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Routines in the calibration procedure

The following routines are available in the Axis Calibration procedure, given at the
beginning of the procedure on the FlexPendant.

Fine calibration routine

Choose this routine to calibrate the robot when there are no tools, process cabling
or equipment fitted to the robot.

Reference calibration routine

Choose this routine to create reference values and to calibrate the robot when the
robot is dressed with tools, process cabling or other equipment.

Also choose this routine if the robot is wall mounted or suspended.

If calibrating the robot with reference calibration there must be reference values
created before repair is made to the robot, if values are not already available.
Creating new values requires possibility to move the robot. The reference values
contain positions of all axes, torque of axes and technical data about the tool
installed. A benefit with reference calibration is that the current state of the robot
is stored and not the state when the robot left the ABB factory. The reference value
will be named according to tool name, date etc.

Follow the instructions given in the reference calibration routine on the FlexPendant
to create reference values.

When reference calibration is performed, the robot is restored to the status given
by the reference values.

Note

When calibrating the robot with the reference calibration routine, the robot must
be dressed with the same tools, process cabling and any other equipment as
when the reference values were created.

Update revolution counters

Choose this routine to make a rough calibration of each manipulator axis by
updating the revolution counter for each axis, using the FlexPendant.

Validation

In the mentioned routines, it is also possible to validate the calibration data.

Position of robot axes

The axis chosen for calibration is automatically run by the calibration program to
its calibration position during the calibration procedure.

In order for the axis to be able to be moved to calibration position, or in order for
getting proper access to the calibration bushing, other axes might need to be
jogged to positions different from 0 degrees. Information about which axes are
allowed to be jogged will be given on the FlexPendant. These axes are marked
with

Unrestricted

in the FlexPendant window.

How to calibrate a suspended or wall mounted robot

The IRB 1600/1660ID is calibrated floor standing in factory, prior to shipping.

Continues on next page

350

Product manual - IRB 1600/1660

3HAC026660-001 Revision: W

© Copyright 2006-2018 ABB. All rights reserved.

5 Calibration

5.4.1 Description of Axis Calibration

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Summary of Contents for IRB 1660

Page 1: ...ROBOTICS Product manual IRB 1600 1660 ...

Page 2: ...Trace back information Workspace R18 2 version a18 Checked in 2018 11 20 Skribenta version 5 3 012 ...

Page 3: ... IRB 1600 7 1 45 type A IRB 1600 8 1 2 type A IRB 1600 8 1 45 type A IRB 1600 10 1 2 type A IRB 1600 10 1 45 type A IRB 1600ID 4 1 5 IRB 1600ID 4 1 5 type A IRB 1660ID 6 1 55 IRB 1660ID 4 1 55 IRC5 Document ID 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved Specifications subject to change without notice ...

Page 4: ... persons or property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission Keep for future reference Additional copies of this manual may be obtained from ABB Original instructions ...

Page 5: ...on and commissioning 49 2 1 Introduction 50 2 2 Unpacking 50 2 2 1 Pre installation procedure 55 2 2 2 Working range 61 2 2 3 Risk of tipping stability 63 2 3 On site installation 63 2 3 1 Lifting robot with roundslings 65 2 3 2 Lifting and turning a suspended mounted robot 66 2 3 3 Manually releasing the brakes 68 2 3 4 Orienting and securing the robot 72 2 3 5 Setting the system parameters for a...

Page 6: ...plete arm system 183 4 4 Upper and lower arm 183 4 4 1 Replacing the complete upper arm IRB 1600 188 4 4 2 Replacing the complete upper arm IRB 1600ID 1660ID 196 4 4 3 Replacing the complete lower arm 201 4 4 4 Replacing the wrist unit IRB 1600 206 4 4 5 Replacing the wrist unit IRB 1600ID 212 4 4 6 Replacing the wrist unit IRB1660ID 220 4 4 7 Replacing the damper axis 2 222 4 4 8 Replacing the da...

Page 7: ... 5 4 2 Calibration tools for Axis Calibration 354 5 4 3 Installation locations for the calibration tools 358 5 4 4 Axis Calibration Running the calibration procedure 366 5 5 Calibrating with Calibration Pendulum method 367 5 6 Verifying the calibration 368 5 7 Checking the synchronization position 369 6 Decommissioning 369 6 1 Environmental information 371 6 2 Scrapping of robot 373 7 Robot descri...

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Page 9: ... IRB 1600 1660ID Some variants and designs may have been removed from the business offer and are no longer available for purchase Organization of chapters The manual is organized in the following chapters Contents Chapter Safety information that must be read through before performing any installation or service work on robot Contains general safety aspects as well as more specific information on h...

Page 10: ...puter DSQC1000 3HAC050941 001 Operating manual IRC5 with FlexPendant 3HAC050944 001 Operating manual Service Information System 3HAC16578 1 Operating manual Calibration Pendulum 3HAC051016 001 Application manual Additional axes and stand alone controller 3HAC030421 001 Application manual CalibWare Field 5 0 3HAC042927 001 Technical reference manual Lubrication in gearboxes 3HAC050948 001 Technical...

Page 11: ... the robot before replacing parts on page 159 Decommissioning chapter added Updates in the chapter Safety Updated safety signal graphics for the levels Danger and Warning see Safety signals in the manual on page 40 New safety labels on the manipulators see Safety symbols on product labels on page 42 Revised terminology robot replaced with manipulator F Content updated in sections Added reference t...

Page 12: ...t numbers for axis 4 axis 5 and axis 6 motors for IRB 1600ID are corrected Added Safety risks during handling of batteries on page 37 J This revision includes the following updates Added range and capacity to the denomination of IRB 1600ID Added information about IRB 1600ID type A on first inside page and as a new section Type A of IRB 1600ID on page 374 Spare part numbers for SAMP motors and uppe...

Page 13: ...orrections M This revision includes the following updates Added instructions for measuring the play in the ID wrist see Measuring the play 1600ID 1660ID axis 5 on page233 and Meas uring the play 1600ID 1660ID axis 6 on page 236 Minor corrections N This revision includes the following updates Added a new variant IRB 1600ID 6 1 55 Updated the loads on foundation see Loads on foundation robot on page...

Page 14: ...ease R18 1 The following updates are made in this revi sion Information added about fatigue to Axis Calibration tool see Cal ibration tools for Axis Calibration on page 352 Added sections in General procedures on page 154 Safety restructured Updated spare part number brake release unit was DSQC574 is DSQC1054 Tool flange figure is updated Note added to calibration chapter to emphasize the requirem...

Page 15: ...ning Reference information safety standards unit conversions screw joints lists of tools Spare parts list with corresponding figures or references to separate spare parts lists References to circuit diagrams Technical reference manuals The technical reference manuals describe reference information for robotics products for example lubrication the RAPID language and system parameters Application ma...

Page 16: ...The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters 16 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved Product documentation Continued ...

Page 17: ...pleted with a reference to the section where the equipment is listed with further information that is article number and dimensions The designation in the procedure for the component or attachment point corresponds to the designation in the referenced list The table below shows an example of a reference to a list of required equipment from a step in a procedure Note Illustration Action Art no is s...

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Page 19: ...ied out by in experienced or non qualified personnel Foreign objects Force majeure Nation region specific regulations To protect personnel the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed To be observed by the supplier of the complete system The integrator is responsi...

Page 20: ...king in the work cell see the section Robot motion in the Product specification Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot Safe handling Users shall not be exposed to hazards including slipping tripping and falling hazards It must be possible to safely turn off tools such as milling cutters etc Make sure that g...

Page 21: ...w The protective stops and emergency stops are described in the product manual for the controller Product manual IRB 1600 1660 21 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 1 Safety 1 1 2 Protective stop and emergency stop ...

Page 22: ...shing Note Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the manipulator or controller 22 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 1 Safety 1 2 1 Fire extinguishing ...

Page 23: ...ay require using an overhead crane or similar equipment Increased injury Before releasing the brakes make sure that the weight of the robot does not increase the pressure on the trapped person further increasing any injury DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unexpected ways Make sure no personnel is near or beneath the robot Product manual...

Page 24: ...rest burn injuries or other severe injuries To avoid these personal injuries switch off the main power on the controller before proceeding work Note Switch off all main power switches in a MultiMove system 24 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 1 Safety 1 2 3 Make sure that the main power has been switched off ...

Page 25: ...ety lock Make sure that no one else can turn on the power to the controller and robot while you are working with the system A good method is to remove the power cable to the controller If the robot is installed at a height hanging or other than standing directly on the floor there may be additional risks than those for a robot standing directly on the floor Energy stored in the robot for the purpo...

Page 26: ...ifications to the robot 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 An external safety function can interact with other machines and peripheral equipment via this interface This means that control signals can act on safety signals received from the peripheral equipment as w...

Page 27: ...top equipment is cor rectly installed and connected 1 How to use the hold to run function is de scribed in section How to use the hold to run function in the Operating manual IRC5 with FlexPendant Usually the hold to run function is active only in manual full speed mode To in crease safety it is also possible to activate hold to run for manual reduced speed with a system parameter 2 The hold to ru...

Page 28: ...re it is powered up 2 Verify that any safety equipment installed to secure the position or restrict the robot motion during service activity is removed 3 Verify that the fixture and work piece are well secured if applicable 4 Install all safety equipment properly 5 Make sure all personnel are standing at a safe distance from the robot and is out of its reach behind safety fences or similar 6 If ma...

Page 29: ... USA or Canada Pay attention to the rotating axes of the robot Keep away from axes to not get entangled with hair or clothing Also be aware of any danger that may be caused by rotating tools or other devices mounted on the robot or inside the cell Keep clear of moving parts so that limbs hands or fingers do not get trapped or crushed by the robot To prevent anyone else from taking control of the r...

Page 30: ...ipulator switches to the MOTORS OFF state To ensure safe use of the teach pendant the following must be implemented The enabling device must never be rendered inoperational 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 Anyone entering the working space of the robot must always hold the teach pendant This is to preve...

Page 31: ...sks IRC5 controller A danger of high voltage is associated with for example the following parts Be aware of stored electrical energy DC link Ultracapacitor bank unit in the controller Units such as I O modules can be supplied with power from an external source The main supply main switch The transformers The power unit The control power supply 230 VAC The rectifier unit 262 400 480 VAC and 400 700...

Page 32: ...live even if the robot system is in the OFF position Power supply cables which are in motion during the working process may be damaged 32 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 1 Safety 1 3 6 Risks associated with live electric parts Continued ...

Page 33: ...raps must be tested frequently to ensure that they are not damaged and are operating cor rectly Product manual IRC5 Product manual IRC5 Compact Product manual IRC5 Panel Mounted Controller Use a wrist strap The wrist strap button is located inside the control ler 1 The mat must be grounded through a current limit ing resistor Use an ESD protective floor mat 2 The mat should provide a controlled di...

Page 34: ...ur hand at some distance to feel if heat is radiating from the potentially hot component before actually touching it Wait until the potentially hot component has cooled if it is to be removed or handled in any other way Do not put anything on hot metal surfaces e g paper or plastic 34 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 1 Safety 1 3 8 ...

Page 35: ... must be released in the complete pneumatic or hydraulic systems before starting to repair them Work on hydraulic equipment may only be performed by persons with special knowledge and experience of hydraulics All pipes hoses and connections have to be inspected regularly for leaks and damage Damage must be repaired immediately Splashed oil may cause injury or fire Safe design Gravity may cause any...

Page 36: ... described below 1 Run each robot axis to a position where the combined weight of the robot arm and any load is maximized maximum static load 2 Switch the motor to the MOTORS OFF 3 Inspect and verify that the axis maintains its position If the robot does not change position as the motors are switched off then the brake function is adequate 36 Product manual IRB 1600 1660 3HAC026660 001 Revision W ...

Page 37: ...ion fire may follow depending upon the circumstances Note Appropriate disposal regulations must be observed Safe handling Use safety glasses when handling the batteries In the event of leakage wear rubber gloves and chemical apron In the event of fire use self contained breathing apparatus Do not short circuit recharge puncture incinerate crush immerse force discharge or expose to temperatures abo...

Page 38: ...n Action Description Warning Make sure that protective gear like goggles and gloves are al ways worn during this activity Changing and draining gearbox oil or grease may require hand ling hot lubricant heated up to 90 C Hot oil or grease Make sure that protective gear like goggles and gloves are al ways worn When working with gearbox lub ricant there is a risk of an allergic reaction Allergic reac...

Page 39: ...ime to heat up the oil Warm oil drains quicker than cold oil Heat up the oil After filling verify that the level is correct The specified amount of oil or grease is based on the total volume of the gearbox When changing the lubricant the amount refilled may differ from the specified amount depending on how much has previously been drained from the gearbox Specified amount de pends on drained volum...

Page 40: ...instructions are not followed that can lead to serious injury pos sibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc WARNING Warns for electrical hazards which could result in severe personal injury or death ...

Page 41: ...onditions NOTE Describes where to find additional information or how to do an operation in an easier way TIP Product manual IRB 1600 1660 41 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 1 Safety 1 4 1 Safety signals in the manual Continued ...

Page 42: ...sh German and French Symbols on safety labels Description Symbol Warning xx0900000812 Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of cru...

Page 43: ... not disassemble xx0900000815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the robot arm can fall down Continues on next page Product manual IRB 1600 1660 43 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights ...

Page 44: ...over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page 44 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 45: ... 06 xx1300001087 Moving robot 1 2 3 4 5 6 xx0900000819 The robot can move unexpectedly xx1000001141 1 2 3 4 xx1500002616 Continues on next page Product manual IRB 1600 1660 45 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 46: ...1242 Lifting of robot xx0900000822 Oil xx0900000823 Can be used in combination with prohibition if oil is not allowed Mechanical stop xx0900000824 Continues on next page 46 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 47: ...t this part is pressurized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller Do not step xx1400002648 Warns that stepping on these parts can cause damage to the parts Product manual IRB 1600 1660 47 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Con...

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Page 49: ...mportant that all safety information is observed There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page19 before performing any installation work Note If the IRB 1600 1660ID is connected to power always make sure that the robot is connected to pr...

Page 50: ...ble to handle the weight of the robot as specified in Weight robot on page 51 5 If the robot is not installed directly it must be stored as described in Storage condi tions robot on page 53 6 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 53 7 Before taking the robot to its installation site make sure...

Page 51: ...1 Force in any direction in the XY plane Fxy Force in the Z plane Fz Bending torque in any direction in the XY plane Txy Bending torque in the Z plane Tz The table shows the various forces and torques working on the robot during different kinds of operation Note These forces and torques are extreme values that are rarely encountered during operation The values also never reach their maximum at the...

