ABB IRBP Product Manual Download Page 7

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217

6.4

Motors ............................................................................................................

217

6.4.1

Replacing motors ....................................................................................

223

6.4.2

Checking insulation .................................................................................

224

6.5

Rotary units .....................................................................................................

224

6.5.1

Replacing rotary unit ................................................................................

226

6.6

Support collar ...................................................................................................

226

6.6.1

Replacing support collar axis .....................................................................

228

6.7

Electrical .........................................................................................................

228

6.7.1

Replacing current collector .......................................................................

230

6.7.2

Replacing SMB board ..............................................................................

232

6.7.3

Station changing indication .......................................................................

235

6.8

Controller ........................................................................................................

235

6.8.1

Overview of the controller .........................................................................

236

6.8.2

Replacing drive module I/O .......................................................................

239

6.8.3

Replacing contactor .................................................................................

243

6.8.4

Replacing auxiliary contact .......................................................................

247

6.8.5

Replacing auxiliary relays for breaker .........................................................

Start up ...........................................................................................................

251

7.1.1

Starting production ..................................................................................

254

7.1.2

Loading the workpiece .............................................................................

255

7.1.3

Stop during loading/unloading ...................................................................

258

7.2

Program stop and restart of program ....................................................................

258

7.2.1

Program stop .........................................................................................

261

7.2.2

Restarting the system ..............................................................................

262

7.2.3

Restarting after an emergency stop ............................................................

263

7.2.4

Measures in the event of disturbances in the operating sequence ....................

265

Calibration information

265

8.1

When to calibrate .............................................................................................

266

8.2

Calibration marks ..............................................................................................

269

8.3

Updating revolution counters ...............................................................................

272

8.4

Manual setting of the calibration values .................................................................

273

8.5

Recalibrating the axes ........................................................................................

274

8.6

Calibration of the station interchange unit for positioner IRBP ...................................

275

8.7

Multi-arc calibration (not IRBP C) .........................................................................

275

8.7.1

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

276

8.7.2

Calibrating the multi-arc system .................................................................

287

8.8

Tool and speed data ..........................................................................................

289

8.9

Drivers ............................................................................................................

289

8.9.1

Identification of load data for positioners IRBP ..............................................

295

8.9.2

Safe position ..........................................................................................

296

8.9.3

Work positions ........................................................................................

297

8.9.4

Process position .....................................................................................

298

8.9.5

Service position ......................................................................................

299

8.9.6

Define payload for a mechanical unit ..........................................................

304

8.9.7

Define base frame ...................................................................................

Environmental information ..................................................................................

307

10 Reference information

307

10.1 Applicable standards .........................................................................................

309

10.2 Unit conversion .................................................................................................

310

10.3 Weight specifications .........................................................................................

311

10.4 Standard toolkit, IRC5 ........................................................................................

312

10.5 Standard tools IRBP ..........................................................................................

Product manual - IRBP /D2009

3HAC037731-001 Revision: T

Table of contents

Summary of Contents for IRBP

Page 1: ...ROBOTICS Product manual IRBP D2009 ...

Page 2: ...Trace back information Workspace 20A version a6 Checked in 2020 03 05 Skribenta version 5 3 033 ...

Page 3: ...Product manual IRBP A IRBP B IRBP C IRBP D IRBP K IRBP R IRBP L IRC5 Document ID 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved Specifications subject to change without notice ...

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

Page 5: ...control units 66 2 5 Safety equipment options 66 2 5 1 Location of safety equipment 68 2 6 Customer options 68 2 6 1 Optional swivels 71 3 Installation and commissioning 71 3 1 Introduction to installation and commissioning 72 3 2 Installation and set up 73 3 3 Unpacking and handling 73 3 3 1 Pre installation procedure IRBP 75 3 3 2 Lifting the IRBP 82 3 3 3 Forces on foundation 86 3 3 4 Recommend...

Page 6: ...P 164 4 7 Safety interface SIB V for positioner A L 167 4 8 Safety interface SIB V for positioner B C D K R 169 5 Maintenance 169 5 1 Introduction 170 5 2 Specification of maintenance intervals 171 5 3 Maintenance schedule and expected component life 171 5 3 1 Maintenance schedule 172 5 4 Inspection activities 172 5 4 1 Inspection cables 177 5 4 2 Inspection current collector 179 5 4 3 Inspection ...

Page 7: ...turbances in the operating sequence 265 8 Calibration information 265 8 1 When to calibrate 266 8 2 Calibration marks 269 8 3 Updating revolution counters 272 8 4 Manual setting of the calibration values 273 8 5 Recalibrating the axes 274 8 6 Calibration of the station interchange unit for positioner IRBP 275 8 7 Multi arc calibration not IRBP C 275 8 7 1 Introduction 276 8 7 2 Calibrating the mul...

Page 8: ...grams 315 11 Lifting instructions 329 12 Spare parts 329 12 1 Spare part lists and illustrations 331 Index 8 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved Table of contents ...

Page 9: ...rained by ABB and have the required knowledge of mechanical and electrical installation repair maintenance work Product manual scope The manual covers covers all variants and designs of the IRBP 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 ...

Page 10: ...RBP D2009 Circuit diagrams on page 313 Circuit diagrams IRBP D 2009 3HAC031045 001 Safety manual for robot Manipulator and IRC5 or OmniCore controller i 3HAC021313 001 Product manual IRC5 IRC5 with main computer DSQC 639 3HAC047136 001 Product manual IRC5 IRC5 with main computer DSQC1000 3HAC050941 001 Operating manual IRC5 with FlexPendant 3HAC16578 1 Operating manual Calibration Pendulum 3HAC051...

Page 11: ... page 82 Added note about other variants in Orienting and securing the manip ulator on page 93 A new SMB unit and battery is introduced with longer battery lifetime D This revision includes the following additions and or changes Instruction for replacement of SMB board added see Replacing SMB board on page 230 Service Information System SIS is not available for IRBP positioners E This revision inc...

Page 12: ... plugs for access to lifting eye holes on the IRBP R frame L Published in release R18 1 This revision includes the following additions and or changes Added section Cut the paint or surface on the robot before replacing parts Safety restructured Information about myABB Business Portal added M Published in release R18 2 This revision includes the following additions and or changes Updated calibratio...

Page 13: ...ification for IRBP C see Identification of load data for positioners IRBP on page 289 S Published in release 20A The following updates are made in this revision Clarified information about pre reset button in complete chapter Oper ation on page 251 Clarified and added information in mounting instructions for rotating sealings see Mounting instructions for sealings on page 190 T Product manual IRBP...

Page 14: ...oning 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 m...

Page 15: ... The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters Product manual IRBP D2009 15 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved Product documentation Continued ...

Page 16: ...mpleted 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 ...

Page 17: ...ation of the robot when the safety devices are defective not in their intended location or in any other way not working When instructions for operation and maintenance are not followed Non authorized design modifications of the robot Repairs on the robot and its spare parts carried out by in experienced or non qualified personnel Foreign objects Force majeure Spare parts and equipment ABB supplies...

Page 18: ...nce of alcohol drugs or any other intoxicating substances are not allowed to install maintain service repair or use the robot The plant liable must make sure that the personnel is trained on the robot and on responding to emergency or abnormal situations Personal protective equipment Use personal protective equipment as stated in the product manual 18 Product manual IRBP D2009 3HAC037731 001 Revis...

Page 19: ...n which if not avoided will result in ser ious injury DANGER Signal word used to indicate a potentially hazardous situation which if not avoided could result in serious injury WARNING Signal word used to indicate a potentially hazardous situation related to electrical hazards which if not avoided could result in serious injury ELECTRICAL SHOCK Signal word used to indicate a potentially hazardous s...

Page 20: ... to indicate where to find additional information or how to do an operation in an easier way TIP 20 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 1 Safety 1 2 1 Safety signals in the manual Continued ...

Page 21: ...iption Symbol Warning xx0900000812 Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc Caution xx0900000...

Page 22: ... 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 22 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights res...

Page 23: ...over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page Product manual IRBP D2009 23 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 24: ... 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 24 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 25: ...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 Product manual IRBP D2009 25 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 26: ... 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 26 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Con...

Page 27: ...otective stops and emergency stops are described in the product manual for the controller For more information see Product manual IRC5 Product manual IRBP D2009 27 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 1 Safety 1 3 Robot stopping functions ...

Page 28: ... device fitted to the robot The maximum TCP speed and the maximum velocity of the robot axes are detailed in the section Robot motion in the product specification for the respective manipulator Consider exposure to hazards such as slipping tripping and falling Consider hazards from other equipment in the robot system for example that guards remain active until identified hazards are reduced to an ...

Page 29: ...grator of the robot system must ensure that emergency stop functions are interlocked in accordance with applicable standards The integrator of the robot system must ensure that safety functions are interlocked in accordance with applicable standards Other hazards WARNING Gravity and the release of braking devices can create additional hazards Never stay beneath a robot arm A robot may perform unex...

Page 30: ... supply The workpiece fixtures and positioner are usually in direct contact with the welding circuit and should therefore be regarded as live Do not touch live parts of the equipment with your bare hands or with damp gloves Connect the supplied 6 mm2 earth conductor between the controller and the positioner The connection points are prepared with M8 bolts See the product manual for the robot contr...

Page 31: ...ting when the operator is inside the service area Action Press the pre reset button this permits a pre reset of the safety circuits for the light barriers of 10 seconds 1 Press and hold the start button operator ready button on the operator panel within 10 seconds 2 Verify the safety functions Before the robot system is put into operation verify that the safety functions are working as intended an...

Page 32: ...bricants oil or grease When handling oil grease or other chemical substances the safety information of the respective manufacturer must be observed Note Take special care when handling hot lubricants Elimination 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 ho...

Page 33: ...how much has previously been drained from the gearbox Specified amount de pends on drained volume For lifetime reasons always drain as much oil as possible from the gearbox The magnetic oil plugs will gather residual metal chips Contaminated oil in gearboxes Hazards related to batteries Under rated conditions the electrode materials and liquid electrolyte in the batteries are sealed and not expose...

Page 34: ...on See also the safety information related to installation and operation 34 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 1 Safety 1 5 1 Maintenance and repair Continued ...

Page 35: ... described below 1 Run each axis to a position where the combined weight of the manipulator 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 manipulator does not change position as the motors are switched off then the brake function is adequate Product manual IRBP D2009 35 3HAC037731 001 Revision T C...

Page 36: ... time DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers A risk assessment must be done to address both robot and robot system specific hazards Related information See also the safety information related to installation operation maintenance and repair 36 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 201...

Page 37: ...1 7 Decommissioning General See section Decommissioning on page 305 Product manual IRBP D2009 37 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 1 Safety 1 7 Decommissioning ...

Page 38: ...This page is intentionally left blank ...

Page 39: ...ontrol cabinet IRC5 Operator panel s Personal safety system Example of single robot system Example of an IRBP D manipulator system xx0900000807 Positioner 1 Robot with pedestal 2 Floor mounting base 3 Safety module 4 Light beam 5 Pre reset 6 Operator panel 7 Continues on next page Product manual IRBP D2009 39 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 2 System descriptio...

Page 40: ...ual jog 8 Service door with gate switch 9 Controller 10 40 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 2 System description 2 1 System overview Continued ...

Page 41: ...C motors with electro magnetic brakes The letter in the positioner name indicates the positioner type and the number indicates its maximum handling capacity in Kg Positioner models Illustration IRBP xx0900000830 IRBP A 250 500 750 Continues on next page Product manual IRBP D2009 41 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 2 System description 2 2 1 IRB Positioner overv...

Page 42: ... IRBP B 250 500 750 xx0900000846 IRBP C 500 1000 Continues on next page 42 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 2 System description 2 2 1 IRB Positioner overview Continued ...

Page 43: ...0000832 IRBP K 300 600 1000 xx0900000845 IRBP L 300 600 1000 2000 5000 Continues on next page Product manual IRBP D2009 43 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 2 System description 2 2 1 IRB Positioner overview Continued ...

Page 44: ...stration IRBP xx0900000838 IRBP R 300 600 1000 44 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 2 System description 2 2 1 IRB Positioner overview Continued ...

