ABB IRB 1600 - 5/1,2 type A Product Manual Download

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1 Safety

1.3.1. Safety signals, general

3HAC023637-001 Revision: B

Electrostatic discharge
(ESD)

ELECTROSTATIC
DISCHARGE (ESD)

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

Note

NOTE

Note symbols alert you to important facts and
conditions.

Tip

TIP

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

Symbol

Designation

Signification

Continued

Summary of Contents for IRB 1600 - 5/1,2 type A

Page 1: ...Product manual Articulated robot IRB 1600 5 1 2 IRB 1600 5 1 45 IRB 1600 7 1 2 IRB 1600 7 1 45 M2004 ...

Page 2: ......

Page 3: ...Product manual IRB 1600 5 1 2 IRB 1600 5 1 45 IRB 1600 7 1 2 IRB 1600 7 1 45 M2004 Document ID 3HAC023637 001 Revision B ...

Page 4: ... specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be prosecuted Additio...

Page 5: ...ns 29 1 3 1 Safety signals general 29 1 3 2 DANGER Moving manipulators are potentially lethal 31 1 3 3 DANGER First test run may cause injury or damage 32 1 3 4 WARNING The brake release buttons may be jammed after service work 33 1 3 5 WARNING The unit is sensitive to ESD 34 1 3 6 WARNING Safety risks during work with gearbox oil 35 2 Installation and commissioning 37 2 1 Introduction 37 2 2 Unpa...

Page 6: ...mplete manipulator 104 4 3 1 Replacement of cable harness 104 4 3 2 Replacement of complete arm system 113 4 4 Upper and lower arm 117 4 4 1 Replacement of complete upper arm 117 4 4 2 Replacement of complete lower arm 121 4 4 3 Replacement of wrist unit 125 4 4 4 Replacement of damper axis 2 128 4 4 5 Replacement of damper axis 3 130 4 4 6 Replacement of damper axis 5 132 4 5 Frame and base 134 4...

Page 7: ... safety standards 188 6 3 Unit conversion 189 6 4 Screw joints 190 6 5 Weight specifications 193 6 6 Standard toolkit 194 6 7 Special tools 195 6 8 Lifting equipment and lifting instructions 196 7 Spare parts and exploded views 197 7 1 Introduction 197 7 2 Spare parts base 198 7 3 Spare parts base connections 200 7 4 Spare parts frame 202 7 5 Spare parts lower arm 204 7 6 Spare parts upper arm 206...

Page 8: ...Table of Contents ...

Page 9: ...l installation repair maintenance work Organization of chapters The manual is organized in the following chapters Chapter Contents Safety service Safety information that must be read through before performing any installation or service work on robot Contains general safety aspects as well as more specific information on how to avoid personal injuries and damage to the product Installation and com...

Page 10: ...n the software is added to the sections in Restricting the working range on page 66 Information about the alternative calibration method Levelmeter 2000 is removed from the manual since the method is not supported for the robot Safety information is added to the procedures Replacement of push button unit on page 142 Replacement of serial measurement unit on page 138 and Replacement of cable harnes...

Page 11: ...ftware Maintenance descriptions of all required preventive maintenance procedures including intervals Repair descriptions of all recommended repair procedures including spare parts Additional procedures if any calibration decommissioning Product manual reference information Reference information article numbers for documentation referred to in Product manual procedures lists of tools safety standa...

Page 12: ...en it is useful What is included e g cables I O boards RAPID instructions system parameters How to use the application Examples of how to use the application Operating manuals This group of manuals is aimed at those having first hand operational contact with the robot i e production cell operators programmers and trouble shooters The group of manuals includes Getting started IRC5 and RobotStudio O...

Page 13: ...pment spare parts tools etc required for the different actions in the procedure The equipment is marked with italic text in the procedures and completed with a reference to the section where the equipment is listed with further information i e article number dimension The denomination in the procedure for the component or attachment point corresponds to the denomination in the referenced list The ...

Page 14: ...How to read the product manual 3HAC023637 001 Revision B 12 ...

Page 15: ...erforming any service work on the robot These are applicable for all service work and are found in section General safety information on page 14 specific safety information pointed out in the procedure at the moment of the danger How to avoid and eliminate the danger is either detailed directly in the procedure or further detailed in separate instructions found in section Safety related instructio...

Page 16: ... robot described in the applicable documents e g User s guide S4Cplus M2000 Operating manual IRC5 with FlexPendant M2004 and Product manual Connection of external safety devices Apart from the built in safety functions the robot is also supplied with an interface for the connection of external safety devices Via this interface an external safety function can interact with other machines and periph...

Page 17: ...ittance must be set up in front of the robot s working space Light beams or sensitive mats are suitable devices Turntables or the like should be used to keep the operator out of the robot s working space The axes are affected by the force of gravity when the brakes are released In addition to the risk of being hit by moving robot parts you run the risk of being crushed by the parallel arm Energy s...

Page 18: ... any necessary measures to ensure that the robot does not collapse as parts are removed e g secure the lower arm with fixtures if removing motor axis 2 Safety risk Description Cable packs are sensitive to mechanical damage CAUTION The cable packs are sensitive to mechanical damage They must be handled with care especially the connectors in order to avoid damaging them Safety risk Description Gears...

Page 19: ...such as milling cutters etc Make sure that guards remain closed until the cutters stop rotating It should be possible to release parts by manual operation valves Safe design Grippers end effectors must be designed so that they retain workpieces in the event of a power failure or a disturbance of the controller CAUTION Ensure that a gripper is prevented from dropping a workpiece if such is used ...

Page 20: ...aulic systems Residual energy Residual energy may be present in these systems After shutdown particular care must be taken The pressure in pneumatic and hydraulic systems must be released before starting to repair them Safe design Gravity may cause any parts or objects held by these systems to drop Dump valves should be used in case of emergency Shot bolts should be used to prevent tools etc from ...

Page 21: ...ly and in accordance with the applicable safety regulations Care must be taken at all times Qualified personnel Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts Extraordinary risks If the working process is interrupted extra care must be taken due to risks other than...

Page 22: ...The mains supply mains switch The transformers The power unit The control power supply 230 VAC The rectifier unit 400 480 VAC and 700 VDC Note Capacitors The drive unit 700 VDC The drive system power supply 230 VAC The service outlets 115 230 VAC The customer power supply 230 VAC The power supply unit for tools or special power supply units for the machining process The external voltage connected ...

Page 23: ...osure to enable it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed Determine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot is working in the work cell see Product Specification Description Robot Motion Also consider the maximum possible impact caused by a breaking or malfunction...

Page 24: ...1 Safety 1 2 3 2 Fire extinguishing 3HAC023637 001 Revision B 22 1 2 3 2 Fire extinguishing NOTE Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the robot manipulator or controller ...

Page 25: ...ing the brake release buttons on the robot How to release the brakes is detailed in section Manually releasing the brakes on page 46 The robot arm may be moved manually on smaller robot models but larger models may require using an overhead crane or similar Increased injury Before releasing the brakes make sure that the weight of the arms does not increase the pressure on the trapped person furthe...

Page 26: ...function of the holding brake of each axis motor may be checked as detailed below 1 Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized max static load 2 Switch the motor to the MOTORS OFF position with the Operating mode selector on the controller 3 Check that the axis maintains its position If the manipulator does not change position...

Page 27: ... 250 mm s 25 3HAC023637 001 Revision B 1 2 3 5 Risk of disabling function Reduced speed 250 mm s NOTE Do not change Transm gear ratio or other kinematic parameters from the Teach Pendant Unit or a PC This will affect the safety function Reduced speed 250 mm s ...

Page 28: ...ed all the way in the robot is taken to the MOTORS OFF state To ensure safe use of the Teach Pendant Unit the following must be implemented The enabling device must never be rendered inoperative in any way During programming and testing the enabling device must be released as soon as there is no need for the robot to move The programmer must always bring the Teach Pendant Unit with him her when en...

Page 29: ...s speed is limited to max 250 mm s when the operating mode selector is in position manual mode with reduced speed This should be the normal position when entering the working space The position manual mode with full speed 100 may only be used by trained personnel who are aware of the risks that this entails Pay attention to the rotating axes of the manipulator Keep a distance to the axes in order ...

Page 30: ...e for adding a fourth language underneath the three standard languages English German and French Add a local language to the label by using a transparent sticker over the standard label with text added in a fourth language Drawings detailing the design text figure dimensions of the standard labels can be ordered from ABB Notice that each label is identified according to the article number located ...

Page 31: ...with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc warning WARNING Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units e...

Page 32: ... ESD symbol indicates electrostatic hazards which could result in severe damage to the product Note NOTE Note symbols alert you to important facts and conditions Tip TIP Tip symbols direct you to specific instructions where to find additional information or how to perform a certain operation in an easier way Symbol Designation Signification Continued ...

Page 33: ...ed within the manipulator working range Elimination Action Note 1 Before attempting to run the manipulator make sure all emergency stop equipment is correctly installed and connected Emergency stop equipment such as gates tread mats light curtains etc 2 If possible use the hold to run button whenever possible The hold to run button is used in manual mode not in automatic mode How to use the hold t...