Page 52: ... foundation where the weight of the installed robot is included Note Value Requirement Flat foundations give better repeatability of the resolver calibration compared to original settings on delivery from ABB 0 5 mm Flatness of foundation surface The value for levelness aims at the circumstance of the anchoring points in the robot base In order to compensate for an uneven surface the robot can be ...

Page 53: ...ry will affect the robot and the tool accuracy The robot has resonance frequencies in the region 10 20 Hz and disturbances in this region will be amplified although somewhat damped by the servo control This might be a problem depending on the requirements from the applications If this is a problem the robot needs to be isolated from the environment Storage conditions robot The table shows the allo...

Page 54: ...tor protection type Standard IRB 1600ID IP 40 IRB 1660ID IP 40 Wrist IP 67 IP 67 Manipulator protection type Foundry Plus IP 54 Manipulator protection type Clean Room IP 67 Manipulator protection type Wash 54 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 2 1 Pre installation procedure Continued ...

Page 55: ... working range for axis 4 and axis 6 can be extended by changing parameter values in the software Option 610 1 Independent axis can be used for resetting the revolution counter after the axis has been rotated no need for rewinding the axis Range of movement IRB 1600ID Range of movement 1 5 m reach Type of motion Axis 180 to 180 i Rotation motion 1 150 to 90 Arm motion 2 79 to 238 Arm motion 3 155 ...

Page 56: ... to 45 ii rev Revolutions iii The default working range for axis 6 can be extended by changing parameter values in the software Option 610 1 Independent axis can be used for resetting the revolution counter after the axis has been rotated no need for rewinding the axis Positions at wrist center 1 2 m reach xx1000000914 Axis 3 angle de grees Axis 2 angle de grees Z mm X mm Position 0 0 962 750 0 90...

Page 57: ... 1 45 m reach xx1000000915 Axis 3 angle de grees Axis 2 angle de grees Z mm X mm Position 0 0 1187 750 0 90 0 1787 150 1 65 0 643 404 2 90 90 487 1450 3 90 150 639 800 4 245 150 478 448 5 65 90 740 6 6 Continues on next page Product manual IRB 1600 1660 57 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range Continued ...

Page 58: ...grees Axis 2 angle de grees Z mm X mm Position 0 0 1297 790 0 80 0 1836 150 1 79 0 579 380 2 80 90 487 1500 3 80 150 737 721 4 238 150 500 398 5 79 90 717 58 6 80 90 487 1200 7 Continues on next page 58 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range Continued ...

Page 59: ...6 5 828 0 81 0 1 873 3 150 1 79 0 691 7 332 2 2 81 90 486 5 1 536 8 3 81 150 714 5 843 4 4 238 150 561 7 413 9 5 79 90 723 7 94 6 6 81 90 486 5 1 236 8 7 Continues on next page Product manual IRB 1600 1660 59 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range Continued ...

Page 60: ...RB 1600 X 1 45 R1225 IRB 1600 X 1 2 180 180 R448 IRB 1600 X 1 45 R495 IRB 1600 X 1 2 R1536 8 IRB 1660ID X 1 55 R393 5 IRB 1660ID X 1 55 xx1500002817 Minimum turning radius axis 1 all models A 60 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range Continued ...

Page 61: ...ip over The shipping position is the most stable position Do not change the robot position before securing it to the foundation Shipping and transportation position This figure shows the robot in its shipping position and transportation position xx1500001247 Continues on next page Product manual IRB 1600 1660 61 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation a...

Page 62: ...ly to be mechanically unstable if not secured to the foundation 62 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 2 3 Risk of tipping stability Continued ...

Page 63: ...ndslings Attaching the roundslings xx1500001247 xx1500001248 Continues on next page Product manual IRB 1600 1660 63 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 3 1 Lifting robot with roundslings ...

Page 64: ...ely at the lifting lug in the frame and at the overhead crane 2 Capacity for the roundsling is specified in Required equipment on page 64 See attachment in Attaching the roundslings on page 63 CAUTION The robot weighs IRB 1600 IRB 1600ID 250 kg IRB 1660ID 260 kg All lifting accessories used must be sized ac cordingly 3 WARNING Personnel must not under any circumstances be present under the suspend...

Page 65: ...C037108 001 is described in the lifting instruction article number 3HAC028664 002 delivered with the turning accessory Contact ABB for more information xx1000000320 Product manual IRB 1600 1660 65 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 3 2 Lifting and turning a suspended mounted robot ...

Page 66: ...unit Note Action xx0400001255 The internal brake release unit is located at the base of the robot and equipped with six buttons for con trolling the axes brakes The buttons are numbered according to the numbers of the axes 1 DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unexpected ways Make sure no personnel is near or beneath the robot arm 2 Releas...

Page 67: ...ed to a resistor di ode and to the system board DANGER Incorrect connections such as supplying power to the wrong pin may cause all brakes to be released simultaneously 1 xx0400001302 Supply 0V on pin C10 24V on pin B8 Connect an external power supply to connect or R1 MP 2 Push the brake release button to release the holding brakes according to the previous procedure 3 Product manual IRB 1600 1660...

Page 68: ...stallation site Hole configuration base The figure shows the hole pattern and dimensions of the robot base xx0400001300 Center of axis 1 A Continues on next page 68 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 3 4 Orienting and securing the robot ...

Page 69: ...70 80 installation on foundation or base plate using guiding sleeves 30 x 17 x 3 Washers 8 8 wall or angle mounted robot Quality 12 9 Quality 200 Nm Tightening torque Guiding sleeves Use a pair of guiding sleeves to make the robot installation easier Continues on next page Product manual IRB 1600 1660 69 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commi...

Page 70: ...urface and guiding sleeve on page 69 Detailed in section Lifting robot with roundslings on page 63 Lift the robot to the installation site 3 Guide the robot gently using two of the attach ment bolts while lowering it into its mounting position 4 Specified in section Attachment bolts specification on page 69 Fit and tighten the bolts and washers in the base attachment holes 5 Isolating AW manipulat...

Page 71: ...uide sleeve E Isolator F Nut M16 G Product manual IRB 1600 1660 71 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 3 4 Orienting and securing the robot Continued ...

Page 72: ...table vibrations and deflections so that optimum performance can be achieved Note The allowed mounting positions are described in the product specification for the robot The requirements on the foundation are described in Requirements foundation on page 52 The x direction in the base coordinate system If the robot is wall mounted or mounted in a tilted position it is important that the x direction...

Page 73: ...pha must be redefined The value of Gravity Alpha should then be π 2 1 570796 The Gravity Alpha is a positive rotation direction around the x axis in the base coordinate system The value is set in radians Note The system parameter Gravity Alpha is not supported for all robot types It is not supported for IRB 140 IRB 1410 IRB 1600ID IRB 2400 IRB 4400 IRB 6400R IRB 6400 except for IRB 6400 200 2 5 an...

Page 74: ...and B is the mounting angle in radians Gravity Beta Mounting angle A Example of position 0 000000 Default 0 Floor mounted 0 523599 30º Tilted mounting 1 570796 90 Wall mounting 3 141593 180 Suspended mounting Continues on next page 74 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 3 5 Setting the system paramete...

Page 75: ...angle 30º B Wall mounted mounting angle 90º C Suspended mounting mounting angle 180º D Continues on next page Product manual IRB 1600 1660 75 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 3 5 Setting the system parameters for a suspended or tilted robot Continued ...

Page 76: ... 0 Floor mounted 1 0 785398 45 Tilted 2 1 570796 90 Wall 3 1 570796 90 Wall 4 Note For suspended robots 180 it is recommended to use Gravity Beta instead of Gravity Alpha Continues on next page 76 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 3 5 Setting the system parameters for a suspended or tilted robot Con...

Page 77: ... angle of the robot The parameters belong to the type Robot in the topic Motion How to calculate a new value is detailed in Mounting angles and values on page74 The system parameters are described in Technical reference manual System parameters The system parameters are redefined in the Configuration Editor in RobotStudio or on the FlexPendant Product manual IRB 1600 1660 77 3HAC026660 001 Revisio...

Page 78: ...bot References Load diagrams permitted extra loads equipment and their positions are specified in the product specification The loads must be defined in the software Operating manual IRC5 with FlexPendant Stopping time and braking distances The performance of the motor brake depends on if there are any loads attached to the robot For more information see product specification for the robot 78 Prod...

Page 79: ...ed load areas IRB 1600 5 kg and 7 kg C B A D E E 150 150 250 100 100 200 300 200 250 350 150 150 250 xx1000000154 Maximum load in load area Robot A B E E D C B A 15 kg 15 kg 15 kg 0 5 kg 5 kg 15 kg IRB 1600 5 X 5 kg 5 kg 15 kg 0 5 kg 5 kg 5 kg IRB 1600 7 X Continues on next page Product manual IRB 1600 1660 79 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and...

Page 80: ...5 kg 15 kg IRB 1600 6 X 5 kg 5 kg 15 kg 0 5 kg 5 kg 5 kg IRB 1600 8 X 5 kg 5 kg 15 kg 0 5 kg 5 kg 5 kg IRB 1600 10 X 15 kg 15 kg 15 kg 15 kg IRB 1600ID 4 1 5 15 kg 15 kg 10 kg 15 kg IRB 1660ID 6 1 55 15 kg 15 kg 12 kg 15 kg IRB 1660ID 4 1 55 Continues on next page 80 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning ...

Page 81: ... 132 131 3x M8 L Axis L Axis 1069 5 65 19 IRB 1600 X 1 2 IRB 1600 X 1 45 xx1000000972 R335 Minimum turning radius A Continues on next page Product manual IRB 1600 1660 81 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 3 7 Fitting equipment on the robot robot dimensions Continued ...

Page 82: ... R335 Minimum turning radius A Continues on next page 82 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 3 7 Fitting equipment on the robot robot dimensions Continued ...

Page 83: ... 19 112 3x 7 242 242 C L Axis 1 A xx1500001250 R335 Minimum turning radius A Continues on next page Product manual IRB 1600 1660 83 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 3 7 Fitting equipment on the robot robot dimensions Continued ...

Page 84: ...A 4xM8 depth 12 mounting holes for equipment B 60 52 30 25 38 A 140 75 0 3 C A B C E D xx1500003262 3xM8 depth 12 mounting holes for equipment A From center line axis 3 B From center line axis 4 C 3xM8 depth 16 mounting holes for equipment D R175 Axis 3 turning radius E Continues on next page 84 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 In...

Page 85: ...om E A 2xM5 depth 7 5 mounting holes for equipment B Design after June 2006 type A xx1500003260 View from E A 2xM6 depth 10 mounting holes for equipment B Continues on next page Product manual IRB 1600 1660 85 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 3 7 Fitting equipment on the robot robot dimensions Continued ...

Page 86: ...7 9 45 5 A A B C B A xx1000000911 R130 smallest circumscribed radius of axis 4 A 2xM8 depth 16 mounting holes for equipment B 2xM8 mounting holes for equipment C Continues on next page 86 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 3 7 Fitting equipment on the robot robot dimensions Continued ...

Page 87: ...ong IRB 1600 IRB 1600ID and IRB 1660ID are the same For holes on the lower arm see Holes for mounting of extra equipment for IRB 1600 on page 84 Continues on next page Product manual IRB 1600 1660 87 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 3 7 Fitting equipment on the robot robot dimensions Continued ...

Page 88: ...R170 4 smallest circumscribed radius of axis 4 A 2xM8 depth 16 mounting holes for equipment B 2xM8 mounting holes for equipment C Continues on next page 88 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 3 7 Fitting equipment on the robot robot dimensions Continued ...

Page 89: ... the lower arm see Holes for mounting of extra equipment for IRB 1600 on page 84 Robot tool flange 6 H9 0 030 0 4 x 9 0 R20 4x M6 Not hardened 15 6 9 0 45 A A B B C C 1 6 0 05 E C 0 3 E C D D 25 H8 0 033 0 6 0 05 A B xx1000000912 Continues on next page Product manual IRB 1600 1660 89 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 3 7 Fittin...

Page 90: ... Before mounting the tool insert the screw and measure the length of the screw sticking out behind the tool The length must not exceed 9 5mm Otherwise there is a risk that the screw damages the sealing behind the tool flange The length 9 5mm refers to the total length of the screw not just the thread length Continues on next page 90 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright ...

Page 91: ... 2003 ABB 1 2 3 4 5 6 A B C D 1 2 3 4 5 6 A B C D 1 1 Latest Revision Description Document Doc type Supplementary document ECO number 80 30 6 x 6 0 8 H7 8 6x M8 10 AY AY 0 05 D E 0 4 D E F F xx1500001254 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 Product manual IRB 160...

Page 92: ... instruction details how to install the signal lamp on IRB 1600 If installing the lamp on an IRB 1600ID or an IRB 1660ID robot see Installation of signal lamp for 1600ID 1660ID option on page 95 Location of signal lamp The signal lamp is fitted to the upper arm housing of the robot as shown in the figure below xx0400001265 Signal lamp A Cable gland C Continues on next page 92 Product manual IRB 16...

Page 93: ... on page 92 Remove the cover from the upper arm housing to get access to the connectors inside the housing 2 xx0400001264 Remove the protection plug A from the inser tion 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 3 A Plug with o ring M10 Connect the lamp connectors R3 H1 and R3 H2 and place the cables safely inside...

Page 94: ...the two mounting holes in the upper arm housing B 6 B Mounting holes M8 x 12 The signal lamp is now ready for use and is lit in MOTORS ON mode 7 94 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 3 8 Installation of signal lamp for 1600 option Continued ...

Page 95: ...ean Room environment Location of signal lamp The signal lamp is fitted to the upper arm housing of the robot as shown in the figure below xx0700000100 Signal lamp A Cover upper arm housing B Required equipment Note Art no Equipment 3HAC9258 1 Signal lamp Diameter 22 5 mm Drill Continues on next page Product manual IRB 1600 1660 95 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserv...

Page 96: ...rm housing 2 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 3 Fit the lamp and tighten the nut 4 In the upper arm housing find the two cables marked R3 H1 and R3 H2 and connect them with the lamp 5 Refit the cover on the upper arm housing 6 The signal lamp is now ready for use and is lit in MOTORS ON mode 7 96 Product manual ...

Page 97: ...Hex socket head cap screw M8x12 F Fitting the wire feeder shelf Note Action Shown in figure Location of shelf wire feeder on page 97 Fit the Shelf wire feeder B using the four 4 Hex socket head cap screw F 1 Continues on next page Product manual IRB 1600 1660 97 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 3 10 Installation of the wire fe...

