ABB IRB 1200 Product Manual
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ABB IRB 1200 Product Manual

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IRB 1200

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Summary of Contents for ABB IRB 1200

  • Page 1 ROBOTICS Product manual IRB 1200...
  • Page 2 Trace back information: Workspace 21D version a15 Checked in 2021-12-16 Skribenta version 5.4.005...
  • Page 3 IRB 1200-5/0.9 type A IRB 1200-5/0.9 type B IRB 1200-7/0.7 IRB 1200-7/0.7 type A IRB 1200-7/0.7 type B IRC5, OmniCore Document ID: 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved. Specifications subject to change without notice.
  • Page 4 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, damage to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    Additional installation procedure, Clean Room ..........Electrical connections ..................2.7.1 Robot cabling and connection points ............2.7.2 Customer connections ................Start of robot in cold environments ..............Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 6 Replacing the sealing set on tool flange of Hygienic robots ......Cleaning activities ..................... 3.5.1 Cleaning the IRB 1200 ................3.5.2 Cleaning the IRB 1200 with protection type Hygienic ........Repair Introduction ...................... General procedures ................... 4.2.1 Cut the paint or surface on the robot before replacing parts ......
  • Page 7 Special tools ....................Lifting accessories and lifting instructions .............. Spare parts Spare part lists and illustrations ................10 Circuit diagrams 10.1 Circuit diagrams ....................Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 8 Table of contents Index Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 9: Overview Of This Manual

    ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Product manual scope The manual covers covers all variants and designs of the IRB 1200. Some variants and designs may have been removed from the business offer and are no longer available for purchase.
  • Page 10 Product manual - OmniCore C90XT 3HAC073706-001 Product manual - OmniCore E10 3HAC079399-001 Operating manual - OmniCore 3HAC065036-001 Revisions Revision Description First edition. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 11 108. Also added to repair pro- cedures, where needed. • Changed pin number for 24V connection, see Manually releasing the brakes on page Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 12 No need to remove tilt covers when replacing axis-5 drive unit, Replacing the axis-5 and axis-6 drive unit on page 778. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 13 Information about Type B robots supporting SafeMove 2 added. • Plug on base added to options IP67 and Foundry Plus. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 14 158. • New article numbers for manipulator cables in section Robot cables on page 106. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 15 Published in release 21D. The following updates are done in this revision: • Hygienic option added. • Controllers OmniCore C30, OmniCore C90XT and OmniCore E10 supported. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 16: Product Documentation

    Product documentation Categories for user documentation from ABB Robotics The user documentation from ABB Robotics is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.
  • Page 17 The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 18: How To Read The Product Manual

    Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 19: Safety

    The installation and/or use of non-original spare parts and equipment can negatively affect the safety, function, performance, and structural properties of the robot. ABB is not liable for damages caused by the use of non-original spare parts and equipment.

  • Page 20: Requirements On Personnel

    The plant liable must make sure that the personnel is trained on the robot, and on responding to emergency or abnormal situations. Personal protective equipment Use personal protective equipment, as stated in the instructions. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 21: Safety Signals And Symbols

    NOTE Signal word used to indicate important facts and conditions. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 22 Symbol Designation Significance Signal word used to indicate where to find additional information or how to do an operation in an easier way. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 23: Safety Symbols On Manipulator Labels

    Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 24 Brake release Pressing this button will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 25 The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 26 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 xx1500002616 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 27 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 28 Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 29: Robot Stopping Functions

    • Product manual - OmniCore C90XT • Product manual - OmniCore E10 • Product manual - IRC5 • Product manual - IRC5 Compact Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 30: Installation And Commissioning

    When the robot is installed at a height, hanging, or other than mounted directly on the floor, there will be additional hazards. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 31 Compressed air • Hydraulics End-effector hazards require particular attention for applications which involve close human collaboration with the robot. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 32 Before the robot system is put into operation, verify that the safety functions are working as intended and that any remaining hazards identified in the risk assessment are mitigated to an acceptable level. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 33: Operation

    A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 34: Maintenance And Repair

    90 °C. Hot oil or grease Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 35 Operating conditions, robot on page See safety instructions for the batteries in Material/product safety data sheet - Battery pack (3HAC043118-001). Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 36 Manipulator movements can cause serious injuries on users and may damage equipment. Related information See also the safety information related to installation and operation. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 37: Emergency Release Of The Robot Axes

    When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways. Make sure no personnel is near or beneath the robot. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 38: Brake Testing

    For robots with the option SafeMove, the Cyclic Brake Check routine is recommended. See the manual for SafeMove in References on page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 39: Troubleshooting

    The manipulator can move unexpectedly at any time. DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers. A risk assessment must be done to address both robot and robot system specific hazards.

  • Page 40: Decommissioning

    A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 41: Installation And Commissioning

    Safety on page 19 before performing any installation work. Note Always connect the IRB 1200 and the robot to protective earth and residual current device (RCD) before connecting to power and starting any installation work. For more information see: •...

  • Page 42: Unpacking

    Robots with manipulator cables routed from the rear of the base: xx1500000243 Robots with manipulator cables routed from below (option 996-1): xx1500000242 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 43 Accessories) must be fitted . 3HAC079172-001 xx2100001272 Further information For installation information, see Orienting and securing the robot on page 74 Electrical connections on page 106. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 44: Protection Covers

    Used with protection type Foundry Plus. Replace if damaged. Protection plug for lifting 3HAC4836-24 Used with protection type Foundry Plus. holes Replace if damaged. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 45: Transportation Bracket

    The bracket must be kept for reuse after removal. Once robot shipping and transportation are required, the transportation bracket has to be reinstalled for securing the robot position. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 46 It is important not to rub against the paint of the robot while performing any service work on the robot. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 47 Remove the two M10 rubber washers, as circled in the figure, together with the bracket and reserve them for further use. xx1600001178 xx1500001400 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 48 After the replacement, wipe clean. xx1600000205 For robots with protection type Foundry Plus Protection plug for lifting holes: Fit protection plugs to the lifting holes. 3HAC4836-24 xx1600001147 Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 49: Pre-Installation Procedure

    It also contains information useful during later re-installation of the robot. Prerequisites for installation personnel Installation personnel working with an ABB product must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work • conform to all national and local codes.
  • Page 50 IRB 1200-5/0.9: 54 kg IRB 1200-7/0.7: 52 kg Note The weight does not include tools and other equipment fitted on the robot. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 51 Force z -550 ±980 N -550 ±1610 N Torque xy ±570 Nm ±1550 Nm Torque z ±280 Nm ±580 Nm Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 52 This might be a problem, depending on the requirements from the applications. If this is a problem, the robot needs to be isolated from the environment. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 53 For robots with food grade lubrication For robots with protection type Hygienic If environment temperature > 35ºC, contact ABB for further information. Protection classes, robot The table shows the available protection types of the robot, with the corresponding protection class.
  • Page 54 2 Installation and commissioning 2.2.4 Pre-installation procedure Continued Protection type Protection class Manipulator, protection type Hygienic IP67 IP69K (max.30bar) on axis 6 flange Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 55: Dimensions

    Minimum turning radius axis 3 R=139 mm Minimum turning radius axis 1 R=138 mm Valid for option Robot cabling routing, 966-1 From below Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 56 Minimum turning radius axis 3 R=139 mm Minimum turning radius axis 1 R=138 mm Valid for option Robot cabling routing, 966-1 From below Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 57 Minimum turning radius axis 3 R=111 mm Minimum turning radius axis 1 R=138 mm Valid for option Robot cabling routing, 966-1 From below Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 58 Minimum turning radius axis 3 R=139 mm Minimum turning radius axis 1 R=138 mm Valid for option Robot cabling routing, 966-1 From below Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 59: Working Range

    2.2.6 Working range 2.2.6 Working range Illustration, working range IRB 1200-7/0.7 IRB 1200-7/0.7 Working range, positions at wrist center and angle of axes 2 and 3 The illustration shows the unrestricted working range of the robot. Pos 1 Pos 0...
  • Page 60 2 Installation and commissioning 2.2.6 Working range Continued Illustration, working range IRB 1200-5/0.9 IRB 1200-5/0.9 Working range, positions at wrist center and angle of axes 2 and 3 The illustration shows the unrestricted working range of the robot. Pos 1 Pos 0...
  • Page 61 Option Independent axis can be used for resetting the revolution counter after the axis has been rotated (no need for "rewinding" the axis). Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 62: Risk Of Tipping/Stability

    Shipping and transportation position This figure shows the robot in its shipping position and transportation position. Taking IRB 1200-5/0.9 as an example xx1500001399 IRB 1200 all variants (not in protection type Hygienic) 10° 25° Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S ©...
  • Page 63 For details, see Transportation bracket on page WARNING The robot will be mechanically unstable if not properly secured to the foundation. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 64: The Unit Is Sensitive To Esd

    The mat must be grounded through a current-limiting resistor. • Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 65: On-Site Installation

    For details, see Transportation bracket on page xx1400000501 Required equipment Equipment, etc. Article number Note Overhead crane Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 66 Hygienic) IRB 1200-7/0.7 (in 11.95° 25.66° protection type Hy- gienic) IRB 1200-5/0.9 (in 11.77° 25.48° protection type Hy- gienic) Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 67 For robots with protection type Foundry Plus Remove the protection plugs in lifting holes. xx1600001147 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 68 Roundsling, 1.5 m xx1400000511 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 69 If the manipulator should be mounted on a wall, or in an suspended position the manipulator can now be tilted slowly by hand. xx1600000005 Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 70: Lifting And Turning A Suspended Mounted Robot

    891. Any additional equipment required is specified in the instruction for the lifting accessory. Contact ABB for more information. How to lift and turn the robot into position for wall position: Contact ABB for more information. How to lift and turn the robot into position for tilted position: Contact ABB for more information.

  • Page 71: Manually Releasing The Brakes

    Location of brake release unit The internal brake release unit is located as shown in the figure. xx1400000030 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 72 DANGER Incorrect connections, such as supplying power to the wrong pin, may cause all brakes to be released simultaneously! Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 73 Do not interchange the 24V and 0V pins. If they are mixed up, damage can be caused to the brake release unit and to the system board. xx1400000031 Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 74: Orienting And Securing The Robot

    Hole configuration, base The illustration shows the hole configuration used when securing the robot. + 0,018 6 H8 0.03 xx1300000368 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 75 For robots with food grade lubrication For robots with protection type Hygienic Used with manipulator cables routed from below xx1500000241 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 76 Tighten the bolts in a criss-cross pattern to en- Tightening torque: sure that the base is not distorted. 55 Nm ± 5 Nm Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 77 Screw joints must be able to withstand the stress loads defined in section Loads on foundation, robot on page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 78: Setting The System Parameters For A Suspended Or Tilted Robot

    Gravity Alpha must be redefined. The value of Gravity Alpha should then be ±π/2 (±1.570796). Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 79 Gravity Beta Floor mounted 0° 0.000000 (Default) Tilted mounting 45° 0.785398 Wall mounting 90° 1.570796 Suspended mounting 180° 3.141593 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 80 Floor mounted Pos 2 Mounting angle 45° (Tilted) Pos 3 Mounting angle 90° (Wall) Pos 4 Mounting angle 180° (Suspended) Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 81 -90° (Wall) -1.570796 Note For suspended robots (180°), it is recommended to use Gravity Beta instead of Gravity Alpha. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 82 The system parameters are described in Technical reference manual - System parameters. The system parameters are configured in RobotStudio or on the FlexPendant. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 83: Loads Fitted To The Robot, Stopping Time And Braking Distances

    The performance of the motor brake depends on if there are any loads attached to the robot. For more information, see product specification for the robot. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 84: Fitting Of Equipment On The Robot

    Holes for fitting extra equipment on page 85). IRB 1200-7/0.7 IRB 1200-5/0.9 xx1300000384 Load area (A) Max load IRB 1200-5/0.9 0.3 kg IRB 1200-7/0.7 Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 85: Holes For Fitting Extra Equipment

    2 x M4 8 2 x M4 2xM5 xx1300000381 Description IRB 1200-5/0.9 = 451 mm, IRB 1200-7/0.7 = 351 mm IRB 1200-5/0.9 = 216 mm, IRB 1200-7/0.7 = 116 mm Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S...
  • Page 86 The two M4 thread holes shown in the following figure are used for fitting the cable harness or air hoses of the tools rather than fitting extra equipment. 2 x M4 8 xx1700002331 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 87 Upper arm for Hygienic robots 2xM4 2xM5 xx2100001279 Description IRB 1200-5/0.9 = 451 mm, IRB 1200-7/0.7 = 351 mm IRB 1200-5/0.9 = 216 mm, IRB 1200-7/0.7 = 116 mm Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S...
  • Page 88 2xM4 xx2100001280 Lower arm 2 x M5 30 ±0,15 122,5 122,5 122,5 122,5 IRB 1200-7/0.7 IRB 1200-5/0.9 xx1300000382 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 89 30 ±0.15 2xM10 xx1400000590 Description Holes on both sides Robot tool flange 0.012 5 H7 0.04 4xM5 0.25 31.5 xx1300000383 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 90 2.3.7.2 Holes for fitting extra equipment Continued Robot tool flange for Foundry Plus robots 0.012 5 H7 0.04 4xM5 0.25 31.5 xx1600001322 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 91 When fitting tools on the tool flange, only use screws with quality 12.9. For other equipment use suitable screws and tightening torque for your application. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 92: Fitting Tools On Hygienic Robots

