wipe the parts free from particles with spirit on a lint free 1 Plate without connector set 3HAC078810 001 If the Hygienic robot not equipped with air hoses and CP CS cabling 2 Gasket 3HAC078804 001 xx2100001433 Check the plate without connector set and the at tached gasket Replace if damaged xx1400000738 Reconnect the air hoses 3 xx1500000252 Reconnect the CP CS cabling 4 Contin...

Page 753: ...rts free from particles with spirit on a lint free Gasket for tubular cable housing cover 3HAC056707 001 not Hygienic robots 3HAC080701 001 Hygienic robots xx1400000345 For robots with protection class IP67 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cable h...

Page 754: ...s with protection class IP67 For robots with protection type Foundry Plus 1 Housing cover gasket IRB 1200 5 0 9 3HAC056697 001 not Hygienic robots 3HAC080699 001 Hygienic robots xx1400000477 For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the gasket Replace if damaged Continues on next page 754 Product manual IRB 1200...

Page 755: ...cation Sealant SikaFlex 521FC For robots with protection type Hygienic For robots with protection type Hygienic Apply a string of the sealant to the joint of the upper arm housing cover Sealant Trans Clear xx1600000215 Smooth out the sealant string using a finger tip Use washing up on finger tips to get a smooth joint If necessary add extra sealant to get a full cover joint Continues on next page ...

Page 756: ...or robots with protection type Hygienic Check the gasket of the cable housing cover Replace if damaged 4 PTFE film on cable housing cover 3HAC044660 001 Check the PTFE film on the cable housing cover 5 Replace if damaged Apply grease to the inner surface of the cable housing cover and the PTFE film surface 6 Continues on next page 756 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 201...

Page 757: ...th protection type Clean Room 8 For robots with food grade lubrication For robots with protection type Hygienic Clean seal and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 158 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth Calibration information is included in sec tion Calibration on...

Page 758: ...or with pulley Used for IRB 1200 Type B See Type B of IRB 1200 on page 873 3HAC061278 001 Motor with pulley SafeMove 2 supported Motor with pulley Hygienic Not used with protection class IP40 3HAC058822 001 3HAC080709 001 Gasket for tubular cover Replace if damaged Not used with protection class IP40 3HAC056707 001 3HAC080701 001 Gasket for tubular cable housing cover Replace if damaged Continues ...

Page 759: ... to beginning the repair work of the robot see the table Note Action Note Calibrating axis 6 always requires tools to be removed from the mounting flange also for reference calibration since the mount ing flange is used for installation of the calibration tool Decide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can sta...

Page 760: ...ll electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot befor...

Page 761: ...ith food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Continues on next page Product manual IRB 1200 761 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 7 Replacing the axis 5...

Page 762: ...tion The tubular cover left hand side cover has two extra screws and washers as encircled in the figure For robots with protection type Hygienic xx2100001406 Note For robots with protection type Hygienic The tubular cover right hand side cover has two extra screws as encircled in the figure Do not remove the two screws when removing the cover The screws are used for blocking the screw holes rather...

Page 763: ...nnecting 3 Removing the axis 5 motor with pulley Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot Se...

Page 764: ...on type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 2 Continues on next page 764 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021...

Page 765: ...m 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002351 Refit the timing belt on the pulley 2 Note Do not strech the timing belt too much Move the motor to a position where a good timing belt tension is reached F 26 N 3 Continues on next page Product man...

Page 766: ...rit on a lint free xx1300002390 Connect the axis 5 FPC connectors and snap them to their holders 2 Connecting the axis 5 motor connectors Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next pa...

Page 767: ...et for tubular cover 3HAC058822 001 not Hygienic robots 3HAC080709 001 Hygienic robots xx1400000034 For robots with protection class IP67 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cover gasket Replace if damaged 2 Continues on next page Product manual IRB ...

Page 768: ...on type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cable housing cover gasket Replace if damaged 3 Continues on next page 768 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 7 Replacing the axis 5 motor with pulley Continued ...

Page 769: ...ean Room For robots with food grade lubrication xx1600001153 For robots with protection type Clean Room For robots with food grade lubrication Remember to refit the extra two screws and washers to the tubular cover Note Only use specified screws never replace them with other screws For robots with protection type Hygienic xx2100001406 Note For robots with protection type Hygienic Check the two ext...

Page 770: ...placing parts on page 158 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth Calibration information is included in sec tion Calibration on page 805 Recalibrate the robot 2 DANGER Make sure all safety requirements are met when performing the first test run 3 770 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved...

Page 771: ...657 001 Timing belt Not used with protection class IP40 3HAC058822 001 3HAC080709 001 Gasket for tubular cover Replace if damaged Required tools and equipment Note Article number Equipment etc Used to release the motor brakes 24 VDC power supply Content is defined in section Standard toolkit on page 890 Standard toolkit Required consumables Note Art no Consumable Isopropanol Cleaning agent Continu...

Page 772: ...he refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference...

Page 773: ...od grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 4 xx1400000033 Remove the left hand side wrist cover 5 Continues on next page Product manual IRB 1200 773 3HAC046983 001 Revision S Copyright 2014 2021 ABB All righ...

Page 774: ... Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300002350 Loosen the screws so that the motor can be moved sideways 3 xx1300002351 Remove the timing belt 4 Continues on next page 774 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB Al...

Page 775: ...have been opened and wipe the parts free from particles with spirit on a lint free xx1300002351 Refit the timing belt on the pulley 2 Belt tension F 26 N Move the motor to achieve correct belt tension F 26 N 3 xx1300002350 Secure the motor with its attachment screws 4 Tightening torque 3 5 Nm Continues on next page Product manual IRB 1200 775 3HAC046983 001 Revision S Copyright 2014 2021 ABB All r...

Page 776: ...g liquid Loctite 243 to the two front screws on the left hand side cover encircled in the figure Note Only use specified screws never replace them with other screws For robots with protection type Clean Room 3 For robots with food grade lubrication For robots with protection type Hygienic Clean seal and paint the joints that have been opened See Cut the paint or surface on the robot before replaci...

