ABB IRB 1600 - 5/1,2 type A Product Manual
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ABB IRB 1600 - 5/1,2 type A Product Manual

Articulated robot
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Product manual
Articulated Robot
IRB 1600 - 5/1,2 type A
IRB 1600 - 5/1,45 type A
IRB 1600 - 6/1,2 type A
IRB 1600 - 6/1,45 type A
IRB 1600 - 7/1,2 type A
IRB 1600 - 7/1,45 type A
IRB 1600 - 8/1,2 type A
IRB 1600 - 8/1,45 type A
IRB 1600ID
M2004

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Summary of Contents for ABB IRB 1600 - 5/1,2 type A

  • Page 1 Product manual Articulated Robot IRB 1600 - 5/1,2 type A IRB 1600 - 5/1,45 type A IRB 1600 - 6/1,2 type A IRB 1600 - 6/1,45 type A IRB 1600 - 7/1,2 type A IRB 1600 - 7/1,45 type A...
  • Page 3 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 1600ID M2004...
  • Page 4 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.

  • Page 5: Table Of Contents

    Table of Contents Overview ................7 Product documentation, M2004 .
  • Page 6 Table of Contents 2.5 Electrical connections ............. . 79 2.5.1 Connectors on robot .
  • Page 7 Table of Contents 4.6 Motors ................177 4.6.1 Replacement of motor, axis 1 .
  • Page 8 Table of Contents 3HAC026660-001 Revision: C...

  • Page 9: Overview

    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:...
  • Page 10 Overview Continued References Documentation referred to in the manual, is listed in the table below. Document name Document Id Note Product specification - IRB 1600 3HAC023604-001 Product manual - IRC5 3HAC021313-001 Operating manual - IRC5 with Flexpendant 3HAC16590-1 Operating manual - Calibration pendulum 3HAC16578-1 Operating manual - Service Information System 3HAC025709-001...

  • Page 11: Product Documentation, M2004

    This means that any given delivery of robot products will not contain all documents listed, only the ones pertaining to the equipment delivered. However, all documents listed may be ordered from ABB. The documents listed are valid for M2004 robot systems.
  • Page 12 Product documentation, M2004 Continued Operating manuals This group of manuals is aimed at those having first hand operational contact with the robot, that is production cell operators, programmers and trouble shooters. The group of manuals includes: • Emergency safety information •...

  • Page 13: How To Read The Product Manual

    How to read the product manual How to read the product manual Reading the procedures The procedures contain references to figures, tools, material etc. The references are read as described below. References to figures The procedures often include references to components or attachment points located on the robot/controller.
  • Page 14 How to read the product manual 3HAC026660-001 Revision: C...

  • Page 15: Safety

    1 Safety 1.1. Introduction 1 Safety 1.1. Introduction Overview The safety information in this manual is divided in 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 section General safety information on page •...

  • Page 16: General Safety Information

    Limitation of liability Any information given in this manual regarding safety, must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. Related information...

  • Page 17: Safety Risks

    Nation/region specific regulations To prevent injuries and damage during the installation of the robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with. Non-voltage related risks •...
  • Page 18 1 Safety 1.2.2.1. Safety risks during installation and service work on robot Continued Complete robot Safety risk Description Hot components! CAUTION! Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! Removed parts may result in collapse of robot! WARNING! Take any necessary measures to ensure that the robot...

  • Page 19: Safety Risks Related To Tools/Workpieces

    1 Safety 1.2.2.2. Safety risks related to tools/workpieces 1.2.2.2. Safety risks related to tools/workpieces 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).

  • Page 20: Safety Risks Related To Pneumatic/Hydraulic Systems

    1 Safety 1.2.2.3. Safety risks related to pneumatic/hydraulic systems 1.2.2.3. Safety risks related to pneumatic/hydraulic systems General Special safety regulations apply to pneumatic and hydraulic systems. Residual energy • Residual energy may be present in these systems. After shutdown, particular care must be taken.

  • Page 21: Safety Risks During Operational Disturbances

    1 Safety 1.2.2.4. Safety risks during operational disturbances 1.2.2.4. Safety risks during operational disturbances General • The industrial robot is a flexible tool which can be used in many different industrial applications. • All work must be carried out professionally and in accordance with the applicable safety regulations.

  • Page 22: Risks Associated With Live Electric Parts

    1 Safety 1.2.2.5. Risks associated with live electric parts 1.2.2.5. Risks associated with live electric parts Voltage related risks, general • Although troubleshooting may, on occasion, have 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.

  • Page 23: Safety Actions

    1 Safety 1.2.3.1. Safety fence dimensions 1.2.3. Safety actions 1.2.3.1. Safety fence dimensions General Install a safety cell around the robot to ensure safe robot installation and operation. Dimensioning Dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed.

  • Page 24: Fire Extinguishing

    1 Safety 1.2.3.2. Fire extinguishing 1.2.3.2. Fire extinguishing NOTE! Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the robot system (robot or controller)! 3HAC026660-001 Revision: C...

  • Page 25: Emergency Release Of The Robot's Arm

    1 Safety 1.2.3.3. Emergency release of the robot’s arm 1.2.3.3. Emergency release of the robot’s arm Description In an emergency situation, any of the robot's axes may be released manually by pushing the brake release buttons on the robot. How to release the brakes is detailed in section: •...

  • Page 26: Brake Testing

    1 Safety 1.2.3.4. Brake testing 1.2.3.4. Brake testing When to test During operation the holding brake of each axis motor wear normally. A test may 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 detailed below: 1.

  • Page 27: Risk Of Disabling Function "Reduced Speed 250 Mm/S

    1 Safety 1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s" 1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s" NOTE! Do not change "Transm gear ratio" or other kinematic system parameters from the FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s". 3HAC026660-001 Revision: C...

  • Page 28: Safe Use Of The Flexpendant

    1 Safety 1.2.3.6. Safe use of the FlexPendant 1.2.3.6. Safe use of the FlexPendant NOTE! The enabling device is a push button located on the side of the FlexPendant which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device is released or pushed all the way in, the robot is taken to the MOTORS OFF state.

  • Page 29: Work Inside The Robot's Working Range

    1 Safety 1.2.3.7. Work inside the robot's working range 1.2.3.7. Work inside the robot's working range WARNING! If work must be carried out within the robot’s work envelope, 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 operative and to block operation from a computer link or remote control panel.

  • Page 30: Signal Lamp (Optional)

    1 Safety 1.2.3.8. Signal lamp (optional) 1.2.3.8. Signal lamp (optional) Description A signal lamp with an yellow fixed light can be mounted on the robot, as a safety device. Function The lamp is active in MOTORS ON mode. Further information Further information about the MOTORS ON/MOTORS OFF mode may be found in the controller documentation.

  • Page 31: Translate The Information On Safety And Information Labels

    Using a transparent sticker over the standard label with text added in a fourth language. Drawings detailing the design (text, figure, dimensions) of the standard labels can be ordered from ABB. Notice that each label is identified according to the article number located in the lower corner of the label.

  • Page 32: Safety Related Instructions

    1 Safety 1.3.1. Safety signals, general 1.3 Safety related instructions 1.3.1. Safety signals, general General This section specifies all dangers that may arise from performing the work detailed in the manual. Each danger is detailed in its own section consisting of: •...
  • Page 33 1 Safety 1.3.1. Safety signals, general Continued Symbol Designation Signification ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates DISCHARGE (ESD) electrostatic hazards which could result in severe damage to the product. Electrostatic discharge (ESD) NOTE Note symbols alert you to important facts and conditions.

  • Page 34: Danger - Moving Robots Are Potentially Lethal

    1 Safety 1.3.2. DANGER - Moving robots are potentially lethal! 1.3.2. DANGER - Moving robots are potentially lethal! Description Any moving robot is a potentially lethal machine. When running the robot, it may perform unexpected and sometimes irrational movements. However, 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 robot.

  • Page 35: Danger - First Test Run May Cause Injury Or Damage

    1 Safety 1.3.3. DANGER - First test run may cause injury or damage! 1.3.3. 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 (repair, installation or maintenance):...

  • Page 36: Warning - The Brake Release Buttons May Be Jammed After Service Work

    1 Safety 1.3.4. WARNING - The brake release buttons may be jammed after service work 1.3.4. WARNING - The brake release buttons may be jammed after service work Description The brake release unit has push buttons for 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.

  • Page 37: Warning - The Unit Is Sensitive To Esd

    1 Safety 1.3.5. WARNING - The unit is sensitive to ESD! 1.3.5. 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.

  • Page 38: Warning - Safety Risks During Work With Gearbox Oil

    1 Safety 1.3.6. WARNING - Safety risks during work with gearbox oil 1.3.6. WARNING - Safety risks during work with gearbox oil Description When handling the gearbox oil, there are several dangers to both personal injuries and product damages! Following safety information must be regarded before performing any work with the oil in the gearboxes! Warnings and elimination Warning...