    Tightening torque: 6 Nm Always apply a little grease Molykote P1900 to the bolt thread before fitting the tool using the bolts. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 93 Robot tool flange on page 5 ~ 6 Greater than 3 + 0.1 ! " # " $ % & 0.2 X 45° xx2100002644 Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 94: Installation Of Options

    The signal lamp is located as shown in the figure. xx1300000455 Required spare parts Spare part Article number Note Signal lamp 3HAC16738-1 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 95 Fit the lamp and tighten the nut. Connect the two lamp cables connectors (R3.H1 and R3.H2) to the cable harness lamp connectors (H1 and H2). Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 96 The signal lamp is now ready for use and is lit in MOTORS ON mode. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 97: Installing The Signal Lamp For Omnicore Robots

    The X15 connector provides MON_LAMP output signals for use. For more details, see chapter Descriptions for connectors in OmniCore product manuals. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 98 Further information about how to set up I/O system may be found in Technical reference manual - System parameters. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 99: Restricting The Working Range

    Note Adjustments must also be made in the robot configuration software (system parameters). References to relevant manuals are included in the installation procedures. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 100: Mechanically Restricting The Working Range

    The figures shows where the mechanical stops are placed on the robot. xx1700001293 Mechanical stop axis 1 (swing) Mechanical stop axis 1 (base) Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 101 2.5.2 Mechanically restricting the working range Continued xx1700001294 Mechanical stop axis 2 (lower arm) Mechanical stop axis 2 (swing) Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 102 2.5.2 Mechanically restricting the working range Continued xx1700001295 Mechanical stop axis 3 (lower arm) Mechanical stop axis 3 (tubular) Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 103 2 Installation and commissioning 2.5.2 Mechanically restricting the working range Continued xx1700001296 xx1700001297 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 104 Replacing the axis-2 mechanical stop on page 454 • Replacing the axis-3 mechanical stop on page 457 • Replacing the axis-4 mechanical stop on page 460 Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 105: Making Robot Ready For Operation

    Any Clean Room parts that are replaced must be replaced with parts designed for use in Clean Room environments. Clean Room class 3 According to IPA test result, the robot IRB 1200 is suitable for use in Clean Room environment. Classification of airborne molecular contamination...

  • Page 106: Electrical Connections

    3 m (IRC5) 3HAC040503-007 7 m (IRC5) 3HAC040503-001 15 m (IRC5) 3HAC040503-002 22 m (IRC5) 3HAC040503-003 30 m (IRC5) 3HAC040503-004 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 107 Bending radius for static floor cables The minimum bending radius is 10 times the cable diameter for static floor cables. xx1600002016 Diameter Diameter x10 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 108 For robots with protection type Clean Room For robots with food grade lubrication For robots with protection type Hygienic Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 109 22 m (IRC5) 3HAC049089-006 30 m (IRC5) 3HAC049089-007 3 m (IRC5C) 3HAC049186-001 7 m (IRC5C) 3HAC049186-004 15 m (IRC5C) 3HAC049186-005 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 110 The following table lists the Ethernet cables for connecting OmniCore controller. Ethernet floor cable length Article number 7 m (OmniCore) 3HAC055518-002 15 m (OmniCore) 3HAC055518-003 Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 111: Customer Connections

    There is also connections for Ethernet, one connector R4.Ethernet at the tubular housing and the corresponding connector R1.Ethernet located at the base. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 112 Connectors, tubular housing Position Description Art. no. Robot Socket connector 10p, flange mounted 3HAC023624-002 Customer connector Connector set R3.CP/CS 3HAC037070-001 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 113 2 Installation and commissioning 2.7.2 Customer connections Continued Air, connector Position Description Art. no. Robot 4xM5 Customer cable Air connector 3HAC032049-001 Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 114: Start Of Robot In Cold Environments

    If the program consists of large wrist movements, it is possible that the reorientation velocity, which is always high in predefined velocities, needs to be included in the ramping up. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 115: Maintenance

    Note If the IRB 1200 is connected to power, always make sure that the IRB 1200 is connected to protective earth and a residual current device (RCD) before starting any maintenance work.

  • Page 116: Maintenance Schedule

    30000 hours. ABB Connected Services and its Assessment tools can help you to identify the real stress level of your robot, and define the optimal ABB support to maintain your robot working. Contact your local ABB Customer Service to get more information.

  • Page 117: Maintenance Schedule

    126 Inspecting the axis-4 mechanical stop Inspecting the timing belts Inspecting timing belts on page 129 Replacement/changing activities Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 118 The table below specifies the required maintenance activities and intervals: Maintenance activities Reference Inspection activities Inspecting the signal lamp Inspecting the signal lamp (option) on page 132 Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 119: Inspection Activities

    Note Always read the instruction in the product data sheet in the paint repair kit for Clean Room/Hygienic. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 120: Inspecting The Robot Cabling

    Look for abrasions, cuts or crush damage. Replace the cabling if wear or damage is detected. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 121: Inspecting The Information Labels

    Absolute Accuracy FOOD GRADE ABB Robotics Products AB LUBRICATION TYPE LABEL Barcodes/Streckkod CP/CS connection IRB 1200-7/0.7 CP/CS connection IRB 1200-5/0.9 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 122 IRB 1200-0.5/9 SECTION A-A VIEW B IRB 1200 Option Description Illustration Calibration label Warning label Flash xx1300001091 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 123 Instruction label Brake release Moving robot Brake release buttons 3HAC 2577-1/ 04 xx1400000519 UL label Rating label Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 124 Continued Warning label Tip risk when loosening bolts 3HAC 037277-001 xx1400000527 Clean Room label xx1600001074 Foundry Plus label xx1600001075 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 125 Type B label xx1600002137 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...

  • Page 126: Inspecting Mechanical Stops

    The mechanical stops on axes 1, 2 and 3 are located as shown in the figures. Axis 1 xx1400000391 Axis 2 xx1400000389 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 127 Axis 3 xx1400000386 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 128 • loose • damaged. Note The expected life of gearboxes can be reduced as a result of collisions with the mechanical stop. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 129: Inspecting Timing Belts

    Cut the paint or surface on the robot before replacing parts on page 158. Location of timing belts The timing belts are located as shown in the figures. Axis 4 xx1400000036 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 130 Check the timing belt pulleys for damage. If any damage or wear is detected, the part must be replaced! Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 131 3 Maintenance 3.3.5 Inspecting timing belts Continued Action Information Check whether timing belts are slack manually. If the belt has no tension, adjust it! Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 132: Inspecting The Signal Lamp (Option)

    Use this procedure to inspect the function of the signal lamp. Action Note Inspect that signal lamp is lit when motors are put in operation ("MOTORS ON"). Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 133 If so, replace it. page 132. • inspecting cable connections. • inspecting the cabling. Replace the cabling if a fault is detected. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 134: Replacement/Changing Activities

    Location of battery pack The battery pack is located as shown in the figure. xx1300002574 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 135 3.4.1 Replacing the battery pack Continued Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 136 Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 137 CAUTION Be aware of the cabling that is attached to the cover! xx1300002427 Valid for IRB 1200 (no type specified) and IRB 1200 Type A Disconnect the connectors on the EIB unit. • R1.ME1-3 •...
  • Page 138 Valid for IRB 1200 (no type spe- cified) and IRB 1200 Type A xx1300002571 Valid for IRB 1200 Type B xx1700000006 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 139 Valid for IRB 1200 (no type spe- remove the battery. cified) and IRB 1200 Type A Note Battery includes protection circuits. Only replace with a specified spare part or with an ABB- ap- proved equivalent. xx1300002579 Valid for IRB 1200 Type B xx1700000007 Refitting the battery pack Use these procedures to refit the battery pack.
  • Page 140 Valid for IRB 1200 (no type spe- cified) and IRB 1200 Type A Note Battery includes protection circuits. Only replace with a specified spare part or with an ABB- ap- proved equivalent. xx1300002579 Valid for IRB 1200 Type B xx1700000007...
  • Page 141 Valid for IRB 1200 (no type spe- cified) and IRB 1200 Type A xx1300002571 Valid for IRB 1200 Type B xx1700000006 Valid for IRB 1200 (not type specified) and IRB 1200 Type A Connect the connectors to the EIB unit. • R1.ME1-3 •...
  • Page 142 Screws: 3HAB3409-207 (M3x8). attachment screws. Tightening torque: 1.5 Nm xx1300002427 Note Only use specified screws, never replace them with other screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 143 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 144: Replacing The Sealing Set On Tool Flange Of Hygienic Robots

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S ©...
  • Page 145 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 146 3/8" (10 mm) socket spanner on the seal ring unit 3HAC079686-001 and loosen the unit. xx2100001452 Remove the gasket and seal ring unit. xx2100001453 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 147 3/8" (10 mm) socket spanner on the seal ring unit 3HAC079686-001 and tighten the unit. Tightening torque: 8 Nm xx2100001456 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 148 Make sure the pin hole on the shaft aligned with the pin on the tool flange. xx2100001458 Secure with screws and washers. Tightening torque: 1.5 Nm xx2100001459 Remove the guide pins. xx2100001460 Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 149: Cleaning Activities

    General To secure high uptime it is important that the IRB 1200 is cleaned regularly. The frequency of cleaning depends on the environment in which the product works. Different cleaning methods are allowed depending on the type of protection of the IRB 1200.
  • Page 150 Cleaning with water and steam Instructions for rinsing with water IRB 1200 with protection class IP67 (option) and with protection type Foundry Plus can be cleaned by rinsing with water (water cleaner). The following list defines the prerequisites: •...
  • Page 151 Remove waste material, such as sand, dust and chips, if it prevents cable movement. • Clean the cables if they have a crusty surface, for example from dry release agents. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 152: Cleaning The Irb 1200 With Protection Type Hygienic

    Cleaning methods also vary according to the to-be-cleaned surfaces and parts of the IRB 1200 with protection type Hygienic. Always use the proper cleaning method according to the actual applications and strictly follow the cleaning procedure.
  • Page 153 Applicable to fat cleaning Always use the recommended detergents listed in previous table for cleaning the IRB 1200 with protection type Hygienic. Contact ABB if using any disinfectants and detergents other than the listed ones before conducting cleaning activities. The following list defines the prerequisites: •...
  • Page 154 3 Maintenance 3.5.2 Cleaning the IRB 1200 with protection type Hygienic Continued Wash down procedure Action Note Before cleaning, • Use protective devices and equipment to make sure the painted surfaces of the robot body (wipe down areas) not exposed dir- ectly to sprayed detergents, disinfectants and ejected water.
  • Page 155 3 Maintenance 3.5.2 Cleaning the IRB 1200 with protection type Hygienic Continued Action Note Rinse thoroughly with water to remove the disin- Water temperature: ambient fection. Wipe the surface dry with lint free cloth. If user tools are removed from the robot flange before the cleaning, then, after cleaning, •...
  • Page 156 This page is intentionally left blank...

  • Page 157: Repair

    Repair activities not described in this chapter must only be carried out by ABB. Report replaced units Note When replacing a part on the IRB 1200, report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit.

  • Page 158: General Procedures

    Carefully grind the paint edge that is left on the structure to a smooth surface. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 159 Note Always read the instruction in the product data sheet in the paint repair kit for Clean Room/Hygienic. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 160 4.2.1 Cut the paint or surface on the robot before replacing parts Continued Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 161: Mounting Instructions For Sealings

    Do not try to grind or polish the shaft surface to get rid of the defect. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 162 Never hammer directly on the sealing as this may result in leakage. xx2000000072 A Gap Make sure that no grease is left on the robot surface. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 163 If the flange surfaces are defective, the parts may not be used because leakage could occur. Clean the surfaces properly in accordance with the recommendations of ABB. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.

  • Page 164: Sealing Differences Depending On Protection Class

    4.2.3 Sealing differences depending on protection class Standard IP40 vs optional IP67 The IRB 1200 has IP40 as standard protection class. If the robot is delivered with option IP67, many of the covers are equipped with gaskets, several components has been applied with locking liquid etc.

