IRC5-IRB7600 Prod Man Part13HAC022033-001 Procedures RevB En

8/9/2019 IRC5-IRB7600 Prod Man Part13HAC022033-001 Procedures RevB En

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Product manual (part 1 of 2), procedures

IRB 7600 - 500/2.3

IRB 7600 - 400/2.55

IRB 7600 - 340/2.8

IRB 7600 - 150/3.5

M2000

M2000A

M2004

Document ID: 3HAC 022033-001

Revision: B


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The information in this manual is subject to change without notice and should not be

construed as a commitment by ABB. ABB assumes no responsibility for any errors that

may appear in this manual.

Except as may be expressly stated anywhere in this manual, nothing herein shall be

construed as any kind of guarantee or warranty by ABB for losses, damages to persons

or property, fitness for a specific purpose or the like.

In no event shall ABB be liable for incidental or consequential damages arising fromuse of this manual and products described herein.

This manual and parts thereof must not be reproduced or copied without ABBs writtenpermission, and contents thereof must not be imparted to a third party nor be used forany unauthorized purpose. Contravention will be prosecuted.

Additional copies of this manual may be obtained from ABB at its then current charge.

Copyright 2004 ABB All right reserved.

ABB Automation Technologies ABRobotics

SE-721 68 Vsters

Sweden


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Table of Contents

33HAC 022033-001 Revision: B

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1 Safety 11

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.2.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.2.2.1 Safety, service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.2.2.2 Limitation of Liability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.2.2.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.2.3 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.2.3.1 Safety risks during service work on robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.2.3.2 Safety risks related to gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.2.3.3 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191.2.3.4 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.2.3.5 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.2.3.6 Safety risks during installation and service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.2.3.7 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.2.4 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.2.4.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.2.4.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.2.4.3 Emergency release of the robots arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.2.4.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.2.4.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.2.4.7 Work inside the manipulators working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301.3 Safety related instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1.3.2 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

1.3.3 WARNING - The brake release buttons may be jammed after service work . . . . . . . . . . . . . . . . 34

1.3.4 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

1.3.5 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

1.3.6 WARNING - Mixed oils may cause severe damage to gearbox! . . . . . . . . . . . . . . . . . . . . . . . . . 38

2 Installation and commissioning 39

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

2.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.2.1 Pre-installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402.2.2 Working range, IRB 7600 - 150/3.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

2.2.3 Working range, IRB 7600 - 340/2.8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

2.2.4 Working range, IRB 7600 - 400/2.55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2.2.5 Working range, IRB 7600 - 500/2.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2.2.6 Risk of tipping / stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

2.3 On-site Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2.3.1 Lifting robot with fork lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2.3.2 Lifting robot with lifting slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

2.3.3 Lifting manipulator with roundslings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

2.3.4 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

2.3.5 Manually releasing the brakes, external brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

2.3.6 Lifting the base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 672.3.7 Securing the base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68


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2.3.8 Orienting and securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

2.3.9 Fitting equipment on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

2.3.10 Installation of chip and dust protection (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

2.3.11 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

2.4 Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

2.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

2.4.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90



2.4.5 Position switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

2.5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

2.5.1 Robot cabling and connection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

3 Maintenance 103

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

3.2 Maintenance schedule and expected life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1043.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

3.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

3.2.3 Expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

3.3.1 Inspection, oil level gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109




3.3.5 Inspection, oil level, gearbox axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121


3.3.7 Inspection, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

3.3.8 Inspection, cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1323.3.9 Inspection, mechanical stop, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

3.3.10 Inspection, mechanical stop, axes 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

3.3.11 Inspection, damper axes 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

3.3.12 Inspection, position switch axes 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

3.3.13 Inspection, information labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

3.3.14 Inspection, UL-lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

3.4 Changing/replacement activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

3.4.1 Oil in gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

3.4.2 Oil change, gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154


3.4.4 Oil change, gearbox, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161




3.5 Lubrication activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

3.5.1 Lubrication, balancing device bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

3.6 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

3.6.1 Flushing a contaminated gearbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

3.6.2 Cleaning, manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

3.7 Service Information System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

3.7.1 Using the SIS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

3.7.2 Description of Service Information System (SIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

3.7.3 SIS system parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

3.7.4 Setting the SIS parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1873.7.5 Reading the SIS output logs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190


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3.7.6 Exporting the SIS data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

4 Repair 193

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

4.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

4.2.2 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

4.2.3 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

4.3 Complete manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

4.3.1 Replacement of cable harness, axes 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

4.3.2 Replacement of cable harness, axes 5-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

4.3.3 Removal of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

4.3.4 Refitting of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

4.4 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

4.4.1 Removal of turning disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

4.4.2 Refitting of turning disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2224.4.3 Removal of complete wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

4.4.4 Refitting of complete wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

4.4.5 Removal of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

4.4.6 Refitting of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

4.5 Lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

4.5.1 Removal of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

4.5.2 Refitting of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

4.6 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

4.6.1 Removal of SMB related equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

4.6.2 Refitting of SMB related equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

4.6.3 Removal of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

4.6.4 Refitting of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2614.6.5 Removal of balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

4.6.6 Refitting of balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

4.6.7 Unloading the balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

4.6.8 Restoring the balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

4.7 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

4.7.1 Removal of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

4.7.2 Refitting of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283





4.7.7 Removal of motor, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3004.7.8 Refitting of motor, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303


