irb 1600 3hac026660-en manual

Product manualIRB 1600 type A

Trace back information:Workspace R14-1 version a5Checked in 2014-04-07Skribenta version 4.0.378

Product manual

IRB 1600 - 5/1.2 type AIRB 1600 - 5/1.45 type A



IRB 1600 - 8/1.2 type AIRB 1600 - 8/1.45 type AIRB 1600 - 10/1.2 type A

IRB 1600 - 10/1.45 type AIRB 1600ID - 4/1.5

IRB 1600ID - 4/1.5 type AIRC5

Document ID: 3HAC026660-001

Revision: L

Copyright 2006-2014 ABB. All rights reserved.

The information in this manual is subject to change without notice and should notbe construed as a commitment by ABB. ABB assumes no responsibility for any errorsthat may appear in this manual.Except as may be expressly stated anywhere in this manual, nothing herein shall beconstrued as any kind of guarantee or warranty by ABB for losses, damages topersons 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 ABB'swritten permission.Additional copies of this manual may be obtained from ABB.The original language for this publication is English. Any other languages that aresupplied have been translated from English.


ABB ABRobotics ProductsSe-721 68 Vsters

Sweden

Table of contents9Overview of this manual ...................................................................................................................

14Product documentation, IRC5 ..........................................................................................................16How to read the product manual ......................................................................................................

171 Safety

171.1 Introduction to safety information .........................................................................181.2 General safety information ..................................................................................181.2.1 Introduction to general safety information ....................................................191.2.2 Safety in the manipulator system ...............................................................201.2.3 Safety risks ............................................................................................201.2.3.1 Safety risks during installation and service work on manipulators .........231.2.3.2 CAUTION - Hot parts may cause burns! ...........................................241.2.3.3 Safety risks related to tools/work pieces ..........................................251.2.3.4 Safety risks related to pneumatic/hydraulic systems ..........................261.2.3.5 Safety risks during operational disturbances .....................................271.2.3.6 Risks associated with live electric parts ...........................................291.2.4 Safety actions .........................................................................................291.2.4.1 Safety fence dimensions ...............................................................301.2.4.2 Fire extinguishing ........................................................................311.2.4.3 Emergency release of the manipulators arm ....................................321.2.4.4 Brake testing ..............................................................................331.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" ........................341.2.4.6 Safe use of the FlexPendant ..........................................................351.2.4.7 Work inside the manipulator's working range ...................................361.2.4.8 Signal lamp (optional) ...................................................................371.2.5 Safety stops ...........................................................................................371.2.5.1 What is an emergency stop? ..........................................................391.3 Safety related instructions ..................................................................................391.3.1 Safety signals in the manual ......................................................................411.3.2 Safety symbols on manipulator labels .........................................................461.3.3 DANGER - Moving manipulators are potentially lethal! ...................................471.3.4 DANGER - First test run may cause injury or damage! ...................................481.3.5 WARNING - The brake release buttons may be jammed after service work ........491.3.6 DANGER - Make sure that the main power has been switched off! ....................511.3.7 WARNING - The unit is sensitive to ESD! .....................................................531.3.8 WARNING - Safety risks during handling of batteries .....................................541.3.9 WARNING - Safety risks during work with gearbox lubricants (oil or grease) ......

572 Installation and commissioning

572.1 Introduction ......................................................................................................582.2 Unpacking .......................................................................................................582.2.1 Pre-installation procedure .........................................................................622.2.2 Working ranges ......................................................................................672.2.3 Risk of tipping/stability .............................................................................682.3 On-site installation ............................................................................................682.3.1 Lifting robot with roundslings ....................................................................702.3.2 Lifting and turning a suspended mounted robot ............................................712.3.3 Manually releasing the brakes ...................................................................732.3.4 Orienting and securing the robot ................................................................762.3.5 Setting the system parameters for a suspended robot ....................................792.3.6 Loads fitted to the robot, stopping time and braking distances .........................802.3.7 Fitting equipment on the robot (robot dimensions) .........................................892.3.8 Installation of signal lamp for 1600 (option) ..................................................922.3.9 Installation of signal lamp for 1600ID (option) ...............................................942.3.10 Installation of the wire feeder shelf for IRB 1600ID .........................................

3HAC026660-001 Revision: L 5 Copyright 2006-2014 ABB. All rights reserved.

Table of contents

962.4 Restricting the working range ..............................................................................962.4.1 Introduction ............................................................................................972.4.2 Installation of additional mechanical stops on axis 1 ......................................

1022.4.3 Installation of additional mechanical stop on axis 2 ........................................1062.4.4 Installation of additional mechanical stops on axis 3 ......................................1102.4.5 Installation of position switch, axis 1 ...........................................................1132.5 Electrical connections ........................................................................................1132.5.1 Customer connectors on the robot .............................................................1162.5.2 Robot cabling and connection points ..........................................................1182.5.3 Customer connections on the robot ............................................................

1213 Maintenance

1213.1 Introduction ......................................................................................................1223.2 Maintenance schedule and expected component life ...............................................1223.2.1 Specification of maintenance intervals ........................................................1233.2.2 Maintenance schedule .............................................................................1243.2.3 Expected component life ..........................................................................1253.3 Inspection activities ...........................................................................................1253.3.1 Inspection, damper axes 2, 3 and 5 .............................................................1283.4 Replacement activities .......................................................................................1283.4.1 Type of lubrication in gearboxes ................................................................1293.4.2 Changing the oil in axes 5 and 6 gearboxes .................................................1323.4.3 Changing the oil, axis 5- 6 gearbox, ID ........................................................1353.4.4 Replacing the battery pack ........................................................................1393.5 Cleaning activities .............................................................................................1393.5.1 Cleaning the IRB 1600 ..............................................................................

1434 Repair

1434.1 Introduction ......................................................................................................1444.2 General procedures ...........................................................................................1444.2.1 Performing a leak-down test ......................................................................1454.2.2 Mounting instructions for bearings .............................................................1474.2.3 Mounting instructions for seals ..................................................................1494.2.4 Replacing parts on Clean Room robots .......................................................1514.3 Complete manipulator ........................................................................................1514.3.1 Replacement of cable harness ...................................................................1604.3.2 Replacement of cable harness, IRB 1600ID ..................................................1664.3.3 Replacement of complete arm system .........................................................1704.4 Upper and lower arm .........................................................................................1704.4.1 Replacement of complete upper arm ...........................................................1754.4.2 Replacing the complete upper arm ID .........................................................1824.4.3 Replacing the complete lower arm ..............................................................1864.4.4 Replacement of wrist unit .........................................................................1894.4.5 Replacing the wrist unit, ID .......................................................................1954.4.6 Replacing the damper, axis 2 .....................................................................1974.4.7 Replacing the damper, axis 3 .....................................................................1994.4.8 Replacing the mechanical stop axis 3, ID variant ...........................................2014.4.9 Replacement of damper, axis 5 ..................................................................2034.4.10 Remove upper arm AW Gun ......................................................................2084.5 Frame and base ................................................................................................2084.5.1 Replacement of base ...............................................................................2124.5.2 Replacing the serial measurement unit ........................................................2184.5.3 Replacing the push button unit ..................................................................2224.6 Motors ............................................................................................................2224.6.1 Replacement of motor, axis 1 ....................................................................2264.6.2 Replacement of motor, axis 2 ....................................................................2314.6.3 Replacement of motor, axis 3 ....................................................................2354.6.4 Replacement of motor, axis 3, IRB 1600ID ...................................................2404.6.5 Replacement of motor, axis 4 ....................................................................