Page 45: ... interchange unit MID 2 1 The station interchange unit for two stations consists of the following xx0900000834 Gear drive 1 AC servo motor with integrated resolver and brake 2 Limit switch with limit position disc 3 Connection panel 4 Continues on next page Product manual IRBP D2009 45 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 2 System description 2 2 2 Station intercha...

Page 46: ...vo motor with integrated resolver and brake 2 Limit switch 3 Limit position disc 4 Connection panel 5 46 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 2 System description 2 2 2 Station interchange unit MID Continued ...

Page 47: ...ically for robot applications and is intended for positioning the workpiece MTD units xx0900000843 MTD 250 MTD 500 750 MTD 2000 MTD 5000 Continues on next page Product manual IRBP D2009 47 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 2 System description 2 2 3 Rotary units ...

Page 48: ...ial grease article number 501 869 001 AC servo motor The AC servo motor is a permanent magnetized 3 phase AC motor and runs smoothly throughout the entire speed range The motor is equipped with high grade permanent magnets that are marginally affected by the temperature The motor has a resolver for motor feedback and position indication The motor is equipped with a brake for locking into a positio...

Page 49: ...nt during rotation xx0900000844 Support collar 1 Shaft with the mounting flange 2 Flange bearing with spherical bearing position 3 Product manual IRBP D2009 49 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 2 System description 2 2 4 Support collar ...

Page 50: ...nstalled on a pivot frame in the Single Cabinet Controller Dual Cabinet Controller Drive module In the Dual Controller the Drive Module DM1 and Control Module CM are jointly connected to incoming power supply Other drive modules DM2 DM4 have separate incoming power sources Continues on next page 50 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 2 Sy...

Page 51: ...or on Control Module or Single Cabinet 7 Diode panel that shows status of safety loops option on Control Module or Single Cabinet 8 Running time meter on Drive Module or Single Cabinet 9 Main power switch Circuit Breaker on Drive Module 10 Stand by lamp indicates that electronic supply is switched on by the Control Module mains switch 11 Flex Pendant 12 Continues on next page Product manual IRBP D...

Page 53: ... screen is easy to clean and resistant to water oil and accidental welding splashes The FlexPendant consists of both hardware and software and is a complete computer in itself It is connected to the robot controller by an integrated cable and connector The hot plug button option makes it possible to disconnect the FlexPendant in automatic mode and continue running without it Continues on next page...

Page 54: ...evice F Stylus pen G Reset button H Joystick Use the joystick to move the manipulator This is called jogging the robot There are several settings for how the joystick will move the manipulator Continues on next page 54 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 2 System description 2 4 1 The FlexPendant Continued ...

Page 55: ...troller Hard buttons There are dedicated hardware buttons on the FlexPendant You can assign your own functions to four of the buttons xx0900000023 Programmable keys 1 4 How to define their respective function is detailed in section Programmable keys in Operating manual IRC5 with FlexPendant A D Select mechanical unit E Toggle motion mode reorient or linear F Toggle motion mode axis 1 3 or axis 4 6...

Page 56: ... position permit robot motion and any hazards controlled by the robot Release of or compression past the center enabled position will stop the hazard for example robot motion CAUTION For safe use of the three position enabling device the following must be implemented The three position enabling device must never be rendered inoperational in any way If there is a need to enter safeguarded space alw...

Page 57: ...le the other hand performs operations on the touch screen A left hander however can easily rotate the display through 180 degrees and use his right hand to support the device en0400000913 Continues on next page Product manual IRBP D2009 57 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 2 System description 2 4 1 The FlexPendant Continued ...

Page 58: ...et menu F Main menu The following items can be selected from the Main menu HotEdit Inputs and Outputs Jogging Production Window Program Editor Program Data Backup and Restore Calibration Control Panel Event Log Continues on next page 58 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 2 System description 2 4 1 The FlexPendant Continued ...

Page 59: ...otors on off program state and so on This is described in section Status bar in Operating manual IRC5 with FlexPendant Close button Tapping the close button closes the presently active view or application Task bar You can open several views from the Main menu but only work with one at a time The task bar displays all open views and is used to switch between these Quickset menu The quickset menu pr...

Page 60: ...nel xx0900000860 Emergency stop 1 Motors On button 2 Operating mode selector 3 Continues on next page 60 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 2 System description 2 4 2 External control units ...

Page 61: ...er working area Single working area This variant applies to stations with one working area for the operator xx0900000863 Emergency stop 1 Entry permitted indication 2 Start process reset toggle function 3 Program start 4 Program stop 5 Continues on next page Product manual IRBP D2009 61 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 2 System description 2 4 2 External contro...

Page 62: ...icationi Press the button after loading the workpiece in the station The indication lamp in the button turns on and 1 Gives the ready signal to the robot system that loading of the workpiece in the station is complete 2 Resets the personal safety protection around the sta tion s working area Press the button a second time to start the process Start processii Press the button once again the status ...

Page 63: ...ess Systems delivered before March 2019 have these two jumpers installed on delivery Manual Jog control panel Manually adjustable load position or Manual Jog is a control panel fitted between the robot controller and the positioner Manual Jog can be used for Positioner IRBP K R Positioner 2 x IRBP L Continues on next page Product manual IRBP D2009 63 3HAC037731 001 Revision T Copyright 2010 2020 A...

Page 64: ... a distance from the positioner axis so that any unsecured fixtures or object parts cannot fall and injure the operator Using Manual Jog in operation Note Action Set the robot to motors on operating mode and deactivate the positioner from the control system 1 Press and hold the SafeBall during the whole op eration 2 Press and hold the buttons for the desired direc tion until the positioner has rea...

Page 65: ...before the indication lamp is turned off the Manual Jog program task gets stuck To recover go into the Manual Jog program task on the FlexPendant and move the program pointer to the start of the task Product manual IRBP D2009 65 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 2 System description 2 4 2 External control units Continued ...

Page 66: ... located on the sidewall of the cabinet The control equipment may also be located on the guard or on a stationary building wall xx0900000796 Continues on next page 66 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 2 System description 2 5 1 Location of safety equipment ...

Page 67: ... 2 IRB 3 Gate switch 4 Gate reset 5 IRBP 6 Manual jog panel 7 Pre reset 8 Operating panel 9 Light barrier 10 Product manual IRBP D2009 67 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 2 System description 2 5 1 Location of safety equipment Continued ...

Page 68: ...ivels Air swivel 1 channel xx1000000177 Air swivel 2 channel xx1000000179 Continues on next page 68 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 2 System description 2 6 1 Optional swivels ...

Page 69: ...1000000178 Air swivel 1 channel and 1 electrical channel xx1000000180 Product manual IRBP D2009 69 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 2 System description 2 6 1 Optional swivels Continued ...

Page 70: ...This page is intentionally left blank ...

Page 71: ... 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 page17 before performing any installation work Note If the IRBP is connected to power always make sure that the robot is connected to protective earth and ...

Page 72: ...eck that the equipment is not damaged in any way Report any visible transport damage immediately Lifting instructions Lifting of the safety equipment must only be carried out using equipment that corresponds with the applicable lifting standards be carried out by authorized personnel Note Lifting eyes standard as well as with swivel are not delivered with the IRBP Use lifting eyes and or swiveled ...

Page 73: ...the requirements 5 Before moving the IRBP system please observe and read the sections regarding lifting of the IRBP system 6 When these prerequisites are met the IRBP system may be taken to its installation site 7 Requirements foundation The positioner requires a good foundation and or a concrete floor with strength according to standard C20 25 or better according to ENV 206 If necessary use shims...

Page 74: ... how to warm up the robot Protection classes The table below shows the protection class of the manipulators Protection class Equipment IP 42 Manipulator IRBP A IP 42 Manipulator IRBP B IP 42 Manipulator IRBP C IP 42 Manipulator IRBP D IP 65 Manipulator IRBP L IP 42 Manipulator IRBP K IP 42 Manipulator IRBP R 74 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights ...

Page 75: ...rding to the specified lifting weight in section Lifting weight WARNING Do not walk under a suspended load WARNING In order to prevent damage only use the pre mounted lifting eyes Lifting weight The table below shows the minimum and maximum weights of the different IRBP models for exact weight see the silver tags on the manipulator Weight IRBP Weight max kg Weight min Handling weight kg IRBP model...

Page 76: ...700 2000 5000 1 515 1090 300 IRBP K 2 570 1980 600 2 570 1980 1000 645 620 300 IRBP R 1 380 1285 600 1 380 1285 1000 Continues on next page 76 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 3 2 Lifting the IRBP Continued ...

Page 77: ... IRBP A xx0900000897 Continues on next page Product manual IRBP D2009 77 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 3 2 Lifting the IRBP Continued ...

Page 78: ...000089 Lifting IRBP D xx1000000090 Continues on next page 78 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 3 2 Lifting the IRBP Continued ...

Page 79: ... R Note Action xx1700001322 Remove the plates to get access to the lifting eye holes in the frame 1 Continues on next page Product manual IRBP D2009 79 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 3 2 Lifting the IRBP Continued ...

Page 80: ...ote Save the plugs for refit after installation 2 2 pcs xx1700001323 Attach the lifting eyes 3 Continues on next page 80 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 3 2 Lifting the IRBP Continued ...

Page 81: ... IRBP L xx1000000093 Lifting beam 4000 mm 1 Product manual IRBP D2009 81 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 3 2 Lifting the IRBP Continued ...

Page 82: ... both the positioner and the robot The forces are the sum of the maximum component for each direction Maximum floor loads in relation to the base coordinate system and indicated per each screw of the base on the positioner see figure below Forces IRBP A xx0900000907 Screw dimen sion Max load at emergency stop N Endurance load in operation N Rotation unit Fz Fxy Fz Fxy M16 11500 1930 6300 800 A 250...

Page 83: ...sion Max load at emergency stop N Endurance load in operation N Rotation unit Fz Fxy Fz Fxy M20 5000 1500 3100 1000 K 300 M20 10200 2000 7000 2000 K 600 M20 10200 2000 7000 2000 K 1000 Continues on next page Product manual IRBP D2009 83 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 3 3 Forces on foundation Continued ...

Page 84: ...1800 5200 500 L 300 M20 18800 2200 12000 1200 L 600 M20 18800 2200 12000 1200 L 1000 M20 36700 3700 25700 1700 L 2000 M20 44500 9000 35000 3000 L 5000 Continues on next page 84 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 3 3 Forces on foundation Continued ...

Page 85: ...9000 20600 5000 B 750 M16 8000 3000 6000 1500 C 500 M20 22300 6400 15000 2700 C 1000 M20 15500 4500 10300 2500 D 300 M20 30900 9000 20600 5000 D 600 M16 7800 3000 5400 1380 R 300 M20 22300 6400 15000 2700 R 600 M20 22300 6400 15000 2700 R 1000 Product manual IRBP D2009 85 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 3 3 Forces on foundati...

Page 86: ...tor to the base See section Screw joints on page 87 Steel structure See section Screw joints on page 87 Concrete floor Note Expansion shell anchor bolts with a notch or chemical anchor are recommended for the IRBP CAUTION It is of the utmost importance that all screw joints be tightened with the correct torque Application The following tightening torques are to be used for all screw joints in meta...

Page 87: ...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 of M6 ...

Page 88: ...aintenance 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 follo...

Page 89: ...orque 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 IRBP D2009 89 3HAC037731 001 Revision...

Page 90: ...dling Note Action Wrist straps must be tested frequently to ensure that they are not damaged and are operating cor rectly Product manual IRC5 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 discharge of static voltages and must be grounded...

Page 91: ...e The pedestal can be placed in different hole groups on the stand Exercise care to ensure the robot and positioner do not collide during station switching Recommended spacing see the chapter for respective positioner Continues on next page Product manual IRBP D2009 91 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 4 1 Securing the robot st...

Page 92: ...hor or chemical type For more information see section Forces on foundation on page 82 Securing the robot stand Use this procedure to secure the robot stand Note Action See instructions in Orienting and securing the manipulator on page 93 Position the robot stand at the intended work site 1 92 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installa...