4.7.10 Refitting of motor, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

4.7.11 Removal of motor, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315

4.7.12 Refitting of motor, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

4.8 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

4.8.1 Replacement of gearbox, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

4.8.2 Removal of gearbox, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328

4.8.3 Refitting of gearbox, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332



4.8.6 Removal of gearbox, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3444.8.7 Refitting of gearbox, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346


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Table of Contents




4.8.10 Removal of gearbox, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360

4.8.11 Refitting of gearbox, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362

5 Calibration information 365

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365

5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366

5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368

5.4 Calibration movement directions for all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369

5.5 Updating revolution counters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370

5.6 Checking the calibration position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374

6 Decommissioning 377

6.1 Environmental information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378

6.2 Decommissioning of balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379


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Overview


Overview

About this manual

This manual contains instructions for

installing the manipulator, mechanically as well as electrically

maintenance of the manipulator

mechanical and electrical repair of the manipulator.

Usage

This manual should be used during

installation, from lifting the manipulator to its work site and securing it to the

foundation to making it ready for operation

maintenance work repair work.

Who should read this manual?

This manual is intended for:

installation personnel

maintenance personnel

repair personnel.

Prerequisites

The reader should...

be a trained maintenance/repair craftsman

have the required knowledge of mechanical and electrical installation/repair/

maintenance work.


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Overview


Organization of chapters

The manual is organized in the following chapters:

Revisions

Chapter Contents

Safety, service Safety information

Installation and

commissioning

Information about installation of the manipulator, including working

ranges, lifting instructions, on-site installation, fitting of extraequipment, etc.

Maintenance Information about maintenance work, including maintenance

schedules.

Repair Information about repair work. Each procedure include necessary

spare parts, tools, etc.

Calibration information Procedures that do not require specific calibration equipment.

General information about calibration.

Decommissioning Environmental information about the manipulator.

Revision Description

- First edition.

Replaces previous manuals:

Installation and Commissioning Manual

Maintenance Manual

Repair Manual, part 1

Repair Manual, part 2.Changes made in the material from the previous manuals:

Model M2004 implemented.

Various corrections due to technical revisions, changes in the toolkitsetc.

A Chapter Calibrationreplaced with chapter Calibration information.

Following corrections are made:

In chapter 3: Maintenancein section Exporting the SIS data, the unitsecondsfor different SIS parameters is replaced by the unit hours. The

change is only valid for RobotWare release 5.0.

Following updates are made:

In chapter 4: Repair, the sections Removal of complete lower armand

Refitting of complete lower armare completed with more detailedinformation about how to use the glycerin pump.

B New lubricating oil in the gearboxes. Changes made in the chapterMaintenance.


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Product documentation, M2000/M2000A


Product documentation, M2000/M2000A

General

The complete product documentation kit for the M2000 robot system, including controller,

robot and any hardware option, consists of the manuals listed below:

Hardware manuals

All hardware, robots and controller cabinets, will be delivered with a Product manualwhich

is divided into two parts:

Product manual, procedures

Safety information

Installation and commissioning (descriptions of mechanical installation, electrical

connections and loading system software)

Maintenance (descriptions of all required preventive maintenance procedures

including intervals)

Repair (descriptions of all recommended repair procedures including spare parts)

Additional procedures, if any (calibration, decommissioning)

Product manual, reference information

Reference information (article numbers for documentation referred to in Product

manual, procedures, lists of tools, safety standards)

Part list

Foldouts or exploded views

Circuit diagrams

Software manuals

The software documentation consists of a wide range of manuals, ranging from manuals for

basic understanding of the operating system to manuals for entering parameters during

operation.

A complete listing of all available software manuals is available from ABB.

Controller hardware option manual

Each hardware option for the controller is supplied with its own documentation. Each

document set contains the types of information specified below:

Installation information

Repair information

Maintenance information

In addition, spare part information is supplied for the entire option.


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Product documentation, M2004



General

The robot documentation may be divided into a number of categories. This listing is based on

the type of information contained within the documents, regardless of whether the products

are standard or optional. This means that any given delivery of robot products will not contain

alldocuments 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.

Hardware manuals

All hardware, robots and controller cabinets, will be delivered with a Product manualwhich

is divided into two parts:

Product manual, procedures

Safety information

Installation and commissioning (descriptions of mechanical installation, electrical

connections and loading system software)

Maintenance (descriptions of all required preventive maintenance procedures

including intervals)

Repair (descriptions of all recommended repair procedures including spare parts)

Additional procedures, if any (calibration, decommissioning)

Product manual, reference information

Reference information (article numbers for documentation referred to in Productmanual, procedures, lists of tools, safety standards)

Part list

Foldouts or exploded views

Circuit diagrams

RobotWare manuals

The following manuals describe the robot software in general and contain relevant reference

information:

RAPID Overview: An overview of the RAPID programming language.

RAPID reference manual part 1: Description of all RAPID instructions.

RAPID reference manual part 2: Description of all RAPID functions and data types.

Technical reference manual - System parameters: Description of system

parameters and configuration workflows.


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Application manuals

Specific applications (e.g. software or hardware options) are described in Application

manuals. An application manual can describe one or several applications.

