ABB IRB 1600 - 5/1 Product Manual Download

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2 Installation and commissioning

2.4.1. Introduction

3HAC026660-001 Revision: C

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2.4 Restricting the working range

2.4.1. Introduction

General

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

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

The working range of the following axes may be restricted:

•

Axis 1, hardware (mechanical stop and position switch)

•

Axis 2, hardware (mechanical stop)

•

Axis 3, hardware (mechanical stop)

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

Notice that adjustments must also be made in the software. References to software manuals

are given in the following installation procedures.

Summary of Contents for IRB 1600 - 5/1

Page 1: ... Articulated Robot IRB 1600 5 1 2 type A IRB 1600 5 1 45 type A IRB 1600 6 1 2 type A IRB 1600 6 1 45 type A IRB 1600 7 1 2 type A IRB 1600 7 1 45 type A IRB 1600 8 1 2 type A IRB 1600 8 1 45 type A IRB 1600ID M2004 ...

Page 2: ......

Page 3: ...roduct manual IRB 1600 5 1 2 type A IRB 1600 5 1 45 type A IRB 1600 6 1 2 type A IRB 1600 6 1 45 type A IRB 1600 7 1 2 type A IRB 1600 7 1 45 type A IRB 1600 8 1 2 type A IRB 1600 8 1 45 type A IRB 1600ID M2004 Document ID 3HAC026660 001 Revision C ...

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

Page 5: ...y and information labels 29 1 3 Safety related instructions 30 1 3 1 Safety signals general 30 1 3 2 DANGER Moving robots are potentially lethal 32 1 3 3 DANGER First test run may cause injury or damage 33 1 3 4 WARNING The brake release buttons may be jammed after service work 34 1 3 5 WARNING The unit is sensitive to ESD 35 1 3 6 WARNING Safety risks during work with gearbox oil 36 2 Installatio...

Page 6: ...1 Cleaning complete robot 105 4 Repair 107 4 1 Introduction 107 4 2 General procedures 108 4 2 1 Performing a leak down test 108 4 2 2 Mounting instructions for bearings 109 4 2 3 Mounting instructions for seals 110 4 3 Complete manipulator 112 4 3 1 Replacement of cable harness 112 4 3 2 Replacement of cable harness IRB 1600ID 121 4 3 3 Replacement of complete arm system 126 4 4 Upper and lower a...

Page 7: ...n information 219 5 1 Introduction 219 5 2 Calibration methods 220 5 3 Calibration scales and correct axis position 222 5 4 Calibration movement directions for all axes 224 5 5 Updating revolution counters 225 5 6 Checking the calibration position 227 6 Robot description 229 6 1 Type A of IRB 1600 229 7 Reference information 231 7 1 Introduction 231 7 2 Applicable safety standards 231 7 3 Unit con...

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

Page 10: ...ing manual Service Information System 3HAC025709 001 Application manual Additional axes and stand alone controller 3HAC021395 001 Technical reference manual System parameter 3HAC17076 1 Revision Description First edition See also Type A of IRB 1600 on page 229 A AW equipped upper arm 1600ID IRB 1600 6 1 2 IRB 1600 6 1 45 IRB 1600 8 1 2 and IRB 1600 8 1 45 added B Cleanroom added Changes made in Pr...

Page 11: ...dures including spare parts Additional procedures if any calibration decommissioning Reference information article numbers for documentation referred to in Product manual procedures lists of tools safety standards Part list Foldouts or exploded views Circuit diagrams Technical reference manuals The following manuals describe the robot software in general and contain relevant reference information ...

Page 12: ...anuals is aimed at those having first hand operational contact with the robot that is production cell operators programmers and trouble shooters The group of manuals includes Emergency safety information Getting started IRC5 and RobotStudio IRC5 with FlexPendant RobotStudio Trouble shooting IRC5 for the controller and robot Continued ...

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

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

Page 16: ...tion and handling of the industrial robot described in the applicable documents for example Operating Manual IRC5 with FlexPendant M2004 Product Manual Connection of external safety devices Apart from the built in safety functions the robot is also supplied with an interface for the connection of external safety devices Via this interface an external safety function can interact with other machine...

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

Page 18: ... of robot WARNING Take any necessary measures to ensure that the robot does not collapse as parts are removed e g secure the lower arm with fixtures if removing motor axis 2 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 ...

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

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

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

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

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

Page 24: ...e extinguishing 3HAC026660 001 Revision C 22 Copyright 2006 2008 ABB All rights reserved 1 2 3 2 Fire extinguishing NOTE Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the robot system robot or controller ...

Page 25: ...eased manually by pushing the brake release buttons on the robot How to release the brakes is detailed in section Manually releasing the brakes on page 47 The robot arm may be moved manually on smaller robot models but larger models may require using an overhead crane or similar Increased injury Before releasing the brakes make sure that the weight of the arms does not increase the pressure on the...

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

Page 27: ...0 001 Revision C Copyright 2006 2008 ABB All rights reserved 1 2 3 5 Risk of disabling function Reduced speed 250 mm s NOTE Do not change Transm gear ratio or other kinematic system parameters from the FlexPendant or a PC This will affect the safety function Reduced speed 250 mm s ...

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

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

Page 30: ...reserved 1 2 3 8 Signal lamp optional Description A signal lamp with an yellow fixed light can be mounted on the robot as a safety device Function The lamp is active in MOTORS ON mode Further information Further information about the MOTORS ON MOTORS OFF mode may be found in the controller documentation ...

Page 31: ...e product contain space for adding a fourth language underneath the three standard languages English German and French Add a local language to the label by Using a transparent sticker over the standard label with text added in a fourth language Drawings detailing the design text figure dimensions of the standard labels can be ordered from ABB Notice that each label is identified according to the a...

Page 32: ...h for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc warning 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 volt...

Page 33: ...lectrostatic 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 ...

Page 34: ...ent located within the working range of the robot Elimination Action Note 1 Before attempting to run the robot make sure all emergency stop equipment is correctly installed and connected Emergency stop equipment such as gates tread mats light curtains etc 2 If possible use the hold to run function whenever possible The hold to run function is used in manual mode not in automatic mode How to use th...

Page 35: ... to take into consideration before the first test run Elimination Follow the procedure below when performing the first test run after a service activity repair installation or maintenance Action 1 Remove all service tools and foreign objects from the robot and its working area 2 Install all safety equipment properly 3 Make sure all personnel are standing at a safe distance from the robot that is o...

Page 36: ...r service work has been performed inside the SMB recess follow the procedure below Action Note Illustration 1 Make sure the power is turned off 2 Refit the push button guard if removed 3 Check the push buttons of the brake release unit by pressing them down one by one Make sure none of the buttons are jammed by the push button guard 4 If a button gets jammed in the depressed position the alignment...

Page 37: ...ot grounded may potentially transfer high static charges This discharge may destroy sensitive electronics Elimination Location of wrist strap button The wrist strap button is located in the right corner as shown in the illustration below xx0500002171 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 p...

Page 38: ...the opening Do not overfill the gearbox when filling Do not overfill Overfilling of gearbox oil can lead to internal over pressure inside the gearbox which in turn may damage seals and gaskets completely press out seals and gaskets prevent the robot 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 Mixin...

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

Page 40: ...allation personnel conforming to all national and local codes are allowed to perform the installation 2 Make sure the robot has not been damaged by visually inspecting its exterior 3 Make sure the lifting device to be used is dimensioned to handle the weight of the robot Weight on page 38 4 If the robot is not to be installed directly it must be stored Storage conditions on page 39 5 Make sure the...

Page 41: ... 2200 N 2500 2200 N 2400 N Torque XY Floor mounted Suspended Wall mounted 1700 Nm 1700 Nm 2310 Nm 3750 Nm 3750 Nm 3850 Nm Torque Z Floor mounted Suspended Wall mounted 855 Nm 855 Nm 855 Nm 1400 Nm 1400 Nm 1430 Nm Force Mounting Endurance load Max load emergency stop Requirement Value Note Levelness max 0 5 mm The value for levelness aims at the circum stance of the three anchoring points in the ro...

Page 42: ...nges for the different robot models The turning radius is also shown separately in the last figure Illustration working range IRB 1600 x 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: ...s reserved Illustration working range IRB 1600 x 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: ...hts reserved Illustration working range IRB 1600 ID xx0700000136 Pos Positions at wrist center mm Angle degrees X Z axis 2 axis 3 0 790 1296 5 0 0 1 150 1836 0 80 2 380 579 0 79 3 1499 5 486 5 90 80 4 720 5 736 5 150 80 5 397 5 499 5 150 238 6 57 5 716 5 90 79 7 1199 5 486 5 90 80 Continued Continues on next page ...

Page 45: ... IRB 1600 8 1 2 IRB 1600 8 1 45 Axis 2 110º to 63º 120º to 90º 136º to 63º with axis 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 11...

Page 46: ...01 Revision C 44 Copyright 2006 2008 ABB All rights reserved 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 47: ...nt Lifting the robot with roundsling A A A A A A A A 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 45 2 Secure the roundsling safely at the lifting eye and at the overhead crane Make sure the roundsling has free space ...

Page 48: ...ion C 46 Copyright 2006 2008 ABB All rights reserved 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 49: ...g the brake release unit when the robot is connected to the controller This section details how to release the holding brakes using the internal brake release unit Action Note Illustration 1 The internal brake release unit is located at the base of the robot and equipped with six buttons for controlling the axes brakes The buttons are numbered according to the numbers of the axes xx0400001255 2 DA...

Page 50: ...the robot is not connected 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...

Page 51: ...BB All rights reserved 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 52: ...hows the dimension of the mounting surface and guiding sleeves if used 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 Continued Continues o...

Page 53: ...ttachment holes If the robot is calibrated with AbsAcc it must be installed using guiding sleeves Hole configuration of the base is shown in the figure Hole configuration base on page 49 Dimension of mounting surface and the guiding sleeves are shown in the figure Dimension mounting surface and guiding sleeve on page 50 3 Lift the robot to the installation site Detailed in section Lifting robot wi...