  • Page 165: Swing Sealing Plug For Clean Room, Food Grade Lubrication And Hygienic Robots

    The swing sealing plug is located as shown in the figure. xx1600000264 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 166 Remove the cable housing cover of the swing by removing the screws. xx1600000207 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 167 If necessary, add extra sealant to get a full cover joint. Make sure the sealant fully covers the gap but is not applied to the screw cavities. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 168 Make sure no space exists between the swing sealing plug and the robot casting, and the sealant string is fully jointed with the plug. xx1600000213 Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 169: Cable Harness

    This section describes both configurations. Connector interface at the rear of the base (standard) xx1300002414 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 170 Connector interface at the bottom of the base (option) xx1400000410 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 171 Manipulator cable harness gienic. without Ethernet (bottom inter- With connector interface at bot- face), Hygienic. tom of the base. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 172 IP40/IP67 robots on page 874. Replace if damaged. Axis-1 sealing ring 3HAC044676-001 / Replace if damaged. 3HAC068107-001 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 173 Gasket on cable housing cover 3HAC056726-001 / Not used for robots with protec- 3HAC080704-001 tion class IP40. Replace if damaged. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 174 Guide pin for axis-1 gear unit 3HAC049703-001 Always use three guide pins together! 24 VDC power supply Used to release the motor brakes. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 175 For robots with protection class IP67. For robots with protection type Foundry Plus. Sealant 3HAC073510-001 Trans Clear For robots with protection type Hygienic Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 176 Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Jog all axes to zero position. xx1300002581 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 177 Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 178 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 179 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 180 Cut the paint or surface on the robot before replacing parts on page 158. Disconnect the air hoses. xx1400000738 If equipped, disconnect the CP/CS connector. xx1500000252 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 181 Cut the paint or surface on the robot before replacing parts on page 158. Remove the cable housing cover. xx1300002400 Remove the plate. xx1300002413 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 182 Cable layout in IRB 1200-7/0.7 : disconnect them. xx1300002412 Cable layout in IRB 1200-5/0.9 : xx1400001471 Remove the small cover of the housing. xx1300002398 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 183 Disconnect the lamp cable connectors R3.H1 and R3.H2 and then lift away the cover completely. xx1300000456 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 184 Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 185 Cut the paint or surface on the robot before replacing parts on page 158. Remove the screw that fastens the air hose hold- xx1300002422 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 186 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 187 The cover can not be removed completely until the connectors and lugs are disconnected, xx1300002427 as shown in following step. Valid for IRB 1200 (no type specified) and IRB 1200 Type A Disconnect the connectors on the EIB unit. •...
  • Page 188 Cut the paint or surface on the robot before replacing parts on page 158. Pull the cable package out from the upper arm housing. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 189 Remove the swing sealing plug. Follow the procedure specified in Removing the swing sealing plug on page 166. xx1600000205 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 190 Remove the swing cable housing cover by remov- ing the screws. xx1300002431 Cut the cable straps. xx1400001528 Remove the axis-2 motor bracket screws. xx1300002432 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 191 Loosen the cable housing from the swing by re- moving the screws. Leave it hanging on the cable package. xx1300002435 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 192 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 193 The robot weighs . IRB 1200-5/0.9: 54 kg IRB 1200-7/0.7: 52 kg All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 194 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 195 4.3.1 Replacing the main cable package Continued Action Note Remove the bottom cover. Rear connector interface: xx1300000469 Bottom connector interface: xx1400000403 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 196 Bottom connector interface: xx1400000404 Loosen the connectors from the bracket by cutting the cable straps, and disconnect the connectors. xx1300002496 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 197 Only tighten the screws lightly in order not to damage the threads. xx1300000467 Remove the screws and washers. xx1300000471 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 198 Remove the swing (including arm system) com- pletely from the base and lay it aside on a safe location. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 199 Cut the paint or surface on the robot before replacing parts on page 158. Open the base cover. xx1300002448 Disconnect the earth cable. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 200 158. Open the base cover. xx1400000405 Remove the brake release button from the base cover. Disconnect the earth cable. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 201 Pull the cable package out from the base, through the bottom. xx1400000411 Refitting the main cable package Use these procedures to refit the cable package. Adjusting the air hose length for IRB 1200-7/0.7 Action Note For robots with protection type Clean Room For robots with food grade lubrication...
  • Page 202 Replace if damaged. xx1400000741 Insert the cable package in and up through the base, through the rear. Reconnect the earth cable. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 203 Insert the cable package in and up through the base, through the bottom. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 204 Check the gasket of the base cover. Replace if damaged. xx1400000413 Reconnect the earth cable. Refit the brake release button to the base cover. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 205 Add sealant to the axis-1 sealing ring. (See Spare part versions for the axis-1 sealing ring on IP40/IP67 robots on page 878.) xx1600001125 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 206 On axis-1 sealing ring version 3HAC068107-001: Axis-1 sealing ring gasket: 3HAC058349-001 (not Hygienic robots) / 3HAC080707-001 (Hygien- ic robots) xx1900001735 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 207 Refit the cable bracket to the cabling, if removed. Tightening torque: 1 Nm. Use Loctite 243 on the screw threads. xx1300002446 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 208 874. CAUTION Do not fit M2 variseal sealing on robots in other protection class or protection types. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 209 CAUTION Be careful not to squeeze any cabling dur- ing the refitting procedure. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 210 Remove the guide pins and refit the remain- ing attachment screws and washers. xx1300000523 Tighten all screws. Tightening torque: 40 Nm. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 211 Screws: 3HAB3409-209 (M3x20). Tightening torque: 1.5 Nm. xx1300000467 Note Only use specified screws, never replace them with other screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 212 Reconnect the connectors and secure the connectors to the bracket with cable straps. xx1300002496 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 213 For robots with food grade lubrication For robots with protection type Hygienic Check the O-ring. Replace if damaged. xx1400000412 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 214 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 215 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 216 For robots with protection type Hygienic Check the gasket of the cable housing plastic plate. Replace if damaged. xx1400000457 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 217 Fasten the plastic plate to the cable housing, if The plastic plate is included in: removed. Cable harness material set: 3HAC049663-001. Replace if damaged. xx1400000023 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 218 Replace if damaged. CAUTION Do not fit M2 variseal sealing on robots in other protection class or protection types. xx1400000454 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 219 Refit the axis-2 sealing ring with the screws. Tightening torque: 1.5 Nm. xx1400000020 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 220 Apply grease to the cable package, cover all moving area of the package. xx1400000481 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 221 Refit the axis-2 motor bracket to the motor. xx1300002432 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 222 See the figure. xx1400001131 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 223 Replace if damaged. Apply grease to the inner surface of the cable housing cover and to the PTFE film surface. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 224 For robots with protection type Foundry Plus Protection plug for lifting holes: 3HAC4836-24 Check the protection plugs for lifting holes. Replace if damaged. xx1600001151 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 225 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 226 For robots with food grade lubrication For robots with protection type Hygienic Check the EIB/SMB cover gasket. Replace if damaged. xx1400000475 Valid for IRB 1200 (no type specified) and IRB 1200 Type A Connect the connectors to the EIB unit. • R1.ME1-3 •...
  • Page 227 Screws: 3HAB3409-207 (M3x8). attachment screws. Tightening torque: 1.5 Nm xx1300002427 Note Only use specified screws, never replace them with other screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 228 Cover all moving area of the package. xx1400000483 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 229 Refit the fix sheet to the motor. Tightening torque: 1.5 Nm. xx1300002423 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 230 Tightening torque for the two M3 screws: 1.5 Nm. xx1300002422 xx1400001133 Reconnect the axis-3 motor connectors. xx1300002420 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 231 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Reconnect the motor connectors. xx1300002371 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 232 Reconnect the FPC connectors. See the number markings on the connectors for help to find the corresponding connector. xx1300002399 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 233 Cable layout in IRB 1200-5/0.9 : xx1400001471 Remove residual locking liquid and other pollut- ants with cleaning agent Loctite 7063. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 234 Use washing-up on finger tips to get a smooth joint. Sealant, Trans Clear If necessary, add extra sealant to get a full cover joint. xx1600000214 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 235 Check the PTFE film on the cable housing. PTFE film on lower arm cable housing: 3HAC044710-001 Replace if damaged. xx1400000740 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 236 Replace if damaged. Apply grease to the inner surface of the cable housing cover and the PTFE film surface. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 237 3HAC049664-001 Replace the air hose connector set if damaged. Air connector set without Ethernet hole in flange: 3HAC049665-001 xx1400000738 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 238 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 239 Check the connectors on the plate with connector Plate with connector set: set and the attached gasket. 3HAC079691-001 Replace if damaged. Gasket: 3HAC078804-001 xx2100001434 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 240 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 241 For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cable housing cover gasket. Replace if damaged. xx1400000345 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 242 Check the two extra screws on the tubular cover (right hand side cover), as encircled in the figure. Replace if damaged or missing. xx2100001406 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 243 R3.H1 and R3.H2 and then secure the cover. xx1300000456 Note Only use specified screws, never replace them with other screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 244 Calibration is detailed in section Calibration on page 805. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 245: Replacing The Axis-4 Fpc Unit, Housing Extender Unit And Housing Extender Sealings

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 246 Loctite 574 For robots with protection class IP67 For robots with protection type Foundry Plus Locking liquid 3HAB7116-1 Loctite 243 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 247 Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Jog axis 4 to zero position. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 248 Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 249 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 250 158. Loosen the screws so that the motor can be moved sideways. xx1300002350 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 251 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 252 Disconnect the connectors shown in the figure. xx1300002353 Disconnect the air hoses. xx1300002355 Remove the connector plate attachment screws. xx1300002356 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 253 Pay special attention to the plastic block on the FPC unit. It is easily pulled off, make sure it stays fitted to the FPC unit. xx1300002611 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 254 Cut the paint or surface on the robot before replacing parts on page 158. Remove the cable housing cover. xx1300002400 Remove the plate. xx1300002413 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 255 Cable layout in IRB 1200-7/0.7 : disconnect them. xx1300002412 Cable layout in IRB 1200-5/0.9 : xx1400001471 Remove the small cover of the housing. xx1300002398 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 256 For robots with protection type Hygienic Remove the plugs covering the extender unit screws with a needle-nose plier. xx1600000262 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 257 158. Remove the mechanical stop assembly from the housing extender unit by removing the screws. xx1300002415 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 258 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 259 Fit the radial sealing into the housing ex- tender unit. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 260 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 261 Loctite 7063. Apply flange sealing Loctite 574 on the mounting surfaces of the housing extender unit. xx1300002613 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 262 For robots with food grade lubrication For robots with protection type Hygienic Press in screw sealing plugs to cover the screws. xx1600000263 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 263 Reconnect the FPC connectors. See the number markings on the connectors for help to find the corresponding connector. xx1300002399 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 264 Cable layout in IRB 1200-5/0.9 : xx1400001471 Remove residual locking liquid and other pollut- ants with cleaning agent Loctite 7063. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 265 Use washing-up on finger tips to get a smooth joint. Sealant, Trans Clear If necessary, add extra sealant to get a full cover joint. xx1600000214 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 266 Check the PTFE film on the cable housing. PTFE film on lower arm cable housing: 3HAC044710-001 Replace if damaged. xx1400000740 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 267 Replace if damaged. Apply grease to the inner surface of the cable housing cover and the PTFE film surface. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 268 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 269 Refit the washer while at the same time putting Washer: 3HAC044869-001 the cables through its center. Replace washer, if damaged. xx1400000001 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 270 Tightening torque: 8 Nm. Put the cables through the plate hole and refit the Tightening torque: 0.3 Nm. plate. xx1300002356 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 271 Note Only use specified screws, never replace them with other screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 272 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 273 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 274 For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cable housing cover gasket. Replace if damaged. xx1400000345 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 275 Check the two extra screws on the tubular cover (right hand side cover), as encircled in the figure. Replace if damaged or missing. xx2100001406 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 276 Calibration information is included in sec- tion Calibration on page 805. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 277: Replacing The Axis-5 Fpc Unit

    The axis-5 FPC unit is located as shown in the figure. xx1300002397 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 278 (DressPack) and tools calibration tool. must be removed from the robot. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 279 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 280 Cut the paint or surface on the robot before replacing parts on page 158. Snap loose and disconnect the axis-5 FPC con- nectors. xx1300002390 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 281 Cut the paint or surface on the robot before replacing parts on page 158. Remove the sleeve screws. xx1300002393 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 282 FPC unit. Make sure that the FPC is in zero position and does not get twisted during refitting. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 283 Tightening torque: 0.3 Nm. screws. Note Check that the FPC unit is at the zero pos- ition when refitting it. xx1300002394 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 284 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 285 Fit the tool plate to the other side of the tubular cable housing with the six screws M6x40. xx1400000485 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 286 Flange sealant, Trans Clear Note For Hygienic robots, wipe clean the overflowing flange sealing if there is any. xx1300002610 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 287 Refit the connector plate and secure with Tightening torque: 0.3 Nm. the M3 screws. xx1400001401 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 288 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 289 Screws: 3HAB3409-207 (M3x8). Tightening torque: 1.5 Nm. xx1300002389 Note Only use specified screws, never replace them with other screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 290 Calibration information is included in sec- tion Calibration on page 805. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 291: Replacing The Eib/Smb Unit

