Page 1 ROBOTICS Product manual IRB 120...
Page 2 Trace back information: Workspace R17-2 version a11 Checked in 2017-09-20 Skribenta version 5.1.011...
Page 4 The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.
Page 5: Table Of Contents
Mechanically restricting the working range ........... Making robot ready for operation ................2.5.1 Additional installation procedure, Clean Room ..........Electrical connections ..................2.6.1 Robot cabling and connection points ............Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 6 When to calibrate ................... Synchronization marks and axis movement directions ..........5.2.1 Synchronization marks and synchronization position for axes ......5.2.2 Calibration movement directions for all axes ..........Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 7 Standard toolkit ....................Special tools ....................Lifting equipment and lifting instructions ..............Spare parts Spare part lists and illustrations ................Circuit diagrams Circuit diagrams ....................Index Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
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Page 9: Overview Of This Manual
• repair personnel. Prerequisites Maintenance/repair/installation personnel working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Organization of chapters The manual is organized in the following chapters: Chapter...
Page 10 • Safety chapter- Revised terminology: robot replaced with manipulator. • Safety chapter - Information not applicable to IRB 120 in WARNING - Safety risks during work with gearbox lubricants (oil or grease) on page 53 removed.
Page 11 Installation chapter - Lifting capacity of roundslings updated. See: Lifting the robot with roundslings on page • Installation chapter - New illustration showing IRB 120 added. See: Setting the system parameters for a suspended or tilted robot on page •...
Page 12 228. • Spare parts chapter - Illustration xx0900000544 updated. See Spare parts - Upper arm unit in Product manual, spare parts - IRB 120. This revision includes the following additions and/or changes: • A new block, about general illustrations, added in section...
Page 13 Updated timing belt tension for axis-3 motor and axis-5 motor This revision includes the following additions and/or changes: • Removed information about signal lamp from the manual since it is not a valid option for IRB 120. • Information about manual break release added to installation chapter. •...
Page 14: Product Documentation, Irc5
This listing is based on the type of information in the documents, regardless of whether the products are standard or optional. All documents listed can be ordered from ABB on a DVD. The documents listed are valid for IRC5 robot systems.
Page 15 • Operating manual - IRC5 Integrator's guide • Operating manual - IRC5 with FlexPendant • Operating manual - RobotStudio • Operating manual - Troubleshooting IRC5 Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 16: How To Read The Product Manual
Likewise, certain work methods or general information that is valid for several robot models, can be illustrated with illustrations that show a different robot model than the one that is described in the current manual. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 17: Safety
Specific safety information, pointed out in the procedures. How to avoid and eliminate the danger is either described directly in the procedure, or in specific instructions in the section Safety related instructions on page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 18: General Safety Information
This section describes actions which may be taken to remedy or avoid dangers. • fire extinguishing • safe use of the teach pendant or jogging device Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 19: Safety In The Robot System
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 20 Load limits for tools and Product specification for the robot Load diagrams workpieces Configuration of safety mod- Application manual - Functional safety ule (requires Functional safety and SafeMove options) Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 21: Protective Stop And Emergency Stop
1.2.3 Protective stop and emergency stop 1.2.3 Protective stop and emergency stop Overview The protective stops and emergency stops are described in the product manual for the controller. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 22: Safety Risks
ABB is not liable for damages caused by the use of non-original spare parts and special equipment. ABB is not liable for damages or injuries caused by unauthorized modifications to the robot system.
Page 23 With a higher environment temperature, more surfaces on the manipulator will get HOT and may also result in burns. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 24 Gears may be damaged if excessive force is used! CAUTION Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 25: Caution - Hot Parts May Cause Burns
Do not put anything on hot metal surfaces, e.g. paper or plastic. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 26: Safety Risks Related To Tools/Work Pieces
Unauthorized modifications of the originally delivered robot are prohibited. Without the consent of ABB it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength could be affected.