An application manual generally contains information about:

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

What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)

How to use the application

Examples of how to use the application

Operators manuals

This group of manuals is aimed at those having first hand operational contact with the robot,

i.e. production cell operators, programmers and trouble shooters. The group of manuals

include: Operators manual - IRC5 with FlexPendant

Operators manual - RobotStudio Online

Trouble shooting manualfor the controller and robot

Miscellaneous

A number of manuals provide generic descriptions of the robot and robot system. These

include:

Robot fundamentals(describing the fundamental aspects, functions, concept and

similar, of a robot system to provide a basic understanding of the robot system)


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How to read the product manual


How to read the product manual

Reading the procedures

The procedures contain references to figures, tools, material 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. The components or attachment points are marked with italic textin the

procedures and completed with a reference to the figure where the current component or

attachment point is shown.

The denomination in the procedure for the component or attachment point corresponds to the

denomination in the referenced figure.

The table below shows an example of a reference to a figure from a step in an procedure.

References to required equipment

The procedures often include references to equipment (spare parts, tools etc.) required for the

different actions in the procedure. The equipment is marked with italic textin the procedures

and completed with a reference to the section where the equipment is listed with further

information, i.e. article number, dimension.

The denomination in the procedure for the component or attachment point corresponds to the

denomination in the referenced list.

The table below shows an example of a reference to a list of required equipment, from a step

in an procedure.

Safety information

The manual includes a separate safety chapter that must be read through before proceeding

with any service or installation procedures. All procedures also include specific safety

information when dangerous steps are to be performed. Read more in chapter Safetyon page

13.

Step Action Note/Illustration

8. Remove the rear attachment screws, gearbox. Shown in the figure Location ofgearbox on page xx.


3. Fit a new sealing, axis 2to the gearbox. Art. no. is specified in Requiredequipment on page xx.


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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 informationon page 14.

specific safety information, pointed out in the procedure at the moment of the danger.

How to avoid and eliminate the danger is either detailed directly in the procedure, or

further detailed in separate instructions, found in section Safety related instructionson

page 33.


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1 Safety

1.2.1. Introduction


1.2 General safety information

1.2.1. Introduction

Definitions

This section details general safety information for service personnel i.e. personnel performing

installation, repair and maintenance work.

Sections

The general safety information is divided into the following sections:

1. General information contains lists of:

Safety, service

Limitation of liability

Referenced documents

2. Safety risks lists dangers relevant when servicing the robot system. The dangers are split

into different categories:

Safety risks during service work on robot

Safety risks related to gripper/end effector

Safety risks related to tools/workpieces

Safety risks related to pneumatic/hydraulic systems

Safety risks during operational disturbances

Safety risks during installation and service

Risks associated with live electric parts

3. Safety actions details actions which may be taken to remedy or avoid dangers.

Safety fence dimensions

Fire extinguishing

Emergency release of the manipulators arm

Brake testing

Risk of disabling function "Reduced speed 250 mm/s"

Safe use of the Teach Pendant Unit enabling device

Work inside the manipulators working range Signal lamp (optional)


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1 Safety

1.2.2.1. Safety, service


1.2.2. General information

1.2.2.1. Safety, service

Validity and responsibility

The information does not cover how to design, install and operate a complete system, nor

does it cover all peripheral equipment, which can influence the safety of the total system. To

protect personnel, the complete system must be designed and installed in accordance with the

safety requirements set forth in the standards and regulations of the country where the robot

is installed.

The users of ABB industrial robots are responsible for ensuring that the applicable safety laws

and regulations in the country concerned are observed and that the safety devices necessary

to protect people working with the robot system have been designed and installed correctly.

Personnel working with robots must be familiar with the operation and handling of theindustrial robot, described in the applicable documents, e.g. Users Guide and Product

Manual.

Connection of external safety devices

Apart from the built-in safety functions, the robot is also supplied with an interface for the

connection of external safety devices. Via this interface, an external safety function can

interact with other machines and peripheral equipment. This means that control signals can

act on safety signals received from the peripheral equipment as well as from the robot.

In the Product Manual - Installation and Commissioning, instructions are provided for

connecting safety devices between the robot and the peripheral equipment.


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1 Safety

1.2.2.2. Limitation of Liability


1.2.2.2. Limitation of Liability

General

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

have been complied with.


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1 Safety

1.2.2.3. Related information


1.2.2.3. Related information

General

The list below specifies documents which contain useful information:

Documents

Type of information Detailed in document Section

Installation of safety devices Product manual for the

manipulator

Installation and commissioning

Changing robot modes Users Guide Start-up

Restricting the working space Product manual for themanipulator

Installation and commissioning


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1 Safety

1.2.3.1. Safety risks during service work on robot


1.2.3. Safety risks


Overview

This section includes information of general safety risks to be considered when performing

service work on the robot.

Complete robot

Cabling

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 robotdoes not collapse as parts are removed, e.g. secure the

lower arm with fixtures if removing motor, axis 2.


Cable packs are sensitive to

mechanical damage!

Caution!

The cable packs are sensitive to mechanical damage!They must be handled with care, especially theconnectors, in order to avoid damaging them!


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1 Safety



Gearboxes and motors

Balancing device


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!

Safety risk DescriptionDangerous balancing device!

Warning!

