IRB 1600 3hac026660-En Manual
IRB 1600 3hac026660-En Manual
Product manual
IRB 1600 - 5/1.2 type A
IRB 1600 - 5/1.45 type A
IRB 1600 - 6/1.2 type A
IRB 1600 - 6/1.45 type A
IRB 1600 - 7/1.2 type A
IRB 1600 - 7/1.45 type A
IRB 1600 - 8/1.2 type A
IRB 1600 - 8/1.45 type A
IRB 1600 - 10/1.2 type A
IRB 1600 - 10/1.45 type A
IRB 1600ID - 4/1.5
IRB 1600ID - 4/1.5 type A
IRC5
Document ID: 3HAC026660-001
Revision: L
The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Additional copies of this manual may be obtained from ABB.
The original language for this publication is English. Any other languages that are
supplied have been translated from English.
Table of contents
Table of contents
Overview of this manual ................................................................................................................... 9
Product documentation, IRC5 .......................................................................................................... 14
How to read the product manual ...................................................................................................... 16
1
Safety
17
1.1
1.2
17
18
18
19
20
20
23
24
25
26
27
29
29
30
31
32
33
34
35
36
37
37
39
39
41
46
47
48
49
51
53
54
1.3
57
2.1
2.2
57
58
58
62
67
68
68
70
71
73
76
79
80
89
92
94
2.3
Introduction ......................................................................................................
Unpacking .......................................................................................................
2.2.1 Pre-installation procedure .........................................................................
2.2.2 Working ranges ......................................................................................
2.2.3 Risk of tipping/stability .............................................................................
On-site installation ............................................................................................
2.3.1 Lifting robot with roundslings ....................................................................
2.3.2 Lifting and turning a suspended mounted robot ............................................
2.3.3 Manually releasing the brakes ...................................................................
2.3.4 Orienting and securing the robot ................................................................
2.3.5 Setting the system parameters for a suspended robot ....................................
2.3.6 Loads fitted to the robot, stopping time and braking distances .........................
2.3.7 Fitting equipment on the robot (robot dimensions) .........................................
2.3.8 Installation of signal lamp for 1600 (option) ..................................................
2.3.9 Installation of signal lamp for 1600ID (option) ...............................................
2.3.10 Installation of the wire feeder shelf for IRB 1600ID .........................................
3HAC026660-001 Revision: L
5
Copyright 2006-2014 ABB. All rights reserved.
Table of contents
2.4
2.5
96
96
97
102
106
110
113
113
116
118
Maintenance
121
3.1
3.2
121
122
122
123
124
125
125
128
128
129
132
135
139
139
3.3
3.4
3.5
4
Introduction ......................................................................................................
Maintenance schedule and expected component life ...............................................
3.2.1 Specification of maintenance intervals ........................................................
3.2.2 Maintenance schedule .............................................................................
3.2.3 Expected component life ..........................................................................
Inspection activities ...........................................................................................
3.3.1 Inspection, damper axes 2, 3 and 5 .............................................................
Replacement activities .......................................................................................
3.4.1 Type of lubrication in gearboxes ................................................................
3.4.2 Changing the oil in axes 5 and 6 gearboxes .................................................
3.4.3 Changing the oil, axis 5- 6 gearbox, ID ........................................................
3.4.4 Replacing the battery pack ........................................................................
Cleaning activities .............................................................................................
3.5.1 Cleaning the IRB 1600 ..............................................................................
Repair
143
4.1
4.2
143
144
144
145
147
149
151
151
160
166
170
170
175
182
186
189
195
197
199
201
203
208
208
212
218
222
222
226
231
235
240
4.3
4.4
4.5
4.6
Introduction ......................................................................................................
General procedures ...........................................................................................
4.2.1 Performing a leak-down test ......................................................................
4.2.2 Mounting instructions for bearings .............................................................
4.2.3 Mounting instructions for seals ..................................................................
4.2.4 Replacing parts on Clean Room robots .......................................................
Complete manipulator ........................................................................................
4.3.1 Replacement of cable harness ...................................................................
4.3.2 Replacement of cable harness, IRB 1600ID ..................................................
4.3.3 Replacement of complete arm system .........................................................
Upper and lower arm .........................................................................................
4.4.1 Replacement of complete upper arm ...........................................................
4.4.2 Replacing the complete upper arm ID .........................................................
4.4.3 Replacing the complete lower arm ..............................................................
4.4.4 Replacement of wrist unit .........................................................................
4.4.5 Replacing the wrist unit, ID .......................................................................
4.4.6 Replacing the damper, axis 2 .....................................................................
4.4.7 Replacing the damper, axis 3 .....................................................................
4.4.8 Replacing the mechanical stop axis 3, ID variant ...........................................
4.4.9 Replacement of damper, axis 5 ..................................................................
4.4.10 Remove upper arm AW Gun ......................................................................
Frame and base ................................................................................................
4.5.1 Replacement of base ...............................................................................
4.5.2 Replacing the serial measurement unit ........................................................
4.5.3 Replacing the push button unit ..................................................................
Motors ............................................................................................................
4.6.1 Replacement of motor, axis 1 ....................................................................
4.6.2 Replacement of motor, axis 2 ....................................................................
4.6.3 Replacement of motor, axis 3 ....................................................................
4.6.4 Replacement of motor, axis 3, IRB 1600ID ...................................................
4.6.5 Replacement of motor, axis 4 ....................................................................
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
Table of contents
4.7
271
5.1
5.2
5.3
5.4
5.5
5.6
271
272
274
276
277
279
Introduction .....................................................................................................
Calibration methods ...........................................................................................
Calibration scale and correct axis position .............................................................
Calibration movement directions for all axes ..........................................................
Updating revolution counters ...............................................................................
Checking the zero position ..................................................................................
Decommissioning
281
Robot description
7.1
7.2
244
247
251
257
260
263
263
269
Calibration information
6.1
6.2
7
283
Reference information
285
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
285
286
288
289
292
293
294
295
Introduction ......................................................................................................
Applicable safety standards ................................................................................
Unit conversion .................................................................................................
Screw joints ....................................................................................................
Weight specifications .........................................................................................
Standard tools ..................................................................................................
Special tools ....................................................................................................
Lifting accessories and lifting instructions ..............................................................
297
10 Circuit diagram
299
301
3HAC026660-001 Revision: L
7
Copyright 2006-2014 ABB. All rights reserved.
Usage
This manual should be used during:
installation, from lifting the robot to its work site and securing it to the
foundation, to making it ready for operation
maintenance work
installation personnel
maintenance personnel
repair personnel.
Prerequisites
A maintenance/repair/installation craftsman working with an ABB Robot must:
Organization of chapters
The manual is organized in the following chapters:
Chapter
Contents
Safety, service
Installation and commis- Required information about lifting and installation of the robot.
sioning
Maintenance
Step-by-step procedures that describe how to perform maintenance of the robot. Based on a maintenance schedule that may
be used to plan periodical maintenance.
Repair
Calibration information
Decommissioning
Reference information
9
Copyright 2006-2014 ABB. All rights reserved.
Chapter
Contents
Spare parts and exploded Complete spare part list and complete list of robot components,
views
shown in exploded views.
Circuit diagram
References
Documentation referred to in the manual, is listed in the table below.
Document name
Document ID
3HAC021351-003
3HAC023604-001
3HAC049104-001
3HAC021313-001
3HAC047136-001
3HAC16590-1
3HAC025709-001
3HAC16578-1
3HAC021395-001
3HAC030421-001
3HAC042927-001
3HAC17076-1
3HAC028664-002
Revisions
Revision
Description
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
Revision
Description
11
Copyright 2006-2014 ABB. All rights reserved.
Revision
Description
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
Revision
Description
3HAC026660-001 Revision: L
13
Copyright 2006-2014 ABB. All rights reserved.
Safety information.
Calibration.
Decommissioning.
Spare parts list with exploded views (or references to separate spare parts
lists).
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
Continues on next page
14
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
What is included (for example cables, I/O boards, RAPID instructions, system
parameters, DVD with PC software).
Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and trouble shooters.
The group of manuals includes (among others):
Operating manual - Trouble shooting IRC5, for the controller and manipulator.
3HAC026660-001 Revision: L
15
Copyright 2006-2014 ABB. All rights reserved.
8.
Action
Note/Illustration
3.
Action
Note/Illustration
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 17.
Illustrations
The robot is illustrated with general figures that does not take painting or protection
type in consideration.
Likewise, certain work methods or general information that is valid for several robot
models, can be illustrated with illustrations that show a different robot model than
the one that is described in the current manual.
16
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.1 Introduction to safety information
1 Safety
1.1 Introduction to safety information
Overview
The safety information in this manual is divided into two categories:
Specific safety information, pointed out in the procedures. How to avoid and
eliminate the danger is either described directly in the procedure, or in specific
instructions in the section Safety related instructions on page 39.
3HAC026660-001 Revision: L
17
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.2.1 Introduction to general safety information
Containing
General information
safety, service
limitation of liability
related information
fire extinguishing
safe use of the FlexPendant
stopping functions
description of emergency stop
description of safety stop
description of safeguarding
18
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.2.2 Safety in the manipulator system
Product manual
Detailed in document
Section
Installation and
commissioning
3HAC026660-001 Revision: L
Installation and
commissioning
19
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.2.3.1 Safety risks during installation and service work on manipulators
Those in charge of operations must make sure that safety instructions are
available for the installation in question.
Those who install the manipulator must have the appropriate training for the
equipment in question and in any safety matters associated with it.
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.2.3.1 Safety risks during installation and service work on manipulators
Continued
Turntables or the like should be used to keep the operator out of the
manipulator's working space.
The axes are affected by the force of gravity when the brakes are released.
In addition to the risk of being hit by moving manipulator parts, there is a risk
of being crushed by the parallel arm (if there is one).
Never use the manipulator as a ladder, which means, do not climb on the
manipulator motors or other parts during service work. There is a serious
risk of slipping because of the high temperature of the motors and oil spills
that can occur on the manipulator.
The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance
with the applicable standards for the emergency stop function.
Complete manipulator
Safety risk
Description
Hot components!
CAUTION
Motors and gears are HOT after running the
manipulator! Touching motors and gears may
result in burns!
With a higher environment temperature, more
surfaces on the manipulator will get HOT and
may also result in burns.
Removed parts may result in collapse of
manipulator!
WARNING
Take any necessary measures to ensure that
the manipulator does not collapse as parts
are removed, e.g. secure the lower arm according to repair instruction if removing motor, axis 2.
WARNING
If the internal cables for the measurement
system have been disconnected during repair
or maintenance, then the revolution counters
must be updated.
21
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.2.3.1 Safety risks during installation and service work on manipulators
Continued
Cabling
Safety risk
Cable packs are sensitive to mechanical
damage!
Description
CAUTION
The cable packs are sensitive to mechanical
damage! They must be handled with care,
especially the connectors, in order to avoid
damaging them!
Description
CAUTION
Whenever parting/mating motor and gearbox,
the gears may be damaged if excessive force
is used!
Safety risk
Description
22
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.2.3.2 CAUTION - Hot parts may cause burns!
Info
3HAC026660-001 Revision: L
23
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.2.3.3 Safety risks related to tools/work pieces
24
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.2.3.4 Safety risks related to pneumatic/hydraulic systems
All pipes, hoses, and connections have to be checked regularly for leaks and
damage. Damage must be repaired immediately.
Gravity may cause any parts or objects held by these systems to drop.
Shot bolts should be used to prevent tools, etc., from falling due to gravity.
Safe design
3HAC026660-001 Revision: L
25
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.2.3.5 Safety risks during operational disturbances
The industrial manipulator is a flexible tool that can be used in many different
industrial applications.
All work must be carried out professionally and in accordance with the
applicable safety regulations.
Qualified personnel
Corrective maintenance must only be carried out by qualified personnel who are
familiar with the entire installation as well as the special risks associated with its
different parts.
Extraordinary risks
If the working process is interrupted, extra care must be taken due to risks other
than those associated with regular operation. Such an interruption may have to be
rectified manually.
26
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.2.3.6 Risks associated with live electric parts
The mains supply to the robot must be connected in such a way that it can
be turned off from outside the robots working space.
Make sure that no one else can turn on the power to the controller and
manipulator while you are working with the system. A good method is to
always lock the main switch on the controller cabinet with a safety lock.
The necessary protection for the electrical equipment and manipulator system
during construction, commissioning, and maintenance is guaranteed if the valid
regulations are followed.
All work must be performed:
by qualified personnel
Units such as I/O modules, can be supplied with power from an external
source.
The transformers
The rectifier unit (262/400-480 VAC and 400/700 VDC. Note: Capacitors!)
The power supply unit for additional tools, or special power supply units for
the machining process.
The external voltage connected to the controller remains live even when the
robot is disconnected from the mains.
Additional connections.
Continues on next page
3HAC026660-001 Revision: L
27
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.2.3.6 Risks associated with live electric parts
Continued
The user connections for tools or other parts of the installation (max. 230
VAC).
See chapter Installation and commissioning on page 57.
28
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.2.4.1 Safety fence dimensions
3HAC026660-001 Revision: L
29
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.2.4.2 Fire extinguishing
Note
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the
manipulator system (manipulator or controller)!
30
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.2.4.3 Emergency release of the manipulators arm
The manipulator arm may be moved manually on smaller manipulator models, but
larger models may require using an overhead crane or similar equipment.
Increased injury
Before releasing the brakes, make sure that the weight of the arms does not
increase the pressure on the trapped person, further increasing any injury!
3HAC026660-001 Revision: L
31
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.2.4.4 Brake testing
32
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s"
Note
Do not change Transm gear ratio or other kinematic system parameters from
the FlexPendant or a PC. This will affect the safety function "Reduced speed 250
mm/s".
3HAC026660-001 Revision: L
33
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.2.4.6 Safe use of the FlexPendant
Anyone entering the manipulator working space must always bring the
FlexPendant with him/her. This is to prevent anyone else from taking control
of the manipulator without his/her knowledge.
Hold-to-run function
The hold-to-run function allows movement when a button connected to the function
is actuated manually and immediately stops any movement when released. The
hold-to-run function can only be used in manual mode.
How to operate the hold-to-run function for IRC5 is described in Operating
manual - IRC5 with FlexPendant.
34
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.2.4.7 Work inside the manipulator's working range
WARNING
If work must be carried out within the manipulators work area, the following
points must be observed:
The operating mode selector on the controller must be in the manual mode
position to render the enabling device operational and to block operation
from a computer link or remote control panel.
The manipulators speed is limited to max. 250 mm/s when the operating
mode selector is in the position Manual mode with reduced speed. This
should be the normal position when entering the working space.
The position Manual mode with full speed (100%) may only be used by
trained personnel who are aware of the risks that this entails. Manual mode
with full speed (100%) is not available in USA or Canada.
Pay attention to the rotating axes of the manipulator. Keep away from axes
to not get entangled with hair or clothing. Also, be aware of any danger that
may be caused by rotating tools or other devices mounted on the manipulator
or inside the cell.
Test the motor brake on each axis, according to the section Brake testing
on page 32.
To prevent anyone else from taking control of the manipulator, always put
a safety lock on the cell door and bring the enabling device with you when
entering the working space.
WARNING
NEVER, under any circumstances, stay beneath any of the manipulators axes!
There is always a risk that the manipulator will move unexpectedly when
manipulator axes are moved using the enabling device or during other work
inside the manipulators working range.
3HAC026660-001 Revision: L
35
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.2.4.8 Signal lamp (optional)
36
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.2.5.1 What is an emergency stop?
The default setting is an uncontrolled stop. However, controlled stops are preferred
since they minimize extra, unnecessary wear on the manipulator and the actions
needed to return the manipulator system back to production. Please consult your
plant or cell documentation to see how your manipulator system is configured.
Note
The emergency stop function may only be used for the purpose and under the
conditions for which it is intended.
Note
The emergency stop function is intended for immediately stopping equipment
in the event of an emergency.
Note
Emergency stop should not be used for normal program stops as this causes
extra, unnecessary wear on the manipulator.
