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IRB 1600 3hac026660-En Manual

Robots
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0% found this document useful (0 votes)
1K views306 pages

IRB 1600 3hac026660-En Manual

Robots
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Product manual

IRB 1600 type A

Trace back information:


Workspace R14-1 version a5
Checked in 2014-04-07
Skribenta version 4.0.378

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

Copyright 2006-2014 ABB. All rights reserved.

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.

Copyright 2006-2014 ABB. All rights reserved.


ABB AB
Robotics Products
Se-721 68 Vsters
Sweden

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

Introduction to safety information .........................................................................


General safety information ..................................................................................
1.2.1 Introduction to general safety information ....................................................
1.2.2 Safety in the manipulator system ...............................................................
1.2.3 Safety risks ............................................................................................
1.2.3.1 Safety risks during installation and service work on manipulators .........
1.2.3.2 CAUTION - Hot parts may cause burns! ...........................................
1.2.3.3 Safety risks related to tools/work pieces ..........................................
1.2.3.4 Safety risks related to pneumatic/hydraulic systems ..........................
1.2.3.5 Safety risks during operational disturbances .....................................
1.2.3.6 Risks associated with live electric parts ...........................................
1.2.4 Safety actions .........................................................................................
1.2.4.1 Safety fence dimensions ...............................................................
1.2.4.2 Fire extinguishing ........................................................................
1.2.4.3 Emergency release of the manipulators arm ....................................
1.2.4.4 Brake testing ..............................................................................
1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" ........................
1.2.4.6 Safe use of the FlexPendant ..........................................................
1.2.4.7 Work inside the manipulator's working range ...................................
1.2.4.8 Signal lamp (optional) ...................................................................
1.2.5 Safety stops ...........................................................................................
1.2.5.1 What is an emergency stop? ..........................................................
Safety related instructions ..................................................................................
1.3.1 Safety signals in the manual ......................................................................
1.3.2 Safety symbols on manipulator labels .........................................................
1.3.3 DANGER - Moving manipulators are potentially lethal! ...................................
1.3.4 DANGER - First test run may cause injury or damage! ...................................
1.3.5 WARNING - The brake release buttons may be jammed after service work ........
1.3.6 DANGER - Make sure that the main power has been switched off! ....................
1.3.7 WARNING - The unit is sensitive to ESD! .....................................................
1.3.8 WARNING - Safety risks during handling of batteries .....................................
1.3.9 WARNING - Safety risks during work with gearbox lubricants (oil or grease) ......

Installation and commissioning

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 .........................................

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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

Restricting the working range ..............................................................................


2.4.1 Introduction ............................................................................................
2.4.2 Installation of additional mechanical stops on axis 1 ......................................
2.4.3 Installation of additional mechanical stop on axis 2 ........................................
2.4.4 Installation of additional mechanical stops on axis 3 ......................................
2.4.5 Installation of position switch, axis 1 ...........................................................
Electrical connections ........................................................................................
2.5.1 Customer connectors on the robot .............................................................
2.5.2 Robot cabling and connection points ..........................................................
2.5.3 Customer connections on the robot ............................................................

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
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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

Environmental information .................................................................................. 281


Scrapping of robot ............................................................................................. 282

Robot description
7.1
7.2

244
247
251
257
260
263
263
269

Calibration information

6.1
6.2
7

4.6.6 Replacement of motor, axis 4, 1600ID .........................................................


4.6.7 Replacement of motor and timing belt, axis 5 ...............................................
4.6.8 Replacement of motor, axis 5, IRB 1600ID ...................................................
4.6.9 Replacement of motor and timing belt, axis 6 ...............................................
4.6.10 Replacement of motor, axis 6 IRB 1600ID ....................................................
Gearboxes .......................................................................................................
4.7.1 Replacement of gearbox, axes 1-2 .............................................................
4.7.2 Service work on gearboxes, axes 3, 4, 5 and 6 ..............................................

283

Type A of IRB 1600 ............................................................................................ 283


Type A of IRB 1600ID ......................................................................................... 284

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 ..............................................................

Spare part lists


9.1

297

Spare part lists and illustrations ........................................................................... 297

10 Circuit diagram

299

10.1 About circuit diagrams ....................................................................................... 299


Index

301

3HAC026660-001 Revision: L

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This page is intentionally left blank

Overview of this manual

Overview of this manual


About this manual
This manual contains instructions for:

mechanical and electrical installation of the robot

maintenance of the robot

mechanical and electrical repair of the robot.

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

repair work and calibration.

Who should read this manual?


This manual is intended for:

installation personnel

maintenance personnel

repair personnel.

Prerequisites
A maintenance/repair/installation craftsman working with an ABB Robot must:

be trained by ABB and have the required knowledge of mechanical and


electrical installation/repair/maintenance work.

Organization of chapters
The manual is organized in the following chapters:
Chapter

Contents

Safety, service

Safety information that must be read through before performing


any installation or service work on robot. Contains general safety
aspects as well as more specific information on how to avoid
personal injuries and damage to the product.

Installation and 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

Step-by-step procedures that describe how to perform repair


activities of the robot. Based on available spare parts.

Calibration information

Procedures that do not require specific calibration equipment.


General information about calibration.

Decommissioning

Environmental information about the robot and its components.

Reference information

Useful information when performing installation, maintenance


or repair work. Includes lists of necessary tools, additional documents, safety standards, etc.

Continues on next page


3HAC026660-001 Revision: L

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Copyright 2006-2014 ABB. All rights reserved.

Overview of this manual


Continued

Chapter

Contents

Spare parts and exploded Complete spare part list and complete list of robot components,
views
shown in exploded views.
Circuit diagram

Reference to the circuit diagram for the robot.

References
Documentation referred to in the manual, is listed in the table below.
Document name

Document ID

Circuit diagram - IRB 1600 type A

3HAC021351-003

Product specification - IRB 1600

3HAC023604-001

Product manual, spare parts - IRB 1600

3HAC049104-001

Product manual - IRC5


IRC5 with main computer DSQC 639.

3HAC021313-001

Product manual - IRC5


IRC5 with main computer DSQC1000.

3HAC047136-001

Operating manual - IRC5 with FlexPendant

3HAC16590-1

Operating manual - Service Information System

3HAC025709-001

Operating manual - Calibration Pendulum

3HAC16578-1

Application manual - Additional axes and stand alone controller

3HAC021395-001

Application manual - CalibWare Field 5.0

3HAC030421-001

Technical reference manual - Lubrication in gearboxes

3HAC042927-001

Technical reference manual - System parameters

3HAC17076-1

Instructions lifting accessory 3HAC024483-001

3HAC028664-002

Revisions
Revision

Description

First edition. See also Type A of IRB 1600 on page 283.

AW equipped upper arm 1600ID, IRB 1600-6/1.2, IRB 1600-6/1.45, IRB


1600-8/1.2 and IRB 1600-8/1.45 added.

Clean Room added.


Changes made in:
Prerequisites in section Overview
Oil change in section Maintenance

Content updated in section:


Making robot ready for operation, Clean Room / Additional installation procedure.

Content updated in chapter/section:


Maintenance/Cleaning of robot
Maintenance/Maintenance schedule: Interval for replacement of
battery pack changed
Section What is an emergency stop? added to chapter Safety.

Content updated in chapter/section:


Maintenance/Oil in gearboxes: Amount of oil in gearboxes axes
1 and 2.

Continues on next page


10

3HAC026660-001 Revision: L
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Overview of this manual


Continued

Revision

Description

Content updated in sections:


New graphics for equipment load areas, see Fitting equipment on
the robot (robot dimensions) on page 80.
Instruction moved from chapter Repair to Installation, see Installation of the wire feeder shelf for IRB 1600ID on page 94.
Spare part list, updated regarding Foundry Plus Cable guard.
Cleaning the IRB 1600 on page 139 in chapter Maintenance updated.
Sealing compound updated in Replacing parts on Clean Room
robots on page 149.
Decommissioning chapter added.
Updates in the chapter Safety:
Updated safety signal graphics for the levels Danger and Warning,
see Safety signals in the manual on page 39.
New safety labels on the manipulators, see Safety symbols on
manipulator labels on page 41.
Revised terminology: robot replaced with manipulator.

Content updated in sections:


Added reference to lifting accessory, see Lifting and turning a
suspended mounted robot on page 70.

Content updated in sections:


Added note about not inserting guide pin too far into the tool
flange, section Fitting equipment on the robot (robot dimensions)
on page 80.
Updated spare part numbers, in sections: Base, frame, upper arm,
upper arm 1600ID and options.
New and updated safety symbols, see Safety symbols on manipulator labels on page 41.

Continues on next page


3HAC026660-001 Revision: L

11
Copyright 2006-2014 ABB. All rights reserved.

Overview of this manual


Continued

Revision

Description

This revision includes the following updates:


A new block, about general illustrations, added in section How to
read the product manual on page 16.
Resolver connection added, connection for resolver signals axis
7 located on the base see section Customer connectors on the
robot on page 113
Added an illustration that shows the directions of the robot stress
forces and changed the value for the force in the Z plane, see
Loads on foundation, robot on page 59.
Improvements made in the instruction for replacing the complete
ID upper arm, see Replacing the complete upper arm ID on
page 175.
Gearboxes and motor pinions from SAMP are added to the spare
part lists together with a table that shows compability between
the motors and gearboxes, see Spare parts -Compatible gearboxes
and motors. The spare part numbers are also removed from the
Required equipment lists in the repair instructions for motors and
gearboxes, and instead replaced with links to the Spare parts
chapter.
The option Foundry Plus Cable Guard is removed.
Some general tightening torques have been changed/added, see
updated values in Screw joints on page 289.
Corrected value for working range of wall mounted robots, added
working range for IRB 1600ID and updated a figure, see Working
ranges on page 62.
Spare part numbers for axis-4, axis-5 and axis-6 motors for IRB
1600ID are corrected.
Added WARNING - Safety risks during handling of batteries on
page 53.

This revision includes the following updates:


Added range and capacity to the denomination of IRB 1600ID.
Added information about IRB 1600ID type A, on first inside page
and as a new section Type A of IRB 1600ID on page 284.
Spare part numbers for SAMP motors and upper arms are corrected, see Spare parts - Compatible gearboxes and motors.
Added variants IRB 1600 - 10/1.2 and IRB 1600 - 10/1.45 to the
manual.
Updated loads on the foundation, see Loads on foundation, robot
on page 59.
Corrected the appearance of figures in section Working ranges
on page 62.
Changed maximum tilt from 60 to 55, see Requirements,
foundation on page 60.
All data about type of lubrication in gearboxes is moved from the
manual to a separate lubrication manual, see Type and amount
of oil in gearboxes on page 128.
Added information about importance to install the robot with correct X direction in the base coordinate system, see Installation of
additional mechanical stops on axis 1 on page 97 and Setting the
system parameters for a suspended robot on page 76.
A new SMB unit and battery is introduced, with longer battery
lifetime.
Added mounting holes on the lower arm, see Fitting equipment
on the robot (robot dimensions) on page 80.

Continues on next page


12

3HAC026660-001 Revision: L
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Overview of this manual


Continued

Revision

Description

This revision includes the following updates:


Spare numbers in general, updated/corrected.
Spare number for Motor axis 3 (Rexnord) changed.
Added information about risks when scrapping a decommissioned
robot, see Scrapping of robot on page 282.
Base connections, illustration updated with new views.
Updated tightening torque for the oil plug on axis 5-6 for IRB
1600ID, see Changing the oil, axis 5- 6 gearbox, ID on page 132.
Spare parts and exploded views are not included in this document
but delivered as a separate document. See Product manual, spare
parts - IRB 1600.
Note about the placement of connectors in ID-upper arm added
in Repair instructions. See Replacement of motor, axis 5, IRB
1600ID on page 251 and Replacing the wrist unit, ID on page 189.
Note about handling the wrist during replacement added. See
Refitting the wrist unit on page 192.

3HAC026660-001 Revision: L

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Copyright 2006-2014 ABB. All rights reserved.

Product documentation, IRC5

Product documentation, IRC5


Categories for manipulator documentation
The manipulator documentation is divided into a number of categories. This listing
is based on the type of information in the documents, regardless of whether the
products are standard or optional.
All documents listed can be ordered from ABB on a DVD. The documents listed
are valid for IRC5 manipulator systems.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware will be
delivered with a Product manual that generally contains:

Safety information.

Installation and commissioning (descriptions of mechanical installation or


electrical connections).

Maintenance (descriptions of all required preventive maintenance procedures


including intervals and expected life time of parts).

Repair (descriptions of all recommended repair procedures including spare


parts).

Calibration.

Decommissioning.

Reference information (safety standards, unit conversions, screw joints, lists


of tools ).

Spare parts list with exploded views (or references to separate spare parts
lists).

Circuit diagrams (or references to circuit diagrams).

Technical reference manuals


The technical reference manuals describe reference information for robotics
products.

Technical reference manual - Lubrication in gearboxes: Description of types


and volumes of lubrication for the manipulator gearboxes.

Technical reference manual - RAPID overview: An overview of the RAPID


programming language.

Technical reference manual - RAPID Instructions, Functions and Data types:


Description and syntax for all RAPID instructions, functions, and data types.

Technical reference manual - RAPID kernel: A formal description of the


RAPID programming language.

Technical reference manual - System parameters: Description of system


parameters and configuration workflows.

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
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Product documentation, IRC5


Continued

An application manual generally contains information about:

The purpose of the application (what it does and when it is useful).

What is included (for example cables, I/O boards, RAPID instructions, system
parameters, DVD with PC software).

How to install included or required hardware.

How to use the application.

Examples of how to use the application.

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 - Emergency safety information

Operating manual - General safety information

Operating manual - Getting started, IRC5 and RobotStudio

Operating manual - Introduction to RAPID

Operating manual - IRC5 with FlexPendant

Operating manual - RobotStudio

Operating manual - Trouble shooting IRC5, for the controller and manipulator.

3HAC026660-001 Revision: L

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How to read the product manual

How to read the product manual


Reading the procedures
The procedures contain references to figures, tools, material, and so on. The
references are read as described below.
References to figures
The procedures often include references to components or attachment points
located on the manipulator/controller. The components or attachment points are
marked with italic text in the procedures and completed with a reference to the
figure where the current component or attachment point is shown.
The denomination in the procedure for the component or attachment point
corresponds to the denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a
procedure.

8.

Action

Note/Illustration

Remove the rear attachment screws, gearbox.

Shown in the figure Location of


gearbox on page xx.

References to required equipment


The procedures often include references to equipment (spare parts, tools, etc.)
required for the different actions in the procedure. The equipment is marked with
italic text in the procedures and completed with a reference to the section where
the equipment is listed with further information, that is article number and
dimensions.
The designation in the procedure for the component or attachment point
corresponds to the designation in the referenced list.
The table below shows an example of a reference to a list of required equipment
from a step in a procedure.

3.

Action

Note/Illustration

Fit a new sealing, axis 2 to the gearbox.

Art. no. is specified in Required


equipment on page xx.

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
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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:

General safety aspects, important to attend to before performing any service


work on the robot. These are applicable for all service work and are found
in General safety information on page 18.

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

1.2 General safety information


1.2.1 Introduction to general safety information
Definitions
This section details general safety information for personnel performing installation,
repair and maintenance work.
Sections
The general safety information is divided into the following sections.
Contents

Containing

General information

safety, service
limitation of liability
related information

Safety risks lists dangers relevant when


working with the product. The dangers are
split into different categories.

safety risks during installation or service


risks associated with live electrical parts

Safety actions describes actions which


may be taken to remedy or avoid dangers.

fire extinguishing
safe use of the FlexPendant

Safety stops describes different types of


stops.

stopping functions
description of emergency stop
description of safety stop
description of safeguarding

18

3HAC026660-001 Revision: L
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1 Safety
1.2.2 Safety in the manipulator system

1.2.2 Safety in the manipulator system


Validity and responsibility
The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment that can influence the safety of
the entire system. To protect personnel, the complete system must be designed
and installed in accordance with the safety requirements set forth in the standards
and regulations of the country where the manipulator is installed.
The users of ABB industrial manipulators are responsible for ensuring that the
applicable safety laws and regulations in the country concerned are observed and
that the safety devices necessary to protect people working with the manipulator
system are designed and installed correctly. Personnel working with manipulators
must be familiar with the operation and handling of the industrial manipulator as
described in the applicable documents, for example:

Operating manual - IRC5 with FlexPendant

Product manual

Connection of external safety devices


Apart from the built-in safety functions, the manipulator is also supplied with an
interface for the connection of external safety devices. An external safety function
can interact with other machines and peripheral equipment via this interface. This
means that control signals can act on safety signals received from the peripheral
equipment as well as from the manipulator.
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial manipulator will not cause injury or damage
even if all safety instructions are complied with.
Related information
Type of information

Detailed in document

Installation of safety devices Product manual for the manipulator


Changing operating modes

Section
Installation and
commissioning

Operating manual - IRC5 with FlexPend- Operating modes


ant

Restricting the working space Product manual for the manipulator

3HAC026660-001 Revision: L

Installation and
commissioning

19
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1 Safety
1.2.3.1 Safety risks during installation and service work on manipulators

1.2.3 Safety risks


1.2.3.1 Safety risks during installation and service work on manipulators
Overview
This section includes information on general safety risks to be considered when
performing installation and service work on the manipulator.
These safety instructions have to be read and followed by any person who deals
with the installation and maintenance of the manipulator. Only persons who know
the manipulator and are trained in the operation and handling of the manipulator
are allowed to maintain the manipulator. Persons who are under the influence of
alcohol, drugs or any other intoxicating substances are not allowed to maintain,
repair, or use the manipulator.
General risks during installation and service
The instructions in the product manual in the chapter Installation and
commissioning must always be followed.

Emergency stop buttons must be positioned in easily accessible places so


that the manipulator can be stopped quickly.

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.

Spare parts and special equipment


ABB does not supply spare parts and special equipment which have not been
tested and approved by ABB. The installation and/or use of such products could
negatively affect the structural properties of the manipulator and as a result of that
affect the active or passive safety operation. ABB is not liable for damages caused
by the use of non-original spare parts and special equipment. ABB is not liable for
damages or injuries caused by unauthorized modifications to the manipulator
system.
Nation/region specific regulations
To prevent injuries and damages during the installation of the manipulator, the
regulations applicable in the country concerned and the instructions of ABB
Robotics must be complied with.
Non-voltage related risks
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.

Safety zones, which must be crossed before admittance, must be set up in


front of the manipulator's working space. Light beams or sensitive mats are
suitable devices.

Continues on next page


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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).

Energy stored in the manipulator for the purpose of counterbalancing certain


axes may be released if the manipulator, or parts thereof, are dismantled.

When dismantling/assembling mechanical units, watch out for falling objects.

Be aware of stored heat energy in the controller.

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.

To be observed by the supplier of the complete system


The supplier of the complete system must ensure that all circuits used in the
safety function are interlocked in accordance with the applicable standards
for that function.

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.

Removed cables to the measurement system

WARNING
If the internal cables for the measurement
system have been disconnected during repair
or maintenance, then the revolution counters
must be updated.

Continues on next page


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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!

Gearboxes and motors


Safety risk
Gears may be damaged if excessive force
is used!

Description
CAUTION
Whenever parting/mating motor and gearbox,
the gears may be damaged if excessive force
is used!

Safety risk

Description

Dangerous balancing device!


WARNING
Do not under any circumstances, deal with
the balancing device in any other way than
that detailed in the product documentation!
For example, attempting to open the balancing device is potentially lethal!

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1 Safety
1.2.3.2 CAUTION - Hot parts may cause burns!

1.2.3.2 CAUTION - Hot parts may cause burns!


Description
During normal operation, many manipulator parts become hot, especially the drive
motors and gears. Sometimes areas around these parts also become hot. Touching
these may cause burns of various severity.
Because of a higher environment temperature, more surfaces on the manipulator
get hot and may result in burns.
Elimination
The instructions below detail how to avoid the dangers specified above:
Action
1

Always use your hand, at some distance, to


feel if heat is radiating from the potentially
hot component before actually touching it.

Wait until the potentially hot component has


cooled if it is to be removed or handled in any
other way.

Info

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1 Safety
1.2.3.3 Safety risks related to tools/work pieces

1.2.3.3 Safety risks related to tools/work pieces


Safe handling
It must be possible to safely turn off tools, such as milling cutters, etc. Make sure
that guards remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
Grippers/end effectors must be designed so that they retain work pieces in the
event of a power failure or a disturbance to the controller.
Unauthorized modifications of the originally delivered manipulator are prohibited.
Without the consent of ABB it is forbidden to attach additional parts through welding,
riveting, or drilling of new holes into the castings. The strength could be affected.
CAUTION
Ensure that a gripper is prevented from dropping a work piece, if such is used.

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1 Safety
1.2.3.4 Safety risks related to pneumatic/hydraulic systems

1.2.3.4 Safety risks related to pneumatic/hydraulic systems


General
Special safety regulations apply to pneumatic and hydraulic systems.
Note
All components that remain pressurized after separating the machine from the
power supply must be provided with clearly visible drain facilities and a warning
sign that indicates the need for pressure relief before adjustments or performing
any maintenance on the manipulator system.
Residual energy

Residual energy can be present in these systems. After shutdown, particular


care must be taken.

The pressure must be released in the complete pneumatic or hydraulic


systems before starting to repair them.

Work on hydraulic equipment may only be performed by persons with special


knowledge and experience of hydraulics.

All pipes, hoses, and connections have to be checked regularly for leaks and
damage. Damage must be repaired immediately.

Splashed oil may cause injury or fire.

Gravity may cause any parts or objects held by these systems to drop.

Dump valves should be used in case of emergency.

Shot bolts should be used to prevent tools, etc., from falling due to gravity.

Safe design

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1 Safety
1.2.3.5 Safety risks during operational disturbances

1.2.3.5 Safety risks during operational disturbances


General

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.

Care must be taken at all times.

Qualified personnel
Corrective maintenance must only be carried out by qualified personnel who are
familiar with the entire installation as well as the special risks associated with its
different parts.
Extraordinary risks
If the working process is interrupted, extra care must be taken due to risks other
than those associated with regular operation. Such an interruption may have to be
rectified manually.

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1 Safety
1.2.3.6 Risks associated with live electric parts

1.2.3.6 Risks associated with live electric parts


Voltage related risks, general
Work on the electrical equipment of the manipulator must be performed by a
qualified electrician in accordance with electrical regulations.

Although troubleshooting may, on occasion, need to be carried out while the


power supply is turned on, the robot must be turned off (by setting the mains
switch to OFF) when repairing faults, disconnecting electric leads and
disconnecting or connecting units.

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

on machine/manipulator system in deadlock

in an isolated state, disconnected from power supply, and protected against


reconnection

Voltage related risks, IRC5 controller


A danger of high voltage is associated with, for example, the following parts:

Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in


the controller.

Units such as I/O modules, can be supplied with power from an external
source.

The mains supply/mains switch

The transformers

The power unit

The control power supply (230 VAC)

The rectifier unit (262/400-480 VAC and 400/700 VDC. Note: Capacitors!)

The drive unit (400/700 VDC)

The drive system power supply (230 VAC)

The service outlets (115/230 VAC)

The customer power supply (230 VAC)

The power supply unit for additional tools, or special power supply units for
the machining 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

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1 Safety
1.2.3.6 Risks associated with live electric parts
Continued

Voltage related risks, manipulator


A danger of high voltage is associated with the manipulator in:

The power supply for the motors (up to 800 VDC).