Page 93: ...000914 Screws for fastening floor bolts 1 Adjusting screws 2 Leveling meter 3 Shim 4 Securing the manipulator IRBP Use this procedure to secure the manipulator Note Action Position the IRBP at the intended work site 1 Continues on next page Product manual IRBP D2009 93 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 4 2 Orienting and securin...

Page 94: ...the frame ends 7 xx1700001324 Valid for IRBP R Refit the protection plugs to the lifting eye holes 8 Securing the manipulator IRBP L using fixture laser Use this procedure to secure the IRBP L using a fixture laser Note Action Position the IRBP L at the intended work site 1 Drill all holes according to the screw manufactures recommenda tion for the specific foundation Facts and drilling recommenda...

Page 95: ...he laser after tightening the floor bolts 6 Example of fixture laser aligning xx1000000984 The figure shows an example of aligning the bearing units using laser sensors for example NXA by Fixturlaser or TKSA41 from SKF turning disc adapters and adjustment tool For more information see Example of adjusting the bearing units for IRBP L on page 96 Continues on next page Product manual IRBP D2009 95 3...

Page 96: ...turning disc adapter is to be considered generic and therefore not available as spare parts delivered by ABB xx1700001361 Gearbox 1 Rotary disc 2 Bearing disc 3 Bearing house 4 Required equipment Article number Equipment 3HAC036527 001 Adjustment tool MTD 250 3HAC036532 001 Adjustment tool MTD 750 3HAC037846 001 Adjustment tool MTD 2000 Laser sensor Turning disc adapter Continues on next page 96 P...

Page 97: ...tools using the adjustment screws 2 xx1700001365 Loosen the bearing screws from both sides of the bearing house 3 xx1700001366 Fasten the turning disc adapter on to the bearing disc using the adapter screws 4 Continues on next page Product manual IRBP D2009 97 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 4 2 Orienting and securing the man...

Page 98: ...en the turning disc adapter on to the rotary disc using the adapter screws 1 xx1700001367 Fit the laser sensor on the indentation of the turning disc adapter 2 Pull the sensor as close as possible to the edge of the indentation 3 Tighten the sensor chain 4 Ensure that the adapter screws are tightened 5 Continues on next page 98 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 202...

Page 99: ...position as position 3 13 Calibrate the positioner 14 Calibrating the positioner Note Action Measure the IRBP L 1 Rotate the bearing disc to 0 degrees 12 o clock 2 Rotate the rotary disc to 0 degrees 12 o clock 3 Adjust the laser value by rotating the vertically aligned set screws 4 Rotate the bearing disc to 90 degrees 9 o clock 5 Rotate the rotary disc to 90 degrees 9 o clock 6 Adjust the laser ...

Page 100: ... 0 44 0 23 0 44 0 0 22 266 83 1160 L 600 1000 L 1250 0 08 0 05 0 08 0 0 04 0 56 0 29 0 56 0 0 28 266 83 1510 L 600 1000 L 1600 0 08 0 05 0 08 0 0 04 0 70 0 36 0 70 0 0 35 266 83 1910 L 600 1000 L 2000 0 08 0 05 0 08 0 0 04 0 88 0 45 0 88 0 0 44 266 83 2410 L 600 1000 L 2500 0 08 0 05 0 08 0 0 04 1 10 0 56 1 10 0 0 55 266 83 3060 L 600 1000 L 3150 0 08 0 05 0 08 0 0 04 1 40 0 71 1 40 0 0 70 266 83 ...

Page 101: ...re of the special risks involved with these various components WARNING Do not walk under a suspended load Lifting instructions The control cabinet is fitted with lifting eyes to facilitate lifting Control equipment may only be lifted by authorized personnel using equipment that complies with applicable lifting standards xx0900000915 Space requirements See installation description in Product manual...

Page 102: ...t is defined in section Standard tools IRBP on page312 Standard toolkit Mounting the shield Note It s important to check tightening torque on all pre mounted fixings Note Action Attach a lifting device to the shield and align it to the beam 1 Continues on next page 102 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3...

Page 103: ...0441 Loosen the locking nut with washer C from the screws in the back of the shields and push the washer towards the nut creating a space of 5 8 mm between the shield and washer 5 A B B xx1700000446 Push down the two inner covers B first and then the outer cover A between the shield and the washer C 6 Tighten the locknuts 7 Product manual IRBP D2009 103 3HAC037731 001 Revision T Copyright 2010 202...

Page 104: ... be able to for example pull cable harness through 12x M24 FAS 3 x 45 180 11x 30 267 370 440 136 140 220 A A 4x M6 85 100 12 17 A A xx1800001201 104 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 4 5 Dimensions of the tailstock IRBP L 5000 ...

Page 105: ...electrically so that a dangerous machine movement can be averted immediately The safety distance between the risk zone and the light field need to be sufficient to ensure that a dangerous machine movement is interrupted before a person can reach the risk zone Mechanical and electrical installations need to be carried out by trained and qualified per sonnel Installation and commissioning of the equ...

Page 106: ... placed on fence 1 Control equipment for safety placed on SC DC 2 Continues on next page 106 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 5 1 Safe positioning of the control equipment Continued ...

Page 107: ...23 Bracket 1 Hole for M8 2 Continues on next page Product manual IRBP D2009 107 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 5 1 Safe positioning of the control equipment Continued ...

Page 108: ... switch 4 Gate reset 5 IRBP 6 Manual jog panel 7 Pre reset 8 Operating panel 9 Light barrier 10 108 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 5 1 Safe positioning of the control equipment Continued ...

Page 109: ...s the risk zone where moving parts are activated Light barriers are an optoelectronics protective device intended to secure dangerous areas xx0900000989 Continues on next page Product manual IRBP D2009 109 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 5 2 Positioning of light barrier ...

Page 110: ...er s LED s to correct the light beams parallel 1 xx1000000036 Adjust to the optimal horizontal position us ing the set screws 1 if necessary 2 Continues on next page 110 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 5 2 Positioning of light barrier Continued ...

Page 111: ... Check that the receiver unit is correctly adjus ted 3 Product manual IRBP D2009 111 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 5 2 Positioning of light barrier Continued ...

Page 112: ...ced make and break safety switch interlock contact Positioning xx0900000925 Safety switch 1 Safety lock 2 Information Action Mount the safety switch and the safety lock in a suitable position 1 Mount the cable using straps 2 Attache the cable according to section Connections safety equipment on page 128 3 112 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights re...

Page 113: ...15 Cable signal IRBP STN1 1 7 10 15 Cable motor IRBP STN1 2 7 10 15 Cable signal IRBP STN2 3 7 10 15 Cable motor IRBP STN2 4 7 10 15 Cable signal robot IRB 5 7 10 15 Cable motor robot IRB 6 2 5 CAN bus cable safety signals cable position switches 7 15 Cable control panel manual jog 8 Continues on next page Product manual IRBP D2009 113 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights r...

Page 114: ...rogramming from operator area STN1 15 7 Cable activation unit Programming from operator area STN2 16 7 Cable pre reset STN1 17 7 Cable pre reset STN2 18 7 10 15 Cable protective earth 19 7 10 15 Cable protective earth 20 IRBP B C D K R 12 xx1000000226 Gate reset A Pre reset B Continues on next page 114 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved ...

Page 115: ...5 Cable signal IRBP 4 7 10 15 Cable motor IRBP 5 7 10 15 Cable signal robot IRB 6 7 10 15 Cable motor robot IRB 7 15 Cable light beam 8 7 Cable pre reset 9 15 Cable external reset push button gate switch 10 7 Cable gate switch 11 7 10 15 Cable protective earth 12 Product manual IRBP D2009 115 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 6...

Page 116: ...See Circuit diagram 1 Connect the ground connection weld negative 2 The positioner chassis is to be separated from the system ground eg cable screen 2 Connect the air 3 to the connections 3 On the rotary unit there is a free cable hose for connection to the fixture 4 Current collectors xx0900000990 Current collector connection 1 1 Current collector connection 2 2 Continues on next page 116 Product...

Page 117: ...1 SMB Resolversignals 5 CS1 Customer Signals 1 6 CS2 Customer Signals 2 7 XS50 XP50 Motor Power 8 Earth connection point 9 Product manual IRBP D2009 117 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 6 2 Electrical assembly IRBP Continued ...

Page 118: ...B Resolver signals IRBP 2 XS41 2 C Resolver signals IRBP 1 XS41 D Jumper connector if only using one IRBP XP41 2 E Cover hood if only using one IRBP F Continues on next page 118 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 6 3 Connections for SC DC DM ...

Page 119: ... B xx0900001005 Motor power XS 101 A Resolver signals XS 41 B Product manual IRBP D2009 119 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 6 3 Connections for SC DC DM Continued ...

Page 120: ...efore handling the unit see The unit is sensitive to ESD on page 90 Note Note that the wiring to the pivot frame must be detached before the pivot frame is opened Opening the pivot frame xx0900001051 Information Action Open the controller cabinet 1 Disconnect the cables on the axis selector unit 2 Continues on next page 120 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 AB...

Page 121: ...pivot frame Information Action Secure the pivot frame with the axis selector plate by tightening the two locking screws pos A 1 Fit the cables on the axis selector unit 2 Product manual IRBP D2009 121 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 6 4 Open and close the pivot frame Continued ...

Page 122: ...tional axis are delivered with this new harness If it is missing the system has to be upgraded before installing the retrofit option Part list Note Article number Equipment Standard set for upgrade 3HAC057115 004 Positioner interface A Drive system 09 3HAC057115 005 Positioner interface B D Drive system 09 3HAC057115 009 Positioner interface C Drive system 09 3HAC057115 008 Positioner interface K ...

Page 123: ...om the inside 1 Fit the arm and mount the shaft through the bushings The bushings are often tight so it is re commended to carefully use a plastic hammer 2 Lock the shaft with a screw 3 Continues on next page Product manual IRBP D2009 123 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 6 5 Retrofit an interface to the IRC5 controller Continu...

Page 124: ...s drive unit to the additional drive units Note 1 2 or 3 drive units depending on the type of the positioner 1 xx1600000457 Attach the SMB2 cable to the X5 connector on the axis computer 2 Continues on next page 124 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 6 5 Retrofit an interface to the IRC5 controller Cont...

Page 125: ...ch the hinge to the attachment plate 4 xx1700001274 Attach the axis selector to the hinge 5 Continues on next page Product manual IRBP D2009 125 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 6 5 Retrofit an interface to the IRC5 controller Continued ...

Page 126: ...ain drive module to attach the rail 6 xx1600000462 Locate the connector A7 XS8 in the signal harness from XS101 and connect it to the existing harness in the bottom of the cabinet 7 xx1600000463 Locate the connector A43 XS11 in the signal har ness from XS101 and connect it to the contactor board at the left side of the cabinet 8 Continues on next page 126 Product manual IRBP D2009 3HAC037731 001 R...

Page 127: ...ctor board A43 X6 Connect the W11 X3 connector on cable item 26 to X3 on the W11 connector 9 Item 24 Cable Patch 3HEA802215 001 Item 25 3 way RJ45 8P 8C shielded MPK402 3HEA802183 001 Item 26 Cable I O RS485 3HEA802201 001 Attach the connectors X1 X2 and A111 TB1 to the axis selector 10 xx1600000465 Attach the ground cable from the axis selector to the chassis 11 Product manual IRBP D2009 127 3HAC...

Page 128: ...y contact block for positioner axes 1 K1 1 Motor contactor with auxiliary contact block for positioner axes 2 K2 2 Motor contactor with auxiliary contact block for positioner axes 3 K3 3 Motor contactor with auxiliary contact block for positioner axes 4 K4 4 Motor contactor with auxiliary contact block for positioner axes 5 K5 5 Auxiliary relays for breaker activation K11 K15 6 Connector Drive uni...

Page 129: ... 0 0 0 1 0 1 1 3 0 1 1 1 1 1 1 4 0 0 0 1 0 1 0 5 2 3 3 5 1 5 4 6 1 1 1 1 1 1 1 7 1 1 1 1 1 1 1 8 1 1 1 1 1 1 1 9 Continues on next page Product manual IRBP D2009 129 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 7 1 Connections safety equipment Continued ...

