IRC5-IRB1600 Prod Man 3HAC023637-001 References Rev- En

Product manual (part 2 of 2), reference informationArticulated robotIRB 1600 - 5/1.2

IRB 1600 - 5/1.45

IRB 1600 - 7/1.2

IRB 1600 - 7/1.45

M2004

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Product manual (part 2 of 2), reference information

IRB 1600 - 5/1.2

IRB 1600 - 5/1.45

IRB 1600 - 7/1.2

IRB 1600 - 7/1.45M2004

Document ID: 3HAC 023637-001

Revision: -

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 from use of this manual and products described herein.

This manual and parts thereof must not be reproduced or copied without ABB’s written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted.

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

© Copyright 2005 ABB All right reserved.

ABB Automation Technologies ABRobotics

SE-721 68 Västerås Sweden

Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1 Reference information 9

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.2 Applicable safety standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151.6 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161.7 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171.8 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181.9 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2 Spare parts and exploded views 21

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212.2 Spare parts - base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222.3 Spare parts - base connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242.4 Spare parts - frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262.5 Spare parts - lower arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282.6 Spare parts - upper arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302.7 Spare parts - options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3 Circuit diagram 35

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

33HAC 023637-001 Revision: -

Overview

Overview

About This Manual

This manual contains reference information for all procedures in part 1: Product manual,

procedures.

Usage

This manual should be used during

• installation

• 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.

Organization of chapters

The manual is organized in the following chapters:

References

See section Document references.

Revisions

Chapter Contents

Reference information

Useful information when performing installation, maintenance or repair work. Includes lists of necessary tools, additional documents, safety standards, etc.

Spare part / Part list

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

Exploded views Detailed illustrations of the robot with reference numbers to the part list.

Circuit diagram Circuit diagram for the robot.

Revision Description

- First edition

3HAC 023637-001 Revision: -4

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

all documents 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 manual which

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

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.

53HAC 023637-001 Revision: -


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

Operator’s 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:

• Operator’s manual - IRC5 with FlexPendant

• Operator’s manual - RobotStudio Online

• Trouble shooting manual for the controller and robot

3HAC 023637-001 Revision: -6

1 Reference information

1.1. Introduction


1.1. Introduction

General

This chapter includes general information, complementing the more specific information in

the Product manual (part 1 of 2), procedures.

73HAC 023637-001 Revision: -


1.2. Applicable safety standards

1.2. Applicable safety standards

Health and safety standards, robotThe robot, controlled by the IRC5, conforms to the following standards:

Standard Description

EN ISO 12100-1 Safety of machinery, terminology

EN ISO 12100-2 Safety of machinery, technical specifications

EN 954-1 Safety of machinery, safety related parts of control systems

EN 775 Manipulating industrial robots, safety

EN 60204 Electrical equipment of industrial machines

EN 61000-6-4 (option) EMC, Generic emission

EN 61000-6-2 EMC, Generic immunity


IEC 204-1 Electrical equipment of industrial machines

IEC 529 Degrees of protection provided by enclosures


ISO 10218 Manipulating industrial robots, safety

ISO 9787 Manipulating industrial robots, coordinate systems and motions


ANSI/RIA 15.06/1999 Safety Requirements for Industrial Robots and Robot Systems

ANSI/UL 1740-1998 (option)

Safety Standard for Robots and Robotic Equipment (Max. payload 6 kg fulfilment).

CAN/CSA Z 434-03 (option)

Industrial Robots and Robot Systems - General Safety Requirements (Max. payload 6 kg fulfilment).

3HAC 023637-001 Revision: -8


1.3. Unit conversion

1.3. Unit conversion

Converter table

Use the table below to convert units used in this manual.

Quantity Units

Length 1 m 3.28 ft 39.37 in

Weight 1 kg 2.21 lb

Pressure 1 bar 100 kPa 14.5 psi

Force 1 N 0.738 lbf

Moment 1 Nm 0.738 lbf-tn

Volume 1 L 0.264 US gal

93HAC 023637-001 Revision: -


1.4. Screw joints

1.4. Screw joints

General

This section details how to tighten the various types of screw joints on the robot and the

controller.

The instructions and torque values are valid for screw joints comprised of metallic materials

and do not apply to soft or brittle materials.

UNBRAKO screws

UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It

features special surface treatment (Gleitmo as described below), and is extremely resistant to

fatigue.

Whenever used, this is specified in the instructions, and in such cases, no other type of

replacement screw is allowed! Using other types of screws will void any warranty and may

potentially cause serious damage or injury!

Gleitmo treated screws

Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.

Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this

the screw must be discarded and replaced with a new one.

When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should

be used.

Screws lubricated in other ways

Screws lubricated with Molycote 1000 should only be used when specified in the repair,

maintenance or installation procedure descriptions.