Page 54: ...ust be updated Gravity beta specifies the robot s mounting angle expressed in radians NOTE It is very important to configure gravity beta correctly so that the robot system can control the movements in the best possible way Incorrect definition of mounting angle gravity beta will result in Overloading the mechanical structure Lower path performance and path accuracy Some functions will not work pr...

Page 55: ...ns in working area If tilting a floor mounted robot or mounting the robot on a wall the working range of axis 1 is limited These limitations are specified in the table Working ranges on page 43 A Floor mounted B Tilted mounting mounting angle 30º C Wall mounted mounting angle 90º D Suspended mounting mounting angle 180º Continued Continues on next page ...

Page 56: ...gs to the type Robot in the topic Motion How to calculate a new value is detailed in Mounting angles and values on page 52 The parameter is further detailed in the Technical reference manual System parameters The parameter can be edited either with the FlexPendant or in RobotStudio Read about how to change the parameter in the Operating manual IRC5 with FlexPendant or in the Operating manual Robot...

Page 57: ...order to avoid jolting movements and overloading the motors If this is not done correctly operation stops may result References Load diagrams permitted extra loads equipment and their positions as specified in the Product Specification The loads must also be defined in the software as detailed in Operating manual IRC5 with FlexPendant Brake performance Manipulator motor brake performance depends o...

Page 58: ...t robot dimensions General This section shows the robot dimensions and available mounting holes on the robot Main dimensions The figures below show the main dimensions of the robot The remaining dimensions and mounting holes on the upper arm frame and turning disk are shown in the following figures xx0400001253 A Centerline of axis 1 B Smallest circumscribed radius axis 1 Continues on next page ...

Page 59: ... dimensions 57 3HAC026660 001 Revision C Copyright 2006 2008 ABB All rights reserved Main dimension 1600 ID The figure below shows the main dimensions for 1600 ID robot xx0700000118 A Centerline of axis 1 B Smallest circumscribed radius axis 1 Continued Continues on next page ...

Page 60: ...6660 001 Revision C 58 Copyright 2006 2008 ABB All rights reserved 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 61: ...Dimensions of the upper arm and mounting holes The figure below shows the dimensions of the upper arm and available mounting holes for equipment on the arm xx0600002859 A Centerline of axis 3 B Centerline of axis 4 C Turning radius for axis 3 D Smallest circumscribed radius for axis 4 E Mounting holes for equipment depth 10 mm Continued Continues on next page ...

Page 62: ... 3HAC026660 001 Revision C 60 Copyright 2006 2008 ABB All rights reserved Dimensions of the upper arm and mounting holes for 1600 ID The figure below shows the dimensions of the upper arm and available mounting holes for equipment on the arm xx0700000119 Continued Continues on next page ...

Page 63: ...g disk The figure below shows the dimensions of the turning disk xx0200000063 Dimensions of the turning disk 1600ID The figure below shows the dimensions of the turning disk on a IRB 1600ID xx0700000090 Fastener quality When fitting tools on the turning disk use only screws with quality 12 9 When fitting equipment on other places standard screws with quality 8 8 can be used Continued ...

Page 64: ... mounted on the robot as a safety device The signal lamp is required on an UL UR approved robot The lamp is active in MOTORS ON mode Location of signal lamp The signal lamp is fitted to the upper arm housing of the robot as shown in the figure below xx0400001265 Required equipment A Signal lamp C Cable gland D Cable bracket E Attachment holes for the signal lamp F Cover upper arm housing Equipment...

Page 65: ...Shown in the figure Location of signal lamp on page 62 3 Remove the protection plug A from the insertion hole in the contact panel Run the cables of the lamp through the hole in the contact panel Secure the cable gland in the hole xx0400001264 A Plug with o ring M10 4 Connect the lamp connectors R3 H1 and R3 H2 and place the cables safely inside the housing 5 Take out the lamp unit through the hol...

Page 66: ...ce The signal lamp is reqired on an UL UR approved robot The lamp is active in MOTORS ON mode Location of signal lamp The signal lamp is fitted to the upper arm housing of the robot as shown in the figure below xx0700000100 Required equipment A Signal lamp B Cover upper arm housing Equipment Art no Note Signal lamp 3HAC9258 1 Spare part list upper arm on page 254 Drill Diameter 22 5 mm Standard to...

Page 67: ... Remove the cover from the upper arm housing Shown in the figure Location of signal lamp on page 64 3 On the cover there is a mark where the lamp is to be installed Find the mark and drill a hole with a diameter of 22 5mm 4 Fit the lamp and tighten the nut 5 In the upper arm housing find the two cables marked R3 H1 and R3 H2 and connect them with the lamp 6 Refit the cover on the upper arm housing...

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

Page 69: ...range of axis 1 can be restricted by fitting one or two additional mechanical stops on the casted groove at the base The figure below shows both the minimum and maximum working range of the robot when restricted by the additional mechanical stops The working range can be restricted freely within the shown scope depending on where the mechanical stop is installed along the casted groove xx040000128...

Page 70: ...hown in the figure below 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 A...

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

Page 72: ...ction details how to install an additional mechanical stop on axis 2 in order to restrict the working range of the axis Restrictions in working range The working range of axis 2 can be restricted by fitting an additional mechanical stop at the frame The working range can only be restricted backwards as shown in the figures below Notice the different working ranges for the different models xx040000...

Page 73: ...l stop axis 2 B Attachment bolts mechanical stop 2 pcs C Attachment holes mechanical stop D Damper axis 2 E Washer F Attachment screw damper 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 DANG...

Page 74: ... 2 pcs M8 x 35 tightening torque 25 Nm 5 Fit the damper to the mechanical stop with its attachment screw and washer Tighten the screw Shown in the figure Illustration mechanical stop axis 2 on page 71 6 The software working range limitations must be re defined to correspond to the changes in the mechanical limitations of the working range The system parameters that must be changed in RobotWare 5 0...

Page 75: ...eneral This section details how to install an additional mechanical stop on axis 3 in order to restrict the working range of the axis Restrictions in working range 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 ra...

Page 76: ...2008 ABB All rights reserved 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: ... DANGER Turn off all electric 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 co...

Page 78: ...x0400001356 Required equipment 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 ...

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

Page 80: ... are specified in section Position switch cables robot base to controller option on page 82 10 The software working range limitations must be re defined to correspond to the changes in the mechanical limitations of the working range The system parameters that must be changed in RobotWare 5 0 Upper joint bound and Lower joint bound are further detailed in Technical reference manual System parameter...

Page 81: ...ight 2006 2008 ABB All rights reserved 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 Continues on next page ...

Page 82: ...ision C 80 Copyright 2006 2008 ABB All rights reserved Connectors on the robot upper arm IRB 1600ID The figure below shows connections on the upper arm IRB 1600 ID xx0700000038 B A F E R4 FB6 R4 FB5 R4 MP5 R4 MP6 R3 FB3 R3 FB4 R3 FB5 R3 FB6 R3 MP3 R3 MP4 R3 MP5 R3 MP6 Continued ...

Page 83: ...Handles supply to and feedback from any position switches on the robot Specified in the table Position switch cables robot base to controller option on page 82 Customer cables option Handles communication with equipment fitted on the robot by the customer low voltage signals and high voltage power supply protective ground See the product manual for the controller 1 Also specified in the table Cust...

Page 84: ...ween robot base and controller Robot cable power 30 m 3HAC2564 1 Cable standard Art no Cable foundry Art no Robot cable power 7 m 3HAC9038 1 Robot cable power 15 m 3HAC9038 2 Robot cable power 22 m 3HAC9038 3 Robot cable power 30 m 3HAC9038 4 Cable Art no Robot cable signal shielded 7 m 3HAC2493 1 Robot cable signal shielded 15 m 3HAC2530 1 Robot cable signal shielded 22 m 3HAC2540 1 Robot cable s...

Page 85: ...ustomer cables for robots with foundry and wash protection Cable standard Art no Connection point robot Customer cable power signal 7 m 3HAC3353 1 R1 CP CS Customer cable power signal 15 m 3HAC3354 1 R1 CP CS Customer cable power signal 22 m 3HAC3355 1 R1 CP CS Customer cable power signal 30 m 3HAC3356 1 R1 CP CS Cable foundry and wash Art no Connection point robot Customer cable power signal 7 m ...

Page 86: ...connectors R2 CS and R2 CP can be used with either a connector set from ABB for standard connection specified connector components from Souriau or connectors that meet Military standard MIL C 26482 series 1 These connectors are further detailed in following sections Connector set from ABB for standard connection Specified connector components from Souriau The components specified below are from co...

Page 87: ...tor standard connection CP Customer Power UT0W6 1210 P H Pin connector integrated wirefeeder cabling CS UT0W6 1626 P H Pin connector Integrated wirefeeder cabling CP UT06 1412 P H04 Turned pins for cable area Pin diameter Souriau art no 0 21 0 93 mm2 standard connection CP CS and integrated wirefeeder cabling CS 1 mm RM18W3K 0 13 0 25 mm2 integrated wirefeeder cabling CP 1 6 mm RM24M9K 0 25 0 5 mm...

Page 88: ...rved Connector for soldering The complete pin connectors for soldering include pin connector backshell and pins Turned pin 0 5 1 5 mm2 M29029 31 228 Connector for crimping Military standard MIL C 26482 Connector for soldering Military standard MIL C 26482 Complete pin connector CS MS3116 1626S Complete pin connector CP MS3116 1210S Continued ...

Page 89: ...ithout cracking the paint The robot is painted with four layers of polyurethane paint The last layer being a varnish over labels in order to simplify cleaning Parts being replaced on a Cleanroom robot must be replaced with other parts designed for use in Cleanroom environments Cleanroom class 5 Particle emission from the robot fulfill Cleanroom class 5 standard according to DIN EN ISO 14644 1 Prep...