Page 34: ...eration before the first test run Elimination Follow the procedure below when performing the first test run after a service activity repair installation or maintenance Action 1 Remove all service tools and foreign objects from the robot and its working area 2 Install all safety equipment properly 3 Make sure all personnel are standing at a safe distance from the robot i e out of its reach behind s...

Page 35: ...n performed inside the SMB recess follow the procedure below Action Note Illustration 1 Make sure the power is turned off 2 Refit the push button guard if removed 3 Check the push buttons of the brake release unit by pressing them down one by one Make sure none of the buttons are jammed by the push button guard 4 If a button gets jammed in the depressed position the alignment of the push button un...

Page 36: ...eld When handling parts or their containers personnel not grounded may potentially transfer high static charges This discharge may destroy sensitive electronics Elimination Action Note 1 Use a wrist strap Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly 2 Use an ESD protective floor mat The mat must be grounded through a current limiting resist...

Page 37: ...ill the gearbox when filling Do not overfill Overfilling of gearbox oil can lead to internal over pressure inside the gearbox which in turn may damage seals and gaskets completely press out seals and gaskets preventthemanipulator from moving freely Make sure not to overfill the gearbox when filling with oil After filling check the correct oil level Do not mix types of oil Mixing types of oil may c...

Page 38: ...1 Safety 1 3 6 WARNING Safety risks during work with gearbox oil 3HAC023637 001 Revision B 36 ...

Page 39: ...nd commissioning 2 1 Introduction General This chapter contains information for installing the robot to the working site More detailed technical data such as load diagram permitted extra loads equipment and location of extra loads equipment may be found in the Product Specification for the robot ...

Page 40: ...tallation 2 Make sure the robot has not been damaged by visually inspecting its exterior 3 Make sure the lifting device to be used is dimensioned to handle the weight of the robot Weight on page 38 4 If the robot is not to be installed directly it must be stored Storage conditions on page 39 5 Make sure the appointed operating environment of the robot conforms to the specifications Operating condi...

Page 41: ... The table below shows the protection class of the robot Force Mounting Endurance load Max load emer gency stop Force XY Floor mounted Inverted Tilted 30º 1600 N 1600 N 2500 N 5000 N 5000 N 6000 N Force Z Floor mounted Inverted Tilted 30º 2500 1600 N 2500 1600 N 2100 1600 N 2500 3000 N 2500 3000 N 2100 3000 N Torque XY All 2000 Nm 5500 Nm Torque Z All 350 Nm 2000 Nm Requirement Value Note Levelnes...

Page 42: ...dels The turning radius is also shown separately in the last figure Illustration working range IRB 1600 5 1 2 and IRB 1600 7 1 2 xx0400001260 Pos Positions at wrist center mm Angle degrees X Z axis 2 axis 3 0 750 961 5 0º 0º 1 150 1561 5 0º 90º 2 494 470 0º 55º 3 1225 486 5 90º 90º 4 897 287 136º 90º 5 386 737 136º 235º 6 321 786 63º 55º 7 808 975 63º 90º Continues on next page ...

Page 43: ...range IRB 1600 5 1 45 and IRB 1600 7 1 45 xx0400001261 Pos Positions at wrist center mm Angle degrees X Z axis 2 axis 3 0 750 1186 5 0º 0º 1 150 1786 5 0º 90º 2 404 643 0º 65º 3 1450 486 5 90º 90º 4 800 639 150º 90º 5 448 478 150º 245º 6 6 740 90º 65º 7 1150 486 5 90º 90º Continued Continues on next page ...

Page 44: ...is 1 limited to 100º 150º to 90º with axis 1 limited to 95º Axis 3 55º to 235º 65º to 245º Axis 4 200º to 200º 200º to 200º Default value 190 to 190 revolutions 190 to 190 revolutions Maximum value The default working range for axis 4 can be extended by changing parameter values in the software Axis 5 115º to 115º 115º to 115º Axis 6 400º to 400º 400º to 400º Default 288 to 288 revolutions 288 to ...

Page 45: ...ing range 43 3HAC023637 001 Revision B Turning radius The turning radius for the robot is shown in the figure below Notice the differences depending on the length of the lower arm xx0400001259 A Minimum turning radius axis 1 all models Continued ...

Page 46: ... robot with roundsling Equipment Art no Note Overhead crane Lifting capacity 500 kg Roundsling Length 2 m Lifting capacity 500 kg Action Note 1 Move the robot to an appropriate lifting position Shown in the figure Recommended lifting position on page 44 2 Secure the roundsling safely at the lifting eye and at the overhead crane Make sure the roundsling has free space and does not wear against any ...

Page 47: ...g 45 3HAC023637 001 Revision B 3 CAUTION The robot weighs 250 kg All lifting equipment must be sized accordingly 4 WARNING Personnel must not under any circumstances be present under the suspended load 5 Raise the overhead crane to lift the robot Action Note Continued ...

Page 48: ...it when the robot is connected to the controller This section details how to release the holding brakes using the internal brake release unit Action Note Illustration 1 The internal brake release unit is located at the base of the robot and equipped with six buttons for controlling the axes brakes The buttons are numbered according to the numbers of the axes xx0400001255 2 DANGER When releasing th...

Page 49: ...cted to the controller Action Note Illustration 1 DANGER Incorrect connections such as supplying power to the wrong pin may cause all brakes to be released simultaneously Also be careful not to interchange the 24V and 0V pins If they are mixed up damage can be caused to a resistor diode and to the system board 2 Connect an external power supply to connector R1 MP Supply 0V on pin C10 24V on pin B8...

Page 50: ... 2 3 3 Orienting and securing the robot General This section details how to orient and secure the robot at a horizontal level at the installation site Hole configuration base The figure below shows the hole pattern and dimensions of the robot base xx0400001300 A Center of axis 1 Continues on next page ...

Page 51: ... xx0400001306 Attachment bolts specification Attachment bolts 3 pcs M16 x 60 installation directly on foundation of steel M16 x 70 80 installation on foundation or base plate using guiding sleeves Washers 3 pcs 17 x 30 x 3 Quality Quality 8 8 wall or angle mounted robot Quality 12 9 Tightening torque 200 Nm Guiding sleeves 2 pcs needed if wall or angle mounted or if the robot is calibrated with Ab...

Page 52: ...alled using guiding sleeves Hole configuration of the base is shown in the figure Hole configuration base on page 48 Dimension of mounting surface and the guiding sleeves are shown in the figure Dimension mounting surface and guiding sleeve on page 49 3 Lift the robot to the installation site Detailed in section Lifting robot with roundsling on page 44 4 Guide the robot gently using two of the M16...

Page 53: ...vity beta specifies the robot s mounting angle expressed in radians NOTE It is very important to configure gravity beta correctly so that the robot system can control the movements in the best possible way Incorrect definition of mounting angle gravity beta will result in Overloading the mechanical structure Lower path performance and path accuracy Some functions will not work properly e g Load Id...

Page 54: ... tilting a floor mounted robot or mounting the robot on a wall the working range of axis 1 is limited These limitations are specified in the table Working ranges on page 42 A Floor mounted B Tilted mounting mounting angle 30º C Wall mounted mounting angle 90º D Inverted mounting mounting angle 180º Continued Continues on next page ...

Page 55: ...in the topic Motion How to calculate a new value is detailed in Mounting angles and values on page 51 The parameter is further detailed in the Technical reference manual System parameters The parameter can be edited either with the FlexPendant or in RobotStudioOnline Read about how to change the parameter in the Operating manual IRC5 with FlexPendant or in the Operating manual RobotStudio Online A...

Page 56: ...ts at the upper arm housing At different arm load and moment of inertia the load diagram will be changed Accurate load diagram For an accurate load diagram please use the calculation program ABB RobotLoad IRB 1600 Stand alone application on Inside abb com atma click on Products Robots IRB 1600 or http www abb com roboticspartner click on Product Range Robots IRB 1600 The application requires Micro...

Page 57: ...2 3 5 Load diagrams 55 3HAC023637 001 Revision B Load diagram IRB 1600 5 1 2 IRB 1600 5 1 45 xx0500001449 Maximum permitted load mounted on the robot tool flange at different positions center of gravity Continued Continues on next page ...

Page 58: ... 2 IRB 1600 5 1 45 Vertical Wrist 10º xx0500001450 Maximum permitted load mounted on the robot tool flange at different positions center of gravity at Vertical Wrist 10º Description Value For wrist down 0º deviation from the vertical line Max load 6 kg ZMax 0 11 m LMax 0 04 m Continued Continues on next page ...

Page 59: ...2 3 5 Load diagrams 57 3HAC023637 001 Revision B Load diagram IRB 1600 7 1 2 IRB 1600 7 1 45 xx0500001451 Maximum permitted load mounted on the robot tool flange at different positions center of gravity Continued Continues on next page ...

Page 60: ...IRB 1600 7 1 45 Vertical Wrist 10º xx0500001452 Maximum permitted load mounted on the robot tool flange at different positions center of gravity at Vertical Wrist 10º Description Value For wrist down 0º deviation from the vertical line Max load 9 kg ZMax 0 075 m LMax 0 045 m 10 º 10 º L Z L Distance m Continued ...