Page 130: ...osition indication for robot travel track A13 X5 4 Home position transport position indication A13 X6 5 Button for pre reset station 1 A13 X4 6 Gate switch A13 X2 1 7 Button for gate reset A13 X2 2 8 Gate switch A13 X2 1 9 Button for gate reset A13 X2 2 10 CAN IN A131 TB6 11 Positioner signals A131 TB2 12 Safety signals A13 X8 13 CAN OUT A13 A35 J1 14 Continues on next page 130 Product manual IRBP...

Page 131: ...2 2 4 Supervision of contactors in drive module A131 TB2 5 CAN OUT A13 A35 J1 6 Safety signals A13 X8 7 Positioners safety signals 8 CAN IN A131 TB6 9 Continues on next page Product manual IRBP D2009 131 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 7 1 Connections safety equipment Continued ...

Page 132: ... block in the safety control equipment xx0900001014 Light barrier 1 1 Button for pre reset station 1 2 Light barrier 2 3 Button for pre reset station 2 4 Home position transport position indication 5 Button for activation unit station 1 6 Button for activation unit station 2 7 Gate switch 8 Continues on next page 132 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All r...

Page 133: ...Light barrier 1 A13 X3 1 Push button for pre reset station 1 A13 X4 2 Gate switch A13 X2 1 3 Push button for resetting gate A13 X2 2 4 Product manual IRBP D2009 133 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 7 1 Connections safety equipment Continued ...

Page 134: ...the separable panel for the control equipment for safety POSITIONER SIGNALS 1 1 xx0900001022 Connect the cable to connection A131 TB2 1 in the control equipment 2 xx0900001026 Make the cable gland in the separable panel on the SC or DC drive mod ule POSITIONER SIG NALS 1 3 Continues on next page 134 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 I...

Page 135: ...e cable to connector A11 X3 or A11 X4 in SCC DCC 1 4 Product manual IRBP D2009 135 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 7 2 Connection of cable for manipulator signals Continued ...

Page 136: ...xx0900001035 Add a cable gland to the separable panel for the control equipment for safety SAFETY SIGNALS 1 1 xx0900001036 Connect the cable to con nector A13 X8 in the control equipment for safety 2 2 Continues on next page 136 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 7 3 Connection of cable for safety signa...

Page 137: ...DCC control module SAFETY SIGNALS 3 3 xx0900001039 Connect the cable to con nector A13 X9 in SCC DCC 4 Product manual IRBP D2009 137 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 7 3 Connection of cable for safety signals Continued ...

Page 138: ...nits are described in the Product manual IRC5 Drive system small manipulators Drive system small manipulators consists of the following Axis computer Main Drive Unit Rectifier Drive unit for positioner Cables and contactors for connecting rotary unit Continues on next page 138 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commiss...

Page 139: ...ositioner A41 5 Drive system large manipulators Drive system large manipulators consists of the following Axis computer Main Drive Unit Rectifier included Drive unit for positioner Cables and contactors for connecting rotary unit Continues on next page Product manual IRBP D2009 139 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 7 4 Drive sy...

Page 140: ...t ADU for positioner A41 3 Additional Drive Unit ADU for positioner A41 4 Additional Drive Unit ADU for positioner A41 5 140 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 7 4 Drive system Continued ...

Page 141: ...al of fourteen axes The measurement system for positioners consists of the following Axis computer Communications cable MS2 Serial measurement board located in the external distribution box Resolver connection cable Connections xx1000000046 A42 X4 Measurement Link 1 1 A42 X5 Measurement Link 2 2 A42 X9 Console port 3 Product manual IRBP D2009 141 3HAC037731 001 Revision T Copyright 2010 2020 ABB A...

Page 142: ... the options and settings that were ordered In some cases it might be necessary to reload the software for example when the RobotWare software needs to be upgraded or when the configuration needs to be changed see Upgrading the software on page 143 142 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 8 1 Starting the...

Page 143: ...g the system Before modifying the system it is recommended to take a backup of the system and put all axes of the robot and any external axes are in their zero positions Creating a system for RobotWare 5 In RobotWare 5 the positioner is loaded as an additional option to the system Before creating the system the positioner option disk must be installed to the RobotStudio mediapool The license file ...

Page 144: ... the positioner can be imported using a settings file Use this procedure to create and download the system Action Create a new system using the Installation Manager in RobotStudio 1 In the Products tab click Add and select the RobotWare and Positioner product manifests 2 In the Licenses tab add the license for RobotWare The positioner does not require a license 3 In the Options tab click the Add s...

Page 145: ...oner position Load difference sides 1 and 2 exceeds specified maximum value If the weight of the fixture exceeds the value of Max load difference sides 1 and 2 run the positioner to the working range end when positioner side 2 is oriented towards the operator side positioner side 1 is toward the welding robot Then the positioner cannot move further downwards when the first fixture is installed 1 I...

Page 146: ...talling fixtures always test the brakes see Brake testing on page 35 146 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 9 1 Installing fixtures Continued ...

Page 147: ...eight of the fixture exceeds the value of Max load difference sides 1 and 2 run the positioner to the working range end when positioner side 2 is oriented towards the operator side positioner side 1 is toward the welding robot Then the positioner cannot move further downwards when the first fixture is removed 1 Remove the fixture on positioner side 1 2 Remove the fixture on positioner side 2 3 If ...

Page 148: ...ng fixtures always test the brakes see Brake testing on page 35 148 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 3 Installation and commissioning 3 9 2 Removing or changing fixtures Continued ...

Page 149: ...s Description Name UnitMap Mechanical unit 1 activated siSTN1_ACT 0 Mechanical unit 2 activated siSTN2_ACT 1 I O Signals configuration for DRIVO_1 Digital outputs TB4 Connected to unit Description Name UnitMap Output Positioner Activate mechanical unit 1 doACT_K1 0 1 Positioner Activate mechanical unit 2 doACT_K2 1 2 Positioner Activate mechanical unit 3 doACT_K3 2 3 Positioner Activate mechanical...

Page 150: ...nit 1 activated diK1_ACT 0 1 Positioner Mechanical unit 2 activated diK2_ACT 1 2 Positioner Mechanical unit 3 activated diK3_ACT 2 3 Positioner Mechanical unit 4 activated diK4_ACT 3 4 4 5 5 6 6 7 0 V input 1 7 8 Continues on next page 150 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 4 Configuration 4 1 Positioner Interface IRBP A Continued ...

Page 151: ...Configuration cross connections xx1000000130 Product manual IRBP D2009 151 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 4 Configuration 4 1 Positioner Interface IRBP A Continued ...

Page 152: ...anical unit 1 activated siSTN1_ACT 0 Mechanical unit 2 activated siSTN2_ACT 1 Mechanical unit 3 activated si_INTCH_ACT 2 I O Signals configuration for DRIVO_1 Digital outputs TB4 Connected to unit Description Name UnitMap Output Positioner Activate mechanical unit 1 doACT_K1 0 1 Positioner Activate mechanical unit 2 doACT_K2 1 2 Positioner Activate mechanical unit 3 doACT_K3 2 3 Positioner Activat...

Page 153: ...t 1 activated diK1_ACT 0 1 Positioner Mechanical unit 2 activated diK2_ACT 1 2 Positioner Mechanical unit 3 activated diK3_ACT 2 3 Positioner Mechanical unit 4 activated diK4_ACT 3 4 Positioner Mechanical unit 5 activated diK5_ACT 4 5 5 6 6 7 0 V input 1 7 8 Continues on next page Product manual IRBP D2009 153 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 4 Configuration 4 ...

Page 154: ...onfiguration cross connections xx1000000131 154 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 4 Configuration 4 2 Positioner Interface IRBP B D Continued ...

Page 155: ...uts for B_POS_SIM Simulated outputs Description Name UnitMap Activate mechanical unit 1 soACT_INTCH 0 Simulated inputs Description Name UnitMap Mechanical unit 1 activated siINTCH_ACT 0 I O Signals configuration for DRIVO_1 Digital outputs TB4 Connected to unit Description Name UnitMap Output 0 1 1 2 2 3 3 4 Positioner Activate mechanical unit 1 doACT_K5 4 5 5 6 6 7 7 8 8 9 Positioner Activate rel...

Page 156: ...nit 1 activ ated diK5_ACT 4 5 Station interchange unit Limit switch station 1 diLS_1_INPOS 5 6 Station interchange unit Limit switch station 2 diLS_2_INPOS 6 7 0 V input 1 7 8 Configuration cross connections xx1000000134 156 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 4 Configuration 4 3 Positioner Interface IRBP C Continued ...

Page 157: ...TN2 1 Activate mechanical unit 3 soACT_INTCH 2 Simulated inputs Description Name UnitMap Mechanical unit 1 activated siSTN1_ACT 0 Mechanical unit 2 activated siSTN2_ACT 1 Mechanical unit 3 activated siINTCH_ACT 2 I O Signals configuration for DRIVO_1 Digital outputs TB4 Connected to unit Description Name UnitMap Output Positioner Activate mechanical unit 1 doACT_K1 0 1 Positioner Activate mechanic...

Page 158: ... diK1_ACT 0 1 Positioner Mechanical unit 2 activ ated diK2_ACT 1 2 2 3 3 4 Positioner Mechanical unit 3 activ ated diK5_ACT 4 5 Station interchange unit Limit switch station 1 diLS_1_INPOS 5 6 Station interchange unit Limit switch station 2 diLS_2_INPOS 6 7 0 V input 1 7 8 Continues on next page 158 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 4 C...

Page 159: ...onfiguration cross connections xx1000000135 Product manual IRBP D2009 159 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 4 Configuration 4 4 Positioner Interface IRBP K R Continued ...

Page 160: ...ical unit 1 soACT_STN1 0 Activate mechanical unit 2 soACT_STN2 1 Simulated inputs Description Name UnitMap Mechanical unit 1 activated siSTN1_ACT 0 Mechanical unit 2 activated siSTN2_ACT 1 I O Signals configuration for DRIVO_1 Digital outputs TB4 Connected to unit Description Name UnitMap Output Positioner Activate mechanical unit 1 doACT_K1 0 1 Positioner Activate mechanical unit 2 doACT_K2 1 2 2...

Page 161: ...ap Input Positioner Mechanical unit 1 activated diK1_ACT 0 1 Positioner Mechanical unit 2 activated diK2_ACT 1 2 2 3 3 4 4 5 5 6 6 7 0 V input 1 7 8 Configuration cross connections xx1000000136 Product manual IRBP D2009 161 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 4 Configuration 4 5 Positioner Interface IRBP L Continued ...

Page 162: ...MotorOn doMON AutoOn doAUTO I O signals configuration for B_OP_SIM Digital outputs Description Name UnitMap CycleOn doCYCLE 10 MotorOn doAUTO 11 AutoOn doMON 12 I O signals configuration for B_OP_21 B_op_22 Digital outputs Description Name UnitMap Output Operator ready activated on work area 1 doPROC1 0 1 Operator ready activated on work area 2 doPROC2 1 2 Permit operator ready on work area 1 doPE...

Page 163: ...ogram start only used when two operat or panels are used diPROG_START2 2 3 Program stop diPROG_STOP 3 4 Program stop only used when two operat or panels are used diPROG_STOP2 3 4 Configuring cross connections xx1100000160 Product manual IRBP D2009 163 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 4 Configuration 4 6 Operator panel IRBP Continued ...

Page 164: ...iguration for SIB_V_B3 Digital inputs Connected to unit Description Name Connection Unit Map Panel board safety switch service door Run chain AS1 diASTOP_CHA TB1 8 0 Panel board safety switch service door Run chain AS2 diASTOP_CHB TB1 4 1 Entrance protection area 1 Channel 1 active diRL1 TB31 2 TB31 15 2 Entrance protection area 2 Channel 2 active diRL2 TB31 1 TB31 16 3 Entrance protection area 1 ...