In such cases, proceed as follows:

1. Apply lubricant to the screw thread.

2. Apply lubricant between the plain washer and screw head.

3. Tighten to the torque specified in section Tightening torque below. Screw dimensions

of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or

smaller may be tightened without a torque wrench if this is done by trained and

qualified personnel.

Lubricant Art. no.

Molycote 1000 (molybdenum disulphide grease) 1171 2016-618

3HAC 023637-001 Revision: -10


1.4. Screw joints

Tightening torque

Before tightening any screw, note the following:

• Determine whether a standard tightening torque or special torque is to be applied. The

standard torques are specified in the tables below. Any special torques are specified in

the Repair, Maintenance or Installation procedure description. Any special torque

specified overrides the standard value.

• Use the correct tightening torque for each type of screw joint.

• Only use correctly calibrated torque keys.

• Always tighten the joint by hand, and never use pneumatical tools.

• Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a slow,

flowing motion.

• Maximum allowed total deviation from the specified value is 10%!

The table below specifies the recommended standard tightening torque for oil-lubricated

screws with slotted or cross-recess head screws.

The table below specifies the recommended standard tightening torque for oil-lubricated

screws with Allen head screws.

The table below specifies the recommended standard tightening torque for Molycote-

lubricated screws with Allen head screws.

Dimension Tightening torque (Nm) Class 4.8, oil-lubricated

M2.5 0.25

M3 0.5

M4 1.2

M5 2.5

M6 5.0

Dimension

Tightening torque (Nm) Class 8.8, oil-lubricated



M5 6 - -

M6 10 - -

M8 24 34 40

M10 47 67 80

M12 82 115 140

M16 200 290 340

DimensionTightening torque (Nm)Class 10.9, Molycote-lubricated

Tightening torque (Nm)Class 12.9, Molycote-lubricated

M8 28 34

113HAC 023637-001 Revision: -


1.4. Screw joints

The table below specifies the recommended standard tightening torque for water and air

connectors when one or both connectors are made of brass.

M10 55 66

M12 96 115

M16 235 280

DimensionTightening torque Nm - Nominal

Tightening torque Nm - Min.

Tightening torque Nm - Max.

1/8 12 8 15

1/4 15 10 20

3/8 20 15 25

1/2 40 30 50

3/4 70 55 90

DimensionTightening torque (Nm)Class 10.9, Molycote-lubricated

Tightening torque (Nm)Class 12.9, Molycote-lubricated

3HAC 023637-001 Revision: -12


1.5. Weight specifications

1.5. Weight specifications

Definition

In all repair and maintenance procedures, weights of the components handled are sometimes

specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.

To avoid injury, ABB recommends the use of lifting equipment when handling components

with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each

manipulator model.

Example

Below is an example of how a weight specification is presented:

CAUTION!

Caution!

The motor weighs 32 kg! All lifting equipment used must be sized accordingly!

133HAC 023637-001 Revision: -


1.6. Standard toolkit

1.6. Standard toolkit

General

All service (repair, maintenance and installation) instructions contain lists of tools required to

perform the specified activity. All special tools, i.e. all tools that are not considered standard

as defined below, are listed in their instructions respectively.

This way, the tools required are the sum of the Standard Toolkit and any tools listed in the

instruction.

Standard toolkit, contents

Qty Art. no. Tool

1 - Ring-open-end spanner 8-19mm

1 - Socket head cap 2,5-17mm

1 - Torx socket no:20-60

1 - Torque wrench 10-100Nm

1 - Small screwdriver

1 - Plastic mallet

1 - Ratchet head for torque wrench 1/2

1 - Socket head cap no:5, socket 1/2"" bit L 20mm



1 - Small cutting plier

3HAC 023637-001 Revision: -14


1.7. Special tools

1.7. Special tools

General

All service instructions contain lists of tools required to perform the specified activity. The

required tools are a sum of standard tools, defined in section Standard toolkit on page 14, and

of special tools, listed directly in the instructions and also gathered in this section.

Special toolsThe table below specifies all the tools, not considered standard, used when performing service activities on the robot.

Description Art. no. Note

Rotation tool, motor 3HAC 022266-003 Used to adjust the gear play on all motors.

Dynamometer Salter - Super Samson 100N

- Supplier: Ahlsell

Hook 3HAC 024045-001 Used to tighten the timing belt of axis 6, together with the dynamometer.

Belt tightener 3HAC 024044-001 Used to tighten the timing belt of axis 5, together with the dynamometer.

Lifting tool, gearbox 3HAC 023364-001

Lifting tool, upper arm 3HAC 023386-001

153HAC 023637-001 Revision: -


1.8. Document references

1.8. Document references

General

The contents of this manual may include references to additional documentation necessary to

perform certain procedures. This section specifies the article numbers for the referenced

documentation.