  • Page 39: Installation And Commissioning

    2 Installation and commissioning 2.1. Introduction 2 Installation and commissioning 2.1. Introduction General This chapter contains information for installing the robot to the working site. More detailed technical data, such as load diagram, permitted extra loads (equipment) and location of extra loads (equipment), may be found in the Product Specification for the robot. 3HAC026660-001 Revision: C...

  • Page 40: Unpacking

    2 Installation and commissioning 2.2.1. Pre-installation procedure 2.2 Unpacking 2.2.1. Pre-installation procedure General This instruction is primarily 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 The check-list below details what must be observed before proceeding with the actual installation of the robot:...
  • Page 41 2 Installation and commissioning 2.2.1. Pre-installation procedure Continued Max. load Force Mounting Endurance load (emergency stop) Force Z Floor mounted - 2500 ± 1150 N - 2500 ± 2200 N Suspended + 2500 ± 1150 N + 2500 ± 2200 N Wall mounted ±...

  • Page 42: Working Range

    2 Installation and commissioning 2.2.2. Working range 2.2.2. Working range General This section specifies the working ranges for the different robot models. The turning radius is also shown separately in the last figure. Illustration, working range IRB 1600 - x/1.2 xx0400001260 Positions at wrist center (mm) Angle (degrees)
  • Page 43 2 Installation and commissioning 2.2.2. Working range Continued Illustration, working range IRB 1600 - x/1.45 xx0400001261 Positions at wrist center (mm) Angle (degrees) axis 2 axis 3 1186.5 0º 0º 1786.5 0º -90º 0º +65º 1450 486.5 +90º -90º -639 +150º...
  • Page 44 2 Installation and commissioning 2.2.2. Working range Continued Illustration, working range IRB 1600 ID xx0700000136 Positions at wrist center (mm) Angle (degrees) axis 2 axis 3 1296,5 1836 1499,5 486,5 720,5 -736,5 +150 397,5 499,5 +150 -238 57,5 716,5 -1199,5 486,5 Continues on next page 3HAC026660-001 Revision: C...
  • Page 45 2 Installation and commissioning 2.2.2. Working range Continued Working ranges Axis IRB 1600 - x/1.2 IRB 1600- x/1.45 Note Axis 1 +180º to -180º +180º to -180º Axis 1 working range has the following limitations: • ±45º when tilting the robot up to 30º.
  • Page 46 2 Installation and commissioning 2.2.2. Working range 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 Minimum turning radius axis 1 (all models) 3HAC026660-001 Revision: C...

  • Page 47: On-Site Installation

    2 Installation and commissioning 2.3.1. Lifting robot with roundsling 2.3 On-site installation 2.3.1. Lifting robot with roundsling Recommended lifting position The figure below shows the recommended lifting positions. It is important that the roundsling has free space and does not wear against any part of the robot. A - A xx0400001296 Required equipment...
  • Page 48 2 Installation and commissioning 2.3.1. Lifting robot with roundsling Continued Action Note CAUTION! The robot weighs 250 kg! All lifting equipment must be sized accordingly! WARNING! Personnel must not, under any circumstances, be present under the suspended load! 5. Raise the overhead crane to lift the robot. 3HAC026660-001 Revision: C...

  • Page 49: Manually Releasing The Brakes

    2 Installation and commissioning 2.3.2. Manually releasing the brakes 2.3.2. 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. •...
  • Page 50 2 Installation and commissioning 2.3.2. 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/Illustration Also, be careful not to interchange the...

  • Page 51: Orienting And Securing The Robot

    2 Installation and commissioning 2.3.3. Orienting and securing the robot 2.3.3. Orienting and securing the robot General This section details how to orient and secure the robot at a horizontal level at the installation site. Hole configuration, base The figure below shows the hole pattern and dimensions of the robot base. xx0400001300 Center of axis 1 Continues on next page...
  • Page 52 2 Installation and commissioning 2.3.3. Orienting and securing the robot Continued Dimension, mounting surface and guiding sleeve The figure below 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)
  • Page 53 2 Installation and commissioning 2.3.3. Orienting and securing the robot Continued Guiding sleeves, 2 pcs (needed if wall or angle mounted, or if the robot is calibrated with AbsAcc) Orienting and securing the robot to installation site Action Note 1. Make sure the installation site for the robot conforms to the specifications in section Pre- installation procedure on page...

  • Page 54: Suspended Mounting

    2 Installation and commissioning 2.3.4. Suspended mounting 2.3.4. Suspended mounting 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...
  • Page 55 2 Installation and commissioning 2.3.4. Suspended mounting Continued xx0600002779 Floor mounted Tilted mounting, mounting angle 30º Wall mounted, mounting angle 90º Suspended mounting, mounting angle 180º 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.
  • Page 56 2 Installation and commissioning 2.3.4. Suspended mounting Continued Defining the parameter 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 The parameter is further detailed in the Technical reference manual - System parameters.

  • Page 57: Loads

    Product Specification. The loads must also be defined in the software as detailed in Operating manual - IRC5 with FlexPendant. Brake performance Manipulator motor brake performance depends on any loads attached. For further information about brake performance, please contact ABB. 3HAC026660-001 Revision: C...

  • Page 58: Fitting Equipment On The Robot (Robot Dimensions)

    2 Installation and commissioning 2.3.6. Fitting equipment on the robot (robot dimensions) 2.3.6. Fitting equipment on the robot (robot dimensions) General This section shows the robot dimensions and available mounting holes on the robot. Main dimensions The figures below show the main dimensions of the robot. The remaining dimensions and mounting holes on the upper arm, frame and turning disk are shown in the following figures.
  • Page 59 2 Installation and commissioning 2.3.6. Fitting equipment on the robot (robot dimensions) Continued Main dimension 1600 ID The figure below shows the main dimensions for 1600 ID robot. xx0700000118 Centerline of axis 1 Smallest circumscribed radius, axis 1 Continues on next page 3HAC026660-001 Revision: C...
  • Page 60 2 Installation and commissioning 2.3.6. Fitting equipment on the robot (robot dimensions) Continued Mounting holes on the frame The three available mounting holes for equipment on the frame must be threaded according to the figure below. xx0400001252 Prepared for threading M8 x max depth 20 mm Continues on next page 3HAC026660-001 Revision: C...
  • Page 61 2 Installation and commissioning 2.3.6. Fitting equipment on the robot (robot dimensions) Continued Dimensions of the upper arm and mounting holes The figure below shows the dimensions of the upper arm and available mounting holes for equipment on the arm. xx0600002859 Centerline of axis 3 Centerline of axis 4...
  • Page 62 2 Installation and commissioning 2.3.6. Fitting equipment on the robot (robot dimensions) Continued Dimensions of the upper arm and mounting holes for 1600 ID The figure below shows the dimensions of the upper arm and available mounting holes for equipment on the arm. xx0700000119 Continues on next page 3HAC026660-001 Revision: C...
  • Page 63 2 Installation and commissioning 2.3.6. Fitting equipment on the robot (robot dimensions) Continued Dimensions of the turning disk The figure below shows the dimensions of the turning disk. xx0200000063 Dimensions of the turning disk 1600ID The figure below shows the dimensions of the turning disk on a IRB 1600ID xx0700000090 Fastener quality When fitting tools on the turning disk, use only screws with quality 12.9.

  • Page 64: Installation Of Signal Lamp For 1600 (Option)

    2 Installation and commissioning 2.3.7. Installation of signal lamp for 1600 (option) 2.3.7. 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.
  • Page 65 2 Installation and commissioning 2.3.7. Installation of signal lamp for 1600 (option) Continued Equipment Art. no. Note Gasket, customer connections 3HAC 022050-001 Replace if damaged. Gasket, upper arm cover 3HAC 022049-001 Replace if damaged. Installation, signal lamp The procedure below details how to install the signal lamp to the robot. Action Note/Illustration DANGER!

  • Page 66: Installation Of Signal Lamp For 1600 Id (Option)

    2 Installation and commissioning 2.3.8. Installation of signal lamp for 1600 ID (option) 2.3.8. Installation of signal lamp for 1600 ID (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.
  • Page 67 2 Installation and commissioning 2.3.8. Installation of signal lamp for 1600 ID (option) Continued Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove the cover from the upper arm housing. Shown in the figure Location of signal lamp on page 3.

  • Page 68: Restricting The Working Range

    2 Installation and commissioning 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: •...

  • Page 69: Installation Of Additional Mechanical Stops On Axis 1

    2 Installation and commissioning 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.
  • Page 70 2 Installation and commissioning 2.4.2. Installation of additional mechanical stops on axis 1 Continued 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...
  • Page 71 2 Installation and commissioning 2.4.2. Installation of additional mechanical stops on axis 1 Continued Installation of mechanical stop, axis 1 The procedure below details how to install the mechanical stop to axis 1. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.