Page 91: ... including intervals and refers to procedures for the activities Each procedure contains all information required to perform the activity that is required tools and materials The procedures are gathered in different sections divided according to the maintenance activity Safety information Before any service work is commenced it is extremely important that all safety information is observed There a...

Page 92: ...ion of maintenance intervals Description The intervals may be specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the robot Calendar time specified in months regardless of whether the robot system is run or not Operating time specified in operating hours More frequent running of the robot means more frequent maintenance activiti...

Page 93: ...e contaminated environment the closer the intervals The more demanding movement pattern sharper bending cable harness the closer the intervals 2 The battery is used as a back up when the robot system is switched off Therefore the life of a lithium battery depends on how frequently the power to the system is switched off and also if the environment temperature is higher than recommended operating t...

Page 94: ...esses 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 IRB 1600 2 000 000 cycles See note 1 Robot cable harness IRB 16...

Page 95: ...6 2008 ABB All rights reserved 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 96: ...it on page 237 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 93 3 Check attachment screws for deformation 4 If any damage is detected the damper must be replaced with a new one Replacement is detail...

Page 97: ...arbox axis 2 C Gearbox axis 3 D Gearbox axis 4 E Gearboxes axes 5 and 6 IRB1600 Gearbox Type of oil Art no Amount Axis 1 Mobilgear 600 XP 320 11712016 604 1200 ml Axis 2 Mobilgear 600 XP 320 11712016 604 1000 ml Axis 3 IRB1600 Mobilgear 600 XP 320 11712016 604 500 ml Axis 4 IRB1600 Mobilgear 600 XP 320 11712016 604 350 ml Axis 5 6 wrist unit IRB1600 Optimol BM 100 3HAC 0860 1 Total amount 350 ml n...

Page 98: ...in gearboxes 1600ID xx0700000285 Gearbox Type of oil Art no Amount Axis 3 IRB1600ID Mobilgear 600 XP 320 11712016 604 500 ml Axis 4 IRB1600ID Mobilgear 600 XP 320 11712016 604 350 ml Axis 5 Mobilgear 600 XP 320 11712016 604 15 ml Wrist Axis 5 6 IRB1600ID Optimol BM 100 3HAC 0860 1 130 ml Wrist Axis 6 IRB1600ID Grease 20 ml Continued ...

Page 99: ...t A Oil plug draining and filling B Oil 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 237 Other tools and procedures may be required See references to these procedures in the step b...

Page 100: ...sks during work with gearbox oil on page 36 3 Position the robot as shown in the figure to the right upper arm upwards for a standing robot axis 4 180º to a position where the oil plug A faces downwards 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 97 xx0500001434 A Oil plu...

Page 101: ...ng please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 36 3 Remove the oil plug draining and filling Shown in the figure Location of oil plugs on page 97 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 throug...

Page 102: ...ain oil from the gearboxes in the wrist unit A Oil plug draining and filling B Oil plug draining ventilation plug Equipment etc Art no Amount Note Lubricating oil 3HAC0860 1 Amount at oil change 100 ml Optimol BM 100 Oil collecting vessel Standard toolkit The contents are defined in section Special tools on page 238 Other tools and procedures may be required See references to these procedures in t...

Page 103: ...the robot as shown in the figure to the right upper arm upwards for a standing robot axis 4 90º to a position where the oil plug A faces downwards NOTE The total amount of oil will not be drained There will remain approxi mately 20 ml in the wrist unit Vessel capacity is specified in section Required equipment on page 100 xx0700000033 4 Remove the oil plug A and the ventilation plug B Shown in fig...

Page 104: ...earboxes in the wrist unit Action Note Illustration 1 Position the robot as shown in the figure to the right upper arm upwards for a standing robot axis 4 90º to a position where the oil plug A faces upwards Fill 180 ml new oil in the wrist Vessel capacity is specified in section Required equipment on page 100 xx0700000034 A oil plugs filling possition 2 Refit the oil plug and the ventilation plug...

Page 105: ...y pack The battery pack 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 Continue...

Page 106: ...sure supplies to the robot 2 Remove the base cover from the robot by unscrewing its attachment screws Shown in the figure Location of battery pack on page 103 3 Disconnect the battery from the serial measurement unit 4 Remove the battery pack 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 104 Shown in the figure ...

Page 107: ...he water jet at bearing seals contacts and other seals Never spray from a distance closer than 0 4 m Never remove any covers or other protective devices before cleaning the robot Never use any cleaning agents e g compressed air or solvents other than those specified above Never spray connectors and similar items with a high pressure cleaner Equipment etc Art no Note May be used on version Foundry ...

Page 109: ...s The procedures are gathered in sections divided according to the component location on the robot Required equipment All equipment required to perform a specific repair activity is listed together with the current procedure The equipment is also gathered in different lists in the chapter Safety information Before any service work is commenced it is extremely important that all safety information ...

Page 110: ...ay be required which are included in the leakdown tester kit Art no is specified above 3 Apply compressed air and raise the pressure with the knob until the correct value is shown on the manometer Recommended value 0 2 0 25 bar 20 25 kPa 4 Disconnect the compressed air supply 5 Wait for approx 8 10 minutes No pressure loss must be detected If the compressed air is signifi cantly colder or warmer t...

Page 111: ...nable the roller elements to adjust to the correct position against the race flange 1 Tension the bearing gradually until the recommended pre tension is achieved Note The roller elements must be rotated a specified number of turns before 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 lif...

Page 112: ...ing over threads keyways etc Equipment etc Art no Note Grease 3HAB3537 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 le...

Page 113: ... defective the parts may not be used because leakage could occur 2 Clean the surfaces properly and in accordance with ABB recommendations 3 Distribute the sealing compound evenly over the surface preferably with a brush 4 Tighten the screws evenly when fastening the flange joint Action Note 1 Ensure that the correct o ring size is used 2 Check the o ring for surface defects burrs shape accuracy et...

Page 114: ...n interface Cable harness IRB 1600 1 45 Customer connections 3HAC 021828 001 Cable harness IRB 1600 1 45 Wire feeder 3HAC 021830 001 Cable harness IRB 1600 1 2 Customer connections 3HAC 021828 003 Gasket upper arm cover 3HAC 022049 001 Replace if damaged Gasket customer connections 3HAC 022050 001 Replace if damaged Gasket base cover 3HAC 022047 001 Replace if damaged Gasket gearbox axis 1 2 3HAC ...

Page 115: ...le harness and all the brackets xx0400001248 Removal cable harness The procedure below details how to remove the complete cable harness from the robot 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 Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressur...

Page 116: ...move all cable ties clamps and brackets inside the upper arm housing Attachment points inside the upper arm housing are shown in the figure Illustration cabling inside upper arm housing on page 115 6 Disconnect all the connectors inside the frame Shown in the figure Illustration cabling inside frame on page 117 7 Remove the fastening plate all cable ties and brackets from inside the frame Remove t...

Page 117: ...nectors for motors on axes 3 4 5 and 6 R3 FB3 R3 FB4 R3 FB5 and R3 FB6 B Power cabling connectors for motors on axes 3 4 5 and 6 R3 MP3 R3 MP4 R3 MP5 and R3 MP6 C Optional connector R2 CP D Optional connector R2 CS E Distance console with contact panel F Cable clamp unit G Attachment screws cable clamp unit 2 pcs only one shown H Clamp signal cabling I Clamp motor cabling J Connector plate K Conne...

Page 118: ...the figure Illustration cabling inside upper arm housing on page 115 5 Fit the motor and signal cabling to the connector plate with clamps Hexagon nut M5 1 pc for each clamp 6 Reconnect the signal cable connectors and slide them into the connector holder Notice that one of the cable ties in the connector holder plate must be removed in order to insert the cables into the holder Refit it when the c...

Page 119: ...12 Continue refitting the cable harness according to procedure Refitting cable harness in frame and base on page 119 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 Attachment screws and nuts Co...

Page 120: ...ase The figure below shows 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 121: ...ckets inside the frame with attachment screws and nuts Shown in the figure Illustration cabling inside frame on page 117 6 In the base secure the cabling to the bottom fastening plate fit the cable clamp unit with two attachment screws M6 fit the separate cables with clamps and hexagon nuts Shown in the figure Illustration cabling inside base on page 118 7 Refit the SMB unit to the fastening plate...

Page 122: ...figure Illustration cabling inside base on page 118 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 113 Spare part no is specified in Required equipment on page 112 13 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration informa...

Page 123: ... the harness The location of the harness is shown in several figures next to the procedures later on in this section xx0700000038 Required equipment A R4 FB6 B R4 FB5 E R4 MP6 F R4 MP5 B A F E R4 FB6 R4 FB5 R4 MP5 R4 MP6 R3 FB3 R3 FB4 R3 FB5 R3 FB6 R3 MP3 R3 MP4 R3 MP5 R3 MP6 Equipment Spare part no Note Standard toolkit Contents standard toolkit Circuit diagram Continues on next page ...

Page 124: ...e complete cable harness in upper arm back xx0700000105 Cable ties VK cover 3HAA 2166 23 Upper and lower covers 2 pcs Cable harness axis 5 6 3HAC027523 002 IRB 1600 AW Equipment Spare part no Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Remove the cover to the upper arm R3 FB3 R3 FB4 R3 FB5 R3 FB6 R3 MP3 R3 MP4 R3 MP5 R3 MP6 Continu...

Page 125: ...moval of the complete cable harness in upper arm tube xx0700000099 3 Remove the hexagon nut with flange A holding the two 2 clamps xx0700000106 A Hexagon nut with flange 4 Disconnect R3 FB3 R3 FB6 5 Disconnect R3 MP3 R3 MP6 6 Remove the cable harness from the lower arm Follow instructions in section Removal cable harness Action Note A Cover plate B Clamp C R4 FB5 D R4 FB6 Continued Continues on ne...