Page 777: ...re all safety requirements are met when performing the first test run 5 Product manual IRB 1200 777 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 8 Replacing the axis 5 timing belt Continued ...

Page 778: ...t are listed in the table can be out of date See the latest spare parts of the IRB 1200 via myABB Business Portal www abb com myABB Note Art no Spare part Includes axis 5 gear unit and axis 6 drive train unit 3HAC059696 001 Drive unit Continues on next page 778 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 9 Replacing the axis 5 and axis...

Page 779: ... Used for IRB 1200 Type B See Type B of IRB 1200 on page 873 3HAC061281 001 Drive unit food grade lubrica tion Used for robots with food grade lubrication Includes axis 5 gear unit and axis 6 drive train unit Used with protection class IP67 3HAC044641 008 M2 variseal sealing Used with protection type Foundry Plus Replace if damaged Replace if damaged 3HAC044641 009 M2 variseal sealing Not used wit...

Page 780: ...n section Standard toolkit on page 890 Standard toolkit Used with robots in protection type Hygienic Used for loosen and tighten the seal ring unit on tool flange of the Hygienic robots 3HAC079686 001 Flange tightening tool Used with robots in protection type Hygienic 3HAC079684 001 Guide pin for stainless shaft on tool flange i The robot is calibrated by either manual calibration or Axis Calibrat...

Page 781: ...outine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calib...

Page 782: ...oom For robots with food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 4 Continues on next page 782 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 9 Repl...

Page 783: ...h food grade lubrication For robots with protection type Hygienic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 Continues on next page Product manual IRB 1200 783 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 9 Replacing the axis 5 a...

Page 784: ...cation The tubular cover left hand side cover has two extra screws and washers as encircled in the figure For robots with protection type Hygienic xx2100001406 Note For robots with protection type Hygienic The tubular cover right hand side cover has two extra screws as encircled in the figure Do not remove the two screws when removing the cover The screws are used for blocking the screw holes rath...

Page 785: ... by first removing the screws 4 xx1300002392 Remove the cable housing of the tubular by first removing the screws Note For robots with protection class IP67 For robots with protection type Foundry Plus For robots with protection type Hygienic The frame is glued and needs to be pried off 5 Removing the axis 5 FPC unit Note Action DANGER Make sure that all supplies for electrical power hydraulic pre...

Page 786: ...s on page 158 2 xx1300002393 Remove the sleeve screws 3 xx1300002582 Remove the sleeve by screwing in two of the screws into the press out holes to force the sleeve out 4 xx1300002394 Remove the FPC unit attachment screws and pull out the FPC unit as far as required for the axis 6 motor connectors to be accessed 5 Continues on next page 786 Product manual IRB 1200 3HAC046983 001 Revision S Copyrig...

Page 787: ...ic Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 158 2 xx1300002350 Loosen the attachment screws of the axis 5 motor so that the motor can slide sideways 3 xx1300002351 Slide the motor sideways to release the tension of the timing belt and remove the timing belt 4 Continues o...

Page 788: ...e unit 7 Refitting the drive unit Use these procedures to refit the drive unit Checking the sealing set on tool flange of Hygienic robots Note Action Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free 1 Continues on next page 788 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 9 Replaci...

Page 789: ...0001450 Insert two M4 screws to the pressed out holes and press out the stainless shaft 4 xx2100001451 Flange tightening tool 3HAC079686 001 xx2100001452 Place the flange tightening tool together with a 3 8 10 mm socket spanner on the seal ring unit and loosen the unit 5 Continues on next page Product manual IRB 1200 789 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repai...

Page 790: ...x2100001454 Apply a little grease to the screw thread 8 xx2100001453 Put the gasket in place and then screw the seal ring unit 9 xx2100001455 Continues on next page 790 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 9 Replacing the axis 5 and axis 6 drive unit Continued ...

Page 791: ...57 Fit two guide pins to the tool flange 11 xx2100001458 Place the stainless shaft on the tool flange with guidance of the two guide pins Make sure the pin hole on the shaft aligned with the pin on the tool flange 12 Tightening torque 1 5 Nm xx2100001459 Secure with screws and washers 13 Continues on next page Product manual IRB 1200 791 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights...

Page 792: ...tion type Foundry Plus Check the protection cover for turning disk and T40 variseal sealing 2 T40 variseal sealing 3HAC044641 012 xx1600001126 Replace if damaged M2 variseal sealing 3HAC044641 008 xx1300002493 For robots with protection class IP67 For robots with protection type Foundry Plus Check the sealing Replace if damaged CAUTION Do not fit M2 variseal sealing on robots in other protection c...

Page 793: ...bots with food grade lubrication For robots with protection type Hygienic Wipe clean the overflowing sealant if there is any For robots with protection type Hygienic Flange sealant Trans Clear xx1400001404 Guide pin for tilt unit axis 5 3HAC049706 001 xx1300002568 Fit guide pins to the axis 5 gearbox 5 Continues on next page Product manual IRB 1200 793 3HAC046983 001 Revision S Copyright 2014 2021...

Page 794: ...569 Refit the drive unit and secure with the screws and washers Secure the screws but do not tighten yet Note If there is glue on the screw please clean it or replace it with a new one 7 Note Only use specified screws never replace them with other screws xx1300002570 Remove the guide pins and refit the remaining screws and washers 8 Continues on next page 794 Product manual IRB 1200 3HAC046983 001...

Page 795: ...ood grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002395 Reconnect the axis 6 motor connectors to the FPC unit 3 Tightening torque 0 3 Nm xx1300002394 Carefully refit the FPC unit and secure with screws Note Check that the FPC unit is at the zero pos ition when refitting it 4...

Page 796: ...ote For Hygienic robots wipe clean the over flowing flange sealing if there is any Sleeve 3HAC044661 001 Refit the sleeve and secure with screws 6 Tightening torque 1 5 Nm xx1300002393 Replace if damaged Checking the tubular cable housing sealings Note Action For robots with protection type Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joint...