  • Page 72: Installation Of Additional Mechanical Stop On Axis 2

    2 Installation and commissioning 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.
  • Page 73 2 Installation and commissioning 2.4.3. Installation of additional mechanical stop on axis 2 Continued 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)
  • Page 74 2 Installation and commissioning 2.4.3. Installation of additional mechanical stop on axis 2 Continued Action Note/Illustration 3. 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. xx0400001292 NOTE! It is important that the mechanical...

  • Page 75: Installation Of Additional Mechanical Stops On Axis 3

    2 Installation and commissioning 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.
  • Page 76 2 Installation and commissioning 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 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)
  • Page 77 2 Installation and commissioning 2.4.4. Installation of additional mechanical stops on axis 3 Continued Required equipment Equipment Art. no. Note Working range limit axis 3 3HAC023109-001 Includes mechanical stop, attachment screws and washers. Technical reference manual - Art. no. is specified in section System parameters (RobotWare 5.0) References on page Installation of mechanical stop, axis 3...

  • Page 78: Installation Of Position Switch, Axis 1

    2 Installation and commissioning 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...
  • Page 79 2 Installation and commissioning 2.4.5. Installation of position switch, axis 1 Continued Installation, position switch axis 1 The procedure below details how to install the position switch to the robot. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.
  • Page 80 2 Installation and commissioning 2.4.5. Installation of position switch, axis 1 Continued Action Note 9. Connect the position switch cabling. The cabling and connection points are specified in section Position switch cables, robot base to controller (option) on page 10. The software working range limitations The system parameters that must be must be re-defined to correspond to the changed in RobotWare 5.0 (Upper joint...

  • Page 81: Electrical Connections

    2 Installation and commissioning 2.5.1. Connectors on robot 2.5 Electrical connections 2.5.1. Connectors on robot Connectors on the robot The figure below shows all connections of the robot cabling, including the customer connectors. xx0400001262 Connection for air Connection for signal lamp Continues on next page 3HAC026660-001 Revision: C...
  • Page 82 2 Installation and commissioning 2.5.1. Connectors on robot Continued Connectors on the robot upper arm IRB 1600ID The figure below shows connections on the upper arm IRB 1600 ID 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 3HAC026660-001 Revision: C...

  • Page 83: Robot Cabling And Connection Points

    2 Installation and commissioning 2.5.2. Robot cabling and connection points 2.5.2. Robot cabling and connection points General 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...
  • Page 84 2 Installation and commissioning 2.5.2. Robot cabling and connection points Continued Cable (standard) Art. no. Robot cable, power, 30 m 3HAC2564-1 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...
  • Page 85 2 Installation and commissioning 2.5.2. Robot cabling and connection points Continued Customer cables (option) The customer cables specified below are connected between robot and controller. The customer cables are ordered according to current protection class of the robot. Customer cables for robots with standard protection Connection Cable (standard) Art.

  • Page 86: Customer Connections On The Robot

    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.
  • Page 87 2 Installation and commissioning 2.5.3. Customer connections on the robot Continued 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...
  • Page 88 2 Installation and commissioning 2.5.3. Customer connections on the robot Continued Connector for crimping Military standard MIL-C-26482 Turned pin 0.5 - 1.5 mm 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...

  • Page 89: Making Robot Ready For Operation (Cleanroom)

    2 Installation and commissioning 2.6.1. Additional installation procedure. 2.6 Making robot ready for operation (Cleanroom) 2.6.1. Additional installation procedure. General Cleanroom robots are specially designed to work in a cleanroom environment. Cleanroom robots are designed in order to prevent from particle emission from the robot. For example is maintenance work possible to perform without cracking the paint.
  • Page 90 2 Installation and commissioning 2.6.1. Additional installation procedure. 3HAC026660-001 Revision: C...

  • Page 91: Maintenance

    3 Maintenance 3.1. Introduction 3 Maintenance 3.1. Introduction Structure of this chapter This chapter details all maintenance activities recommended for the robot and any external units of the robot. It is based on the maintenance schedule, located in the beginning of the chapter. The schedule contains information about required maintenance activities including intervals and refers to procedures for the activities.

  • Page 92: Maintenance Schedule And Expected Component Life

    3 Maintenance 3.2.1. Specification of maintenance intervals 3.2 Maintenance schedule and expected component life 3.2.1. Specification of maintenance intervals Description The intervals may be specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the robot: •...

  • Page 93: Maintenance Schedule

    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. Non-predictable situations also give rise to inspections of the robot. Any damages must be attended to immediately! The inspection intervals do not specify the life of each component.

  • Page 94: Expected Component Life

    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 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...

  • Page 95: Inspection Activities

    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 xx0400001215 Damper, axis 3...
  • Page 96 3 Maintenance 3.3.1. Inspection, damper axes 2, 3 and 5 Continued xx0600002806 Damper, axis 5 Recess Required equipment Equipment Art. no. Note Standard toolkit The contents are defined in section Standard toolkit on page 237. Inspection, dampers The procedure below details how to inspect the dampers. Action Note DANGER!

  • Page 97: Replacement Activities

    3 Maintenance 3.4.1. Oil in gearboxes 3.4 Replacement activities 3.4.1. Oil in gearboxes Location of gearboxes xx0500001427 Gearbox, axis 1 Gearbox, axis 2 Gearbox, axis 3 Gearbox, axis 4 Gearboxes, axes 5 and 6 IRB1600 Type and amount of oil in gearboxes 1600 Gearbox Type of oil Art.
  • Page 98 3 Maintenance 3.4.1. Oil in gearboxes Continued Type and amount of oil in gearboxes 1600ID xx0700000285 Gearbox Type of oil Art. no. Amount Axis 3, IRB1600ID Mobilgear 600 XP 320 11712016-604 500 ml Axis 4, IRB1600ID Mobilgear 600 XP 320 11712016-604 350 ml Axis 5...

  • Page 99: Oil Change, Gearbox Axes 5 And 6

    3 Maintenance 3.4.2. Oil change, gearbox axes 5 and 6 3.4.2. Oil change, gearbox axes 5 and 6 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...
  • Page 100 3 Maintenance 3.4.2. Oil change, gearbox axes 5 and 6 Continued Draining, wrist unit The procedure below details how to drain oil from the gearboxes in the wrist unit. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! WARNING! Handling gearbox oil involves several safety risks.
  • Page 101 3 Maintenance 3.4.2. Oil change, gearbox axes 5 and 6 Continued Filling oil, wrist unit The procedure below details how to fill oil in the gearboxes in the wrist unit. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! WARNING! Handling gearbox oil involves several safety...

  • Page 102: Oil Change, Gearbox Axes 5- 6, Irb 1600Id

    3 Maintenance 3.4.3. Oil change, gearbox axes 5- 6, IRB 1600ID 3.4.3. Oil change, gearbox axes 5- 6, IRB 1600ID Location of oil plugs The oil plug for axes 5 are located in the wrist unit as shown in the figure below. xx0700000030 Oil plug, draining and filling Oil plug, draining ventilation plug.
  • Page 103 3 Maintenance 3.4.3. Oil change, gearbox axes 5- 6, IRB 1600ID Continued Action Note/Illustration WARNING! Handling gearbox oil involves several safety risks. Before proceeding, please observe the safety information in section WARNING - Safety risks during work with gearbox oil on page 3.
  • Page 104 3 Maintenance 3.4.3. Oil change, gearbox axes 5- 6, IRB 1600ID Continued Filling oil, wrist unit The procedure below details how to fill oil in the gearboxes in the wrist unit. Action Note/Illustration 1. Position the robot as shown in the figure to Vessel capacity is specified in section the right: Required equipment on page...

  • Page 105: Replacement Of Measurement System Battery Pack

    3 Maintenance 3.4.4. Replacement of measurement system battery pack 3.4.4. Replacement of measurement system battery pack 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.
  • Page 106 3 Maintenance 3.4.4. Replacement of measurement system battery pack Continued Required equipment Equipment Spare part no. Note Battery pack 3HAC 16831-1 Gasket, base cover 3HAC 022047-001 Replace if damaged. Standard toolkit The contents are defined in section Standard toolkit on page 237.

  • Page 107: Cleaning Activities

    3 Maintenance 3.5.1. Cleaning, complete robot 3.5 Cleaning activities 3.5.1. Cleaning, complete robot General The protection class of Foundry and Wash versions is IP 67, i.e. the robot is watertight. Required equipment Equipment, etc. Art. no. Note May be used on version •...
  • Page 108 3 Maintenance 3.5.1. Cleaning, complete robot 3HAC026660-001 Revision: C...