Page 98: ...th flange M5 B Knob Fit the wire feeder with the mounted bracket on the Shelf wire feeder and mount the two knobs 3 98 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 3 10 Installation of the wire feeder shelf for 1600ID 1660ID Continued ...

Page 99: ...cal stop and position switch and software Axis 2 hardware mechanical stop and software Axis 3 hardware mechanical stop and software This section describes how to install hardware that restricts the working range Note Adjustments must also be made in the robot configuration software system parameters References to relevant manuals are included in the installation procedures Product manual IRB 1600 ...

Page 100: ...e 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 1 6 8 º 1 6 8 º 64º 64º A A B B xx0400001286 Mounting position of two additional stops for maximum working area 168º A Mounting position of two additional stops for minimum working area 64º B ...

Page 101: ... positive direction for example from 0º and upwards to 90º b The stop pin does not manage the extra gravity force that comes from when axis 1 moves in a negative direction for example from 180º downwards to 90º a a a b b xx1300000180 The additional stop pin does not manage the extra gravity force in this restricted working area for tilted or wall mounted robots a The additional stop pin manages to...

Page 102: ...on mechanical stop axis 1 The additional mechanical stop of axis 1 is fitted to the base of the robot as shown in the figure below xx0400001287 Mechanical stop axis 1 additional A Attachment bolts and washers mechanical stop B Continues on next page 102 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 4 2 Installa...

Page 103: ...hrough 10 2 mm If drilling in a stiffening rib drill depth must be min 30 mm Cut the threads M12 4 If cutting in a stiffening rib thread depth must be min 23 mm Fit the stop to the base without tightening the bolts 5 How to release the holding brake of the axis motor is detailed in section Manually releasing the brakes on page 66 Turn axis 1 manually and check the working area between the stops 6 ...

Page 104: ...ovable stops and or additional stops as well as deformed attachment screws must also be replaced after a hard collision 9 104 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 4 2 Installation of additional mechanical stops on axis 1 Continued ...

Page 105: ...is 2 can be restricted by fitting an additional mechanical stop at the frame The working range can only be restricted backwards as shown in the figures below Notice the different working ranges for the different models xx0400001289 Continues on next page Product manual IRB 1600 1660 105 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 4 3 Ins...

Page 106: ... Mechanical stop axis 2 A Attachment bolts mechanical stop 2 pcs B Attachment holes mechanical stop C Damper axis 2 D Washer E Attachment screw damper F Continues on next page 106 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 4 3 Installation of additional mechanical stop on axis 2 Continued ...

Page 107: ... axis 2 on page 106 Fit the mechanical stop to the frame without tightening the bolts 2 xx0400001292 Make sure that the stop is in contact with the lower boss on the gearbox as the arrow shows in the figure to the right 3 Note It is important that the mech anical stop is fitted in contact with the lower boss on the gearbox 2 pcs M8 x 35 tightening torque 25 Nm Tighten the attachment bolts 4 Shown ...

Page 108: ...nd to the mechanical limitations 6 WARNING If the mechanical stop pin is deformed after a hard collision it must be replaced Deformed movable stops and or additional stops as well as deformed attachment screws must also be replaced after a hard collision 7 108 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 4 3 I...

Page 109: ... 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 Working range A A Working range B B Continues on next page Product manual IRB 1600 1660 109 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 4 4 Installati...

Page 110: ...nge A A Working range B B Continues on next page 110 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 4 4 Installation of additional mechanical stops on axis 3 Continued ...

Page 111: ...o Equipment Includes mechanical stop at tachment screws and washers 3HAC026121 001 Working range limit axis 3 Art no is specified in Refer ences on page 10 Technical reference manual System parameters Continues on next page Product manual IRB 1600 1660 111 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 4 4 Installation of additional mechani...

Page 112: ...The system parameters that must be changed Upper joint bound and Lower joint bound are described in Technical reference manual Sys tem parameters Adjust the software working range limitations system parameter configuration to correspond to the mechanical limitations 3 WARNING If the mechanical stop pin is deformed after a hard collision it must be replaced Deformed movable stops and or additional ...

Page 113: ...Position switch A Attachment screws position switch 2 pcs M6 x 30 B Holder ring 2 parts C Attachment screws holder ring 6 pcs M8 x 12 D Cam E Bracket F Attachment screws housing 2 pcs M6 x 8 G Cable straps H Attachment screws attachment plate 2 pcs M6 x 16 I Continues on next page Product manual IRB 1600 1660 113 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation ...

Page 114: ...tion switch axis 1 on page 113 Fit the two holder rings underneath the frame with the six attachment screws 2 6 pcs M8 x 12 Cut the cams according to instructions enclosed with the position switch kit 3 Shown in the figure Location of position switch axis 1 on page 113 Fit the cams to the holder ring with the attachment screws 4 M6 x 12 2 pcs M6 x 30 Attach the position switch to the bracket with ...

Page 115: ...e the housing with cable straps 8 The cabling and connection points are specified in section Position switch cables robot base to controller option on page121 Connect the position switch cabling 9 The system parameters that must be changed Upper joint bound and Lower joint bound are described in Technical reference manual System parameters Adjust the software working range limita tions system para...

Page 116: ...ed cabling for signals and power The 7 axis connection Note No customer application connections are available for IRB 1660ID Connections at robot base The graphics below show the customer connections on the robot base For description of all connection types see Connection table on page 117 xx1000000918 xx1000000919 Continues on next page 116 Product manual IRB 1600 1660 3HAC026660 001 Revision W C...

Page 117: ...mer signal R 1 CP CS D Standard air R 1Air E Customer signal for integrated wirefeed interface R1 CS F Customer power for integrated wirefeed interface R1 CP G Axis 7 connection 1 5 m cable R1 FB7 H Continues on next page Product manual IRB 1600 1660 117 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 1 Customer connectors on the robot Con...

Page 118: ...R2 CS B Standard air R2 Air C Customer power for integrated wirefeed interface R2 CP D Customer signal for integrated wirefeed interface R2 CS E 118 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 1 Customer connectors on the robot Continued ...

Page 119: ...ge 10 Also specified in the table Customer cables option on page 121 Handles power supply to and control of the external axes motors as well as feedback from the servo system External axes cables option See the Application manual Additional axes and stand alone controller M2004 see document number in Refer ences on page 10 Robot cables These cables are included in the standard delivery They are co...

Page 120: ...530 1 Robot cable signal shielded 15 m 3HAC2540 1 Robot cable signal shielded 22 m 3HAC2566 1 Robot cable signal shielded 30 m Bending radius for static floor cables The minimum bending radius is 10 times the cable diameter for static floor cables A B xx1600002016 Diameter A Diameter x10 B Continues on next page 120 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All...

Page 121: ...ble axis 1 30 m Customer cables option The customer cables specified below are connected between robot and controller The customer cables are ordered according to current protection class of the robot Customer cables for robots with standard protection Connection point robot Art no Cable standard R1 CP CS 3HAC3353 1 Customer cable power signal 7 m R1 CP CS 3HAC3354 1 Customer cable power signal 15...

Page 122: ...nal 7 m R1 CP CS 3HAC8183 2 Customer cable power signal 15 m R1 CP CS 3HAC8183 3 Customer cable power signal 22 m R1 CP CS 3HAC8183 4 Customer cable power signal 30 m 122 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 2 Robot cabling and connection points Continued ...

Page 123: ...er diameter 0 8 MPa 115 psi 8 mm Customer connectors R2 CS and R2 CP The customer connectors R2 CS and R2 CP can be used with either a connector set from ABB for standard connection specified connector components from Souriau or connectors that meet Military standard MIL C 26482 series 1 These connectors are further detailed in following sections Connector set from ABB for standard connection Note...

Page 124: ...t no Pin diameter Turned pins for cable area RM18W3K 1 mm 0 21 0 93 mm2 standard connection CP CS and integrated wirefeeder cabling CS RM24M9K 1 6 mm 0 13 0 25 mm2 integrated wirefeeder cabling CP RM20M12K 1 6 mm 0 25 0 5 mm2 integrated wirefeeder cabling CP RM16M23K 1 6 mm 0 5 1 5 mm2 integrated wirefeeder cabling CP Recommended backshell Souriau art no Backshell UT0 16JC Backshell standard conne...

Page 125: ...rd MIL C 26482 Connector for crimping MS3126 1626S Complete pin connector CS MS3126 1210S Complete pin connector CP M39029 31 240 Turned pin 0 2 0 5 mm2 M29029 31 228 Turned pin 0 5 1 5 mm2 Connector for soldering The complete pin connectors for soldering include pin connector backshell and pins Military standard MIL C 26482 Connector for soldering MS3116 1626S Complete pin connector CS MS3116 121...

Page 126: ...ulated with the RAPID instruction VelSet Start the robot with its normal program but with reduced speed 1 Adjusting the speed and acceleration during warm up Depending on how cold the environment is and what program is being used the speed might need to be ramped up until reached maximum The table shows examples of how to adjust the speed Speed velocity AccSet Work cycles v100 100 mm s 20 20 3 Wor...

Page 127: ...ns and divided according to the maintenance activity Safety information Observe all safety information before conducting any service work There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page 19 before performing any service work Note If the IRB...

Page 128: ...g or not Operating time specified in operating hours More frequent running means more frequent maintenance activities SIS specified by the robot s SIS Service Information System A typical value is given for a typical work cycle but the value will differ depending on how hard each part is run The SIS used in M2004 is further described in the Operating manual Service Information System 128 Product m...

Page 129: ...IRB 1660ID X 1 55 Changing Replacing the battery pack on page 144 36 months or bat tery low alert i Battery pack measurement system of type RMU101 or RMU102 3 pole battery contact Replacement Replacing the battery pack on page 144 Battery low alert ii Battery pack measurement system with 2 pole battery contact e g DSQC633A Replacement Cleaning the IRB 1600 1660ID on page149 Regulariii Complete rob...

Page 130: ...ation cycle of the robot its working environment and movement pattern Generally the more contaminated environment the closer the intervals The more demanding movement pattern sharper bending cable harness the closer the intervals 130 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 3 Maintenance 3 2 2 Maintenance schedule Continued ...

Page 131: ...notei 2 000 000 cycles Cabling for position switch 40 000 hrs Gearbox i The expected life can also be affected by grouping harnesses cables other than standard options The life expectancy is based on a test cycle that for every axis goes from the calibration position to minimum angle to maximum angle and back to the calibration position Deviations from this test cycle will result in differences in...

Page 132: ...igure below shows the location of all the dampers to be inspected xx0400001217 Damper axis 2 A Attachment screw B Continues on next page 132 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 3 Maintenance 3 3 1 Inspection damper axes 2 3 and 5 ...

Page 133: ...t tab B xx0600002806 Damper axis 5 A Recess B Continues on next page Product manual IRB 1600 1660 133 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 3 Maintenance 3 3 1 Inspection damper axes 2 3 and 5 Continued ...

Page 134: ...re supply to the robot before entering the robot working area 1 Shown in the figure Location of dampers on page 132 Check all dampers for damage such as cracks or existing impressions that are larger than 1 mm 2 Check attachment screws for deformation 3 Replacement is detailed in sec tions Replacing the damper axis 2 on page 220 Replacing the damper axis 3 on page 222 Replacement of damper axis 5 ...

Page 135: ... 55 IRB 1660ID 4 1 55 IRB 1660ID 6 1 55 IRB 1660ID 4 1 55 B J M C C A G G G G G G G G A A A A A A F A A D H L D K E xx1800001187 ABB logotype A Warning label Brake release B Warning label heat 2 pcs C Rating label D Calibration label E Foundry Plus or CleanRoom logotype if applicable F Warning label Electricity symbol of flash 6 pcs G UL label H Label Max air pressure J Information sign AbsAcc K L...

Page 136: ...tric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 1 See the figure in Location of information labels on page 135 Check all labels 2 Replace any missing or damaged labels 3 136 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 3 Maintenance 3 3 2 Inspecting information labels Continue...

Page 137: ...tact the local ABB Service organization for more information For ABB personnel Always check ABB Library for the latest revision of the manual Technical reference manual Lubrication in gearboxes in order to always get the latest information of updates about lubrication in gearboxes A new revision will be published on ABB Library immediately after updates Location of gearboxes The figure shows the l...

Page 138: ...ent to take the complete amount of oil Oil collecting vessel Content is defined in section Standard tools on page 383 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these pro cedures in the step by step instruc tions below CAUTION Always cut the paint with a knife and grind the paint edge when disassembling pa...

Page 139: ... oil xx0500001434 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 3 A Oil plug draining and filling The position for an inverted robot is the opposite Shown in the figure Location of oil...

Page 140: ...igure Location of oil plugs on page 138 Remove the oil plug draining and filling 3 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 137 xx0500001435 Position the robot as shown in the figure to the right upper arm downwards for a standing robot axis 4 90º to a position where the oil plug A faces upwards Fill oil in the wrist unit through the oil...

Page 141: ...and amount of oil in gearboxes on page 137 The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel Content is defined in section Standard tools on page 383 Standard toolkit See references to these procedures in the step by step instructions below Other tools and procedures may be required CAUTION Always cut the paint with a knife and grind the paint e...

Page 142: ...t as shown in the fig ure to the right upper arm upwards for a stand ing robot axis 4 90º to a position where the oil plug A is faced down wards Note The total amount of oil will not be drained There will remain approxim ately 20 ml in the wrist unit 3 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the excess pressure 4 S...

Page 143: ...ion xx0700000034 Position the robot as shown in the figure to the right axis 4 90º to a position where the oil plug A is faced upwards 1 A Oil plugs Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 137 Fill new oil in the wrist Check the oil level to make sure the filled amount of oil is correct 2 Tightening torque 3 Nm Refit the oil plug and th...

Page 144: ...bot is powered off 2 days week or 18 months if the robot is powered off 16 h day The lifetime can be extended for longer production breaks with a battery shutdown service routine See Operating manual IRC5 with FlexPendant for instructions WARNING See instructions for batteries Safety risks during handling of batteries on page37 Location of battery pack The battery pack for the measurement system i...

Page 145: ...hown in the figure below DSQC 633A xx0500001393 Battery pack battery 2 pole battery contact A Velcro strap B Connector X3 C Continues on next page Product manual IRB 1600 1660 145 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 3 Maintenance 3 4 4 Replacing the battery pack Continued ...

Page 146: ... lifetime for the battery It is important that the SMB unit uses the correct battery Make sure to order the correct spare parts Do not replace the battery contact Note Spare part no Equipment See Spare part lists on page 387 Serial measurement board See Spare part lists on page 387 Battery pack Replace if damaged 3HAC 022047 001 Gasket base cover Continues on next page 146 Product manual IRB 1600 ...