The user connections for tools or other parts of the installation (max. 230
VAC).
See chapter Installation and commissioning on page 57.

Voltage related risks, tools, material handling devices, etc.


Tools, material handling devices, etc., may be live even if the robot system is in
the OFF position. Power supply cables which are in motion during the working
process may be damaged.

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1 Safety
1.2.4.1 Safety fence dimensions

1.2.4 Safety actions


1.2.4.1 Safety fence dimensions
General
Install a safety cell around the manipulator to ensure safe manipulator installation
and operation.
Dimensioning
Dimension the fence or enclosure to enable it to withstand the force created if the
load being handled by the manipulator is dropped or released at maximum speed.
Determine the maximum speed from the maximum velocities of the manipulator
axes and from the position at which the manipulator is working in the work cell
(see the section Robot motion in the Product specification).
Also consider the maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the manipulator.

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1 Safety
1.2.4.2 Fire extinguishing

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)!

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1 Safety
1.2.4.3 Emergency release of the manipulators arm

1.2.4.3 Emergency release of the manipulators arm


Description
In an emergency situation, any of the manipulator's axes may be released manually
by pushing the brake release buttons on the manipulator.
How to release the brakes is detailed in the section:

Manually releasing the brakes on page 71.

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!

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1 Safety
1.2.4.4 Brake testing

1.2.4.4 Brake testing


When to test
During operation, the holding brake of each axis normally wears down. A test can
be performed to determine whether the brake can still perform its function.
How to test
The function of the holding brake of each axis motor may be checked as described
below:
1 Run each manipulator axis to a position where the combined weight of the
manipulator arm and any load is maximized (max. static load).
2 Switch the motor to the MOTORS OFF position with the operating mode
selector on the controller.
3 Check that the axis maintains its position.
If the manipulator does not change position as the motors are switched off,
then the brake function is adequate.

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1 Safety
1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s"

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".

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1 Safety
1.2.4.6 Safe use of the FlexPendant

1.2.4.6 Safe use of the FlexPendant


Enabling device
The enabling device is a manually operated, constant pressure push-button which,
when continuously activated in one position only, allows potentially hazardous
functions but does not initiate them. In any other position, hazardous functions are
stopped safely.
The enabling device is of a specific type where you must press the push-button
only half-way to activate it. In the fully in and fully out positions, manipulator
operation is impossible.
Note
The enabling device is a push-button located on the side of the FlexPendant
which, when pressed halfway in, switches the system to MOTORS ON. When
the enabling device is released or pushed all the way in, the manipulator switches
to the MOTORS OFF state.
To ensure safe use of the FlexPendant, the following must be implemented:

The enabling device must never be rendered inoperational in any way.

During programming and testing, the enabling device must be released as


soon as there is no need for the manipulator to move.

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.

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1 Safety
1.2.4.7 Work inside the manipulator's working range

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.

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1 Safety
1.2.4.8 Signal lamp (optional)

1.2.4.8 Signal lamp (optional)


Description
A signal lamp with a yellow fixed light can be mounted on the manipulator, as a
safety device.
Function
The lamp is active in MOTORS ON mode.
Further information
Further information about the MOTORS ON/MOTORS OFF mode may be found in
the product manual for the controller.

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1 Safety
1.2.5.1 What is an emergency stop?

1.2.5 Safety stops


1.2.5.1 What is an emergency stop?
Definition of emergency stop
An emergency stop is a state that overrides any other manipulator control,
disconnects drive power from the manipulator motors, stops all moving parts, and
disconnects power from any potentially dangerous functions controlled by the
manipulator system.
An emergency stop state means that all power is disconnected from the manipulator
except for the manual brake release circuits. You must perform a recovery
procedure, i.e, resetting the emergency stop button and pressing the Motors On
button, in order to return to normal operation.
The manipulator system can be configured so that the emergency stop results in
either:

An uncontrolled stop, immediately stopping the manipulator actions by


disconnecting power from the motors.

A controlled stop, stopping the manipulator actions with power available to


the motors so that the manipulator path can be maintained. When completed,
power is disconnected from the motors.

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.

Continues on next page


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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...

... then it is classified as...

uncontrolled

category 0 (zero)

controlled

category 1

Emergency stop devices


In a manipulator system there are several emergency stop devices that can be
operated in order to achieve an emergency stop. There are emergency stop buttons
available on the FlexPendant and on the controller cabinet (on the Control Module
on a Dual Cabinet Controller). There can also be other types of emergency stops
on your manipulator. Consult your plant or cell documentation to see how your
manipulator system is configured.

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1 Safety
1.3.1 Safety signals in the manual

1.3 Safety related instructions


1.3.1 Safety signals in the manual
Introduction to safety signals
This section specifies all dangers that can arise when doing the work described
in this manual. Each danger consists of:

A caption specifying the danger level (DANGER, WARNING, or CAUTION)


and the type of danger.

A brief description of what will happen if the operator/service personnel do


not eliminate the danger.

Instruction about how to eliminate danger to simplify doing the work.

Danger levels
The table below defines the captions specifying the danger levels used throughout
this manual.
Symbol

Designation

Significance

DANGER

Warns that an accident will occur if the instructions


are not followed, resulting in a serious or fatal injury
and/or severe 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, and so on.

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.

ELECTRICAL
SHOCK

Warns for electrical hazards which could result in


severe personal injury or death.

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.

xx0200000022

xx0100000002

xx0200000024

xx0100000003

ELECTROSTATIC Warns for electrostatic hazards which could result


DISCHARGE (ESD) in severe damage to the product.

xx0200000023

Continues on next page


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1 Safety
1.3.1 Safety signals in the manual
Continued

Symbol

Designation

Significance

NOTE

Describes important facts and conditions.

TIP

Describes where to find additional information or


how to do an operation in an easier way.

xx0100000004

xx0100000098

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1 Safety
1.3.2 Safety symbols on manipulator labels

1.3.2 Safety symbols on manipulator labels


Introduction to labels
This section describes safety symbols used on labels (stickers) on the manipulator.
Symbols are used in combinations on the labels, describing each specific warning.
The descriptions in this section are generic, the labels can contain additional
information such as values.
Note
The safety and health symbols on the labels on the manipulator must be observed.
Additional safety information given by the system builder or integrator must also
be observed.
Types of labels
Both the manipulator and the controller are marked with several safety and
information labels, containing important information about the product. The
information is useful for all personnel handling the manipulator system, for example
during installation, service, or operation.
The safety labels are language independent, they only use graphics. See Symbols
on safety labels on page 41.
The information labels can contain information in text (English, German, and
French).
Symbols on safety labels
Symbol

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

Continues on next page


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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

Before dismantling see product manual

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

Tip risk when loosening bolts


The manipulator can tip over if the bolts are not securely
fastened.

xx0900000810

Continues on next page


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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

Brake release buttons

xx0900000820

xx1000001140

Continues on next page


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1 Safety
1.3.2 Safety symbols on manipulator labels
Continued

Symbol

Description
Lifting bolt

xx0900000821

Chain sling with shortener

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

Continues on next page


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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

Shut off with handle


Use the power switch on the controller.

xx0900000827

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1 Safety
1.3.3 DANGER - Moving manipulators are potentially lethal!

1.3.3 DANGER - Moving manipulators are potentially lethal!


Description
Any moving manipulator is a potentially lethal machine.
When running, the manipulator may perform unexpected and sometimes irrational
movements. Moreover, all movements are performed with great force and may
seriously injure any personnel and/or damage any piece of equipment located
within the working range of the manipulator.
Elimination
Action

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.

Usually the hold-to-run function is active


only in manual full speed mode. To increase safety it is also possible to activate
hold-to-run for manual reduced speed with
a system parameter.
The hold-to-run function is used in manual
mode, not in automatic mode.

Make sure no personnel are present within


the working range of the manipulator before pressing the start button.

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.

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1 Safety
1.3.4 DANGER - First test run may cause injury or damage!

1.3.4 DANGER - First test run may cause injury or damage!


Description
Since performing a service activity often requires disassembly of the robot, there
are several safety risks to take into consideration before the first test run.
Elimination
Follow the procedure below when performing the first test run after a service
activity, such as repair, installation, or maintenance.
Action
1

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

Install all safety equipment properly

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

Pay special attention to the function of the part previously serviced

Collision risks
CAUTION
When programming the movements of the manipulator always check potential
collision risks before the first test run.

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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

Make sure the power is turned off.

Refit the push button guard, if removed.

Check the push buttons of the brake release


unit by pressing them down, one by one.
Make sure none of the buttons are jammed
by the push button guard!

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.

Refit the push button guard and check the


buttons again by pressing them down, one
by one.

48

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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

Switch off the main switch for the controller.

xx0600003255

Elimination, Single Cabinet Controller


Action
1

Note/illustration

Switch off the main switch on the controller


cabinet.

xx0600002782

A: Main switch

Continues on next page


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1 Safety
1.3.6 DANGER - Make sure that the main power has been switched off!
Continued

Elimination, Dual Cabinet Controller


Action
1

Note/illustration

Switch off the main switch on the Drive


Module.

xx0600002783

K: Main switch, Drive Module


2

Switch off the main switch on the Control A: Main switch, Control Module
Module.

50

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1 Safety
1.3.7 WARNING - The unit is sensitive to ESD!

1.3.7 WARNING - The unit is sensitive to ESD!


Description
ESD (electrostatic discharge) is the transfer of electrical static charge between two
bodies at different potentials, either through direct contact or through an induced
electrical field. When handling parts or their containers, personnel not grounded
may potentially transfer high static charges. This discharge may destroy sensitive
electronics.
Elimination
Action

Note

Use a wrist strap

Wrist straps must be tested frequently to ensure


that they are not damaged and are operating correctly.

Use an ESD protective floor mat.

The mat must be grounded through a current-limiting resistor.

Use a dissipative table mat.

The mat should provide a controlled discharge of


static voltages and must be grounded.

Location of wrist strap button


The location of the wrist strap button is shown in the following illustration.
IRC5
The wrist strap button is located in the top right corner.
A

xx1300000856

Wrist strap button

Continues on next page


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1 Safety
1.3.7 WARNING - The unit is sensitive to ESD!
Continued

Panel Mounted Controller


A

xx1300001960

Wrist strap button

52

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1 Safety
1.3.8 WARNING - Safety risks during handling of batteries

1.3.8 WARNING - Safety risks during handling of batteries


Description
Under normal conditions of use, the electrode materials and liquid electrolyte in
the batteries are not exposed to the outside, provided the battery integrity is
maintained and seals remain intact.
There is a risk of exposure only in case of abuse (mechanical, thermal, electrical)
which leads to the activation of safety valves and/or the rupture of the battery
container. Electrolyte leakage, electrode materials reaction with moisture/water or
battery vent/explosion/fire may follow, depending upon the circumstances.
Note
Appropriate disposal regulations must be observed.
Elimination
Action

Note

Do not short circuit, recharge, puncture, incinerate, crush,


immerse, force discharge or expose to temperatures above
the declared operating temperature range of the product.
Risk of fire or explosion.

Operating temperatures
are listed in Pre-installation procedure on
page 58.

Use safety glasses when handling the batteries.

In the event of leakage, wear gloves and chemical apron.

In the event of fire, use self-contained breathing apparatus.

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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

Changing and draining gearbox Make sure that protective gear


oil or grease may require hand- like goggles and gloves are alling hot lubricant heated up to ways worn during this activity.
90 C.

Hot oil or grease


When working with gearbox lub- Make sure that protective gear
ricant there is a risk of an allergic like goggles and gloves are alreaction.
ways worn.
xx0100000002

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

Continues on next page


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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

Overfilling of gearbox lubricant


can lead to internal over-pressure inside the gearbox which in
turn may:
damage seals and gaskets
completely press out
seals and gaskets
prevent the robot from
moving freely.

Make sure not to overfill the


gearbox when filling it with oil or
grease!
After filling, check the correct
level.

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!

Do not mix types of oil


Warm oil drains quicker than
cold oil.

When changing gearbox oil, first


run the robot for a time to heat
up the oil.

xx0100000098

Heat up the oil

xx0100000004

Specified amount depends on drained


volume

xx0100000003

Contaminated oil in
gear boxes

The specified amount of oil or After refilling, check the lubricant


grease is based on the total
level.
volume of the gearbox. When
changing the lubricant, the
amount refilled may differ from
the specified amount, depending
on how much has previously
been drained from the gearbox.
When draining the oil make sure
that as much oil as possible is
drained from the gearbox. The
reason for this is to drain as
much oil sludge and metal chips
as possible from the gearbox.
The magnetic oil plugs will take
care of any remaining metal
chips.

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2 Installation and commissioning


2.1 Introduction

2 Installation and commissioning


2.1 Introduction
General
This chapter contains assembly instructions and information for installing the IRB
1600 at the working site.
More detailed technical data can be found in the Product specification for the IRB
1600, such as:

Load diagram

Permitted extra loads (equipment)

Location of extra loads (equipment).

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:

Product manual - IRC5

Product manual - IRC5 Panel Mounted Controller

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2 Installation and commissioning


2.2.1 Pre-installation procedure

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:

be trained by ABB and have the required knowledge of mechanical and


electrical installation/maintenance/repair work

conform to all national and local codes.


Action

Visually inspect the robot to make sure that it is not damaged.

Make sure that the lifting accessory used is suitable to handle the weight of the robot
as specified in:
Weight, robot on page 58

If the robot is not installed directly, it must be stored as described in:


Storage conditions, robot on page 60

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

Install required equipment, if any.


Installation of signal lamp for 1600 (option) on page 89

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!

Continues on next page


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2.2.1 Pre-installation procedure
Continued

Loads on foundation, robot


The illustration shows the directions of the robots stress forces. The directions are
valid for all floor mounted and suspended robots.

Txy

Fz
Fxy

Tz

xx1100000521

Fxy

Force in any direction in the XY plane

Fz

Force in the Z plane

Txy

Bending torque in any direction in the XY plane

Tz

Bending torque in the Z plane

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

Endurance load (in operation)

Max. load (emergency stop)

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

Endurance load (in operation)

Max. load (emergency stop)

Force xy

3900 N

5300 N

Force z

1300 N

2800 N

Wall mounted

Continues on next page


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2.2.1 Pre-installation procedure
Continued

Force

Endurance load (in operation)

Max. load (emergency stop)

Torque xy

2310 Nm

3850 Nm

Torque z

855 Nm

1450 Nm

Force

Endurance load (in operation)

Max. load (emergency stop)

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

Flat foundations give better repeatability of the


resolver calibration compared to original settings
on delivery from ABB.
The value for levelness aims at the circumstance
of the anchoring points in the robot base.
In order to compensate for an uneven surface,
the robot can be recalibrated during installation.
If resolver/encoder calibration is changed this
will influence the absolute accuracy.

Maximum tilt

55

The limit for the maximum payload on the robot


is reduced if the robot is tilted from 0.
Contact ABB for further information about acceptable loads.

Minimum resonance
frequency

25 Hz

Storage conditions, robot


The table shows the allowed storage conditions for the robot:
Parameter

Value

Minimum ambient temperature

-25 C

Maximum ambient temperature

+55 C

Maximum ambient temperature (less than 24 hrs)

+70 C

Maximum ambient humidity

95% at constant temperature


(gaseous only)

Note
If the manipulator should not be used immediately, all unpainted / unprotected
surfaces must be treated with a rust inhibitor, type Vaseline or similar.

Continues on next page


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2 Installation and commissioning


2.2.1 Pre-installation procedure
Continued

Operating conditions, robot


The table shows the allowed operating conditions for the robot:
Parameter

Value

Minimum ambient temperature

+5 C

Maximum ambient temperature

+45 C

Maximum ambient humidity

Max. 95% at constant temperature

Protection classes, robot


The table shows the available protection types of the robot, with the corresponding
protection class.
Protection type

Protection class

Manipulator, protection type Standard

IP 54

Manipulator, protection type Foundry Plus

IP 67

Manipulator, protection type Clean Room

IP 54

Manipulator, protection type Wash

IP 67

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2.2.2 Working ranges

2.2.2 Working ranges


Range of movement - IRB 1600
Axis

Type of motion

Range of movement 1.2 m


reach

Range of movement 1.45 m


reach

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

+200 to -200 Default


+200 to -200 Default
+190 rev. ii to -190 rev. max- +190 rev. ii to -190 rev. maximum iii
imum iii

Bend motion

+115 to -115

Turn motion

+400 to -400 default


+400 to -400 default
+288 rev. ii to -288 rev. max- +288 rev. ii to -288 rev. maximum iii
imum iii

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).

Range of movement - IRB 1600ID


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

Working range axis 1 40 with tilt angles up to 30


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).

Continues on next page


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2.2.2 Working ranges
Continued

Positions at wrist center 1.2 m reach

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

Continues on next page


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2.2.2 Working ranges
Continued

Positions at wrist center 1.45 m reach

xx1000000915

Pos No. see


Figure above

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

Continues on next page


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2.2.2 Working ranges
Continued

Positions at wrist center IRB 1600ID-4/1.5

xx0700000136

Pos No. see


Figure above

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

Continues on next page


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2.2.2 Working ranges
Continued

Turning radius
The turning radius for the robot is shown in the figure below. Notice the differences
depending on the length of the lower arm.

xx0400001259

(A)

Minimum turning radius axis 1 (all models)

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2.2.3 Risk of tipping/stability

2.2.3 Risk of tipping/stability


Risk of tipping
If the robot is not fastened to the foundation and standing still, the robot is not
stable in the whole working area. Moving the arms will displace the center of gravity,
which may cause the robot to tip over.
The shipping position is the most stable position.
Do not change the robot position before securing it to the foundation!
Shipping and transport position
This figure shows the robot in its shipping position, which also is a recommended
transport position.

A-A

A
A

xx0400001296

WARNING
The robot is likely to be mechanically unstable if not secured to the foundation!

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2.3.1 Lifting robot with roundslings

2.3 On-site installation


2.3.1 Lifting robot with roundslings
Attaching the roundslings

A-A

A
A

xx0400001296

Required equipment
Equipment

Art. no.

Note

Overhead crane

Lifting capacity: 500 kg.

Roundsling

Length: 2 m.
Lifting capacity: 500 kg.

Lifting the robot with roundslings


Use this procedure to lift the robot with roundslings.
Action

Note

Move the robot to an appropriate lifting posi- See Risk of tipping/stability on


tion.
page 67.

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.

Continues on next page


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2.3.1 Lifting robot with roundslings
Continued

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

Raise the overhead crane to lift the robot.

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2.3.2 Lifting and turning a suspended mounted robot

2.3.2 Lifting and turning a suspended mounted robot


Introduction
How to lift and turn the robot into a suspended position using turning accessory
3HAC037108-001 is described in the lifting instruction (article number
3HAC028664-002) delivered with the turning accessory. Contact ABB for more
information.

xx1000000320

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2.3.3 Manually releasing the brakes

2.3.3 Manually releasing the brakes


General
The section below details how to release the holding brakes of each axis' motor.
This may be done in one of three ways:

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 an external voltage supply directly on the motor connector.

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

The internal brake release unit is located at the base


of the robot and equipped with six buttons for controlling the axes brakes. The buttons are numbered
according to the numbers of the axes.

xx0400001255

2
DANGER
When releasing 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

Release the holding brake on a particular robot axis


by pressing the corresponding button on the internal
brake release panel and keeping it depressed.
The brake will function again as soon as the button is
released.

Continues on next page


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2.3.3 Manually releasing the brakes
Continued

Using the brake release unit with an external power supply


This section details how to release the holding brakes with the internal brake
release unit using an external voltage supply. This is done if the robot is not
connected to the controller.
Action

Note

1
DANGER
Incorrect connections, such as supplying
power to the wrong pin, may cause all brakes
to be released simultaneously!
2

Also, be careful not to interchange the


24V and 0V pins. If they are mixed up,
damage can be caused to a resistor diode and to the system board.

Connect an external power supply to connector R1.MP.

xx0400001302

Supply:
0V on pin C10
24V on pin B8
3

Push the brake release button to release the


holding brakes, according to the previous
procedure.

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2.3.4 Orienting and securing the robot

2.3.4 Orienting and securing the robot


General
This section details how to orient and secure the robot at a horizontal level at the
installation site.
Hole configuration, base
The figure shows the hole pattern and dimensions of the robot base.

xx0400001300

Center of axis 1

Continues on next page


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2.3.4 Orienting and securing the robot
Continued

Dimension, mounting surface and guiding sleeve


The figure shows the dimension of the mounting surface and guiding sleeves, if
used.

xx0400001306

Attachment bolts, specification


Attachment bolts

3 pcs
M16 x 60 (installation directly on foundation of steel), M16 x
70/80 (installation on foundation or base plate, using guiding
sleeves)

Washers

30 x 17 x 3

Quality

8.8 (wall or angle mounted robot: Quality 12.9)

Tightening torque

200 Nm

Guiding sleeves
Use a pair of guiding sleeves to make the robot installation easier.
Continues on next page
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2.3.4 Orienting and securing the robot
Continued

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

Make sure the installation site for the robot


conforms to the specifications in section Preinstallation procedure on page 58.

Prepare the installation site with attachment


holes.
If the robot is calibrated with AbsAcc, it must
be installed using guiding sleeves.

Hole configuration of the base is shown


in the figure Hole configuration, base
on page 73.
Dimension of mounting surface and the
guiding sleeves are shown in the figure
Dimension, mounting surface and
guiding sleeve on page 74.

Lift the robot to the installation site.

Detailed in section Lifting robot with


roundslings on page 68.

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.

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2.3.5 Setting the system parameters for a suspended robot

2.3.5 Setting the system parameters for a suspended robot


General
Initially the system is configured for mounting on the floor, without leaning. The
method for mounting the robot in a suspended position is basically the same as
for floor mounting.
Note
With suspended installation, make sure that the gantry or corresponding structure
is rigid enough to prevent unacceptable vibrations and deflections, so that
optimum performance can be achieved.
X direction downwards in base coordinate system
If the robot is wall mounted or mounted in a tilted position, it is important that the
X direction of the base coordinate system points downwards, as shown in the figure
below.
Z

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:

Overloading the mechanical structure.

Lower path performance and path accuracy.

Some functions will not work properly, for example Load Identification and
Collision detection.

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2.3.5 Setting the system parameters for a suspended robot
Continued

Mounting angles and values


The parameter Gravity Beta specifies the robots mounting angle in radians. It is
calculated in the following way.
Gravity Beta = A x 3.141593/180 = B radians, where A is the mounting angle in
degrees and B is the mounting angle in radians.
Example of position

Mounting angle (A)

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

Tilted mounting, mounting angle 30

Wall mounted, mounting angle 90

Suspended mounting, mounting angle 180

Continues on next page


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2.3.5 Setting the system parameters for a suspended robot
Continued

Limitations in working area


If tilting a floor mounted robot or mounting the robot on a wall, the working range
of axis 1 is limited. These limitations are specified in the table Working ranges on
page 62.
Defining the parameter in the software
The value of the system parameter Gravity Beta must be redefined when changing
the mounting angle of the robot. The parameter belongs to the type Robot, in the
topic Motion.
How to calculate a new value is detailed in Mounting angles and values on page 77.
The parameter is described in Technical reference manual - System parameters.
The parameter can be edited either with the FlexPendant or in RobotStudio. See
Operating manual - IRC5 with FlexPendant or Operating manual - RobotStudio.
Article numbers for the manuals are specified in References on page 10.