Page 61: ...rs If this is not done correctly operational stops may result Permitted extra loads and their positions The shaded areas indicate the permitted positions center of gravity for extra loads mounted on the wrist upper arm housing and on the frame xx0500001448 The center of gravity of the extra load must be within the marked load areas Robot Max load Load area A Load area B Load area A B Load area C L...

Page 62: ...al This section shows the robot dimensions and available mounting holes on the robot Main dimensions The two figures below show the main dimensions of the robot The remaining dimensions and mounting holes on the upper arm frame and turning disk are shown in the following figures xx0400001253 A Centerline of axis 1 B Smallest circumscribed radius axis 1 Continues on next page ...

Page 63: ...obot dimensions 61 3HAC023637 001 Revision B Mounting holes on the frame The three available mounting holes for equipment on the frame must be threaded according to the figure below xx0400001252 1 Prepared for threading M8 x max depth 20 mm Continued Continues on next page ...

Page 64: ...e upper arm and mounting holes The figure below shows the dimensions of the upper arm and available mounting holes for equipment on the arm xx0400001251 A Centerline of axis 3 B Centerline of axis 4 C Turning radius for axis 3 D Smallest circumscribed radius for axis 4 E Mounting holes for equipment Continued Continues on next page ...

Page 65: ... 001 Revision B Dimensions of the turning disk The figure below shows the dimensions of the turning disk xx0200000063 Fastener quality When fitting tools on the turning disk use only screws with quality 12 9 When fitting equipment on other places standard screws with quality 8 8 can be used Continued ...

Page 66: ...bot The lamp is active in MOTORS ON mode Location of signal lamp The signal lamp is fitted to the upper arm housing of the robot as shown in the figure below xx0400001265 Required equipment A Signal lamp C Cable gland D Cable bracket E Attachment holes for the signal lamp F Cover upper arm housing Equipment Art no Note Signal lamp 3HAC 022235 001 Gasket customer connections 3HAC 022050 001 Replace...

Page 67: ...ertion hole in the contact panel Run the cables of the lamp through the hole in the contact panel Secure the cable gland in the hole xx0400001264 A Plug with o ring M10 4 Connect the lamp connectors R3 H1 and R3 H2 and place the cables safely inside the housing 5 Take out the lamp unit through the hole in the upper arm housing cover and refit the cover Make sure the gaskets are not damaged Shown i...

Page 68: ... may collide with other objects its working space should be limited The working range of the following axes may be restricted Axis 1 hardware mechanical stop and position switch Axis 2 hardware mechanical stop Axis 3 hardware mechanical stop This section describes how to install hardware that restricts the working range Notice that adjustments must also be made in the software References to softwa...

Page 69: ...of axis 1 can be restricted by fitting one or two additional mechanical stops on the casted groove at the base The figure below shows both the minimum and maximum working range of the robot when restricted by the additional mechanical stops The working range can be restricted freely within the shown scope depending on where the mechanical stop is installed along the casted groove xx0400001286 A Mo...

Page 70: ...ow xx0400001287 Required equipment A Mechanical stop axis 1 additional B Attachment bolts and washers mechanical stop C Stop pin standard E Casted groove F Guiding pin G Hidden stiffening ribs Equipment Art no Note Working range limit axis 1 3HAC023110 001 Includes mechanical stops 2 pcs attachment bolts and washers Technical reference manual System parameters RobotWare 5 0 Art no is specified in ...

Page 71: ...ar and the elliptical hole Drill the holes through 10 2 mm If drilling in a stiffening rib drill depth must be min 30 mm 4 Cut the threads M12 If cutting in a stiffening rib thread depth must be min 23 mm 5 Fit the stop to the base without tightening the bolts 6 Turn axis 1 manually and check the working area between the stops How to release the holding brake of the axis motor is detailed in secti...

Page 72: ...nstall an additional mechanical stop on axis 2 in order to restrict the working range of the axis Restrictions in working range The working range of axis 2 can be restricted by fitting an additional mechanical stop at the frame The working range can only be restricted backwards as shown in the figures below Notice the different working ranges for the different models xx0400001289 xx0400001290 Cont...

Page 73: ...ment bolts mechanical stop 2 pcs C Attachment holes mechanical stop D Damper axis 2 E Washer F Attachment screw damper Equipment Art no Note Working range limit axis 2 3HAC023108 001 Includes mechanical stop damper and attachment bolts Technical reference manual System parameters RobotWare 5 0 Art no is specified in section References on page 8 Action Note Illustration 1 DANGER Turn off all electr...

Page 74: ...ing torque 25 Nm 5 Fit the damper to the mechanical stop with its attachment screw and washer Tighten the screw Shown in the figure Illustration mechanical stop axis 2 on page 71 6 The software working range limitations must be re defined to correspond to the changes in the mechanical limitations of the working range The system parameters that must be changed in RobotWare 5 0 Upper joint bound and...

Page 75: ...tails how to install an additional mechanical stop on axis 3 in order to restrict the working range of the axis Restrictions in working range The working range of axis 3 can be restricted into two different working areas as shown in the two figures below Notice the differences between the different models xx0400001283 Robot models IRB 1600 x 1 2 A Working range A B Working range B Continues on nex...

Page 76: ...n B 74 xx0400001284 Illustration mechanical stop axis 3 The mechanical stop is installed at the upper arm housing as shown in the figure below xx0400001285 Robot models IRB 1600 x 1 45 A Working range A B Working range B A Mechanical stop axis 3 B Attachment screws and washers 2 pcs Continued Continues on next page ...

Page 77: ...lectric power hydraulic and pneumatic pressure supplies to the robot 2 Fit the mechanical stop to the two mounting holes at the upper arm housing with the two attachment screws and washers Tighten the screws Shown in the figure Illustration mechanical stop axis 3 on page 74 2 pcs M8 x 25 tightening torque 25 Nm 3 The software working range limitations must be re defined to correspond to the change...

Page 78: ...quipment A Position switch B Attachment screws position switch 2 pcs M6 x 30 C Holder ring 2 parts D Attachment screws holder ring 6 pcs M8 x 12 E Cam F Bracket G Attachment screws housing 2 pcs M6 x 8 H Cable straps I Attachment screws attachment plate 2 pcs M6 x 16 Equipment Art no Note Position switch axis 1 3HAC023973 001 Includes 3 switches All parts are included in the delivery Instruction o...

Page 79: ...wn in the figure Location of position switch axis 1 on page 76 M6 x 12 5 Attach the position switch to the bracket with two attachment screws 2 pcs M6 x 30 6 Fit the complete bracket to the base of the robot with the two attachment screws Shown in the figure Location of position switch axis 1 on page 76 2 pcs M6 x 8 7 Fit the attachment plate to the base of the robot with the two attachment screws...

Page 80: ...ion Position switch cables robot base to controller option on page 81 10 The software working range limitations must be re defined to correspond to the changes in the mechanical limitations of the working range The system parameters that must be changed in RobotWare 5 0 Upper joint bound and Lower joint bound are further detailed in Technical reference manual System parameters Action Note Continue...

Page 81: ...9 3HAC023637 001 Revision B 2 5 Electrical connections 2 5 1 Connectors on robot Connectors on the robot The figure below shows all connections of the robot cabling including the customer connectors xx0400001262 A Connection for air B Connection for signal lamp ...

Page 82: ...osition switches on the robot Specified in the table Position switch cables robot base to controller option on page 81 Customer cables option Handles communication with equipment fitted on the robot by the customer low voltage signals and high voltage power supply protective ground See the product manual for the controller 1 Also specified in the table Customer cables option on page 81 External ax...

Page 83: ... 15 m 3HAC 9038 2 Robot cable power 22 m 3HAC 9038 3 Robot cable power 30 m 3HAC 9038 4 Cable Art no Robot cable signal shielded 7 m 3HAC 2493 1 Robot cable signal shielded 15 m 3HAC 2530 1 Robot cable signal shielded 22 m 3HAC 2540 1 Robot cable signal shielded 30 m 3HAC 2566 1 Cable Art no Connection point robot Connection point cabinet Position switch cable axis 1 30 m 3HAC 7997 4 R1 LS XS8 Cab...

Page 84: ...2 CP can be used with either a connector set from ABB for standard connection specified connector components from Souriau or connectors that meet Military standard MIL C 26482 series 1 These connectors are further detailed in following sections Connector set from ABB for standard connection Specified connector components from Souriau The components specified below are from connector manufacturer S...

Page 85: ... UT0W6 1210 P H Pin connector integrated wirefeeder cabling CS UT0W6 1626 P H Pin connector Integrated wirefeeder cabling CP UT06 1412 P H04 Turned pins for cable area Pin diameter Souriau art no 0 21 0 93 mm2 standard connection CP CS and integrated wirefeeder cabling CS 1 mm RM18W3K 0 13 0 25 mm2 integrated wirefeeder cabling CP 1 6 mm RM24M9K 0 25 0 5 mm2 integrated wirefeeder cabling CP 1 6 mm...

Page 86: ...2 Installation and commissioning 2 5 3 Customer connections on the robot 3HAC023637 001 Revision B 84 ...