    Location of EIB/SMB unit The EIB/SMB unit is located as shown in the figure. Note The EIB unit is used for IRB 1200 no type specified and IRB 1200 Type A. The SMB unit is used for IRB 1200 Type B. xx1300002574...
  • Page 292 4.3.4 Replacing the EIB/SMB unit Continued Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 293 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 294 The unit is sensitive to ESD. Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 64 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 295 The cover can not be removed completely until the connectors and lugs are disconnected, xx1300002427 as shown in following step. Valid for IRB 1200 (no type specified) and IRB 1200 Type A Disconnect the connectors on the EIB unit. •...
  • Page 296 • R2.SMB Remove the EIB/SMB cover completely from the lower arm. xx1700000005 Removing the EIB unit (IRB 1200 no type specified and IRB 1200 Type A) Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off.
  • Page 297 158. Disconnect the battery cable. xx1300002571 Remove the battery pack plate by removing the screws. xx1300002572 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 298 Continued Action Note Remove the EIB unit by removing the distance screws. xx1300002573 Removing the SMB unit (IRB 1200 Type B) Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off.
  • Page 299 Remove the battery pack plate by removing the screws. xx1700000008 Remove the SMB unit by removing the distance screws. xx1700000009 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 300 4.3.4 Replacing the EIB/SMB unit Continued Refitting the EIB/SMB unit Use these procedures to refit the EIB/SMB unit. Refitting the EIB unit (IRB 1200 no type specified and IRB 1200 Type A) Action Note ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the...
  • Page 301 Refit the battery pack plate with the screws. Tightening torque: 1.5 Nm. xx1300002572 Reconnect the battery cable. xx1300002571 Refitting the SMB unit (IRB 1200 Type B) Action Note ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the...
  • Page 302 Refit the battery pack plate with the screws. Tightening torque: 1.5 Nm. xx1700000008 Reconnect the battery cable. xx1700000006 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 303 For robots with food grade lubrication For robots with protection type Hygienic Check the EIB/SMB cover gasket. Replace if damaged. xx1400000475 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 304 4 Repair 4.3.4 Replacing the EIB/SMB unit Continued Action Note Valid for IRB 1200 (no type specified) and IRB 1200 Type A Connect the connectors to the EIB unit. • R1.ME1-3 • R1.ME4-6 • R2.EIB WARNING Make sure not to mix the R2.EIB and R2.ME2.
  • Page 305 Refit the fix sheet attachment screws in the lower Tightening torque: 1.5 Nm. arm. xx1300002426 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 306 Replace if damaged. Apply grease to the inner surface of the cable housing cover and the PTFE film surface. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 307 Calibration information is included in sec- tion Calibration on page 805. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 308: Upper And Lower Arms

    The lower arm is located as shown in the figure. xx1400000423 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note Lower arm (IRB 1200-7/0.7 )
  • Page 309 3HAC044894-001 / Not used with protection class 3HAC080695-001 IP40. Replace if damaged. Lower arm cover 3HAC059689-001 Replace if damaged. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 310 Used for robots with food grade lubrication. Swing cover, Hygienic Used with protection type Hy- gienic. Replace if damaged. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 311 Used with protection type Hy- gienic. Includes gasket (3HAC078804- 001). Gasket 3HAC078804-001 Used with protection type Hy- gienic. Replace if damage. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 312 For robots with protection class IP67 For robots with protection type Foundry Plus Sealant 3HAC073510-001 Trans Clear For robots with protection type Hygienic Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 313 Decide which calibration routine to use, and take actions accordingly prior to begin- ning the repair procedure. Jog all axes to zero position. xx1300002581 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 314 Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 315 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 316 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 317 Cut the paint or surface on the robot before replacing parts on page 158. Disconnect the air hoses. xx1400000738 If equipped, disconnect the CP/CS connector. xx1500000252 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 318 Cut the paint or surface on the robot before replacing parts on page 158. Remove the cable housing cover. xx1300002400 Remove the plate. xx1300002413 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 319 Cable layout in IRB 1200-7/0.7 : disconnect them. xx1300002412 Cable layout in IRB 1200-5/0.9 : xx1400001471 Remove the small cover of the housing. xx1300002398 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 320 Disconnect the lamp cable connectors R3.H1 and R3.H2 and then lift away the cover completely. xx1300000456 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 321 Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 322 Cut the paint or surface on the robot before replacing parts on page 158. Remove the screw that fastens the air hose hold- xx1300002422 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 323 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 324 The cover can not be removed completely until the connectors and lugs are disconnected, xx1300002427 as shown in following step. Valid for IRB 1200 (no type specified) and IRB 1200 Type A Disconnect the connectors on the EIB unit. •...
  • Page 325 Cut the paint or surface on the robot before replacing parts on page 158. Pull the cable package out from the upper arm housing. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 326 Remove the swing sealing plug. Follow the procedure specified in Removing the swing sealing plug on page 166. xx1600000205 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 327 Remove the swing cable housing cover by remov- ing the screws. xx1300002431 Cut the cable straps. xx1400001528 Remove the axis-2 motor bracket screws. xx1300002432 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 328 Loosen the cable housing from the swing by re- moving the screws. Leave it hanging on the cable package. xx1300002435 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 329 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 330 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 331 This releases the upper arm from the lower arm. Make sure the weight of the upper arm is properly secured by the lifting slings. xx1300002531 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 332 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 333 17 kg to the total weight. xx1300002552 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 334 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 335 Insert two M4 screws to the press out holes and press out the drive unit. xx1400000008 Carefully pull out the complete drive unit. xx1300002555 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 336 Loctite 7063. Apply flange sealing Loctite 574 on the mounting surfaces of the lower arm. xx1400000006 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 337 • Person 1: Hold the lower arm still. • Person 2: Tighten the screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 338 For robots with food grade lubrication For robots with protection type Hygienic Wipe clean the overflowing Loctite 574 if there is any. xx1400001403 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 339 Fit the lower arm to the swing, with guid- ance from the guide pins. xx1300002563 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 340 Remove the guide pins and refit the remain- ing screws and washers using locking li- quid Loctite 243. xx1300002565 Tighten all screws. Tightening torque: 45 Nm Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 341 Tightening torque: 1.5 Nm. Swing cover: 3HAC059676-001 Swing cover, Clean Room Swing cover, food grade lubrication Swing cover, Hygienic : 3HAC056215-001 xx1300002551 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 342 If necessary, add extra sealant to get a full cover joint. xx1600000217 For robots with protection type Foundry Plus If required, fit two screws for protection. xx1600001154 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 343 Replace if damaged. CAUTION Do not fit M2 variseal sealing on robots in other protection class or protection types. xx1400000474 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 344 Remove the guide pins and refit the remain- ing screws and washers. xx1400000029 Tighten all screws. Tightening torque: 4.5 Nm. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 345 Screws: 3HAB3409-207 (M3x8). Tightening torque: 1.5 Nm. xx1300002528 Note Only use specified screws, never replace them with other screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 346 418. Apply a little grease to the sealing when replacing the radial sealing and wipe clean after the replacement. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 347 For robots with protection type Foundry Plus If required, fit two screws for protection. xx1600001155 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 348 For robots with protection type Hygienic Check the gasket of the cable housing plastic plate. Replace if damaged. xx1400000457 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 349 Fasten the plastic plate to the cable housing, if The plastic plate is included in: removed. Cable harness material set: 3HAC049663-001. Replace if damaged. xx1400000023 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 350 Replace if damaged. CAUTION Do not fit M2 variseal sealing on robots in other protection class or protection types. xx1400000454 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 351 Refit the axis-2 sealing ring with the screws. Tightening torque: 1.5 Nm. xx1400000020 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 352 Apply grease to the cable package, cover all moving area of the package. xx1400000481 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 353 Refit the axis-2 motor bracket to the motor. xx1300002432 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 354 See the figure. xx1400001131 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 355 Replace if damaged. Apply grease to the inner surface of the cable housing cover and to the PTFE film surface. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 356 For robots with protection type Foundry Plus Protection plug for lifting holes: 3HAC4836-24 Check the protection plugs for lifting holes. Replace if damaged. xx1600001151 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 357 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 358 For robots with food grade lubrication For robots with protection type Hygienic Check the EIB/SMB cover gasket. Replace if damaged. xx1400000475 Valid for IRB 1200 (no type specified) and IRB 1200 Type A Connect the connectors to the EIB unit. • R1.ME1-3 •...
  • Page 359 Screws: 3HAB3409-207 (M3x8). attachment screws. Tightening torque: 1.5 Nm xx1300002427 Note Only use specified screws, never replace them with other screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 360 Cover all moving area of the package. xx1400000483 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 361 Refit the fix sheet to the motor. Tightening torque: 1.5 Nm. xx1300002423 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 362 Tightening torque for the two M3 screws: 1.5 Nm. xx1300002422 xx1400001133 Reconnect the axis-3 motor connectors. xx1300002420 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 363 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Reconnect the motor connectors. xx1300002371 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 364 Reconnect the FPC connectors. See the number markings on the connectors for help to find the corresponding connector. xx1300002399 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 365 Cable layout in IRB 1200-5/0.9 : xx1400001471 Remove residual locking liquid and other pollut- ants with cleaning agent Loctite 7063. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 366 Use washing-up on finger tips to get a smooth joint. Sealant, Trans Clear If necessary, add extra sealant to get a full cover joint. xx1600000214 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 367 Check the PTFE film on the cable housing. PTFE film on lower arm cable housing: 3HAC044710-001 Replace if damaged. xx1400000740 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 368 Replace if damaged. Apply grease to the inner surface of the cable housing cover and the PTFE film surface. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 369 3HAC049664-001 Replace the air hose connector set if damaged. Air connector set without Ethernet hole in flange: 3HAC049665-001 xx1400000738 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 370 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 371 Check the connectors on the plate with connector Plate with connector set: set and the attached gasket. 3HAC079691-001 Replace if damaged. Gasket: 3HAC078804-001 xx2100001434 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 372 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 373 For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cable housing cover gasket. Replace if damaged. xx1400000345 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 374 Check the two extra screws on the tubular cover (right hand side cover), as encircled in the figure. Replace if damaged or missing. xx2100001406 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 375 R3.H1 and R3.H2 and then secure the cover. xx1300000456 Note Only use specified screws, never replace them with other screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 376 Calibration is detailed in section Calibration on page 805. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 377: Replacing The Signal Lamp

    The signal lamp is located as shown in the figure. xx1300000455 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 378 Connect lamp connector R3.H1 to cable har- ness connector H1. • Connect lamp connector R3.H2 to cable har- ness connector H2. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 379 158. Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 380: Replacing The Tubular Spare Parts