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2.3.6 Loads fitted to the robot, stopping time and braking distances

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:

Operating manual - IRC5 with FlexPendant

Stopping time and braking distances


The performance of the motor brake depends on if there are any loads attached
to the robot. For more information, see product specification for the robot.

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2.3.7 Fitting equipment on the robot (robot dimensions)

2.3.7 Fitting equipment on the robot (robot dimensions)


Load areas
Extra loads can be mounted on the wrist, the upper arm housing, and on the frame.
Load areas and permitted loads are shown in graphic below. The center of gravity
of the extra load shall be within the marked load areas.
IRB 1600 - 5 kg and 7 kg

A
B

100 100

150 150

250

150

C
150

300

250

200

D
200

250

350
xx1000000154

Robot

Maximum load in load area


A

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

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2.3.7 Fitting equipment on the robot (robot dimensions)
Continued

IRB 1600 - 6 kg, 8 kg, 10 kg and ID


150

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

Maximum load in load area


A

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 -

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2.3.7 Fitting equipment on the robot (robot dimensions)
Continued

Dimensions IRB 1600-X/1.2 (1.45)


252.5
215

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

R335 Minimum turning radius

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2.3.7 Fitting equipment on the robot (robot dimensions)
Continued

Dimensions IRB 1600ID-4/1.5

xx1000000893

R335 Minimum turning radius

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2.3.7 Fitting equipment on the robot (robot dimensions)
Continued

165*
275**

Holes for mounting of extra equipment


The robot has holes for mounting extra equipment.

150

75
4x M8 12
0,3

*IRB 1600-X/1.2
**IRB 1600-X/1.45

xx1000000906

Design until June 2006

xx1000000907

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2.3.7 Fitting equipment on the robot (robot dimensions)
Continued

Design after June 2006, type A

xx1000000908

Design IRB 1600ID-4/1.5

xx1000000909

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2.3.7 Fitting equipment on the robot (robot dimensions)
Continued

Mounting hole for equipment

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.

3xM8 depth 12, mounting holes for equipment

R175, Axis 3 turning radius

3xM8 depth 16, mounting hole for equipment

From center line axis 2

From center line axis 4

Note
Note! When mounting heavier equipment, for example wire feeders, in holes (C)
the bracket must be supported in the opposite holes (E).

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2.3.7 Fitting equipment on the robot (robot dimensions)
Continued

Holes for mounting of extra equipment for IRB 1600ID-4/1.5


120,7

(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

R198, Axis 3 turning radius

2xM8 depth 16, mounting holes for equipment

2xM8, mounting holes for equipment

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2.3.7 Fitting equipment on the robot (robot dimensions)
Continued

Robot tool flange

xx1000000912

Robot tool flange for IRB 1600ID-4/1.5

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.

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2.3.8 Installation of signal lamp for 1600 (option)

2.3.8 Installation of signal lamp for 1600 (option)


General
A signal lamp with an yellow fixed light can be mounted on the robot, as a safety
device. The signal lamp is required on an UL/UR approved robot.
The lamp is active in MOTORS ON mode.
Note
Do not use the signal lamp option in a Clean Room environment.
Different signal lamps on IRB 1600 and IRB 1600ID
This instruction details how to install the signal lamp on IRB 1600. If installing the
lamp on an IRB 1600ID robot, see Installation of signal lamp for 1600ID (option)
on page 92.
Location of signal lamp
The signal lamp is fitted to the upper arm housing of the robot, as shown in the
figure below.

xx0400001265

Signal lamp

Cable gland

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2.3.8 Installation of signal lamp for 1600 (option)
Continued

Cable bracket

Attachment holes for the signal lamp

Cover, upper arm housing

Required equipment
Equipment

Art. no.

Note

Signal lamp

3HAC022235-001

Gasket, customer connections

3HAC022050-001

Replace if damaged.

Gasket, upper arm cover

3HAC022049-001

Replace if damaged.

Installation, signal lamp


The procedure below details how to install the signal lamp to the robot.
Action

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

A: Plug with o-ring, M10

Connect the lamp connectors, R3.H1 and


R3.H2 and place the cables safely inside the
housing.

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.

Continues on next page


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2.3.8 Installation of signal lamp for 1600 (option)
Continued

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

The signal lamp is now ready for use and is lit


in MOTORS ON mode.

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2.3.9 Installation of signal lamp for 1600ID (option)

2.3.9 Installation of signal lamp for 1600ID (option)


General
A signal lamp with an yellow fixed light can be mounted on the robot, as a safety
device. The signal lamp is reqired on an UL/UR approved robot.
The lamp is active in MOTORS ON mode.
Note
Do not use the signal lamp option in a Clean Room environment.
Location of signal lamp
The signal lamp is fitted to the upper arm housing of the robot, as shown in the
figure below

xx0700000100

Signal lamp

Cover, upper arm housing

Required equipment
Equipment

Art. no.

Signal lamp

3HAC9258-1

Drill

Note

Diameter 22.5 mm

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2.3.9 Installation of signal lamp for 1600ID (option)
Continued

Equipment

Art. no.

Note

Standard toolkit

The contents of the toolkit is


defined in section, Standard
tools on page 293

Installation, signal lamp


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

Remove the cover from the upper arm housing.

On the cover there is a mark where the lamp is to


be installed. Find the mark and drill a hole with a
diameter of 22.5mm.

Fit the lamp and tighten the nut.

In the upper arm housing find the two cables marked


R3.H1 and R3.H2 and connect them with the lamp

Refit the cover on the upper arm housing.

The signal lamp is now ready for use and is lit in


MOTORS ON mode.

Shown in the figure Location of


signal lamp on page 92.

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2.3.10 Installation of the wire feeder shelf for IRB 1600ID

2.3.10 Installation of the wire feeder shelf for IRB 1600ID


Location of shelf, wire feeder

A
B

E
D

xx0700000311

Bracket ESAB wire feeder

Shelf, wire feeder

Hexagon nut with flange M5

Knob

Plain washer (8.4x16x1.6)

Hex socket head cap screw (M8x12)

Fitting the wire feeder shelf


Action
1

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).

Continues on next page


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2.3.10 Installation of the wire feeder shelf for IRB 1600ID
Continued

Action
2

Note

Fit the bracket on the wire


feeder using the four (4)
Hexagon nut with flange (A).

xx0700000312

A Hexagon nut with flange M5


B Knob
3

Fit the wire feeder with the


mounted bracket on the
Shelf, wire feeder and mount
the two knobs.

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2.4.1 Introduction

2.4 Restricting the working range


2.4.1 Introduction
General
When installing the robot, make sure that it can move freely within its entire working
space. If there is a risk that it may collide with other objects, its working space
should be limited.
The working range of the following axes may be restricted:

Axis 1, hardware (mechanical stop and position switch) and software

Axis 2, hardware (mechanical stop) and software

Axis 3, hardware (mechanical stop) and software.

This section describes how to install hardware that restricts the working range.
Note
Adjustments must also be made in the robot configuration software (system
parameters). References to relevant manuals are included in the installation
procedures.

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2.4.2 Installation of additional mechanical stops on axis 1

2.4.2 Installation of additional mechanical stops on axis 1


General
This section details how to install additional mechanical stops on axis 1 in order
to restrict the working range of the axis.
Restrictions in working range
The working range of axis 1 can be restricted by fitting one or two additional
mechanical stops on the casted groove at the base.
The figure below shows both the minimum and maximum working range of the
robot, when restricted by the additional mechanical stops. The working range can
be restricted freely within the shown scope, depending on where the mechanical
stop is installed along the casted groove.

-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)

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2.4.2 Installation of additional mechanical stops on axis 1
Continued

Keep X direction downwards (tilted or wall mounted robot)


CAUTION
If the robot is wall mounted or mounted in a tilted position, it is important that
the X direction of the base coordinate system points downwards, as shown in
the figure below.
Z

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).

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2.4.2 Installation of additional mechanical stops on axis 1
Continued

Required equipment
Equipment

Art. no.

Note

Working range limit axis 1

3HAC026119-001

Includes mechanical stops


(2 pcs), attachment bolts and
washers.

Technical reference manual - System


parameters

Art. no. is specified in section References on page 10.

Illustration, mechanical stop, axis 1


The additional mechanical stop of axis 1 is fitted to the base of the robot, as shown
in the figure below.

xx0400001287

Mechanical stop, axis 1 (additional)

Attachment bolts and washers, mechanical stop

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2.4.2 Installation of additional mechanical stops on axis 1
Continued

Stop pin (standard)

Casted groove

Guiding pin

Hidden stiffening ribs

Installation of mechanical stop, axis 1


The procedure below details how to install the mechanical stop to axis 1.
Action

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 stop at the base, with the guiding pin in


the casted groove. Turn the stop until the holes
align with the groove.
The stop can be mounted in either direction, resulting in differences in the working range.

xx0400001288

Also see the figure Illustration,


mechanical stop, axis 1 on
page 99.
3

Drill two holes in the casted groove, with guidance


from the circular and the elliptical hole.
Drill the holes through 10.2 mm.
If drilling in a stiffening rib, drill depth must be min.
30 mm.

Cut the threads M12.


If cutting in a stiffening rib, thread depth must be
min. 23 mm.

Fit the stop to the base without tightening the bolts.

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.

Tighten the bolts.

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.

2 pcs/stop: M12 x 40, tightening


torque: 85 Nm.

Continues on next page


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2.4.2 Installation of additional mechanical stops on axis 1
Continued

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.

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2.4.3 Installation of additional mechanical stop on axis 2

2.4.3 Installation of additional mechanical stop on axis 2


General
This section details how to install an additional mechanical stop on axis 2 in order
to restrict the working range of the axis.
Restrictions in working range
The working range of axis 2 can be restricted by fitting an additional mechanical
stop at the frame. The working range can only be restricted backwards, as shown
in the figures below. Notice the different working ranges for the different models!

xx0400001289

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2.4.3 Installation of additional mechanical stop on axis 2
Continued

xx0400001290

Illustration, mechanical stop, axis 2


The additional mechanical stop for axis 2 is fitted together with a damper to the
frame, as shown in the figure below.

xx0400001291

Mechanical stop, axis 2

Attachment bolts, mechanical stop (2 pcs)

Attachment holes, mechanical stop

Damper, axis 2

Washer

Attachment screw, damper

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2.4.3 Installation of additional mechanical stop on axis 2
Continued

Required equipment
Equipment

Art. no.

Note

Working range limit axis 2

3HAC026120-001

Includes mechanical stop,


damper and attachment bolts.

Technical reference manual - System parameters

Art. no. is specified in section


References on page 10.

Installation of mechanical stop, axis 2


The procedure below details how to install the mechanical stop to axis 2.
Action

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 mechanical stop to the frame, without


tightening the bolts.

Make sure that the stop is in contact with the


lower boss on the gearbox, as the arrow shows
in the figure to the right.

Attachment holes are shown in the


figure Illustration, mechanical stop,
axis 2 on page 103.

xx0400001292

Note! It is important that the mechanical stop is fitted in contact with


the lower boss on the gearbox!
4

Tighten the attachment bolts.

2 pcs; M8 x 35, tightening torque:


25 Nm.

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.

Continues on next page


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2.4.3 Installation of additional mechanical stop on axis 2
Continued

Action
6

Note/Illustration

Adjust the software working range limitations


The system parameters that must
(system parameter configuration) to correspond be changed (Upper joint bound and
to the mechanical limitations.
Lower joint bound) are described in
Technical reference manual - System parameters.

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.

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2.4.4 Installation of additional mechanical stops on axis 3

2.4.4 Installation of additional mechanical stops on axis 3


General
This section details how to install an additional mechanical stop on axis 3 in order
to restrict the working range of the axis.
Restrictions in working range
The working range of axis 3 can be restricted into two different working areas, as
shown in the two figures below. Notice the differences between the different models.

xx0400001283

Robot models IRB 1600 - x/1.2

Working range A

Working range B

Continues on next page


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2.4.4 Installation of additional mechanical stops on axis 3
Continued

xx0400001284

Robot models IRB 1600 - x/1.45

Working range A

Working range B

Continues on next page


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2.4.4 Installation of additional mechanical stops on axis 3
Continued

Illustration, mechanical stop, axis 3


The mechanical stop is installed at the upper arm housing, as shown in the figure
below.

xx0400001285

Mechanical stop, axis 3

Attachment screws and washers (2 pcs)

Required equipment
Equipment

Art. no.

Note

Working range limit axis 3

3HAC026121-001

Includes mechanical stop, attachment screws and washers.

Technical reference manual - System parameters

Art. no. is specified in References on page 10.

Continues on next page


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2.4.4 Installation of additional mechanical stops on axis 3
Continued

Installation of mechanical stop, axis 3


The procedure below details how to install the mechanical stop to axis 3.
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

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.

Adjust the software working range limitations


The system parameters that must
(system parameter configuration) to correspond be changed (Upper joint bound and
to the mechanical limitations.
Lower joint bound) are described in
Technical reference manual - System parameters.

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.

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2.4.5 Installation of position switch, axis 1

2.4.5 Installation of position switch, axis 1


General
This section details how to install the position switch to axis 1.
Location of position switch, axis 1
The position switch is installed between the frame and the base, as shown in the
figure below.

xx0400001356

Position switch

Attachment screws, position switch, 2 pcs: M6 x 30

Holder ring (2 parts)

Attachment screws, holder ring, 6 pcs: M8 x 12

Cam

Bracket

Attachment screws, housing, 2 pcs: M6 x 8

Cable straps

Attachment screws, attachment plate, 2 pcs: M6 x 16

Continues on next page


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2.4.5 Installation of position switch, axis 1
Continued

Required equipment
Equipment

Art. no.

Position switch, axis 1

3HAC023973-001 Includes 3 switches.


All parts are included in the delivery.
Instruction of how to cut the cams is enclosed in the kit.

Technical reference manual - System parameters

Note

Art. no. is specified in section References


on page 10.

Installation, position switch axis 1


The procedure below details how to install the position switch 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.
Shown in the figure Location of position
switch, axis 1 on page 110.
6 pcs, M8 x 12.

Fit the two holder rings underneath the


frame with the six attachment screws.

Cut the cams according to instructions,


enclosed with the position switch kit.

Fit the cams to the holder ring with the


attachment screws.

Attach the position switch to the bracket 2 pcs, M6 x 30.


with two attachment screws.

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.

Shown in the figure Location of position


switch, axis 1 on page 110.
M6 x 12.

Continues on next page


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2 Installation and commissioning


2.4.5 Installation of position switch, axis 1
Continued

Action
7

Note

Fit the attachment plate to the base of the 2 pcs, M6 x 16.


robot with the two attachment screws.
Shown in the figure Location of position
Fit the switches to the attachment plate. switch, axis 1 on page 110.
Adjust the height of the switches with
shims until each roller aligns with corresponding cam.

xx0400001358

A
B
C
D

Attachment plate
Shims
Roller
Cam

Secure the cabling inside the housing


with cable straps.

Shown in the figure Location of position


switch, axis 1 on page 110.

Connect the position switch cabling.

The cabling and connection points are


specified in section Position switch cables,
robot base to controller (option) on page 117.

10

Adjust the software working range limitations (system parameter configuration)


to correspond to the mechanical limitations.

The system parameters that must be


changed (Upper joint bound and Lower joint
bound) are described in Technical reference
manual - System parameters.

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2 Installation and commissioning


2.5.1 Customer connectors on the robot

2.5 Electrical connections


2.5.1 Customer connectors on the robot
General
Customer connections are options, the cables for them are integrated in the robot
and the connectors are placed on the upper arm housing.
The customer connections are:

The standard connections for signals, power and air.

The integrated wire feed cabling for signals and power.

The 7-axis connection.


Note

No customer/application connections are available for IRB 1600ID-4/1.5.


Connections at robot base
The graphics below show the customer connections on the robot base. For
description of all connection types see Connection table on page 114.

xx1000000918

xx1000000919

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2.5.1 Customer connectors on the robot
Continued

xx1000000920

xx1000000921

Connection table
Pos

Connection type

Description

R1.MP

Motor power

R1.SMB

Serial measurement board signal

Robot axes brake release buttons

R.1 CP/CS

Standard customer power and customer signal

R.1Air

Standard air

R1.CS

Customer signal for integrated wirefeed interface

R1.CP

Customer power for integrated wirefeed interface

R1.FB7

Axis 7 connection, 1.5 m cable

Continues on next page


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2 Installation and commissioning


2.5.1 Customer connectors on the robot
Continued

Connections on upper arm

xx1000000922

Pos

Connection type

Description

R2.CP

Standard customer power

R2.CS

Standard customer signal

R2.Air

Standard air

R2.CP

Customer power for integrated wirefeed interface

R2.CS

Customer signal for integrated wirefeed interface

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2 Installation and commissioning


2.5.2 Robot cabling and connection points

2.5.2 Robot cabling and connection points


Introduction
Connect the robot and controller to each other after securing them to the foundation.
The lists below specify which cables to use for each respective application.
Main cable categories
All cables between the robot and controller are divided into the following categories:
Cable category

Description

Robot cables

Handles power supply to and control of the robot's motors


as well as feedback from the serial measurement board.
Specified in the table Robot cables on page 116.

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)

Handles communication with equipment fitted on the robot


by the customer, low voltage signals and high voltage power
supply + protective ground.
See the product manual for the controller, see document
number in References on page 10.
Also specified in the table Customer cables (option) on
page 117.

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

Robot cable, power

Transfers drive power from the XS1


drive units in the control cabinet
to the robot motors.

R1.MP

Robot cable, signals

Transfers resolver data from


XS2
and power supply to the serial
measurement board.

R1.SMB

Robot cable, power, for robots with standard protection


Cable (standard)

Art. no.

Robot cable, power: 7 m

3HAC2492-1

Robot cable, power: 15 m

3HAC2529-1

Robot cable, power: 22 m

3HAC2539-1

Robot cable, power: 30 m

3HAC2564-1

Continues on next page


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2 Installation and commissioning


2.5.2 Robot cabling and connection points
Continued

Robot cable, power, for robots with foundry and wash protection
Cable (foundry)

Art. no.

Robot cable, power: 7 m

3HAC9038-1

Robot cable, power: 15 m

3HAC9038-2

Robot cable, power: 22 m

3HAC9038-3

Robot cable, power: 30 m

3HAC9038-4

Cable

Art. no.

Robot cable signal, shielded: 7 m

3HAC2493-1

Robot cable signal, shielded: 15 m

3HAC2530-1

Robot cable signal, shielded: 22 m

3HAC2540-1

Robot cable signal, shielded: 30 m

3HAC2566-1

Robot cable, signals

Position switch cables, robot base to controller (option)


The cable is delivered in one length only and should be wound to suitable length.
Cabling between robot base and controller
Cable

Art. no.

Connection
point, robot

Connection
point, cabinet

Position switch cable, axis 1, 30 m

3HAC7997-4

R1.LS

XS8

Customer cables (option)


The customer cables specified below are connected between robot and controller.
The customer cables are ordered according to current protection class of the robot.
Customer cables for robots with standard protection
Cable (standard)

Art. no.

Connection
point, robot

Customer cable, power-signal, 7 m

3HAC3353-1

R1.CP/CS

Customer cable, power-signal, 15 m

3HAC3354-1

R1.CP/CS

Customer cable, power-signal, 22 m

3HAC3355-1

R1.CP/CS

Customer cable, power-signal, 30 m

3HAC3356-1

R1.CP/CS

Cable (Foundry, Wash)

Art. no.

Connection
point, robot

Customer cable, power-signal, 7 m

3HAC8183-1

R1.CP/CS

Customer cable, power-signal, 15 m

3HAC8183-2

R1.CP/CS

Customer cable, power-signal, 22 m

3HAC8183-3

R1.CP/CS

Customer cable, power-signal, 30 m

3HAC8183-4

R1.CP/CS

Customer cables for robots with foundry and wash protection

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2 Installation and commissioning


2.5.3 Customer connections on the robot

2.5.3 Customer connections on the robot


General
For connection of equipment on the robot, there are cables integrated into the
robot cabling. This section specifies recommendations for the customer
connections.
The air and electrical connectors are shown in the figure Customer connectors on
the robot on page 113.
Air connection
Connection

Dimension

Air inlet (at the base)


Air outlet (at the upper arm housing)

1/4"

The integrated air hose is sized as specified in the table below.


Inner diameter

Max. pressure

8 mm

0.8 MPa / 115 psi

Customer connectors R2.CS and R2.CP


The customer connectors R2.CS and R2.CP can be used with either:

a connector set from ABB for standard connection

specified connector components from Souriau, or

connectors that meet Military standard MIL-C-26482 series 1.

These connectors are further detailed in following sections.


Connector set from ABB for standard connection
Equipment

ABB art. no.

Note

Connection set R2.CP/R2.CS

3HAC025396-001

Only for standard connection.

Continues on next page


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2 Installation and commissioning


2.5.3 Customer connections on the robot
Continued

Specified connector components from Souriau


The components specified below are from connector manufacturer Souriau and
can be used for connection to R2.CS and R2.CP.

xx0400001339

Pin connector

Pin

Backshell

Recommended pin connectors


Pin connector

Souriau art. no.

Pin connector, standard connection, CS (Customer Signal)

UT0W6 1626 P-H

Pin connector, standard connection, CP (Customer Power)

UT0W6 1210 P-H

Pin connector, integrated wirefeeder cabling, CS

UT0W6 1626 P-H

Pin connector, Integrated wirefeeder cabling, CP

UT06 1412 P-H04

Recommended pins (turned)


Turned pins for cable area...

Pin diameter

Souriau art. no.

0.21 - 0.93 mm 2 (standard connection, CP/CS and

1 mm

RM18W3K

integrated wirefeeder cabling, CS)


0.13 - 0.25 mm 2 (integrated wirefeeder cabling, CP) 1.6 mm

RM24M9K

0.25 - 0.5 mm 2 (integrated wirefeeder cabling, CP)

1.6 mm

RM20M12K

0.5 - 1.5 mm 2 (integrated wirefeeder cabling, CP)

1.6 mm

RM16M23K

Recommended backshell
Backshell

Souriau art. no.

Backshell, standard connection, CS

UT0 16JC

Backshell, standard connection, CP

UT0 12JC

Backshell, integrated wirefeeder cabling, CS

UT0 16JC

Backshell, integrated wirefeeder cabling, CP

UT0 14JC

Continues on next page


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2 Installation and commissioning


2.5.3 Customer connections on the robot
Continued

Connectors that meet Military standard


The connectors specified below meet Millitary standard MIL-C-26482 series 1 and
can be used for connection to R2.CS and R2.CP (only for standard customer
connection).
The figure below shows a complete connector, including pin connector and
backshell.

xx0400001340

Connector for crimping


The complete pin connectors for crimping include pin connector and backshell.
Connector for crimping

Military standard MIL-C-26482

Complete pin connector, CS

MS3126*1626S

Complete pin connector, CP

MS3126*1210S

Turned pin 0.2 - 0.5 mm 2

M39029/31-240

Turned pin 0.5 - 1.5 mm 2

M29029/31-228

Connector for soldering


The complete pin connectors for soldering include pin connector, backshell and
pins.
Connector for soldering

Military standard MIL-C-26482

Complete pin connector, CS

MS3116*1626S

Complete pin connector, CP

MS3116*1210S

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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:

Product manual - IRC5

Product manual - IRC5 Panel Mounted Controller

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3 Maintenance
3.2.1 Specification of maintenance intervals

3.2 Maintenance schedule and expected component life


3.2.1 Specification of maintenance intervals
Introduction
The intervals are specified in different ways depending on the type of maintenance
activity to be carried out and the working conditions of the IRB 1600:

Calendar time: specified in months regardless of whether the system is


running or not.

