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IRB 1600
ABB IRB 1600 User Manual
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ROBOTICS
Product
manual
IRB
1600/1660
2
Table of Contents
Default Chapter
5
Table of Contents
5
Overview of this Manual
9
Product Documentation
15
Safety Information
17
Illustrations
17
How to Read the Product Manual
17
General Safety Information
19
Limitation of Liability
19
Nation/Region Specific Regulations
19
Safe Access
20
Safe Handling
20
Safe Design
20
Protective Stop and Emergency Stop
21
Safety Actions
22
Fire Extinguishing
22
Emergency Release of the Robot Axes
23
Increased Injury
23
Make Sure that the Main Power Has Been Switched off
24
Safety Risks During Installation and Service Work on Robots
25
Requirements on Personnel
25
Safety Risks During Operational Disturbances
25
Spare Parts and Special Equipment
26
Connection of External Safety Devices
26
Personal Protective Equipment
26
Moving Robots Are Potentially Lethal
27
First Test Run May Cause Injury or Damage
28
Work Inside the Working Range of the Robot
29
Enabling Device and Hold-To-Run Functionality
30
Three-Position Enabling Device
30
Hold-To-Run Function
30
Risks Associated with Live Electric Parts
31
Voltage Related Risks, General
31
Voltage Related Risks, IRC5 Controller
31
Voltage Related Risks, Manipulator
31
The Unit Is Sensitive to ESD
33
Hot Parts May Cause Burns
34
Safety Risks Related to Pneumatic/Hydraulic Systems
35
Residual Energy
35
Brake Testing
36
Safety Risks During Handling of Batteries
37
Safety Risks During Work with Gearbox Lubricants (Oil or Grease)
38
Introduction to Safety Signals
40
Danger Levels
40
Safety Signals in the Manual
40
Safety Symbols on Product Labels
42
Introduction to Labels
42
Types of Labels
42
Symbols on Safety Labels
42
2 Installation and Commissioning
49
Introduction
49
Unpacking
50
Pre-Installation Procedure
50
Prerequisites for Installation Personnel
50
Checking the Pre-Requisites for Installation
50
Weight, Robot
51
Loads on Foundation, Robot
51
Floor Mounted
52
Wall Mounted
52
Requirements, Foundation
52
Storage Conditions, Robot
53
Operating Conditions, Robot
53
Protection Classes, Robot
54
Working Range
55
Range of Movement - IRB 1600
55
Range of Movement - IRB 1600ID
55
Range of Movement - IRB 1660ID
55
Positions at Wrist Center IRB 1660ID
59
Turning Radius
60
Risk of Tipping/Stability
61
Shipping and Transportation Position
61
On-Site Installation
63
Lifting Robot with Roundslings
63
Attaching the Roundslings
63
Required Equipment
64
Lifting the Robot with Roundslings
64
Lifting and Turning a Suspended Mounted Robot
65
Manually Releasing the Brakes
66
Using the Brake Release Unit with an External Power Supply
67
Orienting and Securing the Robot
68
Hole Configuration, Base
68
Dimension, Mounting Surface and Guiding Sleeve
69
Attachment Bolts, Specification
69
Guiding Sleeves
69
Orienting and Securing the Robot to Installation Site
70
Isolating AW Manipulator
70
Setting the System Parameters for a Suspended or Tilted Robot
72
The X-Direction in the Base Coordinate System
72
System Parameters
73
Gravity Beta
73
Gamma Rotation
73
Mounting Angles and Values
74
Examples of Mounting Angles Tilted Around the y Axis (Gravity Beta)
75
Examples of Mounting Angles Tilted Around the X Axis (Gravity Alpha)
76
Limitations in Working Area
77
Defining the Parameter in the IRC5 Software
77
Loads Fitted to the Robot, Stopping Time and Braking Distances