Do not under any circumstances, deal with the balancing

device in any other way than that detailed in the productdocumentation! For example, attempting to open thebalancing device is potentially lethal!


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1 Safety

1.2.3.2. Safety risks related to gripper


1.2.3.2. Safety risks related to gripper

CAUTION!

Ensure that a gripper is prevented from dropping a workpiece, if such is used.


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1 Safety

1.2.3.3. Safety risks related to tools/workpieces


1.2.3.3. Safety risks related to tools/workpieces

Safe handling

It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that guards

remain closed until the cutters stop rotating.

It should be possible to release parts by manual operation (valves).

Safe design

Grippers/end effectors must be designed so that they retain workpieces in the event of a power

failure or a disturbance of the controller.


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1 Safety

1.2.3.4. Safety risks related to pneumatic/hydraulic systems


1.2.3.4. Safety risks related to pneumatic/hydraulic systems

General

Special safety regulations apply to pneumatic and hydraulic systems.

Residual energy

Residual energy may be present in these systems so, after shutdown, particular care

must be taken.

The pressure in pneumatic and hydraulic systems must be released before starting to

repair them.

Safe design

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

Dump valves should be used in case of emergency.

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


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1 Safety

1.2.3.5. Safety risks during operational disturbances


1.2.3.5. Safety risks during operational disturbances

General

The industrial 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.

Care must be taken at all times.

Qualified personnel

Remedial action must only be carried out by qualified personnel who are familiar with

the entire installation as well as the special risks associated with its different parts.

Extraordinary risksIf the working process is interrupted, extra care must be taken due to risks other than those

associated with regular operation. Such an interruption may have to be rectified manually.


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1 Safety

1.2.3.6. Safety risks during installation and service


1.2.3.6. Safety risks during installation and service

General risks during installation and service

The instructions in the Product Manual - Installation and Commissioning must always

be followed.

Emergency stop buttons must be positioned in easily accessible places so that the robot

can be stopped quickly.

Those in charge of operations must make sure that safety instructions are available for

the installation in question.

Those who install the robot must have the appropriate training for the robot system in

question and in any safety matters associated with it.

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

Safety zones, which have to be crossed before admittance, must be set up in front of

the robot's working space. Light beams or sensitive mats are suitable devices.

Turntables or the like should be used to keep the operator out of the robot's working

space.

The axes are affected by the force of gravity when the brakes are released. In addition

to the risk of being hit by moving robot parts, you run the risk of being crushed by the

parallel arm.

Energy, stored in the robot for the purpose of counterbalancing certain axes, may be

released if the robot, or parts thereof, is dismantled.

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

Be aware of stored heat energy in the controller.

Never use the robot as a ladder, i.e. do not climb on the robot motors or other part

during service work. There is a serious risk of slipping because of the high temperature

of the motors or oil spills that can occur on the robot.

To be observed by the supplier of the complete system

The supplier of the complete system must ensure that all circuits used in the safety

function are interlocked in accordance with the applicable standards for that function.

The supplier of the complete system must ensure that all circuits used in the

emergency stop function are interlocked in a safe manner, in accordance with the

applicable standards for the emergency stop function.


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1 Safety

1.2.3.7. Risks associated with live electric parts


1.2.3.7. 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.

The mains supply to the robot must be connected in such a way that it can be turned

off outside the robot's working space.

Voltage related risks, controller

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

Be aware of stored electrical energy (DC link) in the controller.

Units inside the controller, e.g. I/O modules, can be supplied with power from an

external source.

The mains supply/mains switch

The power unit

The power supply unit for the computer system (230 VAC)

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

The drive unit (700 VDC)

The service outlets (115/230 VAC)

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

process

The external voltage connected to the control cabinet remains live even when the robot

is disconnected from the mains.

Additional connections

Voltage related risks, robot

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

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

The user connections for tools or other parts of the installation (max. 230 VAC, see

Installation and Commissioning Manual)

Voltage related risks, tools, material handling devices, etc

Tools, material handling devices, etc., may be live even if the robot system is in the OFF

position. Power supply cables which are in motion during the working process may be

damaged.


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1 Safety

1.2.4.1. Safety fence dimensions


1.2.4. Safety actions

1.2.4.1. Safety fence dimensions

General

Install a safety cell around the 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. Determine the maximum

speed from the maximum velocities of the robot axes and from the position at which the robot

is working in the work cell (see Product Specification - Description, Robot Motion).

Also consider the maximum possible impact caused by a breaking or malfunctioning rotating

tool or other device fitted to the manipulator.


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1 Safety

1.2.4.2. Fire extinguishing


1.2.4.2. Fire extinguishing

NOTE!

Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot (manipulatoror controller)!


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1 Safety

1.2.4.3. Emergency release of the robots arm


1.2.4.3. Emergency release of the robots arm

Description

In an emergency situation, any of the robots axes may be released manually by pushing the

brake release buttons on the robot or on an optional external brake release unit.

How to release the brakes is detailed in section:

Manually releasing the brakeson page 63.

The robot arm may be moved manually on smaller robot models, but larger models may

require using an overhead crane or similar.

Increased injury

Before releasing the brakes, make sure that the weight of the arms does not increase the

pressure on the trapped person, further increasing any injury!