6 3HAC026660-001 Revision: L Copyright 2006-2014 ABB. All rights reserved.

Table of contents

2444.6.6 Replacement of motor, axis 4, 1600ID .........................................................2474.6.7 Replacement of motor and timing belt, axis 5 ...............................................2514.6.8 Replacement of motor, axis 5, IRB 1600ID ...................................................2574.6.9 Replacement of motor and timing belt, axis 6 ...............................................2604.6.10 Replacement of motor, axis 6 IRB 1600ID ....................................................2634.7 Gearboxes .......................................................................................................2634.7.1 Replacement of gearbox, axes 1-2 .............................................................2694.7.2 Service work on gearboxes, axes 3, 4, 5 and 6 ..............................................

2715 Calibration information

2715.1 Introduction .....................................................................................................2725.2 Calibration methods ...........................................................................................2745.3 Calibration scale and correct axis position .............................................................2765.4 Calibration movement directions for all axes ..........................................................2775.5 Updating revolution counters ...............................................................................2795.6 Checking the zero position ..................................................................................

2816 Decommissioning

2816.1 Environmental information ..................................................................................2826.2 Scrapping of robot .............................................................................................

2837 Robot description

2837.1 Type A of IRB 1600 ............................................................................................2847.2 Type A of IRB 1600ID .........................................................................................

2858 Reference information

2858.1 Introduction ......................................................................................................2868.2 Applicable safety standards ................................................................................2888.3 Unit conversion .................................................................................................2898.4 Screw joints ....................................................................................................2928.5 Weight specifications .........................................................................................2938.6 Standard tools ..................................................................................................2948.7 Special tools ....................................................................................................2958.8 Lifting accessories and lifting instructions ..............................................................

2979 Spare part lists

2979.1 Spare part lists and illustrations ...........................................................................

29910 Circuit diagram

29910.1 About circuit diagrams .......................................................................................

301Index


Table of contents

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Overview of this manualAbout this manual

This manual contains instructions for:

mechanical and electrical installation of the robot

maintenance of the robot

mechanical and electrical repair of the robot.

UsageThis manual should be used during:

installation, from lifting the robot to its work site and securing it to thefoundation, to making it ready for operation

maintenance work

repair work and calibration.

Who should read this manual?This manual is intended for:

installation personnel

maintenance personnel

repair personnel.

PrerequisitesA maintenance/repair/installation craftsman working with an ABB Robot must:

be trained by ABB and have the required knowledge of mechanical andelectrical installation/repair/maintenance work.

Organization of chaptersThe manual is organized in the following chapters:

ContentsChapter

Safety information that must be read through before performingany installation or service work on robot. Contains general safetyaspects as well as more specific information on how to avoidpersonal injuries and damage to the product.

Safety, service

Required information about lifting and installation of the robot.Installation and commis-sioning

Step-by-step procedures that describe how to perform mainten-ance of the robot. Based on a maintenance schedule that maybe used to plan periodical maintenance.

Maintenance

Step-by-step procedures that describe how to perform repairactivities of the robot. Based on available spare parts.

Repair

Procedures that do not require specific calibration equipment.General information about calibration.

Calibration information

Environmental information about the robot and its components.Decommissioning

Useful information when performing installation, maintenanceor repair work. Includes lists of necessary tools, additional doc-uments, safety standards, etc.

Reference information

Continues on next page3HAC026660-001 Revision: L 9


Overview of this manual

ContentsChapter

Complete spare part list and complete list of robot components,shown in exploded views.

Spare parts and explodedviews

Reference to the circuit diagram for the robot.Circuit diagram

ReferencesDocumentation referred to in the manual, is listed in the table below.

Document IDDocument name

3HAC021351-003Circuit diagram - IRB 1600 type A

3HAC023604-001Product specification - IRB 1600

3HAC049104-001Product manual, spare parts - IRB 1600

3HAC021313-001Product manual - IRC5IRC5 with main computer DSQC 639.

3HAC047136-001Product manual - IRC5IRC5 with main computer DSQC1000.

3HAC16590-1Operating manual - IRC5 with FlexPendant

3HAC025709-001Operating manual - Service Information System

3HAC16578-1Operating manual - Calibration Pendulum

3HAC021395-001Application manual - Additional axes and stand alone controller

3HAC030421-001Application manual - CalibWare Field 5.0

3HAC042927-001Technical reference manual - Lubrication in gearboxes

3HAC17076-1Technical reference manual - System parameters

3HAC028664-002Instructions lifting accessory 3HAC024483-001

Revisions

DescriptionRevision

First edition. See also Type A of IRB 1600 on page 283.-

AW equipped upper arm 1600ID, IRB 1600-6/1.2, IRB 1600-6/1.45, IRB1600-8/1.2 and IRB 1600-8/1.45 added.

A

Clean Room added.BChanges made in:

Prerequisites in section Overview Oil change in section Maintenance

Content updated in section: Making robot ready for operation, Clean Room / Additional install-

ation procedure.

C

Content updated in chapter/section: Maintenance/Cleaning of robot Maintenance/Maintenance schedule: Interval for replacement of

battery pack changed Section What is an emergency stop? added to chapter Safety.

D

Content updated in chapter/section: Maintenance/Oil in gearboxes: Amount of oil in gearboxes axes

1 and 2.

E

Continues on next page10 3HAC026660-001 Revision: L



Continued

DescriptionRevision

Content updated in sections: New graphics for equipment load areas, see Fitting equipment on

the robot (robot dimensions) on page 80. Instruction moved from chapter Repair to Installation, see Install-

ation of the wire feeder shelf for IRB 1600ID on page 94. Spare part list, updated regarding Foundry Plus Cable guard. Cleaning the IRB 1600 on page 139 in chapter Maintenance up-

dated. Sealing compound updated in Replacing parts on Clean Room

robots on page 149. Decommissioning chapter added.

Updates in the chapter Safety: Updated safety signal graphics for the levelsDanger andWarning,

see Safety signals in the manual on page 39. New safety labels on the manipulators, see Safety symbols on

manipulator labels on page 41. Revised terminology: robot replaced with manipulator.

F

Content updated in sections: Added reference to lifting accessory, see Lifting and turning a

suspended mounted robot on page 70.

G

Content updated in sections: Added note about not inserting guide pin too far into the tool

flange, section Fitting equipment on the robot (robot dimensions)on page 80.

Updated spare part numbers, in sections: Base, frame, upper arm,upper arm 1600ID and options.

New and updated safety symbols, see Safety symbols on manip-ulator labels on page 41.

H




Continued

DescriptionRevision

This revision includes the following updates: A new block, about general illustrations, added in section How to

read the product manual on page 16. Resolver connection added, connection for resolver signals axis

7 located on the base see section Customer connectors on therobot on page 113

Added an illustration that shows the directions of the robot stressforces and changed the value for the force in the Z plane, seeLoads on foundation, robot on page 59.

Improvements made in the instruction for replacing the completeID upper arm, see Replacing the complete upper arm ID onpage 175.

Gearboxes and motor pinions from SAMP are added to the sparepart lists together with a table that shows compability betweenthe motors and gearboxes, seeSpare parts -Compatible gearboxesand motors. The spare part numbers are also removed from theRequired equipment lists in the repair instructions for motors andgearboxes, and instead replaced with links to the Spare partschapter.