Page 87: ...refers to procedures for the activities Each procedure contains all information required to perform the activity e g required tools and materials The procedures are gathered in different sections divided according to the maintenance activity Safety information Before any service work is commenced it is extremely important that all safety information is observed There are general safety aspects tha...

Page 88: ...ervals Description The intervals may be specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the robot Calendar time specified in months regardless of whether the robot system is run or not Operating time specified in operating hours More frequent running of the robot means more frequent maintenance activities ...

Page 89: ...ovement pattern Generally the more contaminated environment the closer the intervals The more demanding movement pattern sharper bending cable harness the closer the intervals 2 The battery is used as a back up when the robot system is switched off Therefore the life of a lithium battery depends on how frequently the power to the system is switched off and also if the environment temperature is hi...

Page 90: ...rouping harnesses cables other than standard options The life expectancy is based on a test cycle that for every axis goes from the calibration position to minimum angle to maximum angle and back to the calibration position Deviations from this test cycle will result in differences in expected life Component Expected life Note Robot cable harness 2 000 000 cycles See note 1 Cabling for position sw...

Page 91: ...vision B 3 3 Inspection activities 3 3 1 Inspection damper axes 2 3 and 5 Location of dampers The figure below shows the location of all the dampers to be inspected xx0400001217 xx0400001215 A Damper axis 2 B Attachment screw A Damper axis 3 B Cast tab Continues on next page ...

Page 92: ...t manual Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Check all dampers for damage such as cracks or existing impressions that are larger than 1 mm Shown in the figure Location of dampers on page 89 3 Check attachment screws for deformation 4 If any damage is detected the damper must be replaced with a new one Replacement is detailed in ...

Page 93: ...B Gearbox axis 2 C Gearbox axis 3 D Gearbox axis 4 E Gearboxes axes 5 and 6 Gearbox Type of oil Art no Amount Axis 1 Mobilgear 600 XP320 11712016 604 3 400 ml Axis 2 Mobilgear 600 XP320 11712016 604 3 400 ml Axis 3 Mobilgear 600 XP320 11712016 604 500 ml Axis 4 Mobilgear 600 XP320 11712016 604 350 ml Axis 5 6 wrist unit Optimol BM 100 3HAC 0860 1 Total amount 350 ml new wrist Amount at oil change ...

Page 94: ...l plug vent hole Equipment etc Art no Amount Note Lubricating oil 3HAC 0860 1 Total amount 350 ml new wrist Amount at oil change 300 ml Optimol BM 100 Oil collecting vessel Capacity 400 ml Standard toolkit The contents are defined in section Standard toolkit on page 194 in part 2 of the Product manual Other tools and procedures may be required See references to these procedures in the step by step...

Page 95: ...earbox oil on page 35 3 Position the robot as shown in the figure to the right upper arm upwards for a standing robot axis 4 180º to a position where the oil plug A faces downwards Note The total amount of oil will not be drained There will remain approximately 50 ml in the wrist unit Vessel capacity is specified in section Required equipment on page 92 xx0500001434 A Oil plug draining and filling...

Page 96: ...safety information in section WARNING Safety risks during work with gearbox oil on page 35 3 Remove the oil plug draining and filling Shown in the figure Location of oil plugs on page 92 4 Position the robot as shown in the figure to the right upper arm downwards for a standing robot axis 4 90º to a position where the oil plug A faces upwards Fill oil in the wrist unit through the oil plug The oil...

Page 97: ... for the measurement system is located inside the base of the robot as shown in the figure below xx0500001390 Battery pack on serial measurement unit The battery pack is attached to the serial measurement unit as shown in the figure below xx0500001393 A Base cover including gasket Battery pack is located beneath the cover A Battery pack B Velcro strap C Connector X3 Continues on next page ...

Page 98: ...and pneumatic pressure supplies to the robot 2 Remove the base cover from the robot by unscrewing its attachment screws Shown in the figure Location of battery pack on page 95 3 Disconnect the battery from the serial measurement unit 4 Remove the battery pack 5 Fit the new battery pack and connect it to the serial measurement unit X3 Spare part no is specified in Required equipment on page 96 Show...

Page 99: ... at bearing seals contacts and other seals Never spray from a distance closer than 0 4 m Never remove any covers or other protective devices before cleaning the robot Never use any cleaning agents e g compressed air or solvents other than those specified above Never spray connectors and similar items with a high pressure cleaner Equipment etc Art no Note May be used on Foundry versions only Steam ...

Page 100: ...3 Maintenance 3 5 1 Cleaning complete robot 3HAC023637 001 Revision B 98 ...

Page 101: ...ed according to the component location on the robot Required equipment All equipment required to perform a specific repair activity is listed together with the current procedure The equipment is also gathered in different lists in the Product manual reference information Safety information Before any service work is commenced it is extremely important that all safety information is observed There ...

Page 102: ...re included in the leakdown tester kit Art no is specified above 3 Apply compressed air and raise the pressure with the knob until the correct value is shown on the manometer Recommended value 0 2 0 25 bar 20 25 kPa 4 Disconnect the compressed air supply 5 Wait for approx 8 10 minutes No pressure loss must be detected If the compressed air is signifi cantly colder or warmer than the gearbox to be ...

Page 103: ...ts to adjust to the correct position against the race flange 1 Tension the bearing gradually until the recommended pre tension is achieved Note The roller elements must be rotated a specified number of turns before pre tensioning is carried out and also rotated during the pre tensioning sequence 2 Make sure the bearing is properly aligned as this will directly affect the lifespan of the bearing Gr...

Page 104: ...s etc Equipment etc Art no Note Grease 3HAB 3537 1 Used to lubricate the seals Action Note 1 Check the seal to ensure that the seal is of the correct type provided with cutting edge there is no damage to the sealing edge feel with a fingernail 2 Inspect the sealing surface before mounting If scratches or damage are found the seal must be replaced as it may result in future leakage 3 Lubricate the ...

Page 105: ...ay not be used because leakage could occur 2 Clean the surfaces properly and in accordance with ABB recommendations 3 Distribute the sealing compound evenly over the surface preferably with a brush 4 Tighten the screws evenly when fastening the flange joint Action Note 1 Ensure that the correct o ring size is used 2 Check the o ring for surface defects burrs shape accuracy etc Defective o rings ma...

Page 106: ...r connections 3HAC 021828 001 Cable harness IRB 1600 1 2 Customer connections 3HAC 021828 002 Cable harness IRB 1600 1 45 Wire feeder 3HAC 021830 001 Cable harness IRB 1600 1 2 Wire feeder 3HAC 021830 002 Gasket upper arm cover 3HAC 022049 001 Replace if damaged Gasket customer connections 3HAC 022050 001 Replace if damaged Gasket base cover 3HAC 022047 001 Replace if damaged Gasket gearbox axis 1...

Page 107: ...shows all the covers that must be removed from the robot in order to get access to the cable harness and all the brackets xx0400001248 A Upper and lower VK cover B Arm housing cover with gaskets C VK cover also shown with the cover removed D Cover frame with gasket E Base cover with gasket Continued Continues on next page ...

Page 108: ...e upper arm housing Shown in the figure Illustration cabling inside upper arm housing on page 107 5 Remove all cable ties clamps and brackets inside the upper arm housing Attachment points inside the upper arm housing are shown in the figure Illustration cabling inside upper arm housing on page 107 6 Disconnect all the connectors inside the frame Shown in the figure Illustration cabling inside fra...

Page 109: ...axes 3 4 5 and 6 R3 FB3 R3 FB4 R3 FB5 and R3 FB6 B Power cabling connectors for motors on axes 3 4 5 and 6 R3 MP3 R3 MP4 R3 MP5 and R3 MP6 C Optional connector R2 CP D Optional connector R2 CS E Distance console with contact panel F Cable clamp unit G Attachment screws cable clamp unit 2 pcs only one shown H Clamp signal cabling I Clamp motor cabling J Connector plate K Connector holder L Cable ti...

Page 110: ... attachment screws Shown in the figure Illustration cabling inside upper arm housing on page 107 5 Fit the motor and signal cabling to the connector plate with clamps Hexagon nut M5 1 pc for each clamp 6 Reconnect the signal cable connectors and slide them into the connector holder Notice that one of the cable ties in the connector holder plate must be removed in order to insert the cables into th...

Page 111: ...ired equipment on page 104 12 Continue refitting the cable harness according to procedure Refitting cable harness in frame and base on page 111 Action Note Illustration A Power cabling connectors for motors on axes 1 and 2 R3 MP1 and R3 MP2 B Signal cabling connectors for motors on axes 1 and 2 R3 FB1 and R3 FB2 C Cable clamp unit attachment screws behind the fastening plate D Fastening plate E At...

Page 112: ...hows how the cabling is run inside the base Optional cabling is also shown in the figure but not further specified xx0500001388 A Power cabling B Signal cabling C Clamp with hexagon nut D Attachment screws cable clamp unit E Hexagon nut SMB plate F Fastening plate G SMB unit H Cable clamp unit Continued Continues on next page ...

Page 113: ... with attachment screws and nuts Shown in the figure Illustration cabling inside frame on page 109 6 In the base secure the cabling to the bottom fastening plate fit the cable clamp unit with two attachment screws M6 fit the separate cables with clamps and hexagon nuts Shown in the figure Illustration cabling inside base on page 110 7 Refit the SMB unit to the fastening plate with hexagon nuts Sho...