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1 Safety

1.2.4.4. Brake testing


1.2.4.4. Brake testing

When to test

During operation the holding brakes 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 each axis motor holding brakes may be checked as detailed below:

1. Run each manipulator axis to a position where the combined weight of the manipulator

arm and any load is maximized (max. static load).

2. Switch the motor to the MOTORS OFF position with the Operating mode selector on the

controller.

3. Check that the axis maintains its position.

If the manipulator does not change position as the motors are switched off, then the brake

function is adequate.


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1 Safety

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


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

NOTE!

Do not change "Transm gear ratio" or other kinematic parameters from the Teach PendantUnit or a PC. This will affect the safety function Reduced speed 250 mm/s.


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1 Safety

1.2.4.6. Safe use of the Teach Pendant Unit


1.2.4.6. Safe use of the Teach Pendant Unit

NOTE!

The enabling device is a push button located on the side of the Teach Pendant Unit (TPU)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.

To ensure safe use of the Teach Pendant Unit, the following must be implemented:

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

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

there is no need for the robot to move.

The programmer must always bring the Teach Pendant Unit with him/her, when

entering the robot's working space. This is to prevent anyone else taking control over

the robot without the programmer knowing.


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1 Safety

1.2.4.7. Work inside the manipulators working range


1.2.4.7. Work inside the manipulators working range

WARNING!

If work must be carried out within the robots work envelope, the following points must beobserved:

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.

The robot's speed is limited to max. 250 mm/s when the operating mode selector is in

position < 250 mm/s. This should be the normal position when entering the working

space. The position 100% "full speed" may only be used by trained personnel who are

aware of the risks that this entails.

Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in

order not to get entangled with hair or clothing. Also be aware of any danger that maybe caused by rotating tools or other devices mounted on the manipulator or inside the

cell.

Test the motor brake on each axis, according to sectionBrake testingon page 29.


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1 Safety

1.3.1. Safety signals, general


1.3 Safety related instructions


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:

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

type of danger.

A brief description of what will happen if the operator/service personnel does not

eliminate the danger.

An instruction of how to eliminate the danger to facilitate performing the activity at

hand.

Danger levels

The table below defines the captions specifying the danger levels used throughout this

manual.

Symbol Designation Signification

danger

DANGER Warns that an accident willoccur if the instructions

are not followed, resulting in a serious or fatal injuryand/or severe damage to the product. It applies towarnings that apply to danger with, for example,

contact with high voltage electrical units, explosionor fire risk, risk of poisonous gases, risk of crushing,impact, fall from height etc.

warning

WARNING Warns that an accident mayoccur if the instructions

are not followed, that can lead to serious injury,possibly fatal, and/or great damage to the product. Itapplies to warnings that apply to danger with, for

example, contact with high voltage electrical units,

explosion or fire risk, risk of poisonous gases, risk ofcrushing, impact, fall from height etc.

Electrical shock

ELECTRICAL

SHOCK

The electrocution or electrical shock symbol

indicates electrical hazards which could result insevere personal injury or death.

caution

CAUTION Warns that an accident may occur if the instructions

are not followed, that can result in injury and/ordamage to the product. It also applies to warnings ofrisks that include burns, eye injury, skin injury,

hearing damage, crushing or slipping, tripping,

impact, fall from height etc. Furthermore, it applies towarnings that include function requirements whenfitting and removing equipment, where there is a risk

of damaging the product or causing a breakdown.


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1 Safety



Electrostatic discharge(ESD)

ELECTROSTATICDISCHARGE (ESD)

The electrostatic discharge (ESD) symbol indicateselectrostatic hazards which could result in severe

damage to the product.

Note

NOTE Note symbols alert you to important facts and

conditions.

Tip

TIP Tip symbols direct you to specific instructions, whereto find additional information or how to perform a

certain operation in an easier way.

Symbol Designation Signification


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1 Safety

1.3.2. DANGER - Moving manipulators are potentially lethal!


1.3.2. DANGER - Moving manipulators are potentially lethal!

Description

Any moving manipulator is a potentially lethal machine.

When running the manipulator, 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 manipulator

working range.

Elimination

Step Action Info/Illustration

1. Before attempting to run the manipulator,

make sure all emergency stop equipmenthas been correctly installed and connected.

Emergency stop equipment such as

gates, tread mats, light curtains, etc.

2. If possible, use the hold-to-run buttonwhenever possible.

The hold-to-run button is used in manualmode, not in automatic mode.

How to use the hold-to-run control inRobotWare 5.0 is detailed in sectionHow to use the hold-to-run switchinthe Operators Manual, IRC5.

How to use the hold-to-run control inRobotWare 4.0 is detailed in sectionThe Teach Pendant unitin the Users

Guide.

3. Make sure no personnel is present within

the manipulator working range beforepressing the start button.


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1 Safety

1.3.3. WARNING - The brake release buttons may be jammed after service work


1.3.3. 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!

In case the power is turned on while a brake release button is jammed in depressed position,

the affected motor brake is released! This may cause serious personal injuries and damage to

the robot!

Elimination

To eliminate the danger after service work has been performed inside the SMB recess, follow

the procedure below:

Step Action

1. Make sure the power is turned off.

2. Remove the push button guard, if necessary.

3. Check the push buttons of the brake release unit by pressing them down, one byone.

Make sure none of the buttons are jammed in the tube.

4. If a button gets jammed in the depressed position, the alignment of the brake release

unit must be adjusted so that the buttons can move freely in their tubes!