    Clean Room robots on page 882. Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 381 For information on which tubular cover for Clean Room robots to be ordered, see Spare part versions for the tubular cover on Clean Room robots on page 882. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 382 For robots with protection type Hygienic Locking liquid 3HAB7116-1 Loctite 243 Grease 3HAC070875-001 Molykote P1900 For robots with protection type Hygienic Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 383 Decide which calibration routine to use, and take actions accordingly prior to begin- ning the repair procedure. Jog all axes to zero position. xx1300002581 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 384 Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 385 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 386 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 387 Fit the tool plate to the other side of the tubular cable housing with the six screws M6x40. xx1400000485 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 388 Flange sealant, Trans Clear Note For Hygienic robots, wipe clean the overflowing flange sealing if there is any. xx1300002610 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 389 Refit the connector plate and secure with Tightening torque: 0.3 Nm. the M3 screws. xx1400001401 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 390 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 391 For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cable housing cover gasket. Replace if damaged. xx1400000345 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 392 Check the two extra screws on the tubular cover (right hand side cover), as encircled in the figure. Replace if damaged or missing. xx2100001406 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 393 Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 394 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 395 158. Loosen the screws so that the motor can be moved sideways. xx1300002350 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 396 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 397 Disconnect the connectors shown in the figure. xx1300002353 Disconnect the air hoses. xx1300002355 Remove the connector plate attachment screws. xx1300002356 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 398 Pay special attention to the plastic block on the FPC unit. It is easily pulled off, make sure it stays fitted to the FPC unit. xx1300002611 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 399 Fit guide pins to the gearbox. Guide pin for tilt unit (axis 5): 3HAC049706-001 Always use three guide pins togeth- xx1400000775 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 400 Replace if damaged, as described below. If undamaged and properly seated, skip to the next procedure table. xx2100001448 Remove the screws and washers. xx2100001449 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 401 Remove the gasket and seal ring unit. xx2100001453 Replace the damaged parts with new ones. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 402 3/8" (10 mm) socket spanner on the seal ring unit 3HAC079686-001 and tighten the unit. Tightening torque: 6 Nm xx2100001456 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 403 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 404 For robots with food grade lubrication For robots with protection type Hygienic Wipe clean the overflowing sealant if there is any. xx1400001404 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 405 Make sure the sealing to the tilt covers is intact before the refitting. For robots with protection type Hygienic Hygienic robots do not have tilt covers. xx1600000219 xx1600000220 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 406 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 407 Fit the tool plate to the other side of the tubular cable housing with the six screws M6x40. xx1400000485 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 408 Flange sealant, Trans Clear Note For Hygienic robots, wipe clean the overflowing flange sealing if there is any. xx1300002610 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 409 Pay special attention to the plastic block on the FPC unit. It is easily pulled off, make sure it stays fitted to the FPC unit. xx1300002611 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 410 Note Only use specified screws, never replace them with other screws. Tighten all screws. Tightening torque: 8 Nm. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 411 Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 412 Move the motor to a position where a good timing belt tension is reached (F = 26 N). Note Do not strech the timing belt too much! Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 413 Refit the connector plate and secure with Tightening torque: 0.3 Nm. the M3 screws. xx1400001401 Secure the three M2.5 screws. Tightening torque: 0.3 Nm. xx1400001402 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 414 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 415 For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cable housing cover gasket. Replace if damaged. xx1400000345 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 416 Check the two extra screws on the tubular cover (right hand side cover), as encircled in the figure. Replace if damaged or missing. xx2100001406 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 417 Calibration information is included in sec- tion Calibration on page 805. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 418: Replacing The Axis-3 Radial Sealing And Sealing Ring

    The axis-3 radial sealing and sealing ring are located as shown in the figure. xx1400000336 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 419 890. Required consumables Consumable Art. no. Note Cable straps Cleaning agent Loctite 7063 Locking liquid 3HAB7116-1 Loctite 243 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 420 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 421 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 422 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 423 Cut the paint or surface on the robot before replacing parts on page 158. Disconnect the air hoses. xx1400000738 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 424 Cut the paint or surface on the robot before replacing parts on page 158. Remove the cable housing cover. xx1300002400 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 425 Pull out the FPC connectors from the housing and Cable layout in IRB 1200-7/0.7 : disconnect them. xx1300002412 Cable layout in IRB 1200-5/0.9 : xx1400001471 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 426 Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 427 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 428 Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 429 Do not loosen the cable clamp screw! There is a risk of rearrangement of the cable layout which would result in shortened lifetime of the cable harness. xx1300002424 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 430 Pull the cable harness out from the upper arm housing. Remove the cable housing of the lower arm by removing the screws. xx1300002529 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 431 For robots with protection class IP67 For robots with protection type Foundry Plus Remove the M2 variseal sealing. xx1400000473 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 432 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 433 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 434 Apply a little grease to the sealing when replacing the radial sealing and wipe clean after the replace- ment. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 435 M6X50. Screw the screws, little by little, to press the sealing into place. xx1400000335 Remove the assembly tool. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 436 For robots with food grade lubrication For robots with protection type Hygienic Check the cable housing gasket. Replace if damaged. xx1400000414 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 437 Refit the cable housing of the lower arm. Tightening torque: 4 Nm. xx1300002529 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 438 Cover all moving area of the package. xx1400000483 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 439 Refit the fix sheet to the motor. Tightening torque: 1.5 Nm. xx1300002423 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 440 Tightening torque for the two M3 screws: 1.5 Nm. xx1300002422 xx1400001133 Reconnect the axis-3 motor connectors. xx1300002420 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 441 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Reconnect the motor connectors. xx1300002371 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 442 Reconnect the FPC connectors. See the number markings on the connectors for help to find the corresponding connector. xx1300002399 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 443 Cable layout in IRB 1200-5/0.9 : xx1400001471 Remove residual locking liquid and other pollut- ants with cleaning agent Loctite 7063. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 444 Use washing-up on finger tips to get a smooth joint. Sealant, Trans Clear If necessary, add extra sealant to get a full cover joint. xx1600000214 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 445 Check the PTFE film on the cable housing. PTFE film on lower arm cable housing: 3HAC044710-001 Replace if damaged. xx1400000740 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 446 Replace if damaged. Apply grease to the inner surface of the cable housing cover and the PTFE film surface. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 447 3HAC049664-001 Replace the air hose connector set if damaged. Air connector set without Ethernet hole in flange: 3HAC049665-001 xx1400000738 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 448 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 449 Check the connectors on the plate with connector Plate with connector set: set and the attached gasket. 3HAC079691-001 Replace if damaged. Gasket: 3HAC078804-001 xx2100001434 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 450 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 451 Screws: 3HAB3409-207 (M3x8). Tightening torque: 1.5 Nm. xx1300002389 Note Only use specified screws, never replace them with other screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 452 R3.H1 and R3.H2 and then secure the cover. xx1300000456 Note Only use specified screws, never replace them with other screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 453 Calibration information is included in sec- tion Calibration on page 805. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 454: Replacing The Axis-2 Mechanical Stop

    The axis-2 mechanical stop is located as shown in the figure. xx1400000389 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 455 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 456 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 457: Replacing The Axis-3 Mechanical Stop

    The axis-3 mechanical stop is located as shown in the figure. xx1400000386 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 458 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 459 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 460: Replacing The Axis-4 Mechanical Stop

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 461 Cleaning agent Loctite 7063 Flange sealing 12340011-116 Loctite 574 Used with protection class IP67 Used with protection type Foundry Plus Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 462 Action Note Decide which calibration routine to use, and take actions accordingly prior to begin- ning the repair procedure. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 463 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 464 The screws are used for blocking the screw holes rather than fixing the cover to the tubular. Replace if damaged or missing. xx2100001406 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 465 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 466 Snap loose and disconnect the axis-5 FPC connectors. xx1300002390 Remove the screws and pull out the motor. xx1300002352 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 467 Disconnect the connectors shown in the figure. xx1300002353 Disconnect the air hoses. xx1300002355 Remove the connector plate attachment screws. xx1300002356 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 468 Pay special attention to the plastic block on the FPC unit. It is easily pulled off, make sure it stays fitted to the FPC unit. xx1300002611 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 469 Cut the paint or surface on the robot before replacing parts on page 158. Remove the cable housing cover. xx1300002400 Remove the plate. xx1300002413 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 470 Cable layout in IRB 1200-7/0.7 : disconnect them. xx1300002412 Cable layout in IRB 1200-5/0.9 : xx1400001471 Remove the small cover of the housing. xx1300002398 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 471 For robots with protection type Hygienic Remove the plugs covering the extender unit screws with a needle-nose plier. xx1600000262 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 472 158. Remove the mechanical stop assembly from the housing extender unit by removing the screws. xx1300002415 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 473 FPC unit must be removed from the hous- ing extender unit, if not already removed. xx1400000438 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 474 Check that the sealing is undamaged and properly fitted. Refit both the axis-4 mechanical stop and the axis-4 FPC unit to the housing extender unit. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 475 Tightening torque: 4 Nm. screws. xx1300002415 Note Only use specified screws, never replace them with other screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 476 Note Mate the unit to the two locating pins attached to the housing. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 477 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 478 Cable layout in IRB 1200-5/0.9 : xx1400001471 Remove residual locking liquid and other pollut- ants with cleaning agent Loctite 7063. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 479 Use washing-up on finger tips to get a smooth joint. Sealant, Trans Clear If necessary, add extra sealant to get a full cover joint. xx1600000214 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 480 Check the PTFE film on the cable housing. PTFE film on lower arm cable housing: 3HAC044710-001 Replace if damaged. xx1400000740 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 481 Replace if damaged. Apply grease to the inner surface of the cable housing cover and the PTFE film surface. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 482 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 483 Refit the washer while at the same time putting Washer: 3HAC044869-001 the cables through its center. Replace washer, if damaged. xx1400000001 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 484 Tightening torque: 8 Nm. Put the cables through the plate hole and refit the Tightening torque: 0.3 Nm. plate. xx1300002356 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 485 Note Only use specified screws, never replace them with other screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 486 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 487 Connect the axis-5 FPC connectors and snap them to their holders. xx1300002390 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 488 For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cover gasket. Replace if damaged. xx1400000034 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 489 For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cable housing cover gasket. Replace if damaged. xx1400000345 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 490 Check the two extra screws on the tubular cover (right hand side cover), as encircled in the figure. Replace if damaged or missing. xx2100001406 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 491 Calibration is detailed in section Calibration on page 805. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 492: Swing And Base

