Table Of Contents - ABB IRB 1660 Product Manual

Table of Contents

Table Of Contents5
Overview Of This Manual9
Product Documentation15
Safety Information17
Illustrations17
How To Read The Product Manual17
General Safety Information19
Limitation Of Liability19
Nation/Region Specific Regulations19
Safe Access20
Safe Handling20
Safe Design20
Protective Stop And Emergency Stop21
Safety Actions22
Fire Extinguishing22
Emergency Release Of The Robot Axes23
Increased Injury23
Make Sure That The Main Power Has Been Switched Off24
Safety Risks During Installation And Service Work On Robots25
Requirements On Personnel25
Safety Risks During Operational Disturbances25
Spare Parts And Special Equipment26
Connection Of External Safety Devices26
Personal Protective Equipment26
Moving Robots Are Potentially Lethal27
First Test Run May Cause Injury Or Damage28
Work Inside The Working Range Of The Robot29
Enabling Device And Hold-To-Run Functionality30
Three-Position Enabling Device30
Hold-To-Run Function30
Risks Associated With Live Electric Parts31
Voltage Related Risks, General31
Voltage Related Risks, Irc5 Controller31
Voltage Related Risks, Manipulator31
The Unit Is Sensitive To Esd33
Hot Parts May Cause Burns34
Safety Risks Related To Pneumatic/Hydraulic Systems35
Residual Energy35
Brake Testing36
Safety Risks During Handling Of Batteries37
Safety Risks During Work With Gearbox Lubricants (Oil Or Grease)38
Introduction To Safety Signals40
Danger Levels40
Safety Signals In The Manual40
Safety Symbols On Product Labels42
Introduction To Labels42
Types Of Labels42
Symbols On Safety Labels42
Installation And Commissioning49
Introduction49
Unpacking50
Pre-Installation Procedure50
Prerequisites For Installation Personnel50
Checking The Pre-Requisites For Installation50
Weight, Robot51
Loads On Foundation, Robot51
Floor Mounted52
Wall Mounted52
Requirements, Foundation52
Storage Conditions, Robot53
Operating Conditions, Robot53
Protection Classes, Robot54
Working Range55
Range Of Movement - Irb 160055
Range Of Movement - Irb 1600Id55
Range Of Movement - Irb 1660Id55
Positions At Wrist Center Irb 1660Id59
Turning Radius60
Risk Of Tipping/Stability61
Shipping And Transportation Position61
On-Site Installation63
Lifting Robot With Roundslings63
Attaching The Roundslings63
Required Equipment64
Lifting The Robot With Roundslings64
Lifting And Turning A Suspended Mounted Robot65
Manually Releasing The Brakes66
Using The Brake Release Unit With An External Power Supply67
Orienting And Securing The Robot68
Hole Configuration, Base68
Dimension, Mounting Surface And Guiding Sleeve69
Attachment Bolts, Specification69
Guiding Sleeves69
Orienting And Securing The Robot To Installation Site70
Isolating Aw Manipulator70
Setting The System Parameters For A Suspended Or Tilted Robot72
The X-Direction In The Base Coordinate System72
System Parameters73
Gravity Beta73
Gamma Rotation73
Mounting Angles And Values74
Examples Of Mounting Angles Tilted Around The Y Axis (Gravity Beta)75
Examples Of Mounting Angles Tilted Around The X Axis (Gravity Alpha)76
Limitations In Working Area77
Defining The Parameter In The Irc5 Software77
Loads Fitted To The Robot, Stopping Time And Braking Distances78
Fitting Equipment On The Robot (Robot Dimensions)79
Load Areas79
Dimensions Irb 1600-X/1.2 (1.45)81
Dimensions Irb 1600Id82
Holes For Mounting Of Extra Equipment For Irb 160084
Design Until June 200685
Design After June 2006, Type A85
Holes For Mounting Of Extra Equipment For Irb 1600Id86
Holes For Mounting Of Extra Equipment For Irb 1660Id88
Robot Tool Flange89
Robot Tool Flange For Irb 1600Id90
Robot Tool Flange For Irb 1660Id91
Fastener Quality91
Installation Of Signal Lamp For 1600 (Option)92
Different Signal Lamps On Irb 1600 And Irb 1600Id92
Location Of Signal Lamp92
Installation, Signal Lamp93
Installation Of Signal Lamp For 1600Id/1660Id (Option)95
Installation Of The Wire Feeder Shelf For 1600Id/1660Id97
Location Of Shelf, Wire Feeder97
Restricting The Working Range99
Axes With Restricted Working Range99
Installation Of Additional Mechanical Stops On Axis100
Restrictions In Working Range100
Keep X Direction Downwards (Tilted Or Wall Mounted Robot)101
Installation Of Mechanical Stop, Axis 1103
Installation Of Additional Mechanical Stop On Axis105