Page 126: ...c pressure supplies to the robot 2 Remove the upper arm tube Described in section Replacement of motor axis 5 IRB 1600ID 3 Remove all the Torx pan head screw A holding the cover xx0700000113 A Torx pan head screw M6x12 B Hexagon nut with flange M5 4 Remove the cover plate TIP The spare part cable harness 3HAC027523 002 includes a galvanized coverplate without paint If a painted cover is prefered u...

Page 127: ...able harness 5 Remove the cable pulling it out through the passage A xx0700000114 Action Note A Action Note 1 Refit the cable harness Described in section Refitting cable harness in upper arm housing and lower arm on page 116 2 Refit the upper arm tube Described in section Refitting motor axis 5 on page 207 3 Refit the connections in the upper arm Shown in figure Location of the harness on page 12...

Page 128: ...bot A VK cover attachment screws underneath cover B Cover frame 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 237 Other tools and procedures may be required See references...

Page 129: ...sh out the VK cover from inside of the frame Shown in the figure Location of complete arm system on page 126 6 CAUTION The complete arm system weighs 55 kg All lifting equipment used must be sized accord ingly 7 Fit lifting slings to the upper arm to unload the weight of the complete arm system 8 Unscrew the 12 attachment screws and remove the one washer Be careful when pulling the cabling through...

Page 130: ...nto the frame 7 Fit the lower arm against the frame fit the one washer and secure with the 12 attachment screws 12 pcs M10 x 40 tightening torque 70 Nm 8 Refit the cabling inside the frame and the base Detailed in section Refitting cable harness in frame and base on page 119 9 Fit a new VK cover to the lower arm Art no is specified in Required equipment on page 126 10 Recalibrate the robot Calibra...

Page 131: ...part view Upper arm exploded view 2 on page 252 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 3HAC026567 001 Includes the wrist unit All gearboxes are filled with oil at delivery Note This upper arm spare is in...

Page 132: ...e Illustration 1 Move the upper arm to a horizontal position 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 3 Remove the arm housing cover from the upper arm Shown in the figure Location of upper arm on page 129 4 Disconnect all connectors inside the arm housing and loosen the cabling from straps and brackets The cabling and all connectors inside the up...

Page 133: ...ric power hydraulic and pneumatic pressure supplies to the robot 2 Wipe the contact surfaces clean on both the upper and lower arm 3 CAUTION The complete upper arm weighs 34 kg without any additional equipment fitted Use a suitable lifting device to avoid injury to personnel 4 Attach lifting slings to the upper arm and lift it 5 Lubricate the sealing ring A with grease and fit it to the upper arm ...

Page 134: ...efit the arm housing cover to the upper arm Check the two gaskets in the cover and replace them if damaged Shown in the figure Location of upper arm on page 129 Spare part no is specified in section Required equipment on page 129 11 Refit a new VK cover to the lower arm Shown in the figure Location of upper arm on page 129 Spare part no is specified in section Required equipment on page 129 12 Rec...

Page 135: ...t of upper arm Location of upper arm The complete upper arm is considered a spare part including wrist gearboxes and motors The figure below shows the location of the upper arm and connection to the lower arm xx0700000045 Required equipment A VK Cover B Socket head cap screw M10x40 C Cable harness D V ring Equipment Spare part no Art no Note Upper arm spare Includes the wrist unit All gearboxes ar...

Page 136: ... tool kit Contents standard toolkit VK cover 3HAA 2166 23 V ring axis 3 3HAB3732 19 Gasket customer connections 3HAC 022050 001 Replace if damaged Pendulum calibration tool 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 Put the manipulator in synchroni zation position for Axis 3 xx0700000075 A Synchroniz...

Page 137: ...orx pan head screw 4 Disconnect all connectors inside the arm housing and loosen the cabling from straps and brackets Described in section Removal cable harness lower arm and upper arm back 5 CAUTION The complete upper arm weighs 39 kg without any additional equipment fitted Use a suitable lifting device to avoid injury to personnel 6 Secure the weight of the arm with lifting slings xx0700000060 A...

Page 138: ...ot 7 Knock out the VK cover from the motor side 8 Remove the 10 attachment screws A and the single washer use standard tools xx0700000057 A Socket head cap screw M10x40 9 Carefully remove the upper arm Action Note Action Note 1 Wipe the contact surfaces clean on both the upper and lower arm 2 Attach lifting slings to the upper arm and lift it 3 Clean the contact surface xx0700000076 A Contact surf...

Page 139: ...ynchronization mark Axis 3 5 Refit the 10 attachment screws A and the single washer use standard tools Tightening torque 70 Nm xx0700000057 A Socket head cap screw M10x40 6 Run the cabling through the lower arm and into the arm housing 7 Connect all the connectors in the arm housing and secure the cabling with brackets and straps Refitting of the cabling in the upper arm housing is further detaile...

Page 140: ... the lower arm replace it if damaged Spare part no is specified in section Required equipment on page 129 10 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration information 11 DANGER Make sure all safety requirements are met when performing the first test run These are ...

Page 141: ...tailed view of the lower arm may be found in the spare part view Lower arm exploded view on page 249 in part 2 of the Product manual xx0400001246 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 3HA...

Page 142: ...essure supplies to the robot 2 Remove the complete upper arm Detailed in section Removal complete upper arm on page 130 3 Remove the VK covers 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 ma...

Page 143: ...5 A Sealing ring B Mating surface 3 Lubricate the mating surface on the frame with Loctite 574 4 CAUTION The lower arm weighs 20 kg Use a suitable lifting device to avoid injury to personnel 5 Fit the lifting device to the lower arm and lift it into position 6 Insert the cabling into the lower arm 7 Fit the lower arm against the frame fit the washer and secure with the 12 attachment screws 12 pcs ...

Page 144: ...ed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration information 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 33 Action Note Illustration Continued ...

Page 145: ...7 Required equipment A Attachment screws wrist unit 3 pcs B Oil plug only one shown C Wrist unit Equipment etc Spare part no Art no Note Wrist Standard Foundry 3HAC 026569 001 Standard and Foundry versions O ring sealingplate not included Note The wrist standard Foundry is not interchangeable with art no 3HAC 10475 1 O ring sealingplate 3HAC 025420 001 Must be replaced Note The o ring sealingplate...

Page 146: ...ews Shown in the figure in section Location of wrist unit on page 143 Action Note 1 Move the robot to a position where the upper arm 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 143 4 In order to release the brake connect the 2...

Page 147: ...ailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration information 9 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 33 Action Note Continued ...

Page 148: ...unit The wrist unit is located in the frontmost part of the upper arm xx0700000025 Required equipment A Upper arm B Wrist C Motor axis 6 D Hexagon socket head screw M5x25 E Hexagon socket head screw M5X16 10 9 Short head F Hexagon socket head screw M5x25 G Hexagon socket head screw M8x35 A B E F D C G Equipment Spare part no Art No Note Wrist ID O ring Grease 3HAC3537 1 For lubricating the o ring ...

Page 149: ...uctions below Loctite 542 12690014 412 Equipment Spare part no Art No Note Action Note 1 DANGER Turn of all electric power hydraulic and pneumatic pressure supplies to the robot 2 Remove the AW equipment in the upper arm Shown in Remove AW Gun on page 160 3 The plug A in figure covering the screw C Remove the plug using standard tools B Remove the screw for looking of motor axis 5 C in figure Loca...

Page 150: ...r 5 Gently pull the cables out of the upper arm VK cover hole 6 Disconnect through the VK hole the cable harness contacts R4 FB6 and R4 MP6 xx0700000053 A Contact R4 FB6 B Contact R4 MP6 7 Remove the three attachment screws A xx0700000052 A Hex socket head cap screw M8x35 8 Remove the wrist with motor 6 from the upper arm tube Action Note Continued Continues on next page ...

Page 151: ...P6 C Motor axis 6 D Hexagon socket head screw M8x35 E Hexagon socket head screw M5x25 Action Note Action Note 1 NOTE If the screws A for the Motor Console B are removed use Loctite 542 12690014 412 on the screws when refitting Refit the Hex socket head cap screw M5x25 Tightening torque 4 1 Nm xx0700000353 A Hex socket head cap screw M5x25 B Motor Console 2 Refit the axis 6 motor using the three he...

Page 152: ... Location of wrist unit on page 146 Tightening torque 24 Nm 5 Reconnect through the VK hole the cable harness contacts R4 FB6 and R4 MP6 Make sure that all the cabling is placed correctly inside the upper arm tube 6 Tightening the hexagon socket head screw M5X16 Short head Shown as E in figure Location of wrist unit on page 146 Tightening torque 6 Nm 7 Tightening the plug A Tightening torque 6 Nm ...

Page 153: ... to remove the damper axis 2 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 237 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Actio...

Page 154: ...crewing the single attachment screw and washer Action Note Action Note 1 Run the robot to a position that enables access to the attachment screw of the damper axis 2 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 3 Secure the damper with the attachment screw and washer 1 pc M6 x 16 4 DANGER Make sure all safety requirements are met when performing the f...

Page 155: ...2 of the Product manual xx0400001215 Required equipment Removal damper 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 237 Action Note 1 Run the robot to a position that enables access to damper axis 3 Shown in th...

Page 156: ...o a position that enables access to the location where the damper axis 3 is fitted Shown in the figure Location of damper axis 3 on page 153 2 DANGER 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...

Page 157: ...Removal Mechanical damper axis 3 The procedure below details how to remove the damper axis 3 A Torx counters head screw B Mechanical damper A B Equipment Spare part no Art no Note Mechanical damper 3HAC027626 001 Standard tools The contents are defined in section Standard toolkit on page 237 Action Note 1 Run the robot to a position that enables access to damper axis 3 2 DANGER Turn off all electr...

Page 158: ...below details how to refit the damper axis 3 3 Remove the damper Use standard tools Contents standard toolkit Action Note Action Note 1 Refit the damper Use standard tools Contents standard toolkit 2 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 33 Continued ...

Page 159: ...ss Equipment etc Spare part no Note Damper axis 5 3HAB 8964 1 Standard toolkit The contents are defined in section Standard toolkit on page 237 Action Note 1 Run the robot to a position that enables the end of the damper to be pushed into the recess in the wrist unit Shown in the figure Location of damper axis 5 on page 157 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supp...