    Used for IRB 1200 Type B. grade lubrication. Type B of IRB 1200 on page 873. Used for robots with food grade lubrication. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 493 Replace if damaged. Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 494 Used only on base 3HAC049628-001. See Spare part versions for the base on IP40/IP67 robots on page 874. Replace if damaged. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 495 Plate with connector set 3HAC079691-001 Used with protection type Hy- gienic. Includes Ethernet connector, air connectors, CP/CS connector and gasket (3HAC078804-001). Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 496 Foundry Plus Sealant 12340011-116 Loctite 574 For robots with protection type Clean Room For robots with food grade lubric- ation Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 497 Preparations before removing the cabling Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 498 Cut the paint or surface on the robot before replacing parts on page 158. Remove the wrist cover. xx1300002389 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 499 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 500 Cut the paint or surface on the robot before replacing parts on page 158. Disconnect the air hoses. xx1400000738 If equipped, disconnect the CP/CS connector. xx1500000252 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 501 Cut the paint or surface on the robot before replacing parts on page 158. Remove the cable housing cover. xx1300002400 Remove the plate. xx1300002413 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 502 Cable layout in IRB 1200-7/0.7 : disconnect them. xx1300002412 Cable layout in IRB 1200-5/0.9 : xx1400001471 Remove the small cover of the housing. xx1300002398 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 503 Disconnect the lamp cable connectors R3.H1 and R3.H2 and then lift away the cover completely. xx1300000456 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 504 Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 505 Cut the paint or surface on the robot before replacing parts on page 158. Remove the screw that fastens the air hose hold- xx1300002422 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 506 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 507 The cover can not be removed completely until the connectors and lugs are disconnected, xx1300002427 as shown in following step. Valid for IRB 1200 (no type specified) and IRB 1200 Type A Disconnect the connectors on the EIB unit. •...
  • Page 508 Cut the paint or surface on the robot before replacing parts on page 158. Pull the cable package out from the upper arm housing. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 509 Remove the swing sealing plug. Follow the procedure specified in Removing the swing sealing plug on page 166. xx1600000205 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 510 Remove the swing cable housing cover by remov- ing the screws. xx1300002431 Cut the cable straps. xx1400001528 Remove the axis-2 motor bracket screws. xx1300002432 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 511 Loosen the cable housing from the swing by re- moving the screws. Leave it hanging on the cable package. xx1300002435 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 512 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 513 The robot weighs . IRB 1200-5/0.9: 54 kg IRB 1200-7/0.7: 52 kg All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 514 Fit M4 screws in the cover holes to pull out the cover more easily. Only tighten the screws lightly in order not to damage the threads. xx1300000467 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 515 Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 516 (in the space of the protection sleeve). Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 517 Action Note Fit the new sealing in its groove in the Radial sealing with dust lip: 3HAB3701-47 base. xx1400000270 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 518 The M2 variseal sealing is only installed on base version 3HAC049628-001. See Spare part versions for the base on IP40/IP67 robots on page 874. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 519 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 520 Fit the new protection sleeve and secure with Tightening torque: 0.3 Nm. screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 521 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 522 4.5.1 Replacing the base spare parts (base, axis-1 radial sealing, protection sleeve) Continued Action Note Remove the bottom cover. Rear connector interface: xx1300000469 Bottom connector interface: xx1400000403 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 523 Bottom connector interface: xx1400000404 Loosen the connectors from the bracket by cutting the cable straps, and disconnect the connectors. xx1300002496 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 524 Open the base cover. xx1300002448 Disconnect the earth cable. Pull the cable package out from the base, through the rear. xx1300002456 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 525 Remove the brake release button from the base cover. Disconnect the earth cable. Remove the cable bracket by removing the screws. xx1400000406 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 526 (in the space of the protection sleeve). Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 527 Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 528 Room Apply a little grease to the sealing when replacing the radial sealing and wipe clean after the replacement. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 529 (M10X35) into the axis-1 gear screws little by little. xx1400000271 Remove the assembly tool. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 530 For robots with food grade lubrication For robots with protection type Hygienic Check the gasket on the base cover. Replace if damaged. xx1400000741 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 531 Insert the cable package in and up through the base, through the bottom. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 532 Check the gasket of the base cover. Replace if damaged. xx1400000413 Reconnect the earth cable. Refit the brake release button to the base cover. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 533 Check the axis-1 sealing ring. Axis-1 sealing ring: 3HAC044676- 001 / 3HAC068107-001 Replace if damaged. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 534 On axis-1 sealing ring version 3HAC068107-001: Axis-1 sealing ring gasket: 3HAC058349-001 (not Hygienic robots) / 3HAC080707-001 (Hygien- ic robots) xx1900001735 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 535 Refit the cable bracket to the cabling, if removed. Tightening torque: 1 Nm. Use Loctite 243 on the screw threads. xx1300002446 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 536 874. CAUTION Do not fit M2 variseal sealing on robots in other protection class or protection types. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 537 CAUTION Be careful not to squeeze any cabling dur- ing the refitting procedure. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 538 Remove the guide pins and refit the remain- ing attachment screws and washers. xx1300000523 Tighten all screws. Tightening torque: 40 Nm. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 539 Screws: 3HAB3409-209 (M3x20). Tightening torque: 1.5 Nm. xx1300000467 Note Only use specified screws, never replace them with other screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 540 Reconnect the connectors and secure the connectors to the bracket with cable straps. xx1300002496 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 541 For robots with food grade lubrication For robots with protection type Hygienic Check the O-ring. Replace if damaged. xx1400000412 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 542 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 543 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 544 For robots with protection type Hygienic Check the gasket of the cable housing plastic plate. Replace if damaged. xx1400000457 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 545 Fasten the plastic plate to the cable housing, if The plastic plate is included in: removed. Cable harness material set: 3HAC049663-001. Replace if damaged. xx1400000023 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 546 Replace if damaged. CAUTION Do not fit M2 variseal sealing on robots in other protection class or protection types. xx1400000454 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 547 Refit the axis-2 sealing ring with the screws. Tightening torque: 1.5 Nm. xx1400000020 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 548 Apply grease to the cable package, cover all moving area of the package. xx1400000481 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 549 Refit the axis-2 motor bracket to the motor. xx1300002432 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 550 See the figure. xx1400001131 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 551 Replace if damaged. Apply grease to the inner surface of the cable housing cover and to the PTFE film surface. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 552 For robots with protection type Foundry Plus Protection plug for lifting holes: 3HAC4836-24 Check the protection plugs for lifting holes. Replace if damaged. xx1600001151 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 553 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 554 For robots with food grade lubrication For robots with protection type Hygienic Check the EIB/SMB cover gasket. Replace if damaged. xx1400000475 Valid for IRB 1200 (no type specified) and IRB 1200 Type A Connect the connectors to the EIB unit. • R1.ME1-3 •...
  • Page 555 Screws: 3HAB3409-207 (M3x8). attachment screws. Tightening torque: 1.5 Nm xx1300002427 Note Only use specified screws, never replace them with other screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 556 Cover all moving area of the package. xx1400000483 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 557 Refit the fix sheet to the motor. Tightening torque: 1.5 Nm. xx1300002423 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 558 Tightening torque for the two M3 screws: 1.5 Nm. xx1300002422 xx1400001133 Reconnect the axis-3 motor connectors. xx1300002420 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 559 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Reconnect the motor connectors. xx1300002371 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 560 Reconnect the FPC connectors. See the number markings on the connectors for help to find the corresponding connector. xx1300002399 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 561 Cable layout in IRB 1200-5/0.9 : xx1400001471 Remove residual locking liquid and other pollut- ants with cleaning agent Loctite 7063. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 562 Use washing-up on finger tips to get a smooth joint. Sealant, Trans Clear If necessary, add extra sealant to get a full cover joint. xx1600000214 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 563 Check the PTFE film on the cable housing. PTFE film on lower arm cable housing: 3HAC044710-001 Replace if damaged. xx1400000740 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 564 Replace if damaged. Apply grease to the inner surface of the cable housing cover and the PTFE film surface. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 565 3HAC049664-001 Replace the air hose connector set if damaged. Air connector set without Ethernet hole in flange: 3HAC049665-001 xx1400000738 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 566 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 567 Check the connectors on the plate with connector Plate with connector set: set and the attached gasket. 3HAC079691-001 Replace if damaged. Gasket: 3HAC078804-001 xx2100001434 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 568 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 569 Screws: 3HAB3409-207 (M3x8). Tightening torque: 1.5 Nm. xx1300002389 Note Only use specified screws, never replace them with other screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 570 R3.H1 and R3.H2 and then secure the cover. xx1300000456 Note Only use specified screws, never replace them with other screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 571 Calibration information is included in sec- tion Calibration on page 805. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 572: Replacing The Swing Spare Parts (Swing, Axis-2 Radial Sealing)

    Cable housing of the swing Cable housing cover of the Radial sealing with dust lip swing xx1400000446 xx1400000445 xx1400000444 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 573 Replace if damaged. Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 574 Used with protection type Hy- gienic gienic. Replace if damaged. Cable housing cover of the 3HAC059678-001 Replace if damaged. swing Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 575 Plate with connector set 3HAC079691-001 Used with protection type Hy- gienic. Includes Ethernet connector, air connectors, CP/CS connector and gasket (3HAC078804-001). Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 576 For robots with protection class IP67 For robots with protection type Foundry Plus Sealant 3HAC073510-001 Trans Clear For robots with protection type Hygienic Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 577 Decide which calibration routine to use, and take actions accordingly prior to begin- ning the repair procedure. Jog all axes to zero position. xx1300002581 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 578 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 579 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 580 Cut the paint or surface on the robot before replacing parts on page 158. Disconnect the air hoses. xx1400000738 If equipped, disconnect the CP/CS connector. xx1500000252 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 581 Cut the paint or surface on the robot before replacing parts on page 158. Remove the cable housing cover. xx1300002400 Remove the plate. xx1300002413 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 582 Cable layout in IRB 1200-7/0.7 : disconnect them. xx1300002412 Cable layout in IRB 1200-5/0.9 : xx1400001471 Remove the small cover of the housing. xx1300002398 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 583 Disconnect the lamp cable connectors R3.H1 and R3.H2 and then lift away the cover completely. xx1300000456 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 584 Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 585 Cut the paint or surface on the robot before replacing parts on page 158. Remove the screw that fastens the air hose hold- xx1300002422 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 586 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 587 The cover can not be removed completely until the connectors and lugs are disconnected, xx1300002427 as shown in following step. Valid for IRB 1200 (no type specified) and IRB 1200 Type A Disconnect the connectors on the EIB unit. •...
  • Page 588 Cut the paint or surface on the robot before replacing parts on page 158. Pull the cable package out from the upper arm housing. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 589 Remove the swing sealing plug. Follow the procedure specified in Removing the swing sealing plug on page 166. xx1600000205 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 590 Remove the swing cable housing cover by remov- ing the screws. xx1300002431 Cut the cable straps. xx1400001528 Remove the axis-2 motor bracket screws. xx1300002432 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 591 Loosen the cable housing from the swing by re- moving the screws. Leave it hanging on the cable package. xx1300002435 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 592 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 593 17 kg to the total weight. xx1300002552 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 594 Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 595 The swing can not be removed completely until the axis-1 sealing ring is removed, as shown in following step. xx1400000449 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 596 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the axis-2 radial sealing from the cable housing. xx1400000450 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 597 Add sealant to the axis-1 sealing ring. (See Spare part versions for the axis-1 sealing ring on IP40/IP67 robots on page 878.) xx1600001125 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 598 On axis-1 sealing ring version 3HAC068107-001: Axis-1 sealing ring gasket: 3HAC058349-001 (not Hygienic robots) / 3HAC080707-001 (Hygien- ic robots) xx1900001735 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 599 M3x5: 3HAC14286-4 If replacing the cable protection, use locking liquid Tightening torque: 0.3 Nm Loctite 243 on the screws. xx1400000456 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 600 Lower the swing down into place while at the same time guiding the cabling through the cable hole. xx1400000449 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 601 For robots with food grade lubrication For robots with protection type Hygienic Check the gasket. Replace if damaged. xx1400000425 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 602 For robots with protection type Hygienic Apply a little grease to the sealing and wipe clean after the refitting. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 603 3HAC049694-001 Fit the tool plate to the other side of the cable housing with the six screws M6X50. xx1400000451 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 604 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 605 Fit guide pins to the gearbox. Guide pin for axis-2 gear unit: 3HAC049704-001 xx1300002562 Always use three guide pins together! Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 606 Fit the lower arm to the swing, with guid- ance from the guide pins. xx1300002563 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 607 Remove the guide pins and refit the remain- ing screws and washers using locking li- quid Loctite 243. xx1300002565 Tighten all screws. Tightening torque: 45 Nm Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 608 Tightening torque: 1.5 Nm. Swing cover: 3HAC059676-001 Swing cover, Clean Room Swing cover, food grade lubrication Swing cover, Hygienic : 3HAC056215-001 xx1300002551 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 609 If necessary, add extra sealant to get a full cover joint. xx1600000217 For robots with protection type Foundry Plus If required, fit two screws for protection. xx1600001154 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 610 For robots with protection type Hygienic Check the gasket of the cable housing plastic plate. Replace if damaged. xx1400000457 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 611 Fasten the plastic plate to the cable housing, if The plastic plate is included in: removed. Cable harness material set: 3HAC049663-001. Replace if damaged. xx1400000023 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 612 Replace if damaged. CAUTION Do not fit M2 variseal sealing on robots in other protection class or protection types. xx1400000454 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 613 Refit the axis-2 sealing ring with the screws. Tightening torque: 1.5 Nm. xx1400000020 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 614 Apply grease to the cable package, cover all moving area of the package. xx1400000481 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 615 Refit the axis-2 motor bracket to the motor. xx1300002432 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 616 See the figure. xx1400001131 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 617 Replace if damaged. Apply grease to the inner surface of the cable housing cover and to the PTFE film surface. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 618 For robots with protection type Foundry Plus Protection plug for lifting holes: 3HAC4836-24 Check the protection plugs for lifting holes. Replace if damaged. xx1600001151 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 619 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 620 For robots with food grade lubrication For robots with protection type Hygienic Check the EIB/SMB cover gasket. Replace if damaged. xx1400000475 Valid for IRB 1200 (no type specified) and IRB 1200 Type A Connect the connectors to the EIB unit. • R1.ME1-3 •...
  • Page 621 Screws: 3HAB3409-207 (M3x8). attachment screws. Tightening torque: 1.5 Nm xx1300002427 Note Only use specified screws, never replace them with other screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 622 Cover all moving area of the package. xx1400000483 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 623 Refit the fix sheet to the motor. Tightening torque: 1.5 Nm. xx1300002423 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 624 Tightening torque for the two M3 screws: 1.5 Nm. xx1300002422 xx1400001133 Reconnect the axis-3 motor connectors. xx1300002420 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 625 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Reconnect the motor connectors. xx1300002371 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 626 Reconnect the FPC connectors. See the number markings on the connectors for help to find the corresponding connector. xx1300002399 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 627 Cable layout in IRB 1200-5/0.9 : xx1400001471 Remove residual locking liquid and other pollut- ants with cleaning agent Loctite 7063. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 628 Use washing-up on finger tips to get a smooth joint. Sealant, Trans Clear If necessary, add extra sealant to get a full cover joint. xx1600000214 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 629 Check the PTFE film on the cable housing. PTFE film on lower arm cable housing: 3HAC044710-001 Replace if damaged. xx1400000740 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 630 Replace if damaged. Apply grease to the inner surface of the cable housing cover and the PTFE film surface. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 631 3HAC049664-001 Replace the air hose connector set if damaged. Air connector set without Ethernet hole in flange: 3HAC049665-001 xx1400000738 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 632 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 633 Check the connectors on the plate with connector Plate with connector set: set and the attached gasket. 3HAC079691-001 Replace if damaged. Gasket: 3HAC078804-001 xx2100001434 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 634 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 635 Screws: 3HAB3409-207 (M3x8). Tightening torque: 1.5 Nm. xx1300002389 Note Only use specified screws, never replace them with other screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 636 R3.H1 and R3.H2 and then secure the cover. xx1300000456 Note Only use specified screws, never replace them with other screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 637 Calibration is detailed in section Calibration on page 805. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 638: Replacing The Axis-1 Mechanical Stop