The option Foundry Plus Cable Guard is removed. Some general tightening torques have been changed/added, see

updated values in Screw joints on page 289. Corrected value for working range of wall mounted robots, added

working range for IRB 1600ID and updated a figure, see Workingranges on page 62.

Spare part numbers for axis-4, axis-5 and axis-6 motors for IRB1600ID are corrected.

Added WARNING - Safety risks during handling of batteries onpage 53.

J

This revision includes the following updates: Added range and capacity to the denomination of IRB 1600ID. Added information about IRB 1600ID type A, on first inside page

and as a new section Type A of IRB 1600ID on page 284. Spare part numbers for SAMP motors and upper arms are correc-

ted, see Spare parts - Compatible gearboxes and motors. Added variants IRB 1600 - 10/1.2 and IRB 1600 - 10/1.45 to the

manual. Updated loads on the foundation, see Loads on foundation, robot

on page 59. Corrected the appearance of figures in section Working ranges

on page 62. Changed maximum tilt from 60 to 55, see Requirements,

foundation on page 60. All data about type of lubrication in gearboxes is moved from the

manual to a separate lubrication manual, see Type and amountof oil in gearboxes on page 128.

Added information about importance to install the robot with cor-rect X direction in the base coordinate system, see Installation ofadditional mechanical stops on axis 1 on page 97 and Setting thesystem parameters for a suspended robot on page 76.

A new SMB unit and battery is introduced, with longer batterylifetime.

Added mounting holes on the lower arm, see Fitting equipmenton the robot (robot dimensions) on page 80.

K




Continued

DescriptionRevision

This revision includes the following updates: Spare numbers in general, updated/corrected. Spare number for Motor axis 3 (Rexnord) changed. Added information about risks when scrapping a decommissioned

robot, see Scrapping of robot on page 282. Base connections, illustration updated with new views. Updated tightening torque for the oil plug on axis 5-6 for IRB

1600ID, see Changing the oil, axis 5- 6 gearbox, ID on page 132. Spare parts and exploded views are not included in this document

but delivered as a separate document. See Product manual, spareparts - IRB 1600.

Note about the placement of connectors in ID-upper arm addedin Repair instructions. See Replacement of motor, axis 5, IRB1600ID on page 251 and Replacing the wrist unit, ID on page 189.

Note about handling the wrist during replacement added. SeeRefitting the wrist unit on page 192.

L



Continued

Product documentation, IRC5Categories for manipulator documentation

The manipulator documentation is divided into a number of categories. This listingis based on the type of information in the documents, regardless of whether theproducts are standard or optional.

All documents listed can be ordered from ABB on a DVD. The documents listedare valid for IRC5 manipulator systems.

Product manualsManipulators, controllers, DressPack/SpotPack, and most other hardware will bedelivered with a Product manual that generally contains:

Safety information.

Installation and commissioning (descriptions of mechanical installation orelectrical connections).

Maintenance (descriptions of all required preventive maintenance proceduresincluding intervals and expected life time of parts).

Repair (descriptions of all recommended repair procedures including spareparts).

Calibration.

Decommissioning.

Reference information (safety standards, unit conversions, screw joints, listsof tools ).

Spare parts list with exploded views (or references to separate spare partslists).

Circuit diagrams (or references to circuit diagrams).

Technical reference manualsThe technical reference manuals describe reference information for roboticsproducts.

Technical reference manual - Lubrication in gearboxes: Description of typesand volumes of lubrication for the manipulator gearboxes.

Technical reference manual - RAPID overview: An overview of the RAPIDprogramming language.

Technical referencemanual - RAPID Instructions, Functions and Data types:Description and syntax for all RAPID instructions, functions, and data types.

Technical reference manual - RAPID kernel: A formal description of theRAPID programming language.

Technical reference manual - System parameters: Description of systemparameters and configuration workflows.

Application manualsSpecific applications (for example software or hardware options) are described inApplication manuals. An application manual can describe one or severalapplications.



Product documentation, IRC5

An application manual generally contains information about:

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

What is included (for example cables, I/O boards, RAPID instructions, systemparameters, DVD with PC software).

How to install included or required hardware.

How to use the application.

Examples of how to use the application.

Operating manualsThe operating manuals describe hands-on handling of the products. The manualsare aimed at those having first-hand operational contact with the product, that isproduction cell operators, programmers, and trouble shooters.

The group of manuals includes (among others):

Operating manual - Emergency safety information

Operating manual - General safety information

Operating manual - Getting started, IRC5 and RobotStudio

Operating manual - Introduction to RAPID

Operating manual - IRC5 with FlexPendant

Operating manual - RobotStudio

Operatingmanual - Trouble shooting IRC5, for the controller and manipulator.


Product documentation, IRC5

Continued

How to read the product manualReading the procedures

The procedures contain references to figures, tools, material, and so on. Thereferences are read as described below.

References to figuresThe procedures often include references to components or attachment pointslocated on the manipulator/controller. The components or attachment points aremarked with italic text in the procedures and completed with a reference to thefigure where the current component or attachment point is shown.

The denomination in the procedure for the component or attachment pointcorresponds to the denomination in the referenced figure.

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

Note/IllustrationAction

Shown in the figure Location ofgearbox on page xx.

Remove the rear attachment screws, gearbox.8.

References to required equipmentThe procedures often include references to equipment (spare parts, tools, etc.)required for the different actions in the procedure. The equipment is marked withitalic text in the procedures and completed with a reference to the section wherethe equipment is listed with further information, that is article number anddimensions.

The designation in the procedure for the component or attachment pointcorresponds to the designation in the referenced list.

The table below shows an example of a reference to a list of required equipmentfrom a step in a procedure.

Note/IllustrationAction

Art. no. is specified in Requiredequipment on page xx.

Fit a new sealing, axis 2 to the gearbox.3.

Safety informationThe manual includes a separate safety chapter that must be read through beforeproceeding with any service or installation procedures. All procedures also includespecific safety information when dangerous steps are to be performed.

Read more in the chapter Safety on page 17.

IllustrationsThe robot is illustrated with general figures that does not take painting or protectiontype in consideration.

Likewise, certain work methods or general information that is valid for several robotmodels, can be illustrated with illustrations that show a different robot model thanthe one that is described in the current manual.


How to read the product manual

1 Safety1.1 Introduction to safety information

OverviewThe safety information in this manual is divided into two categories:

General safety aspects, important to attend to before performing any servicework on the robot. These are applicable for all service work and are foundin General safety information on page 18.

Specific safety information, pointed out in the procedures. How to avoid andeliminate the danger is either described directly in the procedure, or in specificinstructions in the section Safety related instructions on page 39.


1 Safety

1.1 Introduction to safety information

1.2 General safety information

1.2.1 Introduction to general safety information

DefinitionsThis section details general safety information for personnel performing installation,repair and maintenance work.

SectionsThe general safety information is divided into the following sections.

ContainingContents

safety, service limitation of liability related information

General information

safety risks during installation or service risks associated with live electrical parts

Safety risks lists dangers relevant whenworking with the product. The dangers aresplit into different categories.

fire extinguishing safe use of the FlexPendant

Safety actions describes actions whichmay be taken to remedy or avoid dangers.

stopping functions description of emergency stop description of safety stop description of safeguarding

Safety stops describes different types ofstops.


1 Safety

1.2.1 Introduction to general safety information

1.2.2 Safety in the manipulator system

Validity and responsibilityThe information does not cover how to design, install and operate a completesystem, nor does it cover all peripheral equipment that can influence the safety ofthe entire system. To protect personnel, the complete system must be designedand installed in accordance with the safety requirements set forth in the standardsand regulations of the country where the manipulator is installed.