Page 160: ...sure supplies to the robot 2 Push the end of the damper into the gap between the wrist unit and upper arm Make sure the damper is turned the correct way 3 Manually move the wrist robot axis 5 in order to pull the damper into position 4 Fold out the damper hooks to secure it in position 5 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed ...

Page 161: ...eserved 4 4 10 Remove upper arm AW Gun Location of AW Gun The location of the AW equipment xx0700000153 Required equipment A Wire feeder customer option B Weld gun BINZEL C Welding cable BINZEL D Brace BINZEL Equipment Spare part no Art no Note Standard tools Contents standard toolkit Continues on next page ...

Page 162: ...tion Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Remove the welding cable C from the weld gun by twisting the locking sleeve A counter clockwise Loosen the locking screw B and pull out the welding cable xx0700000151 A Locking sleeve B Locking screw C Welding cable 3 Remove the two screws holding the brace xx0700000273 A BINZEL Brace Continued ...

Page 163: ... welding cable from the wire feeder and pull it out xx0700000142 A Wire feeder B Welding cable 5 The locking ring A has a thread loosen it counter clockwise and remove it Remove the locking sleeve B Remove all 6x M5 screw C xx0700000150 A Locking ring B Locking sleeve C Screw M5 Action Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Cont...

Page 164: ...sing the 6X Socket head cap screw M5 C Refit the locking sleeve B Lock the sleeve using the locking ring A xx0700000150 A Locking ring B Locking sleeve C Screw M5 3 Refit the welding cable C Lock the cable using the screw B xx0700000151 A Locking sleeve B Locking screw C Welding cable 4 Refit the brace A xx0700000273 Action Note Continued ...

Page 165: ...on of shelf wire feeder xx0700000311 Fitting the wire feeder shelf A Bracket ESAB wire feeder B Shelf wire feeder C Hexagon nut with flange M5 D Knob E Plain washer 8 4x16x1 6 F Hex socket head cap screw M8x12 A B C D E F Action Note 1 Fit the Shelf wire feeder B using the four 4 Hex socket head cap screw F Shown in figure Location of shelf wire feeder on page 163 Continues on next page ...

Page 166: ...Copyright 2006 2008 ABB All rights reserved 2 Fit the bracket on the wire feeder using the four 4 Hexagon nut with flange A xx0700000312 A Hexagon nut with flange M5 B Knob 3 Fit the wire feeder with the mounted bracket on the Shelf wire feeder and mount the two knobs Action Note Continued ...

Page 167: ...e found in the spare part view Base exploded view on page 243 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 t...

Page 168: ...ng inside the base and pull it up to the gearbox unit The cable layout in the base is shown in the figure Illustration cabling inside base on page 118 3 Remove the serial measurement unit Detailed in section Removal serial measurement unit on page 170 4 Unfasten the base from the installation site by removing the attachment bolts from the foundation 5 CAUTION The robot weighs 250 kg All lifting eq...

Page 169: ...ge the motor connectors 3 Clean the mating surfaces between the base and the gearbox unit with isopropanol 4 Check the V ring on the gearbox unit Lubricate with grease if needed Replace it if damaged Spare part no is specified in Required equipment on page 165 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 accord...

Page 170: ...igure Illustration cabling inside base on page 118 14 Refit the serial measurement unit Detailed in section Refitting serial measurement unit on page 171 15 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration infor mation 16 DANGER Make sure all safety requirements are ...

Page 171: ... below A more detailed view of the unit and its position may be found in the spare part view Base exploded view on page 243 in part 2 of the Product manual xx0500001390 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 Co...

Page 172: ...Circuit diagram See chapter Circuit diagram 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 xx0600002744 3 Remove the centering piece B from the push button unit xx0600002776 4 Remove the base cover ...

Page 173: ... 2 Slide the unit into position within the lips and secure with the four hexagon nuts Make sure the unit is positioned as straight as possible The push buttons can otherwise get jammed 3 Reconnect all the connectors to the unit Shown in the figure Serial measurement unit layout on page 169 4 Refit the centering piece B to the push button unit in order to align it vertically Also make sure that the...

Page 174: ...ety information in section WARNING The brake release buttons may be jammed after service work on page 34 7 Check the gasket of the base cover Replace it if damaged Spare part no is specified in Required equipment on page 170 8 Refit the base cover Shown in the figure Location of serial measurement unit on page 169 9 Update the revolution counters Detailed in section Updating revolution counters on...

Page 175: ...is shown in the spare part view Base exploded view on page 243 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 Required equipment A Base cover including gasket Push button unit is located beneath the cover A Push button unit B Hexagon nuts 2 pcs C Hexag...

Page 176: ...te 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 Shown in the figure Location of push button...

Page 177: ...the robot 2 Fit the new push button unit to the serial measurement unit in the robot base Spare part no is specified in Required equipment on page 173 Shown in the figure Push button unit on serial measurement unit on page 173 3 Secure the unit with two hexagon nuts Shown in the figure Push button unit on serial measurement unit on page 173 4 Push in and secure the SMB unit with the four hexagon n...

Page 178: ...the safety information in section WARNING The brake release buttons may be jammed after service work on page 34 8 Reconnect all the connectors to the board 9 Check the gasket of the base cover Replace it if damaged Spare part no is specified in Required equipment on page 173 10 Refit the base cover Shown in the figure Location of push button unit on page 173 Action Note Continued ...

Page 179: ... may be found in the spare part view Frame exploded view on page 247 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 Cable harness motor axes 1 2 must be ordered separately Cable harness mot...

Page 180: ...art 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 frame Shown in the figure Location of motor on page 177 3 Disconnect the connectors for the motor axis 1 4 Loosen the connector plate from the frame and pull out the motor cabling 5 In order to release the brakes connect the 24 VDC power supply to the motor ...

Page 181: ...ar of gearbox axis 1 Use the rotation tool to rotate the motor pinion when mating it to the gear 8 Secure the motor with four attachment screws and washers but do not tighten yet 4 pcs M8 x 25 9 Adjust the motor in relation to the gear in the gearbox use the rotation tool to wiggle the motor shaft back and forth to feel the play Tap with a plastic mallet position the motor pinion at at least two o...

Page 182: ...tailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration information 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 33 Action Note Continued ...

Page 183: ... Cover frame 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 Cable harness motor axes 1 2 must be ordered separately Cable harness motor axes 1 2 3HAC 023754 001 O ring 21522012 428 Must be replaced when replacing motor Gasket gearbox axis 1 2 3HAC 022048 001 Replace if damaged Grease 3...

Page 184: ... connectors inside the frame Connectors R3 MP2 R3 FB2 4 Cut any cable ties and remove any brackets or clamps securing the cables 5 Remove the connector plate by removing its attachment screws and pull the cables out from the frame Shown in the figure Location of motor axis 2 on page 181 6 DANGER Secure the weight of the lower arm properly before releasing the brakes of motor axis 2 When releasing ...

Page 185: ...Art no is specified in section Required equipment on page 181 6 Fit the motor making sure the motor pinion is properly mated to gearbox 2 Use the rotation tool to rotate the motor pinion when mating it to the gear Make sure the motor is turned the right way i e connections upwards Make sure the motor pinion does not get damaged 7 Secure the motor with four attachment screws and plain washers but d...

Page 186: ...n section Performing a leak down test on page 108 17 Refill the gearbox with oil Type of oil and amount is specified in section Amount of oil 18 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration infor mation 19 DANGER Make sure all safety requirements are met when per...

Page 187: ... view Upper arm exploded view 1 on page 251 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 Ga...

Page 188: ...ocedures include references to the tools required Circuit diagram See chapter Circuit diagram 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 189: ...equired equipment on page 185 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 185 6 Fit the ...

Page 190: ...on axis 3 on page 73 13 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration information 14 DANGER 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 ...

Page 191: ...s located inside the upper arm housing as shown in the figure below xx0700000008 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 Equipment Spare part no Art no Note Rot ac motor incl pinion 3HAC 021798 001 O ring 3HAB3772 100 Isopropanol Used for cleaning the mating surfaces Grease Standard t...

Page 192: ...ply to the motor Connect to connector R3 MP3 pin 7 pin 8 3 Remove any additional mechanical stops from axis 3 4 Move axis 2 to calibration position upper arm backwards against the mechanical stop This position enables removal of the motor without draining oil of the gearbox axis 3 xx0700000010 5 Remove the upper arm housing cover Shown in the figure Location of motor on page 189 6 Disconnect the m...

Page 193: ...ment screws and washers Lift the motor gently straight out making sure the motor pinion is not damaged xx0700000050 A Hex socket head cap screw B O ring C Motor axis 3 D Resolver cover E O ring 9 Remove the resolver cover for refitting on the new motor 10 Disconnect the brake release voltage Action Note B C A D E Action Note 1 Clean the mating surfaces inside the upper arm housing and on the motor...

Page 194: ...m 8 Refit the resolver cover on the new motor 9 Reconnect the motor connectors run and secure the cabling correctly inside the upper arm housing Cable layout is shown in the figure Illustration cabling inside upper arm housing on page 115 10 Refit the cover upper arm housing Shown in the figure Location of motor on page 189 Art no is specified in section Required equipment on page 185 11 Refit any...

Page 195: ...exploded view 1 on page 251 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 0...

Page 196: ...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 193 5 Disconnect the...

Page 197: ...e motor in relation to the gear in the gearbox Use the arm tool to wiggle the motor shaft back and forth to feel the play There should be a barely noticable gear play 7 Tighten the motor attachment screws Shown in the figure Location of motor on page 193 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 p...

Page 198: ... 6 6 Replacement of motor axis 4 1600ID NOTE After replacement of motors motor in a manipulator recalibration is required Location of motor xx0700000017 A Motor axis 4 B Cover upper arm housing C Connector plate D Signal connector R3 FB4 E Power connector R3 MP4 F Attachment screw and washer motor 4 pcs Continues on next page ...