Page 797: ...If undamaged and properly seated skip to the next procedure table 3 Apply a little grease to the sealing when replacing the radial sealing and wipe clean after the replacement 4 Fit the radial sealing into the tubular cable housing 5 Axis 5 sealing assembly tool set 3HAC049701 001 xx1400000485 Fit the circular part of the radial sealing assembly tool against the radial sealing 6 Fit the tool plate...

Page 798: ...s with protection class IP67 For robots with protection type Foundry Plus 2 For robots with protection type Foundry Plus For robots with protection type Hygienic Remove residual locking liquid and other pollut ants with cleaning agent Loctite 7063 Flange sealant SikaFlex 521FC For robots with protection type Hygienic Apply flange sealing on the mounting surfaces of the tubular cable housing Note F...

Page 799: ...Clean Room 1 For robots with food grade lubrication For robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1300002351 Refit the timing belt on the pulley 2 Note Do not strech the timing belt too much Move the motor to a position where a good timing belt tension is reached F 26 N 3 Continues on next page Pr...

Page 800: ...ic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Tightening torque 0 3 Nm xx1400001401 Refit the connector plate and secure with the M3 screws 2 Tightening torque 0 3 Nm xx1400001402 Secure the three M2 5 screws 3 Continues on next page 800 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repa...

Page 801: ... robots with protection type Hygienic Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Gasket for tubular cover 3HAC058822 001 not Hygienic robots 3HAC080709 001 Hygienic robots xx1400000034 For robots with protection class IP67 For robots with protection type Foundry Plus For robots with protection type Clean Room For robots with food grade ...

Page 802: ... type Foundry Plus For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cable housing cover gasket Replace if damaged 3 Continues on next page 802 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4 Repair 4 6 9 Replacing the axis 5 and axis 6 drive unit Continued ...

Page 803: ...n Room For robots with food grade lubrication xx1600001153 For robots with protection type Clean Room For robots with food grade lubrication Remember to refit the extra two screws and washers to the tubular cover Note Only use specified screws never replace them with other screws For robots with protection type Hygienic xx2100001406 Note For robots with protection type Hygienic Check the two extra...

Page 804: ...acing parts on page 158 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth Calibration information is included in sec tion Calibration on page 805 Recalibrate the robot 2 DANGER Make sure all safety requirements are met when performing the first test run 3 804 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 4...

Page 805: ...eneric term for all calibration methods that aim to move the robot to calibration position Standard calibration A calibration routine that generates a new zero posi tion of the robot Fine calibration A calibration routine that in the first step generates a reference to current zero position of the robot The same calibration routine can later on be used to re calibrate the robot back to the same po...

Page 806: ...tion due to load Absolute accuracy calibration focuses on pos itioning accuracy in the Cartesian coordinate system for the robot Absolute accuracy calibration option al Absolute accuracy calibration data is found on the SMB serial measurement board in the robot For robots with RobotWare 5 05 or older the absolute accuracy calibration data is delivered in a file absacc cfg supplied with the robot a...

Page 807: ...ng with Axis Calibration method on page 818 The actual instructions of how to perform the calibration procedure and what to do at each step is given on the FlexPendant You will be guided through the calibration procedure step by step Wrist Optimization method Wrist Optimization is a method for improving reorientation accuracy for continuous processes like welding and gluing and is a complement to ...

Page 808: ...nt The Absolute Accuracy option varies according to the robot mounting position This is printed on the robot name plate for each robot The robot must be in the correct mounting position when it is recalibrated for absolute accuracy References Article numbers for the calibration tools are listed in the section Special tools on page 891 808 Product manual IRB 1200 3HAC046983 001 Revision S Copyright...

Page 809: ...age 813 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 is rebuilt for example after a crash or when ...

Page 810: ...tion shows the position of the synchronization marks and the synchronization position for each axis Synchronization marks IRB 1200 xx1400000402 Continues on next page 810 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchronization position for axes ...

Page 811: ...axis 6 on Hygienic robots xx2100001464 Product manual IRB 1200 811 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchronization position for axes Continued ...

Page 812: ...graphic below Calibration service routines will handle the calibration movements automatically and these might be different from the positive directions shown below Manual movement directions A D E F C B xx1300000365 Description Posi tion Description Posi tion Axis 2 B Axis 1 A Axis 4 D Axis 3 C Axis 6 F Axis 5 E 812 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rig...

Page 813: ...1 See Synchronization marks and synchron ization position for axes on page 810 Jog the manipulator to align the synchron ization marks 2 Step 2 Updating the revolution counter with the FlexPendant on page 813 When all axes are positioned update the revolution counter 3 Step 2 Updating the revolution counter with the FlexPendant Use this procedure to update the revolution counter with the FlexPenda...

Page 814: ...e 6 04 and later 3 Calibration method used at factory for each axis is shown as well as calibration method used during last field calibration Tap Manual Method Advanced xx1500000944 Continues on next page 814 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 5 Calibration 5 3 1 Updating revolution counters on IRC5 robots Continued ...

Page 815: ...yed 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 selected revolution counters and removes the tick from the list of axes 7 CAUTION If a revolution counter is incorrectly updated it will cause incorrect manipulator posi tioning which in turn may cause ...

Page 816: ...quired only if you are not already in the Mechanical Unit page when you open Calibrate Note The Mechanical Unit page is displayed only if there are more than one mechanical unit available Otherwise the calibration summary page for the available mechanical unit is displayed Select the mechanical unit for which revolution counter need to be updated 3 The calibration summary page for the selected mec...

Page 817: ...ator posi tioning which in turn may cause damage or injury Check the synchronization position very carefully after each update See Checking the synchronization position on page 865 10 Product manual IRB 1200 817 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 5 Calibration 5 3 2 Updating revolution counters on OmniCore robots Continued ...

Page 818: ... and one mounting hole on the tool flange The Axis Calibration procedure described roughly 1 A removable calibration tool is inserted by the operator into a calibration bushing on the axis chosen for calibration according to instructions on the FlexPendant WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB Using other pins in the calibration bushings ma...