The users of ABB industrial manipulators are responsible for ensuring that theapplicable safety laws and regulations in the country concerned are observed andthat the safety devices necessary to protect people working with the manipulatorsystem are designed and installed correctly. Personnel working with manipulatorsmust be familiar with the operation and handling of the industrial manipulator asdescribed in the applicable documents, for example:

Operating manual - IRC5 with FlexPendant

Product manual

Connection of external safety devicesApart from the built-in safety functions, the manipulator is also supplied with aninterface for the connection of external safety devices. An external safety functioncan interact with other machines and peripheral equipment via this interface. Thismeans that control signals can act on safety signals received from the peripheralequipment as well as from the manipulator.

Limitation of liabilityAny information given in this manual regarding safety must not be construed as awarranty by ABB that the industrial manipulator will not cause injury or damageeven if all safety instructions are complied with.

Related information

SectionDetailed in documentType of information

Installation andcommissioning

Product manual for the manipulatorInstallation of safety devices

Operating modesOperatingmanual - IRC5with FlexPend-ant

Changing operating modes

Installation andcommissioning

Product manual for the manipulatorRestricting the working space


1 Safety

1.2.2 Safety in the manipulator system

1.2.3 Safety risks

1.2.3.1 Safety risks during installation and service work on manipulators

OverviewThis section includes information on general safety risks to be considered whenperforming installation and service work on the manipulator.

These safety instructions have to be read and followed by any person who dealswith the installation and maintenance of the manipulator. Only persons who knowthe manipulator and are trained in the operation and handling of the manipulatorare allowed to maintain the manipulator. Persons who are under the influence ofalcohol, drugs or any other intoxicating substances are not allowed to maintain,repair, or use the manipulator.

General risks during installation and service The instructions in the product manual in the chapter Installation and

commissioning must always be followed.

Emergency stop buttons must be positioned in easily accessible places sothat the manipulator can be stopped quickly.

Those in charge of operations must make sure that safety instructions areavailable for the installation in question.

Those who install the manipulator must have the appropriate training for theequipment in question and in any safety matters associated with it.

Spare parts and special equipmentABB does not supply spare parts and special equipment which have not beentested and approved by ABB. The installation and/or use of such products couldnegatively affect the structural properties of the manipulator and as a result of thataffect the active or passive safety operation. ABB is not liable for damages causedby the use of non-original spare parts and special equipment. ABB is not liable fordamages or injuries caused by unauthorized modifications to the manipulatorsystem.

Nation/region specific regulationsTo prevent injuries and damages during the installation of the manipulator, theregulations applicable in the country concerned and the instructions of ABBRobotics must be complied with.

Non-voltage related risks Make sure that no one else can turn on the power to the controller and

manipulator while you are working with the system. A good method is toalways lock the main switch on the controller cabinet with a safety lock.

Safety zones, which must be crossed before admittance, must be set up infront of the manipulator's working space. Light beams or sensitive mats aresuitable devices.



1 Safety

1.2.3.1 Safety risks during installation and service work on manipulators

Turntables or the like should be used to keep the operator out of themanipulator'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 manipulator parts, there is a riskof being crushed by the parallel arm (if there is one).

Energy stored in the manipulator for the purpose of counterbalancing certainaxes may be released if the manipulator, or parts thereof, are dismantled.

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

Be aware of stored heat energy in the controller.

Never use the manipulator as a ladder, which means, do not climb on themanipulator motors or other parts during service work. There is a seriousrisk of slipping because of the high temperature of the motors and oil spillsthat can occur on the manipulator.

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 standardsfor that function.

The supplier of the complete system must ensure that all circuits used in theemergency stop function are interlocked in a safe manner, in accordancewith the applicable standards for the emergency stop function.

Complete manipulator

DescriptionSafety risk

CAUTION

Motors and gears are HOT after running themanipulator! Touching motors and gears mayresult in burns!With a higher environment temperature, moresurfaces on the manipulator will get HOT andmay also result in burns.

Hot components!

WARNING

Take any necessary measures to ensure thatthe manipulator does not collapse as partsare removed, e.g. secure the lower arm ac-cording to repair instruction if removing mo-tor, axis 2.

Removed parts may result in collapse ofmanipulator!

WARNING

If the internal cables for the measurementsystem have been disconnected during repairor maintenance, then the revolution countersmust be updated.

Removed cables to the measurement sys-tem



1 Safety

1.2.3.1 Safety risks during installation and service work on manipulatorsContinued

Cabling


CAUTION

The cable packs are sensitive to mechanicaldamage! They must be handled with care,especially the connectors, in order to avoiddamaging them!

Cable packs are sensitive to mechanicaldamage!

Gearboxes and motors


CAUTION

Whenever parting/mating motor and gearbox,the gears may be damaged if excessive forceis used!

Gears may be damaged if excessive forceis used!


WARNING

Do not under any circumstances, deal withthe balancing device in any other way thanthat detailed in the product documentation!For example, attempting to open the balan-cing device is potentially lethal!

Dangerous balancing device!


1 Safety

1.2.3.1 Safety risks during installation and service work on manipulatorsContinued

1.2.3.2 CAUTION - Hot parts may cause burns!

DescriptionDuring normal operation, many manipulator parts become hot, especially the drivemotors and gears. Sometimes areas around these parts also become hot. Touchingthese may cause burns of various severity.

Because of a higher environment temperature, more surfaces on the manipulatorget hot and may result in burns.

EliminationThe instructions below detail how to avoid the dangers specified above:

InfoAction

Always use your hand, at some distance, tofeel if heat is radiating from the potentiallyhot component before actually touching it.

1

Wait until the potentially hot component hascooled if it is to be removed or handled in anyother way.

2


1 Safety

1.2.3.2 CAUTION - Hot parts may cause burns!

1.2.3.3 Safety risks related to tools/work pieces

Safe handlingIt must be possible to safely turn off tools, such as milling cutters, etc. Make surethat guards remain closed until the cutters stop rotating.

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

Safe designGrippers/end effectors must be designed so that they retain work pieces in theevent of a power failure or a disturbance to the controller.

Unauthorized modifications of the originally delivered manipulator 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.

CAUTION

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


1 Safety

1.2.3.3 Safety risks related to tools/work pieces

1.2.3.4 Safety risks related to pneumatic/hydraulic systems

GeneralSpecial safety regulations apply to pneumatic and hydraulic systems.

Note

All components that remain pressurized after separating the machine from thepower supply must be provided with clearly visible drain facilities and a warningsign that indicates the need for pressure relief before adjustments or performingany maintenance on the manipulator system.

Residual energy Residual energy can be present in these systems. After shutdown, particular

care must be taken.

The pressure must be released in the complete pneumatic or hydraulicsystems before starting to repair them.

Work on hydraulic equipment may only be performed by persons with specialknowledge and experience of hydraulics.

All pipes, hoses, and connections have to be checked regularly for leaks anddamage. Damage must be repaired immediately.

Splashed oil may cause injury or fire.

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.


1 Safety

1.2.3.4 Safety risks related to pneumatic/hydraulic systems

1.2.3.5 Safety risks during operational disturbances

General The industrial manipulator is a flexible tool that can be used in many different

industrial applications.

All work must be carried out professionally and in accordance with theapplicable safety regulations.

Care must be taken at all times.

Qualified personnelCorrective maintenance must only be carried out by qualified personnel who arefamiliar with the entire installation as well as the special risks associated with itsdifferent parts.