Page 165: ...4 3 19 Panel board Run chain GS1 area 1 diG STOP_CHB_1 TB2 8 TB34 11 20 Panel board Run chain GS1 area 2 diG STOP_CHB_2 TB1 5 TB34 9 21 Safety switch service door Channel 1 active diRL201 TB111 10 TB33 2 24 Safety switch service door Channel 2 active diRL202 TB111 8 TB33 4 25 Safety switch service door Reset control of function safety circuits diRL203 TB111 11 TB33 5 26 Push button service door Ac...

Page 166: ...ration cross connections xx1000000137 166 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 4 Configuration 4 7 Safety interface SIB V for positioner A L Continued ...

Page 167: ...Connec tion Unit Map Panel board safety switch service door Run chain AS1 diASTOP_CHA TB1 8 0 Panel board safety switch service door Run chain AS2 diASTOP_CHB TB1 4 1 Entrance protection area 1 Channel 1 active diRL1 TB31 9 TB31 17 2 Entrance protection area 1 Channel 2 active diRL2 TB31 8 TB31 18 3 Entrance protection area 1 Reset control of func tion safety circuits diRL3 TB1 16 4 Op panel Activ...

Page 168: ...y switch service door Reset control of func tion safety circuits diRL203 TB111 11 TB31 5 26 Push button service door Activate safety circuits service door diRL204 TB111 13 TB31 6 27 Configuration cross connections xx1000000138 168 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 4 Configuration 4 8 Safety interface SIB V for positioner B C D K R Conti...

Page 169: ...ided 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 17 before performing any service work Note If the IRBP is conne...

Page 170: ... whether the system is running or not Operating time specified in operating hours More frequent running means more frequent maintenance activities Robots with the functionality Service Information System activated can show active counters in the device browser in RobotStudio or on the FlexPendant 170 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 5 ...

Page 171: ...Inspection Running Positioner Clean 400h Current collector Lubrication 40 000h Gearbox oil Lubrication Battery low alert i Battery pack measurement system with 2 pole battery contact e g DSQC633A Replacement 36 months or battery low alert ii Battery pack measurement system of type RMU101 or RMU102 3 pole battery con tact Replacement i The battery low alert 38213 Battery charge low is displayed whe...

Page 172: ...SMB 2 signals axis 2 2 Current collector rotary unit 2 3 Current collector rotary unit 1 4 Motor power axis 1 5 SMB 1 signals axis 1 6 Continues on next page 172 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 5 Maintenance 5 4 1 Inspection cables ...

Page 173: ...MB signals axis 2 5 Motor power axis 2 6 Current collector connection point 7 Current collector rotary unit 1 8 SMB signals axis 1 9 Motor power axis 1 10 Continues on next page Product manual IRBP D2009 173 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 5 Maintenance 5 4 1 Inspection cables Continued ...

Page 174: ... 5 Motor power axis 5 3 Current collector rotary unit 5 4 SMB signals axis 1 5 Motor power axis 1 6 Current collector rotary unit 1 7 Continues on next page 174 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 5 Maintenance 5 4 1 Inspection cables Continued ...

Page 175: ...or rotary unit 1 3 SMB signals axis 1 Motor power axis 1 4 Current collector rotary unit 2 5 SMB signals axis 2 Motor power axis 2 6 Continues on next page Product manual IRBP D2009 175 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 5 Maintenance 5 4 1 Inspection cables Continued ...

Page 176: ...B signals axis 1 Motor power axis 1 8 Inspection procedure WARNING Turn off all electrical power supplies to the manipulator before entering its work space Note Action Make an overall visual inspection of the cable harness in order to detect wear and damage 1 Replace the cable harness if wear cracks or damage is detected 2 176 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020...

Page 177: ...nit or through the support collar The contact bar needs to be check for damage caused by sparking during welding start after approximately 1000 hours of operation Inspection procedure xx1000000043 Current Collector 1 Information Action Remove the Current Collector cable 1 Open key 46 mm Remove the Current Collector 2 Continues on next page Product manual IRBP D2009 177 3HAC037731 001 Revision T Co...

Page 178: ...lector surface for damage 3 For assemble see Replacing support collar axis on page 226 4 178 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 5 Maintenance 5 4 2 Inspection current collector Continued ...

Page 179: ...e of the manipulator See also Safety on page 17 Location xx1000000250 Axis sealing 1 Axis sealing 2 Motor sealing 3 Inspection procedure Information Action Check all sealing areas for oil leak 1 Product manual IRBP D2009 179 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 5 Maintenance 5 4 3 Inspection gearbox oil leak ...

Page 180: ...s according to the recommendations see Inspection activities on page 172 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 sho...

Page 181: ...gent Yes Standard 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 Mechanical stops Regularly clean the contact surface of the mechanical stops Product manual IRBP D2009 181 3HAC037731 001 Revision T Copyright 2010 2020 ABB All right...

Page 182: ...ce through a spring loaded contact bar against the shaft The contact bar needs to be lubricated approximately after 400 hours of operation This should be done using a special grease P34 from Nies article number 0501869 001 Required equipment Note Equipment Grease type P34 from Nies Article number 0501869002 Grease Standard tools IRBP on page 312 Standard tools Grease gun Continues on next page 182...

Page 183: ...on Action Note Amount of grease 12 ml Lubricate the current collector using a grease gun 1 Product manual IRBP D2009 183 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 5 Maintenance 5 6 1 Lubricating the current collector Continued ...

Page 184: ...BB Business Portal www mypo rtal abb com Before starting any inspection maintenance or changing activities of lubrication always contact 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...

Page 185: ...rating manual IRC5 with FlexPendant for instructions DANGER Turn off all electrical power hydraulic and pneumatic pressure supplies before entering the workspace of the manipulator See also Safety on page 17 Note This action demands an update of the revolution counters Required equipment Note There are two variants of SMB units and batteries One with 2 pole battery contact and one with 3 pole batt...

Page 186: ... the boards which can result in hazardous failures 1 Locate the SMB backup battery packs 5 2 Cut off the cable strap 4 holding the battery 3 Disconnect the connection cable 3 in figure and remove the battery 4 Use 2 cable straps Fit the new battery in the reverse order 5 Mount the cover 6 186 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 5 Maintena...

Page 187: ...e replaced unit and the replacement unit This is particularly important for safety equipment to maintain the safety integrity of the installation Safety information Make sure to read through the chapter Safety on page 17 before commencing any service work Note The robot should be secured with the transportation brackets during removing from refitting to the foundation Note If the IRBP is connected...

Page 188: ...xposed to any 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 u...

Page 189: ...rted 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 Product manual IRBP D2009...

Page 190: ... before actual mounting The fitting of sealings and gears must be carried out on clean workbenches Use a protective sleeve for the main lip during mounting when sliding over threads keyways or other sharp edges Note Action Check the sealing to ensure that The sealing is of the correct type There is no damage on the main lip 1 Inspect the shaft surface before mounting If scratches or damage are fou...

Page 191: ...space between the dust lip and the main lip with grease If the sealing is without dust lip just lubricate the main lip with a thin layer of grease 3 A xx2000000072 A Gap Mount the sealing correctly with a mounting tool Never hammer directly on the sealing as this may result in leakage 4 Continues on next page Product manual IRBP D2009 191 3HAC037731 001 Revision T Copyright 2010 2020 ABB All right...

Page 192: ... the screws evenly 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 Check the o ring grooves 3 The grooves must be geometrically correct and should b...

Page 193: ...nt Standard Foundry Plus ABB Orange 3HAC037052 001 Touch up paint Standard Foundry Plus 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 Product manual IRBP D2009 193 3HAC037731 001 Revision T Co...

Page 194: ... covers on page 203 Remove the MTD turning disc on page 204 Refit the MTD turning disc on page 204 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space Required equipment Note Equipment For more information see Standard tools IRBP on page 312 Standard tools Continues on next page 194 Product manual IRBP D2009 3HA...

Page 195: ...ws 1 Station frame screws 2 Rotary units screws 3 Turning disc screws 4 Continues on next page Product manual IRBP D2009 195 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 2 1 Replacing frame parts Continued ...

Page 196: ...arts on page 205 Lift the station frame 3 Screw joints MTD axis Tightening torque Nm Screw dim 12 9 Screw dim 12 9 UNB Axis MTD MID 70 10x40 Turning axis MTD 250 300 16x70 Turning axis MTD 500 300 16x70 Turning axis MTD 750 550 20x90 Turning axis MTD 2000 950 24x110 Turning axis MTD 5000 Continues on next page 196 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All righ...

Page 197: ...g Support collar MTD 2000 Refit station frame Note Action Clean the contact surface 1 Described in section Lifting frame parts on page 205 Lift the station frame 2 Tightening torque according to table in Screw joints MTD axis Mount the attachment screws 3 Continues on next page Product manual IRBP D2009 197 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 2 1 Replac...

Page 198: ...Attachment screws M20x90 Steel 12 9 4 Washers 5 Note Action Remove the screws holding the station shield 1 Continues on next page 198 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 2 1 Replacing frame parts Continued ...

Page 199: ...section Lifting frame parts on page 205 Lift the base frame 2 Tightening torque according to table in Screw joints MTD axis Mount the attachment screws 3 Remove the lifting accessories from the frame 4 xx1700001322 Valid for IRBP R Refit the plates at the frame ends 5 Continues on next page Product manual IRBP D2009 199 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair...

Page 200: ...it the protection plugs to the lifting eye holes 6 Refit the station shield 7 Continues on next page 200 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 2 1 Replacing frame parts Continued ...

Page 201: ... 2 Attachment screw M20x90 Steel 12 9 3 Frame 4 Screw M6x10 5 Bottom plate 6 Washer 21x31 4 mm 7 Continues on next page Product manual IRBP D2009 201 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 2 1 Replacing frame parts Continued ...

Page 202: ...r plate 3 Side cover 4 Screw M6x10 xx1000000007 Unscrew 2 and remove the bottom plate 1 2 1 Bottom plate 2 Screw M6x10 Remove the electrical connec tion 3 Continues on next page 202 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 2 1 Replacing frame parts Continued ...

Page 203: ...using the attach ment screws M20x90 Tightening torque is 550 Nm Note Use Molycote lubricant for the screw joints 1 1 Attachment screw M20x90 Steel 12 9 2 Guide pin Mount all electrical connections 2 Mount the bottom plate 3 Mount the side plates and cover 4 Continues on next page Product manual IRBP D2009 203 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 2 1 Repl...

Page 204: ...lding the turning disc 1 Refit the MTD turning disc Note Action Tightening torque according to the table in Screw joints MTD axis Refit the screws by holding the turning disc 1 204 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 2 1 Replacing frame parts Continued ...

Page 205: ...ed WARNING Do not work or walk under a suspended load DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space WARNING Always lift the manipulator in a safe manner using lifting tools according to the specified lifting weight in section Lifting weight Required equipment Note Equipment See section Standard tools IRBP ...

Page 206: ... dist 1000 270 kg 500 750 A B Note Action Attach the lifting eyes with swivel as shown in the figure 1 Stretch the lifting chains 2 Remove the attachment screws 3 Lift the gearbox and the frame 4 Continues on next page 206 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 2 2 Lifting frame parts Continued ...

Page 207: ...te Action Attach the lifting eyes as shown in the figure 1 Stretch the lifting chains 2 Remove the attachment screws 3 Lift the gearbox and the frame 4 Continues on next page Product manual IRBP D2009 207 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 2 2 Lifting frame parts Continued ...

Page 208: ...st 1000 L 2000 808 kg 600D Dist 1200 L 1600 843 kg 600D Dist 1200 L 2000 Note Action Attach the lifting eyes standard and with swivel in the proper positions as shown in the figure 1 Stretch the lifting chains 2 Remove the attachment screws 3 Lift the gearbox and the frame 4 Continues on next page 208 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6...

Page 209: ...600D Dist 1200 L 1600 2 430 kg 600D Dist 1200 L 2000 Note Action Attach the lifting eyes as shown in the figure 1 Stretch the lifting chains 2 Remove the attachment screws 3 Lift the gearbox and the frame 4 Continues on next page Product manual IRBP D2009 209 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 2 2 Lifting frame parts Continued ...