Product specification, robot

The product specification includes generic technical data. The specification listed below is

the English version.

Product manuals, controller

The product manuals include information about installation and service activities. The table

below specifies the article numbers of the product manuals for all controller models. The part

number -001 is the English version.

Operators manual

The operators manual contains instructions for daily operation of robot systems. The table

below specifies the article numbers of the operators manuals for different robot systems.

Calibration manuals

Additional documentation

Document name Document ID

Product specification 3HAC 023604-001 (M2004)

Document name Document ID

Product manual, IRC5 M2004 3HAC 021313-001

Document name Document ID Note

Operator’s manual (IRC5) 3HAC 16590-1


Calibration Pendulum Instruction

3HAC 16578-1 Enclosed with the Calibration Pendulum Toolkit.

Instructions for Levelmeter calibration (alternative method)

3HAC 022907-001

Enclosed with the Levelmeter 2000.

CalibWare 2.0 Users Guide 3HAC 16090-1 Manual for Absolute Accuracy calibration.


Additional axes 3HAC 021395-001 IRC5 based robot systems.

3HAC 023637-001 Revision: -16


1.9. Lifting equipment and lifting instructions


General

Many repair and maintenance activities require different pieces of lifting equipment, which

are specified in each procedure.

The use of each piece of lifting equipment is not detailed in the activity procedure, but in the

instruction delivered with each piece of lifting equipment.

This implies that the instructions delivered with the lifting equipment should be stored for

later reference.

173HAC 023637-001 Revision: -



3HAC 023637-001 Revision: -18

2 Spare parts and exploded views

2.1. Introduction


2.1. Introduction

Overview

This section specifies all articles considered spare parts of the robot. The spare parts are also

specified as required equipment directly in the repair instruction of the current spare part. The

list of required equipment in each instruction also specifies necessary replacement articles

and all required service tools.

193HAC 023637-001 Revision: -


2.2. Spare parts - base


Base, spare part list

The spare parts for the base are listed below and shown in the following figure.

Item no. Description Spare part no. Dimension

1 Base, spare 3HAC 023552-001

2 Stop pin 3HAB 3258-1

3 Cover base, spare 3HAC 023554-001

4 Gasket, base cover 3HAC 022047-001

6 VK-cover 3HAA 2166-26 D=180, B=12

7 Serial measurement unit 3HAC 023424-001

8 Push button unit 3HAC 020967-001

9 Battery pack 3HAC 16831-1 Lithium

34x102x63

11 Push button guard 3HAC 6499-1

12 Signal cable SMB 3HAC 4050-1

13 Torx pan head screw 9ADA 618-56 Steel 8.8-A2F

M6 x 16

100 Cable harness IRB 1600/1.45 3HAC 021827-001

101 Cable harness IRB 1600/1.2 3HAC 021827-008

102 Cable harness IRB 1600/1.45, Customer connections

3HAC 021828-001

103 Cable harness IRB 1600/1.2, Customer connections

3HAC 021828-002

106 Cable harness IRB 1600/1.45, Wire feeder

3HAC 021830-001

107 Cable harness IRB 1600/1.2, Wire feeder 3HAC 021830-002

3HAC 023637-001 Revision: -20



Base, exploded view

xx0500001382

213HAC 023637-001 Revision: -


2.3. Spare parts - base connections


Base connections, spare part list

The spare parts for connections at the base are listed below and shown in the following figure.


80 Gasket 3HAB 9040-1 115x46 T=3

81 Housing 40P 3HAB 6411-1

82 Surface mounted housing HIP. 16/40 AG 3HAC 022964-001

84 Cover, cable harness wire feeder 3HAC 022918-002

85 Cover 3HAC 6823-1

86 Key pin 5217687-9

87 Plug 3HAC 11719-1

88 Protective hood 25222101-8 D=11,4-13

89 Dust cap 5217649-9

90 Environmental dust cap 3HAA 1001-727

92 Dust cap 3HAA 1001-630

93 Protection cover 40-p 3HAC 7816-1

3HAC 023637-001 Revision: -22



Base connections, illustrations

xx0500001383

233HAC 023637-001 Revision: -


2.4. Spare parts - frame


Frame, spare part list

The spare parts are listed below and shown in the following figure.



M6 x 16

20 Gearbox axis 1-2, spare 3HAC 023555-001

21 Stop arm 3HAC 022001-001

22 Cover, gearbox axis 1-2 3HAC 023556-001

23 Gasket, gearbox axis 1-2 3HAC 022048-001

24 Damper, axis 2 3HAC 022013-001

25 V-ring (sealing ring) 3HAB 3732-21 V-150A

135x12.8

26 Sealing ring (V-ring) 3HAB 3732-13 V-110-L

99x10.5

27 Rot. ac motor incl. pinion, spare 3HAC 023557-001

28 O-ring 21522012-428 Nitrile rubber

79.5x3

100-107 Cabling See section .