Extraordinary risksIf the working process is interrupted, extra care must be taken due to risks otherthan those associated with regular operation. Such an interruption may have to berectified manually.


1 Safety

1.2.3.5 Safety risks during operational disturbances

1.2.3.6 Risks associated with live electric parts

Voltage related risks, generalWork on the electrical equipment of the manipulator must be performed by aqualified electrician in accordance with electrical regulations.

Although troubleshooting may, on occasion, need to be carried out while thepower supply is turned on, the robot must be turned off (by setting the mainsswitch to OFF) when repairing faults, disconnecting electric leads anddisconnecting or connecting units.

The mains supply to the robot must be connected in such a way that it canbe turned off from outside the robots working space.

Make sure that no one else can turn on the power to the controller andmanipulator while you are working with the system. A good method is toalways lock the main switch on the controller cabinet with a safety lock.

The necessary protection for the electrical equipment and manipulator systemduring construction, commissioning, and maintenance is guaranteed if the validregulations are followed.

All work must be performed:

by qualified personnel

on machine/manipulator system in deadlock

in an isolated state, disconnected from power supply, and protected againstreconnection

Voltage related risks, IRC5 controllerA danger of high voltage is associated with, for example, the following parts:

Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) inthe controller.

Units such as I/O modules, can be supplied with power from an externalsource.

The mains supply/mains switch

The transformers

The power unit

The control power supply (230 VAC)

The rectifier unit (262/400-480 VAC and 400/700 VDC. Note: Capacitors!)

The drive unit (400/700 VDC)

The drive system power supply (230 VAC)

The service outlets (115/230 VAC)

The customer power supply (230 VAC)

The power supply unit for additional tools, or special power supply units forthe machining process.

The external voltage connected to the controller remains live even when therobot is disconnected from the mains.

Additional connections.



1 Safety

1.2.3.6 Risks associated with live electric parts

Voltage related risks, manipulatorA danger of high voltage is associated with the manipulator in:

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

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

See chapter Installation and commissioning on page 57.

Voltage related risks, tools, material handling devices, etc.Tools, material handling devices, etc., may be live even if the robot system is inthe OFF position. Power supply cables which are in motion during the workingprocess may be damaged.


1 Safety

1.2.3.6 Risks associated with live electric partsContinued

1.2.4 Safety actions

1.2.4.1 Safety fence dimensions

GeneralInstall a safety cell around the manipulator to ensure safe manipulator installationand operation.

DimensioningDimension the fence or enclosure to enable it to withstand the force created if theload being handled by the manipulator is dropped or released at maximum speed.Determine the maximum speed from the maximum velocities of the manipulatoraxes and from the position at which the manipulator is working in the work cell(see the section Robot motion in the Product specification).

Also consider the maximum possible impact caused by a breaking or malfunctioningrotating tool or other device fitted to the manipulator.


1 Safety

1.2.4.1 Safety fence dimensions

1.2.4.2 Fire extinguishing

Note

Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in themanipulator system (manipulator or controller)!


1 Safety

1.2.4.2 Fire extinguishing

1.2.4.3 Emergency release of the manipulators arm

DescriptionIn an emergency situation, any of the manipulator's axes may be released manuallyby pushing the brake release buttons on the manipulator.

How to release the brakes is detailed in the section:

Manually releasing the brakes on page 71.

The manipulator arm may be moved manually on smaller manipulator models, butlarger models may require using an overhead crane or similar equipment.

Increased injuryBefore releasing the brakes, make sure that the weight of the arms does notincrease the pressure on the trapped person, further increasing any injury!


1 Safety

1.2.4.3 Emergency release of the manipulators arm

1.2.4.4 Brake testing

When to testDuring operation, the holding brake of each axis normally wears down. A test canbe performed to determine whether the brake can still perform its function.

How to testThe function of the holding brake of each axis motor may be checked as describedbelow:

1 Run each manipulator axis to a position where the combined weight of themanipulator arm and any load is maximized (max. static load).

2 Switch the motor to the MOTORS OFF position with the operating modeselector 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.


1 Safety

1.2.4.4 Brake testing

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

Note

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


1 Safety

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

1.2.4.6 Safe use of the FlexPendant

Enabling deviceThe enabling device is a manually operated, constant pressure push-button which,when continuously activated in one position only, allows potentially hazardousfunctions but does not initiate them. In any other position, hazardous functions arestopped safely.

The enabling device is of a specific type where you must press the push-buttononly half-way to activate it. In the fully in and fully out positions, manipulatoroperation is impossible.

Note

The enabling device is a push-button located on the side of the FlexPendantwhich, when pressed halfway in, switches the system to MOTORS ON. Whenthe enabling device is released or pushed all the way in, the manipulator switchesto the MOTORS OFF state.

To ensure safe use of the FlexPendant, the following must be implemented:

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

During programming and testing, the enabling device must be released assoon as there is no need for the manipulator to move.

Anyone entering the manipulator working space must always bring theFlexPendant with him/her. This is to prevent anyone else from taking controlof the manipulator without his/her knowledge.

Hold-to-run functionThe hold-to-run function allows movement when a button connected to the functionis actuated manually and immediately stops any movement when released. Thehold-to-run function can only be used in manual mode.

How to operate the hold-to-run function for IRC5 is described in Operatingmanual - IRC5 with FlexPendant.


1 Safety

1.2.4.6 Safe use of the FlexPendant

1.2.4.7 Work inside the manipulator's working range

WARNING

If work must be carried out within the manipulators work area, the followingpoints must be observed:

The operating mode selector on the controller must be in the manual modeposition to render the enabling device operational and to block operationfrom a computer link or remote control panel.

The manipulators speed is limited to max. 250 mm/s when the operatingmode selector is in the position Manual mode with reduced speed. Thisshould be the normal position when entering the working space.

The position Manual mode with full speed (100%) may only be used bytrained personnel who are aware of the risks that this entails. Manual modewith full speed (100%) is not available in USA or Canada.

Pay attention to the rotating axes of the manipulator. Keep away from axesto not get entangled with hair or clothing. Also, be aware of any danger thatmay be caused by rotating tools or other devices mounted on the manipulatoror inside the cell.

Test the motor brake on each axis, according to the section Brake testingon page 32.

To prevent anyone else from taking control of the manipulator, always puta safety lock on the cell door and bring the enabling device with you whenentering the working space.

WARNING

NEVER, under any circumstances, stay beneath any of the manipulators axes!There is always a risk that the manipulator will move unexpectedly whenmanipulator axes are moved using the enabling device or during other workinside the manipulators working range.


1 Safety

1.2.4.7 Work inside the manipulator's working range

1.2.4.8 Signal lamp (optional)

DescriptionA signal lamp with a yellow fixed light can be mounted on the manipulator, as asafety device.

FunctionThe lamp is active in MOTORS ON mode.

Further informationFurther information about the MOTORS ON/MOTORS OFF mode may be found inthe product manual for the controller.


1 Safety

1.2.4.8 Signal lamp (optional)

1.2.5 Safety stops

1.2.5.1 What is an emergency stop?

Definition of emergency stopAn emergency stop is a state that overrides any other manipulator control,disconnects drive power from the manipulator motors, stops all moving parts, anddisconnects power from any potentially dangerous functions controlled by themanipulator system.

An emergency stop state means that all power is disconnected from the manipulatorexcept for the manual brake release circuits. You must perform a recoveryprocedure, i.e, resetting the emergency stop button and pressing the Motors Onbutton, in order to return to normal operation.