  • Page 109: Repair

    4 Repair 4.1. Introduction 4 Repair 4.1. Introduction Structure of this chapter This chapter details all repair activities recommended for the robot and any external units of the robot. It is made up of separate procedures, each detailing a specific repair activity. Each procedure contains all information required to perform the activity, for example spare parts numbers, required special tools and materials.

  • Page 110: General Procedures

    4 Repair 4.2.1. Performing a leak-down test 4.2 General procedures 4.2.1. Performing a leak-down test General After refitting any motor and any 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.

  • Page 111: Mounting Instructions For Bearings

    4 Repair 4.2.2. Mounting instructions for bearings 4.2.2. Mounting instructions for bearings General This section details 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.

  • Page 112: Mounting Instructions For Seals

    4 Repair 4.2.3. Mounting instructions for seals 4.2.3. Mounting instructions for seals General This sections details how to mount different types of seals to the robot. Equipment Equipment, etc. Art. no. Note Grease 3HAB3537-1 Used to lubricate the seals. Rotating seals The procedure below details how to fit rotating seals.
  • Page 113 If the flange surfaces are defective, the parts may not be used because leakage could occur. 2. Clean the surfaces properly and in accordance with ABB recommendations. 3. Distribute the sealing compound evenly over the surface, preferably with a brush.

  • Page 114: Complete Manipulator

    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.
  • Page 115 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)
  • Page 116 4 Repair 4.3.1. Replacement of cable harness Continued Action Note/Illustration 2. Remove all the covers: All the covers are shown in the figure Illustration, covers to remove • Remove the covers of the upper arm on page 113. housing, frame and base. •...
  • Page 117 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;...
  • Page 118 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 115.
  • Page 119 4 Repair 4.3.1. Replacement of cable harness Continued Action Note/Illustration 12. Continue refitting the cable harness according to procedure Refitting, cable harness in frame and base on page 119. Illustration, cabling inside frame The figure below shows how the cabling is run inside the frame. xx0400001249 Power cabling;...
  • Page 120 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...
  • Page 121 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 117 Illustration, cabling inside base on page 118.
  • Page 122 4 Repair 4.3.1. Replacement of cable harness Continued Action Note 11. Connect the: Shown in the figure Illustration, cabling inside base on page 118. • signal cable connectors to the SMB unit • power cable connector to the housing in the base •...

  • Page 123: Replacement Of Cable Harness, Irb 1600Id

    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...
  • Page 124 4 Repair 4.3.2. Replacement of cable harness, IRB 1600ID Continued Equipment Spare part no. Note Cable ties VK- cover 3HAA 2166-23 Upper and lower covers. 2 pcs Cable harness axis 5-6. 3HAC027523-002 IRB 1600 AW Removal, cable harness lower arm and upper arm back The procedure below describes removal of the complete cable harness in upper arm back.
  • Page 125 4 Repair 4.3.2. Replacement of cable harness, IRB 1600ID Continued Action Note 3. Remove the hexagon nut with flange (A) holding the two (2) clamps. xx0700000106 A. Hexagon nut with flange 4. Disconnect R3.FB3 - R3.FB6. 5. Disconnect R3.MP3 - R3.MP6. 6.
  • Page 126 4 Repair 4.3.2. Replacement of cable harness, IRB 1600ID Continued R4.MP6 R4.MP5 R3.MP5 R3.MP6 R3.FB5 R3.FB6 Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove the upper arm tube. Described in section Replacement of motor, axis 5, 1600ID.
  • Page 127 4 Repair 4.3.2. Replacement of cable harness, IRB 1600ID Continued Action Note 5. Remove the cable pulling it out through the passage (A). xx0700000114 Refitting, cable harness The procedure below describes refitting of the complete cable harness. Action Note 1. Refit the cable harness. Described in section Refitting, cable harness in upper arm housing and lower arm on page 116...

  • Page 128: Replacement Of Complete Arm System

    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 arm. xx0500001443 VK-cover (attachment screws underneath cover) Cover, frame Cover, base Required equipment Equipment Art.
  • Page 129 4 Repair 4.3.3. Replacement of complete arm system Continued Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 3. Remove the covers from the base and the frame. 4. 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:...
  • Page 130 4 Repair 4.3.3. Replacement of complete arm system Continued Action Note/Illustration 3. Fit the sealing ring properly to the frame. Replace it Art. no. is specified in Required if damaged. equipment on page 126. xx0400001245 • A: Sealing ring • B: Mating surface 4.

  • Page 131: Upper And Lower Arm

    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.
  • Page 132 4 Repair 4.4.1. Replacement of complete upper arm Continued Equipment Spare part no. Art. no. Note Gasket, customer 3HAC 022050-001 Replace if damaged. connections Grease 3HAB 3537-1 To lubricate the sealing ring (V-ring). Locking liquid Loctite 574 Lifting slings Standard toolkit The contents are defined in section Standard toolkit on...
  • Page 133 4 Repair 4.4.1. Replacement of complete upper arm Continued Action Note/Illustration 8. Remove the 10 attachment screws (A) and the single washer (B). xx0400001219 9. 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.
  • Page 134 4 Repair 4.4.1. Replacement of complete upper arm Continued Action Note/Illustration 7. 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 8.

  • Page 135: Replacement Of Complete Upper Arm, Irb 1600Id

    4 Repair 4.4.2. Replacement of complete upper arm, IRB 1600ID 4.4.2. Replacement of complete upper arm, IRB 1600ID NOTE! Recalibration of robot axis 3-6 is required after replacement of upper arm. Location of upper arm The complete upper arm is considered a spare part, including wrist, gearboxes and motors. The figure below shows the location of the upper arm and connection to the lower arm.
  • Page 136 4 Repair 4.4.2. Replacement of complete upper arm, IRB 1600ID Continued Equipment Spare part no. Art. no. Note Standard tool kit Contents, standard toolkit VK-cover 3HAA 2166-23 V-ring axis 3 3HAB3732-19 Gasket, customer 3HAC 022050-001 Replace if connections damaged Pendulum calibration tool Remove, complete upper arm The procedure below details how to remove the complete upper arm from the robot.
  • Page 137 4 Repair 4.4.2. Replacement of complete upper arm, IRB 1600ID Continued Action Note 3. Remove the cover arm housing from the upper arm, using standard tools. xx0700000077 A. Cover Arm Housing B. Torx pan head screw 4. Disconnect all connectors inside Described in section Removal, cable harness the arm housing and loosen the...
  • Page 138 4 Repair 4.4.2. Replacement of complete upper arm, IRB 1600ID Continued Action Note 7. Knock out the VK-cover from the motor side. 8. Remove the 10 attachment screws (A) and the single washer, use standard tools. xx0700000057 A. Socket head cap screw M10x40 9.
  • Page 139 4 Repair 4.4.2. Replacement of complete upper arm, IRB 1600ID Continued Action Note 4. Carefully refitting the upper arm to the lower arm, make sure that the new upper arm is mounted in the synchronization position. xx0700000075 A. Synchronization mark Axis 3 5.
  • Page 140 4 Repair 4.4.2. Replacement of complete upper arm, IRB 1600ID Continued Action Note 8. Refit the cover arm housing to the upper arm, using standard tools Contents, standard toolkit. xx0700000077 A. Cover Arm Housing B. Torx pan head screw 9. Refit a new VK-cover to the lower Spare part no.

  • Page 141: Replacement Of Complete Lower Arm

    4 Repair 4.4.3. Replacement of complete lower arm 4.4.3. Replacement of complete lower arm Location of lower arm The lower arm is located on the robot as shown in the figure below. A more detailed view of the lower arm may be found in the spare part view Lower arm, exploded view on page 249 in part 2 of the Product manual.
  • Page 142 4 Repair 4.4.3. Replacement of complete lower arm Continued Equipment Spare part no. Note Sealing ring (V-ring) 3HAB 3732-13 Replace if damaged. Isopropanol Used to clean the mating surfaces. Locking liquid Loctite 574 Standard toolkit The contents are defined in section Standard toolkit in the Product...
  • Page 143 4 Repair 4.4.3. Replacement of complete lower arm Continued Action Note/Illustration 9. Check the sealing ring. Replace it if damaged. Spare part no. is specified in Required equipment on page 139. Refitting, lower arm The procedure below details how to refit the complete lower arm. Action Note/Illustration 1.
  • Page 144 4 Repair 4.4.3. Replacement of complete lower arm Continued Action Note/Illustration 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. DANGER! Make sure all safety requirements are met when performing the first test run.