Page 199: ... below These procedures include references to the tools required Circuit Diagram Pendulum Calibration tool 3HAC 4540 1 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 to get access to the axis 4 motor Shown in the figure Location of motor on page 196 4 Disconnect the c...

Page 200: ... the gear as described in following steps only tighten the screws lightly Shown in the figure Location of motor on page 196 Tightening torque approx 2 Nm 4 pcs M6 x 20 4 Tighten the motor attachment screws Shown in the figure Location of motor on page 196 Tightening torque 10 Nm 5 Reconnect the motor connectors R3 MP4 and R3 FB4 6 Refit the connector plate Shown in the figure Location of motor on ...

Page 201: ...r arm housing as shown in the figure below A more detailed view of the motor and its position may be found in the spare part view Upper arm exploded view 1 on page 251 in part 2 of the Product manual 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...

Page 202: ...part no Art no Note Rot ac motor incl pinion 3HAC 021800 001 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 3HAC024044 001 Dynamometer Capacity 100N Standard toolkit The contents are defined in section Standard toolkit on page 237 Other tools and procedures may be required See refer...

Page 203: ...otor and timing belt of axis 6 Detailed in section Removal motor and timing belt axis 6 on page 210 4 Disconnect the axis 5 motor connectors R3 MP5 and R3 FB5 5 Move aside all cabling that is hindering access to the axis 5 motor 6 Remove the motor bracket including the motor by unscrewing the two attachment screws and washers Shown in the figure Location of motor on page 199 7 Remove the timing be...

Page 204: ...htener the dimensions are shown in the figure Belt tightener 3HAC 024044 001 on page 200 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 210 6 Refit the motor of axis 4 Detailed in section Refitting motor axis 4 on page 195 7 Reconnect all connectors and place the cabling correctly inside the upper arm housing Cable layout...

Page 205: ...is located inside the upper arm as shown in the figure below xx0700000020 Required equipment A Arm Tube B Hex socket head cap screw M8X20 C Cable harness IRB1600ID D Rotational ac motor Axis 5 E Hex socket head cap screw M6X20 F O ring Cable harness bracket Equipment etc Spare part no Art no Note Rot ac motor with pinion Axis 5 VK cover 3HAA2166 19 Standard toolkit 3HAC020812 001 The contents are ...

Page 206: ...Whenever parting mating motor and gearbox the gears may be damaged if excessive force is used Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Circuit Diagram 3HAC 6816 3 See chapter Circuit diagram in the Product manual reference information O ring 3HAB3772 81 Nitrite Cabl...

Page 207: ...Remove the AW equipment from the upper arm Shown in section Remove AW Gun on page 160 4 Disconnect connection R4 FB5 and R4 MP5 from the backside xx0700000080 A R4 FB5 5 Remove the VK Cover to access the cable connections inside the arm xx0700000054 A VK Cover 6 Gently pull the cables out of the upper arm 7 Disconnect through the hole connection R4 FB6 and R4 MP6 xx0700000053 Action Note Continued...

Page 208: ...en 7 Hexagon socket head cap screw M8X20 holding the upper arm Position B in figure Location of motor axis 5 on page 203 11 Remove the upper arm 12 Remove the V ring A and the support ring B xx0700000248 A V ring B Support ring 13 Remove the four 4 Hexagon socket head cap screw M6X20 holding motor 5 Position E D in figure Location of motor axis 5 on page 203 14 Remove the O ring and change it if n...

Page 209: ...uired equipment on page 203 6 Adjust the motor in relation to the gear Use the rotation tool to wiggle the motor shaft back and forth to feel the play There should be a barely noticeable gear play 7 Tighten the motors attachment scews Tightening torque 10Nm 8 Refit the V ring and support ring 9 Refit the cable harness bracket G in figure Location of motor axis 5 on page 203 inside the upper arm tu...

Page 210: ...may cause injury or damage on page 33 14 Refit the cover mec stop on the back of the upper arm tube Rotate the upper arm to access all tree screws CAUTION Before refitting of the cover mec stop do not over rotate axis 4 do to risk of cable harness damage 15 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration informa...

Page 211: ...may be found in the spare part view Upper arm exploded view 1 on page 251 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 n...

Page 212: ...in the step by step instructions below These procedures include references to the tools required Circuit diagram See chapter Circuit diagram 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 on pag...

Page 213: ...orce 80 N 3 Refit the complete distance console Shown in the figure Location of motor on page 209 4 Refit the connector plate Refit the cable tie Shown in the figure Location of motor on page 209 5 Reconnect the motor cables R3 MP6 and R3 FB6 6 Place all the cabling correctly inside the upper arm housing Cable layout is shown in the figure Illustra tion cabling inside upper arm housing on page 115...

Page 214: ...e below xx0700000025 Required equipment A Upper arm B Wrist C Motor axis 6 D Hexagon socket head screw M5x25 E Hexagon socket head screw M5x16 10 9 Short head F Hexagon socket head screw M5x25 G Hexagon socket head screw M8x35 A B E F D C G Equipment Spare part no Art no Note Rot ac motor incl pinion 3HAC 021800 001 Standard toolkit Contents standard toolkit Other tools and procedures may be requi...

Page 215: ... rights reserved Removal of motor axis 6 Refitting of motor axis 6 Circuit diagram Equipment Spare part no Art no Note Action Note 1 Remove the motor according to description in Removal wrist unit on page 147 Action Note 1 Refit the motor according to description in Refitting of motor axis 6 on page 213 Continued ...

Page 216: ...re detailed view of the gearbox and its position may be found in the spare part view Frame exploded view on page 247 in part 2 of the Product manual xx0500001400 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 lubri...

Page 217: ...Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Remove the motor axis 1 Detailed in section Removal motor axis 1 on page 178 3 Remove the motor axis 2 Detailed in section Replacement of motor axis 2 on page 181 4 Remove the complete arm system Detailed in section Removal complete arm system on page 126 5 Drain the oil from gearbox axis 1 6 ...

Page 218: ...pressure supplies to the robot 2 CAUTION The complete gearbox unit weighs 120 kg without the base All lifting equipment used must be sized accordingly 3 Place the gearbox unit with the lower arm side downwards on a suitable workbench 4 Clean the mating surfaces of the base and of the gearbox unit with isopropanol 5 Lubricate the V ring with grease and fit it to the gearbox unit Art no is specified...

Page 219: ... the motors axes 1 and 2 Detailed in sections Refitting motor axis 1 on page 179 Refitting motor axis 2 on page 183 14 Perform a leak down test Detailed in section Performing a leak down test on page 108 15 Fill the two gearboxes with oil Type of oil and amount is specified in section Type and amount of oil in gearboxes 16 Fill the two gearboxes with oil Type of oil and amount is specified in sect...

Page 220: ...ntended to run without requiring any repairs or maintenance work This implies that they must under no circumstances be opened or serviced If the gearboxes require replacement axes 3 and 4 the complete upper arm is to be replaced This procedure is detailed in section Replacement of complete upper arm on page 129 axes 5 and 6 the complete wrist unit is to be replaced This procedure is detailed in se...

Page 221: ... Absolute Accuracy calibration it is also recommended but not always needed to be calibrated for new Absolute Accuracy The resolver values will change when parts affecting the calibration position are replaced on the robot for example motors wrist or part of transmission Contents of the revolution counter memory are lost If the contents of the revolution counter memory are lost the counters must b...

Page 222: ...separate file Calibration 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 r...

Page 223: ... different routines further CalibWare Absloute Accuracy calibration In order to achieve a good positioning in the Cartesian coordinate system Absolute Accuracy is used as a TCP calibration The tool CalibWare guides through the calibration process and calculates new compensation parameters This is further detailed in the application manual Absolute Accuracy Calibware 2 0 If a service operation is d...

Page 224: ...rect axis position Introduction This section specifies the calibration scale positions and or correct axis position for all robot models Calibration marks IRB 1600 The illustration below shows the calibration marks and correct positions of the six axes of the robot The marks shown in the figure are numbered according to the number of the axes xx0600002876 Continues on next page ...

Page 225: ...vision C Copyright 2006 2008 ABB All rights reserved Calibration scales IRB 1600ID The illustration below shows the calibration marks and correct positions of the six axes of the robot The marks shown in the figure are numbered according to the number of the axes xx0700000095 6 5 4 3 2 1 Continued ...

Page 226: ...ards the calibration position in the same direction in order to avoid position errors caused by backlash in gears etc Positive directions are shown in the figure below This is normally handled by the robot calibration software Calibration movement directions 6 axes Note The figure shows an IRB 7600 but the positive direction is the same for all 6 axis robots except the positive direction of axis 3...

Page 227: ... 4 or 6 at power up before the revolution counters are updated If one of the below mentioned axes are rotated one or more turns from its calibration position before updating the revolution counter the correct calibration position will be lost due to uneven gear ratio This affects the following robots If the calibration marks seem to be wrong even if the motor calibration data is correct try to rot...

Page 228: ...lect the axis to have its revolution counter updated by Ticking in the box to the left Tapping Select all to update all axes Then tap Update 5 A dialog box is displayed warning that the updating operation cannot be undone Tap Update to proceed with updating the revolution counters Tap Cancel to cancel updating the revolution counters Tapping Update updates the ticked revolution counters and remove...

Page 229: ...u 4 Create the following program MoveAbsJ 0 0 0 0 0 0 9E9 9E9 9E9 9E9 9E9 9E9 NoEOffs v1000 z50 Tool0 5 Run the program in manual mode 6 Check that the calibration marks for the axes align correctly If they do not update the revolution counters The calibration marks are shown in section Calibration scales and correct axis position on page 222 How to update the revolution counters is detailed in se...

Page 230: ......

Page 231: ...t no 3HAC023630 001 Note Software version 5 07 01 is needed The following parts are not interchangeable The wrist unit with spare part no 3HAC026569 001 is not interchangeable with spare part no 3HAC10475 1 The o ring sealingplate with spare part no 3HAC025420 001 is not interchangeable with spare part no 3HAC 7191 1 Other changes in this product manual compared to product manual IRB 1600 3HAC0236...