Page 147: ...ON Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures 2 CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page 159 Disconnect the battery from the serial meas urement unit 3 Valid for battery pack with 2 pol...

Page 148: ...ecified in Required equipment on page 146 Check the base cover gasket replace if dam aged 9 See Location of battery pack on page 144 Refit the base cover to the robot 10 Detailed in section Updating revolution counters on page 345 Update the revolution counters 11 148 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 3 Maintenance 3 4 4 Replacing th...

Page 149: ...tion activities on page 132 2 Write down the oil level 3 Inspect the oil level again after for example 6 months 4 If the oil level is decreased then replace the gearbox Special cleaning considerations This section specifies some special considerations when cleaning the robot Always use cleaning equipment as specified Any other cleaning equipment may shorten the life of the robot Always check that ...

Page 150: ...gent or spirit Yes Wash It is highly recommended that the water and steam contains rust preventive without cleaning deter gents No No Yes With light cleaning deter gent spirit or isopropyl alco hol Yes Clean room i Perform according to section Cleaning with water and steam on page 150 ii Perform according to section Cleaning with water and steam on page 150 Cleaning with water and steam Instructio...

Page 151: ...n 45 spread Minimum distance from nozzle to encapsulation 0 4 meters Maximum water temperature 80 C Cables Movable cables need to be able to move freely Remove waste material such as sand dust and chips if it prevents cable movement Clean the cables if they have a crusty surface for example from dry release agents 2 See Cleaning methods on page 150 for exceptions Product manual IRB 1600 1660 151 3...

Page 152: ...This page is intentionally left blank ...

Page 153: ...m a specific repair activity are listed in the respective procedures The details of equipment are also available in different lists in the chapter Reference information on page 375 Safety information There are general safety information and specific safety information The specific safety information describes the danger and safety risks while performing specific steps in a procedure Make sure to r...

Page 154: ... pressure must under no circumstance be higher than 0 25 bar 20 25 kPa Also during the time when the pressure is raised 3 0 2 0 25 bar 20 25 kPa Disconnect the compressed air supply 4 If the compressed air is signific antly colder or warmer than the gearbox to be tested a slight pressure increase or decrease may occur This is quite normal Wait for approximately 8 10 minutes and make sure that no p...

Page 155: ...ny stresses during the assembly work 3 Assembly of tapered bearings Follow the preceding instructions for the assembly of the bearings when mounting a tapered bearing on the robot In addition to those instructions the following procedure must be carried out to enable the roller elements to adjust to the correct position against the race flange Note Action Tension the bearing gradually until the re...

Page 156: ...ted During operation the bearing should be filled to 70 80 of the available volume Ensure that grease is handled and stored properly to avoid contamination Grease the different types of bearings as following description Grooved ball bearings must be filled with grease from both sides Tapered roller bearings and axial needle bearings must be greased in the split condition 156 Product manual IRB 160...

Page 157: ...rrect type provided with cutting edge There is no damage to the sealing edge feel with a fingernail 1 Inspect the sealing surface before mounting If scratches or damage are found the seal must be replaced since it may result in future leakage 2 Article number is specified in Equipment on page157 Lubricate the seal with grease just before fitting Not too early there is a risk of dirt and foreign pa...

Page 158: ... when fastening the flange joint 4 O rings The following procedure describes how to fit o rings Note Action Ensure that the correct o ring size is used 1 Defective o rings including damaged or deformed o rings may not be used Check the o ring for surface defects burrs shape accuracy or deformation 2 Defective o rings may not be used Check the o ring grooves 3 The grooves must be geometrically corr...

Page 159: ...agent Knife Lint free cloth 3HAC036639 001 Touch up paint Clean Room White 3HAC037052 001 Touch up paint Standard Foundry Plus ABB Orange Removing Description Action xx0900000121 Cut the paint with a knife in the joint between the part that will be removed and the struc ture to avoid that the paint cracks 1 Carefully grind the paint edge that is left on the structure to a smooth surface 2 Refittin...

Page 160: ...e Touch up paint Clean Room white to paint the joint Note Always read the instruction in the product data sheet in the paint repair kit for Clean Room 6 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth 160 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 2 4 Cut the paint or surface on the ro...

Page 161: ...ify that the push buttons of the brake re lease unit are working by pressing them down one by one 3 Make sure none of the buttons are jammed by the push button guard xx0600002777 If a button gets jammed in the depressed po sition the alignment of the push button unit must be adjusted so that the buttons can move freely Remove the push button guard and Make sure the centering piece B is properly fi...

Page 162: ...HAC022049 001 Gasket upper arm cover Replace if damaged 3HAC022050 001 Gasket customer connections Replace if damaged 3HAC 022047 001 Gasket base cover Replace if damaged 3HAC022048 001 Gasket gearbox axis 1 2 Upper and lower covers 3HAA 2166 23 VK cover 2 pcs Middle cover 3HAA 2166 21 VK cover Cable ties Fitted to the push button unit in order to align it correctly 3HAC025815 001 Centering piece ...

Page 163: ...ackets xx0400001248 Upper and lower VK cover A Arm housing cover with gaskets B VK cover also shown with the cover removed C Cover frame with gasket D Base cover with gasket E Continues on next page Product manual IRB 1600 1660 163 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 3 1 Replacing the cable harness IRB 1600 Continued ...

Page 164: ...lues requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 350 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be c...

Page 165: ...ng on page 166 Remove all cable ties clamps and brackets inside the upper arm housing 6 Shown in the figure Illustration cabling inside frame on page 168 Disconnect all the connectors inside the frame 7 Attachment points inside the frame are shown in the figure Illustration cabling inside frame on page 168 Remove the fastening plate all cable ties and brackets from inside the frame Remove the cabl...

Page 166: ... MP4 R3 MP5 and R3 MP6 B Optional connector R2 CP C Optional connector R2 CS D Distance console with contact panel E Cable clamp unit F Attachment screws cable clamp unit 2 pcs only one shown G Clamp signal cabling H Clamp motor cabling I Connector plate J Connector holder K Cable tie connector holder L Continues on next page 166 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 200...

Page 167: ...he cabling inside the upper arm housing by fitting the cable clamp unit to the distance console with two attachment screws 4 Hexagon nut M5 1 pc for each clamp Fit the motor and signal cabling to the connector plate with clamps 5 Shown in the figure Illustration cabling inside upper arm housing on page 166 Reconnect the signal cable connectors and slide them into the connector holder Notice that o...

Page 168: ...ocedure Refitting cable harness in frame and base on page 170 12 Illustration cabling inside frame The figure below shows how the cabling is run inside the frame xx0400001249 Power cabling connectors for motors on axes 1 and 2 R3 MP1 and R3 MP2 A Signal cabling connectors for motors on axes 1 and 2 R3 FB1 and R3 FB2 B Cable clamp unit attachment screws behind the fastening plate C Fastening plate ...

Page 169: ...xx0500001388 Power cabling A Signal cabling B Clamp with hexagon nut C Attachment screws cable clamp unit D Hexagon nut SMB plate E Fastening plate F SMB unit G Cable clamp unit H Continues on next page Product manual IRB 1600 1660 169 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 3 1 Replacing the cable harness IRB 1600 Continued ...

Page 170: ...and nuts 5 Shown in the figure Illustration cabling inside base on page 169 In the base secure the cabling to the bottom fastening plate fit the cable clamp unit with two attach ment screws M6 fit the separate cables with clamps and hexagon nuts 6 Shown in the figure Illustration cabling inside base on page 169 Refit the SMB unit to the fastening plate with hexagon nuts 7 xx0600002777 Refit the ce...

Page 171: ...s if damaged 12 Spare part no is specified in Required equipment on page 162 Pendulum Calibration is described in Operating manual Calibration Pendu lum enclosed with the calibration tools Recalibrate the robot 13 Axis Calibration is described in Calib rating with Axis Calibration method on page 349 General calibration information is in cluded in section Calibration on page 337 Product manual IRB ...

Page 172: ...B5 R4 MP5 R4 MP6 R3 FB3 R3 FB4 R3 FB5 R3 FB6 R3 MP3 R3 MP4 R3 MP5 R3 MP6 xx0700000038 R4 FB6 A R4 FB5 B R4 MP6 E R4 MP5 F Required equipment Note Spare part no Equipment Standard tools on page 383 Standard toolkit Continues on next page 172 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 3 2 Replacing the cable harness 1600ID 1660ID ...

Page 173: ...ion All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is compl...

Page 174: ...e to use and take actions accordingly prior to begin ning the repair procedure 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Remove the cover to the upper arm 3 Continues on next page 174 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 3 2 ...

Page 175: ...e harness IRB 1600 on page 162 Remove the cable harness from the lower arm 7 Removal cable harness upper arm tube The procedure below describes removal of the complete cable harness in upper arm tube xx0700000099 Cover plate A Continues on next page Product manual IRB 1600 1660 175 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 3 2 Replacing the cable harness 1600...

Page 176: ...0ID Replacement of motor axis 5 IRB 1600ID on page 294 IRB 1660ID Replacement of motor axis 5 IRB 1660ID on page 302 Remove the upper arm tube 2 xx0700000113 Remove all the Torx pan head screw A holding the cover 3 A Torx pan head screw M6x12 B Hexagon nut with flange M5 Continues on next page 176 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 ...

Page 177: ...the cable harness 1 Described in section Refitting motor axis 5 on page299 Refit the upper arm tube 2 Shown in figure Location of the harness on page 172 Refit the connections in the upper arm 3 Pendulum Calibration is described in Operating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 4 Axis Calibration is described in Calibrating with Axis Calibration met...

Page 178: ...ment Note Art no Equipment Lifting slings 3HAA 2166 23 VK cover Replace if damaged 3HAB3732 13 Sealing ring V ring Used to clean the mating surfaces Isopropanol Loctite 574 Locking liquid Content is defined in section Standard tools on page 383 Standard toolkit Continues on next page 178 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 3...

Page 179: ...ot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 350 If no previ...

Page 180: ...he VK cover from inside of the frame 6 CAUTION The complete arm system weighs 55 kg All lifting accessories used must be sized ac cordingly 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 9 Be careful when pulling the cabling through base frame and lower arm Use tape to bunch the connectors and prote...

Page 181: ...t holes at the mating surface on the frame with Loctite 574 4 CAUTION The complete arm system weighs 55 kg All lifting accessories used must be sized accord ingly 5 Fit the lifting slings to the complete arm system and lift it into position while inserting the cabling into the frame 6 12 pcs M10 x 40 tightening torque 70 Nm Fit the lower arm against the frame fit the one washer and secure with the...

Page 182: ... on page 349 General calibration information is included in section Calibration on page 337 DANGER Make sure all safety requirements are met when performing the first test run These are further de tailed in the section First test run may cause injury or damage on page 28 11 182 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 3 3 Replace...

Page 183: ...ome of the upper arm components A more detailed view of the upper arm may be found in the spare part view see Spare parts Upper arm exploded view xx0400001218 Arm housing cover including gaskets for the cover and the contact panel A VK cover Upper arm attachment screws inside B Continues on next page Product manual IRB 1600 1660 183 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights rese...

Page 184: ...ls and proced ures may be required See references to these procedures in the step by step instructions be low CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page159 Deciding calibration routine Decide which calibration routine to be used based on the information in the table Depending o...

Page 185: ...ction Decide which calibration routine to use and take actions accordingly prior to beginning the repair procedure 1 Move the upper arm to a horizontal position 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 Shown in the figure Location of upper arm on page 183 Remove the arm housing cover from the upp...

Page 186: ...urfaces clean on both the upper and lower arm 2 CAUTION The complete upper arm weighs 55 kg without any additional equipment fitted All lifting accessories used must be sized ac cordingly 3 Attach lifting slings to the upper arm and lift it 4 xx0400001220 Lubricate the sealing ring A with grease and fit it to the upper arm Replace the sealing ring if damaged 5 A Sealing ring spare part no is speci...

Page 187: ...lace them if damaged 10 Spare part no is specified in section Required equipment on page 184 Shown in the figure Location of upper arm on page 183 Refit a new VK cover to the lower arm 11 Spare part no is specified in section Required equipment on page 184 Pendulum Calibration is described in Operating manual Calibration Pen dulum enclosed with the calibration tools Recalibrate the robot 12 Axis C...

Page 188: ...d 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 VK Cover A Socket head cap screw M10x40 B Cable harness C V ring D Continues on next page 188 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 4 2 Replacing the complete upper arm IRB 1600I...

Page 189: ...ernal cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for ca...

Page 190: ...nchronization mark Axis 3 Put the robot in synchronization position for Axis 3 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 3 Continues on next page 190 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 4 2 Replacing the complete upper arm IR...

Page 191: ...l connectors inside the arm house and loosen the cabling from straps and brackets 5 CAUTION The robot upper arm weighs 39 kg All lifting accessories used must be sized accordingly 6 Continues on next page Product manual IRB 1600 1660 191 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 4 2 Replacing the complete upper arm IRB 1600ID 1660ID Continued ...

Page 192: ...e 8 xx0700000057 Remove the 10 attachment screws A and the single washer use standard tools 9 A Socket head cap screw M10x40 Carefully lift away the upper arm and put it somewhere safe 10 Continues on next page 192 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 4 2 Replacing the complete upper arm IRB 1600ID 1660ID Continued ...

Page 193: ...ft it 2 A xx0700000076 Clean the contact surface 3 A Contact surface xx0700000075 Carefully refit the upper arm to the lower arm making sure that the new upper arm is mounted in the synchronization position 4 A Synchronization mark Axis 3 Continues on next page Product manual IRB 1600 1660 193 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 4 2 Replacing the comple...

Page 194: ...ing with brackets and straps 7 xx0700000077 A Cover Arm Housing B Torx pan head screw Refit the cover arm housing to the upper arm Standard tools on page 383 8 Spare part no is specified in Required equipment on page 189 Refit a new VK cover to the lower arm replace it if damaged 9 Continues on next page 194 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights ...

Page 195: ...eneral calibration information is in cluded in section Calibration on page 337 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 28 11 Product manual IRB 1600 1660 195 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 4 2 Replacing the complet...

Page 196: ... Lower arm exploded view xx0400001246 Lower arm A VK cover B VK cover middle C Required equipment Note Art no Equipment See Spare part lists on page 387 Lower arm 3HAA2166 23 VK cover In the middle of the lower arm 3HAA2166 21 VK cover Continues on next page 196 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 4 3 Replacing the complete ...

Page 197: ... on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the...