3HAC 023637-001 Revision: -24



Frame, exploded view

xx0500001384

253HAC 023637-001 Revision: -


2.5. Spare parts - lower arm


Lower arm, spare part list

The spare parts are listed below and shown in the following figure.


40 Lower arm, spare 3HAC 023558-001

41 Lower arm, short, spare 3HAC 023559-001

42 VK-cover 3HAA 2166-23 D=120, B=12

43 VK-cover 3HAA 2166-21 D=68, B=8


3HAC 023637-001 Revision: -26



Lower arm, exploded view

xx0500001385

273HAC 023637-001 Revision: -


2.6. Spare parts - upper arm


Spare part list, upper arm

The spare parts listed below are shown in the exploded views, located on the next two pages.



M6 x 16

60 Upper arm, spare 3HAC 023630-001

61 Rot. ac motor incl pinion 3HAC 021799-001

62 O-ring 3HAB 3772-81 Nitrile rubber

D1=41, D2=3


64 Timing belt 3HAC 6779-1

65 Timing belt 3HAC 021304-001

66 O-ring sealingplate 3HAC 7191-1

67 Wrist, Standard/Foundry 3HAC 10475-1


69 O-ring 21522012-426 Nitrile rubber

74.5x3

70 Damper, axis 3 3HAC 022260-001

71 Sealing ring (V-ring) 3HAB 3732-19 Flourinated rubber/V-95A

85x11

72 Damper, axis 5 3HAB 8964-1

73 Arm housing cover, spare 3HAC 023560-001

74 Gasket, upper arm cover 3HAC 022049-001

75 Gasket, customer connections 3HAC 022050-001

73 Contact panel 3HAC 022173-001

77 Connector panel 3HAC 022173-002

79 Contact pane, Wire feeder 3HAC 022173-006

88 Protective hood 25222101-8 D=11,4-13

89 Dust cap 5217649-9

90 Environmental dust cap 3HAA 1001-727

91 Dust cap 5217649-82

94 Plug with o-ring M10 3HAC 022881-003

95 Coupling 3HAB 3333-20

96 Lamp unit 3HAC 022235-001


3HAC 023637-001 Revision: -28



Upper arm, exploded view 1

xx0500001386

293HAC 023637-001 Revision: -



Upper arm, exploded view 2

xx0500001387

3HAC 023637-001 Revision: -30


2.7. Spare parts - options


General

This section specifies spare parts that are considered options. The items are not shown in any

figure.

Spare parts - options

Option no. Description Spare part no. Note

213-1 Lamp unit 3HAC 022235-001

25-3 Position switch, axis 1 3HAC 023973-001 Includes 3 switches.

28-1 Working range limit axis 1 3HAC 023110-001



313HAC 023637-001 Revision: -



3HAC 023637-001 Revision: -32

3 Circuit diagram

3.1. Introduction

3 Circuit diagram

3.1. Introduction

Overview

This chapter includes the circuit diagram for the robot.

333HAC 023637-001 Revision: -

Circuit diagram 3HAC 021351-003/Rev. 00

Contents Sheet

List of contents ............................................................................................................. 101 Connection point location............................................................................................. 102 Brake release unit, serial measuring board................................................................... 103 Motor, axes 1-2............................................................................................................. 104 Feedback, axes 1-2 ....................................................................................................... 105 Motor, axes 3-4............................................................................................................. 106 Feedback, axes 3-4 ....................................................................................................... 107 Motor, axes 5-6............................................................................................................. 108 Feedback, axes 5-6 ....................................................................................................... 109 Cable harness, customer connection, options............................................................... 110 Cable harness, customer connection, Wire Feeder, options ......................................... 112 Position indicator, axis 1, options................................................................................. 113

Circuit diagram IRB 1600

Circuit diagram 3HAC 021351-003/Rev. 00

Contents Sheet

2 Circuit diagram IRB 1600

Circuit diagram 3HAC 021351-003

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C

calibration manual, article number 16

D

documentationarticle numbers, other manuals 16calibration 16controller 16robot system 16

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illustrationsbase connections 23base, exploded 21frame, exploded 25lower arm, exploded 27upper arm, exploded 29, 30

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operators manual, article number 16

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product manual, controller, article number 16product specification, article number 16

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spare partsbase 20, 21base connections 22, 23frame 24, 25lower arm 26, 27optional equipment 31upper arm 28, 29, 30

T

tools, article numbers 15

353HAC 023637-001 Revision: -

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IRC5-IRB1600 Prod Man 3HAC023637-001 References Rev- En