    The axis-1 mechanical stop is located as shown in the figure. xx1400000391 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 639 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 640 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 641: Motors And Gearboxes

    The axis-1 gear unit and axis-1 motor is part of the complete base spare part assembly, see Replacing the base spare parts (base, axis-1 radial sealing, protection sleeve) on page 492. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 642: Replacing The Axis-2 Drive Unit

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S ©...
  • Page 643 The robot is calibrated by either manual calibration or Axis Calibration at factory. Always use the same calibration method as used at the factory. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 644 (DressPack) and tools calibration tool. must be removed from the robot. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 645 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 646 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 647 Remove the cable housing cover of the swing by removing the screws. xx1300002431 Cut the cable straps. xx1400001528 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 648 Note The cabling is still connected inside the robot, so be careful not to strain the cables! xx1300002548 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 649 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 650 17 kg to the total weight. xx1300002552 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 651 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 652 Insert two M4 screws to the press out holes and press out the drive unit. xx1400000008 Carefully pull out the complete drive unit. xx1300002555 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 653 Loctite 7063. Apply flange sealing Loctite 574 on the mounting surfaces of the lower arm. xx1400000006 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 654 • Person 1: Hold the lower arm still. • Person 2: Tighten the screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 655 For robots with food grade lubrication For robots with protection type Hygienic Wipe clean the overflowing Loctite 574 if there is any. xx1400001403 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 656 Fit the lower arm to the swing, with guid- ance from the guide pins. xx1300002563 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 657 Remove the guide pins and refit the remain- ing screws and washers using locking li- quid Loctite 243. xx1300002565 Tighten all screws. Tightening torque: 45 Nm Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 658 Tightening torque: 1.5 Nm. Swing cover: 3HAC059676-001 Swing cover, Clean Room Swing cover, food grade lubrication Swing cover, Hygienic : 3HAC056215-001 xx1300002551 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 659 If necessary, add extra sealant to get a full cover joint. xx1600000217 For robots with protection type Foundry Plus If required, fit two screws for protection. xx1600001154 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 660 Refit the cable housing to the swing with Tightening torque: 3 Nm. the screws. xx1300002549 Insert the cable harness into the lower arm. xx1300002548 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 661 Make sure the connector is fixed by its tab to the bracket. xx1400001529 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 662 Screws: 3HAB3409-207 (M3x8). Tightening torque: 1.5 Nm. xx1300002431 Note Only use specified screws, never replace them with other screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 663 Calibration is detailed in section Calibration on page 805. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 664: Replacing The Axis-3 Drive Unit

    The axis-3 drive unit is located as shown in the figure. xx1300002527 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 665 Roundsling, 2 m Length: 2 m. Lifting capacity: 100 kg. 24 VDC power supply Used to release the motor brakes. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 666 The gear is pre-filled at delivery but grease may need to be added depending on the actual condi- tion. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 667 Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Jog all axes to zero position. xx1300002581 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 668 Cut the paint or surface on the robot before replacing parts on page 158. Remove the cable housing cover. xx1300002400 Remove the plate. xx1300002413 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 669 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 670 Note The cabling is still connected inside the robot, so be careful not to strain the cables! xx1300002530 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 671 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 672 This releases the upper arm from the lower arm. Make sure the weight of the upper arm is properly secured by the lifting slings. xx1300002531 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 673 Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 674 Apply more grease, if 001. needed. For robots with food grade lubrication For robots with protection type Hygienic LUBRIPLATE SYNXTREME FG-0: 3HAC043771-001 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 675 Make sure to refit the drive unit correctly oriented. When the upper arm is in its zero position (horizontal), the motor connectors should point downwards. xx1300002534 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 676 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 677 Replace if damaged. CAUTION Do not fit M2 variseal sealing on robots in other protection class or protection types. xx1400000474 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 678 Remove the guide pins and refit the remain- ing screws and washers. xx1400000029 Tighten all screws. Tightening torque: 4.5 Nm. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 679 Screws: 3HAB3409-207 (M3x8). Tightening torque: 1.5 Nm. xx1300002528 Note Only use specified screws, never replace them with other screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 680 418. Apply a little grease to the sealing when replacing the radial sealing and wipe clean after the replacement. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 681 For robots with protection type Foundry Plus If required, fit two screws for protection. xx1600001155 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 682 Refit the fix sheet to the inner plastic guide. Tightening torque: 1.5 Nm. xx1300002421 Reconnect the axis-3 motor connectors. xx1300002420 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 683 For robots with food grade lubrication For robots with protection type Hygienic Check the gasket of the cable housing cover. Replace if damaged. xx1400000048 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 684 Recalibrate the robot. Calibration is detailed in section Calibration on page 805. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 685 4.6.3 Replacing the axis-3 drive unit Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 686: Replacing The Axis-4 Gearbox, Drive Shaft And Pulley

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 687 If no data is found related to standard calibration, manual calibration is used as default. Required consumables Consumable Art. no. Note Cable straps Cleaning agent Loctite 7063 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 688 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 689 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 690 The screws are used for blocking the screw holes rather than fixing the cover to the tubular. Replace if damaged or missing. xx2100001406 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 691 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 692 Snap loose and disconnect the axis-5 FPC connectors. xx1300002390 Remove the screws and pull out the motor. xx1300002352 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 693 Disconnect the connectors shown in the figure. xx1300002353 Disconnect the air hoses. xx1300002355 Remove the connector plate attachment screws. xx1300002356 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 694 Pay special attention to the plastic block on the FPC unit. It is easily pulled off, make sure it stays fitted to the FPC unit. xx1300002611 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 695 R3.H1 and R3.H2 and then lift away the cover completely. xx1300000456 Cut the strap that holds the connectors. xx1300002494 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 696 Cut the paint or surface on the robot before replacing parts on page 158. Remove the cable housing cover. xx1300002400 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 697 Pull out the FPC connectors from the housing and Cable layout in IRB 1200-7/0.7 : disconnect them. xx1300002412 Cable layout in IRB 1200-5/0.9 : xx1400001471 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 698 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 699 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 700 Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 701 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 702 If replacing the drive shaft with a new spare part, remove the sleeve from the shaft and fit it to the new shaft. xx1300002387 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 703 158. Remove the gear attachment screws. xx1300002378 Pull out the gear. xx1300002379 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 704 Tightening torque: 1.1 Nm. xx1300002380 Note Only use specified screws, never replace them with other screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 705 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 706 Screws: 3HAB3409-210 (M3x25). Tightening torque: 1.8 Nm. xx1300002376 Note Only use specified screws, never replace them with other screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 707 Apply a little grease to the sealing when replacing the radial sealing and wipe clean after the replacement. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 708 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 709 Secure with screws and washers, using locking Screws: M4x30. liquid Loctite 243. Tightening torque: 2.7 Nm. xx1300002372 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 710 Place the timing belt at the gear pulley and run the air hoses through the belt. Install the air hoses in and through the housing extender unit. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 711 • the motor is clean and undamaged. Fit the timing belt to the motor pulley. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 712 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pulleys. xx1300002525 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 713 Cable layout in IRB 1200-5/0.9 : xx1400001471 Remove residual locking liquid and other pollut- ants with cleaning agent Loctite 7063. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 714 Use washing-up on finger tips to get a smooth joint. Sealant, Trans Clear If necessary, add extra sealant to get a full cover joint. xx1600000214 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 715 Check the PTFE film on the cable housing. PTFE film on lower arm cable housing: 3HAC044710-001 Replace if damaged. xx1400000740 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 716 Replace if damaged. Apply grease to the inner surface of the cable housing cover and the PTFE film surface. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 717 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Reconnect the motor connectors. xx1300002371 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 718 Pay special attention to the plastic block on the FPC unit. It is easily pulled off, make sure it stays fitted to the FPC unit. xx1300002611 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 719 Note Only use specified screws, never replace them with other screws. Tighten all screws. Tightening torque: 8 Nm. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 720 Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 721 Move the motor to a position where a good timing belt tension is reached (F = 26 N). Note Do not strech the timing belt too much! Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 722 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 723 For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cover gasket. Replace if damaged. xx1400000034 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 724 For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cable housing cover gasket. Replace if damaged. xx1400000345 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 725 Check the two extra screws on the tubular cover (right hand side cover), as encircled in the figure. Replace if damaged or missing. xx2100001406 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 726 Use washing-up on finger tips to get a smooth joint. Sealant, Trans Clear If necessary, add extra sealant to get a full cover joint. xx1600000215 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 727 Calibration is detailed in section Calibration on page 805. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 728: Replacing The Axis-4 Motor With Pulley

    The axis-4 motor is located as shown in the figure. xx1300002474 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 729 (DressPack) and tools calibration tool. must be removed from the robot. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 730 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 731 Disconnect the lamp cable connectors R3.H1 and R3.H2 and then lift away the cover completely. xx1300000456 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 732 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 733 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 734 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 735 • the motor is clean and undamaged. Fit the timing belt to the motor pulley. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 736 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pulleys. xx1300002525 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 737 Reconnect the motor connectors. xx1300002371 Secure the connectors to the motor with a cable strap. xx1300002494 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 738 Screws: 3HAB3409-207 (M3x8). screws. Tightening torque: 1.5 Nm. xx1300000456 Note Only use specified screws, never replace them with other screws. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 739 Calibration information is included in sec- tion Calibration on page 805. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 740: Replacing The Axis-4 Timing Belt

    The axis-4 timing belt is located as shown in the figure. xx1400000036 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 741 For robots with food grade lubric- ation. Sealant 3HAC073510-001 Trans Clear For robots with protection type Hygienic Locking liquid 3HAB7116-1 Loctite 243 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 742 Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Jog all axes to zero position. xx1300002581 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 743 158. Remove the lower arm cable housing cover. xx1300002400 Remove the tubular cable housing cover. xx1300002389 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 744 Disconnect the lamp cable connectors R3.H1 and R3.H2 and then lift away the cover completely. xx1300000456 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 745 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 746 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 747 Cut the paint or surface on the robot before replacing parts on page 158. Remove the axis-4 timing belt. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 748 • the motor is clean and undamaged. Fit the timing belt to the motor pulley. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 749 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pulleys. xx1300002525 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 750 Reconnect the motor connectors. xx1300002371 Secure the connectors to the motor with a cable strap. xx1300002494 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 751 On robots with protection type and wipe clean if there is any overflowing Foundry Plus Loctite 574. Gasket: 3HAC058567-001 xx1500000251 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 752 Check the plate without connector set and the at- Gasket: 3HAC078804-001 tached gasket. Replace if damaged. xx2100001433 Reconnect the air hoses. xx1400000738 Reconnect the CP/CS cabling. xx1500000252 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 753 For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cable housing cover gasket. Replace if damaged. xx1400000345 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 754 For robots with food grade lubrication For robots with protection type Hygienic Check the gasket. Replace if damaged. xx1400000477 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 755 Use washing-up on finger tips to get a smooth joint. If necessary, add extra sealant to get a full cover joint. xx1600000215 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 756 Replace if damaged. Apply grease to the inner surface of the cable housing cover and the PTFE film surface. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 757 Calibration information is included in sec- tion Calibration on page 805. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 758: Replacing The Axis-5 Motor With Pulley

    The axis-5 motor is located as shown in the figure. xx1300002473 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Equipment, etc. Article number Note...
  • Page 759 If no previous reference values exist, and routine on page 819. no new reference values can be created, then reference calibration is not possible. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 760 Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 761 Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 762 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 763 158. Loosen the screws so that the motor can be moved sideways. xx1300002350 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 764 Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 765 Move the motor to a position where a good timing belt tension is reached (F = 26 N). Note Do not strech the timing belt too much! Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 766 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 767 For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cover gasket. Replace if damaged. xx1400000034 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 768 For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cable housing cover gasket. Replace if damaged. xx1400000345 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 769 Check the two extra screws on the tubular cover (right hand side cover), as encircled in the figure. Replace if damaged or missing. xx2100001406 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 770 Calibration information is included in sec- tion Calibration on page 805. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 771: Replacing The Axis-5 Timing Belt

    The axis-5 timing belt is located as shown in the figure. xx1400000032 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 772 Action Note Decide which calibration routine to use, and take actions accordingly prior to begin- ning the repair procedure. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 773 Cut the paint or surface on the robot before replacing parts on page 158. Remove the left hand side wrist cover. xx1400000033 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 774 158. Loosen the screws so that the motor can be moved sideways. xx1300002350 Remove the timing belt. xx1300002351 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 775 Belt tension: F = 26 N. tension (F = 26 N). Secure the motor with its attachment screws. xx1300002350 Tightening torque: 3.5 Nm. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 776 Recalibrate the robot. Calibration information is included in sec- tion Calibration on page 805. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 777 4.6.8 Replacing the axis-5 timing belt Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 778: Replacing The Axis-5 And Axis-6 Drive Unit