Page 819: ...ta about the tool installed A benefit with reference calibration is that the current state of the robot is stored and not the state when the robot left the ABB factory The reference value will be named according to tool name date etc Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values When reference calibration is performed the robot is ...

Page 820: ...d a new SafeMove calibration has to be done Make sure that the user rights admit to change the safety settings and to synchronize SafeMove For robots with EPS the same applies as for SafeMove How to calibrate a suspended or wall mounted robot The IRB 1200 is fine calibrated floor standing in factory prior to shipping To calibrate a suspended or wall mounted robot reference calibration could be use...

Page 821: ... also includes a unique calibra tion pin for IRB 1200 to be fitted to the tool flange during calibration of axis 6 3HAC074119 001 Calibration tool box Axis Calibration i The robot is calibrated by either manual calibration or Axis Calibration at ABB factory before delivery Always use the same calibration method as used at the factory Information about valid calibration method is found on the calib...

Page 822: ...Straightness within 0 005 mm xx1500000951 Outer diameter A Periodic check of the calibration tool for the tool flange 3HAC058238 001 If including the tool flange calibration tool in a local periodic check system the following measures should be checked Outer diameter within Ø5g5 mm Straightness within 0 005 mm Continues on next page 822 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2...

Page 823: ... xx1600001142 Outer diameter A Product manual IRB 1200 823 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 5 Calibration 5 4 2 Calibration tools for Axis Calibration Continued ...

Page 824: ...on each axis as follows If there is not enough space on an axis to install a fixed calibration pin the axis is equipped with two bushings instead for installation of two calibration tools when calibration is carried out This is shown in the figure For axis 6 there is only one bushing the second calibration tool is installed at the mounting flange of the turning disk xx1600001035 Continues on next ...

Page 825: ...ng Used with protection type Clean Room 3HAC059557 001 Protective plug for bushing Clean Room Used for robots with food grade lubrication Protective plug for bushing food grade lubrication Used with protection type Hygien ic Protective plug for bushing Hygien ic Replace if damaged or missing Product manual IRB 1200 825 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 5 Calibra...

Page 826: ...alibration menu on the FlexPendant If no data is found related to standard calibration manual calibration is used as default Required consumables Note Article number Consumable Clean cloth Spare parts Note Article number Spare part Replace if damaged or missing 3HAC059556 001 Protective plug for bushing Used with protection type Clean Room 3HAC059557 001 Protective plug for bushing Clean Room Used...

Page 827: ...escribed in the FlexPendant while conducting it Note Action DANGER While conducting the calibration the robot needs to be connected to power Make sure that the robot s working area is empty as the robot can make unpredictable movements 1 Use a clean cloth Wipe the calibration tool clean Note The calibration method is exact Dust dirt or color flakes will affect the calibration value 2 If the data i...

Page 828: ...e and then tap Calibration The software will automatic ally call for the procedure for the valid calibration method A brief overview of the sequence that will be run on the FlexPendant is given in Overview of the calibra tion procedure on the FlexPendant on page 826 Follow the instructions given on the FlexPendant 6 Fitting of calibration tools The figures show the calibration tools in contact wit...

Page 829: ...600001276 xx1600001277 Axis 4 Axis 3 xx1600001274 xx1600001275 Axis 6 Axis 5 Make sure to orient the tool flange calibration tool correctly xx1600001273 xx1600001272 Continues on next page Product manual IRB 1200 829 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 5 Calibration 5 4 4 Axis Calibration Running the calibration procedure Continued ...

Page 830: ...libration movement directions for all axes on page 812 Axis Calibration with SafeMove option To be able to run Axis Calibration SafeMove needs to be unsynchronized The Axis Calibration routine recognizes if the robot is equipped with SafeMove and will force SafeMove to unsynchronize automatically However SafeMove may generate other warning messages anytime during the Axis Calibration routine When ...

Page 831: ...hing 3HAC059556 001 Protective plug for bushing Clean Room Protective plug for bushing food grade lubrication Protective plug for bushing Hygien ic 3HAC059557 001 See Calibrating with Wrist Optimiz ation method on page 834 If the standard calibration data for axes 4 5 or 6 should be updated with wrist optimization run the calibration routine Wrist Optimization 3 Product manual IRB 1200 831 3HAC046...

Page 832: ...hat the values are saved in RobotStudio or FTP program The files are located in Active system folder name HOME RefCalibFiles 7 Perform the repair 8 Make sure that the tooling and process equipment are the same as when creating the reference Use Reference calibration to update the system with new calibration offset value for the repaired axis 9 Check the position against the verification position s...

Page 833: ...he angle difference ie 96 3 94 2 2 1 degrees 8 Manually jog axis 4 the calculated angle difference 2 1 NOTE The direction shall be the same direction as the direction used when axis 4 was manually jogged to coincide with the verification process In the example 2 1 degrees 9 Make a new manual fine calibration of axis 4 with axis in 2 1 degrees position 10 Check again against the verification positi...

Page 834: ...ed for on the FlexPendant the following sequence will be run 1 Choose calibration routine Wrist Optimization 2 Modify targets for 4 point tool frame definition in Wrist Optimization routine Tip Select positions with large reorientations around the TCP For best results make sure that axis 4 and 5 have large movements en0400000906 a Jog the robot to an appropriate position A for the first approach p...

Page 835: ...bration data WARNING Robot moves automatically when pressing Calibrate 6 Wrist optimization is finished 7 Redefine verify TCP for all tools Product manual IRB 1200 835 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 5 Calibration 5 5 Calibrating with Wrist Optimization method Continued ...

Page 836: ...ibration section respectively The table below specifies the exact axis positions in degrees IRB 1200 7 0 7 IRB 1200 5 0 9 Axis 84 474066º 84 474066º 1 136 862755º 131 862755º 2 72 250000º 72 250000º 3 0º 0º 4 90º 90º 5 0º 0º 6 836 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 5 Calibration 5 6 1 Manual calibration method calibration position ...