Page 114: ...inside base on page 110 12 Refit the covers to the frame and to the base Replace the gaskets if damaged Shown in the figure Illustration covers to remove on page 105 Spare part no is specified in Required equipment on page 104 13 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section ...

Page 115: ...C Cover base Equipment Art no Note Lifting slings VK cover 3HAA 2166 23 Sealing ring V ring 3HAB 3732 13 Replace if damaged Isopropanol Used to clean the mating surfaces Locking liquid Loctite 574 Standard toolkit The contents are defined in section Standard toolkit on page 194 in part 2 of the Product manual Other tools and procedures may be required See references to these procedures in the step...

Page 116: ... inside the base and the frame are shown in the figures Illustration cabling inside base on page 110 Illustration cabling inside frame on page 109 5 Push out the VK cover from inside of the frame Shown in the figure Location of complete arm system on page 113 6 CAUTION The complete arm system weighs 55 kg All lifting equipment used must be sized accord ingly 7 Fit lifting slings to the upper arm t...

Page 117: ...ed equipment on page 113 xx0400001245 A Sealing ring B Mating surface 4 Lubricate the attachment holes at the mating surface on the frame with Loctite 574 5 CAUTION The complete arm system weighs 55 kg All lifting equipment used must be sized accordingly 6 Fit the lifting slings to the complete arm system and lift it into position while inserting the cabling into the frame 7 Fit the lower arm agai...

Page 118: ...n manual enclosed with the calibration tools General calibration information is included in section Calibration information on page 175 11 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 32 Action Note Illustration Continued ...

Page 119: ...xploded view 2 on page 208 in part 2 of the Product manual xx0400001218 Required equipment A Arm housing cover including gaskets for the cover and the contact panel B VK cover Upper arm attachment screws inside Equipment Spare part no Art no Note Upper arm spare 3HAC 023630 001 Includes the wrist unit All gearboxes are filled with oil at delivery VK cover 3HAA 2166 23 Sealing ring V ring 3HAB 3732...

Page 120: ... robot 3 Remove the arm housing cover from the upper arm Shown in the figure Location of upper arm on page 117 4 Disconnect all connectors inside the arm housing and loosen the cabling from straps and brackets The cabling and all connectors inside the upper arm housing are shown in the figure Illustration cabling inside upper arm housing on page 107 5 Remove the VK cover from the lower arm by push...

Page 121: ...Use a suitable lifting device to avoid injury to personnel 4 Attach lifting slings to the upper arm and lift it 5 Lubricate the sealing ring A with grease and fit it to the upper arm Replace the sealing ring if damaged xx0400001220 A Sealing ring spare part no is specified in Required equipment on page 117 B Contact surface 6 Lubricate the the contact surface upper arm with Loctite 574 7 Lift the ...

Page 122: ...arm on page 117 Spare part no is specified in section Required equipment on page 117 11 Refit a new VK cover to the lower arm Shown in the figure Location of upper arm on page 117 Spare part no is specified in section Required equipment on page 117 12 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information i...

Page 123: ...arm exploded view on page 205 in part 2 of the Product manual xx0400001246 Required equipment A Lower arm B VK cover C VK cover middle Equipment Spare part no Note Lower arm spare 3HAC 023558 001 IRB 1600 7 12 IRB 1600 7 1 45 Lower arm short spare 3HAC 023559 001 IRB 1600 5 1 2 IRB 1600 5 1 45 VK cover 3HAA 2166 23 VK cover 3HAA 2166 21 In the middle of the lower arm Sealing ring V ring 3HAB 3732 ...

Page 124: ...ove the VK covers Caution Be careful not to damage the cabling and cable bracket inside the lower arm when removing the middle VK cover The figure to the right shows the space underneath the cover The gray areas are safe for insertion of a tool that may be inserted with a maximum depth of 20 mm Shown in the figure Location of lower arm on page 121 xx0400001247 4 Pull down the cabling through the l...

Page 125: ...e 574 4 CAUTION The lower arm weighs 20 kg Use a suitable lifting device to avoid injury to personnel 5 Fit the lifting device to the lower arm and lift it into position 6 Insert the cabling into the lower arm 7 Fit the lower arm against the frame fit the washer and secure with the 12 attachment screws 12 pcs M10 x 40 tightening torque 70 Nm 8 Push the cabling up through the lower arm and place th...

Page 126: ... manual enclosed with the calibration tools General calibration information is included in section Calibration information on page 175 12 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 32 Action Note Illustration Continued ...

Page 127: ...st unit 3 pcs B Oil plug only one shown C Wrist unit Equipment etc Spare part no Art no Note Wrist Standard Foundry 3HAC 10475 1 Standard and Foundry versions O ring sealingplate not included O ring sealingplate 3HAC 7191 1 Must be replaced Grease 3HAC 3537 1 For lubricating the o ring sealing plate Standard toolkit The contents are defined in section Standard toolkit on page 194 in part 2 of the ...

Page 128: ...rm is vertical 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 3 Lightly lubricate the o ring sealingplate with grease Art no is specified in section Required equipment on page 125 4 In order to release the brake connect the 24 VDC power supply to motors Connect to connector R3 MP5 or 6 pin 7 pin 8 5 Fit the o ring sealingplate to the upper arm Fit the w...

Page 129: ...ion manual enclosed with the calibration tools General calibration information is included in section Calibration information on page 175 9 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 32 Action Note Continued ...

Page 130: ...nt A Damper axis 2 B Attachment screw and washer Equipment etc Spare part no Note Damper axis 2 3HAC 022013 001 Standard toolkit The contents are defined in section Standard toolkit on page 194 in part 2 of the Product manual Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required...

Page 131: ...raulic and pneumatic pressure supplies to the robot 3 Remove the damper by unscrewing the single attachment screw and washer Action Note 1 Run the robot to a position that enables access to the attachment screw of the damper axis 2 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 3 Secure the damper with the attachment screw and washer 1 pc M6 x 16 4 DANG...

Page 132: ...per axis 3 The procedure below details how to remove the damper axis 3 A Damper axis 3 B Cast tab Equipment etc Spare part no Note Damper axis 3 3HAC 022260 001 Standard toolkit The contents are defined in section Standard toolkit on page 194 in part 2 of the Product manual Action Note 1 Run the robot to a position that enables access to damper axis 3 Shown in the figure Location of damper axis 3 ...

Page 133: ...e damper axis 3 is fitted Shown in the figure Location of damper axis 3 on page 130 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 3 Refit the damper by gently pressing it onto the cast tab on the upper arm 4 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run ma...

Page 134: ...mper axis 5 3HAB 8964 1 Standard toolkit The contents are defined in section Standard toolkit on page 194 in part 2 of the Product manual Action Note 1 Run the robot to a position that enables the end of the damper to be pushed into the recess in the wrist unit Shown in the figure Location of damper axis 5 on page 132 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies t...

Page 135: ...obot 2 Push the end of the damper into the gap between the wrist unit and upper arm Make sure the damper is turned the correct way 3 Manually move the wrist robot axis 5 in order to pull the damper into position 4 Fold out the damper hooks to secure it in position 5 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER Firs...

Page 136: ...art view Base exploded view on page 199 in part 2 of the Product manual xx0500001453 Required equipment A Base B Attachment screws and washer base gearbox unit VK cover removed Equipment Spare part no Art no Note Base spare 3HAC 023552 001 V ring sealing ring 3HAB 3732 21 Replace if damaged VK cover 3HAA 2166 26 Lifting slings Locking liquid Loctite 574 For sealing the base to the gearbox 1 2 Grea...

Page 137: ... unit The cable layout in the base is shown in the figure Illustration cabling inside base on page 110 3 Remove the serial measurement unit Detailed in section Removal serial measurement unit on page 139 4 Unfasten the base from the installation site by removing the attachment bolts from the foundation 5 CAUTION The robot weighs 250 kg All lifting equipment must be sized accordingly 6 Fit the lift...

Page 138: ...is specified in Required equipment on page 134 5 Lubricate the mating surface on the base with Loctite 574 6 CAUTION The base weighs 81 kg All lifting equipment used must be sized accordingly 7 Lift the base to mounting position 8 Secure the base to the gearbox unit with the gearbox base attachment screws and washer Shown in the figure Location of base on page 134 16 pcs M10 x 40 tightening torque...

Page 139: ...t Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration information on page 175 16 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 32 Action Note Continued ...

Page 140: ... view of the unit and its position may be found in the spare part view Base exploded view on page 199 in part 2 of the Product manual xx0500001390 Serial measurement unit layout The complete spare part of the serial measurement unit is shown in the figure below xx0500001391 A Base cover including gasket Serial measurement unit is located beneath the cover A Connector SMB B Connector SMB1 4 C Conne...

Page 141: ...n Standard toolkit on page 194 in part 2 of the Product manual Circuit diagram See chapter Circuit diagram in the Product manual reference information Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Remove the push button guard A from the base The guard must be removed to ensure a correct refitting of the brake release buttons ...