Page 198: ...he right shows the space under neath the cover The gray areas are safe for insertion of a tool that may be inserted with a maximum depth of 20 mm 4 Pull down the cabling through the lower arm and pull it out 5 CAUTION The robot lower arm weighs 20 kg All lifting accessories used must be sized accordingly 6 Fit the lifting device to the lower arm to se cure the weight of the arm 7 Unscrew the 12 at...

Page 199: ...lower arm and lift it into position 5 Insert the cabling into the lower arm 6 12 pcs M10 x 40 tightening torque 70 Nm Fit the lower arm against the frame fit the washer and secure with the 12 attachment screws 7 Push the cabling up through the lower arm and place the cable bracket inside the lower arm correctly 8 Spare part no is specified in Required equipment on page 196 Fit new VK covers to the...

Page 200: ...age 349 General calibration information is included in section Calibration on page 337 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 28 12 200 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 4 3 Replacing the...

Page 201: ...rd and Foundry versions 3HAC027003 001 Wrist Stand ard Foundry O ring sealing plate not in cluded Note The wrist stand ard Foundry is not interchange able with art no 3HAC 10475 1 Must be replaced 3HAC025420 001 O ring sealing plate Note The o ring sealing plate is not interchangeable with art no 3HAC 7191 1 For lubricating the o ring sealing plate 3HAC 3537 1 Grease Content is defined in section ...

Page 202: ...dant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference c...

Page 203: ...nit on page 201 Remove the wrist unit by unscrewing its three attachment screws 5 Refitting wrist unit The procedure below details how to refit the complete wrist unit Note Action Clean the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 159 1 Move the robot to a position where the upper arm is vertical 2 DANGER Turn off all electric power supp...

Page 204: ... ively 5 Verify that the parallel pin sticks out from the wrist according to the measurement given below 6 0 5 xx1700000119 Art no is specified in section Required equipment on page 201 Lightly lubricate the o ring sealingplate with grease 6 Connect to connector R3 MP5 or 6 pin 7 pin 8 In order to release the brake connect the 24 VDC power supply to motors 7 Use a new o ring Spare part no is speci...

Page 205: ...m Calibration is described in Oper ating manual Calibration Pendulum en closed with the calibration tools Recalibrate the robot 12 Axis Calibration is described in Calibrating with Axis Calibration method on page 349 General calibration information is included in section Calibration on page 337 DANGER Make sure all safety requirements are met when performing the first test run These are further de...

Page 206: ...pper arm A Wrist B Motor axis 6 C Hexagon socket head screw M5x25 D Hexagon socket head screw M5X16 10 9 Short head E Hexagon socket head screw M5x25 F Hexagon socket head screw M8x35 G Required equipment Note Art No Equipment See Spare part lists on page 387 Wrist ID O ring Continues on next page 206 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserve...

Page 207: ...fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used aft...

Page 208: ... upper arm and wrist 3 xx0700000092 The plug A in figure covering the screw C Remove the plug using standard tools B Remove the screw for looking of motor axis 5 C in figure Location of wrist unit on page 206 4 A Plug B Standard tool Standard tools on page 383 C Hexagon socket head screw M5X16 Short head xx0700000054 A VK Cover Remove the VK Cover 5 Gently pull the cables out through the hole for ...

Page 209: ... 8 8 A2F 3 pcs Remove the wrist with motor 6 from the upper arm tube and put it on a work bench or simil ar CAUTION Be careful when handling the wrist Always hold on the casting do not hold on the wrist cover This can damage the sealing which will cause oil leakage 9 Continues on next page Product manual IRB 1600 1660 209 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repa...

Page 210: ...d motor and scrap it The new console shall be fitted to the axis 6 motor See 1 A Hex socket head cap screw M5x25 B Motor Console Apply a string or similar to the cable harness and run it out through the hole for the VK cover 2 xx0700000093 Carefully fit the wrist with motor axis 6 fitted to the upper arm tube using the string to pull the cable harness back through the hole for the VK cover 3 A Str...

Page 211: ... VK cover 7 xx0700000092 Tightening the plug A Tightening torque 6 Nm 8 Shown in Refitting the wrist unit on page 210 Refit the AW equipment in the upper arm 9 Pendulum Calibration is described in Operating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 10 Axis Calibration is described in Calibrat ing with Axis Calibration method on page 349 General calibrati...

Page 212: ...8 VK cover Loctite 574 Locking liquid Content is defined in section Standard tools on page 383 Standard toolkit These procedures include references to the tools re quired Other tools and procedures may be required See refer ences to these procedures in the step by step instructions below CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint o...

Page 213: ...o move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 350 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be calibrated with fine calibra...

Page 214: ... side facing the wrist 6 A Coupling B Attachment screw A xx1000000875 Remove the attachment screws securing the wrist 7 A Attachment screws 4 pcs Continues on next page 214 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 4 6 Replacing the wrist unit IRB1660ID Continued ...

Page 215: ... the wrist C Division point D Upper arm tube xx1500001259 Pull carefully out the wrist a little to reach the motor cables to motor axis 6 Note The wrist is fitted on cylindrical pins 9 xx1500003257 Fit two short screws in the holes for the at tachment screws to temporarily secure the cover 10 A Short screws 2 pcs B Cover Continues on next page Product manual IRB 1600 1660 215 3HAC026660 001 Revisi...

Page 216: ...tion Clean all assembly surfaces 1 Remove any painting from the assembly surfaces with a knife For details see Replacement of motor axis 6 IRB 1660ID on page 319 Refit motor axis 6 to the wrist 2 Place the wrist with motor axis 6 fitted a little into the upper arm tube 3 R4 MP6 R4 FB6 xx1400002575 Reconnect the cables R4 MP6 and R4 FB6 to motor axis 6 4 Continues on next page 216 Product manual IR...

Page 217: ...he locking liquid is specified in Required equipment on page 212 xx1200000063 Apply locking liquid to the assembly surface on the upper arm tube 6 Continues on next page Product manual IRB 1600 1660 217 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 4 6 Replacing the wrist unit IRB1660ID Continued ...

Page 218: ...ng torque 35 Nm A xx1000000875 Secure the wrist with its attachment screws and washers 8 A Attachment screws 4 pcs Tightening torque 14 Nm Secure the flexible coupling axis 5 with its attachment screw 9 Article number is specified in Required equipment on page 212 xx1000000873 Fit a new VK cover 10 Continues on next page 218 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 201...

Page 219: ...n page349 General calibration information is included in section Calibration on page 337 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page28 12 Product manual IRB 1600 1660 219 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 4 6 Replacing th...

Page 220: ...kit These procedures include references to the tools re quired Other tools and procedures may be required See refer ences to these procedures in the step by step instructions below CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page159 Continues on next page 220 Product manual IRB 1600 ...

Page 221: ...rew and washer 4 Refitting the damper Use this procedure to refit the damper Note Action Run the robot to a position where it is best to enable access to the attachment screw of the damper 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 2 1 pc M6 x 16 Secure the damper with the attachment screw and washe...

Page 222: ...tools on page 383 Standard toolkit CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page159 Removing the damper axis 3 Use this procedure to remove the damper Note Action Shown in the figure Location of damper axis 3 on page 222 Run the robot to a position where it is best to enable acces...

Page 223: ...ss to the location where the axis 3 damper is fitted 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 2 Refit the damper by gently pressing it onto the cast tab on the upper arm 3 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section ...

Page 224: ...e part lists on page 387 Mechanical stop Content is defined in section Standard tools on page 383 Standard tools CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page159 Continues on next page 224 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights re...

Page 225: ...hanical stop 3 Refitting the mechanical stop axis 3 Use this procedure to refit the mechanical stop Note Action Refit the mechanical stop with its attachment screws 1 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 28 2 Product manual IRB 1600 1660 225 3HAC026660 001 Revi...

Page 226: ... grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page159 Removal damper axis 5 The procedure below details how to remove the damper axis 5 Note Action Shown in the figure Location of damper axis 5 on page 226 Run the robot to a position that enables the end of the damper to be pushed into the recess in the wrist unit 1 Continues on ...

Page 227: ...re supply to the robot before entering the robot working area 1 Make sure the damper is turned the correct way Push the end of the damper into the gap between the wrist unit and upper arm 2 Manually move the wrist robot axis 5 in order to pull the damper into position 3 Fold out the damper hooks to secure it in position 4 DANGER Make sure all safety requirements are met when perform ing the first ...

Page 228: ...nt Note Art no Equipment Standard tools on page 383 Standard tools CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page159 Continues on next page 228 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 4 11 Remove upper arm AW Gun...

Page 229: ...xx0700000151 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 2 A Locking sleeve B Locking screw C Welding cable xx0700000273 Remove the two screws holding the brace 3 A BINZEL Brace Continues on next page Product manual IRB 1600 1660 229 3HAC026660 001 Revision W Copyright 2006 2018 ABB All ri...

Page 230: ...king ring A has a thread loosen it counter clock wise and remove it Remove the locking sleeve B Remove all 6x M5 screw C 5 A Locking ring B Locking sleeve C Screw M5 Continues on next page 230 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 4 11 Remove upper arm AW Gun Continued ...

Page 231: ...robot before entering the robot working area 1 xx0700000150 Refit the welding gun using the 6X Socket head cap screw M5 C Refit the locking sleeve B Lock the sleeve using the lock ing ring A 2 A Locking ring B Locking sleeve C Screw M5 Continues on next page Product manual IRB 1600 1660 231 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 4 11 Remove upper arm AW Gu...

Page 232: ... cable using the screw B 3 A Locking sleeve B Locking screw C Welding cable xx0700000273 Refit the brace A 4 232 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 4 11 Remove upper arm AW Gun Continued ...

Page 233: ... tools and procedures may be required See references to these procedures in the step by step instructions below Measurement axis 5 Use this procedure to measure the play of axis 5 Information Action Move the robot to calibration position Turn axis 4 to 90 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 ...

Page 234: ...the measuring tool shaft as shown in the figure 7 Verify that axis 5 is put in calibration posi tion 8 Set the dial indicator to zero 9 xx1500000314 Apply load F with a dynamometer as shown in the figure IRB 1600ID 4 1 5 F 40N IRB 1660ID X 1 55 F 30N Remove the load and make a note of the value from the dynamometer as value a1 10 Continues on next page 234 Product manual IRB 1600 1660 3HAC026660 0...

Page 235: ... Turn axis 5 to 90 14 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 15 Repeat step 10 to step 12 16 Turn on power 17 Turn axis 5 to 90 18 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 19 Repeat step 10 to step 12...

Page 236: ...tools and procedures may be required See references to these procedures in the step by step instructions below Measurement axis 6 Use this procedure to measure the play of axis 6 Information Action Move the robot to calibration position Turn axis 4 to 90 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 A...

Page 237: ...marking as shown in the figure 7 Verify that axis 6 is put in calibration posi tion 8 Set the dial indicator to zero 9 xx1500000317 Apply load F 40N with a dynamometer on the opposite side of the dial indicator as shown in the figure Remove the load and make a note of the value from the dynamometer as value b1 10 Continues on next page Product manual IRB 1600 1660 237 3HAC026660 001 Revision W Cop...

Page 238: ...ulate the play in the axis as b1 b2 The values of b1 and b2 are absolute val ues 12 Turn on power 13 Turn axis 6 to 180 14 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 15 Repeat step 10 to step 12 16 238 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 ...

Page 239: ...ew see Spare parts Base exploded view xx0500001453 Base A Attachment screws and washer base gearbox unit VK cover removed B Required equipment Note Art no Spare part no Equipment For spare part number see Spare part lists on page 387 Base spare Continues on next page Product manual IRB 1600 1660 239 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 5 1 Replacement of...

Page 240: ...obot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair p...

Page 241: ...e cable layout in the base is shown in the figure Illustration cabling inside base on page 169 Remove the cabling inside the base and pull it up to the gearbox unit 4 Detailed in section Removing the serial measurement unit on page247 Remove the serial measurement unit 5 Unfasten the base from the installation site by removing the attachment bolts from the founda tion 6 CAUTION The robot weighs IR...

Page 242: ...g the robot working area 1 Clean the joints that have been opened See Cut the paint or surface on the robot before re placing parts on page 159 2 Place the robot with the side of the lower arm downwards on a workbench 3 Be careful not to damage the motor connectors Clean the mating surfaces between the base and the gearbox unit with isopropanol 4 Spare part no is specified in Required equipment on...

Page 243: ...ed in section Refitting the serial measurement unit on page 249 Refit the serial measurement unit 15 Seal and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 159 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth 16 Pendulum Calibration is described in Operating manual Calibration Pendu lum ...

Page 244: ...ore detailed view of the base may be found in the spare part view see Spare parts Base exploded view xx0500001390 Base cover including gasket Serial measurement unit is located beneath the cover A Continues on next page 244 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the serial measurement unit ...

Page 245: ...r SMB1 4 B Connector SMB 3 6 C Hexagon nuts totally 4 pcs D Hexagon nuts totally 2 pcs Only the outer nuts are used D Battery pack 2 pole battery contact E Battery cable connector F Continues on next page Product manual IRB 1600 1660 245 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the serial measurement unit Continued ...

Page 246: ... has longer lifetime for the battery It is important that the SMB unit uses the correct battery Make sure to order the correct spare parts Do not replace the battery contact Note Art no Equipment See Spare part lists on page 387 Serial measurement unit See Spare part lists on page 387 Battery pack Continues on next page 246 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018...

Page 247: ...e robot before replacing parts on page159 Removing the serial measurement unit Use this procedure remove the serial measurement unit Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 1 The push button guard must be removed to ensure a correct refitting of the push buttons xx0600002744 A Push butt...

Page 248: ...ector to release the lock while pulling the connector upwards 5 Disconnect all remaining connectors to the serial measurement unit and push button units 6 Shown in the figure Serial measurement unit layout on page 245 Unscrew the hexagon nuts on the serial measurement unit a little and slide the SMB unit out Do not remove the nuts 7 xx0500001455 Lift and pull the serial measurement unit backwards ...

Page 249: ...Also make sure that the unit is correctly aligned sideways the measurements x1 and x2 in the figure to the right should not differ more than 1 mm from each other 4 Art no for the centering piece is specified in Required equipment on page 246 Spare part no is specified in Required equipment on page 246 Check the gasket of the base cover Replace it if damaged 5 Shown in the figure Location of serial...

Page 250: ...y and do not stay in any locked position 9 Detailed in section Updating revolution counters on page 345 Update the revolution counters 10 250 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the serial measurement unit Continued ...

Page 251: ... cover including gasket Push button unit is located beneath the cover A Push button unit on serial measurement unit The push button unit is attached to the serial measurement unit as shown in the figure xx0500001394 Push button unit A Hexagon nuts 2 pcs B Hexagon nuts SMB unit 4 pcs Only the outer ones are used C Continues on next page Product manual IRB 1600 1660 251 3HAC026660 001 Revision W Cop...