Page 27: Safety Risks Related To Pneumatic/Hydraulic Systems
• Dump valves should be used in case of emergency. • Shot bolts should be used to prevent tools, etc., from falling due to gravity. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 28: Safety Risks During Operational Disturbances
If the working process is interrupted, extra care must be taken due to risks other than those associated with regular operation. Such an interruption may have to be rectified manually. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 29: Risks Associated With Live Electric Parts
The external voltage connected to the controller remains live even when the robot is disconnected from the mains. • Additional connections. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 30 Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 31: Safety Actions
Robot motion in the Product specification). Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 32: Fire Extinguishing
1.2.5.2 Fire extinguishing 1.2.5.2 Fire extinguishing Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the robot or controller! Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 33: Emergency Release Of The Robot Arm
When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways. Make sure no personnel is near or beneath the robot arm. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 34: Brake Testing
3 Inspect and verify that the axis maintains its position. If the robot does not change position as the motors are switched off, then the brake function is adequate. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 35: Risk Of Disabling Function "Reduced Speed 250 Mm/S
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". Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 36: Enabling Device And Hold-To-Run Functionality
How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 38: Safety Signals And Symbols
ELECTROSTATIC Warns for electrostatic hazards which could result DISCHARGE (ESD) in severe damage to the product. xx0200000023 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 39 Significance NOTE Describes important facts and conditions. xx0100000004 Describes where to find additional information or how to do an operation in an easier way. xx0100000098 Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 40: Safety Symbols On Product Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 41 Brake release Pressing this button will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 42 Tip risk when loosening bolts The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 43 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 xx1500002616 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 44 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 45 Shut off with handle Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 46: Safety Related Instructions
The hold-to-run function is used in manual mode, not in automatic mode. Make sure no personnel are present within the working range of the robot before pressing the start button. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 47: Danger - First Test Run May Cause Injury Or Damage
Pay special attention to the function of the part that previously was serviced. Collision risks CAUTION When programming the movements of the robot, always identify potential collision risks before the first test run. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 48: Danger - Make Sure That The Main Power Has Been Switched Off
Module. xx0600002783 K: Main switch, Drive Module Switch off the main switch on the Control A: Main switch, Control Module Module. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 49 Note that the position of the main switch can vary depend- switch on the controller ing on the year model. cabinet. xx0900000313 A: Main power switch Disconnect the input power cable from the wall socket. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 50: Warning - The Unit Is Sensitive To Esd
Location of wrist strap button The location of the wrist strap button is shown in the following illustration. IRC5 xx1300000856 Wrist strap button Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 51 1 Safety 1.4.4 WARNING - The unit is sensitive to ESD! Continued IRC5 Compact Controller xx1400001622 Wrist strap button Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 52: Warning - Safety Risks During Handling Of Batteries
Use safety glasses when handling the batteries. In the event of leakage, wear rubber gloves and chemical apron. In the event of fire, use self-contained breathing apparatus. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 53: Warning - Safety Risks During Work With Gearbox Lubricants (Oil Or Grease)
Possible pressure build-up in gearbox Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 54 The magnetic oil plugs will take care of any remaining metal Contaminated oil in chips. gear boxes Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 55: Installation And Commissioning
Safety on page 17 before performing any installation work. Note If the IRB 120 is connected to power, always make sure that the robot is connected to protective earth before starting any installation work! For more information see: • Product manual - IRC5...
Page 56: Unpacking
It also contains information useful during later re-installation of the robot. Prerequisites for installation personnel Installation personnel working with an ABB product must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work • conform to all national and local codes.
Page 57 ±515 N Force z -265 ±200 N -265 ±365 N Torque xy ±195 Nm ±400 Nm Torque z ±85 Nm ±155 Nm Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 58 Storage conditions, robot The table shows the allowed storage conditions for the robot: Parameter Value Minimum ambient temperature -25° C Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 59 Otherwise there is a risk that the robot stops or run with lower performance due to temperature dependent oil and grease viscosity. For robots with food grade lubrication, if environment temperature > 35ºC, contact ABB for further information.
Page 60: Working Range And Type Of Motion
-50 mm -110° -110° -67 mm 445 mm -110° +70° -580 mm 270 mm -90° -77° -545 mm 91 mm -110° -77° Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 61 The default working range for axis 6 can be extended by changing parameter values in the software. Option 610-1 Independent axis can be used for resetting the revolution counter after the axis has been rotated (no need for "rewinding" the axis). Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 62: Risk Of Tipping/Stability
This figure shows the robot in its shipping position and transportation position. xx0900000580 WARNING The robot is likely to be mechanically unstable if not secured to the foundation. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 63: On-Site Installation
Attach the roundslings as shown in the figure. CAUTION Use a thick cloth between round sling and robot where robot surface directly contact with round sling. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 64 Lifting instructions Use this procedure to lift the robot in a safe way. Action Note CAUTION The IRB 120 robot weighs 25 kg. All lifting accessories used must be sized accordingly! CAUTION Attempting to lift the robot in any other pos-...
Page 65 8.8-A2F (2 pcs) • E: Upper arm Attach the roundsling. See the figure in: • Lifting on page 63 Lift the robot with an overhead crane. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 67 Continued Brake release button at the front of IRC5 Compact controller The IRB 120 robot has no brake release button, instead use the brake release button on the IRC5 Compact controller. For other controller variants, the placing depends on the design of the cell.
Page 68 Do not interchange the 24V and 0V pins. If they are mixed up, damage can be caused to the brake release unit and to the system board. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 69 A: 0V to pin 12 • B: 24V to pin 13 CAUTION The holding brakes are released to all axes when power is connected to the pins. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 70: Orienting And Securing The Robot
4 pcs Quality 8.8-A3F Suitable washer 10 mm Guide pins 2 pcs, D6x20 ISO 2338-6 m6x30 - A1 Tightening torque 35 Nm Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 71 When bolting a mounting plate or frame to a concrete floor, follow the general instructions for expansion-shell bolts. Screw joints must be able to withstand the stress loads defined in section Loads on foundation, robot on page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 72: Fitting Equipment On Robot
All equipment and cables used on the robot, must be designed and fitted not to damage the robot and/or its parts. Note Never drill a hole in the robot without first consulting ABB! Maximum loads The table shows the maximum permitted loads for any extra equipment fitted in the holes intended for this purpose.