For how to perform normal program stops, see section Stopping programs in
Operating manual - IRC5 with FlexPendant.
37
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.2.5.1 What is an emergency stop?
Continued
Classification of stops
The safety standards that regulate automation and manipulator equipment define
categories in which each type of stop applies:
If the stop is...
uncontrolled
category 0 (zero)
controlled
category 1
38
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.3.1 Safety signals in the manual
Danger levels
The table below defines the captions specifying the danger levels used throughout
this manual.
Symbol
Designation
Significance
DANGER
WARNING
ELECTRICAL
SHOCK
CAUTION
xx0200000022
xx0100000002
xx0200000024
xx0100000003
xx0200000023
39
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.3.1 Safety signals in the manual
Continued
Symbol
Designation
Significance
NOTE
TIP
xx0100000004
xx0100000098
40
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.3.2 Safety symbols on manipulator labels
Description
xx0900000812
xx0900000811
Warning!
Warns that an accident may occur if the instructions are not
followed that can lead to serious injury, possibly fatal, and/or
great damage to the product. It applies to warnings that apply
to danger with, for example, contact with high voltage electrical
units, explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height, etc.
Caution!
Warns that an accident may occur if the instructions are not
followed that can result in injury and/or damage to the product.
It also applies to warnings of risks that include burns, eye injury,
skin injury, hearing damage, crushing or slipping, tripping, impact, fall from height, etc. Furthermore, it applies to warnings
that include function requirements when fitting and removing
equipment where there is a risk of damaging the product or
causing a breakdown.
Prohibition
Used in combinations with other symbols.
xx0900000839
41
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.3.2 Safety symbols on manipulator labels
Continued
Symbol
Description
See user documentation
Read user documentation for details.
Which manual to read is defined by the symbol:
No text: Product manual.
EPS: Application manual - Electronic Position Switches.
xx0900000813
xx0900000816
Do not dismantle
Dismantling this part can cause injury.
xx0900000815
Extended rotation
This axis has extended rotation (working area) compared to
standard.
xx0900000814
Brake release
Pressing this button will release the brakes. This means that
the manipulator arm can fall down.
xx0900000808
xx0900000810
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.3.2 Safety symbols on manipulator labels
Continued
Symbol
Description
Crush
Risk of crush injuries.
xx0900000817
Heat
Risk of heat that can cause burns.
xx0900000818
Moving robot
The robot can move unexpectedly.
xx0900000819
xx1000001141
xx0900000820
xx1000001140
43
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.3.2 Safety symbols on manipulator labels
Continued
Symbol
Description
Lifting bolt
xx0900000821
xx1000001242
Lifting of robot
xx0900000822
Oil
Can be used in combination with prohibition if oil is not allowed.
xx0900000823
Mechanical stop
xx0900000824
No mechanical stop
xx1000001144
Stored energy
Warns that this part contains stored energy.
Used in combination with Do not dismantle symbol.
xx0900000825
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.3.2 Safety symbols on manipulator labels
Continued
Symbol
Description
Pressure
Warns that this part is pressurized. Usually contains additional
text with the pressure level.
xx0900000826
xx0900000827
3HAC026660-001 Revision: L
45
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.3.3 DANGER - Moving manipulators are potentially lethal!
Note
Before attempting to run the manipulator, Emergency stop equipment such as gates,
make sure all emergency stop equipment tread mats, light curtains, etc.
is correctly installed and connected.
How to use the hold-to-run function is described in section How to use the hold-torun function in the Operating manual - IRC5
with FlexPendant.
46
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.3.4 DANGER - First test run may cause injury or damage!
Remove all service tools and foreign objects from the robot and its working area
Check that the fixture and workpiece are well secured, if applicable
Make sure all personnel are standing at a safe distance from the robot, that is out of
its reach behind safety fences, and so on
Collision risks
CAUTION
When programming the movements of the manipulator always check potential
collision risks before the first test run.
3HAC026660-001 Revision: L
47
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.3.5 WARNING - The brake release buttons may be jammed after service work
1.3.5 WARNING - The brake release buttons may be jammed after service work
Description
The brake release unit has push-buttons for the brake release of each axis motor.
When service work is performed inside the SMB recess that includes removal and
refitting of the brake release unit, the brake release buttons may be jammed after
refitting.
DANGER
If the power is turned on while a brake release button is jammed in depressed
position, the affected motor brake is released! This may cause serious personal
injuries and damage to the manipulator.
Elimination
To eliminate the danger after service work has been performed inside the SMB
recess, follow the procedure below.
Action
Note
If a button gets jammed in the depressed position, the alignment of the push button unit
must be adjusted so that the buttons can
move freely!
Remove the push button guard and:
Make sure the centering piece (B) is
properly fitted to the unit. (The piece
aligns the unit vertically.)
Adjust the unit sideways so that the
measurements x1 and x2 in the figure xx0600002777
to the right do not differ more than 1 Art. no. for the centering piece is spemm from each other.
cified in Required equipment on
page 219.
48
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.3.6 DANGER - Make sure that the main power has been switched off!
1.3.6 DANGER - Make sure that the main power has been switched off!
Description
Working with high voltage is potentially lethal. Persons subjected to high voltage
may suffer cardiac arrest, burn injuries, or other severe injuries. To avoid these
dangers, do not proceed working before eliminating the danger as detailed below.
Elimination, Panel Mounted Controller
Action
1
Note/illustration
xx0600003255
Note/illustration
xx0600002782
A: Main switch
49
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.3.6 DANGER - Make sure that the main power has been switched off!
Continued
Note/illustration
xx0600002783
Switch off the main switch on the Control A: Main switch, Control Module
Module.
50
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.3.7 WARNING - The unit is sensitive to ESD!
Note
xx1300000856
51
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.3.7 WARNING - The unit is sensitive to ESD!
Continued
xx1300001960
52
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.3.8 WARNING - Safety risks during handling of batteries
Note
Operating temperatures
are listed in Pre-installation procedure on
page 58.
3HAC026660-001 Revision: L
53
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.3.9 WARNING - Safety risks during work with gearbox lubricants (oil or grease)
1.3.9 WARNING - Safety risks during work with gearbox lubricants (oil or grease)
Description
When handling gearbox lubricants, there is a risk of both personal injury and
product damage occurring. The following safety information must be regarded
before performing any work with lubricants in the gearboxes.
Note
When handling oil, grease, or other chemical substances the safety information
of the manufacturer must be observed.
Note
When aggressive media is handled, an appropriate skin protection must be
provided.
Note
Appropriate disposal regulations must be observed.
Note
Take special care when handling hot lubricants.
Warnings and elimination
Warning
xx0100000002
Description
Elimination/Action
Allergic reaction
xx0100000002
When opening the oil or grease Open the plug carefully and keep
plug, there may be pressure
away from the opening. Do not
present in the gearbox, causing overfill the gearbox when filling.
lubricant to spray from the
opening.
Possible pressure
build-up in gearbox
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
1 Safety
1.3.9 WARNING - Safety risks during work with gearbox lubricants (oil or grease)
Continued
Warning
xx0100000002
Do not overfill
xx0100000002
Description
Elimination/Action
Mixing types of oil may cause When filling gearbox oil, do not
severe damage to the gearbox. mix different types of oil unless
specified in the instructions. Always use the type of oil specified
by the manufacturer!
xx0100000098
xx0100000004
xx0100000003
Contaminated oil in
gear boxes
3HAC026660-001 Revision: L
55
Copyright 2006-2014 ABB. All rights reserved.
Load diagram
Safety information
Before any installation work is commenced, it is extremely important 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 page 17 before performing any installation
work.
Note
If the IRB 1600 is connected to power, always make sure that the robot is
connected to protective earth before starting any installation work!
For more information see:
3HAC026660-001 Revision: L
57
Copyright 2006-2014 ABB. All rights reserved.
2.2 Unpacking
2.2.1 Pre-installation procedure
Introduction
This section is intended for use when unpacking and installing the robot for the
first time. It also contains information useful during later re-installation of the robot.
Checking the pre-requisites for installation
Installation craftsmen working with an ABB robot must:
Make sure that the lifting accessory used is suitable to handle the weight of the robot
as specified in:
Weight, robot on page 58
Make sure that the expected operating environment of the robot conforms to the
specifications as described in:
Operating conditions, robot on page 61
Before taking the robot to its installation site, make sure that the site conforms to:
Loads on foundation, robot on page 59
Protection classes, robot on page 61
Requirements, foundation on page 60
Before moving the robot, please observe the stability of the robot:
Risk of tipping/stability on page 67
When these prerequisites are met, the robot can be taken to its installation site as
described in section:
On-site installation on page 68
Weight, robot
The table shows the weight of the robot.
Robot model
Weight
IRB 1600
250 kg
Note
The weight does not include tools and other equipment fitted on the robot!
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
Txy
Fz
Fxy
Tz
xx1100000521
Fxy
Fz
Txy
Tz
The table shows the various forces and torques working on the robot during different
kinds of operation.
Note
These forces and torques are extreme values that are rarely encountered during
operation. The values also never reach their maximum at the same time!
Floor mounted
Force
Force xy
1700 N
3250 N
Force z
- 2500 1150 N
- 2500 2200 N
Torque xy
1700 Nm
3750 Nm
Torque z
855 Nm
1400 Nm
Force
Force xy
3900 N
5300 N
Force z
1300 N
2800 N
Wall mounted
59
Copyright 2006-2014 ABB. All rights reserved.
Force
Torque xy
2310 Nm
3850 Nm
Torque z
855 Nm
1450 Nm
Force
Force xy
1700 N
3250 N
Force z
+ 2500 1150 N
+ 2500 2200 N
Torque xy
1700 Nm
3750 Nm
Torque z
855 Nm
1400 Nm
Suspended
Requirements, foundation
The table shows the requirements for the foundation where the weight of the
installed robot is included:
Requirement
Value
Note
Maximum deviation
from levelness
0.5 mm
Maximum tilt
55
Minimum resonance
frequency
25 Hz
Value
-25 C
+55 C
+70 C
Note
If the manipulator should not be used immediately, all unpainted / unprotected
surfaces must be treated with a rust inhibitor, type Vaseline or similar.
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
Value
+5 C
+45 C
Protection class
IP 54
IP 67
IP 54
IP 67
3HAC026660-001 Revision: L
61
Copyright 2006-2014 ABB. All rights reserved.
Type of motion
Rotation motion
+180 to -180 i
+180 to -180 i
Arm motion
+110 to -63
+136 to -63 (with axis 1
limited to 100)
+120 to -90
+150 to -90 (with axis 1
limited to 95)
Arm motion
+55 to -235
+65 to -245
Rotation motion
Bend motion
+115 to -115
Turn motion
ii
iii
+115 to -115
The working range of axis 1 has the following limitations for wall mounted robots:
IRB 1600-6/x: 20
IRB 1600-10/x: 60
If the robot is tilted, the following combinations of tilt angles and axis 1 working ranges are allowed:
IRB 1600-6/x: axis 1 45 with tilt angles up to 30
IRB 1600-10/x: axis 1 180 with tilt angles up to 55
rev. = Revolutions
The default working range for axis 4 and axis 6 can be extended by changing parameter values in
the software.
Option 610-1 Independent axis can be used for resetting the revolution counter after the axis has
been rotated (no need for rewinding the axis).
Type of motion
Range of movement
Rotation motion
+180 to -180 i
Arm motion
+150 to -90
Arm motion
+79 to -238
Rotation motion
+155 to -155
Bend motion
+135 to -90
Turn motion
+200 to -200
+288 rev. ii to -288 rev. maximum iii
i
ii
iii
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
xx1000000914
Position num- X Position (mm) Z Position (mm) Axis 2 Angle (de- Axis 3 Angle (deber (see figure)
grees)
grees)
0
750
962
150
1562
-90
494
470
+55
1225
487
+90
-90
897
-287
+136
-90
386
737
+136
-235
321
786
-63
+55
-808
975
-63
-90
63
Copyright 2006-2014 ABB. All rights reserved.
xx1000000915
X Position (mm) Z Position (mm) Axis 2 Angle (de- Axis 3 Angle (degrees)
grees)
750
1187
150
1787
-90
404
643
+65
1450
487
+90
-90
800
-639
+150
-90
448
478
+150
-245
-6
740
-90
+65
-1150
487
-90
-90
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
xx0700000136
X Position (mm) Z Position (mm) Axis 2 Angle (de- Axis 3 Angle (degrees)
grees)
790
1297
150
1836
-80
380
579
+79
1500
487
+90
-80
721
-737
+150
-80
398
500
+150
-238
58
717
-90
+79
-1200
487
-90
-80
65
Copyright 2006-2014 ABB. All rights reserved.
Turning radius
The turning radius for the robot is shown in the figure below. Notice the differences
depending on the length of the lower arm.
xx0400001259
(A)
66
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
A-A
A
A
xx0400001296
WARNING
The robot is likely to be mechanically unstable if not secured to the foundation!
3HAC026660-001 Revision: L
67
Copyright 2006-2014 ABB. All rights reserved.
A-A
A
A
xx0400001296
Required equipment
Equipment
Art. no.
Note
Overhead crane
Roundsling
Length: 2 m.
Lifting capacity: 500 kg.
Note
Secure the roundsling safely at the lifting lug Make sure the roundsling has free
in the frame and at the overhead crane.
space and does not wear against any
part of the robot.
Capacity for the roundsling is specified
in Required equipment on page 68.
See attachment in Attaching the
roundslings on page 68.
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
Action
Note
3
CAUTION
The IRB 1600 robot weighs 250 kg.
All lifting accessories used must be sized accordingly!
4
WARNING
Personnel must not, under any circumstances,
be present under the suspended load!
5
3HAC026660-001 Revision: L
69
Copyright 2006-2014 ABB. All rights reserved.
xx1000000320
70
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
using the brake release unit when the robot is connected to the controller.
using the brake release unit when the robot is disconnected from the
controller, but connected to an external power supply at the connector R1.MP.
Using the brake release unit when the robot is connected to the controller
Use this procedure to release the holding brakes with the internal brake release
unit.
Action
1
Note
xx0400001255
2
DANGER
When releasing the holding brakes, the robot axes
may move very quickly and sometimes in unexpected
ways!
Make sure no personnel is near or beneath the robot
arm!
3
71
Copyright 2006-2014 ABB. All rights reserved.
Note
1
DANGER
Incorrect connections, such as supplying
power to the wrong pin, may cause all brakes
to be released simultaneously!
2
xx0400001302
Supply:
0V on pin C10
24V on pin B8
3
72
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
xx0400001300
Center of axis 1
73
Copyright 2006-2014 ABB. All rights reserved.
xx0400001306
3 pcs
M16 x 60 (installation directly on foundation of steel), M16 x
70/80 (installation on foundation or base plate, using guiding
sleeves)
Washers
30 x 17 x 3
Quality
Tightening torque
200 Nm
Guiding sleeves
Use a pair of guiding sleeves to make the robot installation easier.
Continues on next page
74
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
The guiding sleeves are absolutely needed if the robot is wall or angle mounted,
or if the robot is calibrated with AbsAcc.
Orienting and securing the robot to installation site
Action
Note
Guide the robot gently using two of the attachment bolts while lowering it into its mounting
position.
Fit and tighten the bolts and washers in the Specified in section Attachment bolts,
base attachment holes.
specification on page 74.
3HAC026660-001 Revision: L
75
Copyright 2006-2014 ABB. All rights reserved.
Z
Y
Y
+X
+X
xx1200001354
System parameters
If the robot is mounted at any other angle, the system parameter Gravity Beta must
be updated. Gravity Beta specifies the robots mounting angle expressed in radians.
Note
Gravity Beta must be configured correctly so that the robot system can control
the movements in the best possible way. An incorrect definition of the mounting
angle (Gravity Beta) will result in:
Some functions will not work properly, for example Load Identification and
Collision detection.