  • Page 145: Replacement Of Wrist Unit

    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 .Upper arm, exploded view 1 on page 251 in part 2 of the Product manual.
  • Page 146 4 Repair 4.4.4. Replacement of wrist unit Continued Equipment, etc. Spare part no. Art. no. Note Other tools and These procedures include procedures may be references to the tools required. required. See references to these procedures in the step-by-step instruc- tions below.
  • Page 147 4 Repair 4.4.4. Replacement of wrist unit Continued Action Note 8. 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. DANGER! Make sure all safety requirements are met when performing the first test run.

  • Page 148: Replacement Of Wrist Unit, Irb1600Id

    4 Repair 4.4.5. Replacement of wrist unit, IRB1600ID 4.4.5. Replacement of wrist unit, IRB1600ID 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. xx0700000025 Upper arm Wrist...
  • Page 149 4 Repair 4.4.5. Replacement of wrist unit, IRB1600ID Continued Equipment Spare part no. Art. No. Note 3HAC9037-1 For adjusting the gear play, motor/ pinion. Other tools and procedures See references to may be required. these procedures in the step-by-step instructions below. Loctite 542 12690014-412 Removal, wrist unit...
  • Page 150 4 Repair 4.4.5. Replacement of wrist unit, IRB1600ID Continued Action Note 4. Remove the VK-Cover (A). xx0700000054 A. VK-Cover 5. Gently pull the cables out of the upper arm VK- cover hole. 6. Disconnect through the VK-hole the cable harness contacts, R4.FB6 and R4.MP6.
  • Page 151 4 Repair 4.4.5. Replacement of wrist unit, IRB1600ID Continued Action Note 9. Remove the three screws, hexagon socket head screw M5x25 (E). Remove the axis 6 motor (C). xx0700000091 A. Contact R4.FB6 B. Contact R4.MP6 C. Motor axis 6 D. Hexagon socket head screw M8x35 E.
  • Page 152 4 Repair 4.4.5. Replacement of wrist unit, IRB1600ID Continued Action Note 3. Carefully refit the wrist with motor to the upper arm tube. Use a string to pull the cable harness back through the VK- hole in the upper arm tube. xx0700000093 A.

  • Page 153: Replacement Of Damper, Axis 2

    4 Repair 4.4.6. Replacement of damper, axis 2 4.4.6. Replacement of damper, axis 2 Location of damper, axis 2 The damper, axis 2, is located as shown in the figure below. xx0400001217 Damper, axis 2 Attachment screw and washer Required equipment Equipment, etc.
  • Page 154 4 Repair 4.4.6. Replacement of damper, axis 2 Continued Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 3. Remove the damper by unscrewing the single attachment screw and washer. Refitting, damper axis 2 The procedure below details how to refit the damper, axis 2.

  • Page 155: Replacement Of Damper, Axis 3

    4 Repair 4.4.7. Replacement of damper, axis 3 4.4.7. Replacement of damper, axis 3 Location of damper, axis 3 The damper, axis 3, is shown in the figure below. A more detailed view of the damper and its position may be found in the spare part view Upper arm, exploded view 2 on page 252 in part 2 of the Product manual.
  • Page 156 4 Repair 4.4.7. Replacement of damper, axis 3 Continued Action Note 3. Remove the damper by gently prying it from the cast tab. Refitting, damper axis 3 The procedure below details how to refit the damper, axis 3. Action Note 1.

  • Page 157: Replacement Of Mechanical Damper, Axis 3, Irb 1600Id

    4 Repair 4.4.8. Replacement of Mechanical damper, axis 3, IRB 1600ID 4.4.8. Replacement of Mechanical damper, axis 3, IRB 1600ID Location of damper, axis 3 The location of damper, axis 3. xx0700000043 Torx counters. head screw Mechanical damper Required equipment Equipment Spare part no.
  • Page 158 4 Repair 4.4.8. Replacement of Mechanical damper, axis 3, IRB 1600ID Continued Action Note 3. Remove the damper. Use standard tools, Contents, standard toolkit. Refitting, Mechanical damper axis 3 The procedure below details how to refit the damper, axis 3. Action Note 1.

  • Page 159: Replacement Of Damper, Axis 5

    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.
  • Page 160 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 DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.

  • Page 161: Remove Upper Arm Aw Gun

    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 Spare part no.
  • Page 162 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 DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.
  • Page 163 4 Repair 4.4.10. Remove upper arm AW Gun Continued Action Note 4. 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.
  • Page 164 4 Repair 4.4.10. Remove upper arm AW Gun Continued Action Note 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.

  • Page 165: Fitting Equipment On The Robot, Irb 1600Id

    4 Repair 4.4.11. Fitting equipment on the robot, IRB 1600ID 4.4.11. Fitting equipment on the robot, IRB 1600ID Location of shelf, wire feeder 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...
  • Page 166 4 Repair 4.4.11. Fitting equipment on the robot, IRB 1600ID Continued Action Note 2. Fit the bracket on the wire feeder using the four (4) Hexagon nut with flange (A). xx0700000312 A. Hexagon nut with flange M5 B. Knob 3. Fit the wire feeder with the mounted bracket on the Shelf, wire feeder and mount the two knobs.

  • Page 167: Frame And Base

    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 Base, exploded view on page 243 in part 2 of the Product manual.
  • Page 168 4 Repair 4.5.1. Replacement of base Continued Equipment Spare part no. Art. no. Note Isopropanol For cleaning the mating surfaces. Standard toolkit The contents are defined in section Standard toolkit on page 237. Other tools and These procedures include procedures may be references to the tools required.
  • Page 169 4 Repair 4.5.1. Replacement of base Continued Action Note CAUTION! The base weighs 81 kg! All lifting equipment used must be sized accordingly! 9. Secure the weight of the base and remove the Shown in the figure Location of base gearbox/base attachment screws and washer.
  • Page 170 4 Repair 4.5.1. Replacement of base Continued Action Note 12. Secure the base to the foundation. Attachment bolts and tightening torque are specified in section Attachment bolts, specification on page 13. 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...

  • Page 171: Replacement Of Serial Measurement Unit

    4 Repair 4.5.2. Replacement of serial measurement unit 4.5.2. Replacement of 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 below. A more detailed view of the unit and its position may be found in the spare part view Base, exploded view on page 243 in part 2 of the Product manual.
  • Page 172 4 Repair 4.5.2. Replacement of serial measurement unit Continued Required equipment Equipment Spare part no. Note Serial measurement unit 3HAC 023424-001 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.
  • Page 173 4 Repair 4.5.2. Replacement of serial measurement unit Continued Action Note/Illustration 7. Lift and pull the serial measurement unit backwards, over the lip (A), and lift it away. xx0500001455 Refitting, serial measurement unit The procedure below details how to refit the serial measurement unit to the robot. Action Note/Illustration 1.
  • Page 174 4 Repair 4.5.2. Replacement of serial measurement unit Continued Action Note/Illustration 5. Refit the push button guard to the robot base. 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 7.

  • Page 175: Replacement Of Push Button Unit

    4 Repair 4.5.3. Replacement of push button unit 4.5.3. Replacement of push button unit Location of push button unit The push button unit for brake release is located inside the base of the robot, as shown in the figure below. A more detailed view of the component and its location is shown in the spare part view Base, exploded view on page 243...
  • Page 176 4 Repair 4.5.3. Replacement of push button unit Continued Equipment Spare part no. Note 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 The contents are defined in section Standard toolkit on page 237.
  • Page 177 4 Repair 4.5.3. Replacement of push button unit Continued Action Note/Illustration 7. Lift and pull the serial measurement unit backwards, over the lip (A), and lift it away. xx0500001455 8. Remove the two hexagon nuts from the push Shown in the figure Push button unit on button unit.
  • Page 178 4 Repair 4.5.3. Replacement of push button unit Continued Action Note 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 8. Reconnect all the connectors to the board. 9.

  • Page 179: Motors

    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 below. A more detailed view of the motor and its position may be found in the spare part view Frame, exploded view on page 247 in part 2 of the Product manual.
  • Page 180 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Equipment Spare part no. Art. no. Note Gasket, gearbox axis 1-2 3HAC 022048-001 Replace if damaged. Power supply 24 VDC, max 1.5 A For releasing the brakes. Isopropanol Used to clean mating surfaces.
  • Page 181 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Refitting, motor axis 1 The procedure below details how to refit the motor, axis 1. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.
  • Page 182 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Action Note 16. 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. DANGER! Make sure all safety requirements are met when performing the first test run.