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1 Safety

1.3.4. WARNING - The unit is sensitive to ESD!


1.3.4. WARNING - The unit is sensitive to ESD!

Description

ESD (electro static 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 connected to ground potential may transfer

high static charges. This discharge may destroy sensitive electronics.

Elimination


1. Use a wrist strap Wrist straps must be tested frequently toensure that they are not damaged and areoperating correctly.

2. Use an ESD protective floor mat. The mat must be grounded through a current-limiting resistor.

3. Use a dissipative table mat. The mat should provide a controlled dischargeof static voltages and must be grounded.


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1 Safety

1.3.5. 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 Description Elimination / Action

-

Hot oil!

Changing and draininggearbox oil may require

handling hot oil of up to 90 C!

Make sure that protective gearlike goggles and gloves are

always worn during this activity.

-

Possible pressure build

up in gearbox!

When opening the oil plug,

there may be pressure presentin the gearbox, causing oil tospray from the opening!

Open oil plug carefully and keep

away from the opening. Do notoverfill the gearbox when filling.

-

Do not overfill!

Overfilling of gearbox oil can

lead to internal over-pressureinside the gearbox which in

turn may:

damage seals and

gaskets

completely press outseals and gaskets

prevent the manipulatorfrom moving freely.

Make sure not to overfill the

gearbox when filling with oil!After filling, check the correct oillevel.

-

Do not mix types of oil!

Mixing types of oil may causesevere damage to thegearbox!

When filling gearbox oil, do notmix different types of oil unlessspecified in the instruction.

Always use the type of oil

specified by the manufacturer!

-

Heat up the oil!

Warm oil drains quicker thancold oil.

When changing gearbox oil, firstrun the robot for a time to heatup the oil.


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1 Safety



-

Specified amount

depends on drained

volume!

The specified amount of oil isbased on the total volume of

the gearbox. When changingthe oil, the amount of refilled oilmay differ from the specified

amount, depending on howmuch oil has previously beendrained from the gearbox.

After refilling, check the oil level.

Warning Description Elimination / Action


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1 Safety

1.3.6. WARNING - Mixed oils may cause severe damage to gearbox!


1.3.6. WARNING - Mixed oils may cause severe damage to gearbox!

Description

The six gearboxes of the robot are historically filled with different types of oil. When refilling

a gearbox it is extremely important to fill with exactly the same type of oil that is currently

used! In case the gearbox oil is contaminated with an other type of oil, the gearbox may be

severely damaged and must therefor be rinsed.

Shell Tivela S 150 mixed with Optimol Optigear RMO 150

The procedure below details how to rinse the contaminated gearbox if the oil types Shell

Tivela S 150 and Optimol Optigear RMO 150 are mixed.

Shell Tivela S 150 mixed with Mobil Gearlube X320

The procedure below details how to rinse the contaminated gearbox if the oil types Shell

Tivela S 150 and Mobil Gearlube X320 are mixed.

Step Action Note

1. Flush the gearbox properly three times with the correct typeof oil. Use a service program when flushing.

2. Refill the gearbox with the correct type of oil.

Step Action Note

1. If the gearbox should contain Tivela S 150 and is

contaminated with Gearlube X320:

Flush the gearbox properly three times with Tivela S150. Use a service program when flushing.

Refill the gearbox with Tivela S 150.


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2 Installation and commissioning

2.1. Introduction



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.


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2.2.1. Pre-installation procedure


2.2 Unpacking


General

This instruction is primarily intended for use when unpacking and installing the manipulator

(mechanical robot) for the first time. It also contains information useful during later re-

installation of the manipulator.

Checking the pre-requisites for installation

The checklist below details what must be observed before proceeding with the actual

installation of the manipulator:

Step Action Info/Illustration1. Make sure only qualified installation personnel

conforming to all national and local codes are allowedto perform the installation.

2. Make sure the manipulator has not been damaged,by visually inspecting the manipulator and controlcabinet exterior.

3. Make sure the lifting device used is dimensioned tohandle the weight of the manipulator.

Specified in Weight,manipulatoron page 43.

4. If the manipulator is not to be installed directly, it mustbe stored.

Specified in Storage

conditions, manipulatoronpage 44.

5. Make sure the appointed operating environment ofthe manipulator conforms to the specifications.

Specified in Operatingconditions, manipulatoron

page 44.

6. Before taking the manipulator to its installation site,

make sure the site conforms to the demands.Specified in Loads onfoundation, manipulatoronpage 43, Requirements onfoundation, manipulatoron

page 43and Protection

classes, manipulatoronpage 44Protection classes,

manipulatoron page 44

respectively.

7. Before moving the manipulator, please observe therisk of tipping!

Described in Risk of tipping /stabilityon page 49.

8. When these prerequisites have been met, themanipulator may be taken to its installation site.

Specified in Lifting robot withfork lifton page 50.


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Weight, manipulator

The table below shows the weights of the different models (without DressPack):

Loads on foundation, manipulator

The table below shows the different forces and torques working on the manipulator during

different kinds of operation.

NOTE! These forces and torques are extreme values that are rarely encountered during

operation. The values also never reach their maximum simultaneously!