78
Fitting Equipment on the Robot (Robot Dimensions)
79
Load Areas
79
Dimensions IRB 1600-X/1.2 (1.45)
81
Dimensions IRB 1600ID
82
Holes for Mounting of Extra Equipment for IRB 1600
84
Design until June 2006
85
Design after June 2006, Type a
85
Holes for Mounting of Extra Equipment for IRB 1600ID
86
Holes for Mounting of Extra Equipment for IRB 1660ID
88
Robot Tool Flange
89
Robot Tool Flange for IRB 1600ID
90
Robot Tool Flange for IRB 1660ID
91
Fastener Quality
91
Installation of Signal Lamp for 1600 (Option)
92
Different Signal Lamps on IRB 1600 and IRB 1600ID
92
Location of Signal Lamp
92
Installation, Signal Lamp
93
Installation of Signal Lamp for 1600ID/1660ID (Option)
95
Installation of the Wire Feeder Shelf for 1600ID/1660ID
97
Location of Shelf, Wire Feeder
97
Restricting the Working Range
99
Axes with Restricted Working Range
99
Installation of Additional Mechanical Stops on Axis
100
Restrictions in Working Range
100
Keep X Direction Downwards (Tilted or Wall Mounted Robot)
101
Installation of Mechanical Stop, Axis 1
103
Installation of Additional Mechanical Stop on Axis
105
Installation of Additional Mechanical Stops on Axis
109
Installation of Position Switch, Axis
113
Electrical Connections
116
Customer Connectors on the Robot
116
Connections at Robot Base
116
Connections on Upper Arm
118
Robot Cabling and Connection Points
119
Main Cable Categories
119
Robot Cable, Power, for Robots with Standard Protection
119
Robot Cable, Power, for Robots with Foundry and Wash Protection
120
Robot Cable, Signals
120
Bending Radius for Static Floor Cables
120
Grounding and Bonding Point on Manipulator
121
Cabling between Robot Base and Controller
121
Customer Cables for Robots with Standard Protection
121
Customer Cables for Robots with Foundry and Wash Protection
122
Customer Connections on the Robot
123
Air Connection
123
Customer Connectors R2.CS and R2.CP
123
Connector Set from ABB for Standard Connection
123
Specified Connector Components from Souriau
124
Recommended Pin Connectors
124
Recommended Backshell
124
Connectors that Meet Military Standard
125
Connector for Crimping
125
Connector for Soldering
125
Start of Robot in Cold Environments
126
Problems with Starting the Robot
126
Event Message from Motion Supervision
126
Robot Stopping with Other Event Message
126
3 Maintenance
127
Introduction
127
Maintenance Schedule and Expected Component Life
128
Specification of Maintenance Intervals
128
Maintenance Schedule
129
Expected Component Life
131
Inspection Activities
132
Inspection, Damper Axes 2, 3 and 5
132
Location of Dampers
132
Inspection, Dampers
134
Inspecting Information Labels
135
Location of Information Labels
135
Replacement Activities
137
Type of Lubrication in Gearboxes
137
Type and Amount of Oil in Gearboxes
137
Location of Gearboxes
137
Changing the Oil in Axes 5 and 6 Gearboxes
138
Location of Oil Plugs
138
Draining, Wrist Unit
139
Filling Oil, Wrist Unit
140
Location of Oil Plugs, Axis 5-6 Gearbox
141
Changing the Oil in Axes 5 and Axis 5 and 6 Gearboxes, IRB 1600ID/1660ID
141
Draining, Axis 5-6 Gearbox
142
Filling Oil, Axis 5-6 Gearbox
143
Replacing the Battery Pack
144
Location of Battery Pack
144
Battery Pack on Serial Measurement Unit
145
Replacement, Battery Pack
147
Cleaning Activities
149
Cleaning the IRB 1600/1660ID
149
Oil Spills from Gearboxes
149
Special Cleaning Considerations
149
Cleaning Methods
150
Cleaning with Water and Steam
150