Page 233: ...ol systems EN ISO 10218 1 2006 Robots for industrial environments Safety requirements Part 1 Robot EN ISO 60204 1 2005 Safety of machinery Electrical equipment of machines Part 1 General requirements EN 61000 6 4 option EMC Generic emission EN 61000 6 2 EMC Generic immunity Standard Description IEC 204 1 Electrical equipment of industrial machines IEC 529 Degrees of protection provided by enclosur...

Page 234: ...06 2008 ABB All rights reserved 7 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 235: ...mo is a special surface treatment to reduce the friction when tightening the screw joint Screws treated with Gleitmo may be reused 3 4 times before the coating disappears After this the screw must be discarded and replaced with a new one When handling screws treated with Gleitmo protective gloves of nitrile rubber type should be used Screws lubricated in other ways Screws lubricated with Molycote ...

Page 236: ... Maximum allowed total deviation from the specified value is 10 The table below specifies the recommended standard tightening torque for oil lubricated screws with slotted or cross recess head screws 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 ...

Page 237: ...rved The table below specifies 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 238: ...cified All components exceeding 22 kg 50 lbs are high lighted in this way To avoid injury ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg A wide range of lifting tools and devices are available for each manipulator model Example Below is an example of how a weight specification is presented inside a procedure table Action Note CAUTION The motor we...

Page 239: ...considered standard are gathered in the Standard toolkit and defined in the table below This way the tools required are the sum of the Standard Toolkit and any tools listed in the instruction Contents standard toolkit 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 w...

Page 240: ... robot The special tools 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 ...

Page 241: ...General Many repair and maintenance activities require different pieces of lifting equipment which are specified in each procedure The use of each piece of lifting equipment is not detailed in the activity procedure but in the instruction delivered with each piece of lifting equipment This implies that the instructions delivered with the lifting equipment should be stored for later reference ...

Page 243: ...d views 8 1 Introduction Overview This section specifies all articles considered spare parts of the robot The spare parts are also specified as required equipment directly in the repair instruction of the current spare part The list of required equipment in each instruction also specifies necessary replacement articles and all required service tools ...

Page 244: ...K cover 3HAA 2166 26 D 180 B 12 7 Serial measurement 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 001 102 Cable harness IRB 1600 1 45 Customer ...

Page 246: ...the following figure Item no Description Spare part no Dimension 80 Gasket 3HAB 9040 1 115x46 T 3 81 Housing 40P 3HAB 6411 1 82 Surface mounted housing HIP 16 40 AG 3HAC 022964 001 84 Cover cable harness wire feeder 3HAC 022918 002 85 Cover 3HAC 6823 1 86 Key pin 5217687 9 87 Plug 3HAC 11719 1 88 Protective hood 25222101 8 D 11 4 13 89 Dust cap 5217649 9 90 Environmental dust cap 3HAA 1001 727 92 ...

Page 247: ...8 Spare parts and exploded views 8 3 Spare parts base connections 245 3HAC026660 001 Revision C Copyright 2006 2008 ABB All rights reserved Base connections illustrations xx0500001383 Continued ...

Page 248: ...AC 023555 001 21 Stop arm 3HAC 022001 001 22 Cover gearbox axis 1 2 3HAC 023556 001 23 Gasket gearbox axis 1 2 3HAC 022048 001 24 Damper axis 2 3HAC 022013 001 25 V ring sealing ring 3HAB 3732 21 V 150A 135x12 8 26 Sealing ring V ring 3HAB 3732 13 V 110 L 99x10 5 27 Rot ac motor incl pinion spare 3HAC 023557 001 27 Rot ac motor incl pinion Cleanroom 3HAC031018 001 28 O ring 21522012 428 Nitrile ru...

Page 250: ...er arm spare part list 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 8 100 109 Cabling See section Base spare part list on page 242 Continues on next page ...

Page 252: ...ate 3HAC 025420 001 67 Wrist Standard Foundry 3HAC 026569 001 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...

Page 253: ... Spare parts and exploded views 8 6 Spare parts upper arm 251 3HAC026660 001 Revision C Copyright 2006 2008 ABB All rights reserved Upper arm exploded view 1 xx0600002854 Continued Continues on next page ...

Page 254: ...8 Spare parts and exploded views 8 6 Spare parts upper arm 3HAC026660 001 Revision C 252 Copyright 2006 2008 ABB All rights reserved Upper arm exploded view 2 xx0600002856 Continued ...

Page 255: ...2 CS 3HAC025396 001 Only for standard connection 25 3 Position switch axis 1 3HAC023973 001 Includes 3 switches Installed as detailed in section Installation of position switch axis 1 on page 76 28 1 Working range limit axis 1 3HAC023110 001 Installed as detailed in section Installation of additional mechanical stops on axis 1 on page 67 32 1 Working range limit axis 2 3HAC023108 001 Installed as ...

Page 256: ...r axis 3 Motors and O rings on page 256 3HAC021798 001 4 O ring motor axis 3 Motors and O rings on page 256 2152 2012 426 5 Motor axis 4 and 5 Motors and O rings on page 256 3HAC021799 001 6 O ring motor 4 and 5 Motors and O rings on page 256 3HAB3772 81 7 Motor axis 6 3HAC17342 1 8 Cover arm housing Covers and mechanical stops on page 257 3HAC027874 001 9 Mecanical stop Covers and mechanical stop...

Page 257: ...are parts and exploded views 8 8 Spare parts upper arm 1600ID 255 3HAC026660 001 Revision C Copyright 2006 2008 ABB All rights reserved Cable harness IRB 1600ID xx0700000156 Continued Continues on next page ...

Page 258: ... Spare parts and exploded views 8 8 Spare parts upper arm 1600ID 3HAC026660 001 Revision C 256 Copyright 2006 2008 ABB All rights reserved Motors and O rings xx0700000157 Continued Continues on next page ...

Page 259: ...e parts and exploded views 8 8 Spare parts upper arm 1600ID 257 3HAC026660 001 Revision C Copyright 2006 2008 ABB All rights reserved Covers and mechanical stops xx0700000158 Continued Continues on next page ...

Page 260: ...8 Spare parts and exploded views 8 8 Spare parts upper arm 1600ID 3HAC026660 001 Revision C 258 Copyright 2006 2008 ABB All rights reserved Indicator lamp xx0700000159 Continued Continues on next page ...

Page 261: ...8 Spare parts and exploded views 8 8 Spare parts upper arm 1600ID 259 3HAC026660 001 Revision C Copyright 2006 2008 ABB All rights reserved Exploaded view xx0700000160 13 12 Continued ...

Page 263: ...am 9 1 Introduction 261 3HAC026660 001 Revision C Copyright 2006 2008 ABB All rights reserved 9 Circuit diagram 9 1 Introduction Overview This chapter includes the circuit diagram for the robot Continues on next page ...

Page 265: ...errors that may appear in this document Except as may be expressly stated anywhere in this document nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses damages to persons or property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this document This document and parts thereof...

Page 266: ...GE Title page cover sheet Status Document no 3HAC021351 003 Plant Location Sublocation Rev Ind IRB1600 Manipulator 01 Page Next Total 2 11 15 Approved 2007 03 19 Manufacture Type Control cabinet Mains voltage Supply Control voltage Year of construction 2007 03 22 Type of installation Customer Robot serial number s Drawing number Drawing version Manipulator Project start Project manager Last revisi...

Page 267: ...r Connection Points Location Plant Sublocation Connection Points Manipulator Document no Next Rev Ind 01 Lab Office Status 1 2 3 4 5 6 7 8 R3 MP1 R3 MP2 R3 FB1 R3 FB2 R4 MP1 R4 FB1 R4 MP2 R4 FB2 Air R2 CP R2 CBUS R2 CS R3 MP3 R3 MP4 R3 MP5 R3 MP6 R3 H1 R3 H2 R3 MP3 R3 MP4 R3 MP5 R3 MP6 R3 H1 R3 H2 R3 FB3 R3 FB4 R3 FB5 R3 FB6 R3 FB3 R3 FB4 R3 FB5 R3 FB6 R4 MP6 R4 FB6 R4 MP5 R4 FB5 IRB 1600 ID Air R...

Page 268: ...ke Bleed Circuit Brake Bleed Circuit BU Brake Release Simplified 1 3 2 1 2 3 1 K A K A K A K A K A K A B8 R1 MP C8 C9 C10 B7 BRAKE PB BRAKE REL 0V BRAKE BRAKE REL 0V BRAKE B4 B3 C2 C1 BU BU BU BU BU EXT LIM 2 BU EXT LIM 1 LIM 2 LIM 1 BU BU BU 2 PE PE 4 1 3 8 7 10 9 14 13 16 15 5 6 11 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 BRAKE REL 1 AXIS 1 22 1 0V BRAKE 1 AXIS 1 22 1 BRAKE REL 2 AXIS 2 23 2 0V...

Page 269: ...y date Serial Measuring Board Location Plant Sublocation IRB1600 SMB Document no Next Rev Ind 01 Lab Office Status Approved 2007 03 19 1 2 3 4 5 6 7 8 A B C D E F K KEYPIN M R1 SMB SDI SDI N SDO SDO N 0V 24V BATSUP 0V BATLD WH BU WH OG WH GN GY RD G 0V 9 5 8 4 3 7 2 1 R2 SMB R2 G X3 SMB 9 5 8 4 3 7 2 1 R2 SMB R2 G X3 6 2 L J 6 2 9 2 11 4 12 5 A B C D E F 5 12 4 11 2 9 R1 SMB1 7 R2 FB7 X7 0V X7 Y7 ...