Page 252: ...t Use this procedure to remove the push button unit Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 33 2 The push button guard must be ...

Page 253: ...ctors from the brake release board 7 Shown in the figure Push button unit on serial measurement unit on page 251 Unscrew the four hexagon nuts on the SMB unit enough to enable lifting the unit Do not remove the nuts 8 xx0500001455 Lift and pull the serial measurement unit backwards over the lip A and lift it away 9 Shown in the figure Push button unit on serial measurement unit on page 251 Remove ...

Page 254: ...the new push button unit to the serial measurement unit 3 Spare part no is specified in Required equipment on page 252 Shown in the figure Push button unit on serial measurement unit on page 251 xx0500001392 A Pins Fit the serial measurement unit on to the four pins 4 Make sure the unit is positioned as straight as possible The push buttons can otherwise get jammed Slide the unit into position wit...

Page 255: ...e gasket of the base cover Replace it if damaged 8 Shown in the figure Location of push button unit on page 251 Refit the base cover 9 xx0600002777 Refit the centering piece B to the push but ton unit in order to align it vertically Also make sure that the unit is correctly aligned sideways the measurements x1 and x2 in the figure to the right should not differ more than 1 mm from each other 10 WA...

Page 256: ...etailed in section Updating revolution counters on page 345 Update the revolution counters 14 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section First test run may cause injury or damage on page 28 15 256 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 5 3 Replacing ...

Page 257: ...Motor axis 1 A Connector plate for motor cabling B Cover frame C Attachment screws motor 4 pcs D Motor cover E Required equipment Note Art no Equipment Cable harness motor axes 1 2 must be ordered separately For spare part number see Spare part lists on page 387 Standard Rot ac motor incl pinion Continues on next page Product manual IRB 1600 1660 257 3HAC026660 001 Revision W Copyright 2006 2018 A...

Page 258: ... calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with r...

Page 259: ...ll out the motor cabling carefully 6 Connect to connector R3 MP1 pin 7 pin 8 In order to release the brakes connect the 24 VDC power supply to the motor 7 Shown in the figure Location of motor on page 257 Unscrew the attachment screws securing the motor 8 Remove the motor by gently lifting it straight up making sure the motor pinion is not damaged against the gear 9 Disconnect the brake release vo...

Page 260: ... axis 1 8 Use the rotation tool to rotate the motor pinion when mating it to the gear 4 pcs M8 x 25 Secure the motor with four attachment screws and washers but do not tighten yet 9 There should be a barely noticable gear play 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 th...

Page 261: ... page 349 General calibration information is included in section Calibration on page 337 DANGER Make sure all safety requirements are met when performing the first test run These are further de tailed in the section First test run may cause injury or damage on page 28 18 Product manual IRB 1600 1660 261 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 6 1 Replacemen...

Page 262: ... Motor axis 2 A Cover frame B Connector plate for motor cabling C Bracket and cable tie D Motor cover E Required equipment Note Art no Equipment etc For spare part num ber see Spare part lists on page 387 Rot ac motor with pinion For spare part num ber see Spare part lists on page 387 Cable harness motor axes 1 2 Continues on next page 262 Product manual IRB 1600 1660 3HAC026660 001 Revision W Cop...

Page 263: ...nning the repair work of the robot see the table Note Action Decide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexP...

Page 264: ...figure Location of motor axis 2 on page 262 Remove the cover frame 4 Connectors R3 MP2 R3 FB2 Disconnect the motor connectors inside the frame 5 Cut any cable ties and remove any brackets or clamps securing the cables 6 Shown in the figure Location of motor axis 2 on page 262 Remove the connector plate by removing its attachment screws and pull the cables out from the frame 7 DANGER Secure the wei...

Page 265: ...placing parts on page 159 2 Make sure the mating surfaces on the motor and the gearbox are clean and free from burrs 3 If necessary clean the surfaces with isopropanol Art no is specified in section Re quired equipment on page 262 Replace the o ring if damaged 1 Apply enough Loctite 574 to the motor groove 2 Refit the o ring Make sure the o ring on the circumference of the motor is seated properly...

Page 266: ...neath the frame 16 Shown in the figure Location of mo tor axis 2 on page 262 Refit the cover frame Replace the gasket if damaged 17 Art no for the gasket is specified in section Required equipment on page 262 Detailed in section Performing a leak down test on page 154 Perform a leak down test 18 See Technical reference manu al Lubrication in gearboxes Refill the gearbox with oil 19 Seal and paint ...

Page 267: ...ng the first test run These are further detailed in the section First test run may cause injury or damage on page 28 22 Product manual IRB 1600 1660 267 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 6 2 Replacement of motor axis 2 Continued ...

Page 268: ... A Attachment screws and washers of the motor 4 pcs B Signal connector R3 FB3 C Power connector R3 MP3 D Connector holder E Upper arm housing cover F Cable tie G Required equipment Note Art no Equipment For spare part number see Spare part lists on page 387 Rot ac motor incl pinion Replace if damaged 21522012 426 O ring Continues on next page 268 Product manual IRB 1600 1660 3HAC026660 001 Revisio...

Page 269: ...libration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis ...

Page 270: ... Remove the upper arm housing cover 5 Shown in the figure Location of motor on page 268 Disconnect the motor connectors R3 MP3 and R3 FB3 6 DANGER Secure the weight of the upper arm properly before releasing the brakes of motor axis 3 When releasing the holding brakes of the motor the upper arm will be movable and may fall down 7 Connect to connector R3 MP3 pin 7 pin 8 In order to release the brak...

Page 271: ...ten them yet 6 Shown in the figure Location of motor on page 268 Art no is specified in Required equipment on page 268 Fit the rotation tool to the end of the motor shaft 7 There should be a barely noticable gear play Adjust the motor in relation to the gear Use the rotation tool to wiggle the motor shaft back and forth to feel the play 8 Tightening torque 10 Nm Tighten the motor attachment screws...

Page 272: ... 349 General calibration information is included in section Calibration on page 337 DANGER Make sure all safety requirements are met when performing the first test run These are further de tailed in the section First test run may cause injury or damage on page 28 15 272 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 6 3 Replacement of ...

Page 273: ... and washers of the motor 4 pcs B Signal connector R3 FB3 C Power connector R3 MP3 D Connector holder E Required equipment Note Art no Equipment For spare part number see Spare part lists on page 387 Rot ac motor incl pinion 3HAB3772 100 O ring Used for cleaning the mating surfaces Isopropanol Grease Continues on next page Product manual IRB 1600 1660 273 3HAC026660 001 Revision W Copyright 2006 2...

Page 274: ...s If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 350...

Page 275: ...is 2 to calibration pos ition upper arm backwards against the mechanical stop This position enables removal of the motor without draining oil of the gearbox axis 3 5 Shown in the figure Location of motor on page 273 Remove the upper arm hous ing cover 6 Shown in the figure Location of motor on page 273 Disconnect the motor connect ors R3 MP3 and R3 FB3 7 Continues on next page Product manual IRB 1...

Page 276: ... motor axis 3 by unscrewing its attachment screws and washers Lift the motor gently straight out making sure the motor pinion is not damaged 10 A Hex socket head cap screw B O ring C Motor axis 3 D Resolver cover E O ring Remove the resolver cover for refitting on the new motor 11 Disconnect the brake release voltage 12 Continues on next page 276 Product manual IRB 1600 1660 3HAC026660 001 Revisio...

Page 277: ...a barely notice able gear play Adjust the motor in relation to the gear Use the rotation tool to wiggle the motor shaft back and forth to feel the play 7 Tightening torque 10 Nm Tighten the motor attachment screws 8 Refit the resolver cover on the new motor 9 Cable layout is shown in the figure Illustration cabling inside upper arm housing on page 166 Reconnect the motor connectors run and secure ...

Page 278: ...e first test run These are further de tailed in section First test run may cause injury or damage on page 28 14 278 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 6 4 Replacement of motor axis 3 1600ID 1660ID Continued ...

Page 279: ...400001273 Motor axis 4 A Cover upper arm housing B Connector plate C Signal connector R3 FB4 D Power connector R3 MP4 E Attachment screw and washer motor 4 pcs F Required equipment Note Art no Spare part no Equipment etc For spare part number see Spare part lists on page 387 Rot ac motor with pinion Continues on next page Product manual IRB 1600 1660 279 3HAC026660 001 Revision W Copyright 2006 20...

Page 280: ... cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new refe...

Page 281: ...ing the oil in the gearbox Manually move the robot to a position where the upper arm points straight down 4 Remove the cover from the upper arm housing 5 Shown in the figure Location of motor on page 279 Remove the connector plate to get access to the axis 4 motor 6 Disconnect the connectors R3 MP4 and R3 FB4 from the axis 4 motor 7 Connect to connector R3 MP4 pin 7 pin 8 In order to release the b...

Page 282: ...arely noticable gear play Adjust the motor in relation to the gear in the gearbox 7 Use the arm tool to wiggle the motor shaft back and forth to feel the play Shown in the figure Location of motor on page 279 Tighten the motor attachment screws 8 Tightening torque 10 Nm Reconnect the motor connectors R3 MP4 and R3 FB4 9 Shown in the figure Location of motor on page 279 Refit the connector plate 10...

Page 283: ...e 349 General calibration information is in cluded in section Calibration on page 337 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 28 16 Product manual IRB 1600 1660 283 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 6 5 Replacement of...

Page 284: ... xx0700000017 Motor axis 4 A Cover upper arm housing B Connector plate C Signal connector R3 FB4 D Power connector R3 MP4 E Attachment screw and washer motor 4 pcs F Continues on next page 284 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 6 6 Replacement of motor axis 4 1600ID 1660ID ...

Page 285: ...ble Note Action Decide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robo...

Page 286: ... the motor axis 4 by unscrewing the motor attachment screws 7 Lift the motor to get the pinion away from the gear and disconnect the brake release voltage 8 Make sure the motor pinion is not damaged Remove the motor by gently lifting it out 9 Refitting motor axis 4 Note Action Shown in the figure Location of motor on page 284 Clean the mating surfaces on the motor and the gearbox 1 Art no is speci...

Page 287: ...arm housing 7 Pendulum Calibration is described in Operating manual Calibration Pendulum enclosed with the cal ibration tools Recalibrate the robot 8 Axis Calibration is described in Calibrating with Axis Calibration method on page 349 General calibration information is included in section Calibration on page 337 Product manual IRB 1600 1660 287 3HAC026660 001 Revision W Copyright 2006 2018 ABB Al...

Page 288: ...otor 5 R3 FB5 D Power cable motor 5 R3 MP5 E Attachment screws and washers motor bracket 2 pcs F Motor bracket G Attachment screws and washers motor 3 pcs H Required equipment Note Art no Spare part no Equipment 3HAC021800 003 Rot ac motor incl pinion 3HAC021304 001 Timing belt Replace if damaged 3HAC022049 001 Gasket upper arm cover Replace if damaged 3HAC022050 001 Gasket customer connec tions C...

Page 289: ...Belt tightener 3HAC 024044 001 The belt tightener is a special tool that is used when adjusting the tension of the timing belt of axis 5 The length of the tool is important since the tool is pulled with a given force xx0500001457 CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page159 Co...

Page 290: ...e on page 350 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removal motor axis 5 and timing ...

Page 291: ... to refit the motor and timing belt of axis 5 Note Illustration Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Clean the mating surfaces on the motor and in the upper arm housing 2 3 pcs M6 x 20 Fit the new motor to the motor bracket previ ously removed from the old motor 3 Continues on next page ...

Page 292: ... N Detailed in section Refitting motor and timing belt axis 6 on page 313 Refit the motor and timing belt of axis 6 5 Detailed in section Refitting motor axis 4 on page 282 Refit the motor of axis 4 6 Cable layout shown in the figure Illus tration cabling inside upper arm housing on page 166 Reconnect all connectors and place the cabling correctly inside the upper arm housing 7 Art no is specified...

Page 293: ... first test run These are further detailed in the section First test run may cause injury or damage on page 28 10 Product manual IRB 1600 1660 293 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 6 7 Replacement of motor and timing belt axis 5 IRB 1600 Continued ...

Page 294: ...head cap screw M8X20 B Cable harness IRB1600ID C Rotational ac motor Axis 5 D Hex socket head cap screw M6X20 E O ring F Cable harness bracket G Required equipment Note Art no Equipment etc For spare part number see Spare part lists on page 387 Rot ac motor with pinion 3HAA2166 19 VK cover Continues on next page 294 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All...

Page 295: ...can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be...

Page 296: ...g mating motor and gearbox the gears may be damaged if excessive force is used Note Action Decide which calibration routine to use and take actions accordingly prior to beginning the repair proced ure 1 xx0700000083 Remove the cover C on the back of the upper arm tube A Rotate the upper arm to access all the screws D Remove the screws B holding the cable harness CAUTION After removal of the cover ...

Page 297: ...om the upper arm 4 xx0700000080 Disconnect connectors R4 FB5 and R4 MP5 from the back 5 A R4 FB5 xx0700000054 Remove the VK Cover to access the cable connections inside the arm 6 A VK Cover Gently pull the cables out of the upper arm 7 Continues on next page Product manual IRB 1600 1660 297 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 6 8 Replacement of motor ax...

Page 298: ...ly 9 xx0700000088 Secure the weight of the arm with lifting slings 10 Position B in figure Location of motor axis 5 on page 294 Remove the seven 7 Hexagon socket head cap screw M8X20 holding the upper arm 11 Remove the upper arm 12 Continues on next page 298 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 6 8 Replacement of motor axis 5...

Page 299: ...Part number is specified in section Required equipment on page 294 Make sure the o ring on the circum ference of the motor is seated properly Lubricate it with grease 2 xx1400001567 Position the motor into the upper arm housing with the motor connect or pointing towards the side as shown in the figure Make sure the motor pinion is properly mated to the gear 3 4 pcs M6 x 20 Shown in the figure Loca...

Page 300: ...on of motor axis 5 on page 294 Refitt the upper arm using the 7 Hex socket head cap screw M8X20 10 Tightening torque 24 Nm Reconnect connections R4 FB6 and R4 MP6 through the VK hole Make sure all the cabling is placed correctly inside the upper arm housing 11 Note When reconnecting the connection R4 FB5 make sure to place the connectors as far away from the axis 5 6 cable spiral as possible to av...

Page 301: ...on is described in Operating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 15 Axis Calibration is described in Calibrating with Axis Calibration method on page 349 General calibration information is included in section Calibration on page 337 Product manual IRB 1600 1660 301 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 6 8...