Instructions for Rinsing with Water
150
Instructions for Steam or High Pressure Water Cleaning
151
Cables
151
4 Repair
153
Introduction
153
General Procedures
154
Performing a Leak-Down Test
154
When to Perform a Leak-Down Test
154
Mounting Instructions for Bearings
155
Assembly of All Bearings
155
Assembly of Tapered Bearings
155
Greasing of Bearings
155
Mounting Instructions for Seals
157
Rotating Seals
157
Flange Seals and Static Seals
158
O-Rings
158
Cut the Paint or Surface on the Robot before Replacing Parts
159
The Brake Release Buttons May be Jammed after Service Work
161
Complete Manipulator
162
Replacing the Cable Harness, IRB 1600
162
Illustration, Covers to Remove
163
Deciding Calibration Routine
164
Removal, Cable Harness
164
Illustration, Cabling Inside Upper Arm Housing
166
Refitting, Cable Harness in Upper Arm Housing and Lower Arm
167
Illustration, Cabling Inside Frame
168
Illustration, Cabling Inside Base
169
Refitting, Cable Harness in Frame and Base
170
Replacing the Cable Harness, 1600ID/1660ID
172
Location of the Harness
172
Removal, Cable Harness Lower Arm and Upper Arm Back
174
Removal, Cable Harness Upper Arm Tube
175
Refitting, Cable Harness
177
Replacement of Complete Arm System
178
Location of Complete Arm System
178
Removing the Complete Arm System
179
Refitting, Complete Arm System
181
Upper and Lower Arm
183
Replacing the Complete Upper Arm, IRB 1600
183
Replacing the Complete Upper Arm, IRB 1600ID/1660ID
188
Location of the Complete Upper Arm
188
Refitting the Complete Upper Arm
193
Replacing the Complete Lower Arm
196
Location of Lower Arm
196
Replacing the Wrist Unit, IRB 1600
201
Location of Wrist Unit
201
Replacing the Wrist Unit, IRB 1600ID
206
Replacing the Wrist Unit, IRB1660ID
212
Replacing the Damper, Axis 2
220
Location of Damper, Axis 2
220
Replacing the Damper, Axis 3
222
Location of Damper, Axis 3
222
Replacing the Mechanical Stop Axis 3, IRB 1600ID/1660ID
224
Location of the Mechanical Stop Axis 3
224
Replacement of Damper, Axis 5
226
Location of Damper, Axis 5
226
Remove Upper Arm AW Gun
228
Location of AW Gun
228
Remove AW Gun
229
Refit AW Gun
231
Measuring the Play 1600ID/1660ID, Axis 5
233
Measuring the Play 1600ID/1660ID, Axis 6
236
Frame and Base
239
Replacement of Base
239
Location of Base
239
Removal, Base
241
Replacing the Serial Measurement Unit
244
Location of Serial Measurement Unit
244
Serial Measurement Unit Layout
245
Removing the Serial Measurement Unit
247
Replacing the Push Button Unit
251
Location of Push Button Unit
251
Push Button Unit on Serial Measurement Unit
251
Removing the Push Button Unit
252
Replacement of Motor, Axis 1
257
Replacement of Motor, Axis 2
262
Location of Motor Axis 2
262
Replacement of Motor, Axis 3, IRB 1600
268
Replacement of Motor, Axis 3, 1600ID/1660ID
273
Replacement of Motor, Axis 4, IRB 1600
279
Removal, Motor Axis 4
281
Replacement of Motor, Axis 4, 1600ID/1660ID
284
Replacement of Motor and Timing Belt, Axis 5, IRB 1600
288
Belt Tightener, 3HAC 024044-001
289
Removal, Motor Axis 5 and Timing Belt
290
Refitting, Motor and Timing Belt Axis 5
291
Replacement of Motor, Axis 5, IRB 1600ID
294
Location of Motor, Axis 5
294
Replacement of Motor, Axis 5, IRB 1660ID
302
Location of Motor Axis 5
302
Replacement of Motor and Timing Belt, Axis 6, IRB 1600
311
Replacement of Motor, Axis 6, IRB 1600ID
315
Replacement of Motor, Axis 6, IRB 1660ID
319
Location of Motor Axis 6
319
Removing Axis-6 Motor and Wrist Unit