Page 210: ...5 kg 500 750K D 1200 L 1600 1 188 kg 500 750K D 1200 L 4000 1 036 kg 500 750K D 1400 L 1600 1 248 kg 500 750K D 1400 L 4000 Note Action Attach the lifting eyes as shown in the figure 1 Stretch the lifting chains 2 Remove the attachment screws 3 Lift the gearbox and the frame 4 Continues on next page 210 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved...

Page 211: ... 1250 394 kg 300R L 1600 828 kg 600 1000R D 1000 L 1600 853 kg 600 1000R D 1000 L 2000 884 kg 600 1000R D 1200 L 1600 909 kg 600 1000R D 1200 L 2000 Continues on next page Product manual IRBP D2009 211 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 2 2 Lifting frame parts Continued ...

Page 212: ...gs from the lifting eye holes 2 2 pcs xx1700001323 Attach the lifting eyes 3 Stretch the lifting chains 4 Remove the attachment screws 5 Lift the gearbox and the frame 6 Continues on next page 212 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 2 2 Lifting frame parts Continued ...

Page 213: ... kg MID 1 1 165 kg MID 1 2 370 kg MID 2 1 285 kg MID 2 2 Note Action Attach the lifting eyes as shown in the figure 1 Stretch the lifting chains 2 Remove the attachment screws 3 Lift the gearbox 4 Product manual IRBP D2009 213 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 2 2 Lifting frame parts Continued ...

Page 214: ...tric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space Note Keep the contact surfaces clean Required equipment Note Equipment For more information see Standard tools IRBP on page312 Standard tools See Product manual spare parts IRBP D2009 Stop lug Continues on next page 214 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 201...

Page 215: ...0082 Stop lug 1 Attachment screw M12 x 50 12 9 2 Washer 3 Continues on next page Product manual IRBP D2009 215 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 3 1 Replacing stop lugs Continued ...

Page 216: ...ount the stop lug Note Always use the two locking pins 1 Use standard tools Tightening torque 140 Nm Mount the attachment screws 2 Standard tightening torque see Tightening torque on page 87 Mount the cover 1 3 216 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 3 1 Replacing stop lugs Continued ...

Page 217: ...e motor can seriously damage the motor see section Checking insulation on page 223 Required equipment Note Equipment For more information see Standard tools IRBP on page 312 Standard tools Product Manual Sparepart IRBP D2009 Spareparts Continues on next page Product manual IRBP D2009 217 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 4 1 Replacing motors ...

Page 218: ...achment screws 3 Plain washers 4 Insulating washer 5 Motor 6 Insulating tube 7 O ring 8 Insulating material 9 Continues on next page 218 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 4 1 Replacing motors Continued ...

Page 219: ... Remove the motor by unscrewing the attachment screws and plain washers 3 4 6 Remove the o ring 8 7 Remove the insulating material and insulating tubes 5 7 9 8 Refit motor rotary units axis 1 CAUTION Do not mix motors valid from serial number SEROP POF 110001 CNAUS POF 510001 with motors valid up to serial numbers SEROP POF 110000 CNAUS POF 510000 They are not compatible Note Action Refit the insu...

Page 220: ...ion Tightening torque on page 87 Refit the motor using the attachment screws and plain washers 3 4 4 Connect all connectors 5 Refit the cable gland cover at the cable exit 6 Refit the cover plate 2 7 Detailed in the section Replacing frame parts on page 194 Refit all the covers on the manipulator foot Only axis one 8 Continues on next page 220 Product manual IRBP D2009 3HAC037731 001 Revision T Co...

Page 221: ...supply to the robot before entering the safeguarded space 1 Remove the cover plate 2 on top of the motor by unscrewing the attachment screws 1 2 Remove the cable gland cover at the cable exit by unscrewing its the attachment screws 3 Disconnect all connectors 4 Remove the motor by unscrewing the attachment screws and washers 3 4 5 Continues on next page Product manual IRBP D2009 221 3HAC037731 001...

Page 222: ... the o ring 7 on the motor 2 Use standard torque see section Tightening torque on page 87 3 2 1 xx1500002519 Refit the motor using the attachment screws and plain washers 4 5 Note If countersunk holes in motor flange Make sure that the plane washer is mounted before the insulating washer to fill out the recess 3 1 Attachment screw 2 Insulating washer 3 Plane washer Connect all connectors 4 Refit t...

Page 223: ...ce tests Insulation resistance greater than 2 5 MOhm at 500 V DC between the output shaft Gearbox body and the ground point in the AC motor Voltage tests 1 kVolt AC 50 60 Hz 1 sec between the output shaft gearbox body and the ground point in the AC motor The test voltage is to be supplied from a transformer with a minimum rating of 500 VA Product manual IRBP D2009 223 3HAC037731 001 Revision T Cop...

Page 224: ...s on page 213 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space WARNING Always lift the manipulator in a safe manner using lifting tools according to the specified lifting weight in section Lifting weight Required equipment Note Equipment For more information see Standard tools IRBP on page312 Standard tools S...

Page 225: ...ording to section Lifting rotary units on page 213 4 Refit rotary unit Information Action Lift the rotary unit according to section Lifting rotary units on page 213 1 Use standard tools For Tightening torque see table Screw joints on page 224 Refit the attachment screws and wash ers 2 Assemble the cable harness 3 Product manual IRBP D2009 225 3HAC037731 001 Revision T Copyright 2010 2020 ABB All r...

Page 226: ... equipment Note Equipment Standard tools IRBP on page 312 Standard tools Product manual spare parts IRBP D2009 Spare parts Replacing support collar xx1000000028 Note Action Standard tools Remove screw 12 to loosen the current collector cable 1 Continues on next page 226 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 6 1 Replacing support ...

Page 227: ...tandard torque see Tighten ing torque on page 87 Refit the attachment screws with washers 3 4 2 Refit the bearing housing 8 to the axis 3 Refit the back flange bearing 14 4 Use standard torque see Tighten ing torque on page 87 Refit the attachment screws with washers 15 16 5 Use standard torque see Tighten ing torque on page 87 Tightening the flange bearing locking screw 6 Standard tools open key ...

Page 228: ...t before entering the safeguarded space Required equipment Note Equipment See section Standard tools IRBP on page 312 Standard tools See Product Manual Spareparts IRBP D2009 Current collector Continues on next page 228 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 7 1 Replacing current collector ...

Page 229: ...the spring and the current collector 3 Assemble current collector Note Action Assemble the new current collector 1 Assemble the spring and the spring support using the screws 2 Lubricate the current collector see section Lubricating the current collector on page 182 Assemble the lubrication nipple and the current collector cable 3 Product manual IRBP D2009 229 3HAC037731 001 Revision T Copyright 2...

Page 230: ... DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 1 ELECTROSTATIC DISCHARGE ESD Before handling the unit see The unit is sensitive to ESD on page 90 2 Open the cover on the SMB box CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazard...

Page 231: ... mounting plate 1 Refit and fasten the three screws fully 2 Cross tighten the screws to make sure the sealing is tight Refit the plate and fasten the screws fully 3 Connect the cables and close the cover 4 See Calibration information on page 265 Update the revolution counters 5 Product manual IRBP D2009 231 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 7 2 Replac...

Page 232: ...tering the safeguarded space Required equipment Note Equipment This is detailed in section Standard tools IRBP on page 312 Standard tools Product Manual Spareparts IRBP D2009 Spareparts in Continues on next page 232 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 7 3 Station changing indication ...

Page 233: ...tric power sup ply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 1 Use standard tools Remove the side cover 2 Continues on next page Product manual IRBP D2009 233 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 7 3 Station changing indication Continued ...

Page 234: ... 1 on the station sync cable 3 xx1000000075 Remove the sta tion breaker 4 1 Station indication 2 Screw 3 Nut 234 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 7 3 Station changing indication Continued ...

Page 235: ...controller Location of parts xx1000000230 Drive module 1 Contactor 2 Auxiliary contact 3 Relay 4 Product manual IRBP D2009 235 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 8 1 Overview of the controller ...

Page 236: ...dling the unit read the safety information in section The unit is sensitive to ESD on page 90 Required equipment Note Equipment Product manual spare parts IRBP D2009 Spare parts See Contents standard toolkit IRC5 on page 311 Standard tools Drive module xx1000000231 Drive module I O 1 Continues on next page 236 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights r...

Page 237: ...the cabinet read the safety information in section Electrical safety on page 28 1 xx1000000212 Turn the main power switch to OFF 2 Continues on next page Product manual IRBP D2009 237 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 8 2 Replacing drive module I O Continued ...

Page 238: ... A Mounting foot lower end B Note Action Hook on the mounting foot lower end B on to the mounting rail 1 Press the two mounting foots upper ends A 2 Press the drive module on to the mounting rail 3 Mount the cable harness to the drive module 4 238 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 8 2 Replacing drive module I O Continued ...

Page 239: ...itive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 90 Required equipment Note Equipment See Contents standard toolkit IRC5 on page 311 Standard tools Product manual spare parts IRBP D2009 Spare parts Continues on next page Product manual IRBP D2009 239 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 8 3...

Page 240: ...ctors xx1000000234 Contactor 1 Auxiliary contact 2 Continues on next page 240 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 8 3 Replacing contactor Continued ...

Page 241: ...ge 28 1 xx1000000212 Turn the main power switch to OFF 2 Remove the cable harness from the auxiliary contact and the contactor 3 Press the contactor down 4 Remove the contactor 5 Continues on next page Product manual IRBP D2009 241 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 8 3 Replacing contactor Continued ...

Page 242: ...ontactor down 1 Press in the contactor 2 Refit the cable harness to the auxiliary contact and the contactor 3 242 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 8 3 Replacing contactor Continued ...

Page 243: ... ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 90 Required equipment Note Equipment See Contents standard toolkit IRC5 on page 311 Standard tools Product manual spare parts IRBP D2009 Auxiliary contact Continues on next page Product manual IRBP D2009 243 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 8 4 R...

Page 244: ...0000241 Auxiliary contact 1 Contactor 2 Continues on next page 244 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 8 4 Replacing auxiliary contact Continued ...

Page 245: ...x1000000212 Turn the main power switch to OFF 2 Remove the cable harness from the auxiliary con tact 3 Push the auxiliary contact towards the center of the contactor 4 Remove the auxiliary contact 5 Continues on next page Product manual IRBP D2009 245 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 8 4 Replacing auxiliary contact Continued ...

Page 246: ...e auxiliary contact into the locking rail in the contactor 1 Push the auxiliary contact to the locked position 2 246 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 8 4 Replacing auxiliary contact Continued ...

Page 247: ...efore handling the unit read the safety information in section The unit is sensitive to ESD on page 90 Prerequisites Note Equipment See Standard tools IRBP on page 312 Standard tools Product manual spare parts IRBP D2009 Auxiliary relay Location xx1000000243 Auxiliary relay 1 Continues on next page Product manual IRBP D2009 247 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved ...

Page 248: ...age 28 1 xx1000000212 Turn the main power switch to OFF 2 Remove the cable harness from the auxiliary relay 3 Remove the auxiliary relay using a screw driver 4 Continues on next page 248 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 8 5 Replacing auxiliary relays for breaker Continued ...

Page 249: ...00244 Refit the auxiliary relay using a screw driver 1 Product manual IRBP D2009 249 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 6 Repair 6 8 5 Replacing auxiliary relays for breaker Continued ...

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Page 251: ...nel at front on page 51 Check that The correct program is loaded The program pointer is set to the right start pos ition See the operating manual for the controller 3 Resetting the light barriers during start up Note Action See section Light barriers for positioners on page 31 Press the Pre reset button optional inside the service area 1 Check that the service gate optional is closed 2 Press the s...

Page 252: ...ght barriers will not reset If the above does not work start again from step 1 4 xx1000000214 1 Turn the operating mode selector pos 1 on the control module s con trol panel to the AUTO position pos 2 2 Tap OK when asked Is it OK to switch to automatic operation 3 Press the Motors On button on the control module s control panel pos 3 5 1 Mode selector 100 optional 2 Auto mode 3 Motors On button Se...