Page 837: ...alibration tool axis 4 3HAC055410 001 Conical screw M3 Used together with the calibration tool axis 5 6 3HAC034513 001 Guide pin Fitted on tubular 3HAC051254 001 Calibration block with pin M5x40 9ADA183 19 Hex socket head screw M8x45 9ADA183 41 Hex socket head screw M5x20 9ADA183 15 Hex socket head screw M4x16 9ADA183 5 Hex socket head screw M5x16 9ADA183 14 Hex socket head screw Product manual IR...

Page 838: ...209 Required equipment Note Art no Equipment Includes calibration tools pins and attachment screws for manual calibration method i 3HAC051256 001 Calibration toolkit manual calibra tion Continues on next page 838 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 5 Calibration 5 6 3 Manual calibration method calibrating axis 1 ...

Page 839: ...hod is found on the calibration label or in the calibration menu on the FlexPendant If no data is found related to standard calibration manual calibration is used as default Required consumables Note Art no Equipment Isopropanol Cleaning agent Calibrating axis 1 Moving the robot to calibration position Note Action Jog all axes to zero position 1 xx1400000392 Remove the axis 1 mechanical stop pin 2...

Page 840: ...ion where the axis 1 calibration stop pin can be fitted to the at tachment hole in the base Fit the axis 1 calibration stop pin to the base and secure it with the screw xx1400001100 Jog axis 1 to zero position 4 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 5 xx1400001134 Remove the protection plug from t...

Page 841: ...ke sure no personnel is near or beneath the robot arm 9 How to release the brakes is de tailed in Manually releasing the brakes on page 71 xx1400001209 Release the brakes and manually rotate axis 1 until the two axis 1 calibration pins touches each other gently There should be no pressing force between the pins When doing this pay attention to robot pose in order to avoid arm collision When the ax...

Page 842: ...ters en0400001127 3 Tap Fine Calibration 4 A dialog box is displayed urging you to use ex ternal equipment to perform the actual calibration Make sure all necessary calibration equipment is fitted for the axis to be calibrated A dialog box is displayed warning that updating the revolution counters may change programmed robot positions Tap Yes to proceed Tap No to cancel Select the check box for th...

Page 843: ...p of jog ging 1 Jog axis 1 to zero degree using the FlexPendant 2 xx1400001092 Check that the synchronization marks on axis 1 are aligned with eachother Are they aligned within the tolerances If yes the calibration is verified OK If no redo the fine calibration procedure 3 Protection plug 3HAC051199 001 xx1400001134 Remove the axis 1 calibration pin from the swing and refit the protection plug 4 R...

Page 844: ... parameters on a new label and stick on top of the calibration label on the robot 1 844 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 5 Calibration 5 6 3 Manual calibration method calibrating axis 1 Continued ...

Page 845: ...is required See figures below for reference and follow the step by step procedure that follows Calibration stop Calibration pin xx1400001136 xx1400001135 The axis 2 mechanical stop fitted to the swing is used for calibration of axis 2 The press fit mechanical stop pin fitted to the lower arm is used for calibration of axis 2 No additional equipment is required No additional equipment is required C...

Page 846: ...rated in Required equipment on page 845 xx1400001201 When doing this pay attention to robot pose in order to avoid arm collision When the axis is in position release the brake release button to activate the brakes again Performing the fine calibration procedure Note Action WARNING Do not fine calibrate the robot without special equipment used for axis calibration It would cause an unsatisfied accu...

Page 847: ...alibration of the selected axes will be changed which cannot be undone Tap Calibrate to proceed Tap Cancel to cancel Tapping Calibrate results in briefly displaying a dialog box announcing that the calibration pro cess has started The axis is calibrated and the system returns to the list of available mechanical units Checking and finalizing the calibration Note Action Release the brakes and manual...

Page 848: ... yes the calibration is verified OK If no redo the fine calibration procedure 3 After calibration Note Action Write down the new system parameters on a new label and stick on top of the calibration label on the robot 1 848 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 5 Calibration 5 6 4 Manual calibration method calibrating axis 2 Continued ...

Page 849: ...ne by moving the upper arm so that the calibration pin and calibration stop touches each other gently These parts are already fitted to the robot no extra installation of calibration equipment is required Continues on next page Product manual IRB 1200 849 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 5 Calibration 5 6 5 Manual calibration method calibrating axis 3 ...

Page 850: ...dditional equipment is required No additional equipment is required Calibrating axis 3 Moving the robot to calibration position Note Action Jog all axes to zero position 1 DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unex pected ways Make sure no personnel is near or beneath the robot arm 2 Continues on next page 850 Product manual IRB 1200 3HAC046...

Page 851: ...ion When the axis is in position release the brake release button to activate the brakes again Performing the fine calibration procedure Note Action WARNING Do not fine calibrate the robot without special equipment used for axis calibration It would cause an unsatisfied accuracy in the robot movement 1 Choose fine calibration from Calib menu 2 On the ABB menu tap Calibration All mechanical units c...

Page 852: ...alibration of the selected axes will be changed which cannot be undone Tap Calibrate to proceed Tap Cancel to cancel Tapping Calibrate results in briefly displaying a dialog box announcing that the calibration pro cess has started The axis is calibrated and the system returns to the list of available mechanical units Checking and finalizing the calibration Note Action Release the brakes and manual...

Page 853: ... yes the calibration is verified OK If no redo the fine calibration procedure 3 After calibration Note Action Write down the new system parameters on a new label and stick on top of the calibration label on the robot 1 Product manual IRB 1200 853 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 5 Calibration 5 6 5 Manual calibration method calibrating axis 3 Continued ...

Page 854: ...ory Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant If no data is found related to standard calibration manual calibration is used as default Required consumables Note Art no Equipment Isopropanol Cleaning agent Calibrating axis 4 Moving the robot to calibration position Note Action Jog all axes to zero position 1 Rotate ax...