Page 142: ...it layout on page 138 7 Lift and pull the serial measurement unit backwards over the lip A and lift it away xx0500001455 Action Note Illustration Action Note Illustration 1 Fit the serial measurement unit on to the four pins A xx0500001392 2 Slide the unit into position within the lips and secure with the four hexagon nuts Make sure the unit is positioned as straight as possible The push buttons c...

Page 143: ... Required equipment on page 139 5 Refit the push button guard to the robot base 6 WARNING Before continuing any service work please observe the safety information in section WARNING The brake release buttons may be jammed after service work on page 33 7 Check the gasket of the base cover Replace it if damaged Spare part no is specified in Required equipment on page 139 8 Refit the base cover Shown...

Page 144: ...d view of the component and its location is shown in the spare part view Base exploded view on page 199 in part 2 of the Product manual xx0500001390 Push button unit on serial measurement unit The push button unit is attached to the serial measurement unit as shown in the figure below xx0500001394 A Base cover including gasket Push button unit is located beneath the cover A Push button unit B Hexa...

Page 145: ...4 in part 2 of the Product manual Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Remove the push button guard A from the base The guard must be removed to ensure a correct refitting of the push button unit xx0600002744 3 Remove the centering piece B from the push button unit xx0600002776 4 Remove the base cover from the robot ...

Page 146: ...ew push button unit to the serial measurement unit in the robot base Spare part no is specified in Required equipment on page 143 Shown in the figure Push button unit on serial measurement unit on page 142 3 Secure the unit with two hexagon nuts Shown in the figure Push button unit on serial measurement unit on page 142 4 Push in and secure the SMB unit with the four hexagon nuts Shown in the figu...

Page 147: ... in section WARNING The brake release buttons may be jammed after service work on page 33 8 Reconnect all the connectors to the board 9 Check the gasket of the base cover Replace it if damaged Spare part no is specified in Required equipment on page 143 10 Refit the base cover Shown in the figure Location of push button unit on page 142 Action Note Continued ...

Page 148: ...may be found in the spare part view Frame exploded view on page 203 in part 2 of the Product manual xx0400001256 Required equipment A Motor axis 1 B Connector plate for motor cabling C Cover frame D Attachment screws motor 4 pcs E Motor cover Equipment Spare part no Art no Note Rot ac motor incl pinion spare 3HAC 023557 001 O ring 21522012 428 O ring motor Replace if damaged Gasket gearbox axis 1 ...

Page 149: ... Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Remove the cover frame Shown in the figure Location of motor on page 146 3 Disconnect the connectors for the motor axis 1 4 Loosen the connector plate from the frame and pull out the motor cabling 5 In order to release the brakes connect the 24 VDC power supply to the motor Connect to co...

Page 150: ...se the rotation tool to rotate the motor pinion when mating it to the gear 8 Secure the motor with four attachment screws and washers but do not tighten yet 4 pcs M8 x 25 9 Adjust the motor in relation to the gear in the gearbox use the rotation tool to wiggle the motor shaft back and forth to feel the play Tap with a plastic mallet position the motor pinion at at least two other positions by turn...

Page 151: ...tion manual enclosed with the calibration tools General calibration information is included in section Calibration information on page 175 17 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 32 Action Note Continued ...

Page 152: ...C Connector plate for motor cabling D Bracket and cable tie E Motor cover Equipment etc Spare part no Art no Note Rot ac motor incl pinion spare 3HAC 023557 001 O ring 21522012 428 Must be replaced when replacing motor Gasket gearbox axis 1 2 3HAC 022048 001 Replace if damaged Grease 3HAB 3537 1 For lubricating the o ring Isopropanol For cleaning mating surfaces Standard toolkit The contents are d...

Page 153: ...me Connectors R3 MP2 R3 FB2 4 Cut any cable ties and remove any brackets or clamps securing the cables 5 Remove the connector plate by removing its attachment screws and pull the cables out from the frame Shown in the figure Location of motor axis 2 on page 150 6 DANGER Secure the weight of the lower arm properly before releasing the brakes of motor axis 2 When releasing the holding brakes of the ...

Page 154: ... section Required equipment on page 150 6 Fit the motor making sure the motor pinion is properly mated to gearbox 2 Use the rotation tool to rotate the motor pinion when mating it to the gear Make sure the motor is turned the right way i e connections upwards Make sure the motor pinion does not get damaged 7 Secure the motor with four attachment screws and plain washers but do not tighten yet 4 pc...

Page 155: ...st on page 100 17 Refill the gearbox with oil Type of oil and amount is specified in section Oil in gearboxes on page 91 18 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration information on page 175 19 DANGER Make sure all safety requirements are met when performing th...

Page 156: ...ed view 1 on page 207 in part 2 of the Product manual xx0400001258 Required equipment A Motor axis 3 B Attachment screws and washers of the motor 4 pcs C Signal connector R3 FB3 D Power connector R3 MP3 E Connector holder F Upper arm housing cover G Cable tie Equipment Spare part no Art no Note Rot ac motor incl pinion 3HAC 021798 001 O ring 21522012 426 Replace if damaged Gasket upper arm cover 3...

Page 157: ...ired Circuit diagram See chapter Circuit diagram in the Product manual reference infor mation Equipment Spare part no Art no Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Remove any additional mechanical stops from axis 3 3 Move axis 2 to calibration position upper arm backwards against the mechanical stop This position enables remov...

Page 158: ...age 154 3 In order to release the brakes connect the 24 VDC power supply to the motor Connect to connector R3 MP3 pin 7 pin 8 4 Fit the motor to the upper arm housing making sure the motor pinion is properly mated to the gear of axis 3 5 Fit the attachment screws and washers but do not tighten them yet 4 pcs M6 x 20 Shown in the figure Location of motor on page 154 6 Fit the rotation tool to the e...

Page 159: ...librate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration information on page 175 14 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 32 Action Note C...

Page 160: ...e 207 in part 2 of the Product manual xx0400001273 Required equipment A Motor axis 4 B Cover upper arm housing C Connector plate D Signal connector R3 FB4 E Power connector R3 MP4 F Attachment screw and washer motor 4 pcs Equipment etc Spare part no Art no Note Rot ac motor incl pinion 3HAC 021799 001 O ring 3HAB 3772 81 Replace if damaged Gasket upper arm cover 3HAC 022049 001 Replace if damaged ...

Page 161: ...ff all electric power hydraulic and pneumatic pressure supplies to the robot 2 Manually move the robot to a position where the upper arm points straight down This will enable the motor 4 to be removed without draining the oil in the gearbox 3 Remove the cover from the upper arm housing 4 Remove the connector plate to get access to the axis 4 motor Shown in the figure Location of motor on page 158 ...

Page 162: ...ear in the gearbox Use the arm tool to wiggle the motor shaft back and forth to feel the play There should be a barely noticable gear play 7 Tighten the motor attachment screws Shown in the figure Location of motor on page 158 Tightening torque 10 Nm 8 Reconnect the motor connectors R3 MP4 and R3 FB4 9 Refit the connector plate Shown in the figure Location of motor on page 158 10 Make sure all the...

Page 163: ... in the figure below A more detailed view of the motor and its position may be found in the spare part view Upper arm exploded view 1 on page 207 in part 2 of the Product manual xx0400001279 A Motor axis 5 B Cover upper arm housing C Connector plate D Signal cable motor 5 R3 FB5 E Power cable motor 5 R3 MP5 F Attachment screws and washers motor bracket 2 pcs G Motor bracket H Attachment screws and...

Page 164: ...Timing belt 3HAC 021304 001 Gasket upper arm cover 3HAC 022049 001 Replace if damaged Gasket customer connections 3HAC 022050 001 Replace if damaged Belt tightener 3HAC 024044 001 Dynamometer Capacity 100N Standard toolkit The contents are defined in section Standard toolkit on page 194 in part 2 of the Product manual Other tools and procedures may be required See references to these procedures in...

Page 165: ...f axis 6 Detailed in section Removal motor and timing belt axis 6 on page 166 4 Disconnect the axis 5 motor connectors R3 MP5 and R3 FB5 5 Move aside all cabling that is hindering access to the axis 5 motor 6 Remove the motor bracket including the motor by unscrewing the two attachment screws and washers Shown in the figure Location of motor on page 161 7 Remove the timing belt of axis 5 8 Remove ...

Page 166: ...own in the figure Belt tightener 3HAC 024044 001 on page 162 F Force 24 N 5 Refit the motor and timing belt of axis 6 Detailed in section Refitting motor and timing belt axis 6 on page 167 6 Refit the motor of axis 4 Detailed in section Refitting motor axis 4 on page 160 7 Reconnect all connectors and place the cabling correctly inside the upper arm housing Cable layout shown in the figure Illus t...

Page 167: ...are part view Upper arm exploded view 1 on page 207 in part 2 of the Product manual xx0400001281 Required equipment A Motor axis 6 B Cover upper arm housing C Connector plate D Signal cable axis 6 motor R3 FB6 E Power cable axis 6 motor R3 MP6 F Attachment screws and washers motor 3 pcs G Distance console with cable bracket and contact panel H Cable tie Equipment Spare part no Art no Note Rot ac m...