Page 253: ... Start button See section Operator panel on page 61 Press Program Start on the operator s panel to start the robot program 7 Product manual IRBP D2009 253 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 7 Operation 7 1 1 Starting production Continued ...

Page 254: ... positioners or two work stations If there are two positioners or two work stations on one positioner with station interchange the loading of one of the positioners or one station side can be performed while the robot works on the other one If the welding robot system includes two positioners there is a time pre reset button and a Start Process button for each positioner Once the robot has complet...

Page 255: ...uring the loading unloading of the work station Information Action See section Light barriers for po sitioners on page 31 Press the Pre reset button optional inside the service area 1 Reset external personal protection Note This must be performed within 10 seconds of pressing the pre reset button otherwise the light barriers will not reset 2 Leave the operator area of the station 3 xx1000000213 Pr...

Page 256: ...e As Is 5 1 Operation mode 100 op tional 2 Auto mode 3 Motors on button See section Control system with control panel at front on page 51 Press OK when asked Is it OK to switch to auto matic operation 6 Press the Motors On button on the control module s control panel 3 7 Continues on next page 256 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 7 Ope...

Page 257: ...he operator panel to start the robot program Do not go back to the original station side 9 Run the setting procedure to verify the positioner s station positions See Drivers on page 289 10 Product manual IRBP D2009 257 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 7 Operation 7 1 3 Stop during loading unloading Continued ...

Page 258: ...219 This should always be done using the Pro gram Stop button before the continuous pressure switch on the FlexPendant is re leased Otherwise the system is stopped by AUTO stop which is harder than the computer controlled braking of movement A Manual reduced speed 250mm s B Manual full speed 100 not available in all markets Temporary stop Temporary stops can be performed as follows Button Stopping...

Page 259: ...ger stops can be performed as follows Button Stopping method See The FlexPendant on page 53 Press the Program Stop button on the FlexPendant See Operator panel on page 61 Press the Program Stop button on the operator panel Continues on next page Product manual IRBP D2009 259 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 7 Operation 7 2 1 Program stop Continued ...

Page 260: ...lector on the control module s external control panel Result Motors off A mode selector Switch off the welding power source 260 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 7 Operation 7 2 1 Program stop Continued ...

Page 261: ...and travel track work ing areas are clear 2 Press the service gate s Reset button option 3 See section Light barriers for po sitioners on page 31 Press the Pre reset button optional inside the service area 4 See section Operator panel on page 61 Press the Start Process button for one or two stations for the light barriers on the operator panel Note This step must be performed within 10 seconds of ...

Page 262: ...e robot positioner and travel track working areas are clear 2 Press the service gate s Reset button option 3 See section Light barriers for po sitioners on page 31 Press the Pre reset button optional inside the service area 4 Press the Start Process button for one or two sta tions for the light barriers on the operator panel Note This step must be performed within 10 seconds of pressing the pre re...

Page 263: ...ied out by persons trained in the use of the complete equipment and who are aware of the special risks that exist or may occur when undertaking such actions CAUTION All work carried out on the system shall be performed in a professional manner and conform to applicable safety regulations Product manual IRBP D2009 263 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 7 Operation...

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Page 265: ... is lost If the revolution counter memory is lost the counters must be updated See Updating revolution counters on page 269 This will occur when The battery is discharged A resolver error occurs The signal between a resolver and measurement board is interrupted A robot axis is moved with the control system disconnected The revolution counters must also be updated after the robot and controller are...

Page 266: ...n mark MID station foot xx1000000121 Synchronization mark MID 2 1 1 Continues on next page 266 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 8 Calibration information 8 2 Calibration marks ...

Page 267: ...tion unit xx1000000122 Synchronization mark MTD 1 Continues on next page Product manual IRBP D2009 267 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 8 Calibration information 8 2 Calibration marks Continued ...

Page 268: ...mark MTD rotary unit xx1000000117 Synchronization mark MTD 1 268 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 8 Calibration information 8 2 Calibration marks Continued ...

Page 269: ...See Calibration marks on page 266 Jog the manipulator to align the synchron ization marks 2 Step 2 Updating the revolution counter with the FlexPendant on page 269 When all axes are positioned update the revolution counter 3 Step 2 Updating the revolution counter with the FlexPendant Use this procedure to update the revolution counter with the FlexPendant IRC5 Action On the ABB menu tap Calibratio...

Page 270: ... Tap the mechanical unit in question xx1500000943 A screen is displayed tap Rev Counters en0400000771 3 Continues on next page 270 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 8 Calibration information 8 3 Updating revolution counters Continued ...

Page 271: ...tap Update 5 A dialog box is displayed warning that the updating operation cannot be undone Tap Update to proceed with updating the revolution counters Tap Cancel to cancel updating the revolution counters Tapping Update updates the selected revolution counters and removes the tick from the list of axes 6 CAUTION If a revolution counter is incorrectly updated it will cause incorrect manipulator po...

Page 272: ...vice window 1 Tap Calibration 2 Tap on the mechanical unit to be calibrated When the unit concerned is not visible in the window use the scroll bar arrows in the lower part of the window 3 Tap Calibration Parameters 4 Tap Edit Motor Calibration 5 The system awaits a response Tap Yes to proceed 6 Tap on the axis where the value is to be modified Enter the new value with the help of the keypad 7 Con...

Page 273: ... MTD Note Action Move the positioner s axes axis to respective zero positions synchronization marking Be precise when adjusting the position of the axis so that it lies in the centre of the marking The marking is made up of a machined groove or a machined notch on the gearbox respective faceplates 1 Tap ABB to open the service window 2 Tap Calibration 3 Tap on the mechanical unit to be calibrated ...

Page 274: ...displayed that the station interchange will move to side 1 CAUTION Make sure that you are at a safe distance 5 Tap OK to continue Wait while station side 1 is calibrated 6 A warning is displayed that the station interchange will move to side 2 CAUTION Make sure that you are at a safe distance 7 Tap OK to continue Wait while station side 2 is calibrated 8 Station interchange calibration is finished...

Page 275: ...he world frame Normally the base frame is centered and aligned with the world frame Positioner IRBP C is not calibrated for base frame it has no stations Note Note that the base frame is fixed to the base of the robot Overview xx1400000897 Base coordinate system for robot 2 A Base and world coordinate system for robot 1 B Base Frame for positioner C Product manual IRBP D2009 275 3HAC037731 001 Rev...

Page 276: ...on the turning disc and the bearing disc spigot if available Centre punch and hammer Tool calibration Start to calibrate the welding tool TCP using BullsEye Note Action xx1400000898 Change the mass in the tool data from the negat ive value to the correct value for your tool see figure 1 xx1800000746 Activate the tool 2 Continues on next page 276 Product manual IRBP D2009 3HAC037731 001 Revision T ...

Page 277: ... centre on the turning disc 2 Centre punch and hammer xx1800000750 Valid for positioners that have a tailstock IRBP K IRBP L IRBP R Mark out the centre of the bearing disc spigot and carefully make a small punch mark there 3 Calibrating the base frame of robot 1 Use the procedure to calibrate the base frame of robot 1 The FlexPendant images shown in the procedure can differ between the positioner ...

Page 278: ...BP A IRBP B IRBP D 4 points for Axis 1 or 4 points for Axis 2 Both axes need to be calibrated Choose axis 1 first and run the complete procedure according to the following steps When done repeat the procedure for axis 2 keeping axis 1 at 0 meanwhile IRBP K IRBP L IRBP R 4 points Z 3 xx1800000785 Select the robot you will use to measure the base frame Note If robot 1 ROB_1 is selected you cannot do...

Page 279: ...pointer exactly onto the punch mark 6 xx1800000756 Highlight Point 1 and tap Modify Position 7 xx1800000757 Point 1 will now show Modified and Point 2 will automatically be highlighted 8 Continues on next page Product manual IRBP D2009 279 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 8 Calibration information 8 7 2 Calibrating the multi arc system Continued ...

Page 280: ...ch mark 10 xx1800000760 Ensure that Point 2 is highlighted and tap Modify Position 11 xx1800000761 Point 2 will now show Modified and Point 3 will automatically be highlighted 12 Continues on next page 280 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 8 Calibration information 8 7 2 Calibrating the multi arc system Continued ...

Page 281: ...nch mark 14 xx1800000764 Ensure that Point 3 is highlighted and tap Modify Position 15 xx1800000765 Point 3 will now show Modified and Point 4 will automatically be highlighted 16 Continues on next page Product manual IRBP D2009 281 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 8 Calibration information 8 7 2 Calibrating the multi arc system Continued ...

Page 282: ...oint 4 is highlighted and tap Modify Position 19 xx1800000769 Valid for positioners that have a tailstock IRBP K IRBP L IRBP R Point 4 will now show Modified and Elongator Point Z will automatically be highlighted 20 Continues on next page 282 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 8 Calibration information 8 7 2 Calibrating the multi arc sy...

Page 283: ...Point Z is highlighted and tap Modify Position 22 xx1800000772 The Calculation Result will be shown Tap OK 23 xx1800000773 Restart the controller by tapping Yes 24 Valid for positioners IRBP A IRBP B IRBP D 25 Go to step 2 and repeat the calibration proced ure for the 4 points of the second axis Continues on next page Product manual IRBP D2009 283 3HAC037731 001 Revision T Copyright 2010 2020 ABB ...

Page 284: ...ot 1 base coordinate system to the robot 2 world coordinate system xx1400000897 Base coordinate system for robot 2 A Base and world coordinate system for robot 1 B Base Frame for positioner C Note Action xx1400000905 On the FlexPendant select Calibration 1 Continues on next page 284 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 8 Calibration inform...

Page 285: ... Select Number of points 4 xx1400000909 Point the TCPs of the robots towards each other 5 xx1400000910 Tap Modify position 6 Continues on next page Product manual IRBP D2009 285 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 8 Calibration information 8 7 2 Calibrating the multi arc system Continued ...

Page 286: ... 8 xx1400000911 When all postions are modified tap OK 9 Create a work object according to Operating manual IRC5 with FlexPendant to confirm that the calibration is correct 10 286 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 8 Calibration information 8 7 2 Calibrating the multi arc system Continued ...

Page 287: ... 500 55 0 35 3 3 22 degrees Binzel WH 455 120 0 20 4 4 22 degrees Dinse PP Alu The five standard welding gun types above are predefined with the right tload in the module Tooldata sys Always use one of these tools when using a standard welding gun Duplicate and change the name of the tool data if you want to make your own tool If you use a non standard welding gun it is necessary to run the load i...

Page 288: ...tioner 180 degree s MTD 250 150 degree s MTD 250 150 degree s MTD 750 90 degree s MTD 2000 39 degree s MTD 5000 90 degree s MID 500 90 degree s MID 1000 288 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 8 Calibration information 8 8 Tool and speed data Continued ...

Page 289: ...first time on a specific type of positioner it is recommended that you first run the procedure in slow test mode to prevent any collisions Load identification for IRBP L A simplified view of positioner IRBP L is shown in figure Load identification can be performed in any position for this positioner xx1000000139 Parameters and movements Note The mass of the load must be known in advance The mass d...

Page 290: ... inertia around the axis see figure To perform the identification the positioner moves the load and computes the parameters Continues on next page 290 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 8 Calibration information 8 9 1 Identification of load data for positioners IRBP Continued ...

Page 291: ...n can be performed in positions according to load identification service routine ManLoadIdentify Note The data entered when performing the load identification is the sum of the loads applied Load identification should be performed separately for all different load scenarios that is used Parameters The parameter identified is the total moments of inertia around the axis Note that the mass of the lo...

Page 292: ... end positions This is checked by the load identification procedure xx1000000144 Parameters The identified parameters and movements for each axis are the same as for the IRBP L positioner See Parameters and movements on page 289 Continues on next page 292 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 8 Calibration information 8 9 1 Identification o...

Page 293: ...entification movements for one axis is the same as for the positioner IRBP L To find the extra moment of inertia we also move the interchange axis with the load to two different positions The movements for the interchange axis are the movements described in the figure in section Parameters and movements on page 289 but only at one configuration point CAUTION The identification on one axis will be ...