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
Gravity Beta
Floor (A)
0.000000 (Default)
Tilted (B)
30
0.523599
Wall (C)
90
1.570796
Suspended (D)
180
3.141593
xx0600002779
Floor mounted
77
Copyright 2006-2014 ABB. All rights reserved.
78
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
2.3.6 Loads fitted to the robot, stopping time and braking distances
General
Any loads mounted on the robot must be defined correctly and carefully (with
regard to the position of center of gravity and mass moments of inertia) in order
to avoid jolting movements and overloading motors, gears and structure.
CAUTION
Incorrectly defined loads may result in operational stops or major damage to the
robot.
References
Load diagrams, permitted extra loads (equipment) and their positions are specified
in the product specification. The loads must also be defined in the software as
detailed in:
3HAC026660-001 Revision: L
79
Copyright 2006-2014 ABB. All rights reserved.
A
B
100 100
150 150
250
150
C
150
300
250
200
D
200
250
350
xx1000000154
Robot
A+B+E
IRB 1600-5/X
15 kg
5 kg
0.5 kg
15 kg
15 kg
15 kg
IRB 1600-7/X
5 kg
5 kg
0.5 kg
15 kg
5 kg
5 kg
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
100 100
150
A
250
150
150
300
250
200
250
200
150
350
230
E
500
100
210
50
250
200
200
IRB 1600ID-4/1.5
IRB 1600ID-4/1.5
xx1000000905
Robot
A+B+F
E+F
IRB 1600-6/X
15 kg
5 kg
0.5 kg
15 kg
15 kg
15 kg
IRB 1600-8/X
5 kg
5 kg
0.5 kg
15 kg
5 kg
5 kg
IRB 1600-10/X
5 kg
5 kg
0.5 kg
15 kg
5 kg
5 kg
15 kg
15 kg
15 kg
15 kg
IRB 1600ID-4/1.5 -
81
Copyright 2006-2014 ABB. All rights reserved.
161
131 (3x) M8
840
600
AN
65
AN
242
486.5
1069.5*
1294.5**
19
475*
700**
112 (3x 7)
150
278
242
648
A
*IRB 1600-X/1.2
**IRB 1600-X/1.45
132
62 M6 (2x)
CL Axis
10
CL Axis
(A)
xx1000000972
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
xx1000000893
83
Copyright 2006-2014 ABB. All rights reserved.
165*
275**
150
75
4x M8 12
0,3
*IRB 1600-X/1.2
**IRB 1600-X/1.45
xx1000000906
xx1000000907
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
xx1000000908
xx1000000909
85
Copyright 2006-2014 ABB. All rights reserved.
xx1000000910
View E
Design until June 2006: 2x M5 depth 7.5, mounting holes for equipment. Design
after June 2006, Type A: 2x M6 depth 10, mounting holes for equipment.
Note
Note! When mounting heavier equipment, for example wire feeders, in holes (C)
the bracket must be supported in the opposite holes (E).
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
(A)
84
113,2
97,9
58
45,5
(B)
146,6
170
(C)
1022.5
252.5 160
200
640
215
AA
242
150
4x M8
75
12
486.5
112 (3x 7)
1392
810
275
150
242
278
648
A
CL Axis 1
A
CL Axis 1
xx1000000911
87
Copyright 2006-2014 ABB. All rights reserved.
xx1000000912
xx1000000913
Note
Make sure that the guide pin is not inserted more than max. 9.5mm in the tool
flange.
Before mounting the tool, insert the screw and measure the length of the screw
sticking out, behind the tool. The length must not exceed 9.5mm. Otherwise there
is a risk that the screw damages the sealing behind the tool flange.
The length, 9.5mm, refers to the total length of the screw, not just the thread
length.
Fastener quality
When fitting tools on the turning disk, use only screws with quality 12.9. When
fitting equipment on other places, standard screws with quality 8.8 can be used.
88
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
xx0400001265
Signal lamp
Cable gland
89
Copyright 2006-2014 ABB. All rights reserved.
Cable bracket
Required equipment
Equipment
Art. no.
Note
Signal lamp
3HAC022235-001
3HAC022050-001
Replace if damaged.
3HAC022049-001
Replace if damaged.
Note/Illustration
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working
area.
2
Remove the cover from the upper arm housing Shown in the figure Location of signal
to get access to the connectors inside the
lamp on page 89.
housing.
Remove the protection plug (A) from the insertion hole in the contact panel.
Run the cables of the lamp through the hole in
the contact panel. Secure the cable gland in
the hole.
xx0400001264
Take out the lamp unit through the hole in the Shown in the figure Location of signal
upper arm housing cover and refit the cover. lamp on page 89.
Make sure the gaskets are not damaged.
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
Action
6
Note/Illustration
Fit the cable bracket of the signal lamp to the Shown in the figure Location of signal
two mounting holes in the upper arm housing lamp on page 89.
(B).
xx0400001263
B: Mounting holes, M8 x 12
3HAC026660-001 Revision: L
91
Copyright 2006-2014 ABB. All rights reserved.
xx0700000100
Signal lamp
Required equipment
Equipment
Art. no.
Signal lamp
3HAC9258-1
Drill
Note
Diameter 22.5 mm
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
Equipment
Art. no.
Note
Standard toolkit
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
2
3HAC026660-001 Revision: L
93
Copyright 2006-2014 ABB. All rights reserved.
A
B
E
D
xx0700000311
Knob
Note
Fit the Shelf, wire feeder (B) Shown in figure Location of shelf, wire feeder on page 94
using the four (4) Hex socket
head cap screw (F).
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
Action
2
Note
xx0700000312
3HAC026660-001 Revision: L
95
Copyright 2006-2014 ABB. All rights reserved.
This section describes how to install hardware that restricts the working range.
Note
Adjustments must also be made in the robot configuration software (system
parameters). References to relevant manuals are included in the installation
procedures.
96
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
-6
4
+6
+16
8
-168
B
B
xx0400001286
Mounting position of two additional stops for maximum working area (168)
Mounting position of two additional stops for minimum working area (64)
97
Copyright 2006-2014 ABB. All rights reserved.
Z
Y
Y
+X
+X
xx1200001354
Negative directions in axis 1 have extra gravity force (tilted or wall mounted robots)
If the robot is wall mounted or mounted in a tilted position, the additional mechanical
stop pin restricts the robot when the axis 1 moves in a positive direction, for example
from 0 and upwards to 90 (b).
The stop pin does not manage the extra gravity force that comes from when axis
1 moves in a negative direction, for example from 180 downwards to 90 (a).
(a)
(a)
(b)
(b)
xx1300000180
(a)
The additional stop pin does not manage the extra gravity force in this restricted
working area (for tilted or wall mounted robots).
(b)
The additional stop pin manages to restrict this working area (for tilted or wall
mounted robots).
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
Required equipment
Equipment
Art. no.
Note
3HAC026119-001
xx0400001287
99
Copyright 2006-2014 ABB. All rights reserved.
Casted groove
Guiding pin
Note/Illustration
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
2
xx0400001288
Turn axis 1 manually and check the working area How to release the holding brake
between the stops.
of the axis motor is detailed in
section Manually releasing the
brakes on page 71.
Adjust the software working range limitations (sys- The system parameters that must
tem parameter configuration) to correspond to the be changed (Upper joint bound
mechanical limitations.
and Lower joint bound) are described in Technical reference
manual - System parameters.
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
Action
Note/Illustration
9
WARNING
If the mechanical stop pin is deformed after a hard
collision, it must be replaced!
Deformed movable stops and/or additional stops
as well as deformed attachment screws must also
be replaced after a hard collision.
3HAC026660-001 Revision: L
101
Copyright 2006-2014 ABB. All rights reserved.
xx0400001289
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
xx0400001290
xx0400001291
Damper, axis 2
Washer
103
Copyright 2006-2014 ABB. All rights reserved.
Required equipment
Equipment
Art. no.
Note
3HAC026120-001
Note/Illustration
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working
area.
2
xx0400001292
Fit the damper to the mechanical stop, with its Shown in the figure Illustration,
attachment screw and washer. Tighten the screw. mechanical stop, axis 2 on page 103.
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
Action
6
Note/Illustration
7
WARNING
If the mechanical stop pin is deformed after a
hard collision, it must be replaced!
Deformed movable stops and/or additional stops
as well as deformed attachment screws must
also be replaced after a hard collision.
3HAC026660-001 Revision: L
105
Copyright 2006-2014 ABB. All rights reserved.
xx0400001283
Working range A
Working range B
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
xx0400001284
Working range A
Working range B
107
Copyright 2006-2014 ABB. All rights reserved.
xx0400001285
Required equipment
Equipment
Art. no.
Note
3HAC026121-001
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working
area.
2
Fit the mechanical stop to the two mounting holes See Illustration, mechanical stop,
at the upper arm housing, with the two attachment axis 3 on page 108.
screws and washers. Tighten the screws.
2 pcs: M8 x 25, tightening torque:
25 Nm.
4
WARNING
If the mechanical stop pin is deformed after a
hard collision, it must be replaced!
Deformed movable stops and/or additional stops
as well as deformed attachment screws must also
be replaced after a hard collision.
3HAC026660-001 Revision: L
109
Copyright 2006-2014 ABB. All rights reserved.
xx0400001356
Position switch
Cam
Bracket
Cable straps
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
Required equipment
Equipment
Art. no.
Note
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot
working area.
Shown in the figure Location of position
switch, axis 1 on page 110.
6 pcs, M8 x 12.
Fit the complete bracket to the base of Shown in the figure Location of position
the robot with the two attachment screws. switch, axis 1 on page 110.
2 pcs, M6 x 8.
111
Copyright 2006-2014 ABB. All rights reserved.
Action
7
Note
xx0400001358
A
B
C
D
Attachment plate
Shims
Roller
Cam
10
112
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
xx1000000918
xx1000000919
113
Copyright 2006-2014 ABB. All rights reserved.
xx1000000920
xx1000000921
Connection table
Pos
Connection type
Description
R1.MP
Motor power
R1.SMB
R.1 CP/CS
R.1Air
Standard air
R1.CS
R1.CP
R1.FB7
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
xx1000000922
Pos
Connection type
Description
R2.CP
R2.CS
R2.Air
Standard air
R2.CP
R2.CS
3HAC026660-001 Revision: L
115
Copyright 2006-2014 ABB. All rights reserved.
Description
Robot cables
Position switch cables (option) Handles supply to and feedback from any position switch
on the robot.
Specified in the table Position switch cables, robot base to
controller (option) on page 117.
Customer cables (option)
External axes cables (option) Handles power supply to and control of the external axes'
motors as well as feedback from the servo system.
See the Application manual - Additional axes and stand
alone controller (M2004), see document number in References on page 10.
Robot cables
These cables are included in the standard delivery. They are completely
pre-manufactured and ready to plug in.
Cable sub-category
Description
Connection
point, cabinet
Connection
point, robot
R1.MP
R1.SMB
Art. no.
3HAC2492-1
3HAC2529-1
3HAC2539-1
3HAC2564-1
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
Robot cable, power, for robots with foundry and wash protection
Cable (foundry)
Art. no.
3HAC9038-1
3HAC9038-2
3HAC9038-3
3HAC9038-4
Cable
Art. no.
3HAC2493-1
3HAC2530-1
3HAC2540-1
3HAC2566-1
Art. no.
Connection
point, robot
Connection
point, cabinet
3HAC7997-4
R1.LS
XS8
Art. no.
Connection
point, robot
3HAC3353-1
R1.CP/CS
3HAC3354-1
R1.CP/CS
3HAC3355-1
R1.CP/CS
3HAC3356-1
R1.CP/CS
Art. no.
Connection
point, robot
3HAC8183-1
R1.CP/CS
3HAC8183-2
R1.CP/CS
3HAC8183-3
R1.CP/CS
3HAC8183-4
R1.CP/CS
3HAC026660-001 Revision: L
117
Copyright 2006-2014 ABB. All rights reserved.
Dimension
1/4"
Max. pressure
8 mm
Note
3HAC025396-001
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
xx0400001339
Pin connector
Pin
Backshell
Pin diameter
1 mm
RM18W3K
RM24M9K
1.6 mm
RM20M12K
1.6 mm
RM16M23K
Recommended backshell
Backshell
UT0 16JC
UT0 12JC
UT0 16JC
UT0 14JC
119
Copyright 2006-2014 ABB. All rights reserved.
xx0400001340
MS3126*1626S
MS3126*1210S
M39029/31-240
M29029/31-228
MS3116*1626S
MS3116*1210S
120
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
3 Maintenance
3.1 Introduction
3 Maintenance
3.1 Introduction
Structure of this chapter
This chapter describes all the maintenance activities recommended for the IRB
1600.
It is based on the maintenance schedule found at the beginning of the chapter.
The schedule contains information about required maintenance activities including
intervals, and refers to procedures for the activities.
Each procedure contains all the information required to perform the activity,
including required tools and materials.
The procedures are gathered in different sections and divided up 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 IRB 1600 is connected to power, always make sure that the IRB 1600 is
connected to protective earth before starting any maintenance work!
For more information see:
3HAC026660-001 Revision: L
121
Copyright 2006-2014 ABB. All rights reserved.
3 Maintenance
3.2.1 Specification of maintenance intervals
122
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
3 Maintenance
3.2.2 Maintenance schedule
Equipment
Interval
Detailed in section
Changing
20,000 hrs
Changing
20,000 hrs
Replacement
Battery pack, measurement 36 months or batsystem of type RMU101 or tery low alert i
RMU102 (3-pole battery
contact)
Replacement
Cleaning
Complete robot
Regular iii
The battery low alert (38213 Battery charge low) is displayed when the battery needs to be replaced.
The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned
on until the battery is to be replaced.
See the replacement instruction for more details.
ii The battery low alert (38213 Battery charge low) is displayed when remaining backup capacity
(robot powered off) is less than 2 months. The typical lifetime of a new battery is 36 months if the
robot is powered off 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime
can be extended with a battery shutdown service routine. See Operating manual - IRC5 with
FlexPendant for instructions.
iii A regular interval implies that the activity is to be performed regularly, but the actual interval may
not be specified by the robot manufacturer. The interval depends on the operation cycle of the
robot, its working environment and movement pattern. Generally, the more contaminated
environment, the closer the intervals. The more demanding movement pattern (sharper bending
cable harness), the closer the intervals.
3HAC026660-001 Revision: L
123
Copyright 2006-2014 ABB. All rights reserved.
3 Maintenance
3.2.3 Expected component life
Expected life
Note
2,000,000 cycles
See note 1)
2,000,000 cycles
See note 1)
2,000,000 cycles
See note 1)
Gearbox
40,000 hours
124
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
3 Maintenance
3.3.1 Inspection, damper axes 2, 3 and 5
xx0400001217
Damper, axis 2
Attachment screw
125
Copyright 2006-2014 ABB. All rights reserved.
3 Maintenance
3.3.1 Inspection, damper axes 2, 3 and 5
Continued
xx0400001215
Damper, axis 3
Cast tab
xx0600002806
Damper, axis 5
Recess
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
3 Maintenance
3.3.1 Inspection, damper axes 2, 3 and 5
Continued
Required equipment
Equipment
Art. no.
Note
Standard toolkit
Inspection, dampers
The procedure below details how to inspect the dampers.
Action
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working
area.
2
Check all dampers for damage, such as cracks Shown in the figure Location of
or existing impressions that are larger than 1 mm. dampers on page 125.
3HAC026660-001 Revision: L
127
Copyright 2006-2014 ABB. All rights reserved.
3 Maintenance
3.4.1 Type of lubrication in gearboxes
Note
Oil dispenser
128
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
3 Maintenance
3.4.2 Changing the oil in axes 5 and 6 gearboxes
xx0600002846
Required equipment
Equipment, etc.
Note
Lubricating oil
Information about the oil is found in Technical reference manual - Lubrication in gearboxes.
See Type and amount of oil in gearboxes on
page 128.
Standard toolkit
Other tools and procedures may be These procedures include references to the tools
required. See references to these pro- required.
cedures in the step-by-step instructions below.
129
Copyright 2006-2014 ABB. All rights reserved.