Page 302: ... Content is defined in section Standard tools on page 383 Standard toolkit These procedures include references to the tools re quired Other tools and procedures may be required See refer ences to these procedures in the step by step instructions below CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replaci...

Page 303: ...the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 350 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendul...

Page 304: ...d on the upper arm and wrist 7 How to remove the wrist see the section Replacing the wrist unit IRB1660ID on page 212 Remove the wrist and disconnect those cables to motor axis 6 8 Note Make a note of the position of axis 4 before continuing the removal process It is important to refit the mechanical stop and cable harness spiral with axis 4 in the same position as it was before the removal If axi...

Page 305: ...1500001265 Remove the two VK covers covering the attachment screws securing the cable har ness to the upper arm tube 13 A VK covers 2 pcs xx1500001262 Remove the attachment screws 7 pcs se curing the tube of the armhouse Note The screws are secured with locking liquid Loctite 243 14 A Attachment screws 7 pcs Continues on next page Product manual IRB 1600 1660 305 3HAC026660 001 Revision W Copyrigh...

Page 306: ...o damage the cable harness in the process The space is cramp 16 R4 MP5 R4 FB5 xx1400002576 Disconnect connectors R4 MP5 and R4 FB5 to motor axis 5 17 Remove the upper arm tube with the cable harness to motor axis 6 CAUTION Be careful not to damage the cable harness to motor axis 6 in the process 18 Continues on next page 306 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 201...

Page 307: ... 5 by unscrewing its at tachment screws 20 A Upper arm tube B Motor axis 5 C Cable harness to motor axis 6 Refitting motor axis 5 Use this procedure to refit motor axis 5 Information Action Place motor axis 5 in the upper arm tube 1 Continues on next page Product manual IRB 1600 1660 307 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 6 9 Replacement of motor axis ...

Page 308: ...6 Connect connectors R4 MP5 and R4 FB5 to motor axis 5 6 xx1000000998 Secure the cable harness with its attach ment screws to the upper arm tube 7 A Bracket B Attachment screws 2 pcs C Connectors motor axis 5 D Motor axis 5 See section Replacing the cable harness 1600ID 1660ID on page 172 Examine the spiral of the cable harness to make sure it is fitted correctly 8 Continues on next page 308 Produ...

Page 309: ...s 5 pcs B Mechanical stop C O ring D Distance ring E Bracket F Cover See figure above Refit the bracket with the remaining attach ment screws 11 xx1500001269 Apply Sikaflex 521FC on the surface along the red curve in the figure 12 Refit the mechanical stop 13 Continues on next page Product manual IRB 1600 1660 309 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 6 9...

Page 310: ...ibration tools Recalibrate the robot 17 Axis Calibration is described in Calibrating with Axis Calibration method on page349 General calibration information is included in section Calibration on page 337 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page28 18 310 Product man...

Page 311: ...r axis 6 A Cover upper arm housing B Connector plate C Signal cable axis 6 motor R3 FB6 D Power cable axis 6 motor R3 MP6 E Attachment screws and washers motor 3 pcs F Distance console with cable bracket and contact panel G Cable tie H Required equipment Note Art no Spare part no Equipment 3HAC021800 003 Rot ac motor incl pinion Continues on next page Product manual IRB 1600 1660 311 3HAC026660 00...

Page 312: ...ternal cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create ne...

Page 313: ...4 Shown in the figure Location of motor on page 311 Remove the complete distance console with cable brackets and contact panel 5 Disconnect the motor cables for the axis 6 motor R3 MP6 and R3 FB6 6 Remove the axis 6 motor by unscrewing its three attach ment screws and washers 7 Remove the timing belt 8 Refitting motor and timing belt axis 6 The procedure below details how to refit the motor and ti...

Page 314: ...ble tie 4 Reconnect the motor cables R3 MP6 and R3 FB6 5 Cable layout is shown in the figure Illus tration cabling inside upper arm housing on page 166 Place all the cabling correctly inside the upper arm housing 6 Art no is specified in Required equip ment on page 311 Refit the cover to the upper arm housing Check both the gaskets and replace if damaged 7 Pendulum Calibration is described in Op e...

Page 315: ...Wrist B Motor axis 6 C Hexagon socket head screw M5x25 D Hexagon socket head screw M5x16 10 9 Short head E Hexagon socket head screw M5x25 F Hexagon socket head screw M8x35 G Required equipment Note Art no Equipment For spare part number see Spare part lists on page 387 Rot ac motor incl pinion Continues on next page Product manual IRB 1600 1660 315 3HAC026660 001 Revision W Copyright 2006 2018 AB...

Page 316: ...e calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration...

Page 317: ... and scrap it 1 Remove the new console from the new spare part wrist 2 Tightening torque 6 Nm Fit the new console to the axis 6 motor 3 Use Loctite 243 on the attachment screws Fit motor with the new console fitted to the new wrist 4 Tighten the attachment screws just enough to still be able to move motor and console 5 Use caution and rotate the coupling manually 6 This will help the coupling and ...

Page 318: ...ing with Axis Calibration method on page 349 General calibration information is included in section Calibration on page 337 DANGER Make sure all safety requirements are met when performing the first test run These are further de tailed in the section First test run may cause injury or damage on page 28 14 318 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights...

Page 319: ... a new when removed 3HAA2166 18 VK cover Loctite 574 Locking liquid Content is defined in section Standard tools on page 383 Standard toolkit These procedures include references to the tools re quired Other tools and procedures may be required See refer ences to these procedures in the step by step instructions below CAUTION Always cut the paint with a knife and grind the paint edge when disassemb...

Page 320: ... more about reference calibration for Axis Calibration in Reference calibration routine on page 350 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be calibrated with fine calibration Remove all exter...

Page 321: ...ide facing the wrist 6 A Coupling B Attachment screw A xx1000000875 Remove the attachment screws securing the wrist 7 A Attachment screws 4 pcs Continues on next page Product manual IRB 1600 1660 321 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 6 12 Replacement of motor axis 6 IRB 1660ID Continued ...

Page 322: ...wrist C Division point D Upper arm tube xx1500001259 Pull carefully out the wrist a little to reach the motor cables to motor axis 6 Note The wrist is fitted on cylindrical pins 9 xx1500003257 Fit two short screws to the holes for the at tachment screws to temporarily secure the cover 10 A Short screws 2 pcs B Cover Continues on next page 322 Product manual IRB 1600 1660 3HAC026660 001 Revision W ...

Page 323: ...ion as they were before the removal 13 xx1000000931 Remove the cable protection by removing the nuts securing it 14 A Cable protection B Nuts 2 pcs C Connector motor axis 6 A B C xx1000000930 Open the flexible coupling securing motor axis 6 15 A Attachment screw coupling B Flexible coupling C Motor axis 6 Continues on next page Product manual IRB 1600 1660 323 3HAC026660 001 Revision W Copyright 2...

Page 324: ... Use this procedure to refit the axis 6 motor and the wrist unit Information Action xx1000000929 Place the motor axis 6 into the flexible coupling axis 6 1 A Attachment screws bracket B Flexible coupling C Attachment screws motor 3 pcs D Cylindrical pins 2 pcs E Motor axis 6 Tightening torque 6 Nm Secure the motor with its attachment screws 2 Continues on next page 324 Product manual IRB 1600 1660...

Page 325: ... Nuts 2 pcs C Connector motor axis 6 Clean all assembly surfaces 5 Remove any painting from the assembly surfaces with a knife Place the wrist with motor axis 6 fitted a little into the upper arm tube 6 R4 MP6 R4 FB6 xx1400002575 Reconnect the cables R4 MP6 and R4 FB6 to motor axis 6 7 Continues on next page Product manual IRB 1600 1660 325 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rig...

Page 326: ...locking liquid is specified in Required equipment on page 319 xx1200000063 Apply locking liquid to the assembly surface on the upper arm tube 9 Continues on next page 326 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 6 12 Replacement of motor axis 6 IRB 1660ID Continued ...

Page 327: ...orque 35 Nm A xx1000000875 Secure the wrist with its attachment screws and washers 11 A Attachment screws 4 pcs Tightening torque 14 Nm Secure the flexible coupling axis 5 with its attachment screw 12 Article number is specified in Required equipment on page 319 xx1000000873 Fit a new VK cover 13 Continues on next page Product manual IRB 1600 1660 327 3HAC026660 001 Revision W Copyright 2006 2018 ...

Page 328: ...page349 General calibration information is included in section Calibration on page 337 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page28 15 328 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 6 12 Replacement o...

Page 329: ...unit A more detailed view of the gearbox and its position may be found in the spare part view Spare parts Frame exploded view xx0500001400 Gearbox unit axes 1 2 A Attachment screws and washer base gearbox unit VK cover is removed B Continues on next page Product manual IRB 1600 1660 329 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 4 Repair 4 7 1 Replacement of gearbox axes...

Page 330: ... tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues ar...

Page 331: ... Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot be fore replacing parts on page 159 3 xx0800000260 A Oil plug B Drain pump Remove the oil plug and drain all oil from gearbox axis...

Page 332: ...the foundation 9 CAUTION The gearbox unit weighs 120 kg The base weighs 81 kg All lifting accessories used must be sized accordingly 10 Fit the lifting slings to the base gearbox unit and place it with the lower arm side downwards on top of a suitable workbench 11 Remove the VK cover from the bottom of the robot base 12 Tip When the cabling is removed it may be easier to drill a hole through the c...

Page 333: ...weighs 120 kg All lifting accessories used must be sized accordingly 3 Clean the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 159 4 Place the gearbox unit with the lower arm side downwards on a suitable workbench 5 Clean the mating surfaces of the base and of the gearbox unit with isopropanol 6 Art no is specified in Required equip ment on p...

Page 334: ... a leak down test on page 154 Perform a leak down test 16 See Technical reference manual Lubric ation in gearboxes Fill the two gearboxes with oil 17 Seal and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 159 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth 18 Pendulum Calibration is des...

Page 335: ... require replacement axes 3 and 4 the complete upper arm is to be replaced This procedure is detailed in section Replacing the complete upper arm IRB 1600 on page183 axes 5 and 6 the complete wrist unit is to be replaced This procedure is detailed in section Replacing the wrist unit IRB 1600 on page 201 Product manual IRB 1600 1660 335 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights r...

Page 336: ...This page is intentionally left blank ...

Page 337: ...is used for calibration of the robot Calibration position A generic term for all calibration methods that aim to move the robot to calibration position Standard calibration A calibration routine that generates a new zero posi tion of the robot Fine calibration A calibration routine that in the first step generates a reference to current zero position of the robot The same calibration routine can l...

Page 338: ...nate system for the robot Absolute accuracy calibration option al Absolute accuracy calibration data is found on the SMB serial measurement board in the robot For robots with RobotWare 5 05 or older the absolute accuracy calibration data is delivered in a file absacc cfg supplied with the robot at delivery The file replaces the calib cfg file and identifies motor positions as well as absolute accu...

Page 339: ... of how to perform the calibration procedure and what to do at each step is given on the FlexPendant You will be guided through the calibration procedure step by step CalibWare Absolute Accuracy calibration To achieve a good positioning in the Cartesian coordinate system Absolute Accuracy calibration is used as a TCP calibration The CalibWare tool guides through the calibration process and calcula...

Page 340: ...er memory is lost If the revolution counter memory is lost the counters must be updated See Updating revolution counters on page 345 This will occur when The battery is discharged A resolver error occurs The signal between a resolver and measurement board is interrupted A robot axis is moved with the control system disconnected The revolution counters must also be updated after the robot and contr...

Page 341: ...e position of the synchronization marks and the synchronization position for each axis Synchronization marks IRB 1600 IRB 1660ID IRB 1600 xx0600002876 Continues on next page Product manual IRB 1600 1660 341 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchronization position for axes ...

Page 342: ...illustration valid for IRB 1600 for axes 1 2 and 3 xx1500001256 IRB 1660ID xx1700000115 Continues on next page 342 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchronization position for axes Continued ...

Page 343: ...1700000116 Product manual IRB 1600 1660 343 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchronization position for axes Continued ...

Page 344: ... will handle the calibration movements automatically and these might be different from the positive directions shown below Manual movement directions 6 axes Note The graphic shows an IRB 7600 The positive direction is the same for all 6 axis robots except the positive direction of axis 3 for IRB 6400R which is in the opposite direction xx0200000089 344 Product manual IRB 1600 1660 3HAC026660 001 R...

Page 345: ...tion mode 1 See Synchronization marks and synchron ization position for axes on page 341 Jog the manipulator to align the synchron ization marks 2 Step 2 Updating the revolution counter with the FlexPendant on page 346 When all axes are positioned update the revolution counter 3 Correct calibration position of axis 4 and 6 When jogging the manipulator to synchronization position it is extremely im...

Page 346: ... wrong even if the motor calibration data is correct try to rotate the axis one turn update the revolution counter and check the synchronization marks again try both directions if needed Step 2 Updating the revolution counter with the FlexPendant Use this procedure to update the revolution counter with the FlexPendant IRC5 Action On the ABB menu tap Calibration xx1500000942 1 Continues on next pag...

Page 347: ...botWare 6 02 and later 3 Calibration method used at factory for each axis is shown as well as calibration method used during last field calibration Tap Manual Method Advanced xx1500000944 Continues on next page Product manual IRB 1600 1660 347 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 5 Calibration 5 3 Updating revolution counters Continued ...

Page 348: ...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 selected revolution counters and removes the tick from the list of axes 7 CAUTION If a revolution counter is incorrectly updated it will cause incorrect manipulator posi tioning which in turn may ...

Page 349: ...le calibration tool is inserted by the operator into a calibration bushing on the axis chosen for calibration according to instructions on the FlexPendant WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB Using other pins in the calibration bushings may cause severe damage to the robot and or personnel WARNING The calibration tool must be fully inserte...

Page 350: ...hen reference calibration is performed the robot is restored to the status given by the reference values Note When calibrating the robot with the reference calibration routine the robot must be dressed with the same tools process cabling and any other equipment as when the reference values were created Update revolution counters Choose this routine to make a rough calibration of each manipulator a...

Page 351: ... mounted at its working position not standing on a floor To calibrate a suspended or wall mounted robot with the fine calibration routine the robot must first be taken down and mounted standing on the floor Product manual IRB 1600 1660 351 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 5 Calibration 5 4 1 Description of Axis Calibration Continued ...

Page 352: ... or personnel Note Article number Equipment etc Delivered as a set of calibration tools Required if Axis Calibration is the valid calib ration method for the robot Contains a removal tool for removing special protection plugs on the turning disc 3HAC062326 001 Calibration tool box Axis Calibration Examining the calibration tool Check prior to usage Before using the calibration tool make sure that ...