Requirements on foundation, manipulatorThe table below shows the requirements for the foundation where the manipulator is to be

fitted:

Manipulator model Weight

IRB 7600 - 500/2.3 2400 kg

IRB 7600 - 400/2.55 2400 kg

IRB 7600 - 340/2.8 2450 kg

IRB 7600 - 150/3.5 2450 kg

Force Endurance load (operation) Max. load (emergency stop)

Force xy 14000 N 31000 N

Force z 32000 10000 N 39000 16000 N

Torque xy 42000 Nm 72000 Nm

Torque z 11000 Nm 19500 Nm

Requirement Value Note

Min. levelness 0.5 mm

Max. tilt 5 The limit for the maximum payload on the

manipulator is reduced if the manipulator istilted from 0.

Contact ABB for further information about

acceptable payload.Min. resonancefrequency

22 Hz


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Storage conditions, manipulator

The table below shows the allowed storage conditions for the manipulator:

Operating conditions, manipulator

The table below shows the allowed operating conditions for the manipulator:

Protection classes, manipulator

The table below shows the protection class of the manipulator:

Parameter Value

Min. ambient temperature -25 C

Max. ambient temperature +55C

Max. ambient temperature (less than 24 h) +70C

Max. ambient humidity Max. 95% at constant temperature

Parameter Value

Min. ambient temperature +5 C

Max. ambient temperature +50C

Max. ambient humidity Max. 95% at constant temperature

Equipment Protection class

Manipulator, IRB 7600 IP 67


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2.2.2. Working range, IRB 7600 - 150/3.5



Illustration

The illustration below shows the unrestricted working range of IRB 7600 - 150/3.5:

xx0100000101


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Illustration


xx0300000296


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Illustration


xx0100000100


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Illustration


en0100000099


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2.2.6. Risk of tipping / stability


2.2.6. Risk of tipping / stability

Risk of tipping

When the robot is not fastened to the foundation and standing still, the robot is not stable in

the whole working area. Moving the arms will displace the center of gravity, which may cause

the robot to tip over. Do notchange the robot position before securing it to the foundation.

Stabililty

The figure below shows the robot in its shipping position, which also is its most stable

position.

xx0100000103

WARNING!

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


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2.3.1. Lifting robot with fork lift


2.3 On-site Installation


General

The robot may be moved using a fork lift, provided that available special aids are used.

This section describes how to attach the fork lift equipment to the robot.

Different designs

There are two different versions of the fork lift that fit one design of the frame respectevily.

The different designs of the frame and of the fork lift attachments are shown in the figure

below. Determine which fork lift set fits the current robot.

Note!The distance between the attachment holes for the fork lift pockets, shown in the figure

below, are different depending on the design of the frame. This means that the fork lift sets

are unique for one type of frame and not compatible!

Except for the shorter distance between the attachment holes, the later design of the frame

also includes an extra oil plug, located as shown in the figure below.

xx0200000386

1 Frame version withoutan oil plug, use the fork lift set: 3HAC 0604-2

2 Frame version withan oil plug (C), use the fork lift set: 3HAC 0604-1

A Attachment holes, fork lift 3HAC 0604-2

B Attachment holes, fork lift 3HAC 0604-1

C Oil plug


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Attachment points

The attachment points for the fork lift equipment are shown in the figure below.

xx0400000707

Required equipment

To determine which fork lift set to use, see the sectionDifferent designson page 50.

A Attachment points, spacer and horizontal attachment screws

B Attachment points, horizontal attachment screws

C Attachment points, vertical attachment screws

D Attachment points, horizontal attachment screws

Equipment, etc. Art. no. Note

Fork lift set, incl. all required

hardware

3HAC 0604-2 See the figure Fork lift set, 3HAC 0604-2

on page 52.

Fork lift set, incl. all required

hardware

3HAC 0604-1 See the figure Fork lift set, 3HAC 0604-1

on page 53.


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Fork lift set, 3HAC 0604-2

The fork lift set, 3HAC 0604-2, is fitted to the robot as shown in the figure below.

xx0100000102

Standard toolkit 3HAC 1557-1 The contents are defined in sectionStandard toolkitin the Product manual,

reference information!

Equipment, etc. Art. no. Note

A Vertical attachment screws (4 pcs / fork lift pocket)

B Fork lift pockets (2 pcs)

C Spacer (2 pcs)


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Fork lift set, 3HAC 0604-1

The fork lift set, 3HAC 0604-1, is fitted to the robot as shown in the figure below.

xx0200000379

A Fork lift pocket (2 pcs, different from each other)

B Spacer (2 pcs)

C Horizontal attachment screws (4 pcs / fork li ft pocket)

D Vertical attachment screws (2 pcs)


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Lifting the robot with fork lift

The section below details how to secure the fork lift set to the robot in order to lift and move

the robot using the fork lift ONLY!


1. If a cooling fan for the axis 1 motor is used,it must be removed in order to use the fork

lift device!

2. Position the robot as shown in the figure to

the right!

Note!No load is permitted on the robot ifthe fork lift set 3HAC 0604-2 is used!

Release the brakes if required as

detailed in section Manually releasingthe brakeson page 63.

xx0200000079

When using fork lift set 3HAC 0604-2,

no load is permitted on the robot!

xx0200000387

3. Fit the two spacersto the robot and

secure.

Attachment points on the robot are

shown in the figure Attachment pointson page 51.


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4.

Caution!

Caution!