The manipulator system can be configured so that the emergency stop results ineither:

An uncontrolled stop, immediately stopping the manipulator actions bydisconnecting power from the motors.

A controlled stop, stopping the manipulator actions with power available tothe motors so that the manipulator path can be maintained. When completed,power is disconnected from the motors.

The default setting is an uncontrolled stop. However, controlled stops are preferredsince they minimize extra, unnecessary wear on the manipulator and the actionsneeded to return the manipulator system back to production. Please consult yourplant or cell documentation to see how your manipulator system is configured.

Note

The emergency stop function may only be used for the purpose and under theconditions for which it is intended.

Note

The emergency stop function is intended for immediately stopping equipmentin the event of an emergency.

Note

Emergency stop should not be used for normal program stops as this causesextra, unnecessary wear on the manipulator.

For how to perform normal program stops, see section Stopping programs inOperating manual - IRC5 with FlexPendant.



1 Safety

1.2.5.1 What is an emergency stop?

Classification of stopsThe safety standards that regulate automation and manipulator equipment definecategories in which each type of stop applies:

... then it is classified as...If the stop is...

category 0 (zero)uncontrolled

category 1controlled

Emergency stop devicesIn a manipulator system there are several emergency stop devices that can beoperated in order to achieve an emergency stop. There are emergency stop buttonsavailable on the FlexPendant and on the controller cabinet (on the Control Moduleon a Dual Cabinet Controller). There can also be other types of emergency stopson your manipulator. Consult your plant or cell documentation to see how yourmanipulator system is configured.


1 Safety

1.2.5.1 What is an emergency stop?Continued

1.3 Safety related instructions

1.3.1 Safety signals in the manual

Introduction to safety signalsThis section specifies all dangers that can arise when doing the work describedin this manual. Each danger consists 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 donot eliminate the danger.

Instruction about how to eliminate danger to simplify doing the work.

Danger levelsThe table below defines the captions specifying the danger levels used throughoutthis manual.

SignificanceDesignationSymbol

Warns that an accident will occur if the instructionsare 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, and so on.

DANGER

xx0200000022

Warns that an accident may occur if the instructionsare not followed that can lead to serious injury, pos-sibly fatal, and/or great damage to the product. Itapplies to warnings that apply to danger with, forexample, contact with high voltage electrical units,explosion or fire risk, risk of poisonous gases, riskof crushing, impact, fall from height, etc.

WARNING

xx0100000002

Warns for electrical hazards which could result insevere personal injury or death.

ELECTRICALSHOCK

xx0200000024

Warns that an accident may occur if the instructionsare not followed that can result in injury and/ordamage to the product. It also applies to warningsof risks that include burns, eye injury, skin injury,hearing damage, crushing or slipping, tripping, im-pact, fall from height, etc. Furthermore, it applies towarnings that include function requirements whenfitting and removing equipment where there is a riskof damaging the product or causing a breakdown.

CAUTION

xx0100000003

Warns for electrostatic hazards which could resultin severe damage to the product.

ELECTROSTATICDISCHARGE (ESD)

xx0200000023



1 Safety

1.3.1 Safety signals in the manual

SignificanceDesignationSymbol

Describes important facts and conditions.NOTE

xx0100000004

Describes where to find additional information orhow to do an operation in an easier way.

TIP

xx0100000098


1 Safety

1.3.1 Safety signals in the manualContinued

1.3.2 Safety symbols on manipulator labels

Introduction to labelsThis section describes safety symbols used on labels (stickers) on the manipulator.

Symbols are used in combinations on the labels, describing each specific warning.The descriptions in this section are generic, the labels can contain additionalinformation such as values.

Note

The safety and health symbols on the labels on the manipulator must be observed.Additional safety information given by the system builder or integrator must alsobe observed.

Types of labelsBoth the manipulator and the controller are marked with several safety andinformation labels, containing important information about the product. Theinformation is useful for all personnel handling the manipulator system, for exampleduring installation, service, or operation.

The safety labels are language independent, they only use graphics. See Symbolson safety labels on page 41.

The information labels can contain information in text (English, German, andFrench).

Symbols on safety labels

DescriptionSymbol

Warning!

xx0900000812

Warns that an accident may occur if the instructions are notfollowed that can lead to serious injury, possibly fatal, and/orgreat damage to the product. It applies to warnings that applyto danger with, for example, contact with high voltage electricalunits, explosion or fire risk, risk of poisonous gases, risk ofcrushing, impact, fall from height, etc.

Caution!

xx0900000811

Warns that an accident may occur if the instructions are notfollowed that can result in injury and/or damage to the product.It also applies to warnings of risks that include burns, eye injury,skin injury, hearing damage, crushing or slipping, tripping, im-pact, fall from height, etc. Furthermore, it applies to warningsthat include function requirements when fitting and removingequipment where there is a risk of damaging the product orcausing a breakdown.

Prohibition

xx0900000839

Used in combinations with other symbols.



1 Safety

1.3.2 Safety symbols on manipulator labels

DescriptionSymbol

See user documentation

xx0900000813

Read user documentation for details.Which manual to read is defined by the symbol:

No text: Product manual. EPS: Application manual - Electronic Position Switches.

Before dismantling see product manual

xx0900000816

Do not dismantle

xx0900000815

Dismantling this part can cause injury.

Extended rotation

xx0900000814

This axis has extended rotation (working area) compared tostandard.

Brake release

xx0900000808

Pressing this button will release the brakes. This means thatthe manipulator arm can fall down.

Tip risk when loosening bolts

xx0900000810

The manipulator can tip over if the bolts are not securelyfastened.



1 Safety

1.3.2 Safety symbols on manipulator labelsContinued

DescriptionSymbol

Crush

xx0900000817

Risk of crush injuries.

Heat

xx0900000818

Risk of heat that can cause burns.

Moving robot

xx0900000819

The robot can move unexpectedly.

xx1000001141

Brake release buttons

xx0900000820

xx1000001140



1 Safety


DescriptionSymbol

Lifting bolt

xx0900000821

Chain sling with shortener

xx1000001242

Lifting of robot

xx0900000822

Oil

xx0900000823

Can be used in combination with prohibition if oil is not allowed.

Mechanical stop

xx0900000824

No mechanical stop

xx1000001144

Stored energy

xx0900000825

Warns that this part contains stored energy.Used in combination with Do not dismantle symbol.



1 Safety


DescriptionSymbol

Pressure

xx0900000826

Warns that this part is pressurized. Usually contains additionaltext with the pressure level.

Shut off with handle

xx0900000827

Use the power switch on the controller.


1 Safety


1.3.3 DANGER - Moving manipulators are potentially lethal!

DescriptionAny moving manipulator is a potentially lethal machine.

When running, the manipulator may perform unexpected and sometimes irrationalmovements. Moreover, all movements are performed with great force and mayseriously injure any personnel and/or damage any piece of equipment locatedwithin the working range of the manipulator.

Elimination

NoteAction

Emergency stop equipment such as gates,tread mats, light curtains, etc.

Before attempting to run the manipulator,make sure all emergency stop equipmentis correctly installed and connected.

1

How to use the hold-to-run function is de-scribed in section How to use the hold-to-run function in theOperatingmanual - IRC5with FlexPendant.

Usually the hold-to-run function is activeonly in manual full speed mode. To in-crease safety it is also possible to activatehold-to-run for manual reduced speed witha system parameter.

2

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

Make sure no personnel are present withinthe working range of the manipulator be-fore pressing the start button.