Page 73 Max. 172 mm Max. radius 75 mm NOTE! Fitting holes at the base of the robot are placed on each side. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 74 Continued Fitting equipment on mounting flange The illustration shows the mechanical interface for the mounting flange. +0.012 5 H7 0 4xM5 8 0.04 0.25 xx0900000261 Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 75: Setting The System Parameters For A Suspended Or Tilted Robot
If the robot is wall mounted or mounted in a tilted position, it is important that the x-direction of the robot base coordinate system points downwards, as shown in the following figure. xx1400000737 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 76 7 axes high performance motion is set, see Technical reference manual - System parameters. Gamma Rotation Gamma Rotation defines the orientation of the robot foot on the travel carriage (track motion). Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 77 Pos 1 Floor mounted Pos 2 Mounting angle 45° (Tilted) Pos 3 Mounting angle 90° (Wall) Pos 4 Mounting angle 180° (Suspended) Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 78 Robot, in the topic Motion. How to calculate a new value is detailed in Mounting angles and values on page Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 79 The system parameters are described in Technical reference manual - System parameters. The system parameters are redefined in the Configuration Editor, in RobotStudio or on the FlexPendant. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 80: Loads Fitted To The Robot, Stopping Time And Braking Distances
The performance of the motor brake depends on if there are any loads attached to the robot. For more information, see product specification for the robot. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 81: Restricting The Working Range
This section describes how to install hardware that restricts the working range. Note Adjustments must also be made in the robot configuration software (system parameters). References to relevant manuals are included in the installation procedures. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 82: Mechanically Restricting The Working Range
Mechanical stop axis 1 (base) Mechanical stop axis 1 (swing plate) xx0900000583 Mechanical stop axis 2 (swing housing) Mechanical stops axis 2 (upper arm) Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 83 2 Installation and commissioning 2.4.2 Mechanically restricting the working range Continued xx1000000003 Mechanical stop axis 3 (lower arm) Mechanical stops axis 2 (lower arm) Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 84: Making Robot Ready For Operation
Any Clean Room parts that are replaced must be replaced with parts designed for use in Clean Room environments. Clean Room class 5 According to IPA test result, the robot IRB 120 is suitable for use in Clean Room environment when these requirements are fulfilled: •...
Page 85: Electrical Connections
Cable Art. no. Robot cable, signal: L=3 m 3HAC035320-001 Robot cable, signal: L=7 m 3HAC2493-1 Robot cable, signal: L=15 m 3HAC2530-1 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 86 Continued Bending radius for static floor cables The minimum bending radius is 10 times the cable diameter for static floor cables. xx1600002016 Diameter Diameter x10 Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 87: Customer Connections On The Robot
Customer connector Connector set R3.CP/CS 3HAC037070-001 Air, connector Position Description Art. no. Robot 4xM5 Customer cable SMC KJS04-M5 air connector 3HAC032049-001 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 88 Customer connections, upper arm housing. xx0900000640 Connection Description Number Value R3.CP/CS Customer power/signal 49 V, 500 mA Max 5 bar Inner house diameter 4 mm Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 89: Start Of Robot In Cold Environments
If the program consists of large wrist movements, it is possible that the reorientation velocity, which is always high in predefined velocities, needs to be included in the ramping up. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
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Page 91: Maintenance
Safety on page 17 before performing any service work! Note If the IRB 120 is connected to power, always make sure that the IRB 120 is connected to protective earth before starting any maintenance work! For more information see: •...
Page 92: Maintenance Schedule
3.2.1 Specification of maintenance intervals Introduction The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the IRB 120: • Calendar time: specified in months regardless of whether the system is running or not.
Page 93: Maintenance Schedule
The more demanding movement pattern (sharper bending cable harness), the shorter intervals. Service inspection including dismounting of robot parts shall always be done outside the clean room area. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 94 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime can be extended with a battery shutdown service routine. See Operating manual - IRC5 with FlexPendant for instructions. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 95: Inspection Activities
Look for abrasions, cuts or crush damages. Replace the cabling if wear or damage is detected. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 96: Inspecting Mechanical Stops
The mechanical stops on axes 1, 2 and 3 are located as shown in the figures. Axis 1 xx1000000002 Mechanical stop axis 1 (base) Mechanical stop axis 1 (swing plate) Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 97 Mechanical stop axis 3 (upper arm) Axis 3 xx1000000003 Mechanical stop axis 3 (lower arm) Mechanical stops axis 2 (lower arm) Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 98 Continued Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest revision of Product manual, spare parts - IRB 1200 on ABB Library. Spare part Article number Note...