3 Maintenance
3.4.2 Changing the oil in axes 5 and 6 gearboxes
Continued
Note/Illustration
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working
area.
2
WARNING
Handling gearbox oil involves several safety
risks. Before proceeding, please read the safety
information in the section WARNING - Safety
risks during work with gearbox lubricants (oil
or grease) on page 54.
3
Position the robot as shown in the figure to the The capacity of the vessel must be
right:
sufficient to take the complete amount
upper arm: upwards for a standing robot of oil.
axis 4: 180, to a position where the oil
plug (A), faces downwards.
Note! The total amount of oil will not be drained.
There will remain approximately 50 ml in the
wrist unit.
xx0500001434
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
3 Maintenance
3.4.2 Changing the oil in axes 5 and 6 gearboxes
Continued
Note/Illustration
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working
area.
2
WARNING
Handling gearbox oil involves several safety
risks. Before proceeding, please read the
safety information in the section WARNING Safety risks during work with gearbox lubricants (oil or grease) on page 54.
Shown in the figure Location of oil
plugs on page 129!
Position the robot as shown in the figure to the Where to find type of oil and total
right:
amount is detailed in Type of lubrica upper arm: downwards for a standing tion in gearboxes on page 128.
robot
axis 4: 90, to a position where the oil
plug (A), faces upwards.
Fill oil in the wrist unit through the oil plug.
xx0500001435
3HAC026660-001 Revision: L
131
Copyright 2006-2014 ABB. All rights reserved.
3 Maintenance
3.4.3 Changing the oil, axis 5- 6 gearbox, ID
xx0700000030
Required equipment
Equipment
Note
Lubricating oil
Standard toolkit
Other tools and procedures may be required. See references to these procedures in the
step-by-step instructions below.
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot
working area.
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
3 Maintenance
3.4.3 Changing the oil, axis 5- 6 gearbox, ID
Continued
Action
Note
2
WARNING
Handling gearbox oil involves several
safety risks. Before proceeding, please
observe the safety information in section WARNING - Safety risks during
work with gearbox lubricants (oil or
grease) on page 54.
3
Position the robot as shown in the fig- The capacity of the vessel must be sufficient
to take the complete amount of oil.
ure to the right:
upper arm: upwards for a standing robot.
axis 4: - 90, to a position where
the oil plug (A) is faced downwards.
Note
The total amount of oil will not be
drained. There will remain approximately 20 ml in the wrist unit.
xx0700000033
4
CAUTION
The gearbox can contain an excess of
pressure that can be hazardous. Open
the oil plug carefully in order to let out
the excess pressure.
5
Remove the oil plug (A) and the ventil- Shown in figure Location of oil plugs, axis 5-6
ation plug (B).
gearbox on page 132.
About 100 ml
133
Copyright 2006-2014 ABB. All rights reserved.
3 Maintenance
3.4.3 Changing the oil, axis 5- 6 gearbox, ID
Continued
Note
xx0700000034
A Oil plugs
2
Refit the oil plug and the ventilation plug. Tightening torque: 3 Nm.
134
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
3 Maintenance
3.4.4 Replacing the battery pack
Note
The battery low alert (38213 Battery charge low) is displayed when the battery
needs to be replaced. The recommendation to avoid an unsynchronized robot
is to keep the power to the controller turned on until the battery is to be replaced.
For an SMB board with 3-pole battery contact (RMU101 3HAC044168-001 or
RMU102 3HAC043904-001), the lifetime of a new battery is typically 36 months.
For an SMB board with 2-pole battery contact, the typical lifetime of a new battery
is 36 months if the robot is powered off 2 days/week or 18 months if the robot is
powered off 16 h/day. The lifetime can be extended for longer production breaks
with a battery shutdown service routine. See Operating manual - IRC5 with
FlexPendant for instructions.
WARNING
See instructions for batteries, WARNING - Safety risks during handling of batteries
on page 53.
Location of battery pack
The battery pack for the measurement system is located inside the base of the
robot, as shown in the figure below.
xx0500001390
Base cover, including gasket. Battery pack is located beneath the cover.
135
Copyright 2006-2014 ABB. All rights reserved.
3 Maintenance
3.4.4 Replacing the battery pack
Continued
xx0500001393
Velcro strap
Connector X3
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
3 Maintenance
3.4.4 Replacing the battery pack
Continued
RMU 101
7
8
11
xx1300000332
BU unit
10
Required equipment
Note
There are two variants of SMB units and batteries. One with 2-pole battery contact
and one with 3-pole battery contact. The variant with the 3-pole battery contact
has longer lifetime for the battery.
It is important that the SMB unit uses the correct battery. Make sure to order the
correct spare parts. Do not replace the battery contact!
Equipment
Serial measurement
board
Battery pack
3HAC 022047-001
Note
Replace if damaged.
137
Copyright 2006-2014 ABB. All rights reserved.
3 Maintenance
3.4.4 Replacing the battery pack
Continued
Equipment
Note
Standard toolkit
Circuit diagram
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working
area.
2
Fit the new battery pack and connect it to the See Battery pack on serial measureserial measurement unit (X3).
ment unit on page 136.
Check the base cover gasket, replace if dam- Spare part no. is specified in Required
aged.
equipment on page 137.
10
11
138
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
3 Maintenance
3.5.1 Cleaning the IRB 1600
WARNING
Turn off all electrical power supplies to the manipulator before entering its work
space.
General
To secure high uptime it is important that the IRB 1600 is cleaned regularly. The
frequency of cleaning depends on the environment in which the manipulator works.
Different cleaning methods are allowed depending on the type of protection of the
IRB 1600.
Note
Always check the serial number label for verification of the protection type.
Cleaning methods
These following table defines what cleaning methods are allowed for ABB
manipulators depending on the protection type.
Note
Rinsing with water is not allowed for a robot with integrated dressing (ID variants)!
Protection
type
Standard
Cleaning method
Vacuum
cleaner
Yes
Yes i .
It is highly recommended
that the water and steam
contains rust preventive,
without cleaning detergents.
Wash
Yes ii .
It is highly recommended
that the water and steam
contains rust preventive,
without cleaning detergents.
Yes
139
Copyright 2006-2014 ABB. All rights reserved.
3 Maintenance
3.5.1 Cleaning the IRB 1600
Continued
Protection
type
Clean room
i
ii
Cleaning method
Vacuum
cleaner
Yes
No
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.
Always check that all protective covers are fitted to the robot before cleaning!
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
3 Maintenance
3.5.1 Cleaning the IRB 1600
Continued
Never!
Never use solvents that are not approved by ABB to clean the robot!
Never remove any covers or other protective devices before cleaning the
robot!
3HAC026660-001 Revision: L
141
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.1 Introduction
4 Repair
4.1 Introduction
Structure of this chapter
This chapter describes all repair activities recommended for the IRB 1600 and any
external unit.
It is made up of separate procedures, each describing a specific repair activity.
Each procedure contains all the information required to perform the activity, for
example spare parts numbers, required special tools, and materials.
The procedures are gathered in sections, divided according to the component
location on the IRB 1600.
Required equipment
The details of the equipment required to perform a specific repair activity are listed
in the respective procedures.
The details of equipment are also available in different lists in the chapter Reference
information on page 285.
Safety information
There are general safety information and specific safety information. The specific
safety information describes the danger and safety risks while performing specific
steps in a procedure. Make sure to read through the chapter Safety on page 17
before commencing any service work.
Note
If the IRB 1600 is connected to power, always make sure that the IRB 1600 is
connected to earth before starting any repair work.
For more information see:
3HAC026660-001 Revision: L
143
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.2.1 Performing a leak-down test
Article number
Leak-down tester
3HAC0207-1
Note
Note
Remove the topmost oil plug on the gear in question Art. no. is specified in Required
equipment on page 144.
and replace it with the leak-down tester.
Regulators, which are included in the leak-down test,
may be required.
Correct value:
0.2 - 0.25 bar (20 - 25 kPa)
CAUTION
The pressure must under no circumstance be higher
than 0.25 bar (20 - 25 kPa). Also during the time when
the pressure is raised!
4
Wait for approximately 8-10 minutes and make sure If the compressed air is significthat no pressure loss occurs.
antly colder or warmer than the
gearbox to be tested, a slight
pressure increase or decrease
may occur. This is quite normal.
Spray any suspected leak areas with the leak detection spray. Bubbles indicate a leak.
144
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.2.2 Mounting instructions for bearings
Art. no.
Note
Grease
3HAB3537-1
Note
Ensure that the parts included in the bearing fitting are free from
burrs, grinding waste, and other contamination. Cast components
must be free of foundry sand.
Bearing rings, inner rings, and roller elements must not be subjected to direct impact. The roller elements must not be exposed to
any stresses during the assembly work.
Note
Note
The roller elements must be rotated a specified number of turns before pretensioning is carried out and also rotated during the pre-tensioning sequence.
2
Make sure the bearing is properly aligned as this will directly affect the durability of the bearing.
Greasing of bearings
The bearings must be greased after assembly according to the following
instructions:
The bearings must not be completely filled with grease. However, if space
is available beside the bearing fitting, the bearing may be totally filled with
grease when mounted, as excessive grease will be pressed out from the
bearing when the robot is started.
145
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.2.2 Mounting instructions for bearings
Continued
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.
146
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.2.3 Mounting instructions for seals
Art. no.
Note
Grease
3HAB3537-1
Rotating seals
The procedure below describes how to fit rotating seals.
CAUTION
Please observe the following before commencing any assembly of seals:
Keep the seal in its original wrappings or protect it well before actual
mounting.
The fitting of seals and gears must be carried out on clean workbenches.
Use a protective sleeve for the sealing lip during mounting, when sliding
over threads, keyways, etc.
Action
Note
Lubricate the seal with grease just before fitting. (Not too Art. no. is specified in
early - there is a risk of dirt and foreign particles adhering Equipment on page 147.
to the seal.)
Fill 2/3 of the space between the dust tongue and sealing
lip with grease. The rubber coated external diameter must
also be greased, unless otherwise specified.
147
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.2.3 Mounting instructions for seals
Continued
Check the flange surfaces. They must be even and free from pores.
It is easy to check flatness using a gauge on the fastened joint (without sealing compound).
If the flange surfaces are defective, the parts may not be used because leakage could
occur.
Distribute the sealing compound evenly over the surface, preferably with a brush.
O-rings
The following procedure describes how to fit o-rings.
Action
Note
148
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.2.4 Replacing parts on Clean Room robots
Spare parts
Note
Sealing compound
Tooling pin
Cleaning agent
Ethanol
Knife
Lint free cloth
Touch up paint Clean Room,
White
3HAC036639-001
Removing
Use this procedure when removing a part for replacement on a Clean Room robot.
Action
1
Description
xx0900000121
Refitting
Action
Description
Before the parts are refitted, clean the joint Use ethanol on a lint free cloth.
so that it is free from oil and grease.
149
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.2.4 Replacing parts on Clean Room robots
Continued
Action
3
Description
xx0900000122
xx0900000125
Wait 15 minutes.
Note
Always read the instruction in the product
data sheet in the paint repair kit for Foundry
Prime.
7
3HAC036639-001
Note
Always read the instruction in the product
data sheet in the paint repair kit for Clean
Room.
Note
After all repair work, wipe the robot free from particles with spirit on a lint free
cloth.
150
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness
Note
3HAC 021827-001
No application interface.
3HAC 021828-001
3HAC022049-001
Replace if damaged.
3HAC022050-001
Replace if damaged.
3HAC 022047-001
Replace if damaged.
3HAC022048-001
Replace if damaged.
VK-cover
3HAA 2166-23
VK-cover
3HAA 2166-21
Middle cover.
3HAC025815-001
Cable ties
Centering piece
Standard toolkit
Circuit diagram
151
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness
Continued
xx0400001248
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness
Continued
Note/Illustration
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working
area.
2
Remove all cable ties, clamps and brackets inside Attachment points inside the upper
the upper arm housing.
arm housing are shown in the figure Illustration, cabling inside upper arm housing on page 154.
Disconnect all the connectors at the base and re- Shown in the figure Illustration,
move the SMB unit from the base.
cabling inside base on page 157.
Note! Do not lose the centering piece fitted to the
push button unit!
10
11
153
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness
Continued
xx0400001250
Connector plate
Connector holder
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness
Continued
Note/Illustration
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working
area.
2
Place the cable bracket correctly inside the lower Spare part no. is specified in Rearm and secure it by refitting the VK-cover.
quired equipment on page 151.
xx0400001247
Fasten the cabling inside the upper arm housing Shown in the figure Illustration,
by fitting the cable clamp unit to the distance
cabling inside upper arm housing on
console with two attachment screws.
page 154.
Fit the motor and signal cabling to the connector Hexagon nut: M5. 1 pc for each
plate with clamps.
clamp.
Reconnect the signal cable connectors and slide Shown in the figure Illustration,
them into the connector holder.
cabling inside upper arm housing on
Notice that one of the cable ties in the connector page 154.
holder plate must be removed in order to insert
the cables into the holder. Refit it when the connectors are inserted.
The cable layout is shown in the figure Illustration, cabling inside upper
arm housing on page 154.
155
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness
Continued
Action
Note/Illustration
10
Refit the arm housing cover with eight attach- 8 pcs, M6.
ment screws. Check the two gaskets and replace, Shown in the figure Illustration, covif damaged.
ers to remove on page 152.
Spare part no. is specified in Required equipment on page 151.
11
12
xx0400001249
Power cabling; connectors for motors on axes 1 and 2: R3.MP1 and R3.MP2
Signal cabling; connectors for motors on axes 1 and 2: R3.FB1 and R3.FB2
Fastening plate
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness
Continued
xx0500001388
Power cabling
Signal cabling
Fastening plate
SMB unit
157
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness
Continued
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working
area.
2
Fit the cable clamp unit to the fastening plate Shown in the figure Illustration, cabling
with two attachment screws, but do not secure inside frame on page 156.
the plate to the frame yet.
Connect all the connectors inside the frame Shown in the figure Illustration, cabling
and secure all plates and cable brackets inside inside frame on page 156.
the frame with attachment screws and nuts.
In the base, secure the cabling to the bottom Shown in the figure Illustration, cabling
fastening plate:
inside base on page 157.
fit the cable clamp unit with two attachment screws (M6).
fit the separate cables with clamps and
hexagon nuts.
Refit the SMB unit to the fastening plate with Shown in the figure Illustration, cabling
inside base on page 157.
hexagon nuts.
xx0600002777
10
WARNING
Before continuing any service work, please
observe the safety information in section
WARNING - The brake release buttons may be
jammed after service work on page 48!
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness
Continued
Action
Note
11
Connect the:
Shown in the figure Illustration, cabling
signal cable connectors to the SMB unit inside base on page 157.
power cable connector to the housing
in the base
optional cabling, if any
ground cable.
12
Refit the covers to the frame and to the base. Shown in the figure Illustration, covers
to remove on page 152.
Replace the gaskets, if damaged.
Spare part no. is specified in Required
equipment on page 151.
13
3HAC026660-001 Revision: L
159
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.3.2 Replacement of cable harness, IRB 1600ID
R4.FB6
R4.MP5
R4.MP6
R3.FB3
R3.FB4
R3.FB5
R3.FB6
R3.MP3
R3.MP4
R3.MP5
R3.MP6
xx0700000038
R4.FB6
R4.FB5
R4.MP6
R4.MP5
Required equipment
Equipment
Standard toolkit
Note
Standard tools on page 293
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.3.2 Replacement of cable harness, IRB 1600ID
Continued
Equipment
Note
VK- cover
3HAA 2166-23
3HAC027523-002
IRB 1600 AW
Circuit diagram
Cable ties
CAUTION
Be careful when handling the wrist. Always hold on the casting, do not hold on
the wrist cover. This can damage the sealing which will cause oil leakage.
Removal, cable harness lower arm and upper arm back
The procedure below describes removal of the complete cable harness in upper
arm back.