Operating time: specified in operating hours. More frequent running means


more frequent maintenance activities.

SIS: specified by the robot's SIS (Service Information System). A typical


value is given for a typical work cycle, but the value will differ depending on
how hard each part is run. The SIS used in M2004 is further described in the
Operating manual - Service Information System.

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3 Maintenance
3.2.2 Maintenance schedule

3.2.2 Maintenance schedule


General
The robot must be maintained regularly to ensure proper function. The maintenance
activities and intervals are specified in the table below.
Unexpected situations that arise prompt inspection of the robot. Any damage must
be attended to immediately!
The inspection intervals do not specify the life of each component.
Maintenance schedule
The table below specifies the required maintenance activities and intervals:
Maintenance
activity

Equipment

Interval

Detailed in section

Changing

Gearbox oil, axes 5 and 6


IRB1600

20,000 hrs

Changing the oil in axes


5 and 6 gearboxes on
page 129.

Changing

Gearbox oil, axes 5-6


IRB1600ID

20,000 hrs

Changing the oil, axis 56 gearbox, ID on


page 132

Replacement

Battery pack, measurement 36 months or batsystem of type RMU101 or tery low alert i
RMU102 (3-pole battery
contact)

Replacing the battery


pack on page 135

Replacement

Battery pack, measurement Battery low alert ii


system with 2-pole battery
contact, e.g. DSQC633A

Replacing the battery


pack on page 135.
Replacing the battery
pack on page 135.
Replacing the battery
pack on page 135.
Replacing the battery
pack on page 135.
Replacing the battery
pack on page 135.
Replacing the battery
pack on page 135.
Replacing the battery
pack on page 135.

Cleaning

Complete robot

Regular iii

Cleaning the IRB 1600


on page 139

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.

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3 Maintenance
3.2.3 Expected component life

3.2.3 Expected component life


General
The life of any component depends on how hard it is run, and it can vary greatly.
Expected component life
Component

Expected life

Note

Robot cable harness IRB 1600

2,000,000 cycles

See note 1)

Robot cable harness IRB 1600ID

2,000,000 cycles

See note 1)

Cabling for position switch

2,000,000 cycles

See note 1)

Gearbox

40,000 hours

1 The expected life can also be affected by grouping harnesses/cables other


than standard options. The life expectancy is based on a test cycle that for
every axis goes from the calibration position to minimum angle, to maximum
angle and back to the calibration position. Deviations from this test cycle will
result in differences in expected life!

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3 Maintenance
3.3.1 Inspection, damper axes 2, 3 and 5

3.3 Inspection activities


3.3.1 Inspection, damper axes 2, 3 and 5
Location of dampers
The figure below shows the location of all the dampers to be inspected.

xx0400001217

Damper, axis 2

Attachment screw

Continues on next page


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3 Maintenance
3.3.1 Inspection, damper axes 2, 3 and 5
Continued

xx0400001215

Damper, axis 3

Cast tab

xx0600002806

Damper, axis 5

Recess

Continues on next page


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3 Maintenance
3.3.1 Inspection, damper axes 2, 3 and 5
Continued

Required equipment
Equipment

Art. no.

Note

Standard toolkit

Content is defined in section Standard tools on


page 293.

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.

Check attachment screws for deformation.

If any damage is detected, the damper must be


replaced with a new one!

Replacement is detailed in sections:


Replacing the damper, axis
2 on page 195
Replacing the damper, axis
3 on page 197
Replacement of damper,
axis 5 on page 201.

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3 Maintenance
3.4.1 Type of lubrication in gearboxes

3.4 Replacement activities


3.4.1 Type of lubrication in gearboxes
Introduction
This section describes where to find information about the type of lubrication,
article number and the amount of lubrication in the specific gearbox. It also
describes the equipment needed when working with lubrication.
CAUTION
Always read the specific instructions for Clean Room robots before doing any
repair work, see Replacing parts on Clean Room robots on page 149.
Type and amount of oil in gearboxes
Information about the type of lubrication, article number as well as the amount in
the specific gearbox can be found in Technical reference manual - Lubrication in
gearboxes. In order to always get the latest information of updates about lubrication
in gearboxes, always check on ABB Library for the latest revision of the manual.
A new revision will be published on ABB Library immediately after any updates.
Before starting any inspection, maintenance, or changing activities of lubrication,
always check ABB Library for the latest revision of this manual. The revision of
the manual published on the Documentation DVD (released twice a year) will only
contain the latest updates when the Documentation DVD is released. Any updates
of the manual in between these releases will be published on ABB Library. Therefore
the manual published on the documentation DVD may not contain the latest updates
about lubrication. If ABB Library cannot be reached, contact the local ABB Service
organization for more information.
Location of gearboxes
The figure shows the location of the gearboxes.
Equipment
Equipment

Note

Oil dispenser

Includes pump with outlet pipe.


Use the suggested dispenser or a similar one:
Orion OriCan art. no. 22590 (pneumatic)

Nipple for quick connect fitting, with o-ring


Expansion container, gearbox axis 1

Used when the robot is fitted in a suspended


position.

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3 Maintenance
3.4.2 Changing the oil in axes 5 and 6 gearboxes

3.4.2 Changing the oil in axes 5 and 6 gearboxes


Location of oil plugs
The gearboxes for axes 5 and 6 are located in the wrist unit as shown in the figure
below.

xx0600002846

Oil plug, draining and filling

Oil plug, vent hole

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.

Oil collecting vessel

The capacity of the vessel must be sufficient to take


the complete amount of oil.

Standard toolkit

Content is defined in section Standard tools on


page 293.

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.

Continues on next page


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3 Maintenance
3.4.2 Changing the oil in axes 5 and 6 gearboxes
Continued

Draining, wrist unit


The procedure below details how to drain oil from the gearboxes in the wrist unit.
Action

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

A Oil plug, draining and filling


The position for an inverted robot is
the opposite!
4

Remove the both oil plugs.


Shown in the figure Location of oil
Both oil plugs must be removed in order to drain plugs on page 129.
the wrist unit properly.

Refit the oil plug, vent hole.

Continues on next page


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3 Maintenance
3.4.2 Changing the oil in axes 5 and 6 gearboxes
Continued

Filling oil, wrist unit


The procedure below details how to fill oil in the gearboxes in the wrist unit.
Action

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!

Remove the oil plug, draining and filling.

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

A: Oil plug, draining and filling


The position for an inverted robot is
the opposite.
5

Refit the oil plug.

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3 Maintenance
3.4.3 Changing the oil, axis 5- 6 gearbox, ID

3.4.3 Changing the oil, axis 5- 6 gearbox, ID


Location of oil plugs, axis 5-6 gearbox
The oil plugs for the axis 5-6 gearbox are located in the wrist unit as shown in the
figure below.

xx0700000030

Oil plug, draining and filling

Oil plug, draining ventilation plug.

Required equipment
Equipment

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.

Oil collecting vessel

The capacity of the vessel must be sufficient


to take the complete amount of oil.

Standard toolkit

Content is defined in section Standard tools


on page 293.

Other tools and procedures may be required. See references to these procedures in the
step-by-step instructions below.

Draining, axis 5-6 gearbox


Use this procedure to drain the axis 5-6 gearbox.
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.

Continues on next page


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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.

Drain the wrist of oil.

About 100 ml

Refit the oil plugs.

Tightening torque: 3 Nm.

Continues on next page


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3 Maintenance
3.4.3 Changing the oil, axis 5- 6 gearbox, ID
Continued

Filling oil, axis 5-6 gearbox


Use this procedure to fill the axis 5-6 gearbox with oil.
Action
1

Note

Position the robot as shown in the figure


to the right:
axis 4: + 90, to a position where the
oil plug (A) is faced upwards.

xx0700000034

A Oil plugs
2

Fill new oil in the wrist.


Where to find type of oil and total amount
Check the oil level to make sure the filled is detailed in Type and amount of oil in
gearboxes on page 128.
amount of oil is correct.

Refit the oil plug and the ventilation plug. Tightening torque: 3 Nm.

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Copyright 2006-2014 ABB. All rights reserved.

3 Maintenance
3.4.4 Replacing the battery pack

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.

Continues on next page


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3 Maintenance
3.4.4 Replacing the battery pack
Continued

Battery pack on serial measurement unit


The battery pack is attached to the serial measurement unit as shown in the figure
below.
DSQC 633A

xx0500001393

Battery pack battery (2-pole battery contact)

Velcro strap

Connector X3

Continues on next page


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3 Maintenance
3.4.4 Replacing the battery pack
Continued

RMU 101

7
8
11

xx1300000332

Serial measurement board RMU 101

BU unit

Battery pack (3-pole battery contact)

10

Push button guard

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

Spare part no.

Serial measurement
board

See Spare part lists on


page 297.

Battery pack

See Spare part lists on


page 297.

Gasket, base cover

3HAC 022047-001

Note

Replace if damaged.

Continues on next page


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3 Maintenance
3.4.4 Replacing the battery pack
Continued

Equipment

Spare part no.

Note

Standard toolkit

Content is defined in section Standard


tools on page 293.

Circuit diagram

See chapter Circuit diagram on page 299.

Replacement, battery pack


The procedure below details how to replace the battery pack.
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

Remove the base cover from the robot by


unscrewing its attachment screws.

Disconnect the battery from the serial measurement unit.

Valid for battery pack with 2-pole battery


contact:
Open the velcro strap and remove the battery
pack.

Valid for battery pack with 3-pole battery


contact.
Cut the cable strap and remove the battery
pack.

Fit the new battery pack and connect it to the See Battery pack on serial measureserial measurement unit (X3).
ment unit on page 136.

Valid for battery pack with 2-pole battery


contact:
Close the velcro strap around the battery
pack.

Valid for battery pack with 3-pole battery


contact.
Secure the battery with a cable strap.

Check the base cover gasket, replace if dam- Spare part no. is specified in Required
aged.
equipment on page 137.

10

Refit the base cover to the robot.

See Location of battery pack on


page 135.

11

Update the revolution counters.

Detailed in section Updating revolution


counters on page 277.

See Location of battery pack on


page 135.

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3 Maintenance
3.5.1 Cleaning the IRB 1600

3.5 Cleaning activities


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

Wipe with cloth Rinse with water

High pressure water or


steam

Yes

Yes. With light Yes. It is highly re- No


cleaning deter- commended that
gent.
the water contains
a rust-prevention
solution and that
the manipulator is
dried afterwards.

Foundry Plus Yes

Yes. With light Yes. It is highly recleaning deter- commended that


gent or spirit. the water contains
a rust-prevention
solution.

Yes i .
It is highly recommended
that the water and steam
contains rust preventive,
without cleaning detergents.

Wash

Yes. With light Yes. It is highly recleaning deter- commended that


gent or spirit. the water contains
a rust-prevention
solution.

Yes ii .
It is highly recommended
that the water and steam
contains rust preventive,
without cleaning detergents.

Yes

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3 Maintenance
3.5.1 Cleaning the IRB 1600
Continued

Protection
type

Clean room

i
ii

Cleaning method
Vacuum
cleaner

Wipe with cloth Rinse with water

High pressure water or


steam

Yes

Yes. With light No


cleaning detergent, spirit or
isopropyl alcohol.

No

Perform according to section .


Perform according to section Cleaning with water and steam on page 140.

Cleaning with water and steam


Instructions for rinsing with water
ABB robots with protection types Standard, Foundry Plus, Wash, or Foundry Prime
can be cleaned by rinsing with water (water cleaner). 1
The following list defines the prerequisites:

Maximum water pressure at the nozzle: 700 kN/m 2 (7 bar) I

Fan jet nozzle should be used, min. 45 spread

Minimum distance from nozzle to encapsulation: 0.4 meters

Maximum flow: 20 liters/min I

Typical tap water pressure and flow

Instructions for steam or high pressure water cleaning


ABB robots with protection types Foundry Plus, Wash, or Foundry Prime can be
cleaned using a steam cleaner or high pressure water cleaner.1
The following list defines the prerequisites:

Maximum water pressure at the nozzle: 2,500 kN/m 2 (25 bar)

Fan jet nozzle should be used, min. 45 spread

Minimum distance from nozzle to encapsulation: 0.4 meters

Maximum water temperature: 80 C

Cables
Movable cables need to be able to move freely:

Remove waste material, such as sand, dust and chips, if it prevents cable
movement.

Clean the cables if they have a crusty surface, for example from dry release
agents.

Dos and don'ts!


The section below specifies some special considerations when cleaning the robot.
Always!

Always use cleaning equipment as specified above! Any other cleaning


equipment may shorten the life of the robot.

Always check that all protective covers are fitted to the robot before cleaning!

See Cleaning methods on page 139 for exceptions.

Continues on next page


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3 Maintenance
3.5.1 Cleaning the IRB 1600
Continued

Never!

Never point the water jet at connectors, joints, sealings, or gaskets!

Never use compressed air to clean the robot!

Never use solvents that are not approved by ABB to clean the robot!

Never spray from a distance closer than 0.4 meters!

Never remove any covers or other protective devices before cleaning the
robot!

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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:

Product manual - IRC5

Product manual - IRC5 Panel Mounted Controller

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4 Repair
4.2.1 Performing a leak-down test

4.2 General procedures


4.2.1 Performing a leak-down test
When to perform a leak-down test
After refitting any motor and gearbox, the integrity of all seals enclosing the gearbox
oil must be tested. This is done in a leak-down test.
Required equipment
Equipment, etc.

Article number

Leak-down tester

3HAC0207-1

Leak detection spray

Note

Performing a leak-down test


Action

Note

Finish the refitting procedure of the motor or gear in


question.

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.

Use caution, apply compressed air and raise the


pressure with the knob until the correct value is
shown on the manometer.

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

Disconnect the compressed air supply.

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.

If any pressure drop occurred, then localize the leak


as described in step 7.
If no pressure drop occurred, then remove the leakdown tester and refit the oil plug. The test is complete.

Spray any suspected leak areas with the leak detection spray. Bubbles indicate a leak.

When the leak has been localized, take the necessary


measures to correct the leak.

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4 Repair
4.2.2 Mounting instructions for bearings

4.2.2 Mounting instructions for bearings


General
This section describes how to mount and grease different types of bearings on the
robot.
Equipment
Equipment, etc.

Art. no.

Note

Grease

3HAB3537-1

Used to grease the bearings, if not


specified otherwise.

Assembly of all bearings


Follow the following instructions while mounting a bearing on the robot.
Action

Note

To avoid contamination, let a new bearing remain in its wrapping


until it is time for fitting.

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.

Assembly of tapered bearings


Follow the preceding instructions for the assembly of the bearings when mounting
a tapered bearing on the robot.
In addition to those instructions, the following procedure must be carried out to
enable the roller elements to adjust to the correct position against the race flange.
Action

Note

Tension the bearing gradually until the recommended pre-tension is achieved.

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.

Continues on next page


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4 Repair
4.2.2 Mounting instructions for bearings
Continued

During operation, the bearing should be filled to 70-80% of the available


volume.

Ensure that grease is handled and stored properly to avoid contamination.

Grease the different types of bearings as following description:

Grooved ball bearings must be filled with grease from both sides.

Tapered roller bearings and axial needle bearings must be greased in the
split condition.

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4 Repair
4.2.3 Mounting instructions for seals

4.2.3 Mounting instructions for seals


General
This section describes how to mount different types of seals onto the robot.
Equipment
Equipment, etc.

Art. no.

Note

Grease

3HAB3537-1

Used to lubricate the seals.

Rotating seals
The procedure below describes how to fit rotating seals.
CAUTION
Please observe the following before commencing any assembly of seals:

Protect the sealing surfaces during transport and mounting.

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

Check the seal to ensure that:


The seal is of the correct type (provided with cutting
edge).
There is no damage to the sealing edge (feel with a
fingernail).

Inspect the sealing surface before mounting. If scratches


or damage are found, the seal must be replaced since it
may result in future leakage.

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.

Mount the seal correctly with a mounting tool.


Never hammer directly on the seal as this may result in
leakage.

Continues on next page


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4 Repair
4.2.3 Mounting instructions for seals
Continued

Flange seals and static seals


The following procedure describes how to fit flange seals and static seals.
Action
1

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.

Clean the surfaces properly in accordance with the recommendations of ABB.

Distribute the sealing compound evenly over the surface, preferably with a brush.

Tighten the screws evenly when fastening the flange joint.

O-rings
The following procedure describes how to fit o-rings.
Action

Note

Ensure that the correct o-ring size is used.

Check the o-ring for surface defects, burrs,


shape accuracy, and so on.

Check the o-ring grooves.


Defective o-rings may not be used.
The grooves must be geometrically correct and
should be free of pores and contamination.

Lubricate the o-ring with grease.

Tighten the screws evenly while assembling.

Defective o-rings may not be used.

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4 Repair
4.2.4 Replacing parts on Clean Room robots

4.2.4 Replacing parts on Clean Room robots


General
When replacing parts on a Clean Room robot, it is important to make sure that
after the replacement, no particles will be emitted from the joint between the
structure and the new part, and that the easy cleaned surface is retained.
Required equipment
Equipment

Spare parts

Note

Sealing compound

Sikaflex 521 FC. Color white.

Tooling pin

Width 6-9 mm, made of wood.

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

Cut the paint with a knife in the joint between


the part that will be removed and the structure, to avoid that the paint cracks.

xx0900000121

Carefully grind the paint edge that is left on


the structure to a smooth surface.

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.

Place the tooling pin in hot water.

Continues on next page


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4 Repair
4.2.4 Replacing parts on Clean Room robots
Continued

Action
3

Description

Seal all refitted joints with Sikaflex 521FC.

xx0900000122

Use the tooling pin to even out the surface


of the Sikaflex seal.

xx0900000125

Wait 15 minutes.

Sikaflex 521FC skin dry time (15 minutes).


3HAC035355-001

Note
Always read the instruction in the product
data sheet in the paint repair kit for Foundry
Prime.
7

Use Touch up paint Clean Room, white to


paint the joint.

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.

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4 Repair
4.3.1 Replacement of cable harness

4.3 Complete manipulator


4.3.1 Replacement of cable harness
Location of cable harness
The cable harness is run through the robot from the base to the upper arm housing.
The location of the harness is shown in several figures, next to the procedures,
later on in this section.
Views of the cable harness may also be found in the chapter Spare part lists on
page 297.
Required equipment
Equipment

Spare part no.

Note

Cable harness IRB 1600/1.45

3HAC 021827-001

No application interface.

Cable harness IRB 1600/1.45,


Customer connections

3HAC 021828-001

Cable harness IRB 1600/1.45, Wire 3HAC 021830-001


feeder
Cable harness IRB 1600/1.2, Cus- 3HAC 021828-003
tomer connections
Gasket, upper arm cover

3HAC022049-001

Replace if damaged.

Gasket, customer connections

3HAC022050-001

Replace if damaged.

Gasket, base cover

3HAC 022047-001

Replace if damaged.

Gasket, gearbox axis 1-2

3HAC022048-001

Replace if damaged.

VK-cover

3HAA 2166-23

Upper and lower covers.


2 pcs

VK-cover

3HAA 2166-21

Middle cover.

3HAC025815-001

Fitted to the push button unit in


order to align it correctly.
Replace if damaged.

Cable ties
Centering piece

Standard toolkit

Content is defined in section


Standard tools on page 293.

Circuit diagram

See chapter Circuit diagram on


page 299.

Continues on next page


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4 Repair
4.3.1 Replacement of cable harness
Continued

Illustration, covers to remove


The figure below shows all the covers that must be removed from the robot in order
to get access to the cable harness and all the brackets.

xx0400001248

Upper and lower VK-cover

Arm housing cover, with gaskets

VK-cover (also shown with the cover removed)

Cover, frame, with gasket

Base cover, with gasket

Continues on next page


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4 Repair
4.3.1 Replacement of cable harness
Continued

Removal, cable harness


The procedure below details how to remove the complete cable harness from the
robot.
Action

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 the covers:


All the covers are shown in the fig Remove the covers of the upper arm hous- ure Illustration, covers to remove
ing, frame and base.
on page 152.
Push out the upper and lower VK-cover
from the inside.
Remove the middle VK-cover from the
lower arm.
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

The cable bracket inside the lower arm is attached


to the cable harness. Move the bracket to the new
cabling.

Disconnect all the connectors inside the upper


arm housing.

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 inside the frame.

Remove the fastening plate, all cable ties and


Attachment points inside the frame
brackets from inside the frame. Remove the cable are shown in the figure Illustration,
clamp unit from the fastening plate.
cabling inside frame on page 156.

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!

Remove all cable ties and brackets at the base.

10

Pull out the cabling from the upper arm housing


and pull it down through the lower arm.

11

Continue pulling down the cable harness through


the frame and pull it out at the rear of the base.

Shown in the figure Illustration,


cabling inside upper arm housing
on page 154.

Shown in the figure Illustration,


cabling inside frame on page 156.

Shown in the figure Illustration,


cabling inside base on page 157.

Continues on next page


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4 Repair
4.3.1 Replacement of cable harness
Continued

Illustration, cabling inside upper arm housing


The figure below shows how the cabling is run inside the upper arm housing.

xx0400001250

Signal cabling; connectors for motors on axes 3, 4, 5 and 6: R3.FB3, R3.FB4,


R3.FB5 and R3.FB6

Power cabling; connectors for motors on axes 3, 4, 5 and 6: R3.MP3, R3.MP4,


R3.MP5 and R3.MP6

Optional connector: R2.CP

Optional connector: R2.CS

Distance console with contact panel

Cable clamp unit

Attachment screws, cable clamp unit (2 pcs, only one shown)

Clamp, signal cabling

Clamp, motor cabling

Connector plate

Connector holder

Cable tie, connector holder

Continues on next page


154

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4 Repair
4.3.1 Replacement of cable harness
Continued

Refitting, cable harness in upper arm housing and lower arm


The procedure below details how to refit the cabling inside the upper arm housing.
The cable layout is shown in the figure Illustration, cabling inside upper arm housing
on page 154.
Action

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

Insert the cabling to axes 3, 4, 5 and 6 up through


the lower arm and into the upper arm housing.

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

Cable bracket is attached to the


cabling with 2 screws, M6x8.
4

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.

Reconnect the motor cable connectors.

Reconnect optional connectors, if any, at the


contact panel.

Place the cabling correctly inside the housing


and secure it with cable ties.

The cable layout is shown in the figure Illustration, cabling inside upper
arm housing on page 154.

Continues on next page


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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

Fit new VK-covers to the lower arm.

12

Continue refitting the cable harness according


to procedure Refitting, cable harness in frame
and base on page 158.

Spare part no. is specified in Required equipment on page 151.