Page 99: Inspecting Dampers
Dampers, axis 2 Required equipment Equipment Art. no. Note Standard toolkit The content is defined in the section Standard toolkit on page 260. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 100 1 mm. Check all attachment screws for deformation. If any damage is detected, the damper must be replaced with a new one! Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 101: Inspecting Timing Belts
The timing belts are located as shown in the figures. Axis 3 xx0900000610 Timing belt, axis 3 Timing belt pulley (2 pcs) Lower arm cover Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 102 New belt: F = 18-19.7N Used belt: F = 12.5-14.3N Axis 5 New belt: F = 7.6-8.4N Used belt: F = 5.3-6.1N Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 103 Gain access to each timing belt by removing the cover. Check the timing belts for damage or wear. xx1300002286 xx1300002287 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 104 If the belt tension is not correct, adjust it! New belt: F = 18-19.7N Used belt: F = 12.5-14.3N Axis 5: . New belt: F = 7.6-8.4N Used belt: F = 5.3-6.1N Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 105: Inspecting Plastic Covers
Plastic covers are located as shown in the figure. xx0900000607 Lower arm cover (2 pcs) Wrist side cover (2 pcs) Wrist support Housing cover Tilt cover Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 106 Check the plastic covers for: • cracks • other kind of damage. Replace the plastic cover if cracks or damage is detected. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 107: Replacement/Changing Activities
Before starting any inspection, maintenance, or changing activities of lubrication, always contact the local ABB Service organization for more information. For ABB personnel: Always check ABB Library for the latest revision of the manual Technical reference manual - Lubrication in gearboxes, in order to always get the latest information of updates about lubrication in gearboxes.
Page 108 Includes pump with outlet pipe. Use the suggested dispenser or a similar one: • Orion OriCan article number 22590 (pneumatic) Nipple for quick connect fitting, with o-ring Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 109: Replacing The Battery Pack
The location of the battery pack is inside the base cover as shown in the figure. xx0900000588 Cable strap Battery pack Base cover Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 110 Refit the base cover to the robot with its attachment See the figure in: screws. • Location of the battery pack on page 109 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 111 118 Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. Update the revolution counters. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 112: Cleaning Activities
General To secure high uptime it is important that the IRB 120 is cleaned regularly. The frequency of cleaning depends on the environment in which the manipulator works. Different cleaning methods are allowed depending on the type of protection of the IRB 120.
Page 113 Remove waste material, such as sand, dust and chips, if it prevents cable movement. • Clean the cables if they have a crusty surface, for example from dry release agents. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
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Page 115: Repair
Make sure to read through the chapter Safety on page 17 before commencing any service work. Note If the IRB 120 is connected to power, always make sure that the IRB 120 is connected to earth before starting any repair work. For more information see: •...
Page 116: General Procedures
Never hammer directly on the seal as this may result in leakage. Make sure no grease left on the robot surface. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 117 If the flange surfaces are defective, the parts may not be used because leakage could occur. Clean the surfaces properly in accordance with the recommendations of ABB. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.
Page 118: Replacing Parts On The Robot
Use ethanol on a lint free cloth. so that it is free from oil and grease. Place the tooling pin in hot water. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 119 Clean Room. Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 120: Cable Harness
Location of the cable harness. The cable harness is located as shown in the figure. xx0900000905 Motor axis 6 Motor axis 5 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 121 3 to +50° position • axis 4 to 0° position • axis 5 to +90° position • axis 6 - no significance Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 122 Wrist side covers (2 pcs) • Attachment screws (6 pcs) Remove the tilt cover. xx1400002900 Parts: • Attachment screws(4 pcs) • Tilt cover Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 123 Disconnect customer contact R2.CP/CS Remove the connector support at axis 5. xx0900000888 Parts: • A: Attachment screws (2 pcs) • B: Connector support Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 124 R2.MP6 and R2. ME6, motor axis 6. Gently pull the cables from motor axis 5 and motor axis 6 out of the wrist housing. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 125 • Attachment screws and washers (2 pcs) Tilt the motor axis 5 to be able to remove the timing belt. xx0900001019 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 126 Parts: • A: Attachment screws (4 pcs) • B: Cable bracket • (C: Axis 5 shall be in 90° position) Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 127 Cut cable ties at cable bracket A. xx0900001023 Parts: • A: Cable bracket • B: Cable bracket Disconnect connectors: • R2.MP4 • R2.ME4. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 128 Cut cable ties for motor axis 3 cables. Pull the cable harness out through the upper arm housing to axis 3. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 129 CAUTION Do not stretch the cable harness. Cut cable ties at motor axis 2. Disconnect connectors: • R2.MP2 • R2.ME2 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 130 Guide the cable harness and pull it carefully in below motor in axis 2. Take a picture of cable harness placement in the swing housing before removal. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 131 Remove the base cover from the robot by removing its attachment screws. xx0900000842 Base cover Plate Encoder Interface Board (EIB board) Bracket Battery pack Cable tie Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 132 Parts: • A: Swing plate • B: Cable holder • C: Attachment screws (2 pcs) • D: Cable ties (4 pcs) Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 133 Cable harness and hoses are sensitive equipment. Use caution when handling cable harness. Carefully push and pull the complete cable harness past motor axis 1. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 134: Refitting The Cable Harness