  • Page 183: Replacement Of Motor, Axis 2

    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 below. A more detailed view of the motor and its position may be found in the spare part view Frame, exploded view on page 247 in part 2 of the Product manual.
  • Page 184 4 Repair 4.6.2. Replacement of motor, axis 2 Continued Equipment, etc. Spare part no. Art. no. Note Power supply 24 VDC, 1.5 A. For releasing the brakes. Other tools and These procedures include procedures may be references to the tools required.
  • Page 185 4 Repair 4.6.2. Replacement of motor, axis 2 Continued Action Note 10. Remove the motor by gently pulling it out, making sure the motor pinion does not get damaged while moving it away from the gear. 11. Disconnect the brake release voltage. 12.
  • Page 186 4 Repair 4.6.2. Replacement of motor, axis 2 Continued Action Note 15. Refit the cover, frame. Replace the gasket, if Shown in the figure Location of damaged. motor axis 2 on page 181. Art. no. for the gasket is specified in section Required equipment on page...

  • Page 187: Replacement Of Motor, Axis 3

    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 Upper arm, exploded view 1 on page 251 in part 2 of the Product manual.
  • Page 188 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Equipment Spare part no. Art. no. Note Isopropanol Used for cleaning the mating surfaces. Grease 3HAB 3537-1 Used for lubricating the o- ring. Rotation tool, motor 3HAC022266-003 For adjusting the gear play.
  • Page 189 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note 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.
  • Page 190 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note 12. Refit any additional mechanical stops. Detailed in section Installation of additional mechanical stops on axis 3 on page 13. Recalibrate the robot! Calibration is detailed in a separate calibration manual, enclosed with the calibration tools.

  • Page 191: Replacement Of Motor, Axis 3, Irb 1600Id

    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)
  • Page 192 4 Repair 4.6.4. Replacement of motor, axis 3, IRB 1600ID Continued Removal, motor axis 3 Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. In order to release the brakes, Connect to connector R3.MP3: connect the 24 VDC power •...
  • Page 193 4 Repair 4.6.4. Replacement of motor, axis 3, IRB 1600ID Continued Action Note 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.
  • Page 194 4 Repair 4.6.4. Replacement of motor, axis 3, IRB 1600ID Continued Action Note 3. Fit the new motor to the upper arm housing, making sure the motor pinion is properly mated to the gear of axis 3. 4. Fit the attachment screws and washers but do not 4 pcs, M6 x 20.

  • Page 195: Replacement Of Motor, Axis 4

    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 Upper arm, exploded view 1 on page 251 in part 2 of the Product manual.
  • Page 196 4 Repair 4.6.5. Replacement of motor, axis 4 Continued Equipment, etc. Spare part no. Art. no. Note Standard toolkit The contents are defined in section Standard toolkit on page 237. Power supply 24 VDC, max. 1,5 A. For releasing the brakes. Rotation tool, motor 3HAC022266- For adjusting the gear play.
  • Page 197 4 Repair 4.6.5. Replacement of motor, axis 4 Continued Refitting, motor axis 4 The procedure below details how to refit the motor, axis 4. Action Note 1. Clean the mating surfaces on the motor and the Shown in the figure Location of motor gearbox.

  • Page 198: Replacement Of Motor, Axis 4, 1600Id

    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)
  • Page 199 4 Repair 4.6.6. Replacement of motor, axis 4, 1600ID Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Rot. ac motor incl pinion 3HAC 021799-001 O-ring 3HAB 3772-81 Standard toolkit The contents are defined in section Standard toolkit on page 237, in part 2 of the Product manual.
  • Page 200 4 Repair 4.6.6. Replacement of motor, axis 4, 1600ID Continued Action Note 2. 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. 3. Fit the motor with the attachment screws and Shown in the figure Location of washers.

  • Page 201: Replacement Of Motor And Timing Belt, Axis 5

    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.
  • Page 202 4 Repair 4.6.7. Replacement of motor and timing belt, axis 5 Continued Required equipment Equipment Spare part no. Art. no. Note Rot. ac motor incl pinion 3HAC 021800-001 Timing belt 3HAC 021304-001 Gasket, upper arm cover 3HAC 022049-001 Replace if damaged. Gasket, customer 3HAC 022050-001 Replace if damaged.
  • Page 203 4 Repair 4.6.7. Replacement of motor and timing belt, axis 5 Continued 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 DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.
  • Page 204 4 Repair 4.6.7. Replacement of motor and timing belt, axis 5 Continued Action Note/Illustration 4. Follow the steps below when fitting the motor: Art. no. is specified in Required equipment on page 200. • Place the timing belt (B) round the motor pinion and place the belt round the axis 5 as fitting the motor in the upper arm housing.

  • Page 205: Replacement Of Motor, Axis 5, Irb 1600Id

    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...
  • Page 206 4 Repair 4.6.8. Replacement of motor, axis 5, IRB 1600ID Continued Equipment, etc. Spare part no. Art. no. Note Other tools and These procedures procedures may be include references to required. See references the tools required. to these procedures in the step-by-step instructions below.
  • Page 207 4 Repair 4.6.8. Replacement of motor, axis 5, IRB 1600ID Continued Action Note DANGER! Turn of all electric power, hydraulic and pneumatic pressure supplies to the robot!. 3. Remove the AW equipment from Shown in section Remove AW Gun on page 160 the upper arm.
  • Page 208 4 Repair 4.6.8. Replacement of motor, axis 5, IRB 1600ID Continued Action Note CAUTION! The upper arm tube weighs 12,3 kg without any additional equipment fitted. Use a suitable lifting device to avoid injury to personnel. 9. Secure the weight of the arm with lifting slings.
  • Page 209 4 Repair 4.6.8. Replacement of motor, axis 5, IRB 1600ID Continued Refitting, motor axis 5 The procedure below details how to refit the motor of axis 5. Action Note 1. Clean the mating surfaces inside the upper arm housing and on the motor with Isopropanol.
  • Page 210 4 Repair 4.6.8. Replacement of motor, axis 5, IRB 1600ID Continued Action Note 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 14.

  • Page 211: Replacement Of Motor And Timing Belt, Axis 6

    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.
  • Page 212 4 Repair 4.6.9. Replacement of motor and timing belt, axis 6 Continued Equipment Spare part no. Art. no. Note Gasket, customer 3HAC 022050-001 Replace if damaged. connections Hook 3HAC024045-001 Dynamometer Capacity: 100N Standard toolkit The contents are defined in section Standard toolkit on page 237.
  • Page 213 4 Repair 4.6.9. Replacement of motor and timing belt, axis 6 Continued Action Note/Illustration 2. 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.

  • Page 214: Replacement Of Motor, Axis 6 Irb 1600Id

    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. xx0700000025 Upper arm Wrist...
  • Page 215 4 Repair 4.6.10. Replacement of motor, axis 6 IRB 1600ID Continued Equipment Spare part no. Art. no. Note Circuit diagram Removal of motor axis 6 Action Note 1. Remove the motor according to description in Removal, wrist unit on page 147 Refitting of motor axis 6 Action Note...

  • Page 216: Gearboxes

    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 Frame, exploded view on page 247...
  • Page 217 4 Repair 4.7.1. Replacement of gearbox, axes 1-2 Continued Equipment Spare part no. Art. no. Note Grease 3HAB 3537-1 For lubricating the V-ring. Locking liquid Loctite 574 Lifting slings Standard toolkit The contents are defined in section Standard toolkit on page 237.
  • Page 218 4 Repair 4.7.1. Replacement of gearbox, axes 1-2 Continued Action Note 9. 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.
  • Page 219 4 Repair 4.7.1. Replacement of gearbox, axes 1-2 Continued Action Note CAUTION! The complete gearbox unit and base weighs 201 kg together! (Base: 81 kg, gearbox unit: 120 kg.) All lifting equipment used must be sized accordingly! 10. Fit the lifting slings to the base/gearbox unit, turn it right side up and move it to the instal- lation site.

  • Page 220: Service Work On Gearboxes, Axes 3, 4, 5 And 6

    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.

  • Page 221: Calibration Information

    The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied from ABB. Calibrate the robot carefully with standard calibration. The different methods are briefly described in section Calibration methods on page 220, and further detailed in separate Calibration manuals.

  • Page 222: Calibration Methods

    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 from ABB. Types of calibration Type of Description Calibration method calibration Standard The calibrated robot is positioned at home...
  • Page 223 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.

  • Page 224: Calibration Scales And Correct Axis Position

    5 Calibration information 5.3. Calibration scales and correct axis position 5.3. Calibration scales and correct axis position Introduction This section specifies the calibration scale positions and/or correct axis position for all robot models. Calibration marks, IRB 1600 The illustration below shows the calibration marks and correct positions of the six axes of the robot.
  • Page 225 5 Calibration information 5.3. Calibration scales 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 3HAC026660-001 Revision: C...

  • Page 226: Calibration Movement Directions For All Axes

    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 etc. Positive directions are shown in the figure below.