Illustration, cabling inside frame


The figure below shows how the cabling is run inside the frame.

xx0400001249

Power cabling; connectors for motors on axes 1 and 2: R3.MP1 and R3.MP2

Signal cabling; connectors for motors on axes 1 and 2: R3.FB1 and R3.FB2

Cable clamp unit (attachment screws behind the fastening plate)

Fastening plate

Attachment screws and nuts

Continues on next page


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4 Repair
4.3.1 Replacement of cable harness
Continued

Illustration, cabling inside base


The figure below shows how the cabling is run inside the base. Optional cabling
is also shown in the figure, but not further specified.

xx0500001388

Power cabling

Signal cabling

Clamp with hexagon nut

Attachment screws, cable clamp unit

Hexagon nut, SMB plate

Fastening plate

SMB unit

Cable clamp unit

Continues on next page


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4 Repair
4.3.1 Replacement of cable harness
Continued

Refitting, cable harness in frame and base


The procedure below details how to refit the cabling inside the frame and the base.
The cable layout is shown in the figures Illustration, cabling inside frame on page 156
and Illustration, cabling inside base on page 157.
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

Run the cables from the lower arm into the


frame.

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.

Run the cabling down to the base. Pull it out


at the rear of the base.

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.

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

Art. no. for the centering piece is specified in Required equipment on


page 151.
9

Refit the push button guard to the robot base.

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!

Continues on next page


158

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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

Recalibrate the robot!

Calibration is detailed in a separate


calibration manual enclosed with the
calibration tools.
General calibration information is included in section Calibration information on page 271.

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4 Repair
4.3.2 Replacement of cable harness, IRB 1600ID

4.3.2 Replacement of cable harness, IRB 1600ID


Location of the harness
The location of the harness is shown in several figures, next to the procedures,
later on in this section.
R4.FB5

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

Spare part no.

Standard toolkit

Note
Standard tools on page 293

Continues on next page


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4 Repair
4.3.2 Replacement of cable harness, IRB 1600ID
Continued

Equipment

Spare part no.

Note

VK- cover

3HAA 2166-23

Upper and lower covers.


2 pcs

Cable harness axis 5-6.

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

Continues on next page


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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

Remove the cover to the upper arm.

Remove the hexagon nut with flange (A)


holding the two (2) clamps.

xx0700000106

A Hexagon nut with flange


4

Disconnect R3.FB3 - R3.FB6.

Disconnect R3.MP3 - R3.MP6.

Remove the cable harness from the lower Follow instructions in section Replacement
of cable harness on page 151.
arm.

Continues on next page


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4 Repair
4.3.2 Replacement of cable harness, IRB 1600ID
Continued

Removal, cable harness upper arm tube 1600ID


The procedure below describes removal of the complete cable harness in upper
arm tube.

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.

Continues on next page


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4 Repair
4.3.2 Replacement of cable harness, IRB 1600ID
Continued

Action

Note

Remove the upper arm tube.

Described in section Replacement of motor, axis 5,


IRB 1600ID on page 251.

Remove all the Torx pan head


screw (A) holding the cover.

xx0700000113

A Torx pan head screw M6x12


B Hexagon nut with flange M5
4

Remove the cover plate.


Tip
The spare part cable harness 3HAC027523-002 includes a galvanized coverplate without paint. If a
painted cover is prefered, use the old cover plate.

Remove the cable pulling it out


through the passage (A).

xx0700000114

Continues on next page


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4 Repair
4.3.2 Replacement of cable harness, IRB 1600ID
Continued

Refitting, cable harness


The procedure below describes refitting of the complete cable harness.
Action

Note

Refit the cable harness.

Described in section Refitting, cable harness in upper


arm housing and lower arm on page 155

Refit the upper arm tube.

Described in section Refitting, motor axis 5 on page 255.

Refit the connections in the


upper arm.

Shown in figure Location of the harness on page 160.

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4 Repair
4.3.3 Replacement of complete arm system

4.3.3 Replacement of complete arm system


Location of complete arm system
The complete arm system includes complete upper and lower arms.

xx0500001443

VK-cover (attachment screws underneath cover)

Cover, frame

Cover, base

Required equipment
Equipment

Art. no.

Note

Lifting slings

VK-cover

3HAA 2166-23

Sealing ring (V-ring)

3HAB3732-13

Replace if damaged.

Isopropanol

Used to clean the mating surfaces.

Locking liquid

Loctite 574

Standard toolkit

Content is defined in section


Standard tools on page 293.

Continues on next page


166

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4 Repair
4.3.3 Replacement of complete arm system
Continued

Equipment

Art. no.

Other tools and procedures may


be required. See references to
these procedures in the step-bystep instructions below.

Note
These procedures include references to the tools required.

Removing the complete arm system


Use this procedure to remove the complete arm system from the robot.
Action
1

Note

Move the robot to its calibration position.

2
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working
area.
3

Remove the covers from the base and the


frame.

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

Fit lifting slings to the upper arm to unload the


weight of the complete arm system.

Unscrew the 12 attachment screws and remove


the one washer.
Be careful when pulling the cabling through
base, frame and lower arm. Use tape to bunch
the connectors and protect them.

Gently pull out the cabling from the frame and


base while lifting away the complete arm system.

10

Secure the cable harness to the arm system in


a way that it is not damaged in the continued
process.

11

Check the sealing ring. Replace if damaged.

Continues on next page


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4 Repair
4.3.3 Replacement of complete arm system
Continued

Refitting, complete arm system


The procedure below details how to refit the complete arm system to the robot.
Action

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

Clean the mating surfaces on both the lower arm


and on the frame with isopropanol. Also clean the
area where the sealing ring is fitted, if it has been
removed.

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

Lubricate the attachment holes at the mating surface


on the frame with Loctite 574.

5
CAUTION
The complete arm system weighs 55 kg.
All lifting accessories used must be sized accordingly!
6

Fit the lifting slings to the complete arm system and


lift it into position while inserting the cabling into the
frame.

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.

Refit the cabling inside the frame and the base.

Detailed in section Refitting,


cable harness in frame and base
on page 158.

Fit a new VK-cover to the lower arm.

Art. no. is specified in Required


equipment on page 166.

Continues on next page


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4 Repair
4.3.3 Replacement of complete arm system
Continued

10

Action

Note/Illustration

Recalibrate the robot!

Calibration is detailed in a separate calibration manual enclosed


with the calibration tools.
General calibration information
is included in section Calibration
information on page 271.

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.

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4 Repair
4.4.1 Replacement of complete upper arm

4.4 Upper and lower arm


4.4.1 Replacement of complete upper arm
General
The complete upper arm is considered a spare part, including wrist, gearboxes
and motors.
Location of upper arm
The figure below shows the location of the upper arm on the robot and some of
the upper arm components.
A more detailed view of the upper arm may be found in the spare part view, see
Spare parts - Upper arm, exploded view.

xx0400001218

Arm housing cover, including gaskets for the cover and the contact panel

VK cover. Upper arm attachment screws inside

Continues on next page


170

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4 Repair
4.4.1 Replacement of complete upper arm
Continued

Required equipment
Equipment

Spare part no.

Upper arm

For spare part number, see:


Spare part
lists on
page 297.

VK-cover

3HAA 2166-23

Sealing ring (V-ring)

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.

Gasket, upper arm cover 3HAC022049-001

Replace if damaged.

Gasket, customer connections

Replace if damaged.

3HAC022050-001

Grease

3HAB 3537-1 To lubricate the sealing ring


(V-ring).

Locking liquid

Lifting slings

Loctite 574

Standard toolkit

Content is defined in section


Standard tools on page 293.

Other tools and procedures may be required.


See references to these
procedures in the stepby-step instructions below.

These procedures include


references to the tools required.

Removal, complete upper arm


The procedure below details how to remove the complete upper arm from the robot.
Action
1

Note/Illustration

Move the upper arm to a horizontal position.

2
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working
area.
3

Remove the arm housing cover from the upper Shown in the figure Location of upper
arm.
arm on page 170.

Disconnect all connectors inside the arm


housing and loosen the cabling from straps
and brackets.

The cabling and all connectors inside


the upper arm housing are shown in
the figure Illustration, cabling inside
upper arm housing on page 154.

Continues on next page


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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.

Secure the weight of the arm with lifting slings.

7
CAUTION
The complete upper arm weighs 55 kg without
any additional equipment fitted!
All lifting accessories used must be sized accordingly!
8

Remove the 10 attachment screws (A) and the


single washer (B).

xx0400001219

Remove the upper arm, lift it away and place


it securely.

Refitting, complete upper arm


The procedure below details how to refit the complete upper arm to the robot.
Action

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

Wipe the contact surfaces clean on both the


upper and lower arm.

3
CAUTION
The complete upper arm weighs 55 kg without
any additional equipment fitted!
All lifting accessories used must be sized accordingly!
4

Attach lifting slings to the upper arm and lift it.

Continues on next page


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4 Repair
4.4.1 Replacement of complete upper arm
Continued

Action
5

Note/Illustration

Lubricate the sealing ring (A) with grease and


fit it to the upper arm.
Replace the sealing ring, if damaged.

xx0400001220

A: Sealing ring, spare part no.


is specified in Required equipment on page 171.
B: Contact surface.

Lubricate the the contact surface, upper arm,


with Loctite 574.

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

Run the cabling through the lower arm and into


the arm housing.

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

Refit a new VK-cover to the lower arm.

Shown in the figure Location of upper


arm on page 170.
Spare part no. is specified in section
Required equipment on page 171.

12

Recalibrate the robot!

Calibration is detailed in a separate


calibration manual enclosed with the
calibration tools.
General calibration information is included in section Calibration information on page 271.

Continues on next page


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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

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4 Repair
4.4.2 Replacing the complete upper arm ID

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

Socket head cap screw M10x40

Cable harness

V-ring

Continues on next page


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4 Repair
4.4.2 Replacing the complete upper arm ID
Continued

Required equipment
Equipment

Art. no.

Note

Upper arm, spare

For spare part number, see:


Includes the wrist unit. All
Spare part lists on page 297. gearboxes are filled with oil at
delivery.

VK-cover

3HAA2166-23

Gasket, customer con- 3HAC 022050-001


nections

Replace if damaged

Standard toolkit

Content is defined in section


Standard tools on page 293.

Removing the complete upper arm


Use this procedure to remove the complete upper arm.
Action
1

Note

Put the robot in synchronization position for


Axis 3.

xx0700000075

A Synchronization mark Axis 3


2
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.

Continues on next page


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4 Repair
4.4.2 Replacing the complete upper arm ID
Continued

Action
3

Note

Remove the cover arm housing.

xx0700000077

A Cover Arm Housing


B Torx pan head screw
4

Disconnect all connectors inside the armhouse and loosen the cabling from straps
and brackets.

Described in section Replacement of


cable harness on page 151

5
CAUTION
The robot upper arm weighs 39 kg.
All lifting accessories used must be sized
accordingly!

Continues on next page


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4 Repair
4.4.2 Replacing the complete upper arm ID
Continued

Action
6

Note

Secure the weight of the upper arm with a


roundsling.
Apply the roundsling through the hole in the
upper arm. See figure!

xx0700000060

Knock out the VK-cover from the motor side.

Remove the 10 attachment screws (A) and


the single washer, use standard tools.

xx0700000057

A Socket head cap screw M10x40


9

Remove the axis 3 motor.

See Replacement of motor, axis 3, IRB


1600ID on page 235.

10 Carefully lift away the upper arm and put it


somewhere safe.

Continues on next page


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4 Repair
4.4.2 Replacing the complete upper arm ID
Continued

Refitting the complete upper arm


Use this procedure to refit the complete upper arm.
Action

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

A Synchronization mark Axis 3

Continues on next page


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4 Repair
4.4.2 Replacing the complete upper arm ID
Continued

Action

Note

5 Refit the 10 attachment screws (A) and the single


washer, use standard tools.
Tightening torque: 70 Nm.

xx0700000057

A Socket head cap screw M10x40


6 Refit the motor.

See Replacement of motor, axis 3, IRB


1600ID on page 235.

7 Run the cabling through the lower arm and into


the arm housing.
8 Connect all the connectors in the armhouse and
secure the cabling with brackets and straps.
9 Refit the cover arm housing to the upper arm
Standard tools on page 293.

xx0700000077

A Cover Arm Housing


B Torx pan head screw
10 Refit a new VK-cover to the lower arm. replace
it, if damaged.

Spare part no. is specified in Required


equipment on page 176.

11 Recalibrate the robot.

Calibration is detailed in a separate


calibration manual enclosed with the
calibration tools.
General calibration information is included in section Calibration information on page 271.

Continues on next page


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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.

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4 Repair
4.4.3 Replacing the complete lower arm

4.4.3 Replacing the complete lower arm


Location of lower arm
The lower arm is located on the robot as shown in the figure.
A more detailed view of the lower arm may be found in the spare part view, Spare
parts - Lower arm, exploded view.

xx0400001246

Lower arm

VK-cover

VK-cover, middle

Required equipment
Equipment

Art. no.

Lower arm

See Spare part lists on


page 297.

VK-cover

3HAA2166-23

VK-cover

3HAA2166-21

Note

In the middle of the lower


arm.

Continues on next page


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4 Repair
4.4.3 Replacing the complete lower arm
Continued

Equipment

Art. no.

Note

Sealing ring (V-ring)

3HAB3732-13

Replace if damaged.

Isopropanol

Used to clean the mating surfaces.

Locking liquid

Loctite 574

Standard toolkit

Content is defined in section


Standard tools on page 293.

Other tools and procedures


may be required. See references to these procedures in
the step-by-step instructions
below.

These procedures include


references to the tools required.

Removing the lower arm


Use this procedure to remove the lower arm.
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

Remove the complete upper arm.

See section Replacing the complete upper


arm ID on page 175.

Remove the VK-covers.

Shown in the figure Location of lower arm


on page 182.

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

Pull down the cabling through the lower arm


and pull it out.

5
CAUTION
The robot lower arm weighs 20 kg.
All lifting accessories used must be sized
accordingly!
6

Fit the lifting device to the lower arm to secure the weight of the arm.

Continues on next page


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4 Repair
4.4.3 Replacing the complete lower arm
Continued

Action

Note

Unscrew the 12 attachment screws and remove the single washer.

Gently pull out the cabling while lifting away


the lower arm. Be careful with the connectors,
they are sensitive to damage!

Check the sealing ring. Replace it if damaged. Spare part no. is specified in Required
equipment on page 182.

Refitting the lower arm


Use this procedure to refit the complete lower arm.
Action

Note

Clean the mating surfaces on both the lower


arm and on the frame with isopropanol. Also
clean the area where the sealing ring is fitted.

Fit the sealing ring properly to the frame.


Replace it if damaged.

Spare part no. is specified in Required


equipment on page 182.

xx0400001245

A: Sealing ring
B: Mating surface

Lubricate the mating surface on the frame


with Loctite 574.

4
CAUTION
The robot lower arm weighs 20 kg.
All lifting accessories used must be sized
accordingly!
5

Fit the lifting device to the lower arm and lift


it into position.

Insert the cabling into the lower arm.

Fit the lower arm against the frame, fit the


washer and secure with the 12 attachment
screws.

Push the cabling up through the lower arm


and place the cable bracket inside the lower
arm correctly.

12 pcs; M10 x 40, tightening torque: 70


Nm.

Continues on next page


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4 Repair
4.4.3 Replacing the complete lower arm
Continued

Action
9

Note

Fit new VK-covers to the lower arm.


Spare part no. is specified in Required
Make sure that the cable bracket inside the equipment on page 182.
lower arm is secured beneath the middle VKcover.

10 Refit the upper arm.

See section Replacing the complete upper


arm ID on page 175.

11 Recalibrate the robot!

Calibration is detailed in a separate calibration manual enclosed with the calibration tools.
General calibration information is included
in section Calibration information on
page 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.

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4 Repair
4.4.4 Replacement of wrist unit

4.4.4 Replacement of wrist unit


Location of wrist unit
The wrist unit is located in the frontmost part of the upper arm.
A more detailed view of the upper arm, including the wrist unit, is found in the spare
part view, see Spare parts - Upper arm, exploded view.

xx0600002847

Attachment screws, wrist unit (3 pcs)

Oil plug (only one shown)

Wrist unit

Required equipment
Equipment, etc.

Spare part no.

Wrist Standard/Foundry

3HAC027003-001

Standard and Foundry versions.


O-ring sealing plate not included!
Note! The wrist, standard/Foundry is not interchangeable with art. no. 3HAC 10475-1!

O-ring sealing plate 3HAC025420-001

Must be replaced.
Note! The o-ring sealing plate is
not interchangeable with art.no.
3HAC 7191-1!

Grease

Art. no.

Note

3HAC 3537-1 For lubricating the o-ring sealing


plate.

Standard toolkit

Content is defined in section


Standard tools on page 293.

Continues on next page


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4 Repair
4.4.4 Replacement of wrist unit
Continued

Equipment, etc.

Spare part no.

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.

Removal, wrist unit


The procedure below details how to remove the complete wrist unit.
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

Drain the oil from the wrist unit.

Detailed in section Changing the oil in


axes 5 and 6 gearboxes on page 129.

Remove the wrist unit by unscrewing its


three attachment screws.

Shown in the figure in section Location


of wrist unit on page 186.

Refitting, wrist unit


The procedure below details how to refit the complete wrist unit.
Action

Note

Clean Room robots: clean the joints that


have been opened. See Replacing parts
on Clean Room robots on page 149

Move the robot to a position where the


upper arm is vertical.

3
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot
working area.

Continues on next page


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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.

In order to release the brake, connect


the 24 VDC power supply to motors:

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.

Perform a leak-down test.

Detailed in section Performing a leak-down


test on page 144.

Refill the wrist unit with oil.

Detailed in section Changing the oil in axes


5 and 6 gearboxes on page 129.

Clean Room robots: seal and paint the


joints that have been opened. See Replacing parts on Clean Room robots on
page 149

Connect to connector R3.MP5 or 6:


+: pin 7
-: pin 8

Note
After all repair work, wipe the robot free
from particles with spirit on a lint free
cloth.
10

Recalibrate the robot!

Calibration is detailed in a separate calibration manual enclosed with the calibration


tools.
General calibration information is included
in section Calibration information on
page 271.

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.

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4 Repair
4.4.5 Replacing the wrist unit, ID

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

Hexagon socket head screw M5x25

Hexagon socket head screw M5X16 (10.9) (Short head)

Hexagon socket head screw M5x25

Hexagon socket head screw M8x35

Required equipment
Equipment

Art. No.

Wrist, ID

See Spare part lists on


page 297.

Note

O-ring

Continues on next page


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4 Repair
4.4.5 Replacing the wrist unit, ID
Continued

Equipment

Art. No.

Note

Grease

3HAC3537-1

For lubricating the o-ring


sealing plate.

Arm

3HAC9037-1

For adjusting the gear play,


motor/pinion.

Loctite 242

1269-0014-410

Standard toolkit

Content is defined in section


Standard tools on page 293.

Other tools and procedures


may be required. See references to these procedures in
the step-by-step instructions
below.

These procedures include


references to the tools required.

Removing the wrist unit


Use this procedure to remove the complete wrist unit.
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

Remove all extra equipment fitted on upper Shown in Remove AW Gun on page 204
arm and wrist.

The plug (A) in figure covering the screw (C).


Remove the plug using standard tools (B).
Remove the screw for looking of motor axis
5, (C) in figure Location of wrist unit on
page 189.

xx0700000092

A Plug
B Standard tool, Standard tools on
page 293
C Hexagon socket head screw
M5X16 (Short head)

Continues on next page


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4 Repair
4.4.5 Replacing the wrist unit, ID
Continued

Action
4

Note

Remove the VK-Cover.

xx0700000054

A VK-Cover
5

Gently pull the cables out through the hole


for the VK- cover in the armtube.

Disconnect the connectors R4.FB6 and


R4.MP6 to motor axis 6, through the hole for
the VK cover.

xx0700000053

A: Connectors R4.FB6 & R4.MP6

Remove the attachment screws securing the


wrist.

xx0700000052

A: Hex socket head cap screw


M8x35 quality 8.8-A2F (3 pcs)

Continues on next page


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4 Repair
4.4.5 Replacing the wrist unit, ID
Continued

Action
8

Note

Remove the wrist with motor 6 from the upper


arm tube and put it on a work bench or similar.
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.

Remove the three screws, hexagon socket


head screw M5x25 (E) securing the motor
axis 6 and remove the motor (C).

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

Refitting the wrist unit


Use this procedure to refit the complete wrist unit.
Action

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

A Hex socket head cap screw M5x25


B Motor Console
2

Apply a string or similar to the cable harness


and run it out through the hole for the VK
cover.

Continues on next page


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4 Repair
4.4.5 Replacing the wrist unit, ID
Continued

Action
3

Note

Carefully fit the wrist (with motor axis 6 fitted)


to the upper arm tube, using the string to pull
the cable harness back through the hole for
the VK cover.

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

Reconnect connectors R4.FB6 and R4.MP6,


through the hole for the VK cover.

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.

Tighten the hexagon socket head screw


M5X16 (Short head).

Refit the VK cover.

Tightening the plug (A).


Tightening torque 6 Nm

Shown as (E) in figure Location of wrist


unit on page 189.
Tightening torque 6 Nm

xx0700000092

Refit the AW equipment in the upper arm.

Shown in Refitting the wrist unit on


page 192

Continues on next page


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4 Repair
4.4.5 Replacing the wrist unit, ID
Continued

Action

Note

10 Recalibrate the robot.

Calibration is described in a separate


calibration manual enclosed with the calibration tools.
General calibration information is included
in section Calibration information on
page 271.

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.

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4 Repair
4.4.6 Replacing the damper, axis 2

4.4.6 Replacing the damper, axis 2


Location of damper, axis 2
The damper, axis 2, is located as shown in the figure.

xx0400001217

Damper, axis 2

Attachment screw and washer

Required equipment
Equipment, etc.

Art. no.

Damper, axis 2

3HAC022013-001

Standard toolkit

Other tools and procedures


may be required. See references to these procedures in
the step-by-step instructions
below.

Note

Content is defined in section


Standard tools on page 293.
These procedures include
references to the tools required.

Continues on next page


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4 Repair
4.4.6 Replacing the damper, axis 2
Continued

Removing the damper


Use this procedure to remove the damper.
Action

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

Run the robot to a position where it is best


to enable access to the attachment screw of
the damper.

3
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
4

Remove the damper by unscrewing the attachment screw and washer.

Refitting the damper


Use this procedure to refit the damper.
Action
1

Note

Run the robot to a position where it is best


to enable access to the attachment screw of
the damper.

2
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
3

Secure the damper with the attachment screw 1 pc: M6 x 16.


and washer.

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.

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4 Repair
4.4.7 Replacing the damper, axis 3

4.4.7 Replacing the damper, axis 3


Location of damper, axis 3
The damper axis 3, is located as shown in the figure.
A more detailed view of the damper and its position may be found in the spare part
view, see Spare parts - Upper arm, exploded view.

xx0400001215

Damper, axis 3

Cast tab

Required equipment
Equipment, etc.

Art. no.

Damper, axis 3

3HAC022260-001

Note

Standard toolkit

Content is defined in section


Standard tools on page 293.

Removing the damper axis 3


Use this procedure to remove the damper.

Action

Note

Run the robot to a position where it is best


to enable access to the access 3 damper.

Shown in the figure Location of damper,


axis 3 on page 197.

Continues on next page


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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

Remove the damper by gently prying it from


the cast tab.