Installation Of Position Switch, Axis113
Electrical Connections116
Customer Connectors On The Robot116
Connections At Robot Base116
Connections On Upper Arm118
Robot Cabling And Connection Points119
Main Cable Categories119
Robot Cable, Power, For Robots With Standard Protection119
Robot Cable, Power, For Robots With Foundry And Wash Protection120
Robot Cable, Signals120
Bending Radius For Static Floor Cables120
Grounding And Bonding Point On Manipulator121
Cabling Between Robot Base And Controller121
Customer Cables For Robots With Standard Protection121
Customer Cables For Robots With Foundry And Wash Protection122
Customer Connections On The Robot123
Air Connection123
Customer Connectors R2.Cs And R2.Cp123
Connector Set From Abb For Standard Connection123
Specified Connector Components From Souriau124
Recommended Pin Connectors124
Recommended Backshell124
Connectors That Meet Military Standard125
Connector For Crimping125
Connector For Soldering125
Start Of Robot In Cold Environments126
Problems With Starting The Robot126
Event Message From Motion Supervision126
Robot Stopping With Other Event Message126
Maintenance127
Maintenance Schedule And Expected Component Life128
Specification Of Maintenance Intervals128
Maintenance Schedule129
Expected Component Life131
Inspection Activities132
Location Of Dampers132
Inspection, Damper Axes 2, 3 And 5132
Inspection, Dampers134
Inspecting Information Labels135
Location Of Information Labels135
Replacement Activities137
Type Of Lubrication In Gearboxes137
Type And Amount Of Oil In Gearboxes137
Location Of Gearboxes137
Changing The Oil In Axes 5 And 6 Gearboxes138
Location Of Oil Plugs138
Draining, Wrist Unit139
Filling Oil, Wrist Unit140
Location Of Oil Plugs, Axis 5-6 Gearbox141
Changing The Oil In Axes 5 And Axis 5 And 6 Gearboxes, Irb 1600Id/1660Id141
Draining, Axis 5-6 Gearbox142
Filling Oil, Axis 5-6 Gearbox143
Replacing The Battery Pack144
Location Of Battery Pack144
Battery Pack On Serial Measurement Unit145
Replacement, Battery Pack147
Cleaning Activities149
Cleaning The Irb 1600/1660Id149
Oil Spills From Gearboxes149
Special Cleaning Considerations149
Cleaning Methods150
Cleaning With Water And Steam150
Instructions For Rinsing With Water150
Instructions For Steam Or High Pressure Water Cleaning151
Cables151
Repair153
General Procedures154
Performing A Leak-Down Test154
When To Perform A Leak-Down Test154
Mounting Instructions For Bearings155
Assembly Of All Bearings155
Assembly Of Tapered Bearings155
Greasing Of Bearings155
Mounting Instructions For Seals157
Rotating Seals157
Flange Seals And Static Seals158
O-Rings158
Cut The Paint Or Surface On The Robot Before Replacing Parts159
The Brake Release Buttons May Be Jammed After Service Work161
Complete Manipulator162
Replacing The Cable Harness, Irb 1600162
Illustration, Covers To Remove163
Deciding Calibration Routine164
Removal, Cable Harness164
Illustration, Cabling Inside Upper Arm Housing166
Refitting, Cable Harness In Upper Arm Housing And Lower Arm167
Illustration, Cabling Inside Frame168
Illustration, Cabling Inside Base169
Refitting, Cable Harness In Frame And Base170
Replacing The Cable Harness, 1600Id/1660Id172
Location Of The Harness172
Removal, Cable Harness Lower Arm And Upper Arm Back174
Removal, Cable Harness Upper Arm Tube175
Refitting, Cable Harness177
Replacement Of Complete Arm System178
Location Of Complete Arm System178
Removing The Complete Arm System179
Refitting, Complete Arm System181
Upper And Lower Arm183
Replacing The Complete Upper Arm, Irb 1600183
Replacing The Complete Upper Arm, Irb 1600Id/1660Id188
Location Of The Complete Upper Arm188
Refitting The Complete Upper Arm193
Replacing The Complete Lower Arm196
Location Of Lower Arm196
Replacing The Wrist Unit, Irb 1600201
Location Of Wrist Unit201
Replacing The Wrist Unit, Irb 1600Id206
Replacing The Wrist Unit, Irb1660Id212
Replacing The Damper, Axis 2220
Location Of Damper, Axis 2220
Replacing The Damper, Axis 3222
Location Of Damper, Axis 3222
Replacing The Mechanical Stop Axis 3, Irb 1600Id/1660Id224
Location Of The Mechanical Stop Axis 3224
Replacement Of Damper, Axis 5226
Location Of Damper, Axis 5226
Remove Upper Arm Aw Gun228
Location Of Aw Gun228
Remove Aw Gun229
Refit Aw Gun231
Measuring The Play 1600Id/1660Id, Axis 5233