The cable harness is located as shown in the figure. xx0900000905 Motor axis 6 Motor axis 5 Motor axis 4 Cable harness Motor axis 3 Motor axis 2 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 135 • Place a cable tie close to the bracket • Cut old cable ties xx1500000001 Refit the plate with EIB board. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 136 Cable harness and hoses are sensitive equipment. Use caution when handling cable harness. Put some cable grease on the cable harness (including air hoses). Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 137 Attachment screw (4 pcs) M3x8 Refit the EIB plate. Attachment screw (4 pcs) M3x8 CAUTION Cables are sensitive equipment. Use caution when handling cables. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 138 Secure the cable harness on the swing plate with cable ties. Put cable ties on the motor connections to ease the mounting in axis-2 motor. xx1500000003 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 139 • R2.MP3 • R2.ME3. Place the connector cables by the motor and fasten the connectors with cable ties around the motor. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 140 B: Attachment screws (2 pcs) Pull the cable harness through the upper arm housing. Verify that the cable harness is not twisted. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 141 Parts: • A: Cable bracket • B: Cable bracket Push the cable harness in through the wrist housing. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 142 Tension the timing belt to 7.6 - 8.4 Nm. Use a tension scale to have the correct torque. Tighten motor attachment screws. Tightening torque: 5.5 Nm Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 143 • A: Attachment screws, M3x8 (2 pcs) • B: Connector support (plastic) Fasten cables to axis 6 in the connector support. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 144 6. xx0900000912 Parts: • A: Attachment screw • B: Clamp Reconnect connectors: • R2.MP6 • R2.ME6. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 145 Put cable grease on the cable harness in the wrist. Clean all the covers if they are dirty. Put cable grease inside the covers. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 146 - First test run may cause injury or damage! on page Jog the robot to 90° in axis 1. Fasten the two remaining screws at swing plate/base. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 147 These are further detailed in the section DANGER - First test run may cause injury or damage! on page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 148: Replacing The Encoder Interface Board
Other tools and procedures may be required. These procedures include references to the See references to these procedures in the tools required. step-by-step instructions below. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 149 See the figure in: • Location of the Encoder Interface board on page 148 Reconnect connectors: • R1.ME1-3 • R1.ME4-6 • R2.EIB. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 150 These are further detailed in the section DANGER - First test run may cause injury or damage! on page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 151: Plastic Covers
The section describes how to replace the plastic covers on the robot. CAUTION Always read the section "General procedures" before doing any repair work. Replacing parts on the robot on page 118 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 152 Other tools and procedures may be re- These procedures include references to the quired. See references to these procedures tools required. in the step-by-step instructions below. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 153 Which attachment screws to use is described in the table: • Attachment screws and tightening torques on page 153 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 154 Replacing parts on the robot on page 118 Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 155: Upper Arm
Location of upper arm The upper and lower arms are located as shown in the figure. xx0900000924 Upper arm, complete with wrist Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 156 Always cut the paint with a knife and grind the paint edge when disassembling parts of a Clean Room robot! See Replacing parts on the robot on page 118 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 157 C: Axis 5 shall be in 90° position Remove the cable harness in the upper arm See section housing. • Removing the cable harness on page 120. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 158 Remove the cable harness in the lower arm. See section • Removing the cable harness on page 120. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 159 Required equipment on page 156 upper arm, using Loctite 7063. Apply Loctite 574 on the assembly surfaces on gearbox axis 3 and the upper arm. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 160 F: Cable guide Secure the cable harness to the lower arm See section plate. • Refitting the cable harness on page 134 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 161 4. xx0900001023 Parts: • A: Cable bracket • B: Cable bracket Push the cable harness into the wrist. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 162 118 Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 163 These are further detailed in the section DANGER - First test run may cause injury or damage! on page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 164: Lower Arm
These procedures include references to See references to these procedures in the step- the tools required. by-step instructions below. Flange sealant for example Loctite 574 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 165 Unscrew the attachment screws securing the motor cover to the lower arm plate. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 166 Apply flange sealant on the assembly sur- faces on axis-2 gearbox and lower arm. Remove the screw from the air release hole of lower arm housing. xx1700000766 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 167 (16 pcs). Refit the cable harness in the lower arm. See section • Refitting the cable harness on page 134 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 168 These are further detailed in the section DANGER - First test run may cause injury or damage! on page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 169: Motors And Motors With Gearboxes