Refitting the damper axis 3


Use this procedure to refit the damper.

Action

Note

Run the robot to a position where it is best


to enable access to the location where the
axis 3 damper is fitted.

Shown in the figure Location of damper,


axis 3 on page 197.

2
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
3

Refit the damper by gently pressing it onto


the cast tab on the upper arm.

4
DANGER
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in the section DANGER - First
test run may cause injury or damage! on
page 47.

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4 Repair
4.4.8 Replacing the mechanical stop axis 3, ID variant

4.4.8 Replacing the mechanical stop axis 3, ID variant


Location of the mechanical stop axis 3
The mechanical stop axis 3 is located as shown in the figure.

A
B
xx0700000043

Torx counters. head screw

Mechanical damper

Required equipment
Equipment

Art. no.

Note

Mechanical stop

See Spare part lists on


page 297.

Standard tools

Content is defined in section


Standard tools on page 293.

Removing the mechanical stop axis 3


Use this procedure to remove the mechanical stop.
Action
1

Note

Run the robot to a position that enables access to the mechanical stop.

Continues on next page


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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

Remove the mechanical stop.

Refitting the mechanical stop axis 3


Use this procedure to refit the mechanical stop.
Action
1

Note

Refit the mechanical stop with its attachment


screws.

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.

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4 Repair
4.4.9 Replacement of damper, axis 5

4.4.9 Replacement of damper, axis 5


Location of damper, axis 5
The damper, axis 5, is located as shown in the figure below!

xx0600002806

Damper, axis 5

Recess

Required equipment
Equipment, etc.

Spare part no.

Damper, axis 5

3HAB 8964-1

Standard toolkit

Note

Content is defined in section Standard


tools on page 293.

Removal, damper axis 5


The procedure below details how to remove the damper, axis 5.
Action
1

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

Unhook the end of the damper, and push it into the


recess.

Manually move the wrist (robot axis 5) away from the


damper to pull it out.

Continues on next page


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4 Repair
4.4.9 Replacement of damper, axis 5
Continued

Refitting, damper axis 5


The procedure below details how to refit the damper, axis 5.
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

Push the end of the damper into the gap between the
wrist unit and upper arm.

Manually move the wrist (robot axis 5) in order to pull


the damper into position.

Fold out the damper hooks to secure it in position.

Make sure the damper is


turned the correct way!

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.

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4 Repair
4.4.10 Remove upper arm AW Gun

4.4.10 Remove upper arm AW Gun


Location of AW Gun
The location of the AW equipment.

xx0700000153

Wire feeder (customer option)

Weld gun (BINZEL)

Welding cable (BINZEL)

Brace (BINZEL)

Required equipment
Equipment

Art. no.

Note

Standard tools

Standard tools on page 293.

Continues on next page


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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

Remove the welding cable (C)


from the weld gun by twisting
the locking sleeve (A) counter
clockwise.
Loosen the locking screw (B)
and pull out the welding cable.

xx0700000151

A Locking sleeve
B Locking screw
C Welding cable
3

Remove the two screws holding


the brace.

xx0700000273

A BINZEL Brace

Continues on next page


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4 Repair
4.4.10 Remove upper arm AW Gun
Continued

Action
4

Note

Remove the welding cable from


the wire feeder and pull it out.

xx0700000142

A Wire feeder
B Welding cable
5

The locking ring (A) has a


thread, loosen it counter clockwise and remove it.
Remove the locking sleeve (B).
Remove all 6x M5 screw (C).

xx0700000150

A Locking ring
B Locking sleeve
C Screw M5

Continues on next page


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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

Refit the welding gun using the


6X Socket head cap screw M5
(C).
Refit the locking sleeve (B).
Lock the sleeve using the locking ring (A).

xx0700000150

A Locking ring
B Locking sleeve
C Screw M5

Continues on next page


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4 Repair
4.4.10 Remove upper arm AW Gun
Continued

Action
3

Note

Refit the welding cable (C).


Lock the cable using the screw
(B).

xx0700000151

A Locking sleeve
B Locking screw
C Welding cable
4

Refit the brace (A).

xx0700000273

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4 Repair
4.5.1 Replacement of base

4.5 Frame and base


4.5.1 Replacement of base
Location of base
The base is located at the bottom of the robot as shown in the figure below.
A more detailed view of the base may be found in the spare part view, see Spare
parts - Base, exploded view.

xx0500001453

Base

Attachment screws and washer, base-gearbox unit (VK-cover removed)

Required equipment
Equipment

Spare part no.

Base, spare

3HAC023552-001

V-ring (sealing ring)

3HAB3732-21

VK-cover

3HAA2166-26

Art. no.

Note

Replace if damaged.

Continues on next page


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4 Repair
4.5.1 Replacement of base
Continued

Equipment

Spare part no.

Lifting slings

Art. no.

Note

Locking liquid

Grease

Loctite 574
For sealing the base to the
gearbox 1-2.
3HAB3537-1

Isopropanol

For lubricating the V-ring.


For cleaning the mating
surfaces.

Standard toolkit

Content is defined in section Standard tools on


page 293.

Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.

These procedures include


references to the tools required.

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.

Remove the serial measurement unit.

Unfasten the base from the installation site by


removing the attachment bolts from the foundation.

Detailed in section Removing the


serial measurement unit on page 215.

Continues on next page


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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!

Remove the VK-cover from the base.


Tip! Push out the cover from inside or drill a
hole in the cover through which a tool can be
inserted in order to bend out the cover.

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

Separate the base from the gearbox unit.

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

Clean Room robots: clean the joints that have


been opened. See Replacing parts on Clean
Room robots on page 149

Place the robot with the side of the lower arm


downwards on a workbench.
Be careful not to damage the motor connectors.

Clean the mating surfaces between the base


and the gearbox unit with isopropanol.

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.

Lubricate the mating surface on the base with


Loctite 574.

Continues on next page


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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

Lift the base to mounting position.

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

Refit a new VK-cover to the base.

Spare part no. is specified in Required


equipment on page 208.

11
CAUTION
The robot weighs 250 kg.
All lifting accessories used must be sized accordingly!
12

Turn the robot to stand upright.

13

Secure the base to the foundation.

Attachment bolts and tightening


torque are specified in section Attachment bolts, specification on page 74.

14

Pull down the cabling and refit it inside the


base.

The cable layout inside the base is


shown in the figure Illustration, cabling
inside base on page 157.

15

Refit the serial measurement unit.

Detailed in section Refitting the serial


measurement unit on page 216.

16

Clean Room robots: seal and paint the joints


that have been opened. See Replacing parts
on Clean Room robots on page 149
Note
After all repair work, wipe the robot free from
particles with spirit on a lint free cloth.

17

Recalibrate the robot.

Calibration is detailed in a separate


calibration manual enclosed with the
calibration tools.
General calibration information is included in section Calibration information on page 271.

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.

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4 Repair
4.5.2 Replacing the serial measurement unit

4.5.2 Replacing the serial measurement unit


Location of serial measurement unit
The serial measurement unit is located inside the base of the robot, as shown in
the figure.
A more detailed view of the base may be found in the spare part view, see Spare
parts - Base, exploded view.

xx0500001390

Base cover, including gasket. Serial measurement unit is located beneath the
cover.

Continues on next page


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4 Repair
4.5.2 Replacing the serial measurement unit
Continued

Serial measurement unit layout


The complete spare part of the serial measurement unit is shown in the figure.
DSQC 633A

xx0500001391

Connector SMB

Connector SMB1-4

Connector SMB 3-6

Hexagon nuts (totally 4 pcs)

Hexagon nuts (totally 2 pcs). Only the outer nuts are used.

Battery pack (2-pole battery contact)

Continues on next page


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4 Repair
4.5.2 Replacing the serial measurement unit
Continued

RMU 101

D
E

xx1300000331

Connector SMB

Connector SMB1-4

Connector SMB 3-6

BU unit

Battery pack (3-pole battery contact)

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.

Serial measurement unit

See Spare part lists on


page 297.

Battery pack

See Spare part lists on


page 297.

Gasket, base cover

See Spare part lists on


page 297.

Note

Continues on next page


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4 Repair
4.5.2 Replacing the serial measurement unit
Continued

Equipment

Art. no.

Note

Centering piece

3HAC025815-001

Fitted to the push button unit


in order to align it correctly.
Replace if damaged.

Standard toolkit

Content is defined in section


Standard tools on page 293.

Circuit diagram

See chapter Circuit diagram


on page 299.

Removing the serial measurement unit


Use this procedure remove the serial measurement unit.
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

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

A Push button guard


3

Remove the centering piece from the push


button unit.

xx0600002776

Remove the base cover.

Disconnect all the connectors to the serial


measurement unit and push button units.

B: Centering piece

Shown in the figure Location of serial


measurement unit on page 212.

Continues on next page


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4 Repair
4.5.2 Replacing the serial measurement unit
Continued

Action

Note

Unscrew the hexagon nuts on the serial


Shown in the figure Serial measurement
measurement unit a little and slide the SMB unit layout on page 213.
unit out. Do not remove the nuts!

Lift and pull the serial measurement unit


backwards, over the lip (A), and lift it away.

xx0500001455

Refitting the serial measurement unit


Use this procedure refit the serial measurement unit.
Action
1

Note

Fit the serial measurement unit on to the four


pins.

xx0500001392

A Pins
2

Slide the unit into position, within the lips,


and secure with the four hexagon nuts.

Make sure the unit is positioned as


straight as possible! The push buttons
can otherwise get jammed.

Reconnect all the connectors.

Shown in the figure Serial measurement


unit layout on page 213.

Continues on next page


216

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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

Art. no. for the centering piece is specified


in Required equipment on page 214.
5

Refit the base cover.

Refit the push button guard to the robot base.

Shown in the figure Location of serial


measurement unit on page 212.

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.

Update the revolution counters!

Detailed in section Updating revolution


counters on page 277.

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4 Repair
4.5.3 Replacing the push button unit

4.5.3 Replacing the push button unit


Location of push button unit
The push button unit for brake release is located inside the base of the robot.
A more detailed view of the component and its location is shown in the spare part
view, see Spare parts - Base, exploded view..

xx0500001390

Base cover, including gasket. Push button unit is located beneath the cover.

Push button unit on serial measurement unit


The push button unit is attached to the serial measurement unit as shown in the
figure.

xx0500001394

Push button unit

Hexagon nuts (2 pcs)

Hexagon nuts, SMB unit (4 pcs). Only the outer ones are used.

Continues on next page


218

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4 Repair
4.5.3 Replacing the push button unit
Continued

Required equipment
Equipment

Art. no.

Note

Push button unit

See Spare part lists on


page 297.

Includes brake release board


and push buttons.

Gasket, base cover

3HAC 022047-001

Centering piece

3HAC025815-001

Fitted to the push button unit


in order to align it correctly.
Replace if damaged.

Standard toolkit

Content is defined in section


Standard tools on page 293.

Removing the push button unit


Use this procedure to remove the push button unit.
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

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

A Push button guard


3

Remove the centering piece from the push


button unit.

xx0600002776

Remove the base cover from the robot.

Disconnect all the connectors from the brake


release board.

B: Centering piece

Shown in the figure Location of push


button unit on page 218.

Continues on next page


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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.

Lift and pull the serial measurement unit


backwards, over the lip (A), and lift it away.

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.

Remove the push button unit by lifting it up.

Refitting the push button unit


Use this procedure to refit the push button unit.
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.
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 new push button unit to the serial


measurement unit in the robot base.

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

Continues on next page


220

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4 Repair
4.5.3 Replacing the push button unit
Continued

Action
6

Note

Refit the push button guard to the robot base.

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

Reconnect all the connectors to the board.

Check the gasket of the base cover. Replace Spare part no. is specified in Required
it if damaged.
equipment on page 219.

10 Refit the base cover.

Shown in the figure Location of push


button unit on page 218.

11 Update the revolution counters!

Detailed in section Updating revolution


counters on page 277.

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.

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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

Connector plate for motor cabling

Cover, frame

Attachment screws, motor (4 pcs)

Motor cover

Required equipment
Equipment

Art. no.

Note

Standard, Rot. ac motor incl.


pinion

For spare part number,


Cable harness, motor axes 1see:
2 must be ordered separately.
Spare part lists on
page 297

Continues on next page


222

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4 Repair
4.6.1 Replacement of motor, axis 1
Continued

Equipment

Art. no.

Note

Cable harness, motor axes 1-2

For spare part number,


see:
Spare part lists on
page 297

O-ring

21522012-428

Gasket, gearbox axis 1-2

For spare part number,


Replace if damaged.
see:
Spare part lists on
page 297

Power supply

24 VDC, max 1.5 A


For releasing the brakes.

Isopropanol

Used to clean mating surfaces.

Grease

3HAB 3537-1

Rotation tool, motor

3HAC022266-003

Standard toolkit

Content is defined in section


Standard tools on page 293.

Circuit diagram

See Circuit diagram on


page 299.

O-ring, motor.
Replace if damaged.

Removing the motor axis 1


Use this procedure to remove the motor, axis 1.
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.
Shown in the figure Location
of motor on page 222.

Remove the cover, frame.

Disconnect the connectors for the motor.

Loosen the connector plate from the frame.

Pull out the motor cabling carefully.

In order to release the brakes, connect the 24 VDC power Connect to connector
supply to the motor.
R3.MP1:
+: pin 7
-: pin 8

Unscrew the attachment screws securing the motor.

Remove the motor by gently lifting it straight up, making


sure the motor pinion is not damaged against the gear.

Shown in the figure Location


of motor on page 222.

Continues on next page


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4 Repair
4.6.1 Replacement of motor, axis 1
Continued

Action
9

Note

Disconnect the brake release voltage from the motor


connector.

Refitting the motor axis 1


Use this procedure to refit the motor, axis 1.
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
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

Clean the mating surfaces.

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.

Remove the motor cover from top of the motor.

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.

Fit the motor, making sure the motor pinion is


properly mated to the gear of gearbox, axis 1.
Use the rotation tool to rotate the motor pinion,
when mating it to the gear.

Secure the motor with four attachment screws and 4 pcs, M8 x 25.
washers, but do not tighten yet.

10

Adjust the motor in relation to the gear in the


There should be a barely noticable
gearbox:
gear play.
use the rotation tool to wiggle the motor
shaft back and forth to feel the play. Tap
with a plastic mallet.
position the motor pinion at at least two
other positions by turning axis 1 manually
and check the gear play again.

11

Tighten the motor attachment screws.

Shown in the figure Location of


motor on page 222.

Tightening torque: 35 Nm.

Continues on next page


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4 Repair
4.6.1 Replacement of motor, axis 1
Continued

Action

Note

12

Disconnect the brake release voltage.

13

Refit the motor cover to top of the motor.

14

Insert the motor cabling through the frame and


4 pcs.
secure the connector plate with attachment screws.

15

Connect all the connectors.

16

Refit the cover, frame. Replace the gasket, if


damaged.

17

Recalibrate the robot!

Shown in the figure Location of


motor on page 222.

The cable layout is shown in the


figure Illustration, cabling inside
frame on page 156.

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.

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.

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4 Repair
4.6.2 Replacement of motor, axis 2

4.6.2 Replacement of motor, axis 2


Location of motor axis 2
The motor axis 2 is located on the front of the robot 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.

xx0400001257

Motor, axis 2

Cover, frame

Connector plate for motor cabling

Bracket and cable tie

Motor cover

Required equipment
Equipment, etc.

Spare part no.

Art. no.

Rot. ac motor with


pinion

For spare part


number, see:
Spare
part lists
on
page 297

Cable harness, motor


axes 1-2

For spare part


number, see:
Spare
part lists
on
page 297

O-ring

21522012-428

Note

Must be replaced when replacing motor.

Continues on next page


226

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4 Repair
4.6.2 Replacement of motor, axis 2
Continued

Equipment, etc.

Spare part no.

Art. no.

Note

Gasket, gearbox axis


1-2

For spare part Replace if damaged.


number, see:
Spare
part lists
on
page 297

Grease

3HAB 3537-1

For lubricating the o-ring.

Isopropanol

For cleaning mating surfaces.

Standard toolkit

Content is defined in section


Standard tools on page 293.

Rotation tool, motor

3HAC022266003

For adjusting the gear play,


motor/pinion

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

These procedures include references to the tools required.

See chapter Circuit diagram on


page 299.

Removal, motor axis 2


The procedure below details how to remove the axis 2 motor.
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 cover, frame.

Shown in the figure Location


of motor axis 2 on page 226.

Disconnect the motor connectors inside the frame.

Connectors:
R3.MP2
R3.FB2

Cut any cable ties and remove any brackets or clamps


securing the cables.

Continues on next page


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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

In order to release the brakes, connect the 24 VDC


power supply to the motor.

Connect to connector R3.MP2


+: pin 7
-: pin 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

Remove the motor by gently pulling it out, making sure


the motor pinion does not get damaged while moving
it away from the gear.

12

Disconnect the brake release voltage.

13

Remove any remaining oil from the gearbox by siphoning it off.

Refitting, motor axis 2


The procedure below details how to refit the axis 2 motor.
Action

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

Clean Room robots: clean the joints that have


been opened. See Replacing parts on Clean
Room robots on page 149

Make sure the mating surfaces on the motor and


the gearbox are clean and free from burrs.
If necessary, clean the surfaces with isopropanol.

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.

Continues on next page


228

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4 Repair
4.6.2 Replacement of motor, axis 2
Continued

Action

Note

In order to release the brakes, connect the 24


VDC power supply to the motor.

Connect to connector R3.MP2:


+: pin 7
-: pin 8

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.

Fit the motor, making sure the motor pinion is


properly mated to gearbox 2.
Use the rotation tool to rotate the motor pinion,
when mating it to the gear.

Make sure the motor is turned the


right way, i.e. connections upwards.
Make sure the motor pinion does
not get damaged!

Secure the motor with four attachment screws


and plain washers, but do not tighten yet.

4 pcs, M8 x 25.
Tightening torque: approx 2 Nm.

10

Adjust the motor in relation to the gear in the


There should be a barely noticable
gearbox.
gear play.
Use the rotation tool to wiggle the motor shaft
back and forth to feel the play. Tap with a plastic
mallet.

11

Refit the motor cover to the top of the motor.


Be careful not to damage the cables!

12

Tighten the motor attachment screws.

13

Disconnect the brake release voltage.

14

Refit the connector plate with its attachment


screws.

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

Refit the cover, frame. Replace the gasket, if


damaged.

Shown in the figure Location of motor axis 2 on page 226.


Art. no. for the gasket is specified
in section Required equipment on
page 226.

18

Perform a leak-down test.

Detailed in section Performing a


leak-down test on page 144.

19

Refill the gearbox with oil.

Oil: Mobilgear 600 XP 32


Art.no: 11712016-604
Volume: 3400 ml

20

Clean Room robots: seal and paint the joints that


have been opened. See Replacing parts on Clean
Room robots on page 149

Tightening torque: 35 Nm.

Shown in the figure Location of motor axis 2 on page 226.

Note
After all repair work, wipe the robot free from
particles with spirit on a lint free cloth.

Continues on next page


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4 Repair
4.6.2 Replacement of motor, axis 2
Continued

21

Action

Note

Recalibrate the robot!

Calibration is detailed in a separate


calibration manual enclosed with the
calibration tools.
General calibration information is
included in section Calibration information on page 271.

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

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4 Repair
4.6.3 Replacement of motor, axis 3

4.6.3 Replacement of motor, axis 3


Location of motor
The motor of axis 3 is located inside the upper arm housing, as shown in the figure
below.
A more detailed view of the motor and its position may be found in the spare part
view, Spare parts - Upper arm, exploded view.

xx0400001258

Motor, axis 3

Attachment screws and washers of the motor (4 pcs)

Signal connector R3.FB3

Power connector R3.MP3

Connector holder

Upper arm housing cover

Cable tie

Required equipment
Equipment

Art. no.

Rot. ac motor incl pinion

For spare part number,


see:
Spare part lists on
page 297

O-ring

21522012-426

Note

Replace if damaged.

Continues on next page


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4 Repair
4.6.3 Replacement of motor, axis 3
Continued

Equipment

Art. no.

Note

Gasket, upper arm cover

3HAC022049-001

Replace if damaged.

Gasket, customer connections

3HAC022050-001

Replace if damaged.

Isopropanol

Used for cleaning the mating surfaces.

Grease

3HAB3537-1

Used for lubricating the o-ring.

Rotation tool, motor

3HAC022266-003

For adjusting the gear play.

Other tools and procedures


may be required. See references to these procedures
in the step-by-step instructions below.

These procedures include references to the tools required.

Circuit diagram

See chapter Circuit diagram on


page 299.

Removal, motor axis 3


The procedure below details how to remove the axis 3 motor.
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

Remove any additional mechanical stops from axis 3.

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

Shown in the figure Location


of motor on page 231.

Remove the upper arm housing cover.

Disconnect the motor connectors R3.MP3 and R3.FB3. Shown in the figure Location
of motor on page 231.

Continues on next page


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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

In order to release the brakes, connect the 24 VDC


power supply to the motor.

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.

Disconnect the brake release voltage.

Connect to connector R3.MP3:


+: pin 7
-: pin 8

Refitting, motor axis 3


The procedure below details how to refit the axis 3 motor.
Action

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

Clean the mating surfaces inside the upper arm


housing and on the motor with isopropanol.

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 motor to the upper arm housing, making


sure the motor pinion is properly mated to the gear
of axis 3.

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.

Adjust the motor in relation to the gear.


There should be a barely noticable
Use the rotation tool to wiggle the motor shaft back gear play.
and forth to feel the play.

Tighten the motor attachment screws.

10

Disconnect the brake release voltage.

Tightening torque: 10 Nm.

Continues on next page


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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

Refit the cover, upper arm housing. Check both


the gaskets and replace, if damaged.

Shown in the figure Location of


motor on page 231.
Art. no. is specified in section Required equipment on page 231.

13

Refit any additional mechanical stops.

Detailed in section Installation of


additional mechanical stops on
axis 3 on page 106.

14

Recalibrate the robot!

Calibration is detailed in a separate


calibration manual enclosed with
the calibration tools.
General calibration information is
included in section Calibration information on page 271.

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

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4 Repair
4.6.4 Replacement of motor, axis 3, IRB 1600ID

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

Attachment screws and washers of the motor (4 pcs)

Signal connector R3.FB3

Power connector R3.MP3

Connector holder

Required equipment
Equipment

Art.no.

Rot. ac motor incl pinion

For spare part number, see:


Spare part lists on
page 297.

O-ring

3HAB3772-100

Isopropanol

Note

Used for cleaning the


mating surfaces.

Grease

Continues on next page


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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

Removal, motor axis 3


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

In order to release the brakes, Connect to connector R3.MP3:


connect the 24 VDC power
+: pin 7
supply to the motor.
-: pin 8

Remove any additional mechanical stops from axis 3.

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

Continues on next page


236

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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

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.

B
C
A
E
D
xx0700000050

A
B
C
D
E
9

Hex socket head cap screw


O-ring
Motor axis 3
Resolver cover
O-ring

Remove the resolver cover for


refitting on the new motor.

10 Disconnect the brake release


voltage.

Continues on next page


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4 Repair
4.6.4 Replacement of motor, axis 3, IRB 1600ID
Continued

Refitting, motor axis 3


The procedure below details how to refit the axis 3 motor.
Action

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

Clean the mating surfaces inside the upper arm


housing and on the motor with Isopropanol.