Measuring The Play 1600Id/1660Id, Axis 6236
Frame And Base239
Replacement Of Base239
Location Of Base239
Removal, Base241
Replacing The Serial Measurement Unit244
Location Of Serial Measurement Unit244
Serial Measurement Unit Layout245
Removing The Serial Measurement Unit247
Replacing The Push Button Unit251
Location Of Push Button Unit251
Push Button Unit On Serial Measurement Unit251
Removing The Push Button Unit252
Replacement Of Motor, Axis 1257
Replacement Of Motor, Axis 2262
Location Of Motor Axis 2262
Replacement Of Motor, Axis 3, Irb 1600268
Replacement Of Motor, Axis 3, 1600Id/1660Id273
Replacement Of Motor, Axis 4, Irb 1600279
Removal, Motor Axis 4281
Replacement Of Motor, Axis 4, 1600Id/1660Id284
Replacement Of Motor And Timing Belt, Axis 5, Irb 1600288
Belt Tightener, 3Hac 024044-001289
Removal, Motor Axis 5 And Timing Belt290
Refitting, Motor And Timing Belt Axis 5291
Replacement Of Motor, Axis 5, Irb 1600Id294
Location Of Motor, Axis 5294
Replacement Of Motor, Axis 5, Irb 1660Id302
Location Of Motor Axis 5302
Replacement Of Motor And Timing Belt, Axis 6, Irb 1600311
Replacement Of Motor, Axis 6, Irb 1600Id315
Replacement Of Motor, Axis 6, Irb 1660Id319
Location Of Motor Axis 6319
Removing Axis-6 Motor And Wrist Unit320
Gearboxes329
Replacement Of Gearbox, Axes329
Location Of Gearbox Unit, Axes 1-2329
Removal, Gearbox Unit Axes 1-2331
Service Work On Gearboxes, Axes 3, 4, 5 And 6335
Gearboxes, Replacement335
Introduction And Calibration Terminology337
Calibration Methods338
Types Of Calibration338
Brief Description Of Calibration Methods339
Calibration Pendulum Method339
Axis Calibration Method339
Calibware - Absolute Accuracy Calibration339
When To Calibrate340
The Revolution Counter Memory Is Lost340
The Robot Is Rebuilt340
The Resolver Values Are Changed340
Synchronization Marks And Axis Movement Directions341
Synchronization Marks And Synchronization Position For Axes341
Calibration Movement Directions For All Axes344
Manual Movement Directions, 6 Axes344
Updating Revolution Counters345
Coupled Axes345
Correct Calibration Position Of Axis 4 And 6345
Updating The Revolution Counter With The Flexpendant346
Calibrating With Axis Calibration Method349
Description Of Axis Calibration349
Overview Of The Axis Calibration Procedure349
Routines In The Calibration Procedure350
Fine Calibration Routine350
Reference Calibration Routine350
Update Revolution Counters350
Calibration Tools For Axis Calibration352
Examining The Calibration Tool352
Check Prior To Usage352
Periodic Check Of The Calibration Tool353
Installation Locations For The Calibration Tools354
Location Of Fixed Calibration Items354
Axis Calibration - Running The Calibration Procedure358
Overview Of The Calibration Procedure On The Flexpendant358
Preparation Prior To Calibration360
Starting The Calibration Procedure360
Restarting An Interrupted Calibration Procedure361
Axis Calibration With Safemove Option362
Safety Controller Not Synchronized - Safemove Message362
Calibrating With Calibration Pendulum Method366
Where To Find Information For Calibration Pendulum366
Verifying The Calibration367
Checking The Synchronization Position368
Using A Moveabsj Instruction368
Using The Jogging Window368
Decommissioning369
Environmental Information369
Hazardous Material369
Oil And Grease369
Scrapping Of Robot371
Important When Scrapping The Robot371
Robot Description373
Type A Of Irb 1600373
How To Know Which Type The Robot Is?373
Which Parts Are Interchangeable And Which Are Not?373
Type A Of Irb 1600Id374
Upgrade From Irb 1600Id To Irb 1600Id Type A374
Reference Information375
Applicable Standards376
Standards, En Iso376
European Standards376
Unit Conversion378
Converter Table378
Screw Joints379
Unbrako Screws379
Gleitmo Treated Screws379
Screws Lubricated In Other Ways379
Oil-Lubricated Screws With Slotted Or Cross-Recess Head Screws380
Oil-Lubricated Screws With Allen Head Screws380
Water And Air Connectors381
Weight Specifications382
Definition382
Standard Tools383
Contents, Standard Toolkit383
Special Tools384
Measuring Tools, Play384
Calibration Equipment, Calibration Pendulum384
Calibration Equipment, Axis Calibration385
Lifting Accessories And Lifting Instructions386
Spare Part Lists And Illustrations387
Circuit Diagram389
Controllers389
Index391