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IRB 120
ABB IRB 120 User Manual
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1.2.5.2
Fire
extinguishing
Note
Use
a
CARBON
DIOXIDE
(CO
2
)
extinguisher
in
the
event
of
a
fire
in
the
robot
or
controller!
32
Product
manual
-
IRB
120
3HAC035728-001
Revision:
N
©
Copyright
2009-2017
ABB.
All
rights
reserved.
1
Safety
1.2.5.2
Fire
extinguishing
31
33
Table of Contents
Default Chapter
5
Table of Contents
5
Overview of this Manual
9
Product Documentation, IRC5
14
How to Read the Product Manual
16
1 Safety
17
Introduction to Safety Information
17
General Safety Information
18
Introduction to General Safety Information
18
Safety in the Robot System
19
Protective Stop and Emergency Stop
21
Safety Risks
22
Safety Risks During Installation and Service Work on Manipulators
22
CAUTION - Hot Parts May Cause Burns
25
Safety Risks Related to Tools/Work Pieces
26
Safety Risks Related to Pneumatic/Hydraulic Systems
27
Safety Risks During Operational Disturbances
28
Risks Associated with Live Electric Parts
29
Safety Actions
31
Safety Fence Dimensions
31
Fire Extinguishing
32
Emergency Release of the Robot Arm
33
Brake Testing
34
Risk of Disabling Function "Reduced Speed 250 MM/S
35
Enabling Device and Hold-To-Run Functionality
36
Work Inside the Working Range of the Robot
37
Safety Signals and Symbols
38
Safety Signals in the Manual
38
Safety Symbols on Product Labels
40
Safety Related Instructions
46
DANGER - Moving Robots Are Potentially Lethal
46
DANGER - First Test Run May Cause Injury or Damage
47
DANGER - Make Sure that the Main Power Has Been Switched off
48
WARNING - the Unit Is Sensitive to ESD
50
WARNING - Safety Risks During Handling of Batteries
52
WARNING - Safety Risks During Work with Gearbox Lubricants (Oil or Grease)
53
2 Installation and Commissioning
55
Introduction
55
Product Manual - IRC5
55
Unpacking
56
Pre-Installation Procedure
56
Working Range and Type of Motion
60
Risk of Tipping/Stability
62
On-Site Installation
63
Lifting the Robot with Roundslings
63
Manually Releasing the Brakes
66
Orienting and Securing the Robot
70
Fitting Equipment on Robot
72
Setting the System Parameters for a Suspended or Tilted Robot
75
Loads Fitted to the Robot, Stopping Time and Braking Distances
80
Restricting the Working Range
81
Axes with Restricted Working Range
81
Mechanically Restricting the Working Range
82
Making Robot Ready for Operation
84
Additional Installation Procedure, Clean Room
84
Electrical Connections
85
Robot Cabling and Connection Points
85
Customer Connections on the Robot
87
Start of Robot in Cold Environments
89
3 Maintenance
91
Introduction
91
Product Manual - IRC5
91
Maintenance Schedule
92
Specification of Maintenance Intervals
92
Maintenance Schedule
93
Inspection Activities
95
Inspecting the Robot Cabling
95
Inspecting Mechanical Stops
96
Inspecting Dampers
99
Inspecting Timing Belts
101
Inspecting Plastic Covers
105
Replacement/Changing Activities
107
Type of Lubrication in Gearboxes
107
Replacing the Battery Pack
109
On Page
109
Continues on Next Page
109
Cleaning Activities
112
Cleaning the IRB 120
112
4 Repair
115
Introduction
115
Safety
115
Warning
115
General Procedures
116
Mounting Instructions for Seals
116
Replacing Parts on the Robot
118
Cable Harness
120
Removing the Cable Harness
120
Product Manual - IRB
120
Refitting the Cable Harness
134
Replacing the Encoder Interface Board
148
Plastic Covers
151
Replacing Plastic Covers
151
Upper Arm
155
Replacing the Upper Arm
155
Lower Arm
164
Replacing the Lower Arm
164
Motors and Motors with Gearboxes
169
Replacing Axis-1 Motor with Gearbox
169
Replacing Axis-2 Motor with Gearbox
190
Replacing Axis-3 Motor with Gearbox
202
Replacing Motor Axis 4, with Gearbox
210
Replacing Motor Axis 5
211
Replacing Motor Axis 6
217
Gearboxes
218
Replacing Gearbox Axis 1
218
Replacing Gearbox Axis 2
219
Replacing Gearbox Axis 3
220
Replacing Gearbox Axis 4
221
Replacing Gearbox Axis 5
222
Replacing Gearbox Axis 6
223
5 Calibration
225
Introduction to Calibration
225
Introduction and Calibration Terminology
225
Calibration Methods
226
When to Calibrate
227
Synchronization Marks and Axis Movement Directions
228
Synchronization Marks and Synchronization Position for Axes
228
Calibration Movement Directions for All Axes
230
Updating Revolution Counters
231
Calibrating with Axis Calibration Method
235
Description of Axis Calibration
235
Axis Calibration - Running the Calibration Procedure
237
Calibrating with Manual Calibration Method
242
Verifying the Calibration
248
Checking the Synchronization Position
249
6 Decommissioning
251
Introduction
251
Environmental Information
252
Scrapping of Robot
253
7 Reference Information
255
Introduction
255
Applicable Standards
256
Unit Conversion
257
Screw Joints
258
Weight Specifications
259
Standard Toolkit
260
Special Tools
261
Lifting Equipment and Lifting Instructions
262
8 Spare Parts
263
Spare Part Lists and Illustrations
263
9 Circuit Diagrams
265
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ABB IRB 120 Specifications
General
Brand
ABB
Model
IRB 120
Category
Robotics
Language
English
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