Page 294: ...rs identified are the center of gravity and three moments of inertia at the center of gravity see figure The mass of the load must be known in advance The mass data is entered when performing the load identification Movements The motion for each axis is in principal the same as for the positioner IRBP L see figure in section Parameters and movements on page289 However axis 1 only performs its move...

Page 295: ...t the Robot Safe Position is teached The driver requires this position to safely perform a station interchange Move the robot to a safe position for the positioner s work area 2 Tap Start To update the safe position or if you want to do it manually you can move PP to the procedure SetSafePos Tap Debug and then Move PP to routine 3 Product manual IRBP D2009 295 3HAC037731 001 Revision T Copyright 2...

Page 296: ... so that it is in a suitable position for the operator to load remove the workpiece The value is saved in data type partadv in the component loadAngle which the pertinent part refers to in the component advPart Procedures Note Action To change load position the ABB menu must be opened Tap Production Manager 1 Tap Setup 2 Choose the station for which the load position will be changed Tap GO 3 If a ...

Page 297: ...onent advPart Procedures Note Action To change process position the ABBmenu must be opened Tap Production Manager 1 Tap Setup 2 Choose the station for which the process position will be changed Tap GO 3 If a part is not activated for the selected station one must be activated for the station See section Parts handling section 5 1 2 on how to do this 4 Specify the desired process position in degree...

Page 298: ...ion To change service position the ABB menu must be opened Tap Production Manager 1 Tap Setup 2 Choose the station for which the service position will be changed Tap GO 3 If a part is not activated for the selected station one must be activated for the station See section Parts handling section 5 1 2 on how to do this 4 Specify the desired service position in degrees 5 298 Product manual IRBP D200...

Page 299: ...les of the instruction MechUnitLoad are illustrated below The following figure shows axis 1 on a mechanical unit named STN1 of type IRBP L xx0500002142 Example 1 ActUnit STN1 MechUnitLoad STN1 1 load0 Activate mechanical unit STN1 and define the payload load0 corresponding to no load at all mounted on axis 1 Example 2 ActUnit STN1 MechUnitLoad STN1 1 fixture1 Activate mechanical unit STN1 and defi...

Page 300: ...em The default payload at cold start for a certain mechanical unit type is the predefined maximalpayload for this mechanical unit type When another payload is used the actual payload for the mechanical unit and axis should beredefined with this instruction This should always be done after activation of the mechanicalunit The defined payload will survive a power failure restart The defined payload ...

Page 301: ... mechanical unit xx1000000153 Fixture 1 Mechanical unit 2 Center of gravity for the payload fixture work piece 3 Work piece 4 Continues on next page Product manual IRBP D2009 301 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 8 Calibration information 8 9 6 Define payload for a mechanical unit Continued ...

Page 302: ...ple 1 MoveL homeside1 v1000 fine gun1 ActUnit INTERCH The whole mechanical unit INTERCH is activated Example 2 MechUnitLoad INTERCH 2 workpiece1 Defines payload workpiece1 on the mechanical unit INTERCH axis 2 Continues on next page 302 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 8 Calibration information 8 9 6 Define payload for a mechanical uni...

Page 303: ...ng special system events PowerOn Stop QStop Restart or Step Syntax MechUnitLoad MechUnit variable VAR of mecunit AxisNo expression IN of num Load persistent PERS of loaddata Related information Described in Information Technical reference manual RAPID Instruc tions Functions and Data types data type mecunit Mechanical units Technical reference manual RAPID Instruc tions Functions and Data types da...

Page 304: ...e frame must be defined See Application manual Additional axes and stand alone controller Coordinated track motion 304 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 8 Calibration information 8 9 7 Define base frame ...

Page 305: ...earboxes Cast iron nodular iron Frame Steel Brakes motors Neodymium Cables connectors drive belts and so on Plastic rubber Gearboxes Oil grease Oil and grease Where possible arrange for oil and grease to be recycled Dispose of via an authorized person contractor in accordance with local regulations Do not dispose of oil and grease near lakes ponds ditches down drains or onto soil Incineration must...

Page 306: ...n penetrate the soil causing ground water contamination 306 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 9 Decommissioning 9 1 Environmental information Continued ...

Page 307: ...robotic devices Coordinate systems and motion nomenclatures ISO 9787 2013 Manipulating industrial robots performance criteria and related test methods ISO 9283 1998 Classification of air cleanliness EN ISO 14644 1 2015i 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 6100...

Page 308: ...cts Principles for design EN 574 1996 A1 2008 UL ANSI and other standards Description Standard Safety requirements for industrial robots and robot systems ANSI RIA R15 06 Safety standard for robots and robotic equipment ANSI UL 1740 Industrial robots and robot Systems General safety require ments CAN CSA Z 434 14 308 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All r...

Page 309: ... 37 in 3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume Product manual IRBP D2009 309 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 10 Reference information 10 2 Unit conversion ...

Page 310: ...ory when handling components with a weight exceeding 22 kg A wide range of lifting accessories and devices are available for each manipulator model Example Following is an example of a weight specification in a procedure Note Action CAUTION The robot weighs xx kg All lifting accessories used must be sized accord ingly 310 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB ...

Page 311: ...ools required are the sum of the Standard Toolkit and any tools listed in the instructions Contents standard toolkit IRC5 Remark Tool Tx10 Screw driver Torx Tx20 Screw driver Torx Tx25 Screw driver Torx Tx25 Ball tipped screw driver Torx 4 mm Screw driver flat blade 8 mm Screw driver flat blade 12 mm Screw driver flat blade Phillips 1 Screw driver 8 mm Box spanner Product manual IRBP D2009 311 3HA...

Page 312: ...uctions Contents standard toolkit Rem Tool Qty Ring open end spanner 8 19 mm 1 Socket head cap 5 17 mm 1 Torx socket no 20 60 1 Box spanner set 1 Torque wrench 75 400 Nm 1 Torque wrench 500 1500 Nm 1 Ratchet head for torque wrench 1 2 1 Hexagon headed screw M10x100 2 Socket head cap no 14 socket 40 mm bit L 100 mm 1 To be shortened to 12 mm Socket head cap no 14 socket 40 mm bit L 20 mm 1 Socket h...

Page 313: ...ram IRBP C 3HAC035753 002 Circuit diagram Service diagram IRBP L 3HAC035753 003 Circuit diagram Service diagram IRBP K R 3HAC035753 004 Circuit diagram Service diagram IRBP A 3HAC035753 005 Circuit diagram Service diagram IRBP B D 3HAC035754 001 Circuit diagram Service diagram IRBP IF C 3HAC035754 002 Circuit diagram Service diagram IRBP IF L 3HAC035754 003 Circuit diagram Service diagram IRBP IF ...

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Page 315: ... Min 500 Mass center Mass max 470kg Lifting eye bolt M20 DIN 580 2x Art no 9ADA337 5 IRBP A 250 xx1500002131 Continues on next page Product manual IRBP D2009 315 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 11 Lifting instructions ...

Page 316: ...max 870kg Mass center D 1450 Angle 12 D 1000 Angle 17 Lifting eye bolt M20 DIN 580 2x Art no 9ADA337 5 IRBP A 500 750 xx1500002132 Continues on next page 316 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 11 Lifting instructions Continued ...

Page 317: ...max 915 kg xx1500002133 IRBP B 500 750 5 5 2355 1000 Min 770 20 mass center Mass center Lifting eye bolt M20 2x Art no 3HAC038304 002 Mass max 1750 kg IRBP B 500 750 xx1500002134 Continues on next page Product manual IRBP D2009 317 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 11 Lifting instructions Continued ...

Page 318: ...ting eye bolt M16 DIN 580 2x Art no 9ADA337 4 Mass center Mass max 380kg IRBP C 500 xx1500002135 Continues on next page 318 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 11 Lifting instructions Continued ...

Page 319: ...6 Lifting eye bolt M16 2x 3HAC038304 001 Mass center Mass max 660kg IRBP C 1000 xx1500002136 Continues on next page Product manual IRBP D2009 319 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 11 Lifting instructions Continued ...

Page 320: ...eye bolt M20 2x Art no 3HAC038304 002 Mass max 1560kg Mass center IRBP D 300 xx1500002137 Continues on next page 320 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 11 Lifting instructions Continued ...

Page 321: ...g eye M20 2x Art no 3HAC038295 002 Mass max 2960kg Mass center IRBP D 600 xx1500002138 Continues on next page Product manual IRBP D2009 321 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 11 Lifting instructions Continued ...

Page 322: ... Positioner length Mass kg L1 mm L2 mm L 1600 1170 1025 2590 L 2000 1250 1200 2990 L 2500 1310 1405 3490 L 3150 1400 1685 4140 L 3500 1450 1840 4490 L 4000 1515 2060 4990 IRBP K 300 xx1500002139 Continues on next page 322 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 11 Lifting instructions Continued ...

Page 323: ...Positioner length Mass kg L1 mm L2 mm L 1600 2080 980 2826 L 2000 2190 1145 3226 L 2500 2290 1345 3726 L 3150 2410 1615 4376 L 3500 2480 1760 4726 L 4000 2570 1970 5226 IRBP K 600 1000 xx1500002140 Continues on next page Product manual IRBP D2009 323 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 11 Lifting instructions Continued ...

Page 324: ...m L2 mm L 1250 250 485 1433 L 1600 255 625 1783 L 2000 260 785 2183 L 2500 270 985 2683 L 3150 280 1250 3333 L 4000 300 1610 4183 IRBP L 300 xx1500002141 Continues on next page 324 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 11 Lifting instructions Continued ...

Page 325: ...IN 580 2x Positioner length Mass kg L1 mm L2 mm L 1250 465 685 1725 L 1600 470 820 2075 L 2000 480 975 2475 L 2500 485 1170 2975 L 3150 500 1430 3625 L 4000 515 1770 4475 L 600 1000 xx1500002142 Continues on next page Product manual IRBP D2009 325 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 11 Lifting instructions Continued ...

Page 326: ...580 2x Positioner length Mass kg L1 mm L2 mm L 1250 700 690 1870 L 1600 705 815 2220 L 2000 710 950 2620 L 2500 720 1130 3120 L 3150 730 1360 3770 L 4000 740 1670 4620 IRBP L 2000 xx1500002143 Continues on next page 326 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 11 Lifting instructions Continued ...

Page 327: ...tion F 3780N Mass center Lifting eye bolt M16 2x Art no 3HAC038304 001 Mass max 645 kg IRBP R 300 xx1500002144 Continues on next page Product manual IRBP D2009 327 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 11 Lifting instructions Continued ...

Page 328: ...0 2337 25 mass center Lifting eye bolt M20 2x Art no 3HAC038304 002 Mass max 1380 kg IRBP R 600 1000 xx1500002145 328 Product manual IRBP D2009 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 11 Lifting instructions Continued ...

Page 329: ...ws 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 IRBP D2009 329 3HAC037731 001 Revision T Copyright 2010 2020 ABB All rights reserved 12 Spare parts 12 1 Spare part lists and illustrations ...

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Page 331: ...ld 57 left hander 57 main parts 54 overview 53 screen 58 updating revolution counters 269 floor bolts 93 Floor mount base 91 forward button 55 foundation forces 82 requirements 73 G grease 32 disposal 305 H hanging installed hanging 28 Hard buttons 55 hazard levels 19 hazardous material 305 height installed at a height 28 hold to run button 54 HRA 28 I install fixtures 145 instructions ActUnit 299...

Page 332: ...es 29 safety hazard hydraulic system 30 pneumatic system 30 safety signals in manual 19 safety standards 307 Safety switch 112 screw joints 87 service position 298 service routine ManLoadIdentify 289 signals safety 19 siSTN1_ACT 149 152 155 157 160 SMB board 230 soACT_STN1 149 152 155 157 160 standards 307 ANSI 308 CAN 308 EN 308 EN IEC 307 EN ISO 307 start button 55 status bar 58 steel disposal 3...

Page 333: ......

Page 334: ...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 3HAC037731 001 Rev T en Copyright 2010 2020 ABB All rights reserved Specifications subject to change without notice ...

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