Page 353: ...hould be checked Outer diameter within Ø12g4 mm Ø8g4 mm or Ø6g5 mm depending on calibration tool size Straightness within 0 005 mm xx1500000951 Outer diameter A Product manual IRB 1600 1660 353 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 5 Calibration 5 4 2 Calibration tools for Axis Calibration Continued ...

Page 354: ... bushing for the movable calibration tool are located on each axis as follows If there is not enough space on an axis to install a fixed calibration pin the axis is equipped with two bushings instead for installation of two calibration tools when calibration is carried out This is shown in the figure IRB 1600 xx1700000113 Continues on next page 354 Product manual IRB 1600 1660 3HAC026660 001 Revis...

Page 355: ...0114 Continues on next page Product manual IRB 1600 1660 355 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 5 Calibration 5 4 3 Installation locations for the calibration tools Continued ...

Page 356: ...111 xx1700000112 Continues on next page 356 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 5 Calibration 5 4 3 Installation locations for the calibration tools Continued ...

Page 357: ...te Article number Spare part Contains replacement calibration pin covers and protective plugs for the bushing 3HAC059487 001 Protection cover and plug set Replace if damaged or missing 3HAC057676 001 IRB 1660ID Protective plug on turning disc 3HAC061134 001 IRB 1600 Product manual IRB 1600 1660 357 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 5 Calibration 5 4 3 Installati...

Page 358: ...ushing 3HAC059487 001 Protection cover and plug set Replace if damaged or missing 3HAC057676 001 IRB 1660ID Protective plug on turning disc 3HAC061134 001 IRB 1600 Overview of the calibration procedure on the FlexPendant The actual instructions of how to perform the calibration procedure and what to do at each step is given on the FlexPendant You will be guided through the calibration procedure st...

Page 359: ...s the calibration tool to stick out on the other side of the turning disc Any equipment fitted to the turning disc must therefor either be removed or designed with a cavity giving space to the calibration tool to stick out 7 The robot performs a measurement sequence by rotating the axis back and forth 8 Remove the calibration tool and reinstall the protective cover on the fixed pin and the protect...

Page 360: ... to power Make sure that the robots working area is empty as the robot can make unpredictable movements 1 Use a clean cloth Wipe the calibration tool clean Note The calibration method is exact Dust dirt or color flakes will affect the calibration value 2 Starting the calibration procedure Use this procedure to call for the Axis Calibration method on the FlexPendant Note Action On the ABB menu tap ...

Page 361: ...he FlexPendant is given in Overview of the calibra tion procedure on the FlexPendant on page 358 Follow the instructions given on the FlexPendant 4 Restarting an interrupted calibration procedure If the Axis Calibration procedure is interrupted before the calibration is finished the RobotWare program needs to be started again Use this procedure to take required action Action Situation Press and ho...

Page 362: ...bration SafeMove needs to be unsynchronized The Axis Calibration routine recognizes if the robot is equipped with SafeMove and will force SafeMove to unsynchronize automatically However SafeMove may generate other warning messages anytime during the Axis Calibration routine Safety controller not synchronized SafeMove message Note Action SafeMove generates the message Safety control ler not synchro...

Page 363: ...synchronized time limit expired SafeMove message anytime during Axis Calibration routine Note Action SafeMove generates the message Unsynchron ized time limit expired anytime xx1500002482 1 Press OK to continue Axis Calibration procedure 2 Restart Axis Calibration procedure by pressing Play 3 Continues on next page Product manual IRB 1600 1660 363 3HAC026660 001 Revision W Copyright 2006 2018 ABB ...

Page 364: ...nd plug set 3HAC059487 001 xx1500000952 Reinstall the protective plug and sealing in the bushing on each axis directly after the axis has been calibrated Ensure that the sealing is not damaged Replace the plug and the sealing with new spare part if missing or damaged 3 Protection cover and plug set 3HAC059487 001 Continues on next page 364 Product manual IRB 1600 1660 3HAC026660 001 Revision W Cop...

Page 365: ... calibration tool box 4 IRB 1660ID xx1700000411 IRB 1600 xx1700000901 Remove the tool from the protection plug 5 IRB 1660ID xx1700000902 Product manual IRB 1600 1660 365 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 5 Calibration 5 4 4 Axis Calibration Running the calibration procedure Continued ...

Page 366: ...lum Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools 366 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 5 Calibration 5 5 Calibrating with Calibration Pendulum method ...

Page 367: ...m twice Do not change the position of the robot axes after running the program 1 This is detailed in section Synchronization marks and synchronization position for axes on page 341 Adjust the synchronization marks when the calibration is done if necessary 2 Write down the values on a new label and stick it on top of the calibration label 3 xx Remove any calibration equipment from the robot 4 Produ...

Page 368: ...ge 341 and Updating revolution counters on page 345 Check that the synchronization marks for the axes align correctly If they do not update the revolu tion counters 6 Using the jogging window Use this procedure to jog the robot to the synchronization position of all axes Note Action On the ABB menu tap Jogging 1 Tap Motion mode to select group of axes to jog 2 Tap to select the axis to jog axis 1 ...

Page 369: ...Copper Base lower arm Cast iron nodular iron Gears screws base frame and so on Steel Brakes motors Neodymium Cables connectors drive belts and so on Plastic rubber Gearboxes Oil grease Covers synchronization brackets upper arm Aluminium Turning disc foundry Nickel Oil and grease Where possible arrange for oil and grease to be recycled Dispose of via an authorized person contractor in accordance wi...

Page 370: ...organisms Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination 370 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 6 Decommissioning 6 1 Environmental information Continued ...

Page 371: ...ery is exposed to heat for example from a blow torch it will explode Always remove all oil grease in gearboxes If exposed to heat for example from a blow torch the oil grease will catch fire When motors are removed from the robot the robot will collapse if it is not properly supported before the motor is removed Product manual IRB 1600 1660 371 3HAC026660 001 Revision W Copyright 2006 2018 ABB All...

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Page 373: ...026569 001 is not interchangeable with spare part no 3HAC10475 1 The o ring sealingplate with spare part no 3HAC025420 001 is not interchangeable with spare part no 3HAC 7191 1 Other changes in this product manual compared to product manual IRB 1600 3HAC023637 001 The content in this product manual is the same as in the product manual with art no 3HAC023637 001 except for the new upper arm complet...

Page 374: ... key with Type A version of the robot is needed The new key then has to be used instead of the old by modifying the existing system in System Builder in RobotStudio Please contact Robotics After Sales for more information and purchase of a new key After the upgrade the existing programs may require a touch up of positions Further information Technote 110912 includes more detailed information Conta...

Page 375: ...er includes general information complementing the more specific information in the different procedures in the manual Product manual IRB 1600 1660 375 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 8 Reference information 8 1 Introduction ...

Page 376: ...i Ergonomics of the thermal environment Part 1 EN ISO 13732 1 2008 EMC Generic emission EN 61000 6 4 2007 A1 2011 IEC 61000 6 4 2006 A1 2010 option 129 1 EMC Generic immunity EN 61000 6 2 2005 IEC 61000 6 2 2005 Arc welding equipment Part 1 Welding power sources EN IEC 60974 1 2012ii Arc welding equipment Part 10 EMC requirements EN IEC 60974 10 2014ii Safety of machinery Electrical equipment of m...

Page 377: ...5 06 Safety standard for robots and robotic equipment ANSI UL 1740 Industrial robots and robot Systems General safety require ments CAN CSA Z 434 14 Product manual IRB 1600 1660 377 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 8 Reference information 8 2 Applicable standards Continued ...

Page 378: ...37 in 3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume 378 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 8 Reference information 8 3 Unit conversion ...

Page 379: ...uld be used Screws lubricated in other ways Screws lubricated with Molycote 1000 should only be used when specified in the repair maintenance or installation procedure descriptions In such cases proceed as follows 1 Apply lubricant to the screw thread 2 Apply lubricant between the plain washer and screw head 3 Screw dimensions of M8 or larger must be tightened with a torque wrench Screw dimensions...

Page 380: ...r maintenance or installation procedure overrides the standard torque Tightening torque Nm Class 12 9 oil lubric ated Tightening torque Nm Class 10 9 oil lubric ated Tightening torque Nm Class 8 8 oil lubricated Dimension 6 M5 10 M6 40 34 24 M8 80 67 47 M10 140 115 82 M12 340 290 200 M16 670 560 400 M20 1150 960 680 M24 Lubricated screws Molycote Gleitmo or equivalent with allen head screws The fo...

Page 381: ...ng torque for water and air connectors when one or both connectors are made of brass Note A special torque specified in the repair maintenance or installation procedure overrides the standard torque Tightening torque Nm Max Tightening torque Nm Min Tightening torque Nm Nominal Dimension 15 8 12 1 8 20 10 15 1 4 25 15 20 3 8 50 30 40 1 2 90 55 70 3 4 Product manual IRB 1600 1660 381 3HAC026660 001 ...

Page 382: ...mponents with a weight exceeding 22 kg A wide range of lifting accessories and devices are available for each manipulator model Example Following is an example of a weight specification in a procedure Note Action CAUTION The robot weighs IRB 1600 IRB 1600ID 250 kg IRB 1660ID 260 kg All lifting accessories used must be sized accord ingly 382 Product manual IRB 1600 1660 3HAC026660 001 Revision W Co...

Page 383: ...toolkit and any tools listed in the instruction Contents standard toolkit Tool Qty Ring open end spanner 8 19 mm 1 Socket head cap 2 5 17 mm 1 Torx socket no 20 60 1 Torque wrench 10 100 Nm 1 Small screwdriver 1 Plastic mallet 1 Ratchet head for torque wrench 1 2 1 Socket head cap no 5 socket 1 2 bit L 20 mm 1 Socket head cap no 6 socket 1 2 bit L 20 mm 1 Socket head cap no 8 socket 1 2 bit L 20 m...

Page 384: ...ity 100N Dynamometer Used to tighten the timing belt of axis 6 together with the dynamometer 3HAC024045 001 Hook Used to tighten the timing belt of axis 5 together with the dynamometer 3HAC024044 001 Belt tightener 3HAC023364 001 Lifting tool gearbox 3HAC062980 001 Lifting tool upper arm Calibration equipment Calibration Pendulum The following table specifies the calibration equipment needed when ...

Page 385: ...tion label or in the calibration menu on the FlexPendant If no data is found related to standard calibration Calibration Pendulum is used as default Note Art no Description Delivered as a set of calibration tools 3HAC062326 001 Calibration tool box Axis Cal ibration Required if Axis Calibration is the valid calibration method for the robot Contains a removal tool for removing special protection pl...

Page 386: ...g accessories is not detailed in the activity procedure but in the instruction delivered with each piece of lifting accessories This implies that the instructions delivered with the lifting accessories should be stored for later reference 386 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 8 Reference information 8 8 Lifting accessories and liftin...

Page 387: ...s are not included in the manual but delivered as a separate document for registered users on myABB Business Portal www mypo rtal abb com Product manual IRB 1600 1660 387 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 9 Spare part lists 9 1 Spare part lists and illustrations ...

Page 388: ...This page is intentionally left blank ...

Page 389: ...40 type C 3HAC025611 001 Circuit diagram IRB 260 3HAC028647 009 Circuit diagram IRB 360 3HAC036446 005 Circuit diagram IRB 460 3HAC025691 001 Circuit diagram IRB 660 3HAC025691 001 Circuit diagram IRB 760 3HAC046307 003 Circuit diagram IRB 1200 3HAC2800 3 Circuit diagram IRB 1410 3HAC021351 003 Circuit diagram IRB 1600 1660 3HAC039498 007 Circuit diagram IRB 1520 3HAC6670 3 Circuit diagram IRB 240...

Page 390: ...50S 3HAC025744 001 3HAC025744 001 Circuit diagram IRB 6660 3HAC029940 001 3HAC043446 005 Circuit diagram IRB 6700 3HAC13347 1 Circuit diagram IRB 7600 3HAC025744 001 3HAC050778 003 Circuit diagram Product ProductName 3HAC056159 002 Circuit diagram IRB 910SC 390 Product manual IRB 1600 1660 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved 10 Circuit diagram 10 1 Circuit diagram...

Page 391: ...y to motor axis 4 281 C cabinet lock 25 31 cable harness inside base figure 169 inside frame figure 168 inside upper arm figure 166 replacing 162 spare part number 162 cabling inside base figure 169 inside frame figure 168 inside upper arm figure 166 replacing 162 spare part number 162 cabling robot 119 cabling between robot and controller 119 calibrating robot 349 roughly 345 calibrating robot 34...

Page 392: ...alled hanging 25 hazardous material 369 height installed at a height 25 hold to run 30 hole configuration base 68 HRA 20 humidity operation 53 storage 53 I illustrations base hole configuration 68 brake release buttons 66 cabling inside base 169 cabling inside frame 168 cabling inside upper arm housing 166 mounting surface 69 power supply to connector R1 MP 67 inspection 132 installation equipment...

Page 393: ...s axes 5 and 6 intervals 129 safety risks 38 wrist unit 138 wrist unit intervals 129 operating conditions 53 orienting robot 68 P pedestal installed on pedestal 25 plastic disposal 369 position robot when draining wrist unit 139 142 143 when filling oil in wrist unit 140 positions at wrist center IRB 1600 1 2 m reach 56 IRB 1600 1 45 m reach 57 IRB 1600ID 4 1 5 58 IRB 1660ID 59 position switch axi...

Page 394: ...s 341 system integrator requirements 19 system parameter Gravity Alpha 73 Gravity Beta 73 T temperatures operation 53 storage 53 testing brakes 36 three position enabling device 30 tightening torques attachment screws base gearbox unit 243 lower arm frame 199 mechanical stop axis 1 103 mechanical stop axis 2 107 mechanical stop axis 3 112 motor axis 1 260 motor axis 2 266 motor axis 3 271 277 moto...

Page 395: ...180 181 base 242 332 334 gearbox 1 332 334 robot 64 198 199 241 243 382 upper arm 185 186 191 193 upper arm tube 298 working range 55 restricting axis 1 113 wrist unit oil change 138 replacing 201 screws tightening torque 204 spare part number 201 Z zero position checking 368 Product manual IRB 1600 1660 395 3HAC026660 001 Revision W Copyright 2006 2018 ABB All rights reserved Index ...

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Page 398: ...Telephone 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics and Motion No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics and Motion 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC026660 001 Rev W en Copyright 2006 2018 ABB All rights reserved Specifications subject to change without notice ...

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