Location of axis-1 motor with gearbox The axis-1 motor with gearbox is located as shown in the figure. xx0900000871 Axis-1 motor with gearbox Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 170 Cable grease, for food grade lubrication Mobil FM222. Used for lubrication of cable contact areas for robots with food grade lubrication. Loctite 243 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 171 Remove the two attachment screws secur- ing the swing housing to the base. (Not possible to reach with axis 1 in 0° position.) xx1300001598 xx1300001599 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 172 Replacing parts on the robot on page 118 Remove the lower arm cover on the side of the lower arm plate. xx1300001124 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 173 Remove the remaining attachment screws securing the swing housing. xx1300001604 If needed, use two screws to press the swing housing out. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 174 Some plastic in the bottom of the box makes a good "bed" for the robot Do not stretch the cable harness. to rest on. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 175 Clean Room robot! See Replacing parts on the robot on page 118 Remove the base cover. xx0900000829 Base cover Attachment screws (4 pcs) Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 176 Always cut the paint with a knife and grind the paint edge when disassembling parts of a Clean Room robot! See Replacing parts on the robot on page 118 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 177 Do not damage the cable harness! xx1300001606 CAUTION Protect the gearbox from dust and/or foreign particles. Remove screw from swing plate centre. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 178 Do not damage the cable harness in the process! xx1300001608 Remove the attachment screws securing the axis-1 motor with gearbox. xx0900001054 Attachment screws (12 pcs) Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 179 If robot has an air release hole: Remove the screw in the air release hole on the swing plate to release pressure inside the base. xx1500000112 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 180 With motor and gearbox fitted and motorcables out of the hole, remove the cable ties. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 181 Secure the cable guide with its attachment Tightening torque: 2 Nm. screws. Apply cable grease on the inside surfaces of the cable guide. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 182 Apply cable grease on cables and hoses before running the package in through the cable guide. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 183 Connect connectors: • R2.MP1 • R2.ME1 To facilitate assembly of cable ties, loosen the screws holding the plate a little bit. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 184 A: Plate • B: Attachment screws M3x8 q12.8 (4 pcs) Secure the plate with its attachment screws. Tightening torque: 2 Nm. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 185 • Person 1 holding the armsystem in an angle • Person 2 fitting the cable holder. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 186 Loctite and other contamination. Use caution and move the swing house over the cable harness and put it into fitting pos- ition. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 187 Arrange the axis-2 motor cables so that they will not be damaged. Secure the motor cables around the axis-2 motor with a cable tie. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 188 Fit the cable bracket on the lower arm plate. xx0900000879 Cable bracket Attachment screws M3x8 (2 pcs) Lubricant the inside of the lower arm cover with cable grease. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 189 These are further detailed in the section DANGER - First test run may cause injury or damage! on page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 190: Replacing Axis-2 Motor With Gearbox
Gearbox axis 2 is a part of motor axis 2 when ordered as a spare part. The procedure below describes the replacement of motor and gearbox axis 2 as one unit. For information how to replace gearbox axis 2, please contact ABB. CAUTION Always read the section "General procedures"...
Page 191 Use extreme caution performing these procedures. The cable harness will still be fitted or be partly fitted during the procedures. Action Information Jog the robot to calibration position. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 192 Remove the lower arm covers on both sides of the lower arm. xx0900000848 Disconnect connectors: • R2.MP3 • R2.ME3 xx0900000850 Parts: • A: Connectors Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 193 B: Attachment screws (2 pcs) Remove both cable guides. xx0900000857 Parts: • A: Attachment screws (2+2 pcs) • B: Cable guides (2 pcs) Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 194 C: Motor cover • D: Attachment screws (4 pcs) • E: Holes for attachment screws (4 pcs) • F: Cable guide Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 196 Remove old residues of Loctite and other contamination, from the assembly surfaces of the lower arm. Wipe clean screw and countersink hole on swing plate. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 197 Secure the axis-2 motor with gearbox to the Tightening torque: 4 Nm. swing housing with its attachment screws. xx1300001122 Attachment screws M4x20 q12.9 (12 pcs) Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 198 If the robot has an air release hole: Add Loctite 243 and refit the screw in the air re- lease hole on the lower arm housing. xx1500000113 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 199 Refit the two cable guides. Tightening torque : 1 Nm. xx0900000857 Parts: • A: Attachment screws M3x8 (2 pcs) • B: Cable guides (2 pcs) Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 200 • B: Attachment screws M3x8 (2 pcs) DANGER Check that the cable harness is intact and connected correctly on all axes! Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 201 These are further detailed in the section DANGER - First test run may cause injury or damage! on page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 202: Replacing Axis-3 Motor With Gearbox