Page 270: ... 3 2 3 2 3 GNYE M 3 S V T W R U PE Brake 1 2 3 PE 7 8 PE PE 7 8 5 B2 5 4 1 5 2 6 3 Resolver R4 FB1 4 1 5 2 6 3 SMB IS 2 23 1 IS 3 24 1 IS 4 25 1 IS 5 26 1 IS 6 27 1 00ID 28 1 00ID 29 1 2 14 3 15 6 18 14 3 15 6 18 1 1 1 2 1 3 M1R M1S M1T M1R M1S M1T GNYE PE BRAKE REL 1 0V BRAKE 1 PTC1 WHBU BU WHOG OG GN WHGN X1 0V X1 Y1 0V Y1 0V EXC EXC 1 10 1 12 1 11 M1R M1S M1T BRAKE REL 1 0V BRAKE 1 9 9 6 6 7 7 ...

Page 271: ...4 5 6 7 8 SMB AXIS 1 22 1 4 16 5 17 7 19 PE D1 D2 16 5 17 7 19 1 14 1 19 M2R M2R M2S M2S M2T M2T GN WH YE WH WH OG 0V BRAKE 2 BRAKE REL 2 1 13 1 18 1 15 1 20 1 16 1 17 X2 0V X2 Y2 0V Y2 0V EXC EXC 1 3 9 5 6 7 8 6 1 7 2 8 3 1 2 3 9 5 6 7 8 6 1 7 2 8 3 M2R M2S M2T PE BRAKE REL 2 0V BRAKE 2 BU OG GN WHBU WHOG WHGN X2 0V X2 Y2 0V Y2 0V EXC EXC 4 1 5 2 6 3 2 3 PE 7 8 1 2 3 PE 7 8 4 1 5 2 6 3 GNYE M 3 S...

Page 272: ...1 Lab Office Status Approved 2007 03 19 1 2 3 4 5 6 7 8 SMB AXIS 1 22 1 25 D4 B1 B5 23 2 11 M3R M3S M3T RDBN RDGN RDYE RDGY BKGY BKYE BRAKE REL 3 2 10 2 12 2 13 2 6 X3 0V X3 Y3 0V Y3 0V EXC EXC 6 1 7 2 8 3 1 2 3 PE 7 8 1 2 3 PE 7 8 6 1 7 2 8 3 GNYE M 3 S V T W R U PE Brake Resolver 5 6 5 6 MP3 FB3 R1 MP R3 MP3 D3 11 1 1 SIGNAL LAMP OPTION 1 1 R3 H1 R3 H2 A K C7 MONLMP BU 20 7 BU BRAKE REL 3 AXIS 4...

Page 273: ...ice Status Approved 2007 03 19 1 2 3 4 5 6 7 8 SMB AXIS 1 22 1 PE A9 A8 2 15 M4R M4S M4T RDBU RD BKBN BKGN BU BUPK BRAKE REL 4 2 14 2 16 2 17 X4 0V X4 Y4 0V Y4 0V EXC EXC 6 1 7 2 8 3 1 2 3 9 7 8 1 2 3 9 7 6 1 7 2 8 3 PE M 3 S V T W R U PE Brake Resolver 5 6 5 6 2 9 R3 MP4 R3 FB4 R1 MP MU4 FB4 A10 8 BU 20 7 BU BRAKE REL 4 PTC34 AXIS 3 24 6 B6 7 19 2 14 3 15 2 14 3 15 7 19 PE43 AXIS 3 24 6 0V BRAKE4...

Page 274: ...pproved 2007 03 19 1 2 3 4 5 6 7 8 D10 D9 A7 B9 C5 R1 MP 2 19 M5R M5S M5T 0V PTC 0V BRAKE 5 BRAKE REL 5 2 18 2 20 2 23 2 22 2 21 R3 MP5 R3 FB5 1 2 3 9 5 6 7 8 6 1 7 2 8 3 MU5 AXIS 5 IRB1600ID 28 7 FB5 AXIS 5 IRB1600ID 28 7 1 2 3 9 7 8 6 1 7 2 8 3 5 6 GNYE M 3 S V T W R U PE Brake Resolver SMB AXIS 1 22 1 4 16 5 17 16 5 17 4 X5 Y5 0V X5 0V Y5 BKPK BKBU BKRD BK AXIS 6 27 6 PE65 BU 20 7 BU BRAKE REL ...

Page 275: ...e Status Approved 2007 03 19 1 2 3 4 5 6 7 8 PE D8 D7 B10 C6 R1 MP 2 2 M6R M6S M6T BRAKE REL 6 2 1 2 8 2 4 R3 MP6 R3 FB6 1 2 3 9 5 6 7 8 6 1 7 2 8 3 MU6 AXIS 6 IRB1600ID 29 7 FB6 AXIS 6 IRB1600ID 29 7 1 2 3 9 5 6 7 8 6 1 7 2 8 3 GNYE M 3 S V T W R U PE Brake Resolver SMB AXIS 1 22 1 9 21 10 22 9 21 10 22 R2 FB3 6 BUBN BUGN BUYE BUGY X6 Y6 0V Y6 0V X6 PE65 AXIS 5 26 6 2 3 PE 2 5 2 7 PTC 0V BRAKE 6 ...

Page 276: ...RAKE 2 BRAKE REL 5 2 18 2 20 2 22 2 21 2 23 X5 0V X5 Y5 0V Y5 2 3 9 5 6 7 8 6 1 7 2 8 3 1 2 3 9 5 6 7 8 6 1 7 2 8 3 R3 FB5 M5R M5S M5T PE BRAKE REL 5 0V BRAKE 5 WH WH WH GN YE OG X5 0V X5 Y5 0V Y5 0V EXC EXC 24 6 1 7 2 8 3 1 2 3 9 7 8 1 2 3 9 7 8 6 1 7 2 8 3 GNYE M 3 S V T W R U PE Brake Resolver 5 6 5 6 R1 MP R4 MP5 R4 FB5 A7 1 R3 MP5 MU5 AXIS 5 26 7 FB5 AXIS 5 26 7 C5 4 16 5 17 4 16 5 17 AXIS 6 ...

Page 277: ...22 2 2 M6R M6S M6T BUBN BUGN BUYE BUGY BRAKE REL 6 2 1 2 3 2 4 X6 0V X6 Y6 0V Y6 2 3 9 5 6 7 8 6 1 7 2 8 3 1 2 3 9 5 6 7 8 6 1 7 2 8 3 R3 FB6 M6R M6S M6T PE BRAKE REL 6 0V BRAKE 6 WH WH WH GY VT BU X6 0V X6 Y6 0V Y6 0V EXC EXC 8 6 1 7 2 8 3 1 2 3 9 7 8 1 2 3 9 7 8 6 1 7 2 8 3 GNYE M 3 S V T W R U PE Brake Resolver 5 6 5 6 R1 MP R2 SMB3 6 MU6 AXIS 6 27 7 FB6 AXIS 6 27 7 1 D8 9 R3 MP6 R4 MP6 R4 FB6 ...

Page 278: ... A3 B5 C5 D5 A6 B6 C6 D6 A7 B7 C7 D7 A8 B8 C8 D8 A9 B9 C9 D9 A10 B10 C10 D10 R2 CS A B C D E F G H J K L M N P R S T U V W X Y Z CPA CPB CPC CPD CPE CPF CPJ CPK CPH CSA CSB CSC CSD CSE CSF CSG CSH CSJ CSK CSL CSM CSN CSP CSR CSS CST CSU CSV CSW CSX CSY CSZ G BK BN RD OG YE GN BU VT GY WHBN WHRD WHOG WHYE WHGN WHBU WHVT WHGY GYBK GYBN GYRD GYOG GYYE GYGN GYBU GYVT GYWH GNBK GNBN GNRD GNOG GNBU GNVT...

Page 279: ...31 15 Total 3HAC021351 003 Latest revision Approved by date Position Indicator Axis 1 Option Location Plant Sublocation IRB1600 LS Document no Next Rev Ind 01 Lab Office Status Approved 2007 03 19 1 2 3 4 5 6 7 8 A B D C E F H G J K M L BK BN BU BK R2 LS1 1 BK BN BU BK BK BN BU BK R2 LS1 2 R2 LS1 3 One switch En brytare Two switches Två brytare Three switches Tre brytare PE PE PE Z KEY PIN STIFT G...

Page 280: ...e part number 112 cabling between robot and controller 81 cabling robot 81 calibrating roughly 225 calibration Absolute Accuracy type 220 marks scales 222 rough 225 standard type 220 when to calibrate 219 calibration manuals 221 calibration position 225 checking 227 jogging to FlexPendant 227 scales 222 calibration Absolute Accuracy 221 CalibWare 220 check installation site 38 cleaning robot inter...

Page 281: ...r R1 MP 48 upper arm exploded 251 252 inspection 93 installation checking site prior robot installation 38 equipment 56 mechanical stop axis 2 70 mechanical stops axis 3 73 mechanical stops axis 1 67 position switch axis 1 76 robot attachment bolts 50 signal lamp 62 intervals maintenance 91 inverted mounting 52 L lamp unit article number 62 installation 62 lifting robot 45 limitations in working r...

Page 282: ...g brakes external power supply to connector R1 MP 48 manually 47 replacing together 126 requirements foundation 39 restricting working range axis 1 67 76 axis 2 70 axis 3 73 revolution counters storing on FlexPendant 225 updating 225 robot cleaning 105 connectors 79 dimensions 56 equipment fitting 56 lifting 45 orienting and securing 49 robot position 222 when draining wrist unit 98 101 102 when f...

Page 283: ...ration Pendulum equipment 238 dynamometer axis 5 and 6 209 for service 238 hook axis 6 article number 209 rotational tool article number 193 turning radius 44 U updating revolution counters 225 upper and lower arm 126 upper arm removing together with lower arm 126 replacing 129 screws tightening torque 132 spare part number 129 V Validity and responsibility 14 VK covers spare part number at base 1...

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Page 285: ...ABB AB Robotics Products S 721 68 VÄSTERÅS SWEDEN Telephone 46 0 21 344000 Fax 46 0 21 132592 3HAC026660 001 Revision C en ...

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