Page 855: ...ake sure there is no paint or burrs on these surfaces 4 Screws M4x16 xx1400001208 Fit the calibration block to the tubular 5 Locate the calibration tool by the location surface on the housing Tip Press down slightly on the calibration tool to make sure the tool attaches the location surface tightly 6 Continues on next page Product manual IRB 1200 855 3HAC046983 001 Revision S Copyright 2014 2021 A...

Page 856: ...se the brakes is de tailed in Manually releasing the brakes on page 71 xx1400001207 Release the brakes and manually rotate axis 4 until the axis 4 calibration tool and the calibration block touches each other gently There should be no pressing force between the pins When doing this pay attention to robot pose in order to avoid arm collision When the axis is in position release the brake release bu...

Page 857: ...ters en0400001127 3 Tap Fine Calibration 4 A dialog box is displayed urging you to use ex ternal equipment to perform the actual calibration Make sure all necessary calibration equipment is fitted for the axis to be calibrated A dialog box is displayed warning that updating the revolution counters may change programmed robot positions Tap Yes to proceed Tap No to cancel Select the check box for th...

Page 858: ...his is done to avoid damage on the pins if incorrect operation should occur during next step of jog ging 1 Remove the calibration tool of axes 4 5 and 6 from the tubular 2 Remove the axis 4 calibration tool from the housing 3 Jog axis 4 to zero degree using the FlexPendant 4 xx1400001095 Check that the synchronization marks on axis 4 are aligned with eachother Are they aligned within the tolerance...

Page 859: ... parameters on a new label and stick on top of the calibration label on the robot 1 Product manual IRB 1200 859 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 5 Calibration 5 6 6 Manual calibration method calibrating axis 4 Continued ...

Page 860: ...rmation about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant If no data is found related to standard calibration manual calibration is used as default Required consumables Note Art no Equipment Isopropanol Cleaning agent Calibrating axis 5 and axis 6 Moving the robot to calibration position Note Action Jog all axes to zero position 1 DANGER...

Page 861: ... releasing the brakes on page 71 xx1400001206 Release the brakes and manually rotate axes 5 and 6 until the axis 5 6 calibration tool and the calibration block touches each other gently There should be no pressing force between the pins When doing this pay attention to robot pose in order to avoid arm collision When the axis is in position release the brake release button to activate the brakes ag...

Page 862: ...en0400001127 3 Tap Fine Calibration 4 A dialog box is displayed urging you to use ex ternal equipment to perform the actual calibration Make sure all necessary calibration equipment is fitted for the axis to be calibrated A dialog box is displayed warning that updating the revolution counters may change programmed robot positions Tap Yes to proceed Tap No to cancel Select the check box for the cur...

Page 863: ...correct operation should occur during next step of jog ging 1 Jog axis 5 and 6 to zero degree using the Flex Pendant 2 xx1400001096 Check that the synchronization marks on axis 5 and axis 6 are aligned with eachother Are they aligned within the tolerances If yes the calibration is verified OK If no redo the fine calibration procedure 3 xx1400001097 Remove the calibration block from the tubular 4 R...

Page 864: ...program twice Do not change the position of the robot axes after running the program 1 This is detailed in section Synchronization marks and synchronization position for axes on page 810 Adjust the synchronization marks when the calibration is done if necessary 2 Write down the values on a new label and stick it on top of the calibration label 3 The label is located on one side of the base 864 Pro...

Page 865: ... axes on page 810 and Updating revolution counters on page 813 Check that the synchronization marks for the axes align correctly If they do not update the revolu tion counters 6 Using the jogging window Use this procedure to jog the robot to the synchronization position of all axes Note Action On the ABB menu tap Jogging 1 Tap Motion mode to select group of axes to jog 2 Tap to select the axis to ...

Page 866: ...ition of all axes Note Action Tap Jog 1 From the Mechanical unit list select a mechanical unit 2 From the Motion mode section select an axis set that need to be jogged 3 For example to jog axis 2 select the axis set Axis 1 3 Follow the screen instruction on joystick movements to understand the direction of the axis that you want to move and move the joystick 4 Manually run the robots axes to a pos...

Page 867: ... the country in which the robot and the control unit are installed If the robot or the control unit is partially or completely disposed of the various parts must be grouped together according to their nature which is all iron together and all plastic together and disposed of accordingly These parts must also be disposed of in accordance with the current legislation of the country in which the robo...

Page 868: ...ective content see table below xx1800000058 Hazardous material The table specifies some of the materials in the product and their respective use throughout the product Dispose components properly according to local regulations to prevent health or environmental hazards Example application Material Base lower arm upper arm Aluminium Encoder interface board Batteries Lithium Gears Cast iron nodular ...

Page 869: ...ncineration must be carried out under controlled conditions in accordance with local regulations Also note that Spills can form a film on water surfaces causing damage to organisms Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination Product manual IRB 1200 869 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 6 Decommissioni...

Page 870: ...attery is exposed to heat for example from a blow torch it will explode Always remove all oil grease in gearboxes If exposed to heat for example from a blow torch the oil grease will catch fire When motors are removed from the robot the robot will collapse if it is not properly supported before the motor is removed 870 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All r...

Page 871: ... The following table lists the supported controller type for IRB 1200 in different protection classes types Controller type Protection OmniCore E line OmniCore C line IRC5C IRC5 X X X X Standard IP40 X X X X Standard IP67 X X X X Clean Room X X Food grade lubrication X X X X Foundry plus X X Hygienic For details see Product specification IRB 1200 Product manual IRB 1200 871 3HAC046983 001 Revision...

Page 872: ...een IRB 1200 Type A and IRB 1200 Type B is that Type B also supports SafeMove 2 See Type B of IRB 1200 on page 873 How to know which type the robot is The type label on the base of the robot tells if the robot is calibrated with Axis Calibration Those robots are named IRB 1200 Type A Note If no type label attached on the robot use the bushings on each axis to identify a robot calibrated with Axis ...

Page 873: ...s 6 Motor with pulley axis 4 and axis 5 Manipulator cable harness Battery pack SMB unit replacing EIB unit IRB 1200 Type B is designed based on IRB 1200 Type A so that Type B has the bushings for installation of calibration tools too How to know which type the robot is The type label on the base of the robot tells if the robot supports SafeMove 2 Those robots are named IRB 1200 Type B Product manu...