R3.FB3
R3.FB4
R3.FB5
R3.FB6
R3.MP3
R3.MP4
R3.MP5
R3.MP6
xx0700000105
161
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.3.2 Replacement of cable harness, IRB 1600ID
Continued
Action
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot
working area.
2
xx0700000106
Remove the cable harness from the lower Follow instructions in section Replacement
of cable harness on page 151.
arm.
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.3.2 Replacement of cable harness, IRB 1600ID
Continued
xx0700000099
Cover plate
Clamp
R4.FB5
R4.FB6
R4.MP6
R4.MP5
R3.MP5
R3.MP6
R3.FB5
R3.FB6
Action
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the
robot working area.
163
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.3.2 Replacement of cable harness, IRB 1600ID
Continued
Action
Note
xx0700000113
xx0700000114
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.3.2 Replacement of cable harness, IRB 1600ID
Continued
Note
3HAC026660-001 Revision: L
165
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.3.3 Replacement of complete arm system
xx0500001443
Cover, frame
Cover, base
Required equipment
Equipment
Art. no.
Note
Lifting slings
VK-cover
3HAA 2166-23
3HAB3732-13
Replace if damaged.
Isopropanol
Locking liquid
Loctite 574
Standard toolkit
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.3.3 Replacement of complete arm system
Continued
Equipment
Art. no.
Note
These procedures include references to the tools required.
Note
2
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working
area.
3
Release the cable harness from below upwards The cable layouts inside the base and
to the lower arm by:
the frame are shown in the figures:
disconnecting all the connectors inside
Illustration, cabling inside base
the base and the frame.
on page 157.
removing all cable ties and brackets in Illustration, cabling inside
side the base and the frame.
frame on page 156.
Push out the VK-cover from inside of the frame. Shown in the figure Location of complete arm system on page 166.
6
CAUTION
The complete arm system weighs 55 kg.
All lifting accessories used must be sized accordingly!
7
10
11
167
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.3.3 Replacement of complete arm system
Continued
Note/Illustration
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
2
Fit the sealing ring properly to the frame. Replace Art. no. is specified in Required
it if damaged.
equipment on page 166.
xx0400001245
A: Sealing ring
B: Mating surface
5
CAUTION
The complete arm system weighs 55 kg.
All lifting accessories used must be sized accordingly!
6
Fit the lower arm against the frame, fit the one
12 pcs; M10 x 40, tightening
washer and secure with the 12 attachment screws. torque: 70 Nm.
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.3.3 Replacement of complete arm system
Continued
10
Action
Note/Illustration
11
DANGER
Make sure all safety requirements are met when
performing the first test run. These are further detailed in the section DANGER - First test run may
cause injury or damage! on page 47.
3HAC026660-001 Revision: L
169
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.1 Replacement of complete upper arm
xx0400001218
Arm housing cover, including gaskets for the cover and the contact panel
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.1 Replacement of complete upper arm
Continued
Required equipment
Equipment
Upper arm
VK-cover
3HAA 2166-23
3HAB3732-19
Art. no.
Note
Includes the wrist unit. All
gearboxes are filled with oil
at delivery.
Note! This upper arm spare
is interchangeable with upper arm spare with art. no.
3HAC 023630-001. But this
change of upper arm requires software 5.07.01.
Replace if damaged.
Replace if damaged.
Replace if damaged.
3HAC022050-001
Grease
Locking liquid
Lifting slings
Loctite 574
Standard toolkit
Note/Illustration
2
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working
area.
3
Remove the arm housing cover from the upper Shown in the figure Location of upper
arm.
arm on page 170.
171
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.1 Replacement of complete upper arm
Continued
Action
Note/Illustration
Remove the VK-cover from the lower arm by Shown in the figure Location of upper
pushing it out from the inside.
arm on page 170.
Pull out the cabling from the arm housing.
7
CAUTION
The complete upper arm weighs 55 kg without
any additional equipment fitted!
All lifting accessories used must be sized accordingly!
8
xx0400001219
Note/Illustration
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working
area.
2
3
CAUTION
The complete upper arm weighs 55 kg without
any additional equipment fitted!
All lifting accessories used must be sized accordingly!
4
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.1 Replacement of complete upper arm
Continued
Action
5
Note/Illustration
xx0400001220
Lift the upper arm to mounting position, fit the 10 pcs: M10 x 40.
washer (B) and secure the upper arm with the Tightening torque: 70 Nm.
10 attachment screws (A).
xx0400001219
Connect all the connectors in the arm housing Refitting of the cabling in the upper
and secure the cabling with brackets and straps. arm housing is further detailed in
section Refitting, cable harness in
upper arm housing and lower arm on
page 155.
10
Refit the arm housing cover to the upper arm. Shown in the figure Location of upper
Check the two gaskets in the cover and replace arm on page 170.
them, if damaged.
Spare part no. is specified in section
Required equipment on page 171.
11
12
173
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.1 Replacement of complete upper arm
Continued
Action
Note/Illustration
13
DANGER
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run
may cause injury or damage! on page 47.
174
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.2 Replacing the complete upper arm ID
Note
Recalibration of robot axis 3-6 is required after replacement of upper arm.
Location of the complete upper arm
The complete upper arm is considered a spare part, including wrist, gearboxes
and motors. The figure below shows the location of the upper arm and connection
to the lower arm.
xx0700000045
VK -Cover
Cable harness
V-ring
175
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.2 Replacing the complete upper arm ID
Continued
Required equipment
Equipment
Art. no.
Note
VK-cover
3HAA2166-23
Replace if damaged
Standard toolkit
Note
xx0700000075
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.2 Replacing the complete upper arm ID
Continued
Action
3
Note
xx0700000077
Disconnect all connectors inside the armhouse and loosen the cabling from straps
and brackets.
5
CAUTION
The robot upper arm weighs 39 kg.
All lifting accessories used must be sized
accordingly!
177
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.2 Replacing the complete upper arm ID
Continued
Action
6
Note
xx0700000060
xx0700000057
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.2 Replacing the complete upper arm ID
Continued
Note
1
CAUTION
The robot upper arm weighs 39 kg.
All lifting accessories used must be sized accordingly!
2 Attach a roundsling to the upper arm and lift it.
3 Clean the contact surface.
xx0700000076
A Contact surface.
4 Carefully refit the upper arm to the lower arm,
making sure that the new upper arm is mounted
in the synchronization position.
xx0700000075
179
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.2 Replacing the complete upper arm ID
Continued
Action
Note
xx0700000057
xx0700000077
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.2 Replacing the complete upper arm ID
Continued
Action
Note
12
DANGER
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run
may cause injury or damage! on page 47.
3HAC026660-001 Revision: L
181
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.3 Replacing the complete lower arm
xx0400001246
Lower arm
VK-cover
VK-cover, middle
Required equipment
Equipment
Art. no.
Lower arm
VK-cover
3HAA2166-23
VK-cover
3HAA2166-21
Note
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.3 Replacing the complete lower arm
Continued
Equipment
Art. no.
Note
3HAB3732-13
Replace if damaged.
Isopropanol
Locking liquid
Loctite 574
Standard toolkit
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
2
CAUTION
Be careful not to damage the cabling and
cable bracket inside the lower arm when removing the middle VK-cover!
The figure to the right shows the space underneath the cover. The gray areas are safe for
insertion of a tool that may be inserted with
a maximum depth of 20 mm!
xx0400001247
5
CAUTION
The robot lower arm weighs 20 kg.
All lifting accessories used must be sized
accordingly!
6
Fit the lifting device to the lower arm to secure the weight of the arm.
183
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.3 Replacing the complete lower arm
Continued
Action
Note
Check the sealing ring. Replace it if damaged. Spare part no. is specified in Required
equipment on page 182.
Note
xx0400001245
A: Sealing ring
B: Mating surface
4
CAUTION
The robot lower arm weighs 20 kg.
All lifting accessories used must be sized
accordingly!
5
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.3 Replacing the complete lower arm
Continued
Action
9
Note
Calibration is detailed in a separate calibration manual enclosed with the calibration tools.
General calibration information is included
in section Calibration information on
page 271.
12
DANGER
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in the section DANGER - First
test run may cause injury or damage! on
page 47.
3HAC026660-001 Revision: L
185
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of wrist unit
xx0600002847
Wrist unit
Required equipment
Equipment, etc.
Wrist Standard/Foundry
3HAC027003-001
Must be replaced.
Note! The o-ring sealing plate is
not interchangeable with art.no.
3HAC 7191-1!
Grease
Art. no.
Note
Standard toolkit
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of wrist unit
Continued
Equipment, etc.
Art. no.
Other tools and procedures may be required. See references to these procedures in the stepby-step instructions
below.
Note
These procedures include references to the tools required.
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot
working area.
2
CAUTION
Always cut the paint with a knife and grind
the paint edge when disassembling parts of
a Clean Room robot! See Replacing parts
on Clean Room robots on page 149
3
Note
3
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot
working area.
187
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of wrist unit
Continued
Action
Note
Lightly lubricate the o-ring sealingplate Art. no. is specified in section Required
with grease.
equipment on page 186.
Fit the o-ring sealingplate to the upper Use a new o-ring! Spare part no. is specified
arm. Fit the wrist unit to the upper arm in Required equipment on page 186.
with the three attachment screws, while 3 pcs, M8 x 25, tightening torque: 28 Nm.
making sure that the gears mate properly.
Note
After all repair work, wipe the robot free
from particles with spirit on a lint free
cloth.
10
11
DANGER
Make sure all safety requirements are
met when performing the first test run.
These are further detailed in the section
DANGER - First test run may cause injury or damage! on page 47.
188
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.5 Replacing the wrist unit, ID
Note
After replacement of motors/motor or gearbox in a manipulator, recalibration is
required.
Location of wrist unit
The wrist unit is located in the frontmost part of the upper arm.
G
B
F
C
xx0700000025
Upper arm
Wrist
Motor axis 6
Required equipment
Equipment
Art. No.
Wrist, ID
Note
O-ring
189
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.5 Replacing the wrist unit, ID
Continued
Equipment
Art. No.
Note
Grease
3HAC3537-1
Arm
3HAC9037-1
Loctite 242
1269-0014-410
Standard toolkit
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
2
Remove all extra equipment fitted on upper Shown in Remove AW Gun on page 204
arm and wrist.
xx0700000092
A Plug
B Standard tool, Standard tools on
page 293
C Hexagon socket head screw
M5X16 (Short head)
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.5 Replacing the wrist unit, ID
Continued
Action
4
Note
xx0700000054
A VK-Cover
5
xx0700000053
xx0700000052
191
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.5 Replacing the wrist unit, ID
Continued
Action
8
Note
xx0700000091
A: Contact R4.FB6
B: Contact R4.MP6
C: Motor axis 6
D: Hexagon socket head screw
M8x35
F: Hexagon socket head screw
M5x25
Note
1
Note
Remove the console from the old motor and
scrap it.
The new console shall be fitted to the axis-6
motor. See .
xx0700000353
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.5 Replacing the wrist unit, ID
Continued
Action
3
Note
xx0700000093
A: String
4
Use standard tools to refit the three hexagon Shown as (H) in figure Location of wrist
socket head screw (M8x35).
unit on page 189.
Tightening torque 24 Nm
Note
When reconnecting the connectors
R4.FB6 and R4.MP6, make sure to push
the connectors towards the wrist as far
away from the axis 5-6 cable spiral as
possible, to avoid grease to accumulate
on the resolver connector.
xx0700000092
193
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.5 Replacing the wrist unit, ID
Continued
Action
Note
11
DANGER
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in section DANGER - First
test run may cause injury or damage! on
page 47.
194
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.6 Replacing the damper, axis 2
xx0400001217
Damper, axis 2
Required equipment
Equipment, etc.
Art. no.
Damper, axis 2
3HAC022013-001
Standard toolkit
Note
195
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.6 Replacing the damper, axis 2
Continued
Note
1
CAUTION
Always cut the paint with a knife and grind
the paint edge when disassembling parts of
a Clean Room robot! See Replacing parts on
Clean Room robots on page 149
2
3
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
4
Note
2
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
3
4
DANGER
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in the section DANGER - First
test run may cause injury or damage! on
page 47.
196
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.7 Replacing the damper, axis 3
xx0400001215
Damper, axis 3
Cast tab
Required equipment
Equipment, etc.
Art. no.
Damper, axis 3
3HAC022260-001
Note
Standard toolkit
Action
Note
197
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.7 Replacing the damper, axis 3
Continued
Action
Note
2
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
3
Action
Note
2
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
3
4
DANGER
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in the section DANGER - First
test run may cause injury or damage! on
page 47.
198
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.8 Replacing the mechanical stop axis 3, ID variant
A
B
xx0700000043
Mechanical damper
Required equipment
Equipment
Art. no.
Note
Mechanical stop
Standard tools
Note
Run the robot to a position that enables access to the mechanical stop.
199
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.8 Replacing the mechanical stop axis 3, ID variant
Continued
Action
Note
2
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
3
Note
2
DANGER
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in the section DANGER - First
test run may cause injury or damage! on
page 47.
200
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.9 Replacement of damper, axis 5
xx0600002806
Damper, axis 5
Recess
Required equipment
Equipment, etc.
Damper, axis 5
3HAB 8964-1
Standard toolkit
Note
Note
Run the robot to a position that enables the end of Shown in the figure Location of
the damper to be pushed into the recess in the wrist damper, axis 5 on page 201.
unit.
2
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
3
201
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.9 Replacement of damper, axis 5
Continued
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
2
Push the end of the damper into the gap between the
wrist unit and upper arm.
5
DANGER
Make sure all safety requirements are met when performing the first test run. These are further detailed in the
section DANGER - First test run may cause injury or
damage! on page 47.
202
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.10 Remove upper arm AW Gun
xx0700000153
Brace (BINZEL)
Required equipment
Equipment
Art. no.
Note
Standard tools
203
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.10 Remove upper arm AW Gun
Continued
Remove AW Gun
The section below shows how to remove the AW. equipment from the upper arm
of a IRB 1600 ID.
Action
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the
robot working area.
2
xx0700000151
A Locking sleeve
B Locking screw
C Welding cable
3
xx0700000273
A BINZEL Brace
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.10 Remove upper arm AW Gun
Continued
Action
4
Note
xx0700000142
A Wire feeder
B Welding cable
5
xx0700000150
A Locking ring
B Locking sleeve
C Screw M5
205
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.10 Remove upper arm AW Gun
Continued
Refit AW Gun
The section below shows how to refit the AW. equipment to the upper arm of a IRB
1600 ID.
Action
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the
robot working area.
2
xx0700000150
A Locking ring
B Locking sleeve
C Screw M5
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.4.10 Remove upper arm AW Gun
Continued
Action
3
Note
xx0700000151
A Locking sleeve
B Locking screw
C Welding cable
4
xx0700000273
3HAC026660-001 Revision: L
207
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.5.1 Replacement of base
xx0500001453
Base
Required equipment
Equipment
Base, spare
3HAC023552-001
3HAB3732-21
VK-cover
3HAA2166-26
Art. no.
Note
Replace if damaged.
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.5.1 Replacement of base
Continued
Equipment
Lifting slings
Art. no.
Note
Locking liquid
Grease
Loctite 574
For sealing the base to the
gearbox 1-2.
3HAB3537-1
Isopropanol
Standard toolkit
Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.
Removal, base
The procedure below details how to remove the base from the robot.
Action
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working
area.
2
CAUTION
Always cut the paint with a knife and grind the
paint edge when disassembling parts of a Clean
Room robot! See Replacing parts on Clean
Room robots on page 149
3
Remove the cabling inside the base and pull it The cable layout in the base is shown
up to the gearbox unit.
in the figure Illustration, cabling inside
base on page 157.
209
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.5.1 Replacement of base
Continued
Action
Note
6
CAUTION
The robot weighs 250 kg.
All lifting accessories used must be sized accordingly!
7
Fit the lifting slings to the robot, lift it and place Art. no. is specified in Required
it with the side of the lower arm downwards on equipment on page 208.
a work bench.
Be careful not to damage the motor connectors!