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 new motor to the upper arm housing, making


sure the motor pinion is properly mated to the gear
of axis 3.

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.

Fit the rotation tool to the end of the motor shaft.

Adjust the motor in relation to the gear.


There should be a barely noticeUse the rotation tool to wiggle the motor shaft back able gear play.
and forth to feel the play.

Tighten the motor attachment screws.

Refit the resolver cover on the new motor.

Part number is specified in Required equipment on page 231.

Tightening torque: 10 Nm.

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.

Shown in the figure Location of


motor on page 235.
Art. no. is specified in section Required equipment on page 231.

12 Refit any additional mechanical stops.

Detailed in section Installation of


additional mechanical stops on
axis 3 on page 106.

13 Recalibrate the robot.

Calibration is detailed in a separate calibration manual, enclosed


with the calibration tools.
General calibration information is
included in section Calibration information on page 271.

Continues on next page


238

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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

4.6.5 Replacement of motor, axis 4


Location of motor
The axis 4 motor is located inside the upper arm housing, as shown in the figure
below.
A more detailed view of the component and its position may be found in the spare
part view, Spare parts - Upper arm, exploded view.

xx0400001273

Motor, axis 4

Cover, upper arm housing

Connector plate

Signal connector, R3.FB4

Power connector, R3.MP4

Attachment screw and washer, motor (4 pcs)

Required equipment
Equipment, etc.

Spare part no.

Art. no.

Note

Rot. ac motor with pinion For spare part


number, see:
Spare part
lists on
page 297

Continues on next page


240

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4 Repair
4.6.5 Replacement of motor, axis 4
Continued

Equipment, etc.

Spare part no.

O-ring

Art. no.

Note

3HAB3772-81

Replace if damaged.

Gasket, upper arm cover 3HAC022049-001

Replace if damaged.

Gasket, customer connections

Replace if damaged.

Grease

3HAC022050-001
3HAB3537-1

Standard toolkit

Used for lubricating the oring.


Content is defined in section
Standard tools on page 293.

Power supply

24 VDC, max. 1,5 A.


For releasing the brakes.

Rotation tool, motor

3HAC022266003

For adjusting the gear play.

Other tools and procedures may be required.


See references to these
procedures in the stepby-step instructions below.

These procedures include


references to the tools required.

Circuit Diagram

See chapter Circuit diagram


on page 299.

Removal, motor axis 4


The procedure below details how to remove the motor, axis 4.
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

Manually move the robot to a position where the


upper arm points straight down.

This will enable the motor 4 to be


removed without draining the oil
in the gearbox.

Remove the cover from the upper arm housing.

Remove the connector plate to get access to the Shown in the figure Location of
axis 4 motor.
motor on page 240.

Disconnect the connectors R3.MP4 and R3.FB4


from the axis 4 motor.

Continues on next page


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241
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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

Remove the motor by gently lifting it out.

Make sure the motor pinion is not


damaged!

Refitting, motor axis 4


The procedure below details how to refit the motor, axis 4.
Action

Note

Clean Room robots: clean the joints that have


been opened. See Replacing parts on Clean
Room robots on page 149

Clean the mating surfaces on the motor and


the gearbox.

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 .

In order to release the brakes, connect the 24 Connect to connector R3.MP4


VDC power supply to the motor.
+: pin 7
-: pin 8

Fit the motor with the attachment screws and


washers.
Until the motor shaft is adjusted to the gear, as
described in following steps, only tighten the
screws lightly.

Shown in the figure Location of motor


on page 240.
Tightening torque: approx. 2 Nm.
4 pcs, M6 x 20.

Fit the rotational tool to the end of the motor


shaft.

Art. no. is specified in section Required equipment on page 240.

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.

Tighten the motor attachment screws.

Reconnect the motor connectors R3.MP4 and


R3.FB4.

10

Refit the connector plate.

Shown in the figure Location of motor


on page 240.

11

Make sure all the cabling is placed correctly


inside the upper arm housing.

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.

Shown in the figure Location of motor


on page 240.

Shown in the figure Location of motor


on page 240.
Tightening torque: 10 Nm.

Continues on next page


242

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4 Repair
4.6.5 Replacement of motor, axis 4
Continued

Action

Note

13

Perform a leak-down test.

Detailed in section Performing a leakdown test on page 144.

14

Clean Room robots: seal and paint the joints


that have been opened. See Replacing parts
on Clean Room robots on page 149
Note
After all repair work, wipe the robot free from
particles with spirit on a lint free cloth.

15

Recalibrate the robot!

Calibration is detailed in a separate


calibration manual enclosed with the
calibration tools.
General calibration information is included in section Calibration information on page 271.

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
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4 Repair
4.6.6 Replacement of motor, axis 4, 1600ID

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

Cover, upper arm housing

Connector plate

Signal connector, R3.FB4

Power connector, R3.MP4

Attachment screw and washer, motor (4 pcs)

Continues on next page


244

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4 Repair
4.6.6 Replacement of motor, axis 4, 1600ID
Continued

Required equipment
Equipment, etc.

Art. no.

Rot. ac motor incl pinion

For spare part number, see:


Spare part
lists on
page 297

O-ring

3HAB3772-81

Standard toolkit
Power supply

Note

The contents are defined in section


Standard tools on page 293.
-

24 VDC, max. 1,5 A.


For releasing the brakes.

Rotation tool, motor

For adjusting the gear play.

Other tools and procedures may


be required. See references to
these procedures in the step-bystep instructions below.

These procedures include references to the tools required.

Circuit Diagram

See Circuit diagram on page 299.

Pendulum Calibration tool

See Special tools on page 294.

Removal, motor axis 4


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

Remove the cover from the upper arm housing.

Remove the connector plate to get access to the


axis 4 motor.

Disconnect the connectors R3.MP4 and R3.FB4


from the axis 4 motor.

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.

Remove the motor by gently lifting it out.

Make sure the motor pinion is not


damaged!

Action

Note

Clean the mating surfaces on the motor and the


gearbox.

Shown in the figure Location of


motor on page 244.

Shown in the figure Location of


motor on page 244.

Refitting, motor axis 4

Continues on next page


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245
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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.

Fit the motor with the attachment screws and


washers.
Until the motor shaft is adjusted to the gear, as described in following steps, only tighten the screws
lightly.

Shown in the figure Location of


motor on page 244.
Tightening torque: approx. 2 Nm.
4 pcs, M6 x 20.

Tighten the motor attachment screws.

Shown in the figure Location of


motor on page 244.
Tightening torque: 10 Nm.

Reconnect the motor connectors R3.MP4 and


R3.FB4.

Refit the connector plate.

Refit the cover to the upper arm housing.

Recalibrate the robot.

Shown in the figure Location of


motor on page 244.

General calibration information is


included in section Calibration information on page 271.

246

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4 Repair
4.6.7 Replacement of motor and timing belt, axis 5

4.6.7 Replacement of motor and timing belt, axis 5


Location of motor
The motor and timing belt of axis 5 is located inside the upper arm housing, as
shown in the figure below.
A more detailed view of the motor and its position may be found in the spare part
view, Spare parts - Upper arm, exploded view.

xx0400001279

Motor, axis 5

Cover, upper arm housing

Connector plate

Signal cable, motor 5: R3.FB5

Power cable, motor 5: R3.MP5

Attachment screws and washers, motor bracket (2 pcs)

Motor bracket

Attachment screws and washers, motor (3 pcs)

Required equipment
Equipment

Spare part no.

Art. no.

Note

Rot. ac motor incl pinion 3HAC021800-003


Timing belt

3HAC021304-001

Gasket, upper arm cover 3HAC022049-001

Replace if damaged.

Gasket, customer connec- 3HAC022050-001


tions

Replace if damaged.

Continues on next page


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247
Copyright 2006-2014 ABB. All rights reserved.

4 Repair
4.6.7 Replacement of motor and timing belt, axis 5
Continued

Equipment

Spare part no.

Art. no.

Note

Belt tightener

3HAC024044-001

Dynamometer

Capacity: 100N

Standard toolkit

Content is defined in
section Standard tools
on page 293.

Other tools and procedures may be required.


See references to these
procedures in the step-bystep instructions below.

These procedures include references to the


tools required.

Circuit diagram

See chapter Circuit


diagram on page 299.

Belt tightener, 3HAC 024044-001


The belt tightener is a special tool that is used when adjusting the tension of the
timing belt of axis 5. The length of the tool is important, since the tool is pulled with
a given force.

xx0500001457

Removal, motor axis 5 and timing belt


The procedure below details how to remove the motor and the timing belt of axis
5.
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

Remove the axis 4 motor.

Detailed in section Removal, motor


axis 4 on page 241.

Continues on next page


248

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4 Repair
4.6.7 Replacement of motor and timing belt, axis 5
Continued

Action

Note

Remove the motor and timing belt of axis 6.

Detailed in section Removal, motor


and timing belt, axis 6 on page 258.

Disconnect the axis 5 motor connectors: R3.MP5


and R3.FB5.

Move aside all cabling that is hindering access


to the axis 5 motor.

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.

Remove the timing belt of axis 5.

Remove the motor bracket from the motor.

Refitting, motor and timing belt axis 5


The procedure below details how to refit the motor and timing belt of axis 5.
Action

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

Clean the mating surfaces on the motor and in


the upper arm housing.

Fit the new motor to the motor bracket, previ- 3 pcs, M6 x 20.
ously removed from the old motor.

Continues on next page


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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

Refit the motor and timing belt of axis 6.

Detailed in section Refitting, motor and


timing belt, axis 6 on page 258.

Refit the motor of axis 4.

Detailed in section Refitting, motor


axis 4 on page 242.

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.

Refit the cover to the upper arm housing.


Check both the gaskets and replace, if damaged.

Art.no. is specified in Required equipment on page 247.

Recalibrate the robot!

Calibration is detailed in a separate


calibration manual enclosed with the
calibration tools.
General calibration information is included in section Calibration information on page 271.

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

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4 Repair
4.6.8 Replacement of motor, axis 5, IRB 1600ID

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

Hex socket head cap screw M8X20

Cable harness IRB1600ID

Rotational ac motor Axis 5

Hex. socket head cap screw M6X20

O-ring

Cable harness bracket

Required equipment
Equipment, etc.

Art. no.

Rot. ac motor with pinion

For spare part number, see:


Spare part lists on
page 297

VK cover

3HAA2166-19

Note

Continues on next page


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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

The contents are defined in


section Standard tools on
page 293, in part 2 of the
Product manual.

Other tools and procedures


may be required. See references to these procedures in
the step-by-step instructions
below.

These procedures include


references to the tools required.

Circuit Diagram

3HAC6816-3

See chapter Circuit diagram


on page 299.

O-ring

3HAB3772-81

Nitrite

Cable grease
Isopropanol

Removal, motor axis 5


The procedure below details how to remove motor, axis 5.
WARNING
Please observe the following before commencing any repair work on the
manipulator:

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

Whenever parting/mating motor and gearbox, the gears may be damaged if


excessive force is used.

Continues on next page


252

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4 Repair
4.6.8 Replacement of motor, axis 5, IRB 1600ID
Continued

Action
1

Note

Remove the cover (C) on the back


of the upper arm tube (A). Rotate
the upper arm to access all the
screws (D).
Remove the screws (B) holding the
cable harness.
CAUTION
After removal of the cover (mec
stop), do not rotate axis 4 do to risk
of cable harness damage.

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

Remove the AW equipment from


the upper arm.

Disconnect connectors R4.FB5 and


R4.MP5, from the backside.

Shown in section Remove AW Gun on page 204

xx0700000080

A R4.FB5
5

Remove the VK- Cover to access


the cable connections inside the
arm.

xx0700000054

A VK-Cover

Continues on next page


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4 Repair
4.6.8 Replacement of motor, axis 5, IRB 1600ID
Continued

Action

Note

Gently pull the cables out of the


upper arm.

Disconnect through the hole connection R4.FB6 and R4.MP6.

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

Secure the weight of the arm with


lifting slings.

xx0700000088

10 Remove the seven (7) Hexagon


socket head cap screw M8X20,
holding the upper arm.

Position (B) in figure Location of motor, axis 5 on


page 251.

Continues on next page


254

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4 Repair
4.6.8 Replacement of motor, axis 5, IRB 1600ID
Continued

Action

Note

11 Remove the upper arm.


A

12 Remove the V-ring (A) and the support ring (B).

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.

Refitting, motor axis 5


The procedure below details how to refit the motor of axis 5.
Action

Note

Clean the mating surfaces inside


the upper arm housing and on the
motor with Isopropanol.

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.

Fit the motor to the upper arm


housing, making sure the motor
pinion is properly mated to the gear
of axis 3.

Fit the attachment screws and


washers but do not tighten them
yet.

4 pcs, M6 x 20. Shown in the figure Location of


motor, axis 5 on page 251.

Fit the rotation tool to the end of


motor shaft.

Part number is specified in Required equipment


on 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.

Tighten the motors attachment


scews.

Refit the V-ring and support ring.

Tightening torque: 10Nm

Continues on next page


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4 Repair
4.6.8 Replacement of motor, axis 5, IRB 1600ID
Continued

Action
9

Note

Refit the cable harness bracket (G)


in figure Location of motor, axis 5
on page 251, inside the upper arm
tube, use the two torx pan head
screw M6X12 (B). Wind the cable
harness (A), in a spiral with four free
turns around the axis as in figure
Location of motor, axis 5 on
page 251 Grease the cable harness
with cable grease.

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.

Calibration is detailed in a separate calibration


manual, enclosed with the calibration tools.
General calibration information is included in
sections described in Calibration information on
page 271

256

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4 Repair
4.6.9 Replacement of motor and timing belt, axis 6

4.6.9 Replacement of motor and timing belt, axis 6


Location of motor
The motor and timing belt of axis 6 are located inside the upper arm housing, as
shown in the figure below.
A more detailed view of the motor and its position may be found in the spare part
view, Spare parts - Upper arm, exploded view.

xx0400001281

Motor, axis 6

Cover, upper arm housing

Connector plate

Signal cable, axis 6 motor: R3.FB6

Power cable, axis 6 motor: R3.MP6

Attachment screws and washers, motor (3 pcs)

Distance console with cable bracket and contact panel

Cable tie

Required equipment
Equipment

Spare part no.

Art. no.

Note

Rot. ac motor incl pinion 3HAC021800-003

Continues on next page


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257
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4 Repair
4.6.9 Replacement of motor and timing belt, axis 6
Continued

Equipment

Spare part no.

Timing belt

3HAC6779-1

Art. no.

Note

Gasket, upper arm cover 3HAC022049-001

Replace if damaged.

Gasket, customer connec- 3HAC022050-001


tions

Replace if damaged.

Hook

3HAC024045-001

Dynamometer

Capacity: 100N

Standard toolkit

Content is defined in
section Standard tools
on page 293.

Other tools and procedures may be required. See


references to these procedures in the step-bystep instructions below.

These procedures include references to the


tools required.

Circuit diagram

See chapter Circuit


diagram on page 299.

Removal, motor and timing belt, axis 6


The procedure below details how to remove the motor and timing belt of axis 6.
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

Remove the cover from the upper arm housing.

Remove the connector plate.

Shown in the figure Location


of motor on page 257.

Remove the complete distance console with cable


brackets and contact panel.

Shown in the figure Location


of motor on page 257.

Disconnect the motor cables for the axis 6 motor;


R3.MP6 and R3.FB6.

Remove the axis 6 motor by unscrewing its three attachment screws and washers.

Remove the timing belt.

Refitting, motor and timing belt, axis 6


The procedure below details how to refit the motor and timing belt of axis 6.
Action
1

Note

Clean the mating surfaces on the motor and


in the upper arm housing.

Continues on next page


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4 Repair
4.6.9 Replacement of motor and timing belt, axis 6
Continued

Action
2

Note

Follow the steps below when fitting the


motor:
Place the timing belt (B) round the
motor pinion and place the belt round
the axis 6 as fitting the motor in the
upper arm housing.
Secure the motor with its tree attachment screws and washers (C), but
do not tighten them yet.
Attach the hook round the motor
pinion (underneath the motor) and
adjust the belt tension with a force
of 80 N, using a dynamometer.
Shown in the figure to the right.
Tighten the motor attachment screws
with a torque of 10 Nm.

xx0400001282

A Motor, axis 6
B Timing belt, axis 6
C Attachment screws and washers,
motor, 3 pcs, M6 x 20
D Hook (motor pinion: 24.07 mm)
F (Force): 80 N.
3

Refit the complete distance console.

Shown in the figure Location of motor on


page 257.

Refit the connector plate. Refit the cable


tie.

Shown in the figure Location of motor on


page 257.

Reconnect the motor cables: R3.MP6 and


R3.FB6.

Place all the cabling correctly inside the


upper arm housing.

Cable layout is shown in the figure Illustration, cabling inside upper arm housing
on page 154.

Refit the cover to the upper arm housing.


Check both the gaskets and replace, if
damaged.

Art. no. is specified in Required equipment on page 257.

Recalibrate the robot!

Calibration is detailed in a separate calibration manual enclosed with the calibration tools.
General calibration information is included
in section Calibration information on
page 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.

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4 Repair
4.6.10 Replacement of motor, axis 6 IRB 1600ID

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

Hexagon socket head screw M5x25

Hexagon socket head screw M5x16 10.9 (Short head)

Hexagon socket head screw M5x25

Hexagon socket head screw M8x35

Required equipment
Equipment

Art. no.

Rot. ac motor incl pinion

For spare part number,


see:
Spare part lists on
page 297

Note

Continues on next page


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4 Repair
4.6.10 Replacement of motor, axis 6 IRB 1600ID
Continued

Equipment

Art. no.

Note

Standard toolkit

Standard tools on page 293

Other tools and procedures may


be required. See references to
these procedures in the step-bystep instructions below.
Circuit diagram

These procedures include


references to the tools required.
-

See Circuit diagram on


page 299.

Removal of motor axis 6


Action
1

Note

Move the upper arm to the sync. position.

2
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
3

Remove all extra equipment fitted on the upper arm See Remove AW Gun on page 204
and wrist.

Remove the wrist.

See Removing the wrist unit on


page 190

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

Put the wrist on a work bench or similar.

Remove the cable protection by removing the nuts


that holds it.

Open the flexible coupling of the axis-6 motor.

Remove the attachment screws that holds the console and the axis-6 motor.

Remove the motor.

Refitting of motor axis 6


Action

Note

Remove the old console from the removed axis-6


motor, and scrap it.

Remove the new console from the new spare part


wrist.

Fit the new console to the axis-6 motor.

Tightening torque: 6 Nm

Fit motor with the new console fitted to the new


wrist.

Use Loctite 243 on the attachment


screws.

Continues on next page


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4 Repair
4.6.10 Replacement of motor, axis 6 IRB 1600ID
Continued

Action

Note

Tighten the attachment screws just enough to still


be able to move motor and console.

Use caution and rotate the coupling manually.


This will help the coupling and motor shaft to be
aligned.

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.

Tighten the lock screw on the coupling.

10 Fit the cable protection cover.

Tightening torque: 6 Nm
Tightening torque: 6 Nm

11 Secure the cables to the attachment point with a


cable strap.
12 Refit the wrist.
13 Recalibrate the robot!

Calibration is detailed in a separate calibration manual enclosed


with the calibration tools.
General calibration information is
included in section Calibration information on page 271.

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.

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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

Gearbox unit, axes 1-2

Attachment screws and washer, base-gearbox unit (VK-cover is removed)

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4 Repair
4.7.1 Replacement of gearbox, axes 1-2
Continued

Required equipment
Equipment

Art. no.

Note

Gearbox, axis 1 and 2

For spare part num- Includes:


gearbox
ber, see:
Spare part lists
V-ring (sealing ring)
on page 297.
lubricating oil in vessel
stop arm

VK-cover

3HAA2166-26

Isopropanol

For cleaning the mating surfaces before


fitting.

Grease

3HAB3537-1

For lubricating the V-ring.

Locking liquid

Loctite 574

Lifting slings

Standard toolkit

Content is defined in section Standard


tools on page 293.

Other tools and procedures may be required. See


references to these procedures in the step-bystep instructions below.

These procedures include references to


the tools required.

Removal, gearbox unit axes 1-2


The procedure below details how to remove the complete gearbox unit, axes 1-2.
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

Continues on next page


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4 Repair
4.7.1 Replacement of gearbox, axes 1-2
Continued

Action
3

Note

Remove the oil plug and drain all


oil from gearbox axis 1 using a
drain pump.

xx0800000260

A Oil plug
B Drain pump
4

Remove the oil plug and drain all


oil from gearbox axis 2 using a
drain pump.

xx0800000261

A Oil plug
B Drain pump
5

Remove the motor, axis 2.

Detailed in section Replacement of motor, axis 2


on page 226.

Remove the motor, axis 1.

Detailed in section Removing the motor axis 1 on


page 223.

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.

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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

Fit the lifting slings to the


base/gearbox unit and place it with
the lower arm side downwards, on
top of a suitable workbench.

11

Remove the VK-cover from the


bottom of the robot base.
Tip! When the cabling is removed,
it may be easier to drill a hole
through the cover or to try and
push it out from the inside.

12

Secure the weight of the base with


lifting slings.

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

Separate the base from the gearbox unit.

Refitting, gearbox unit axes 1-2


The procedure below details how to refit the complete gearbox unit, axes 1-2.
Action

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.

Continues on next page


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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

Clean Room robots: clean the joints that


have been opened. See Replacing parts on
Clean Room robots on page 149

Place the gearbox unit with the lower arm


side downwards on a suitable workbench.

Clean the mating surfaces of the base and


of the gearbox unit with isopropanol.

Lubricate the V-ring with grease and fit it to Art. no. is specified in Required equipthe gearbox unit.
ment on page 264.

Fit a small amount of Loctite 574 on the


mating surface in the gearbox unit.

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

Fit the lifting slings to the base/gearbox unit,


turn it right side up and move it to the installation site.

13

Secure the base to the foundation.

Attachment bolts and the tightening


torque are specified in section Attachment
bolts, specification on page 74.

14

Refit the complete arm system.

Detailed in section Refitting, complete


arm system on page 168.

15

Refit the motors, axes 1 and 2.

Detailed in sections:
Refitting the motor axis 1 on
page 224
Refitting, motor axis 2 on page 228.

16

Perform a leak-down test.

Detailed in section Performing a leakdown test on page 144.

Continues on next page


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4 Repair
4.7.1 Replacement of gearbox, axes 1-2
Continued

Action

Note

17

Fill the two gearboxes with oil.

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

Clean Room robots: seal and paint the


joints that have been opened. See Replacing parts on Clean Room robots on
page 149
Note
After all repair work, wipe the robot free
from particles with spirit on a lint free cloth.

19

Recalibrate the robot.

Calibration is detailed in a separate calibration manual enclosed with the calibration tools.
General calibration information is included
in section Calibration information on
page 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.

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4 Repair
4.7.2 Service work on gearboxes, axes 3, 4, 5 and 6

4.7.2 Service work on gearboxes, axes 3, 4, 5 and 6


Gearboxes, replacement
The gearboxes of axes 3, 4, 5 and 6 are intended to run without requiring any
repairs or maintenance work. This implies that they must under no circumstances
be opened or serviced.
If the gearboxes require replacement:

axes 3 and 4: the complete upper arm is to be replaced. This procedure is


detailed in section Replacement of complete upper arm on page 170.

axes 5 and 6: the complete wrist unit is to be replaced. This procedure is


detailed in section Replacement of wrist unit on page 186.