Page 874: ...Config Base installed on ro bot spare part num ber Look on the outside of the base Order base 3HAC059553 001 swing 3HAC059554 001 IP40 sealing ring 3HAC068107 001 IP67 sealing ring gasket V ring 3HAC059791 001 3HAC044533 001 3HAC049628 001 Base 3HAC049628 001 has no hole on the side of the base xx1600000124 Base 3HAC057999 001 has a hole on the side of the base xx1600000051 Order base 3HAC059553 0...

Page 875: ...e 3HAC059553 001 has a bushing for fitting calibration tool for Axis Calib ration xx1600001037 Order base 3HAC059553 001 3HAC058386 001 3HAC059553 001 Product manual IRB 1200 875 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 7 Robot description 7 4 1 Spare part versions for the base on IP40 IP67 robots Continued ...

Page 876: ...hat to order Article number in WebConfig Swing installed on ro bot spare part num ber Look underneath the swing the sur face is flat xx1600000052 Order swing 3HAC059554 001 IP67 sealing ring gasket V ring 3HAC059791 001 3HAC044534 001 3HAC049632 001 Look underneath the swing there is a groove xx1600000053 Order swing 3HAC059554 001 3HAC056656 001 3HAC058000 001 Continues on next page 876 Product m...

Page 877: ...er The swing has a bushing for fitting calibration tool for Axis Calibration xx1600001038 Order swing 3HAC059554 001 3HAC058387 001 3HAC059554 001 Product manual IRB 1200 877 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 7 Robot description 7 4 2 Spare part versions for the swing on IP40 IP67 robots Continued ...

Page 878: ...flat xx1600000125 Order sealing ring 3HAC044676 001 3HAC044676 001 3HAC044676 001 The sealing ring has one folded wall on both sides xx1600000126 Order IP40 sealing ring 3HAC068107 001 IP67 sealing ring gasket V ring 3HAC059791 001 3HAC056658 001 3HAC056658 001 The sealing ring is flat and the edge is thinner xx1600001039 Order sealing ring 3HAC068107 001 3HAC058568 001 3HAC058568 001 The sealing ...

Page 879: ...er How to see which kind of cable harness is installed on robot Order corresponding cable harness See Manipulator cable harness in Product manual spare parts IRB 1200 for spare part numbers sealing ring 3HAC068107 001 xx1900001602 Order corresponding cable harness See Manipulator cable harness in Product manual spare parts IRB 1200 for spare part numbers xx1900001601 Product manual IRB 1200 879 3H...

Page 880: ...g 3HAC059680 001 has no painting while that on housing 3HAC059721 001 is painted xx1600001127 Order housing IRB 1200 7 0 7 3HAC059680 001 3HAC044544 001 3HAC059680 001 IRB 1200 7 0 7 Order housing IRB 1200 7 0 7 3HAC059721 001 3HAC058389 001 3HAC059721 001 The plane encircled in the figure on housing 3HAC059681 001 has no painting while that on housing 3HAC059722 001 is painted xx1600001129 Order ...

Page 881: ... is installed on robot What to order Article number in WebConfig Tubular installed on robot spare part number The plane encircled in the fig ure on tubular 3HAC059693 001 has no painting while that on tubular 3HAC059723 001 is painted xx1600001128 Order tubular with sleeve 3HAC059693 001 3HAC044548 001 3HAC059693 001 Order tubular with sleeve 3HAC059723 001 3HAC058390 001 3HAC059723 001 Product ma...

Page 882: ... version is in stalled on robot What to order Article number in WebConfig Tubular cover installed on Clean Room robots spare part number Tubular cover 3HAC056144 001 has six screw holes xx1600001117 Order tubular cover clean room 3HAC056144 001 3HAC044550 001 3HAC056144 001 Tubular cover 3HAC059708 001 has eight screw holes xx1600001118 Order tubular cover clean room 3HAC059708 001 3HAC058929 001 ...

Page 883: ...pter includes general information complementing the more specific information in the different procedures in the manual Product manual IRB 1200 883 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 8 Reference information 8 1 Introduction ...

Page 884: ...ery Electrical equipment of machines Part 1 General requirements normative reference from ISO 10218 1 IEC 60204 Electromagnetic compatibility EMC Part 6 2 Generic standards Immunity standard for industrial environments IEC 61000 6 2 Electromagnetic compatibility EMC Part 6 4 Generic standards Emission standard for industrial environments IEC 61000 6 4 Safety of machinery Safety related parts of co...

Page 885: ...39 37 in 3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume Product manual IRB 1200 885 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 8 Reference information 8 3 Unit conversion ...

Page 886: ...ctive gloves of nitrile rubber type should be used Screws lubricated in other ways Screws lubricated with Molycote 1000 should only be used when specified in the repair maintenance or installation procedure descriptions In such cases proceed as follows 1 Apply lubricant to the screw thread 2 Apply lubricant between the plain washer and screw head 3 Tighten to the torque as described in the procedu...

Page 887: ...edure overrides the standard torque Tightening torque Nm Class 12 9 oil lubric ated Tightening torque Nm Class 10 9 oil lubric ated Tightening torque Nm Class 8 8 oil lubricated Dimension 6 M5 10 M6 40 34 24 M8 80 67 47 M10 140 115 82 M12 340 290 200 M16 670 560 400 M20 1150 960 680 M24 Lubricated screws Molycote Gleitmo or equivalent with allen head screws The following table specifies the recomm...

Page 888: ... lubricated i Dimension 120 96 M12 300 235 M16 550 460 M20 950 790 M24 i Lubricated with Molycote 1000 Gleitmo 603 or equivalent 888 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 8 Reference information 8 4 Screw joints Continued ...

Page 889: ...essory when handling components with a weight exceeding 22 kg A wide range of lifting accessories and devices are available for each manipulator model Example Following is an example of a weight specification in a procedure Note Action CAUTION The arm weighs 25 kg All lifting accessories used must be sized accord ingly Product manual IRB 1200 889 3HAC046983 001 Revision S Copyright 2014 2021 ABB A...