9
CAUTION
The robot base weighs 81 kg.
All lifting accessories used must be sized accordingly!
10
Secure the weight of the base and remove the Shown in the figure Location of base
gearbox/base attachment screws and washer. on page 208.
11
Refitting, base
The procedure below details how to refit the base to the robot.
Action
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working
area.
2
Check the V-ring on the gearbox unit. Lubricate Spare part no. is specified in Required
with grease if needed. Replace it if damaged! equipment on page 208.
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.5.1 Replacement of base
Continued
Action
Note
7
CAUTION
The robot base weighs 81 kg.
All lifting accessories used must be sized accordingly!
8
Secure the base to the gearbox unit with the Shown in the figure Location of base
gearbox/base attachment screws and washer. on page 208.
16 pcs, M10 x 40, tightening torque:
70 Nm.
10
11
CAUTION
The robot weighs 250 kg.
All lifting accessories used must be sized accordingly!
12
13
14
15
16
17
18
DANGER
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run
may cause injury or damage! on page 47.
3HAC026660-001 Revision: L
211
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.5.2 Replacing the serial measurement unit
xx0500001390
Base cover, including gasket. Serial measurement unit is located beneath the
cover.
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.5.2 Replacing the serial measurement unit
Continued
xx0500001391
Connector SMB
Connector SMB1-4
Hexagon nuts (totally 2 pcs). Only the outer nuts are used.
213
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.5.2 Replacing the serial measurement unit
Continued
RMU 101
D
E
xx1300000331
Connector SMB
Connector SMB1-4
BU unit
Required equipment
Note
There are different variants of SMB units and batteries. The variant with the
3-pole battery contact has longer lifetime for the battery.
It is important that the SMB unit uses the correct battery. Make sure to order the
correct spare parts. Do not replace the battery contact!
Equipment
Art. no.
Battery pack
Note
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.5.2 Replacing the serial measurement unit
Continued
Equipment
Art. no.
Note
Centering piece
3HAC025815-001
Standard toolkit
Circuit diagram
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
2
Remove the push button guard from the base. The push button guard must be removed
to ensure a correct refitting of the push
buttons.
xx0600002744
xx0600002776
B: Centering piece
215
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.5.2 Replacing the serial measurement unit
Continued
Action
Note
xx0500001455
Note
xx0500001392
A Pins
2
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.5.2 Replacing the serial measurement unit
Continued
Action
4
Note
Refit the centering piece (B) to the push button unit in order to align it vertically.
Also make sure that the unit is correctly
aligned sideways: the measurements x1 and
x2 in the figure to the right should not differ
more than 1 mm from each other!
xx0600002777
7
WARNING
Before continuing any service work, please
observe the safety information in section
WARNING - The brake release buttons may
be jammed after service work on page 48!
8
Check the gasket of the base cover. Replace Spare part no. is specified in Required
it if damaged.
equipment on page 214.
3HAC026660-001 Revision: L
217
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.5.3 Replacing the push button unit
xx0500001390
Base cover, including gasket. Push button unit is located beneath the cover.
xx0500001394
Hexagon nuts, SMB unit (4 pcs). Only the outer ones are used.
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.5.3 Replacing the push button unit
Continued
Required equipment
Equipment
Art. no.
Note
3HAC 022047-001
Centering piece
3HAC025815-001
Standard toolkit
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
2
Remove the push button guard from the base. The push button guard must be removed
to ensure a correct refitting of the push
button unit.
xx0600002744
xx0600002776
B: Centering piece
219
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.5.3 Replacing the push button unit
Continued
Action
Note
Unscrew the four hexagon nuts on the SMB Shown in the figure Push button unit on
unit enough to enable lifting the unit. Do not serial measurement unit on page 218.
remove the nuts.
xx0500001455
Remove the two hexagon nuts from the push Shown in the figure Push button unit on
serial measurement unit on page 218.
button unit.
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
Spare part no. is specified in Required
equipment on page 219.
Shown in the figure Push button unit on
serial measurement unit on page 218.
Fit the push button guard and secure it with Shown in the figure Push button unit on
two hexagon nuts.
serial measurement unit on page 218.
Push in and secure the SMB unit with the four Shown in the figure Push button unit on
hexagon nuts.
serial measurement unit on page 218.
Refit the centering piece (B) to the push button unit in order to align it vertically.
Also make sure that the unit is correctly
aligned sideways: the measurements x1 and
x2 in the figure to the right should not differ
more than 1 mm from each other!
xx0600002777
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.5.3 Replacing the push button unit
Continued
Action
6
Note
7
WARNING
Before continuing any service work, please
observe the safety information in section
WARNING - The brake release buttons may
be jammed after service work on page 48!
8
Check the gasket of the base cover. Replace Spare part no. is specified in Required
it if damaged.
equipment on page 219.
12
DANGER
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in section DANGER - First
test run may cause injury or damage! on
page 47.
3HAC026660-001 Revision: L
221
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.1 Replacement of motor, axis 1
4.6 Motors
4.6.1 Replacement of motor, axis 1
Location of motor
The axis 1 motor is located on the frame, as shown in the figure.
A more detailed view of the motor and its position may be found in the spare part
view, see Spare parts - Frame, exploded view.
xx0400001256
Motor, axis 1
Cover, frame
Motor cover
Required equipment
Equipment
Art. no.
Note
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.1 Replacement of motor, axis 1
Continued
Equipment
Art. no.
Note
O-ring
21522012-428
Power supply
Isopropanol
Grease
3HAB 3537-1
3HAC022266-003
Standard toolkit
Circuit diagram
O-ring, motor.
Replace if damaged.
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
Shown in the figure Location
of motor on page 222.
In order to release the brakes, connect the 24 VDC power Connect to connector
supply to the motor.
R3.MP1:
+: pin 7
-: pin 8
223
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.1 Replacement of motor, axis 1
Continued
Action
9
Note
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working
area.
2
Note
It is important that the gearbox and the mating
motor pinion are provided by the same sub-supplier, make sure to order the correct spare part! To
determine the correct spare part, see Compatible
gearboxes and motors in Product manual, spare
parts - IRB 1600.
3
Make sure the o-ring on the circumference of the Spare part number is specified in
motor is seated properly. Lubricate the o-ring with Required equipment on page 222.
grease.
In order to release the brakes, connect the 24 VDC Connect to connector R3.MP1:
power supply to the motor.
+: pin 7
-: pin 8
Fit the rotation tool to the end of the motor shaft. Article number is specified in Required equipment on page 222.
Secure the motor with four attachment screws and 4 pcs, M8 x 25.
washers, but do not tighten yet.
10
11
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.1 Replacement of motor, axis 1
Continued
Action
Note
12
13
14
15
16
17
18
DANGER
Make sure all safety requirements are met when
performing the first test run. These are further detailed in the section DANGER - First test run may
cause injury or damage! on page 47.
3HAC026660-001 Revision: L
225
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.2 Replacement of motor, axis 2
xx0400001257
Motor, axis 2
Cover, frame
Motor cover
Required equipment
Equipment, etc.
Art. no.
O-ring
21522012-428
Note
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.2 Replacement of motor, axis 2
Continued
Equipment, etc.
Art. no.
Note
Grease
3HAB 3537-1
Isopropanol
Standard toolkit
3HAC022266003
Power supply
24 VDC, 1.5 A.
For releasing the brakes.
Other tools and procedures may be required. See references to these procedures in the stepby-step instructions
below.
Circuit Diagram
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
2
CAUTION
Always cut the paint with a knife and grind the paint
edge when disassembling parts of a Clean Room robot!
See Replacing parts on Clean Room robots on page 149
3
Connectors:
R3.MP2
R3.FB2
227
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.2 Replacement of motor, axis 2
Continued
Action
6
Note
Remove the connector plate by removing its attachment Shown in the figure Location
screws, and pull the cables out from the frame.
of motor axis 2 on page 226.
7
DANGER
Secure the weight of the lower arm properly before releasing the brakes of motor, axis 2!
When releasing the holding brakes of the motor, the
lower arm will be movable and may fall down!
8
9
WARNING
Oil will be running out of the motor attachment hole
when removing the motor! It may also be hot! Take any
necessary measures to collect the oil.
10
Remove the motor by unscrewing its four attachment Shown in the figure Location
screws and plain washers.
of motor axis 2 on page 226.
11
12
13
Note
1
Note
It is important that the gearbox and the mating
motor pinion are provided by the same sub-supplier, make sure to order the correct spare part!
To determine the correct spare part, see Compatible gearboxes and motors in Product manual,
spare parts - IRB 1600.
2
Make sure the o-ring on the circumference of the Art. no. is specified in section Required equipment on page 226.
motor is seated properly.
Lightly lubricate the o-ring with grease.
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.2 Replacement of motor, axis 2
Continued
Action
Note
Remove the motor cover from top of the motor. Shown in the figure Location of motor axis 2 on page 226.
Fit the rotation tool to the end of the motor shaft. Art. no. is specified in section Required equipment on page 226.
4 pcs, M8 x 25.
Tightening torque: approx 2 Nm.
10
11
12
13
14
15
Reconnect the motor connectors inside the frame. Cable layout is shown in the figure
Illustration, cabling inside frame on
page 156.
16
Refit all cable ties, and the bracket underneath Shown in the figure Location of motor axis 2 on page 226.
the frame.
17
18
19
20
Note
After all repair work, wipe the robot free from
particles with spirit on a lint free cloth.
229
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.2 Replacement of motor, axis 2
Continued
21
Action
Note
22
DANGER
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run
may cause injury or damage! on page 47.
230
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.3 Replacement of motor, axis 3
xx0400001258
Motor, axis 3
Connector holder
Cable tie
Required equipment
Equipment
Art. no.
O-ring
21522012-426
Note
Replace if damaged.
231
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.3 Replacement of motor, axis 3
Continued
Equipment
Art. no.
Note
3HAC022049-001
Replace if damaged.
3HAC022050-001
Replace if damaged.
Isopropanol
Grease
3HAB3537-1
3HAC022266-003
Circuit diagram
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
2
Move:
axis 2 to calibration position
upper arm backwards against the mechanical
stop.
This position enables removal of the motor without
draining of the gearbox, axis 3.
xx0500001447
Disconnect the motor connectors R3.MP3 and R3.FB3. Shown in the figure Location
of motor on page 231.
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.3 Replacement of motor, axis 3
Continued
Action
Note
6
DANGER
Secure the weight of the upper arm properly before
releasing the brakes of motor, axis 3.
When releasing the holding brakes of the motor, the
upper arm will be movable and may fall down!
7
Remove the motor, axis 3, by unscrewing its attachment screws and washers.
Lift the motor gently straight out, making sure the
motor pinion is not damaged.
Note
1
Note
It is important that the gearbox and the mating
motor pinion are provided by the same sub-supplier, make sure to order the correct spare part! To
determine the correct spare part, see Compatible
gearboxes and motors in Product manual, spare
parts - IRB 1600.
2
Make sure the o-ring on the circumference of the Replace the o-ring if damaged. Art
motor is seated properly. Ligthly lubricate it with .no. is specified in section Regrease.
quired equipment on page 231.
In order to release the brakes, connect the 24 VDC Connect to connector R3.MP3:
power supply to the motor.
+: pin 7
-: pin 8.
Fit the attachment screws and washers but do not 4 pcs, M6 x 20.
tighten them yet.
Shown in the figure Location of
motor on page 231.
Fit the rotation tool to the end of the motor shaft. Art. no. is specified in Required
equipment on page 231.
10
233
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.3 Replacement of motor, axis 3
Continued
Action
Note
11
Reconnect the motor connectors, run and secure Cable layout is shown in the figure
the cabling correctly inside the upper arm housing. Illustration, cabling inside upper
arm housing on page 154.
12
13
14
15
DANGER
Make sure all safety requirements are met when
performing the first test run. These are further detailed in the section DANGER - First test run may
cause injury or damage! on page 47.
234
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.4 Replacement of motor, axis 3, IRB 1600ID
Note
After replacement of motors/motor in a manipulator, recalibration is required.
Location of motor
The motor of axis 3 is located inside the upper arm housing, as shown in the figure
below.
xx0700000008
Motor, axis 3
Connector holder
Required equipment
Equipment
Art.no.
O-ring
3HAB3772-100
Isopropanol
Note
Grease
235
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.4 Replacement of motor, axis 3, IRB 1600ID
Continued
Equipment
Art.no.
Standard tools
Note
Standard tools on
page 293
Circuit diagram
Pendulum Calibration tool
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering
the robot working area.
2
Move:
axis 2 to calibration position
upper arm backwards
against the mechanical
stop
This position enables removal
of the motor without draining
oil of the gearbox, axis 3.
xx0700000010
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.4 Replacement of motor, axis 3, IRB 1600ID
Continued
Action
Note
Remove the upper arm hous- Shown in the figure Location of motor on page 235
ing cover.
Disconnect the motor connect- Shown in the figure Location of motor on page 235
ors R3.MP3 and R3.FB3.
7
DANGER
Secure the weight of the upper
arm properly before releasing
the brakes of motor, axis 3.
When releasing the holding
brakes of the motor, the upper
arm will be movable and fall
down!
8
B
C
A
E
D
xx0700000050
A
B
C
D
E
9
237
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.4 Replacement of motor, axis 3, IRB 1600ID
Continued
Note
1
Note
It is important that the gearbox and the mating motor
pinion are provided by the same sub-supplier, make
sure to order the correct spare part! To determine
the correct spare part, see Compatible gearboxes
and motors in Product manual, spare parts - IRB
1600.
2
Make sure the o-ring on the circumference of the Replace the o-ring if damaged.
motor is seated properly. Lubricate it with grease. Part number is specified in section Required equipment on
page 231.
Fit the attachment screws and washers but do not 4 pcs, M6 x 20.
tighten them yet.
Shown in the figure Location of
motor on page 235.
10 Reconnect the motor connectors, run and secure Cable layout is shown in the figure
the cabling correctly inside the upper arm housing. Illustration, cabling inside upper
arm housing on page 154.
11 Refit the cover, upper arm housing.
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.4 Replacement of motor, axis 3, IRB 1600ID
Continued
Action
Note
14
DANGER
Make sure all safety requirements are met when
performing the first test run. These are further detailed in section DANGER - First test run may cause
injury or damage! on page 47.
3HAC026660-001 Revision: L
239
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.5 Replacement of motor, axis 4
xx0400001273
Motor, axis 4
Connector plate
Required equipment
Equipment, etc.
Art. no.
Note
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.5 Replacement of motor, axis 4
Continued
Equipment, etc.
O-ring
Art. no.
Note
3HAB3772-81
Replace if damaged.
Replace if damaged.
Replace if damaged.
Grease
3HAC022050-001
3HAB3537-1
Standard toolkit
Power supply
3HAC022266003
Circuit Diagram
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
2
CAUTION
Always cut the paint with a knife and grind the paint
edge when disassembling parts of a Clean Room
robot! See Replacing parts on Clean Room robots
on page 149
3
Remove the connector plate to get access to the Shown in the figure Location of
axis 4 motor.
motor on page 240.
241
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.5 Replacement of motor, axis 4
Continued
Action
Note
In order to release the brakes, connect the 24 VDC Connect to connector R3.MP4
power supply to the motor.
+: pin 7
-: pin 8
Remove the motor, axis 4 by unscrewing the motor Shown in the figure Location of
attachment screws.
motor on page 240.
Lift the motor to get the pinion away from the gear
and disconnect the brake release voltage.
10
Note
Make sure the o-ring on the circumference of Art. no. is specified in section Rethe motor is seated properly. Lightly lubricate quired equipment on page 240.
the o-ring with grease .
Adjust the motor in relation to the gear in the There should be a barely noticable
gearbox.
gear play.
Use the arm tool to wiggle the motor shaft back
and forth to feel the play.
10
11
Cable layout is shown in the figure Illustration, cabling inside upper arm
housing on page 154.
12
Refit the cover to the upper arm housing. Check Art. no. is specified in Required
both the gaskets and replace, if damaged.
equipment on page 240.