3


1 Safety

1.3.3 DANGER - Moving manipulators are potentially lethal!

1.3.4 DANGER - First test run may cause injury or damage!

DescriptionSince performing a service activity often requires disassembly of the robot, thereare several safety risks to take into consideration before the first test run.

EliminationFollow the procedure below when performing the first test run after a serviceactivity, such as repair, installation, or maintenance.

Action

Remove all service tools and foreign objects from the robot and its working area1

Check that the fixture and workpiece are well secured, if applicable2

Install all safety equipment properly3

Make sure all personnel are standing at a safe distance from the robot, that is out ofits reach behind safety fences, and so on

4

Pay special attention to the function of the part previously serviced5

Collision risks

CAUTION

When programming the movements of the manipulator always check potentialcollision risks before the first test run.


1 Safety

1.3.4 DANGER - First test run may cause injury or damage!

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

DescriptionThe brake release unit has push-buttons for the brake release of each axis motor.When service work is performed inside the SMB recess that includes removal andrefitting of the brake release unit, the brake release buttons may be jammed afterrefitting.

DANGER

If the power is turned on while a brake release button is jammed in depressedposition, the affected motor brake is released! This may cause serious personalinjuries and damage to the manipulator.

EliminationTo eliminate the danger after service work has been performed inside the SMBrecess, follow the procedure below.

NoteAction

Make sure the power is turned off.1

Refit the push button guard, if removed.2

Check the push buttons of the brake releaseunit by pressing them down, one by one.

3

Make sure none of the buttons are jammedby the push button guard!

xx0600002777

If a button gets jammed in the depressed po-sition, the alignment of the push button unitmust be adjusted so that the buttons canmove freely!Remove the push button guard and:

Make sure the centering piece (B) isproperly fitted to the unit. (The piecealigns the unit vertically.)

Adjust the unit sideways so that themeasurements x1 and x2 in the figureto the right do not differ more than 1mm from each other.

4

Art. no. for the centering piece is spe-cified in Required equipment onpage 219.

Refit the push button guard and check thebuttons again by pressing them down, oneby one.

5


1 Safety

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

1.3.6 DANGER - Make sure that the main power has been switched off!

DescriptionWorking with high voltage is potentially lethal. Persons subjected to high voltagemay suffer cardiac arrest, burn injuries, or other severe injuries. To avoid thesedangers, do not proceed working before eliminating the danger as detailed below.

Elimination, Panel Mounted Controller

Note/illustrationAction

xx0600003255

Switch off the main switch for the controller.1

Elimination, Single Cabinet Controller


xx0600002782

Switch off the main switch on the controllercabinet.

1

A: Main switch



1 Safety

1.3.6 DANGER - Make sure that the main power has been switched off!

Elimination, Dual Cabinet Controller


xx0600002783

Switch off the main switch on the DriveModule.

1

K: Main switch, Drive Module

A: Main switch, Control ModuleSwitch off the main switch on the ControlModule.

2


1 Safety

1.3.6 DANGER - Make sure that the main power has been switched off!Continued

1.3.7 WARNING - The unit is sensitive to ESD!

DescriptionESD (electrostatic discharge) is the transfer of electrical static charge between twobodies at different potentials, either through direct contact or through an inducedelectrical field. When handling parts or their containers, personnel not groundedmay potentially transfer high static charges. This discharge may destroy sensitiveelectronics.

Elimination

NoteAction

Wrist straps must be tested frequently to ensurethat they are not damaged and are operating cor-rectly.

Use a wrist strap1

The mat must be grounded through a current-limit-ing resistor.

Use an ESD protective floor mat.2

The mat should provide a controlled discharge ofstatic voltages and must be grounded.

Use a dissipative table mat.3

Location of wrist strap buttonThe location of the wrist strap button is shown in the following illustration.

IRC5The wrist strap button is located in the top right corner.

A

xx1300000856

Wrist strap buttonA



1 Safety

1.3.7 WARNING - The unit is sensitive to ESD!

Panel Mounted Controller

AA

xx1300001960

Wrist strap buttonA


1 Safety

1.3.7 WARNING - The unit is sensitive to ESD!Continued

1.3.8 WARNING - Safety risks during handling of batteries

DescriptionUnder normal conditions of use, the electrode materials and liquid electrolyte inthe batteries are not exposed to the outside, provided the battery integrity ismaintained and seals remain intact.

There is a risk of exposure only in case of abuse (mechanical, thermal, electrical)which leads to the activation of safety valves and/or the rupture of the batterycontainer. Electrolyte leakage, electrode materials reaction with moisture/water orbattery vent/explosion/fire may follow, depending upon the circumstances.

Note

Appropriate disposal regulations must be observed.

Elimination

NoteAction

Operating temperaturesare listed in Pre-install-ation procedure onpage 58.

Do not short circuit, recharge, puncture, incinerate, crush,immerse, force discharge or expose to temperatures abovethe declared operating temperature range of the product.Risk of fire or explosion.

1

Use safety glasses when handling the batteries.2

In the event of leakage, wear gloves and chemical apron.3

In the event of fire, use self-contained breathing apparatus.4


1 Safety

1.3.8 WARNING - Safety risks during handling of batteries

1.3.9 WARNING - Safety risks during work with gearbox lubricants (oil or grease)

DescriptionWhen handling gearbox lubricants, there is a risk of both personal injury andproduct damage occurring. The following safety information must be regardedbefore performing any work with lubricants in the gearboxes.

Note

When handling oil, grease, or other chemical substances the safety informationof the manufacturer must be observed.

Note

When aggressive media is handled, an appropriate skin protection must beprovided.

Note

Appropriate disposal regulations must be observed.

Note

Take special care when handling hot lubricants.

Warnings and elimination

Elimination/ActionDescriptionWarning

Make sure that protective gearlike goggles and gloves are al-ways worn during this activity.

Changing and draining gearboxoil or grease may require hand-ling hot lubricant heated up to90 C.

xx0100000002

Hot oil or grease

Make sure that protective gearlike goggles and gloves are al-ways worn.

When working with gearbox lub-ricant there is a risk of an allergicreaction.

xx0100000002

Allergic reaction

Open the plug carefully and keepaway from the opening. Do notoverfill the gearbox when filling.

When opening the oil or greaseplug, there may be pressurepresent in the gearbox, causinglubricant to spray from theopening.xx0100000002

Possible pressurebuild-up in gearbox



1 Safety

1.3.9 WARNING - Safety risks during work with gearbox lubricants (oil or grease)

Elimination/ActionDescriptionWarning

Make sure not to overfill thegearbox when filling it with oil orgrease!

Overfilling of gearbox lubricantcan lead to internal over-pres-sure inside the gearbox which inturn may:

damage seals and gas-kets

completely press outseals and gaskets

prevent the robot frommoving freely.

xx0100000002

Do not overfill

After filling, check the correctlevel.

When filling gearbox oil, do notmix different types of oil unlessspecified in the instructions. Al-ways use the type of oil specifiedby the manufacturer!

Mixing types of oil may causesevere damage to the gearbox.

xx0100000002

Do not mix types of oil

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

Warm oil drains quicker thancold oil.

xx0100000098

Heat up the oil

After refilling, check the lubricantlevel.