  • Page 227: Updating Revolution Counters

    This procedure details the second step when updating the revolution counter; storing the revolution counter setting with the FlexPendant (RobotWare 5.0). Action 1. On the ABB menu, tap Calibration. All mechanical units connected to the system are shown along with their calibration status.
  • Page 228 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 3. Tap Update Revolution Counters..A dialog box is displayed, warning that updating the revolution counters may change programmed robot positions: •...

  • Page 229: Checking The Calibration Position

    This section describes how to create a program, which runs all the robot axes to their zero position. Action Note 1. On ABB menu tap Program Editor. 2. Create a new program. 3. Use MoveAbsJ in the Motion&Proc menu. 4. Create the following program: MoveAbsJ...

  • Page 231: Robot Description

    6 Robot description 6.1. Type A of IRB 1600 6 Robot description 6.1. 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: •...
  • Page 232 6 Robot description 6.1. Type A of IRB 1600 3HAC026660-001 Revision: C...

  • Page 233: Reference Information

    7 Reference information 7.1. Introduction 7 Reference information 7.1. Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. 7.2. Applicable safety standards Health and safety standards, robot The robot, controlled by the IRC5, conforms to the following standards: Standard Description EN ISO 12100-1...

  • Page 234: Unit Conversion

    7 Reference information 7.3. Unit conversion 7.3. Unit conversion Converter table Use the table below to convert units used in this manual. Quantity Units Length 3.28 ft 39.37 in Weight 1 kg 2.21 lb Pressure 1 bar 100 kPa 14.5 psi Force 0.738 lbf Moment...

  • Page 235: Screw Joints

    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.
  • Page 236 7 Reference information 7.4. Screw joints Continued 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 tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure description.
  • Page 237 7 Reference information 7.4. Screw joints Continued The table below specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass. Tightening torque Tightening torque Tightening torque Dimension Nm - Nominal Nm - Min.

  • Page 238: Weight Specifications

    All components exceeding 22 kg (50 lbs) are high-lighted in this way. To avoid injury, ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each manipulator model.

  • Page 239: Standard Toolkit

    7 Reference information 7.6. Standard toolkit 7.6. Standard toolkit General All service (repairs, maintenance and installation) procedures contain 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 table below.

  • Page 240: Special Tools

    7 Reference information 7.7. Special tools 7.7. 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 section Standard toolkit on page 237, and of special tools, listed directly in the instructions and also gathered in this section.

  • Page 241: Lifting Equipment And Lifting Instructions

    7 Reference information 7.8. Lifting equipment and lifting instructions 7.8. Lifting equipment and lifting instructions General Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each procedure. The use of each piece of lifting equipment is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting equipment.
  • Page 242 7 Reference information 7.8. Lifting equipment and lifting instructions 3HAC026660-001 Revision: C...

  • Page 243: Spare Parts And Exploded Views

    8 Spare parts and exploded views 8.1. Introduction 8 Spare parts and exploded views 8.1. Introduction Overview This section specifies all articles considered spare parts of the robot. The spare parts are also specified as required equipment directly in the repair instruction of the current spare part. The list of required equipment in each instruction also specifies necessary replacement articles and all required service tools.

  • Page 244: Spare Parts - Base

    8 Spare parts and exploded views 8.2. Spare parts - base 8.2. Spare parts - base Base, spare part list The spare parts for the base are listed below and shown in the following figure. Item no. Description Spare part no. Dimension Base, spare 3HAC 023552-001...
  • Page 245 8 Spare parts and exploded views 8.2. Spare parts - base Continued Base, exploded view xx0500001382 3HAC026660-001 Revision: C...

  • Page 246: Spare Parts - Base Connections

    8 Spare parts and exploded views 8.3. Spare parts - base connections 8.3. Spare parts - base connections Base connections, spare part list The spare parts for connections at the base are listed below and shown in the following figure. Item no.
  • Page 247 8 Spare parts and exploded views 8.3. Spare parts - base connections Continued Base connections, illustrations xx0500001383 3HAC026660-001 Revision: C...

  • Page 248: Spare Parts - Frame

    8 Spare parts and exploded views 8.4. Spare parts - frame 8.4. Spare parts - frame Frame, spare part list The spare parts are listed below and shown in the following figure. Item no. Description Spare part no. Dimension Torx pan head screw 9ADA 618-56 Steel 8.8-A2F M6 x 16...
  • Page 249 8 Spare parts and exploded views 8.4. Spare parts - frame Continued Frame, exploded view xx0600002845 3HAC026660-001 Revision: C...

  • Page 250: Spare Parts - Lower Arm

    8 Spare parts and exploded views 8.5. Spare parts - lower arm 8.5. Spare parts - lower arm Lower arm, spare part list The spare parts are listed below and shown in the following figure. Item no. Description Spare part no. Dimension Lower arm, spare 3HAC 023558-001...
  • Page 251 8 Spare parts and exploded views 8.5. Spare parts - lower arm Continued Lower arm, exploded view xx0500001385 3HAC026660-001 Revision: C...

  • Page 252: Spare Parts - Upper Arm

    8 Spare parts and exploded views 8.6. Spare parts - upper arm 8.6. Spare parts - upper arm Spare part list, upper arm The spare parts listed below are shown in the exploded views, located on the next two pages. Item no.
  • Page 253 8 Spare parts and exploded views 8.6. Spare parts - upper arm Continued Upper arm, exploded view 1 xx0600002854 Continues on next page 3HAC026660-001 Revision: C...
  • Page 254 8 Spare parts and exploded views 8.6. Spare parts - upper arm Continued Upper arm, exploded view 2 xx0600002856 3HAC026660-001 Revision: C...

  • Page 255: Spare Parts - Options

    8 Spare parts and exploded views 8.7. Spare parts - options 8.7. Spare parts - options General This section specifies available options for the robot. Spare parts - options Option no. Description Spare part no. Note 213-1 Lamp unit 3HAC022235-001 Installed as detailed in section Installation of...

  • Page 256: Spare Parts - Upper Arm 1600Id

    8 Spare parts and exploded views 8.8. Spare parts - upper arm 1600ID 8.8. Spare parts - upper arm 1600ID Location of upper arm 1600ID The location of upper arm 1600ID. Spare part list, upper arm The spare parts listed below are shown in the exploded views, located on the next pages. Item no.
  • Page 257 8 Spare parts and exploded views 8.8. Spare parts - upper arm 1600ID Continued Cable harness IRB 1600ID xx0700000156 Continues on next page 3HAC026660-001 Revision: C...
  • Page 258 8 Spare parts and exploded views 8.8. Spare parts - upper arm 1600ID Continued Motors and O-rings xx0700000157 Continues on next page 3HAC026660-001 Revision: C...
  • Page 259 8 Spare parts and exploded views 8.8. Spare parts - upper arm 1600ID Continued Covers and mechanical stops xx0700000158 Continues on next page 3HAC026660-001 Revision: C...
  • Page 260 8 Spare parts and exploded views 8.8. Spare parts - upper arm 1600ID Continued Indicator lamp xx0700000159 Continues on next page 3HAC026660-001 Revision: C...
  • Page 261 8 Spare parts and exploded views 8.8. Spare parts - upper arm 1600ID Continued Exploaded view xx0700000160 3HAC026660-001 Revision: C...
  • Page 262 8 Spare parts and exploded views 8.8. Spare parts - upper arm 1600ID 3HAC026660-001 Revision: C...

  • Page 263: Circuit Diagram

    9 Circuit diagram 9.1. Introduction 9 Circuit diagram 9.1. Introduction Overview This chapter includes the circuit diagram for the robot. Continues on next page 3HAC026660-001 Revision: C...
  • Page 264 9 Circuit diagram 9.1. Introduction Continued 3HAC026660-001 Revision: C...