The fork lift pocket weighs 60 kg!

5. Secure the longer fork lift pocketto thespacers with four of the horizontalattachment screwsand washers.

Note!The vertically and the horizontally

attached screws are identical, buttightened with different torques!

Make sure the original screws arealways used (or replacements of

equivalent quality: M16, quality 12.9)!



xx0400001068

A: horizontal attachmentscrews, 4 pcs, M16 x 60.

Tightening torque: 60 Nm.

B: spacers, 2 pcs.

6. Make sure the securing screw is removedfrom the fork lift pocket!

It is only used for robot model IRB 6650S.

xx0400000977

A: securing screw



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7. Secure the fork lift pocket to the robot withthe two vertical attachment screwsand

washers.(only valid for the fork lift set 3HAC 0604-1)

Note!The vertically and the horizontally

attached screws are identical, buttightened with different torques!

xx0300000464

A: vertical attachment screws, 2

pcs, M16x60; tightening torque:270 Nm.

Make sure the original screws arealways used (or replacements of

equivalent quality: M16, quality 12.9)!



8.

Caution!

Caution!The fork lift pocket weighs 22 kg!

9. Secure the shorter fork lift pocket on the

other side of the robot with the fourremaining horizontal attachment screws.

4 pcs, M16x60; tightening torque: 60

Nm.

Make sure the original screws are

always used (or replacements ofequivalent quality: M16, quality 12.9)!



10. Double-check that the pockets are

properly secured to the robot! Insert the

fork lift forks into the pockets.

xx0200000380

Reposition the harness, if any, before

using a fork lift!



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11.

Caution!

Caution!

The robot weighs 2550 kg! All lifting

equipment used must be dimensionedaccordingly!

12. Carefully lift the robot and move it to itsinstallation site.

13.

Warning!

WARNING!

Personnel must not, under any

circumstances, be present under thesuspended load!



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2.3.2. Lifting robot with lifting slings



General

This section contains a general overview of how to lift the complete robot using special lifting

equipment. More detailed instructions are included with the equipment.

Illustration, lifting slings

The figure below shows how to lift the complete robot with lifting slings.

Note the recommended robot position shown in the figure below and in the instruction!

Attempting to lift a robot in any other position may result in the robot tipping over, causing

severe damage or injury!

xx0200000153

A Load hook

B Swivelling lifting eyes, 4 pcs

C Shortening hook

D Chain

E M12 lifting eye

F Lifting devices eye

I Lifting slings, 4 pcsL Hook


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Required equipment

Slings attached directly onto robot

The section below details how to lift and move the robot using lifting slings when these are

attached directly onto the robot frame.

Equipment Art. no. NoteLifting device, manipulator 3HAC 15607-1 Includes

user instructions (3HAC 15971-2).

Step Action Note

1. Run the overhead crane to a positionabove the robot.

2. Make sure the robot is positioned asshown in the figure on the right. If it isnot, position it that way.

Release the brakes if required as detailedin section Manually releasing the brakeson page 63.

xx0100000103

3. Fit the lifting device, manipulator to therobot as described in the enclosed

instruction!

Art. no. is specified in Requiredequipmenton page 59!

4.

Caution!

Caution!

The robot weighs 2550 kg! All lifting

equipment used must be dimensionedaccordingly!


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5.

Warning!

WARNING!

Personnel must not, under anycircumstances, be present under the

suspended load!

6. Raise the overhead crane to lift the

robot.

Make sure all hooks and attachments

maintain their correct positions whilelifting the robot!

Always move the robot at very lowspeeds, making sure it does not tip.

Step Action Note


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2.3.3. Lifting manipulator with roundslings



General

The figure below shows how to lift the complete manipulator with roundslings.

Note the recommended manipulator position shown in the figure below!

Roundslings attached to the manipulator

xx0200000315

Required equipment

A Chain sling with shortener, 4250 kg, 3 pcs (0.5 m, 0.5 m, 0.265 m)

B Roundsling, 1000 kg, 2 pcs

C Roundsling, 2000 kg, 3 pcs (4 m)

Equipment Note

Chain sling with shortener, 4250 kg, 3 pcs Lengths: 0.5 m (2 pcs), 0.265 m (1 pc).

Roundslings, 1000 kg, 2 pcs

Roundslings, 2000 kg, 3 pcs Lengths: 4 m (3 pcs).


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Safety information

Read the safety information before lifting the manipulator!

CAUTION!

The manipulator weighs 2550 kg! All lifting equipment used must be dimensioned

accordingly!

Slings attached directly on to manipulator

The section below details how to attach roundslings to the manipulator in order to lift the

complete robot.

Step Action Note

1.

Caution!

Attempting to lift a manipulator in any other

position than the recommended may result inthe manipulator tipping over and causing

severe damage or injury!

Recommended manipulatorposition is described in section

Risk of tipping / stabilityon page49.

2. Run the overhead crane to a position above the

manipulator.

3. Attach the threechain slings with shortenersto

the overhead crane hook.

Shown in the figure Roundslingsattached to the manipulatoronpage 61!

Lengths are specified in Required

equipmenton page 61!

4. Fit the threeroundslings, 2000 kg to the robot.Attach the roundslings to the chain slingshanging from the overhead crane.

Shown in the figure Roundslings

attached to the manipulatoronpage 61!

Lengths are specified in Re