Page 168: ... These procedures include references to the tools required Circuit diagram See chapter Circuit diagram in the Product manual reference information Equipment Spare part no Art no Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Remove the cover from the upper arm housing 3 Remove the connector plate Shown in the figure Location of motor ...

Page 169: ...ension with a force of 80 N using a dynamometer Shown in the figure to the right Tighten the motor attachment screws with a torque of 10 Nm xx0400001282 A Motor axis 6 B Timing belt axis 6 C Attachment screws and washers motor 3 pcs M6 x 20 D Hook motor pinion Ø24 07 mm F Force 80 N 3 Refit the complete distance console Shown in the figure Location of motor on page 165 4 Refit the connector plate ...

Page 170: ...ation manual enclosed with the calibration tools General calibration information is included in section Calibration information on page 175 9 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 32 Action Note Illustration Continued ...

Page 171: ...e gearbox and its position may be found in the spare part view Frame exploded view on page 203 in part 2 of the Product manual xx0500001400 Required equipment A Gearbox unit axes 1 2 B Attachment screws and washer base gearbox unit VK cover is removed Equipment Spare part no Art no Note Gearbox axis 1 2 spare 3HAC 023555 001 Includes gearbox axis 1 2 V ring sealing ring lubricating oil in vessel s...

Page 172: ... robot 2 Remove the motor axis 1 Detailed in section Removal motor axis 1 on page 147 3 Remove the motor axis 2 Detailed in section Replacement of motor axis 2 on page 150 4 Remove the complete arm system Detailed in section Removal complete arm system on page 114 5 Drain the oil from gearbox axis 1 6 Unfasten the base from the installation site by removing the attachment bolts from the foundation...

Page 173: ...e mating surfaces of the base and of the gearbox unit with isopropanol 5 Lubricate the V ring with grease and fit it to the gearbox unit Art no is specified in Required equipment on page 169 6 Fit a small amount of Loctite 574 on the mating surface in the gearbox unit 7 Fit the base to the gearbox unit and secure it with the attachment screws and the washer Shown in the figure Location of gearbox ...

Page 174: ...s 2 on page 152 14 Perform a leak down test Detailed in section Performing a leak down test on page 100 15 Fill the two gearboxes with oil Type of oil and amount is specified in section Oil in gearboxes on page 91 16 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration i...

Page 175: ... requiring any repairs or maintenance work This implies that they must under no circumstances be opened or serviced If the gearboxes require replacement axes 3 and 4 the complete upper arm is to be replaced This procedure is detailed in section Replacement of complete upper arm on page 117 axes 5 and 6 the complete wrist unit is to be replaced This procedure is detailed in section Replacement of w...

Page 176: ...4 Repair 4 7 2 Service work on gearboxes axes 3 4 5 and 6 3HAC023637 001 Revision B 174 ...

Page 177: ...racy calibration it is also recommended but not always needed to be calibrated for new Absolute Accuracy The resolver values will change when parts affecting the calibration position are replaced on the robot e g motors wrist or part of transmission Contents of the revolution counter memory are lost If the contents of the revolution counter memory are lost the counters must be updated as detailed ...

Page 178: ...n Pendulum standard method Absolute Accuracy calibration optional Based on standard calibration and besides positioning the robot at home position the Absolute Accuracy calibration also compensates for mechanical tolerances in the robot structure deflection due to load Absolute Accuracy calibration focuses on positioning accuracy in the Cartesian coordinate system for the robot Absolute Accuracy d...

Page 179: ...fferent routines further CalibWare Absolute Accuracy calibration In order to achieve a good positioning in the Cartesian coordinate system Absolute Accuracy is used as a TCP calibration The tool CalibWare guides through the calibration process and calculates new compensation parameters This is detailed further in the manual CalibWare 2 0 Users Guide M2000 If a service operation is done to a robot ...

Page 180: ...position Introduction This section specifies the calibration scale positions and or correct axis position for all robot models Calibration marks IRB 1600 The illustration below shows the calibration marks and correct positions of the six axes of the robot The marks shown in the figure are numbered according to the number of the axes xx0500001423 ...

Page 181: ...osition in the same direction in order to avoid position errors caused by backlash in gears etc Positive directions are shown in the figure below This is normally handled by the robot calibration software Calibration movement directions 6 axes Note The figure shows an IRB 7600 but the positive direction is the same for all 6 axis robots except the positive direction of axis 3 for IRB 6400R which i...

Page 182: ...a label located either on the lower arm or underneath the flange plate on the base At delivery the robot is in the correct position do NOT rotate axis 4 or 6 at power up before the revolution counters are updated If one of the below mentioned axes are rotated one or more turns from its calibration position before updating the revolution counter the correct calibration position will be lost due to ...

Page 183: ...re shown along with their calibration status 2 Tap the mechanical unit in question A screen is displayed tap Rev Counters en0400000771 3 Tap Update Revolution Counters A dialog box is displayed warning that updating the revolution counters may change programmed robot positions Tap Yes to update the revolution counters Tap No to cancel updating the revolution counters Tapping Yes displays the axis ...

Page 184: ... Tap Cancel to cancel updating the revolution counters Tapping Update updates the ticked revolution counters and removes the tick from the list of axes 6 CAUTION If a revolution counter is incorrectly updated it will cause incorrect robot positioning which in turn may cause damage or injury Check the calibration position very carefully after each update See section Checking the calibration positio...

Page 185: ...ng program MoveAbsJ 0 0 0 0 0 0 9E9 9E9 9E9 9E9 9E9 9E9 NoEOffs v1000 z50 Tool0 5 Run the program in manual mode 6 Check that the calibration marks for the axes align correctly If they do not update the revolution counters The calibration marks are shown in section Calibration scales and correct axis position on page 178 How to update the revolution counters is detailed in section Updating revolut...

Page 186: ......

Page 187: ...on craftsman working with an ABB Robot must be trained by ABB and have the required knowledge of mechanical and electrical installation repair maintenance work Organization of chapters The manual is organized in the following chapters Chapter Contents Reference information Useful information when performing installation maintenance or repair work Includes lists of necessary tools additional docume...

Page 188: ...tion is added to the procedures Replacement of push button unit on page 142 Replacement of serial measurement unit on page 138 and Replacement of cable harness on page 104 Also a new section is added to the chapter Safety WARNING The brake release buttons may be jammed after service work on page 33 Connector set for standard customer connection is added to section Customer connections on the robot...

Page 189: ...6 1 Introduction 187 3HAC023637 001 Revision B 6 Reference information 6 1 Introduction General This chapter includes general information complementing the more specific information in the Product manual part 1 of 2 procedures ...

Page 190: ... EN 60204 2005 Safety of machinery Electrical equipment of machines Part 1 General requirements EN 61000 6 4 option EMC Generic emission EN 61000 6 2 EMC Generic immunity Standard Description IEC 204 1 Electrical equipment of industrial machines IEC 529 Degrees of protection provided by enclosures Standard Description ISO 9787 Manipulating industrial robots coordinate systems and motions Standard ...

Page 191: ...evision B 6 3 Unit conversion Converter table Use the table below to convert units used in this manual Quantity Units Length 1 m 3 28 ft 39 37 in Weight 1 kg 2 21 lb Pressure 1 bar 100 kPa 14 5 psi Force 1 N 0 738 lbf Moment 1 Nm 0 738 lbf tn Volume 1 L 0 264 US gal ...

Page 192: ...urface treatment to reduce the friction when tightening the screw joint Screws treated with Gleitmo may be reused 3 4 times before the coating disappears After this the screw must be discarded and replaced with a new one When handling screws treated with Gleitmo protective gloves of nitrile rubber type should be used Screws lubricated in other ways Screws lubricated with Molycote 1000 should only ...

Page 193: ...eviation from the specified value is 10 The table below specifies the recommended standard tightening torque for oil lubricated screws with slotted or cross recess head screws The table below specifies the recommended standard tightening torque for oil lubricated screws with Allen head screws The table below specifies the recommended standard tightening torque for Molycote lubricated screws with A...

Page 194: ...pecifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass Dimension Tightening torque Nm Nominal Tightening torque Nm Min Tightening torque Nm Max 1 8 12 8 15 1 4 15 10 20 3 8 20 15 25 1 2 40 30 50 3 4 70 55 90 Continued ...

Page 195: ...exceeding 22 kg 50 lbs are high lighted in this way To avoid injury ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg A wide range of lifting tools and devices are available for each manipulator model Example Below is an example of how a weight specification is presented inside a procedure table Action Note CAUTION The motor weighs 32 kg All lifting...

Page 196: ...e gathered in the Standard toolkit and defined in the table below This way the tools required are the sum of the Standard Toolkit and any tools listed in the instruction Contents standard toolkit Qty Tool 1 Ring open end spanner 8 19 mm 1 Socket head cap 2 5 17 mm 1 Torx socket no 20 60 1 Torque wrench 10 100 Nm 1 Small screwdriver 1 Plastic mallet 1 Ratchet head for torque wrench 1 2 1 Socket hea...

Page 197: ... are also listed directly in the instructions Calibration equipment Calibration Pendulum The table below specifies the calibration equipment needed when calibrating the robot with the Calibration Pendulum method Description Art no Note Rotation tool motor 3HAC022266 003 Used to adjust the gear play on all motors Dynamometer Capacity 100N Hook 3HAC024045 001 Used to tighten the timing belt of axis ...