Location of axis-3 motor The axis-3 motor is located as shown in the figure. xx0900000847 Cable harness Motor axis 3 Motor axis 2 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 203 118 Remove the lower arm covers on both sides of the of the lower arm. xx0900000848 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 204 Parts: • A: Cable straps (2 pcs) Disconnect connectors: • R2.MP3 • R2.ME3. xx0900000850 Parts: • A: Connectors R2.MP3 and R2.ME3 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 205 Action Information Clean Room robots: clean the joints that have been opened. See Replacing parts on the robot on page 118 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 206 Use a handheld spring balance to measure the timing belt tension. xx1400002560 Secure the axis-3 motor with its attachment Tightening torque: 4 Nm. screws and washers. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 207 D: Attachment screws (4 pcs) • E: Holes for attachment screws (4 pcs) • F: Cable guide Reconnect connectors: • R2.MP3 • R2.ME3. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 208 Put the strap tie on the side in order to make the lower arm cover fit well. xx0900000849 Parts: • A: Cable ties (2 pcs) Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 209 These are further detailed in the section DANGER - First test run may cause injury or damage! on page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 210: Replacing Motor Axis 4, With Gearbox
Replacing the upper arm on page 155 Location of motor axis 4, with gearbox Motor axis 4, with gearbox is located as shown in the figure: xx0900000785 Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 211: Replacing Motor Axis 5
Other tools and procedures may be required. These procedures include references to See references to these procedures in the step- the tools required. by-step instructions below. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 212 A: Wrist side covers (2 pcs) Loosen the attachment screw securing the clamp. xx0900000887 Parts: • A: Attachment screw • B: Clamp Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 213 A: Cable straps (2 pcs) Disconnect connectors for motor axis 5: • R2.MP5 • R2.ME5 Unscrew the attachment screws securing motor axis 5. xx1100000960 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 214 Refit the timing belt on the pulleys. xx0900000611 Parts: • A: Wrist side cover • B: Pulley (2 pcs) • C: Timing belt Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 215 B: Connector support Refit the clamp with its attachment screw. Tightening torque: 1 Nm. xx0900000887 Parts: • A: Attachment screw • B: Clamp Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 216 These are further detailed in the section DANGER - First test run may cause injury or damage! on page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 217: Replacing Motor Axis 6
155. Motor axis 6 is a part of the upper arm when ordered as a spare part. For more information how to replace motor axis 6, please contact ABB. Location of motor axis 6 Motor axis 6 is located as shown in the figure.
Page 218: Gearboxes
The gearbox axis 1 is delivered as a part of motor axis 1. For information how to replace motor with gearbox axis 1, see section Replacing axis-1 motor with gearbox on page 169. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 219: Replacing Gearbox Axis 2
The gearbox axis 2 is delivered as a part of motor axis 2. For information how to replace motor with gearbox axis 2, see section Replacing axis-2 motor with gearbox on page 190. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 220: Replacing Gearbox Axis 3
Overview Gearbox axis 3 is delivered as a part of the lower arm. For more information how to replace gearbox axis 3, please contact ABB. Location of gearbox axis 3 Gearbox axis 3 is located as shown in the figure.
Page 221: Replacing Gearbox Axis 4
How to replace the upper arm see: • Replacing the upper arm on page 155 For more information how to replace gearbox axis 4, please contact ABB. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 222: Replacing Gearbox Axis 5
Replacing the upper arm on page 155. For more information how to replace gearbox axis 5, please contact ABB. Location of gearbox axis 5 Gearbox axis 5 is located as shown in the figure. xx0900001041...
Page 223: Replacing Gearbox Axis 6
Replacing the upper arm on page 155. For more information how to replace gearbox axis 6, please contact ABB. Location of gearbox axis 6 Gearbox axis 6 is located as shown in the figure: xx0900000910...
Page 224 This page is intentionally left blank...
Page 225: Calibration
Term Definition Calibration method A collective term for several methods that might be available for calibrating the ABB robot. Each method contains calibration routines. Synchronization position Known position of the complete robot where the angle of each axis can be checked against visual synchronization marks.
Page 226: Calibration Methods
Brief description of calibration methods Axis Calibration method Axis Calibration is a standard calibration method for calibration of IRB 120 and is the most accurate method for the standard calibration. It is the recommended method in order to achieve proper performance.
Page 227: When To Calibrate
The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration, according to information in this manual. The resolver values will change when parts affecting the calibration position are replaced on the robot, for example motors or parts of the transmission.
Page 228: Synchronization Marks And Axis Movement Directions
Introduction This section shows the position of the synchronization marks and the synchronization position for each axis. Synchronization marks, IRB 120 The illustrations show the synchronization marks on IRB 120. xx0900000574 Calibration mark axis 1 Calibration mark axis 2 Calibration mark axis 3...
Page 229 5 Calibration 5.2.1 Synchronization marks and synchronization position for axes Continued xx0900000575 Calibration marks axis 4 Calibration marks axis 5 Calibration marks axis 6 Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 230: Calibration Movement Directions For All Axes
Manual movement directions Axis 3 Axis 4 Axis 5 Axis 6 Axis 2 Axis 1 xx0900000262 Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 232 All mechanical units connected to the system are shown with their calibration status. Tap the mechanical unit in question. xx1500000943 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 233 Calibration method used at factory for each axis is shown, as well as calibration method used during last field calibration. Tap Manual Method (Advanced). xx1500000944 A screen is displayed, tap Rev. Counters. en0400000771 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 234 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 249. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 235: Calibrating With Axis Calibration Method
FlexPendant. Validation In the mentioned routines, it is also possible to validate the calibration data. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 236 Unrestricted in the FlexPendant window. How to calibrate a suspended or wall mounted robot The IRB 120 is calibrated floor standing in factory, prior to shipping. To calibrate a suspended or wall mounted robot with the fine calibration routine, the robot must first be taken down and mounted standing on the floor.