Page 890: ...red are the sum of the standard toolkit and any tools listed in the instruction Contents standard toolkit Rem Tool Qty Socket head cap 2 17 mm 1 Torque wrench 0 3 45 Nm 1 For securing robot to foundation Torque wrench 55 Nm 5 Nm 1 Ratchet head for torque wrench 1 2 1 Hex socket head cap no 2 5 socket 1 2 bit L 110 mm 1 Small screwdriver 1 T handle with ball head 1 Small cutting plier 1 Plastic mal...

Page 891: ... sum of standard tools defined in the section Standard toolkit on page 890 and of special tools listed directly in the instructions and also gathered in this section Special tools Continues on next page Product manual IRB 1200 891 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 8 Reference information 8 7 Special tools ...

Page 892: ... 3 3 3 Guide pin for axis 1 gear unit 3HAC049703 001 3 3 Guide pin for axis 2 gear unit 3HAC049704 001 3 Guide pin for upper arm 3HAC049705 001 3 3 Guide pin for tilt unit axis 5 3HAC049706 001 2 2 xx2100001461 Guide pin for stainless shaft on tool flange 3HAC079684 001 Lifting accessories 1 1 xx1400000542 Lifting accessory robot Includes lifting accessories lifting beam and screws 3HAC049711 001 ...

Page 893: ...ealing assembly tool set Used to refit the radial sealing if replacement is needed 3HAC049694 001 1 xx1400000538 Axis 3 sealing assembly tool set Used to refit the axis 3 radial sealing 3HAC049697 001 1 1 1 xx1400000539 Axis 4 sealing assembly tool set Used to refit the radial sealing if replacement is needed 3HAC049699 001 1 1 1 xx1400000540 Axis 5 sealing assembly tool set Used to refit the radi...

Page 894: ...Lower arm Swing spare parts Base spare parts Housing extender unit including sealings Axis 5 FPC unit Axis 4 FPC unit EIB SMB unit Cable harness Tools and equipment with spare part number These tools can be ordered from ABB 1 1 1 1 1 1 1 1 1 1 1 1 1 Calibration tool box Axis Calibration 3HAC074119 001 1 1 xx2100001462 Flange tightening tool 3HAC079686 001 Continues on next page 894 Product manual ...

Page 895: ...ce of lifting accessories is not detailed in the activity procedure but in the instruction delivered with each piece of lifting accessories The instructions delivered with the lifting accessories should be stored for later reference Product manual IRB 1200 895 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 8 Reference information 8 8 Lifting accessories and lifting instructi...

Page 896: ...This page is intentionally left blank ...

Page 897: ...but delivered as a separate document for registered users on myABB Business Portal www abb com myABB Tip All documents can be found via myABB Business Portal www abb com myABB Product manual IRB 1200 897 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 9 Spare parts 9 1 Spare part lists and illustrations ...

Page 898: ...This page is intentionally left blank ...

Page 899: ... cabinet Manipulators Article numbers for circuit diagrams Product 3HAC031408 003 Circuit diagram IRB 120 3HAC6816 3 Circuit diagram IRB 140 type C 3HAC025611 001 Circuit diagram IRB 260 3HAC028647 009 Circuit diagram IRB 360 3HAC036446 005 Circuit diagram IRB 460 3HAC025691 001 Circuit diagram IRB 660 3HAC025691 001 Circuit diagram IRB 760 3HAC046307 003 Circuit diagram IRB 1200 3HAC2800 3 Circui...

Page 900: ...iagram IRB 6660 3HAC029940 001 3HAC043446 005 Circuit diagram IRB 6700 IRB 6790 3HAC13347 1 Circuit diagram IRB 7600 3HAC025744 001 3HAC050778 003 Circuit diagram IRB 14000 3HAC056159 002 Circuit diagram IRB 910SC 900 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved 10 Circuit diagrams 10 1 Circuit diagrams Continued ...

Page 901: ...e routine 134 brakes testing function 38 C cabinet lock 31 cable package main replacing 169 cabling robot 106 cabling between robot and controller 106 calibrating robot 818 roughly 813 816 calibrating robot 818 834 calibration Absolute Accuracy type 806 rough 813 816 standard type 806 verification 864 when to calibrate 809 calibration Absolute Accuracy 807 calibration manuals 808 calibration marks...

Page 902: ...ng 308 lubricants 34 M main power connector o ring 108 maintenance intervals 117 maintenance schedule 117 mechanical stop axis 4 460 axis 3 457 axis 2 454 axis 1 638 mechanical stop location 126 motor axis 6 778 axis 5 758 axis 4 728 axis 3 664 motor unit axis 2 642 mounting equipment 84 MoveAbsJ instruction 865 866 N national regulations 30 negative directions axes 812 neodymium disposal 868 nodu...

Page 903: ... inspecting 120 S safety brake testing 38 ESD 64 fire extinguishing 31 release robot axes 37 signals 21 signals in manual 21 symbols 21 symbols on robot 23 safety devices 31 safety equipment signal lamp 132 safety hazard hydraulic system 32 pneumatic system 32 safety signals in manual 21 safety standards 884 scales on robot 810 schedule of maintenance 117 screw joints 886 securing robot 74 signal ...

Page 904: ... and responsibility 19 velocity adjusting 114 verifying calibration 864 W wall mounting 78 weight 50 robot 69 Wrist Optimization overview of method 834 Z zero position checking 865 904 Product manual IRB 1200 3HAC046983 001 Revision S Copyright 2014 2021 ABB All rights reserved Index ...

Page 905: ......

Page 906: ... 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics Discrete Automation No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics Discrete Automation 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC046983 001 Rev S en Copyright 2014 2021 ABB All rights reserved Specifications subject to change without notice ...

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Summary of Contents for IRB 1200

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ABB IRB 1200, Product Manual, Page: 6 / 906

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Summary of Contents for IRB 1200

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