Page 198: ...d maintenance activities require different pieces of lifting equipment which are specified in each procedure The use of each piece of lifting equipment is not detailed in the activity procedure but in the instruction delivered with each piece of lifting equipment This implies that the instructions delivered with the lifting equipment should be stored for later reference ...

Page 199: ...on Overview This section specifies all articles considered spare parts of the robot The spare parts are also specified as required equipment directly in the repair instruction of the current spare part The list of required equipment in each instruction also specifies necessary replacement articles and all required service tools ...

Page 200: ...unit 3HAC 023424 001 8 Push button unit 3HAC 020967 001 9 Battery pack 3HAC 16831 1 Lithium 34x102x63 11 Push button guard 3HAC 6499 1 12 Signal cable SMB 3HAC 4050 1 13 Torx pan head screw 9ADA 618 56 Steel 8 8 A2F M6 x 16 14 Centering piece 3HAC025815 001 100 Cable harness IRB 1600 1 45 3HAC 021827 001 101 Cable harness IRB 1600 1 2 3HAC 021827 008 102 Cable harness IRB 1600 1 45 Customer connec...

Page 201: ...7 Spare parts and exploded views 7 2 Spare parts base 199 3HAC023637 001 Revision B Base exploded view xx0500001382 Continued ...

Page 202: ...tem no Description Spare part no Dimension 80 Gasket 3HAB 9040 1 115x46 T 3 81 Housing 40P 3HAB 6411 1 82 Surface mounted housing HIP 16 40 AG 3HAC 022964 001 84 Cover cable harness wire feeder 3HAC 022918 002 85 Cover 3HAC 6823 1 86 Key pin 5217687 9 87 Plug 3HAC 11719 1 88 Protective hood 25222101 8 D 11 4 13 89 Dust cap 5217649 9 90 Environmental dust cap 3HAA 1001 727 92 Dust cap 3HAA 1001 630...

Page 203: ...7 Spare parts and exploded views 7 3 Spare parts base connections 201 3HAC023637 001 Revision B Base connections illustrations xx0500001383 Continued ...

Page 204: ...8 A2F M6 x 16 20 Gearbox axis 1 2 spare 3HAC 023555 001 21 Stop arm 3HAC 022001 001 22 Cover gearbox axis 1 2 3HAC 023556 001 23 Gasket gearbox axis 1 2 3HAC 022048 001 24 Damper axis 2 3HAC 022013 001 25 V ring sealing ring 3HAB 3732 21 V 150A 135x12 8 26 Sealing ring V ring 3HAB 3732 13 V 110 L 99x10 5 27 Rot ac motor incl pinion spare 3HAC 023557 001 28 O ring 21522012 428 Nitrile rubber 79 5x3...

Page 205: ...7 Spare parts and exploded views 7 4 Spare parts frame 203 3HAC023637 001 Revision B Frame exploded view xx0500001384 Continued ...

Page 206: ... The spare parts are listed below and shown in the following figure Item no Description Spare part no Dimension 40 Lower arm spare 3HAC 023558 001 41 Lower arm short spare 3HAC 023559 001 42 VK cover 3HAA 2166 23 D 120 B 12 43 VK cover 3HAA 2166 21 D 68 B 8 100 107 Cabling See section Base spare part list on page 198 Continues on next page ...

Page 207: ...7 Spare parts and exploded views 7 5 Spare parts lower arm 205 3HAC023637 001 Revision B Lower arm exploded view xx0500001385 Continued ...

Page 208: ... Wrist Standard Foundry 3HAC 10475 1 68 Rot ac motor incl pinion 3HAC 021798 001 69 O ring 21522012 426 Nitrile rubber 74 5x3 70 Damper axis 3 3HAC 022260 001 71 Sealing ring V ring 3HAB 3732 19 Flourinated rubber V 95A 85x11 72 Damper axis 5 3HAB 8964 1 73 Arm housing cover spare 3HAC 023560 001 74 Gasket upper arm cover 3HAC 022049 001 75 Gasket customer connections 3HAC 022050 001 73 Contact pa...

Page 209: ...7 Spare parts and exploded views 7 6 Spare parts upper arm 207 3HAC023637 001 Revision B Upper arm exploded view 1 xx0500001386 Continued Continues on next page ...

Page 210: ...7 Spare parts and exploded views 7 6 Spare parts upper arm 3HAC023637 001 Revision B 208 Upper arm exploded view 2 xx0500001387 Continued ...

Page 211: ...r standard connection 25 3 Position switch axis 1 3HAC023973 001 Includes 3 switches Installed as detailed in section Installation of position switch axis 1 on page 76 28 1 Working range limit axis 1 3HAC023110 001 Installed as detailed in section Installation of additional mechanical stops on axis 1 on page 67 32 1 Working range limit axis 2 3HAC023108 001 Installed as detailed in section Install...

Page 212: ...7 Spare parts and exploded views 7 7 Spare parts options 3HAC023637 001 Revision B 210 ...

Page 213: ...8 Circuit diagram 8 1 Introduction 211 3HAC023637 001 Revision B 8 Circuit diagram 8 1 Introduction Overview This chapter includes the circuit diagram for the robot ...

Page 214: ...cation 102 Brake release unit serial measuring board 103 Motor axes 1 2 104 Feedback axes 1 2 105 Motor axes 3 4 106 Feedback axes 3 4 107 Motor axes 5 6 108 Feedback axes 5 6 109 Cable harness customer connection options 110 Cable harness customer connection Wire Feeder options 112 Position indicator axis 1 options 113 ...

Page 215: ...Circuit diagram 3HAC 021351 003 Rev 00 Contents Sheet 2 Circuit diagram IRB 1600 ...

Page 216: ...Revision 00 sheet 101 Circuit diagram 3HAC 021351 003 List of contents ...

Page 217: ...Revision 00 sheet 102 Circuit diagram 3HAC 021351 003 Connection point location ...

Page 218: ...Revision 00 sheet 103 Circuit diagram 3HAC 021351 003 Brake release unit serial measuring board ...

Page 219: ...Revision 00 sheet 104 Circuit diagram 3HAC 021351 003 Motor axes 1 2 ...

Page 220: ...Revision 00 sheet 105 Circuit diagram 3HAC 021351 003 Feedback axes 1 2 ...

Page 221: ...Revision 00 sheet 106 Circuit diagram 3HAC 021351 003 Motor axes 3 4 ...

Page 222: ...Revision 00 sheet 107 Circuit diagram 3HAC 021351 003 Feedback axes 3 4 ...

Page 223: ...Revision 00 sheet 108 Circuit diagram 3HAC 021351 003 Motor axes 5 6 ...

Page 224: ...Revision 00 sheet 109 Circuit diagram 3HAC 021351 003 Feedback axes 5 6 ...

Page 225: ...Revision 00 sheet 110 Circuit diagram 3HAC 021351 003 Cable harness customer connection options ...

Page 226: ...Revision 00 sheet 112 Circuit diagram 3HAC 021351 003 Cable harness customer connection Wire Feeder options ...

Page 227: ...Revision 00 sheet 113 Circuit diagram 3HAC 021351 003 Position indicator axis 1 options ...

Page 228: ......

Page 229: ...en robot and controller 80 cabling robot 80 calibrating roughly 180 calibration Absolute Accuracy type 176 Calibration Pendulum 177 marks scales 178 rough 180 standard method 177 standard type 176 when to calibrate 175 calibration manuals 177 Calibration Pendulum 177 calibration position 180 checking 183 jogging to FlexPendant 183 scales 178 calibration Absolute Accuracy 177 CalibWare 176 check in...

Page 230: ...pply to connector R1 MP 47 upper arm exploded 207 208 inspection 89 installation checking site prior robot installation 38 equipment 60 mechanical stop axis 2 70 mechanical stops axis 3 73 mechanical stops axis 1 67 position switch axis 1 76 robot attachment bolts 49 signal lamp 64 intervals maintenance 87 inverted mounting 51 L lamp unit article number 64 installation 64 lifting robot 44 limitati...

Page 231: ...g 142 spare part number 143 R releasing brakes external power supply to connector R1 MP 47 manually 46 replacing together 113 requirements foundation 39 restricting working range axis 1 67 axis 2 70 axis 3 73 revolution counters storing on FlexPendant 181 updating 180 robot cleaning 97 connectors 79 dimensions 60 equipment fitting 60 lifting 44 orienting and securing 48 robot position 178 when dra...

Page 232: ...alibration Pendulum equipment 195 dynamometer axis 5 and 6 165 for service 195 hook axis 6 article number 165 rotational tool article number 158 turning radius 43 U updating revolution counters 180 upper and lower arm 113 upper arm removing together with lower arm 113 replacing 117 screws tightening torque 119 spare part number 117 V Validity and responsibility 14 VK covers spare part number at ba...

Page 233: ......

Page 234: ...ABB Automation Technologies AB Robotics S 721 68 VÄSTERÅS SWEDEN Telephone 46 0 21 344000 Telefax 46 0 21 132592 3HAC 023637 001 Revision B en ...

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