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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 battery is discharged

A resolver error occurs

The signal between a resolver and measurement board is interrupted

A robot axis is moved with the control system disconnected

The revolution counters must also be updated after the robot and controller are
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.

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5 Calibration information
5.2 Calibration methods

5.2 Calibration methods


Overview
This section specifies the different types of calibration and the calibration methods
that are supplied by ABB.
Types of calibration
Type of
calibration

Description

Calibration method

Standard calibration The calibrated robot is positioned at home


Calibration Pendulum
position, that is when the positions of the axes (standard method)
(angles) are set to 0.
Standard calibration data is found on the SMB
(serial measurement board) in the robot.
For robots with RobotWare 5.04 or older, the
calibration data is delivered in a file, calib.cfg,
supplied with the robot at delivery. The file
identifies the correct resolver/motor position
corresponding to the robot home position.
Absolute accuracy Based on standard calibration, and besides CalibWare
calibration (option- positioning the robot at home position, the
al)
Absolute accuracy calibration also compensates for:
Mechanical tolerances in the robot
structure
Deflection due to load
Absolute accuracy calibration focuses on positioning accuracy in the Cartesian coordinate
system for the robot.
Absolute accuracy calibration data is found
on the SMB (serial measurement board) in the
robot.
For robots with RobotWare 5.05 or older, the
absolute accuracy calibration data is delivered
in a file, absacc.cfg, supplied with the robot at
delivery. The file replaces the calib.cfg file and
identifies motor positions as well as absolute
accuracy compensation parameters.
A robot calibrated with absolute accuracy has
a sticker next to the identification plate of the
robot.
To regain 100% absolute accuracy performance, the robot must be recalibrated for absolute accuracy!

xx0400001197

Continues on next page


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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

The calibration equipment for Calibration Pendulum is delivered as a complete


toolkit, including the Operating manual - Calibration Pendulum, which describes
the method and the different routines further.
CalibWare - Absolute Accuracy calibration
To achieve a good positioning in the Cartesian coordinate system, Absolute
Accuracy calibration is used as a TCP calibration. The CalibWare tool guides
through the calibration process and calculates new compensation parameters.
This is further detailed in the Application manual - CalibWare Field 5.0.
If a service operation is done to a robot with the option Absolute Accuracy, a new
absolute accuracy calibration is required in order to establish full performance.
For most cases after motor and transmission replacements that do not include
taking apart the robot structure, standard calibration is sufficient. Standard
calibration also supports wrist exchange.
References
Article numbers for the calibration tools are listed in the section Special tools on
page 294.
The calibration equipment for Calibration Pendulum is delivered as a complete
toolkit, including the Operating manual - Calibration Pendulum, which describes
the method and the different routines further.

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5 Calibration information
5.3 Calibration scale and correct axis position

5.3 Calibration scale and correct axis position


Introduction
This section specifies the calibration scale positions and/or correct axis positions.
Calibration marks, IRB 1600
The illustration below shows the calibration marks and correct positions of the six
axes of the robot. The marks shown in the figure are numbered according to the
number of the axes.

xx0600002876

Continues on next page


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5 Calibration information
5.3 Calibration scale and correct axis position
Continued

Calibration scales, IRB 1600ID


The illustration below shows the calibration marks and correct positions of the six
axes of the robot. The marks shown in the figure are numbered according to the
number of the axes.

xx0700000095

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5 Calibration information
5.4 Calibration movement directions for all axes

5.4 Calibration movement directions for all axes


Overview
When calibrating, the axis must consistently be run towards the calibration position
in the same direction in order to avoid position errors caused by backlash in gears
and so on. Positive directions are shown in the graphic below.
This is normally handled by the robot calibration software.
Calibration movement directions, 6 axes
Note! The graphic shows an IRB 7600. The positive direction is the same for all
6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in the
opposite direction!

xx0200000089

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5 Calibration information
5.5 Updating revolution counters

5.5 Updating revolution counters


Introduction
This section describes how to do a rough calibration of each manipulator axis,
which is updating the revolution counter value for each axis using the FlexPendant.
Step 1 - Manually running the manipulator to the calibration position
Use this procedure to manually run the manipulator to the calibration position.
Action

Note

Select axis-by-axis motion mode.

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.

Correct calibration position of axis 4 and 6


When running the manipulator to calibration position, it is extremely important to
make sure that axes 4 and 6 of the following mentioned manipulators are positioned
correctly. The axes can be calibrated at the wrong turn, resulting in an incorrectly
calibrated manipulator.
Make sure the axes are positioned according to the correct calibration values, not
only according to the calibration marks. The correct values are found on a label,
located either on the lower arm, underneath the flange plate on the base or on the
frame.
At delivery the manipulator is in the correct position, do NOT rotate axis 4 or 6 at
power up before the revolution counters are updated.
If one of the following mentioned axes are rotated one or more turns from its
calibration position before updating the revolution counter, the correct calibration
position will be lost due to uneven gear ratio. This affects the following manipulators:
Manipulator variant

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

On the ABB menu, tap Calibration.


All mechanical units connected to the system are shown with their calibration status.

Continues on next page


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5 Calibration information
5.5 Updating revolution counters
Continued

Action
2

Tap the mechanical unit in question.


A screen is displayed, tap Rev. Counters.

en0400000771

Tap Update Revolution Counters....


A dialog box is displayed warning that updating the revolution counters may change
programmed manipulator positions:
Tap Yes to update the revolution counters.
Tap No to cancel updating the revolution counters.
Tapping Yes displays the axis selection window.

Select the axis to have its revolution counter updated by:


Ticking in the box to the left
Tapping Select all to update all axes.
Then tap Update.

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.

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5 Calibration information
5.6 Checking the zero position

5.6 Checking the zero position


Introduction
Check the zero position of the robot before beginning any programming of the
robot system. This may be done:

Using a MoveAbsJ instruction with argument zero on all axes.

Using the Jogging window on the FlexPendant.

Using a MoveAbsJ instruction


Use this procedure to create a program that runs all the robot axes to their zero
position.
Action

Note

On ABB menu tap Program editor.

Create a new program.

Use MoveAbsJ in the Motion&Proc menu.

Create the following program:


MoveAbsJ [[0,0,0,0,0,0],
[9E9,9E9,9E9,9E9,9E9,9E9]]
\NoEOffs, v1000, fine, tool0

Run the program in manual mode.

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.

Using the jogging window


Use this procedure to jog the robot to the zero position of all axes.
Action

Note

On the ABB menu, tap Jogging.

Tap Motion mode to select group of axes


to jog.

Tap to select the axis to jog, axis 1, 2, or


3.

Manually run the robots axes to a position


where the axis position value read on the
FlexPendant, is equal to zero.

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.

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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

Batteries, NiCad or Lithium

Serial measurement board

Copper

Cables, motors

Cast iron/nodular iron

Base, lower arm

Steel

Gears, screws, base frame, and so on.

Neodymium

Brakes, motors

Plastic/rubber

Cables, connectors, drive belts, and so on.

Oil, grease

Gearboxes

Aluminium

Covers, synchronization brackets, upper arm

Oil and grease


Where possible, arrange for oil and grease to be recycled. Dispose of via an
authorized person/contractor in accordance with local regulations. Do not dispose
of oil and grease near lakes, ponds, ditches, down drains, or onto soil. Incineration
must be carried out under controlled conditions in accordance with local regulations.
Also note that:

Spills can form a film on water surfaces causing damage to organisms.


Oxygen transfer could also be impaired.

Spillage can penetrate the soil causing ground water contamination.

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6 Decommissioning
6.2 Scrapping of robot

6.2 Scrapping of robot


Important when scrapping the robot
DANGER
When a robot is disassembled while being scrapped, it is very important to
remember the following before disassembling starts, in order to prevent injuries:

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.

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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:

Upper arm, complete

Wrist unit

O-ring sealingplate

How to know which type the robot is?


The identification plate on the cabinet and the lower arm of the robot tells if the
robot has a new upper arm and wrist or not.
Those robots with a new upper arm and wrist are named IRB 1600, type A.
Those robots which are not equipped with a new upper arm and wrist are simply
named IRB 1600 (no type specified).
Which parts are interchangeable and which are not?
The following parts are interchangeable.

The upper arm, complete with spare part no. 3HAC026567-001 is


interchangeable with spare part no. 3HAC023630-001. Note! Software version
5.07.01 is needed!

The following parts are not interchangeable:

The wrist unit with spare part no. 3HAC026569-001 is not interchangeable
with spare part no. 3HAC10475-1.

The o-ring sealingplate with spare part no. 3HAC025420-001 is not


interchangeable with spare part no. 3HAC 7191-1.

Other changes in this product manual, compared to product manual IRB 1600, 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.

Some cable harnesses have been replaced.

For details, see Base, spare part list and Frame, spare part list, in Product manual,
spare parts - IRB 1600.

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7 Robot description
7.2 Type A of IRB 1600ID

7.2 Type A of IRB 1600ID


Type A - changes in the ISO data
IRB 1600ID robots delivered as from R 11.2/RW 5.14.02, have designation Type A
due to new basic tuning and a different MOC.cfg structure.
Upgrade from IRB 1600ID to IRB 1600ID type A
To upgrade an existing installation with the IRB 1600ID to the IRB 1600ID Type A
version, with improved performance, a new drive module key with Type A version
of the robot is needed. The new key then has to be used instead of the old by
modifying the existing system in System Builder in RobotStudio. Please contact
Robotics After Sales for more information and purchase of a new key.
After the upgrade the existing programs may require a touch-up of positions.
Further information
Technote 110912 includes more detailed information. Contact Robotics After Sales.

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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.

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8 Reference information
8.2 Applicable safety standards

8.2 Applicable safety standards


Standards, EN ISO
The manipulator system is designed in accordance with the requirements of:
Standard

Description

EN ISO 12100 -1

Safety of machinery - Basic concepts, general principles for


design - Part 1: Basic terminology, methodology

EN ISO 12100 -2

Safety of machinery - Basic concepts, general principles for


design - Part 2: Technical principles

EN ISO 13849-1

Safety of machinery, safety related parts of control systems Part 1: General principles for design

EN ISO 13850

Safety of machinery - Emergency stop - Principles for design

EN ISO 10218-1 i

Robots for industrial environments - Safety requirements -Part


1 Robot

EN ISO 9787

Manipulating industrial robots, coordinate systems, and motion


nomenclatures

EN ISO 9283

Manipulating industrial robots, performance criteria, and related


test methods

EN ISO 14644-1 ii

Classification of air cleanliness

EN ISO 13732-1

Ergonomics of the thermal environment - Part 1

EN IEC 61000-6-4 (option EMC, Generic emission


129-1)
EN IEC 61000-6-2

EMC, Generic immunity

EN IEC 60974-1 iii

Arc welding equipment - Part 1: Welding power sources

EN IEC 60974-10 iii

Arc welding equipment - Part 10: EMC requirements

EN IEC 60204-1

Safety of machinery - Electrical equipment of machines - Part


1 General requirements

IEC 60529

Degrees of protection provided by enclosures (IP code)

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

Safety of machinery - Ergonomic design principles - Part 1:


Terminology and general principles

EN 574

Safety of machinery - Two-hand control devices - Functional


aspects - Principles for design

EN 953

Safety of machinery - General requirements for the design and


construction of fixed and movable guards

Standard

Description

ANSI/RIA R15.06

Safety requirements for industrial robots and robot systems

Other standards

Continues on next page


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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

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8 Reference information
8.3 Unit conversion

8.3 Unit conversion


Converter table
Use the following table to convert units used in this manual.
Quantity

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

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8 Reference information
8.4 Screw joints

8.4 Screw joints


General
This section describes how to tighten the various types of screw joints on the IRB
1600.
The instructions and torque values are valid for screw joints comprised of metallic
materials and do not apply to soft or brittle materials.
UNBRAKO screws
UNBRAKO is a special type of screw recommended by ABB for certain screw joints.
It features special surface treatment (Gleitmo as described below) and is extremely
resistant to fatigue.
Whenever used, this is specified in the instructions, and in such cases, no other
type of replacement screw is allowed. Using other types of screws will void any
warranty and may potentially cause serious damage or injury.
Gleitmo treated screws
Gleitmo is a special surface treatment to reduce the friction when tightening the
screw joint. Screws treated with Gleitmo may be reused 3-4 times before the coating
disappears. After this the screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber
type should be used.
Screws lubricated in other ways
Screws lubricated with Molycote 1000 should only be used when specified in the
repair, maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1 Apply lubricant to the screw thread.
2 Apply lubricant between the plain washer and screw head.
3 Screw dimensions of M8 or larger must be tightened with a torque wrench.
Screw dimensions of M6 or smaller may be tightened without a torque wrench
if this is done by trained and qualified personnel.
Lubricant

Art. no.

Molycote 1000 (molybdenum disulphide grease)

11712016-618

Tightening torque
Before tightening any screw, note the following:

Determine whether a standard tightening torque or special torque is to be


applied. The standard torques are specified in the following tables. Any
special torques are specified in the repair, maintenance or installation
procedure descriptions. Any special torque specified overrides the standard
torque!

Use the correct tightening torque for each type of screw joint.

Only use correctly calibrated torque keys.


Continues on next page

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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.

Maximum allowed total deviation from the specified value is 10%!

Oil-lubricated screws with slotted or cross-recess head screws


The following table specifies the recommended standard tightening torque for
oil-lubricated screws with slotted or cross-recess head screws.
Dimension

Tightening torque (Nm)


Class 4.8, oil-lubricated

M2.5

0.25

M3

0.5

M4

1.2

M5

2.5

M6

5.0

Oil-lubricated screws with allen head screws


The following table specifies the recommended standard tightening torque for
oil-lubricated screws with allen head screws.
Dimension

Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm)


Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubricated
ated

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

Lubricated screws (Molycote, Gleitmo or equivalent) with allen head screws


The following table specifies the recommended standard tightening torque for
screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head
screws.
Dimension

Tightening torque (Nm)


Class 10.9, lubricated i

Tightening torque (Nm)


Class 12.9, lubricated i

M8

28

35

M10

55

70

M12

96

120

M16

235

280

M20

460

550

Continues on next page


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8 Reference information
8.4 Screw joints
Continued

Dimension

Tightening torque (Nm)


Class 10.9, lubricated i

Tightening torque (Nm)


Class 12.9, lubricated i

M24

790

950

Lubricated with Molycote 1000, Gleitmo 603 or equivalent

Water and air connectors


The following table specifies the recommended standard tightening torque for
water and air connectors when one or both connectors are made of brass.
Dimension

Tightening torque Nm - Tightening torque Nm - Tightening torque Nm Nominal


Min.
Max.

1/8

12

15

1/4

15

10

20

3/8

20

15

25

1/2

40

30

50

3/4

70

55

90

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8 Reference information
8.5 Weight specifications

8.5 Weight specifications


Definition
In installation, repair, and maintenance procedures, weights of the components
handled are sometimes specified. All components exceeding 22 kg (50 lbs) are
highlighted in this way.
To avoid injury, ABB recommends the use of a lifting accessory when handling
components with a weight exceeding 22 kg. A wide range of lifting accessories
and devices are available for each manipulator model.
Example
Following is an example of a weight specification in a procedure:
Action

Note
CAUTION

The robot weighs 250 kg.


All lifting accessories used must be sized accordingly!

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8 Reference information
8.6 Standard tools

8.6 Standard tools


General
All service (repairs, maintenance, and installation) procedures contains lists of
tools required to perform the specified activity.
All special tools required are listed directly in the procedures while all the tools
that are considered standard are gathered in the standard toolkit and defined in
the following table.
This way, the tools required are the sum of the standard toolkit and any tools listed
in the instruction.
Contents, standard toolkit
Qty

Tool

Ring-open-end spanner 8-19 mm

Socket head cap 2.5-17 mm

Torx socket no: 20-60

Torque wrench 10-100 Nm

Small screwdriver

Plastic mallet

Ratchet head for torque wrench 1/2"

Socket head cap no: 5, socket 1/2" bit L 20 mm

Socket head cap no: 6, socket 1/2" bit L 20 mm

Socket head cap no: 8, socket 1/2" bit L 20 mm

Small cutting plier

T-handle with ball head

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8 Reference information
8.7 Special tools

8.7 Special tools


General
All service instructions contain lists of tools required to perform the specified
activity. The required tools are a sum of standard tools, defined in the section
Standard tools on page 293, and of special tools, listed directly in the instructions
and also gathered in this section.
Special tools
The following table specifies all the tools, not considered standard, used when
performing service activities on the robot. The special tools are also listed directly
in the instructions.
Description

Art. no.

Note

Rotation tool, motor

3HAC022266-003

Used to adjust the gear play on all motors.

Dynamometer

Capacity: 100N

Hook

3HAC024045-001

Used to tighten the timing belt of axis 6,


together with the dynamometer.

Belt tightener

3HAC024044-001

Used to tighten the timing belt of axis 5,


together with the dynamometer.

Lifting tool, gearbox

3HAC023364-001

Lifting tool, upper arm

3HAC023386-001

Calibration equipment, Calibration Pendulum


The following table specifies the calibration equipment needed when calibrating
the robot with the Calibration Pendulum method.
Description

Art. no.

Calibration Pendulum toolkit 3HAC15716-1

Note
Complete kit that also includes operating
manual.

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8 Reference information
8.8 Lifting accessories and lifting instructions

8.8 Lifting accessories and lifting instructions


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

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9 Spare part lists


9.1 Spare part lists and illustrations

9 Spare part lists


9.1 Spare part lists and illustrations
Location
Spare parts and exploded views are not included in the manual but delivered as
a separate document on the documentation DVD.

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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

Article numbers for circuit diagrams

Circuit diagram - IRC5 (drive system 09)

3HAC024480-005

Circuit diagram - IRC5 (main computer


DSQC1000)

3HAC024480-011

Circuit diagram - IRC 5 Compact

3HAC031403-003

Circuit diagram - IRC5 Panel Mounted Con- 3HAC026871-006


troller
Circuit diagram - IRC5 Panel Mounted Con- 3HAC026871-020
troller (main computer DSQC1000)
Circuit diagram - Euromap

3HAC024120-004

Product

Article numbers for circuit diagrams

Circuit diagram - IRB 120

3HAC031408-003

Circuit diagram - IRB 1200

3HAC046307-003

Circuit diagram - IRB 140 type C

3HAC6816-3

Circuit diagram - IRB 260

3HAC025611-001

Circuit diagram - IRB 360

3HAC028647-009

Circuit diagram - IRB 460

3HAC036446-005

Circuit diagram - IRB 660

3HAC025691-001

Circuit diagram - IRB 760

3HAC025691-001

Circuit diagram - IRB 1410

3HAC2800-3

Circuit diagram - IRB 1600 type A

3HAC021351-003

Circuit diagram - IRB 1520

3HAC039498-007

Circuit diagram - IRB 2400

3HAC6670-3

Circuit diagram - IRB 2600

3HAC029570-007

Circuit diagram - IRB 4400/4450S

3HAC9821-1

Circuit diagram - IRB 4600

3HAC029038-003

Circuit diagram - IRB 6400RF

3HAC8935-1

Circuit diagram - IRB 6600 type A

3HAC13347-1
3HAC025744-001

Circuit diagram - IRB 6600 type B

3HAC13347-1
3HAC025744-001

Robots

Continues on next page


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10 Circuit diagram
10.1 About circuit diagrams
Continued

Product

Article numbers for circuit diagrams

Circuit diagram - IRB 6620

3HAC025090-001

Circuit diagram - IRB 6620 / IRB 6620LX

3HAC025090-001

Circuit diagram - IRB 6640

3HAC025744-001

Circuit diagram - IRB 6650S

3HAC13347-1
3HAC025744-001

Circuit diagram - IRB 6660

3HAC025744-001
3HAC029940-001

Circuit diagram - IRB 6700

3HAC043446-005

Circuit diagram - IRB 7600

3HAC13347-1
3HAC025744-001

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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

spare part number, 151


cabling, robot, 116
cabling between robot and controller, 116
calibrating
roughly, 277
calibration
Absolute Accuracy type, 272
rough, 277
standard type, 272
when to calibrate, 271
calibration, Absolute Accuracy, 273
calibration manuals, 273
calibration marks, 274
calibration position, 277
jogging to, 279
scales, 274
calibration scales, 274
CalibWare, 272
carbon dioxide extinguisher, 30
cast iron
disposal, 281
cleaning, 139
robot, interval, 123
complete arm system
replacing, 166
connecting the robot and controller, cabling, 116
connection
external safety devices, 19
connectors
air, 118
customer, 118
MIL-C-26482 series 1, 120
R2.CS and R2.CP
pins, customer connection, 118
Souriau, 119
copper
disposal, 281
cracks, damper, 127

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

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Index

environmental information, 281


equipment, robot, 80
ESD
damage elimination, 51
sensitive equipment, 51
wrist strap connection point, 51
extra equipment, 80

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

power supply to connector R1.MP, 72


inspection, 125
installation
equipment, 80
mechanical stop axis 2, 102
mechanical stops, axis 1, 97
mechanical stops axis 3, 106
position switch axis 1, 110
robot, attachment bolts, 74
signal lamp, 89
instructions for assembly, 57
intervals, maintenance, 123
inverted mounting, 76

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

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Index

brake release with power supply, 223


replacing, 222
spare part number, 222
tightening torque, 224
motor axis 2
brake release with power supply, 228
replacing, 226
spare part number, 226
tightening torque, 229
motor axis 3
brake release with power supply, 233
replacing, 231
screws, tightening torque, 233, 238
spare part number, 231
motor axis 4
brake release with power supply, 242
replace, 240
screws, tightening torque, 242, 246
spare part number, 240
motor axis 5
replacing, 247
screws, tightening torque, 250
spare part number, 247
motor axis 6
replacing, 257
screws, tightening torque, 259
spare part number, 257
mounting, equipment, 80
mounting holes for equipment, 84
MoveAbsJ instruction, 279

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

article number, 111


positive directions, axes, 276
protection classes, 61
protection standards, 286
protection type, 61
push button unit
releasing the brakes, 71
replacing, 218
spare part number, 219

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

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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

motor axis 2, 229


motor axis 3, 233, 238
motor axis 4, 242, 246
motor axis 5, 250
motor axis 6, 259
robot to foundation, attachment bolts, 74
upper arm, 173
wrist unit, 188
tilted mounting, 77
timing belt axis 5
adjusting the tension, 250
replacing, 247
spare part number, 247
timing belt axis 6
adjusting the tension, 259
replacing, 257
spare part number, 257
tools
belt tightener axis 5, article number, 247
belt tightener axis 5, measure, 248
Calibration Pendulum equipment, 294
dynamometer axis 5 and 6, 257
for service, 294
hook axis 6, article number, 257
rotational tool, article number, 240
torques on foundation, 59
turning
accessory, 70
turning radius, 66

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

ABB AS, Robotics


Discrete Automation and Motion
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 51489000

ABB Engineering (Shanghai) Ltd.


5 Lane 369, ChuangYe Road
KangQiao Town, PuDong District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666
www.abb.com/robotics

3HAC026660-001, Rev L, en

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