Page 237: Axis Calibration - Running The Calibration Procedure
The calibration tools used for Axis Calibration are designed to meet requirements for calibration performance and durability. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration holes may cause severe damage to the robot and/or personnel. Equipment, etc. Article number...
Page 238 Wipe the calibration tool clean. Use a clean cloth. Note The calibration method is exact. Dust, dirt or color flakes will affect the calibration value. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 239 All mechanical units connected to the system are shown with their calibration status. Tap the mechanical unit in question. xx1500000943 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 240 Calibration movement directions for all axes on page 230 After calibration Action Note Check that all dampers are refitted on axes 1, 2 and 3. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 241 5.4.2 Axis Calibration - Running the calibration procedure Continued Action Note Remove the tool on axis 6. xx1000000005 Parts: A Attachment screws (4 pcs) B Calibration tool C Guide pin Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 242: Calibrating With Manual Calibration Method
Calibration, axis 4. (Rotate axis 4 -174.7°) Calibration pins, axis 4 Calibration, axis 5-6. (Rotate axis 5 -90° and axis 6 90°) Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 243 • Location of calibration pins on each other. page 242 Choose fine calibration from Calib menu. Choose Calibrate on the FlexPendant. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 244 • Synchronization marks and synchronization position for axes on page 228 Choose Update Revolution counters from the Calib menu. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 245 • Location of calibration pins on page 242 Release the brakes. See section • Manually releasing the brakes on page 66 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 246 228 Choose Update Revolution counters from the Calib menu. Choose Axis 4 on the FlexPendant and update the revoultion counters. Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 247 228 Choose Update Revolution counters from the Calib menu. Choose Axis 5 to 6 on the FlexPendant and update the revoultion counters. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 248: Verifying The Calibration
228. Write down the values on a new label and stick it on top of the calibration label. Remove any calibration equipment from the robot. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 249: Checking The Synchronization Position
If they do not, up- ization position for axes on page 228 date the revolution counters. Updating revolution counters on page 231. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
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Page 251: Decommissioning
These parts must also be disposed of in accordance with the current legislation of the country in which the robot and control unit are installed. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 252: Environmental Information
Spills can form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. • Spillage can penetrate the soil causing ground water contamination. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 253: Scrapping Of Robot
• When motors are removed from the robot, the robot will collapse if it is not properly supported before the motor is removed. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
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Page 255: 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. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 256: Applicable Standards
Safety of machinery - Ergonomic design principles - Part 1: Terminology and general principles EN 574:1996 + A1:2008 Safety of machinery - Two-hand control devices - Functional aspects - Principles for design Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 257: Unit Conversion
1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 258: 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 259: Weight Specifications
All components exceeding 22 kg (50 lbs) are highlighted in this way. To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.
Page 260: Standard Toolkit
Plastic mallet Ratchet head for torque wrench 1/2 Socket head cap no. 2.5, socket 1/2" bit L 110 mm Small cutting plier T-handle with ball head Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 261: Special Tools
Attachment screws DIN912 (swing hous- ing) M4x8 quality Steel 8.8-ELZN (2 pcs) • Conical spring washers 4 mm (swing housing) 4.3x9x1.3 quality Steel-MZn12C (2 pcs) Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 262: Lifting Equipment And Lifting Instructions
This implies that the instructions delivered with the lifting equipment should be stored for later reference. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 263: Spare Parts
8.1 Spare part lists and illustrations Location Spare parts and exploded views are not included in the manual but delivered as a separate document on the documentation DVD. Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
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Page 265: Circuit Diagrams
Circuit diagram - IRB 6600 type A 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6600 type B 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6620 3HAC025090-001 Continues on next page Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 266 Circuit diagram - IRB 6700 3HAC043446-005 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 14000 3HAC050778-003 Circuit diagram - IRB 910SC 3HAC056159-002 Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 267 38 drive module, 48 direction of axes, 230 manually releasing brakes, 66 mechanical stop location, 96 MoveAbsJ instruction, 249 enabling device, 36 environmental information, 252 Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 268 248 symbols on robot, 40 test run, 47 working range, 37 wall mounting, 75 wrist strap, 50 weight, 56 safety risk robot, 64, 259 Product manual - IRB 120 3HAC035728-001 Revision: N © Copyright 2009-2017 ABB. All rights reserved.
Page 272 ABB AS, Robotics Robotics and Motion Nordlysvegen 7, N-4340 BRYNE, Norway Box 265, N-4349 BRYNE, Norway Telephone: +47 22 87 2000 ABB Engineering (Shanghai) Ltd. Robotics and Motion No. 4528 Kangxin Highway PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc.

ABB IRB 120 Product Manual

1 Safety

2 Installation and Commissioning

3 Maintenance

4 Repair

5 Calibration

6 Decommissioning

7 Reference Information

8 Spare Parts

9 Circuit Diagrams

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