  • Page 265: Index

    ABB for losses, damages to persons or property, fitness for a specific purpose or the like. In no event shall ABB be liable for incidental or consequential damages arising from use of this document. This document and parts thereof must not be reproduced or copied without ABB's written permission, and contents therof must not be imparted to a third party nor be used for any unauthorized purpose.
  • Page 266 Customer Robot serial number(s) Drawing number Manipulator Drawing version 2007-03-22 Manufacture Type Type of installation Control cabinet Mains voltage Supply Control voltage Year of construction Project start Project manager Last revision Designed by sestper Designed date 2007-03-22 Number of pages Lab/Office: Latest revision: Status:...
  • Page 267 R4.MP5 R4.FB5 R3.FB3 R3.FB4 R3.FB5 IRB 1600 ID R3.FB6 R4.MP6 R4.FB6 R3.MP3 R3.MP4 R3.MP5 R3.MP6 R2.CS R3.H1 R2.CP R3.H2 R2.CBUS R3.FB3 R3.FB4 R3.FB5 R3.MP3 R3.FB6 R3.MP4 R3.MP5 R3.MP6 R3.H1 R3.MP1 R3.H2 R3.MP2 R3.FB1 R3.FB2 R4.FB1 R1.CP/CS R4.MP1 R4.MP2 R1.CBUS R4.FB2 R1.CP R1.CS R1.LS...
  • Page 268 -BU Brake Release (Simplified)1 -R1.MP R2.BU BRAKE REL R2.BU1-6 BRAKE REL -BRAKE REL 1 / +AXIS 1/22.1 BRAKE PB Brake Bleed Circuit 0V BRAKE -0V BRAKE 1 / +AXIS 1/22.1 0V BRAKE -BRAKE REL 2 / +AXIS 2/23.2 Brake Bleed Circuit EXT LIM 2 -0V BRAKE 2 / +AXIS 2/23.2 EXT LIM 1...
  • Page 269 R2.SMB R1.SMB R2.SMB SDI-N SDO-N SIGNAL CABLE AXIS 7 (OPTION) R2.FB7 R1.SMB1.7 R1.SMB1.7 +24V +BATSUP 0V X7 0V BATLD 0V Y7 0V EXC 2 KEYPIN EXC 2 R2.G(X3) R2.G(X3) Lab/Office: Latest revision: Status: 2007-03-19 Plant: IRB1600 Location: Approved Serial Measuring Board Sublocation: Document no.
  • Page 270 -MU1 -R3.MP1 -R4.MP1 -R1.MP R (U) 1.10 T (W) S (V) 1.11 1.12 GNYE GNYE -PE12 / +AXIS 2/23.4 PTC1 -PTC12 / +AXIS 2/23.4 +BU/20.7 / +BU-BRAKE REL 1 BRAKE REL.1 BRAKE REL.1 Brake +BU/20.7 / +BU-0V BRAKE 1 0V BRAKE.1 0V BRAKE.1 -FB1 -SMB...
  • Page 271 -MU2 -R1.MP -R3.MP2 -R4.MP2 1.13 R (U) 1.18 T (W) 1.14 S (V) 1.19 1.15 1.20 GNYE GNYE +AXIS 1/22.3 / -PE12 +AXIS 1/22.3 / -PTC12 +BU/20.7 / -PTC2 PTC 2 1.22 +BU/20.7 / +BU-BRAKE REL 2 BRAKE REL.2 1.16 BRAKE REL.2 Brake +BU/20.7 / +BU-0V BRAKE 2...
  • Page 272 -MP3 -R1.MP -R3.MP3 2.10 R (U) T (W) 2.11 S (V) 2.12 +AXIS 4/25.5 / -PE43 GNYE +AXIS 4/25.5 / -PTC34 -PTC35 / +AXIS 5/26.6 +AXIS 5 IRB1600ID/28.4 +BU/20.7 / +BU-BRAKE REL 3 BRAKE REL.3 2.13 Brake -0V BRAKE 3 / +AXIS 6/27.6 +AXIS 6 IRB1600ID/29.3 SIGNAL LAMP (OPTION) R3.H1...
  • Page 273 -MU4 -R1.MP -R3.MP4 2.14 R (U) T (W) 2.15 S (V) 2.16 -PE43 / +AXIS 3/24.6 +AXIS 6/27.5 +AXIS 6 IRB1600ID/29.4 / -PTC46 -PTC34 / +AXIS 3/24.6 +BU/20.7 / +BU-BRAKE REL 4 BRAKE REL.4 2.17 Brake -0V BRAKE4 / +AXIS 5/26.6 +AXIS 5 IRB1600ID/28.3 -SMB -FB4...
  • Page 274 -MU5 -R1.MP -R3.MP5 +AXIS 5 IRB1600ID/28.7 2.18 R (U) T (W) 2.19 S (V) 2.20 +AXIS 6/27.6 / -PE65 GNYE +AXIS 3/24.5 / +AXIS 3-PTC35 0V PTC 2.22 +BU/20.7 / +BU-BRAKE REL 5 BRAKE REL.5 2.21 Brake +BU/20.7 / +BU-0V BRAKE 5 0V BRAKE 5 2.23 +AXIS 4/25.5 / +AXIS 4-0V BRAKE4...
  • Page 275 -MU6 -R3.MP6 -R1.MP +AXIS 6 IRB1600ID/29.7 R (U) T (W) S (V) GNYE -PE65 / +AXIS 5/26.6 +BU/20.7 / +BU-PTC6 +AXIS 4-PTC46 / +AXIS 4/25.6 +BU/20.7 / +BU-BRAKE REL 6 BRAKE REL.6 Brake 0V BRAKE 6 +BU/20.7 / +BU-0V BRAKE 6 +AXIS 3/24.5 / +AXIS 3-0V BRAKE 3 -SMB -FB6...
  • Page 276 -MU5 -R3.MP5 -R4.MP5 -R1.MP +AXIS 5/26.7 2.18 R (U) T (W) 2.19 S (V) 2.20 +AXIS 6 IRB1600ID/29.4 / -PE65 GNYE +AXIS 3/24.5 / +AXIS 3-PTC35 0V PTC 2.22 BRAKE REL.5 +BU/20.7 / +BU-BRAKE REL 5 BRAKE REL.5 2.21 Brake +BU/20.7 / +BU-0V BRAKE 5 0V BRAKE.2 2.23...
  • Page 277 -MU6 -R1.MP -R3.MP6 -R4.MP6 +AXIS 6/27.7 R (U) T (W) S (V) GNYE -PE65 / +AXIS 5 IRB1600ID/28.4 +BU/20.7 / +BU-PTC6 +AXIS 4-PTC46 / +AXIS 4/25.6 +BU/20.7 / +BU-BRAKE REL 6 BRAKE REL.6 BRAKE REL.6 Brake 0V BRAKE.6 / +BU-0V BRAKE 6 0V BRAKE.6 +AXIS 3/24.5 / +AXIS 3-0V BRAKE 3 -SMB...
  • Page 278 -R2.CP -R1.CP/CS- -R2.CP -R1.CP/CS- CBUS1 CUSTOMER CONNECTION CUSTOMER CONNECTION CBUS2 CANBUS (OPTION) POWER (OPTION) KUNDANSLUTNING KUNDANSLUTNING CANBUS (OPTION) KRAFT (OPTION) GNYE -R2.CS WHBN WHRD CUSTOMER CONNECTION SIGNAL (OPTION) WHOG KUNDANSLUTNING WHYE SIGNAL (OPTION) WHGN WHBU WHVT WHGY GYBK GYBN GYRD GYOG GYYE GYGN...
  • Page 279 R1.LS R2.LS1-1 GNYE switch brytare switches Två R2.LS1-2 brytare GNYE Three switches brytare R2.LS1-3 GNYE KEY PIN / STIFT Lab/Office: Latest revision: Status: 2007-03-19 Plant: IRB1600 Location: Approved Position Indicator Axis 1; Option Sublocation: Document no. Rev. Ind Page Next 3HAC021351-003 Prepared by, date: Approved by, date:...
  • Page 280 Index calibration manuals 221 calibration position 225 Absolute Accuracy, calibration 221 checking 227 Absolute Accuracy, guiding sleeves 51 jogging to, FlexPendant 227 air connections, pressure 84 scales 222 arm system calibration, Absolute Accuracy 221 replacing 126 CalibWare 220 attachment bolts, robot-foundation 50 check, installation site 38 cleaning robot, interval 91...
  • Page 281 Index cabling inside base 118 installation cabling inside frame 117 checking site prior robot installation 38 cabling inside upper arm housing 115 equipment 56 connectors on robot 79 mechanical stop axis 2 70 gearboxes 95 mechanical stops axis 3 73 mounting surface 50 mechanical stops, axis 1 67 power supply to connector R1.MP 48...
  • Page 282 Index motor axis 4 axis 2 70 brake release with power supply 194 axis 3 73 replace 193 revolution counters screws, tightening torque 195 storing on FlexPendant 225 spare part number 193 updating 225 motor axis 5 robot replacing 199 cleaning 105 screws, tightening torque 202 connectors 79...
  • Page 283 Index mechanical stop axis 3 75 screws, tightening torque 144 motor axis 1 179 spare part number 143 motor axis 2 183 motor axis 3 187 motor axis 4 195 motor axis 5 202 motor axis 6 211 robot to foundation, attachment bolts 50 upper arm 132 wrist unit 144 tilted mounting 52...
  • Page 285 ABB AB Robotics Products S-721 68 VÄSTERÅS SWEDEN Telephone : +46 (0) 21 344000 Fax : +46 (0) 21 132592...

This manual is also suitable for:

Irb 1600 - 7/1,45 type aIrb 1600 - 8/1,2 type aIrb 1600 - 8/1,45 type aIrb 1600idIrb 1600 - 5/1,45 type aIrb 1600 - 6/1,2 type a ... Show all

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