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.5 Replacement of motor, axis 4
Continued
Action
Note
13
14
15
16
DANGER
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run
may cause injury or damage! on page 47.
3HAC026660-001 Revision: L
243
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.6 Replacement of motor, axis 4, 1600ID
Note
After replacement of motors/motor in a manipulator, recalibration is required.
Location of motor
xx0700000017
Motor, axis 4
Connector plate
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.6 Replacement of motor, axis 4, 1600ID
Continued
Required equipment
Equipment, etc.
Art. no.
O-ring
3HAB3772-81
Standard toolkit
Power supply
Note
Circuit Diagram
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
2
Remove the motor, axis 4 by unscrewing the motor Shown in the figure Location of
attachment screws.
motor on page 244.
Lift the motor to get the pinion away from the gear
and disconnect the brake release voltage.
Action
Note
245
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.6 Replacement of motor, axis 4, 1600ID
Continued
Action
Note
Make sure the o-ring on the circumference of the Art. no. is specified in section.
motor is seated properly. Lightly lubricate the o-ring
with grease.
246
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.7 Replacement of motor and timing belt, axis 5
xx0400001279
Motor, axis 5
Connector plate
Motor bracket
Required equipment
Equipment
Art. no.
Note
3HAC021304-001
Replace if damaged.
Replace if damaged.
247
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.7 Replacement of motor and timing belt, axis 5
Continued
Equipment
Art. no.
Note
Belt tightener
3HAC024044-001
Dynamometer
Capacity: 100N
Standard toolkit
Content is defined in
section Standard tools
on page 293.
Circuit diagram
xx0500001457
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working
area.
2
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.7 Replacement of motor and timing belt, axis 5
Continued
Action
Note
Remove the motor bracket, including the motor, Shown in the figure Location of moby unscrewing the two attachment screws and tor on page 247.
washers.
Note/Illustration
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working
area.
2
Fit the new motor to the motor bracket, previ- 3 pcs, M6 x 20.
ously removed from the old motor.
249
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.7 Replacement of motor and timing belt, axis 5
Continued
Action
4
Note/Illustration
Follow the steps below when fitting the motor: Art. no. is specified in Required
Place the timing belt (B) round the motor equipment on page 247.
pinion and place the belt round the axis
5 as fitting the motor in the upper arm
housing.
Fasten the motor bracket with two attachment screws (C), but do not tighten the
screws yet. Use correct attachment
holes, shown in the figure to the right!
Adjust the belt tension by pulling the
motor bracket, using the belt tightener
and dynamometer, as shown in the figure to the right.
Tighten the two attachment screws of
the bracket (C) with a torque of 10 Nm.
xx0400001280
A Motor axis 5
B Timing belt, axis 5
C Attachment screws and washers, motor bracket, 2 pcs, M6 x
20
D Belt tightener, the dimensions
are shown in the figure Belt
tightener, 3HAC 024044-001 on
page 248.
F (Force): 24 N.
5
Reconnect all connectors and place the cabling Cable layout shown in the figure Illuscorrectly inside the upper arm housing.
tration, cabling inside upper arm
housing on page 154.
10
DANGER
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in the section DANGER - First
test run may cause injury or damage! on
page 47.
250
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.8 Replacement of motor, axis 5, IRB 1600ID
Note
After replacement of motors/motor in a manipulator, recalibration is required.
Location of motor, axis 5
The motor of axes 5 is located inside the upper arm as shown in the figure below.
xx0700000020
Arm Tube
O-ring
Required equipment
Equipment, etc.
Art. no.
VK cover
3HAA2166-19
Note
251
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.8 Replacement of motor, axis 5, IRB 1600ID
Continued
Equipment, etc.
Art. no.
Note
Standard toolkit
Circuit Diagram
3HAC6816-3
O-ring
3HAB3772-81
Nitrite
Cable grease
Isopropanol
Motors and gears are HOT after running the robot! Touching the motors and
gears may result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to
the robot!
Take any necessary measures to ensure that the manipulator does not
collapse as parts are removed, e.g. secure the lower arm with fixtures if
removing motor, axis 2.
Note
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.8 Replacement of motor, axis 5, IRB 1600ID
Continued
Action
1
Note
xx0700000083
A
B
C
D
Arm Tube
Torx pan head screw M6X12
Cover
Torx pan head screw M6X12
2
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
3
xx0700000080
A R4.FB5
5
xx0700000054
A VK-Cover
253
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.8 Replacement of motor, axis 5, IRB 1600ID
Continued
Action
Note
xx0700000053
8
CAUTION
The upper arm tube weighs 12.3 kg
without any additional equipment
fitted.
All lifting accessories used must be
sized accordingly!
9
xx0700000088
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.8 Replacement of motor, axis 5, IRB 1600ID
Continued
Action
Note
xx0700000248
A V-ring
B Support ring
13 Remove the four (4) Hexagon sock- Position (E), (D) in figure Location of motor, axis
et head cap screw M6X20 holding 5 on page 251
motor 5.
14 Remove the O-ring and change it if Position (F) in figure Location of motor, axis 5 on
necessary.
page 251.
15 Remove the resolver cover for reuse.
Note
Make sure the o-ring on the circum- Replace the o-ring if damaged. Part number is
ference of the motor is seated
specified in section Required equipment on
properly. Lubricate it with grease. page 251.
Adjust the motor in relation to the There should be a barely noticeable gear play.
gear. Use the rotation tool to wiggle
the motor shaft back and forth to
feel the play.
255
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.8 Replacement of motor, axis 5, IRB 1600ID
Continued
Action
9
Note
xx0700000089
A Cable harness
B Torx pan head screw M6X12
10 Refitt the upper arm using the 7 Hex Shown in figure Location of motor, axis 5 on
socket head cap screw M8X20.
page 251.
Tightening torque: 24 Nm
11 Reconnect connections R4.FB6,
and R4.MP6 through the VK-hole.
Make sure all the cabling is placed
correctly inside the upper arm
housing.
12 Reconnect connection R4.FB5 and
R4.MP5 from the backside.
Note
When reconnecting the connection R4.FB5, make
sure to place the connectors as far away from the
axis 5-6 cable spiral as possible, to avoid grease
to accumulate on the resolver connector.
13
DANGER
Make sure all safety requirements
are met when performing the first
test run. These are further detailed
in the section DANGER - First test
run may cause injury or damage!
on page 47.
14 Refit the cover (mec stop) on the
back of the upper arm tube. Rotate
the upper arm to access all tree
screws.
CAUTION
Before refitting of the cover (mec
stop), do not over rotate axis 4 do
to risk of cable harness damage.
15 Recalibrate the robot.
256
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.9 Replacement of motor and timing belt, axis 6
xx0400001281
Motor, axis 6
Connector plate
Cable tie
Required equipment
Equipment
Art. no.
Note
257
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.9 Replacement of motor and timing belt, axis 6
Continued
Equipment
Timing belt
3HAC6779-1
Art. no.
Note
Replace if damaged.
Replace if damaged.
Hook
3HAC024045-001
Dynamometer
Capacity: 100N
Standard toolkit
Content is defined in
section Standard tools
on page 293.
Circuit diagram
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
2
Remove the axis 6 motor by unscrewing its three attachment screws and washers.
Note
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.9 Replacement of motor and timing belt, axis 6
Continued
Action
2
Note
xx0400001282
A Motor, axis 6
B Timing belt, axis 6
C Attachment screws and washers,
motor, 3 pcs, M6 x 20
D Hook (motor pinion: 24.07 mm)
F (Force): 80 N.
3
Cable layout is shown in the figure Illustration, cabling inside upper arm housing
on page 154.
Calibration is detailed in a separate calibration manual enclosed with the calibration tools.
General calibration information is included
in section Calibration information on
page 271.
9
DANGER
Make sure all safety requirements are met
when performing the first test run. These
are further detailed in the section DANGER
- First test run may cause injury or damage!
on page 47.
3HAC026660-001 Revision: L
259
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.10 Replacement of motor, axis 6 IRB 1600ID
Note
After replacement of motors/motor in a manipulator, recalibration is required.
Location of motor
The motor of axis 6 is located inside the upper arm housing, as shown in the figure
below.
G
B
F
C
xx0700000025
Upper arm
Wrist
Motor, axis 6
Required equipment
Equipment
Art. no.
Note
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.10 Replacement of motor, axis 6 IRB 1600ID
Continued
Equipment
Art. no.
Note
Standard toolkit
Note
2
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
3
Remove all extra equipment fitted on the upper arm See Remove AW Gun on page 204
and wrist.
CAUTION
Be careful when handling the wrist. Always hold on
the casting, do not hold on the wrist cover. This can
damage the sealing which will cause oil leakage.
5
Remove the attachment screws that holds the console and the axis-6 motor.
Note
Tightening torque: 6 Nm
261
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.6.10 Replacement of motor, axis 6 IRB 1600ID
Continued
Action
Note
Tighten the attachment screws that holds the con- Tightening torque: 6 Nm
sole to the wrist.
Check wrist motion by rotating the coupling manually. The motion shall be smoth and even. If not
unscrew the attachment screws that holds motor
and console, and redo the process.
Tightening torque: 6 Nm
Tightening torque: 6 Nm
14
DANGER
Make sure all safety requirements are met when
performing the first test run. These are further detailed in the section DANGER - First test run may
cause injury or damage! on page 47.
262
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.7.1 Replacement of gearbox, axes 1-2
4.7 Gearboxes
4.7.1 Replacement of gearbox, axes 1-2
Location of gearbox unit, axes 1-2
The gearboxes of axes 1 and 2 are located as shown in the figure below. Note that
both gearboxes, 1 and 2, are a single unit!
A more detailed view of the gearbox and its position may be found in the spare
part view, Spare parts - Frame, exploded view.
xx0500001400
263
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.7.1 Replacement of gearbox, axes 1-2
Continued
Required equipment
Equipment
Art. no.
Note
VK-cover
3HAA2166-26
Isopropanol
Grease
3HAB3537-1
Locking liquid
Loctite 574
Lifting slings
Standard toolkit
Note
1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the
robot working area.
2
CAUTION
Always cut the paint with a knife
and grind the paint edge when
disassembling parts of a Clean
Room robot! See Replacing parts
on Clean Room robots on page 149
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.7.1 Replacement of gearbox, axes 1-2
Continued
Action
3
Note
xx0800000260
A Oil plug
B Drain pump
4
xx0800000261
A Oil plug
B Drain pump
5
Remove the complete arm system. Detailed in section Removing the complete arm
system on page 167.
Unfasten the base from the installation site by removing the attachment bolts from the foundation.
265
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.7.1 Replacement of gearbox, axes 1-2
Continued
Action
Note
9
CAUTION
The gearbox unit weighs 120 kg.
The base weighs 81 kg.
All lifting accessories used must
be sized accordingly!
10
11
12
13
Remove the gearbox/base attach- Shown in the figure Location of gearbox unit, axes
ment screws and washer.
1-2 on page 263.
14
Note
1
Note
It is important that the gearbox and the
mating motor pinion are provided by the
same sub-supplier, make sure to order the
correct spare part! To determine the correct
spare part, see Compatible gearboxes and
motors in Product manual, spare parts - IRB
1600.
2
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot
working area.
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.7.1 Replacement of gearbox, axes 1-2
Continued
Action
Note
3
CAUTION
The gearbox unit weighs 120 kg.
All lifting accessories used must be sized
accordingly!
4
Lubricate the V-ring with grease and fit it to Art. no. is specified in Required equipthe gearbox unit.
ment on page 264.
Fit the base to the gearbox unit and secure Shown in the figure Location of gearbox
it with the attachment screws and the
unit, axes 1-2 on page 263.
washer.
16 pcs, M10 x 40, tightening torque: 70
Nm.
10
Fit a new VK-cover to the base of the robot. Shown in the figure Location of gearbox
unit, axes 1-2 on page 263.
Spare part no. is specified in Required
equipment on page 264.
11
CAUTION
The gearbox unit weighs 120 kg.
The base weighs 81 kg.
All lifting accessories used must be sized
accordingly!
12
13
14
15
Detailed in sections:
Refitting the motor axis 1 on
page 224
Refitting, motor axis 2 on page 228.
16
267
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.7.1 Replacement of gearbox, axes 1-2
Continued
Action
Note
17
Axis 1 gearbox:
Oil: Mobilgear 600 XP 320
Art.no: 11712016-604
Volume: 3400 ml
Axis 2 gearbox:
Oil: Mobilgear 600 XP 32
Art.no: 11712016-604
Volume: 3400 ml
18
19
Calibration is detailed in a separate calibration manual enclosed with the calibration tools.
General calibration information is included
in section Calibration information on
page 271.
20
DANGER
Make sure all safety requirements are met
when performing the first test run. These
are further detailed in the section DANGER
- First test run may cause injury or damage!
on page 47.
268
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
4 Repair
4.7.2 Service work on gearboxes, axes 3, 4, 5 and 6
3HAC026660-001 Revision: L
269
Copyright 2006-2014 ABB. All rights reserved.
5 Calibration information
5.1 Introduction
5 Calibration information
5.1 Introduction
General
This chapter includes general information about the different calibration methods
and also the detailed procedures that do not require specific calibration equipment.
When the robot system must be recalibrated, it is done according to the
documentation enclosed with the calibration tools.
When to calibrate
The system must be calibrated if any of the following situations occur.
The resolver values are changed
If resolver values are changed, the robot must be recalibrated using the calibration
methods supplied by ABB. Calibrate the robot carefully with standard calibration.
The different methods are briefly described in the section Calibration methods on
page 272 , and further detailed in separate calibration manuals.
If the robot has absolute accuracy calibration, it is also recommended, but not
always necessary to calibrate for new absolute accuracy.
The resolver values will change when parts affecting the calibration position are
replaced on the robot, for example motors or parts of the transmission.
The revolution counter memory is lost
If the revolution counter memory is lost, the counters must be updated. See
Updating revolution counters on page 277. This will occur when:
The revolution counters must also be updated after the robot and controller are
connected at the first installation.
The robot is rebuilt
If the robot is rebuilt, for example, after a crash or when the reach ability of a robot
is changed, it needs to be recalibrated for new resolver values.
If the robot has absolute accuracy calibration, it needs to be calibrated for new
absolute accuracy.
3HAC026660-001 Revision: L
271
Copyright 2006-2014 ABB. All rights reserved.
5 Calibration information
5.2 Calibration methods
Description
Calibration method
xx0400001197
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
5 Calibration information
5.2 Calibration methods
Continued
Calibration methods
Each calibration method is detailed in a separate manual. Following is a brief
description of the methods available.
Calibration Pendulum - standard method
Calibration Pendulum is the standard method for calibration of all ABB robots
(except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S) and is also the most
accurate method for the standard type of calibration. It is the recommended method
in order to achieve proper performance.
Two different routines are available for the Calibration Pendulum method:
Calibration Pendulum II
Reference calibration
3HAC026660-001 Revision: L
273
Copyright 2006-2014 ABB. All rights reserved.
5 Calibration information
5.3 Calibration scale and correct axis position
xx0600002876
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
5 Calibration information
5.3 Calibration scale and correct axis position
Continued
xx0700000095
3HAC026660-001 Revision: L
275
Copyright 2006-2014 ABB. All rights reserved.
5 Calibration information
5.4 Calibration movement directions for all axes
xx0200000089
276
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
5 Calibration information
5.5 Updating revolution counters
Note
Jog the manipulator to place the calibration See Calibration scale and correct axis pomarks within the tolerance zones.
sition on page 274.
When all axes are positioned, store the re- Step 2 - Storing the revolution counter
volution counter settings.
setting with the FlexPendant on page 277.
Axis 4
Axis 6
IRB 1600
No
Yes
If the calibration marks seem to be wrong (even if the motor calibration data is
correct), try to rotate the axis one turn, update the revolution counter and check
the calibration marks again (try both directions, if needed).
Step 2 - Storing the revolution counter setting with the FlexPendant
Use this procedure to store the revolution counter setting with the FlexPendant
(IRC5).