320
Gearboxes
329
Replacement of Gearbox, Axes
329
Location of Gearbox Unit, Axes 1-2
329
Removal, Gearbox Unit Axes 1-2
331
Service Work on Gearboxes, Axes 3, 4, 5 and 6
335
Gearboxes, Replacement
335
Introduction and Calibration Terminology
337
Calibration Methods
338
Types of Calibration
338
Brief Description of Calibration Methods
339
Calibration Pendulum Method
339
Axis Calibration Method
339
Calibware - Absolute Accuracy Calibration
339
When to Calibrate
340
The Revolution Counter Memory Is Lost
340
The Robot Is Rebuilt
340
The Resolver Values Are Changed
340
Synchronization Marks and Axis Movement Directions
341
Synchronization Marks and Synchronization Position for Axes
341
Calibration Movement Directions for All Axes
344
Manual Movement Directions, 6 Axes
344
Updating Revolution Counters
345
Coupled Axes
345
Correct Calibration Position of Axis 4 and 6
345
Updating the Revolution Counter with the Flexpendant
346
Calibrating with Axis Calibration Method
349
Description of Axis Calibration
349
Overview of the Axis Calibration Procedure
349
Routines in the Calibration Procedure
350
Fine Calibration Routine
350
Reference Calibration Routine
350
Update Revolution Counters
350
Calibration Tools for Axis Calibration
352
Examining the Calibration Tool
352
Check Prior to Usage
352
Periodic Check of the Calibration Tool
353
Installation Locations for the Calibration Tools
354
Location of Fixed Calibration Items
354
Axis Calibration - Running the Calibration Procedure
358
Overview of the Calibration Procedure on the Flexpendant
358
Preparation Prior to Calibration
360
Starting the Calibration Procedure
360
Restarting an Interrupted Calibration Procedure
361
Axis Calibration with Safemove Option
362
Safety Controller Not Synchronized - Safemove Message
362
Calibrating with Calibration Pendulum Method
366
Where to Find Information for Calibration Pendulum
366
Verifying the Calibration
367
Checking the Synchronization Position
368
Using a Moveabsj Instruction
368
Using the Jogging Window
368
6 Decommissioning
369
Environmental Information
369
Hazardous Material
369
Oil and Grease
369
Scrapping of Robot
371
Important When Scrapping the Robot
371
7 Robot Description
373
Type a of IRB 1600
373
How to Know Which Type the Robot Is?
373
Which Parts Are Interchangeable and Which Are Not?
373
Type a of IRB 1600ID
374
Upgrade from IRB 1600ID to IRB 1600ID Type a
374
8 Reference Information
375
Introduction
375
Applicable Standards
376
Standards, en ISO
376
European Standards
376
Unit Conversion
378
Converter Table
378
Screw Joints
379
UNBRAKO Screws
379
Gleitmo Treated Screws
379
Screws Lubricated in Other Ways
379
Oil-Lubricated Screws with Slotted or Cross-Recess Head Screws
380
Oil-Lubricated Screws with allen Head Screws
380
Water and Air Connectors
381
Weight Specifications
382
Definition
382
Standard Tools
383
Contents, Standard Toolkit
383
Special Tools
384
Measuring Tools, Play
384
Calibration Equipment, Calibration Pendulum
384
Calibration Equipment, Axis Calibration
385
Lifting Accessories and Lifting Instructions
386
Spare Part Lists and Illustrations
387
10 Circuit Diagram
389
Controllers
389
Index
391
5
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ABB IRB 1600 Specifications
General
Number of Axes
6
Repeatability
±0.05 mm
Protection
IP 40
Controller
IRC5
Weight
250 kg
Reach
1.2 m
Mounting
Floor, Inverted
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