The specified amount of oil orgrease is based on the totalvolume of the gearbox. Whenchanging the lubricant, theamount refilled may differ fromthe specified amount, dependingon how much has previouslybeen drained from the gearbox.

xx0100000004

Specified amount de-pends on drainedvolume

When draining the oil make surethat as much oil as possible isdrained from the gearbox. Thereason for this is to drain asmuch oil sludge and metal chipsas possible from the gearbox.The magnetic oil plugs will takecare of any remaining metalchips.

xx0100000003

Contaminated oil ingear boxes


1 Safety

1.3.9 WARNING - Safety risks during work with gearbox lubricants (oil or grease)Continued

This page is intentionally left blank

2 Installation and commissioning2.1 Introduction

GeneralThis chapter contains assembly instructions and information for installing the IRB1600 at the working site.

More detailed technical data can be found in the Product specification for the IRB1600, such as:

Load diagram

Permitted extra loads (equipment)

Location of extra loads (equipment).

Safety informationBefore any installation work is commenced, it is extremely important that all safetyinformation is observed!

There are general safety aspects that must be read through, as well as more specificsafety information that describes the danger and safety risks when performing theprocedures. Read the chapterSafety on page17 before performing any installationwork.

Note

If the IRB 1600 is connected to power, always make sure that the robot isconnected to protective earth before starting any installation work!

For more information see:

Product manual - IRC5

Product manual - IRC5 Panel Mounted Controller



2.1 Introduction

2.2 Unpacking

2.2.1 Pre-installation procedure

IntroductionThis section is intended for use when unpacking and installing the robot for thefirst time. It also contains information useful during later re-installation of the robot.

Checking the pre-requisites for installationInstallation craftsmen working with an ABB robot must:

be trained by ABB and have the required knowledge of mechanical andelectrical installation/maintenance/repair work

conform to all national and local codes.

Action

Visually inspect the robot to make sure that it is not damaged.1

Make sure that the lifting accessory used is suitable to handle the weight of the robotas specified in:

Weight, robot on page 58

2

If the robot is not installed directly, it must be stored as described in: Storage conditions, robot on page 60

3

Make sure that the expected operating environment of the robot conforms to thespecifications as described in:

Operating conditions, robot on page 61

4

Before taking the robot to its installation site, make sure that the site conforms to: Loads on foundation, robot on page 59 Protection classes, robot on page 61 Requirements, foundation on page 60

5

Before moving the robot, please observe the stability of the robot: Risk of tipping/stability on page 67

6

When these prerequisites are met, the robot can be taken to its installation site asdescribed in section:

On-site installation on page 68

7

Install required equipment, if any. Installation of signal lamp for 1600 (option) on page 89

8

Weight, robotThe table shows the weight of the robot.

WeightRobot model

250 kgIRB 1600

Note

The weight does not include tools and other equipment fitted on the robot!




2.2.1 Pre-installation procedure

Loads on foundation, robotThe illustration shows the directions of the robots stress forces. The directions arevalid for all floor mounted and suspended robots.

xy

xy

z

z

T

F

F

T

xx1100000521

Force in any direction in the XY planeFxy

Force in the Z planeFz

Bending torque in any direction in the XY planeTxy

Bending torque in the Z planeTz

The table shows the various forces and torques working on the robot during differentkinds of operation.

Note

These forces and torques are extreme values that are rarely encountered duringoperation. The values also never reach their maximum at the same time!

Floor mounted

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

3250 N 1700 NForce xy

- 2500 2200 N- 2500 1150 NForce z

3750 Nm 1700 NmTorque xy

1400 Nm 855 NmTorque z

Wall mounted



2800 N 1300 NForce z




2.2.1 Pre-installation procedureContinued




Suspended



+ 2500 2200 N+ 2500 1150 NForce z



Requirements, foundationThe table shows the requirements for the foundation where the weight of theinstalled robot is included:

NoteValueRequirement

Flat foundations give better repeatability of theresolver calibration compared to original settingson delivery from ABB.

0.5 mmMaximum deviationfrom levelness

The value for levelness aims at the circumstanceof the anchoring points in the robot base.In order to compensate for an uneven surface,the robot can be recalibrated during installation.If resolver/encoder calibration is changed thiswill influence the absolute accuracy.

The limit for the maximum payload on the robotis reduced if the robot is tilted from 0.

55Maximum tilt

Contact ABB for further information about accept-able loads.

25 HzMinimum resonancefrequency

Storage conditions, robotThe table shows the allowed storage conditions for the robot:

ValueParameter

-25 CMinimum ambient temperature

+55 CMaximum ambient temperature

+70 CMaximum ambient temperature (less than 24 hrs)

95% at constant temperature(gaseous only)

Maximum ambient humidity

Note

If the manipulator should not be used immediately, all unpainted / unprotectedsurfaces must be treated with a rust inhibitor, type Vaseline or similar.





Operating conditions, robotThe table shows the allowed operating conditions for the robot:

ValueParameter

+5 CMinimum ambient temperature

+45 CMaximum ambient temperature

Max. 95% at constant temperat-ure

Maximum ambient humidity

Protection classes, robotThe table shows the available protection types of the robot, with the correspondingprotection class.

Protection classProtection type

IP 54Manipulator, protection type Standard

IP 67Manipulator, protection type Foundry Plus

IP 54Manipulator, protection type Clean Room

IP 67Manipulator, protection type Wash




2.2.2 Working ranges

Range of movement - IRB 1600

Range of movement 1.45 mreach

Range of movement 1.2 mreach

Type of motionAxis

+180 to -180 i+180 to -180 iRotation motion1

+120 to -90+110 to -63Arm motion2+150 to -90 (with axis 1limited to 95)

+136 to -63 (with axis 1limited to 100)

+65 to -245+55 to -235Arm motion3

+200 to -200 Default+200 to -200 DefaultRotation motion4+190 rev. ii to -190 rev. max-imum iii

+190 rev. ii to -190 rev. max-imum iii

+115 to -115+115 to -115Bend motion5

+400 to -400 default+400 to -400 defaultTurn motion6+288 rev. ii to -288 rev. max-imum iii

+288 rev. ii to -288 rev. max-imum iii

i The working range of axis 1 has the following limitations for wall mounted robots: IRB 1600-6/x: 20 IRB 1600-10/x: 60

If the robot is tilted, the following combinations of tilt angles and axis 1 working ranges are allowed: IRB 1600-6/x: axis 1 45 with tilt angles up to 30 IRB 1600-10/x: axis 1 180 with tilt angles up to 55

ii rev. = Revolutionsiii The default working range for axis 4 and 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 hasbeen rotated (no need for rewinding the axis).

Range of movement - IRB 1600ID

Range of movementType of motionAxis

+180 to -180 iRotation motion1

+150 to -90Arm motion2

+79 to -238Arm motion3

+155 to -155Rotation motion4

+135 to -90Bend motion5

+200 to -200Turn motion6+288 rev. ii to -288 rev. maximum iii

i Working range axis 1 40 with tilt angles up to 30ii rev. = Revolutionsiii The default working range for axis 4 and 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 hasbeen rotated (no need for rewinding the axis).




2.2.2 Working ranges

Positions at wrist center 1.2 m reach

xx1000000914

Axis 3 Angle (de-grees)


Z Position (mm)X Position (mm)Position num-ber (see figure)

009627500

-90015621501

+5504704942

-90+9048712253

-90+136-2878974

-235+1367373865

+55-637863216

-90-63975-8087




2.2.2 Working rangesContinued

Positions at wrist center 1.45 m reach

xx1000000915



Z Position (mm)X Position (mm)Pos No. seeFigure above

0011877500

-90017871501

+6506434042

-90+9048714503

-90+150-6398004

-245+1504784485

+65-90740-66

-90-9

irb 1600 3hac026660-en manual

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