Action
1
277
Copyright 2006-2014 ABB. All rights reserved.
5 Calibration information
5.5 Updating revolution counters
Continued
Action
2
en0400000771
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 positioning, which in turn may cause damage or injury!
Check the calibration position very carefully after each update. See Checking the zero
position on page 279.
278
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
5 Calibration information
5.6 Checking the zero position
Note
Check that the calibration marks for the axes align See Calibration scale and correct
axis position on page 274, and Updatcorrectly. If they do not, update the revolution
counters.
ing revolution counters on page 277.
Note
Check that the calibration marks for the See Calibration scale and correct axis posaxes align correctly. If they do not, update ition on page 274, and Updating revolution
the revolution counters!
counters on page 277.
3HAC026660-001 Revision: L
279
Copyright 2006-2014 ABB. All rights reserved.
6 Decommissioning
6.1 Environmental information
6 Decommissioning
6.1 Environmental information
Hazardous material
The table specifies some of the materials in the product and their respective use
throughout the product.
Dispose components properly to prevent health or environmental hazards.
Material
Example application
Copper
Cables, motors
Steel
Neodymium
Brakes, motors
Plastic/rubber
Oil, grease
Gearboxes
Aluminium
3HAC026660-001 Revision: L
281
Copyright 2006-2014 ABB. All rights reserved.
6 Decommissioning
6.2 Scrapping of robot
Always remove all batteries from the robot. If a battery is exposed to heat,
for example from a blow torch, it will explode.
Always remove all oil in gearboxes. If exposed to heat, for example from a
blow torch, the oil will catch fire.
When motors are removed from the robot, the robot will collapse if it is not
properly supported before the motor is removed.
282
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
7 Robot description
7.1 Type A of IRB 1600
7 Robot description
7.1 Type A of IRB 1600
Type A - new upper arm and wrist
Type A of IRB 1600 have a new upper arm, complete and a new wrist unit. As a
result of this, the following parts differ from earlier versions:
Wrist unit
O-ring sealingplate
The wrist unit with spare part no. 3HAC026569-001 is not interchangeable
with spare part no. 3HAC10475-1.
Other changes in this product manual, compared to product manual IRB 1600, 3HAC023637-001
The content in this product manual is the same as in the product manual with art.
no. 3HAC023637-001, except for the new upper arm complete and the new wrist
unit for type A. In order to distinguish IRB 1600 type A from earlier versions, a new
art. no. has been created.
There has been a few other changes in the manual, not related to the IRB 1600
type A. These changes are described below:
The cable harness for motors axes 1-2 has got a new spare part no. The
motors axes 1-2 (3HAC023557-001) and the cable harness, motors axes 1-2
(3HAC023754-001) now have two separate spare part no:s.
For details, see Base, spare part list and Frame, spare part list, in Product manual,
spare parts - IRB 1600.
3HAC026660-001 Revision: L
283
Copyright 2006-2014 ABB. All rights reserved.
7 Robot description
7.2 Type A of IRB 1600ID
284
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
8 Reference information
8.1 Introduction
8 Reference information
8.1 Introduction
General
This chapter includes general information, complementing the more specific
information in the different procedures in the manual.
3HAC026660-001 Revision: L
285
Copyright 2006-2014 ABB. All rights reserved.
8 Reference information
8.2 Applicable safety standards
Description
EN ISO 12100 -1
EN ISO 12100 -2
EN ISO 13849-1
Safety of machinery, safety related parts of control systems Part 1: General principles for design
EN ISO 13850
EN ISO 10218-1 i
EN ISO 9787
EN ISO 9283
EN ISO 14644-1 ii
EN ISO 13732-1
EN IEC 60204-1
IEC 60529
i
ii
iii
There is a deviation from paragraph 6.2 in that only worst case stop distances and stop times are
documented.
Only robots with protection Clean Room.
Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.
European standards
Standard
Description
EN 614-1
EN 574
EN 953
Standard
Description
ANSI/RIA R15.06
Other standards
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
8 Reference information
8.2 Applicable safety standards
Continued
Standard
Description
ANSI/UL 1740 (option 429- Safety standard for robots and robotic equipment
1)
CAN/CSA Z 434-03 (option Industrial robots and robot Systems - General safety require429-1)
ments
3HAC026660-001 Revision: L
287
Copyright 2006-2014 ABB. All rights reserved.
8 Reference information
8.3 Unit conversion
Units
Length
1m
3.28 ft.
Weight
1 kg
2.21 lb.
Weight
1g
0.035 ounces
Pressure
1 bar
100 kPa
Force
1N
0.225 lbf
Moment
1 Nm
0.738 lbf-ft
Volume
1L
0.264 US gal
288
39.37 in
14.5 psi
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
8 Reference information
8.4 Screw joints
Art. no.
11712016-618
Tightening torque
Before tightening any screw, note the following:
Use the correct tightening torque for each type of screw joint.
3HAC026660-001 Revision: L
289
Copyright 2006-2014 ABB. All rights reserved.
8 Reference information
8.4 Screw joints
Continued
Always tighten the joint by hand, and never use pneumatic tools.
Use the correct tightening technique, that is do not jerk. Tighten the screw
in a slow, flowing motion.
M2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
M5
M6
10
M8
24
34
40
M10
47
67
80
M12
82
115
140
M16
200
290
340
M20
400
560
670
M24
680
960
1150
M8
28
35
M10
55
70
M12
96
120
M16
235
280
M20
460
550
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
8 Reference information
8.4 Screw joints
Continued
Dimension
M24
790
950
1/8
12
15
1/4
15
10
20
3/8
20
15
25
1/2
40
30
50
3/4
70
55
90
3HAC026660-001 Revision: L
291
Copyright 2006-2014 ABB. All rights reserved.
8 Reference information
8.5 Weight specifications
Note
CAUTION
292
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
8 Reference information
8.6 Standard tools
Tool
Small screwdriver
Plastic mallet
3HAC026660-001 Revision: L
293
Copyright 2006-2014 ABB. All rights reserved.
8 Reference information
8.7 Special tools
Art. no.
Note
3HAC022266-003
Dynamometer
Capacity: 100N
Hook
3HAC024045-001
Belt tightener
3HAC024044-001
3HAC023364-001
3HAC023386-001
Art. no.
Note
Complete kit that also includes operating
manual.
294
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
8 Reference information
8.8 Lifting accessories and lifting instructions
3HAC026660-001 Revision: L
295
Copyright 2006-2014 ABB. All rights reserved.
3HAC026660-001 Revision: L
297
Copyright 2006-2014 ABB. All rights reserved.
10 Circuit diagram
10.1 About circuit diagrams
10 Circuit diagram
10.1 About circuit diagrams
Overview
The circuit diagrams are not included in this manual, but delivered as separate
documents on the documentation DVD. See the article numbers in the tables below.
Controllers
Product
3HAC024480-005
3HAC024480-011
3HAC031403-003
3HAC024120-004
Product
3HAC031408-003
3HAC046307-003
3HAC6816-3
3HAC025611-001
3HAC028647-009
3HAC036446-005
3HAC025691-001
3HAC025691-001
3HAC2800-3
3HAC021351-003
3HAC039498-007
3HAC6670-3
3HAC029570-007
3HAC9821-1
3HAC029038-003
3HAC8935-1
3HAC13347-1
3HAC025744-001
3HAC13347-1
3HAC025744-001
Robots
299
Copyright 2006-2014 ABB. All rights reserved.
10 Circuit diagram
10.1 About circuit diagrams
Continued
Product
3HAC025090-001
3HAC025090-001
3HAC025744-001
3HAC13347-1
3HAC025744-001
3HAC025744-001
3HAC029940-001
3HAC043446-005
3HAC13347-1
3HAC025744-001
300
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
Index
Index
A
Absolute Accuracy, calibration, 273
Absolute Accuracy, guiding sleeves, 75
air connections, pressure, 118
aluminum
disposal, 281
ambient humidity
operation, 61
storage, 60
ambient temperature
operation, 61
storage, 60
arm system
replacing, 166
assembly instructions, 57
attachment bolts, robot-foundation, 74
B
backshells, customer connection, 118
base
brake release buttons, 71
hole configuration, 73
replacing, 208
screws, tightening torque, 211
spare part number, 208
batteries
disposal, 281
handling, 53
battery
replacing, 135
battery pack
replacing, interval, 123
spare part number, 137
battery shutdown
service routine, 135
belt tightener axis 5
article number, 247
measure, 248
brake release unit
releasing the brakes, 71
replacing, 218
spare part number, 219
brakes
testing function, 32
brakes, releasing
external power supply to connector R1.MP, 72
manually, 71
power supply on motor axis 1, 223
power supply to motor axis 2, 228
power supply to motor axis 3, 233
power supply to motor axis 4, 242
C
cable harness
inside base, figure, 157
inside frame, figure, 156
inside upper arm, figure, 154
replacing, 151
spare part number, 151
cabling
inside base, figure, 157
inside frame, figure, 156
inside upper arm, figure, 154
replacing, 151
D
damage, damper, 127
damper, axis 2, 125
attachment screw, 196
replacing, 195
spare part number, 195
damper, axis 3
inspection, 125
replacing, 197
spare part number, 197
damper, axis 5
inspection, 125
replacing, 201
spare part number, 201
danger levels, 39
dimensions
guiding sleeves, 74
mounting surface, 74
robot, 80
dimensions, IRB 1600, 82
dimensions, IRB 1600ID, 83
direction of axes, 276
E
emergency stop
definition, 37
devices, 38
enabling device, 34
3HAC026660-001 Revision: L
301
Copyright 2006-2014 ABB. All rights reserved.
Index
F
fence dimensions, 29
figures
base, hole configuration, 73
brake release buttons, 71
cabling inside base, 157
cabling inside frame, 156
cabling inside upper arm housing, 154
mounting surface, 74
power supply to connector R1.MP, 72
fire extinguishing, 30
fitting, equipment, 80
FlexPendant
jogging to calibration position, 279
MoveAbsJ instruction, 279
updating revolution counters, 277
foundation
requirements, 60
frame
replacing, 263
spare part number, 264
G
gaskets, spare part number
base cover, 219
gearbox axis 1-2, 222
upper arm cover, 257
upper arm customer connections, 257
gearbox, axes 1-2
replacing, 263
spare part number, 264
gearboxes
location of, 128
gearboxes, axes 3-6
replacing, 269
service work, 269
gearboxes, axes 5 and 6
oil change, 129
Gravity Beta, 76
grease
disposal, 281
H
hazardous material, 281
hold-to-run, 34
hole configuration
base, 73
humidity
operation, 61
storage, 60
I
illustrations
base, hole configuration, 73
brake release buttons, 71
cabling inside base, 157
cabling inside frame, 156
cabling inside upper arm housing, 154
mounting surface, 74
L
labels
manipulator, 41
lamp unit
article number, 90
installation, 89
leak-down test, 144
lifting
accessory, 70
lifting, robot, 68
lifting accessory, 292
Lithium
disposal, 281
load areas, 80
load areas, mounting holes, 84
loads on foundation, 59
lower arm
removing together with upper arm, 166
replacing, 182
screws, tightening torque, 184
spare part number, 182
lubrication
amount in gearboxes, 128
type of lubrication, 128
M
main power
switching off, 49
main switch
controller cabinet, 49
control module, 50
drive module, 50
maintenance intervals, 123
maintenance schedule, 123
manipulator
symbols, 41
measurement system battery pack, spare part
number, 137
mechanical stop axis 2
article number, 104
installation, 102
mechanical stop axis 3
article number, 108
screws, tightening torque, 109
mechanical stops axis 1
article number, 99
installation, 97
screws, tightening torque, 100
mechanical stops axis 2
screws, tightening torque, 104
mechanical stops axis 3
installation, 106
motor axis 1
302
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
Index
N
negative directions, axes, 276
neodymium
disposal, 281
NiCad
disposal, 281
nodular iron
disposal, 281
O
oil
amount in gearboxes, 128
disposal, 281
type of oil, 128
oil change
gearbox axes 5 and 6, 129
gearboxes, axes 5 and 6, intervals, 123
safety risks, 54
wrist unit, 129
wrist unit, intervals, 123
operating conditions, 61
orienting, robot, 73
P
plastic
disposal, 281
position, robot
when draining wrist unit, 130, 133134
when filling oil in wrist unit, 131
positions at wrist center
IRB 1600 - 1.2 m reach, 63
IRB 1600 - 1.45 m reach, 64
IRB 1600ID - 4/1.5, 65
position switch
axis 1, 110
position switch axis 1
R
range of movement
IRB 1600, 62
IRB 1600ID, 62
releasing brakes
external power supply to connector R1.MP, 72
manually, 71
replacing together, 166
requirements on foundation, 60
responsibility and validity, 19
restricting working range
axis 1, 97, 110
axis 2, 102
axis 3, 106
revolution counters
storing on FlexPendant, 277
updating, 277
risk of tipping, 67
robot
dimensions, 80
equipment, fitting, 80
lifting, 68
orienting and securing, 73
protection class, 61
protection types, 61
symbols, 41
robot position
when draining wrist unit, 130, 133134
when filling oil in wrist unit, 131
rubber
disposal, 281
S
safety
brake testing, 32
emergency stop, 37
ESD, 51
fence dimensions, 29
fire extinguishing, 30
FlexPendant, 34
introduction, 17
manipulator system, 19
moving manipulators, 46
reduced speed function, 33
release manipulator arm, 31
service, 19
signal lamp, 36
signals, 39
signals in manual, 39
symbols, 39
symbols on manipulator, 41
test run, 47
working range, 35
wrist strap, 51
safety equipment
position switch axis 1, 110
safety risk
3HAC026660-001 Revision: L
303
Copyright 2006-2014 ABB. All rights reserved.
Index
electric parts, 27
hot parts, 23
hydraulic system, 25
installation, 20
oil change, 54
operational disturbance, 26
pneumatic system, 25
service work, 20
tools, 24
voltage, 27
work pieces, 24
safety signals
in manual, 39
safety standards, 286
scales on robot, 274
schedule, maintenance, 123
securing, robot, 7374
serial measurement unit
battery pack, spare part number, 137
replacing, 212
spare part number, 214
signal lamp, 36
article number, 90
installation, 89
signals
safety, 39
SMB battery
extension of lifetime, 135
replacing, 135
SMB unit
battery pack, spare part number, 137
replacing, 212
spare part number, 214
Souriau, connector, 119
special tools, 294
stability, 67
standards
ANSI, 286
CAN, 286
EN, 286
EN IEC, 286
EN ISO, 286
protection, 286
safety, 286
steel
disposal, 281
storage conditions, 60
suspended mounting, 76
symbols
safety, 39
sync marks, 274
system parameter
Gravity Beta, 76
T
temperatures
operation, 61
storage, 60
testing
brakes, 32
tightening torques, attachment screws
base-gearbox unit, 211
lower arm-frame, 184
mechanical stop axis 1, 100
mechanical stop axis 2, 104
mechanical stop axis 3, 109
motor axis 1, 224
U
updating revolution counters, 277
upper and lower arm, 166
upper arm
removing together with lower arm, 166
replacing, 170
screws, tightening torque, 173
spare part number, 171
V
validity and responsibility, 19
VK-covers, spare part number
at base, 208
lower arm, lower, 182
lower arm, middle, 182
lower arm, upper, 171
W
wall mounting, 77
weight, 58
arm, 167168
base, 210211, 266267
gearbox 1, 266267
robot, 69, 183184, 210211, 292
upper arm, 172, 177, 179
upper arm tube, 254
working range, 62
restricting axis 1, 110
wrist unit
oil change, 129
replacing, 186
screws, tightening torque, 188
spare part number, 186
Z
zero position
checking, 279
304
3HAC026660-001 Revision: L
Copyright 2006-2014 ABB. All rights reserved.
ABB AB
Discrete Automation and Motion
Robotics
S-721 68 VSTERS, Sweden
Telephone +46 (0) 21 344 400
3HAC026660-001, Rev L, en
Contact us