    The drive unit of axis-5 and axis-6 is located as shown in the figure. xx1300002467 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1200 via myABB Business Portal, www.abb.com/myABB. Spare part Art. no. Note...
  • Page 779 Gasket for tubular cable 3HAC056707-001 / Not used with protection class housing cover 3HAC080701-001 IP40. Replace if damaged. Tubular cable housing 3HAC059695-001 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 780 Loctite 574 For robots with protection class IP67 For robots with protection type Foundry Plus Flange sealing 3HAC026759-003 Sikaflex 521FC Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 781 Action Note Decide which calibration routine to use, and take actions accordingly prior to begin- ning the repair procedure. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 782 See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 783 Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 784 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 785 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 786 Remove the FPC unit attachment screws and pull out the FPC unit as far as required for the axis-6 motor connectors to be accessed. xx1300002394 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 787 Slide the motor sideways to release the tension of the timing belt, and remove the timing belt. xx1300002351 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 788 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 789 Flange tightening tool: 3/8" (10 mm) socket spanner on the seal ring unit 3HAC079686-001 and loosen the unit. xx2100001452 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 790 Apply a little grease to the screw thread. Grease: Molykote P1900 xx2100001454 Put the gasket in place and then screw the seal ring unit. xx2100001453 xx2100001455 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 791 Make sure the pin hole on the shaft aligned with the pin on the tool flange. xx2100001458 Secure with screws and washers. Tightening torque: 1.5 Nm xx2100001459 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 792 Replace if damaged. CAUTION Do not fit M2 variseal sealing on robots in other protection class or protection types. xx1300002493 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 793 Wipe clean the overflowing sealant if there is any. xx1400001404 Fit guide pins to the axis-5 gearbox. Guide pin for tilt unit (axis 5): 3HAC049706-001 xx1300002568 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 794 Only use specified screws, never replace them with other screws. Remove the guide pins and refit the remaining screws and washers. xx1300002570 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 795 Tightening torque: 0.3 Nm. screws. Note Check that the FPC unit is at the zero pos- ition when refitting it. xx1300002394 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 796 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 797 Fit the tool plate to the other side of the tubular cable housing with the six screws M6x40. xx1400000485 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 798 Flange sealant, Trans Clear Note For Hygienic robots, wipe clean the overflowing flange sealing if there is any. xx1300002610 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 799 Move the motor to a position where a good timing belt tension is reached (F = 26 N). Note Do not strech the timing belt too much! Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 800 Refit the connector plate and secure with Tightening torque: 0.3 Nm. the M3 screws. xx1400001401 Secure the three M2.5 screws. Tightening torque: 0.3 Nm. xx1400001402 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 801 For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cover gasket. Replace if damaged. xx1400000034 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 802 For robots with food grade lubrication For robots with protection type Hygienic Check the tubular cable housing cover gasket. Replace if damaged. xx1400000345 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 803 Check the two extra screws on the tubular cover (right hand side cover), as encircled in the figure. Replace if damaged or missing. xx2100001406 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 804 Calibration information is included in sec- tion Calibration on page 805. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 805: Calibration

    A calibration routine to make a rough calibration of each manipulator axis. Synchronization mark Visual marks on the robot axes. When marks are aligned, the robot is in synchronization position. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 806: Calibration Methods

    Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 807 Brief description of calibration methods Axis Calibration method Axis Calibration is a standard calibration method for calibration of IRB 1200. It is the recommended method in order to achieve proper performance. The following routines are available for the Axis Calibration method: •...
  • Page 808 References Article numbers for the calibration tools are listed in the section Special tools on page 891. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 809: When To Calibrate

    The resolver values are changed If resolver values are changed, the robot must be re-calibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration, according to information in this manual. If the robot has absolute accuracy calibration, it is also recommended, but not always necessary to calibrate for new absolute accuracy.

  • Page 810: Synchronization Marks And Axis Movement Directions

    This section shows the position of the synchronization marks and the synchronization position for each axis. Synchronization marks, IRB 1200 xx1400000402 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 811 5 Calibration 5.2.1 Synchronization marks and synchronization position for axes Continued Synchronization marks at axis 6 on Hygienic robots xx2100001464 Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 812: Calibration Movement Directions For All Axes

    Manual movement directions xx1300000365 Posi- Description Posi- Description tion tion Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6 Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 813: Updating Revolution Counters

    Use this procedure to update the revolution counter with the FlexPendant (IRC5). Action On the ABB menu, tap Calibration. xx1500000942 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 814 Calibration method used at factory for each axis is shown, as well as calibration method used during last field calibration. Tap Manual Method (Advanced). xx1500000944 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 815 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 865. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 816: Updating Revolution Counters On Omnicore Robots

    Tap Update to proceed with updating the revolution counters. • Tap Cancel to cancel updating the revolution counters. Tapping Update and a confirmation window is displayed. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 817 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 865. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 818: Calibrating With Axis Calibration Method

    FlexPendant. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. WARNING The calibration tool must be fully inserted into the calibration bushing, until the steel spring ring snaps into place.
  • Page 819 A benefit with reference calibration is that the current state of the robot is stored and not the state when the robot left the ABB factory. The reference value will be named according to tool name, date etc.
  • Page 820 For robots with EPS, the same applies as for SafeMove. How to calibrate a suspended or wall mounted robot The IRB 1200 is fine calibrated floor standing in factory, prior to shipping. To calibrate a suspended or wall mounted robot, reference calibration could be used.

  • Page 821: Calibration Tools For Axis Calibration

    IRB 1200 to be fitted to the tool flange during calibration of axis 6. The robot is calibrated by either manual calibration or Axis Calibration at ABB factory before delivery. Always use the same calibration method as used at the factory.
  • Page 822 If including the tool flange calibration tool in a local periodic check system, the following measures should be checked. • Outer diameter within Ø5g5 mm. • Straightness within 0.005 mm. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 823 5 Calibration 5.4.2 Calibration tools for Axis Calibration Continued xx1600001142 Outer diameter Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 824: Installation Locations For The Calibration Tools

    For axis 6 there is only one bushing, the second calibration tool is installed at the mounting flange of the turning disk. xx1600001035 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 825 Used for robots with food grade grade lubrication lubrication Protective plug for bushing, Hygien- Used with protection type Hygien- Replace if damaged or missing. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 826: Axis Calibration - Running The Calibration Procedure

    6. The robot is calibrated by either manual calibration or Axis Calibration at ABB factory before delivery. Always use the same calibration method as used at the factory. Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant.
  • Page 827 Use this procedure to start the Axis Calibration routine on the FlexPendant. Action Note Tap the calibration icon and enter the calibration main page. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 828 0 degrees. Information about which axes are Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 829 Axis 4 xx1600001275 xx1600001274 Axis 5 Axis 6 Make sure to orient the tool flange calibration tool correctly. xx1600001273 xx1600001272 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 830 Note For robots with protection type Hygienic Hygienic robots do not have the o-ring on the plug. xx1600001143 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 831 If the standard calibration data for axes 4, 5 or 6 Calibrating with Wrist Optimiz- should be updated with wrist optimization, run the ation method on page 834. calibration routine Wrist Optimization. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 832: Reference Calibration

    (step 5, see Brief introduction to Reference Calibration on page 832). Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 833 11 Repeat the manual tuning if needed. 12 Create a new reference if the intention is to use the reference in the future. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 834: Calibrating With Wrist Optimization Method

    3 Improved calibration data to the wrist axes is identified and presented. 4 Optimized positions for the wrist axes are presented. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 835 WARNING Robot moves automatically when pressing Calibrate. 6 Wrist optimization is finished. 7 Redefine / verify TCP for all tools. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 836: Calibrating With Manual Calibration Method

    The table below specifies the exact axis positions in degrees. Axis IRB 1200-5/0.9 IRB 1200-7/0.7 +84.474066º +84.474066º +131.862755º +136.862755º +72.250000º +72.250000º 0º 0º -90º -90º 0º 0º Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 837: Manual Calibration Method - Content Of Calibration Toolkit 3Hac051256-001

    Hex socket head screw 9ADA183-41 M8x45 Hex socket head screw 9ADA183-15 M5x20 Hex socket head screw 9ADA183-5 M4x16 Hex socket head screw 9ADA183-14 M5x16 Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 838: Manual Calibration Method - Calibrating Axis 1

    Art. no. Note Calibration toolkit, manual calibra- 3HAC051256-001 Includes calibration tools, pins tion and attachment screws for manual calibration method. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 839 Moving the robot to calibration position Action Note Jog all axes to zero position. Remove the axis-1 mechanical stop pin. xx1400000392 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 840 Remove the protection plug from the swing. xx1400001134 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 841 When the axis is in position, release the brake release button to activate the brakes again. xx1400001209 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 842 Tap Yes to proceed. • Tap No to cancel. Select the check-box for the current axis/axes to be calibrated. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 843 Remove the axis-1 calibration stop pin from the Tightening torque: 12 Nm base and refit the axis-1 mechanical stop. xx1400000392 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 844 Action Note Write down the new system parameters on a new label and stick on top of the calibration label on the robot. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 845: Manual Calibration Method - Calibrating Axis 2

    2. swing is used for calibration of axis 2. No additional equipment is required. No additional equipment is required. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 846 On the ABB menu, tap Calibration. All mechanical units connected to the system are shown along with their calibration status. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 847 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 848 Action Note Write down the new system parameters on a new label and stick on top of the calibration label on the robot. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 849: Manual Calibration Method - Calibrating Axis 3

    These parts are already fitted to the robot, no extra installation of calibration equipment is required. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 850 Make sure no personnel is near or beneath the robot arm! Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 851 On the ABB menu, tap Calibration. All mechanical units connected to the system are shown along with their calibration status. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 852 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 853 Action Note Write down the new system parameters on a new label and stick on top of the calibration label on the robot. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 854: Manual Calibration Method - Calibrating Axis 4

    Rotate axis 4 some degrees toward positive direc- tion to avoid interference between the calibration tools when fitting them. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 855 Press down slightly on the calibration tool to make sure the tool attaches the location surface tightly. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 856 When the axis is in position, release the brake release button to activate the brakes again. xx1400001207 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 857 Tap Yes to proceed. • Tap No to cancel. Select the check-box for the current axis/axes to be calibrated. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 858 If yes, the calibration is verified OK. • If no, redo the fine calibration procedure. xx1400001095 Refit the protection cover to the housing. xx1400001205 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 859 Action Note Write down the new system parameters on a new label and stick on top of the calibration label on the robot. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 860: Manual Calibration Method - Calibrating Axis 5 And Axis 6

    • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 861 When the axis is in position, release the brake release button to activate the brakes again. xx1400001206 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 862 Tap Yes to proceed. • Tap No to cancel. Select the check-box for the current axis/axes to be calibrated. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 863 Action Note Write down the new system parameters on a new label and stick on top of the calibration label on the robot. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 864: Verifying The Calibration

    Write down the values on a new label and stick it on top of the calibration label. The label is located on one side of the base. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 865: Checking The Synchronization Position

    If they do not, up- ization position for axes on page 810 date the revolution counters. Updating revolution counters on page 813. Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 866 If they do not, up- ization position for axes on page 810 date the revolution counters. Updating revolution counters on page 813. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 867: Decommissioning

    These parts must also be disposed of in accordance with the current legislation of the country in which the robot and control unit are installed. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 868: Environmental Information

    6.2 Environmental information 6.2 Environmental information Introduction ABB robots contain components in different materials. During decommissioning, all materials should be dismantled, recycled, or reused responsibly, according to the relevant laws and industrial standards. Robots or parts that can be reused or upcycled helps to reduce the usage of natural resources.
  • Page 869 Spills can form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. • Spillage can penetrate the soil causing ground water contamination. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 870: Scrapping Of Robot

    • When motors are removed from the robot, the robot will collapse if it is not properly supported before the motor is removed. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 871: Robot Description

    7.1 Introduction Manipulator description IRB 1200 is one of ABB 6-axis industrial robots, with multiple variants designed to work in various environments. Different IRB 1200 variant supports to work with either IRC5/IRC5C controller or OmniCore controller, or both. The following table lists the supported controller type for IRB 1200 in different protection classes/types.

  • Page 872: Type A Of Irb 1200

    As a result of this, the castings differ between IRB 1200 and IRB 1200 Type A. Note IRB 1200 Type B is designed based on IRB 1200 Type A so that Type B has the bushings for installation of calibration tools too.

  • Page 873: Type B Of Irb 1200

    Battery pack • SMB unit (replacing EIB unit) IRB 1200 Type B is designed based on IRB 1200 Type A so that Type B has the bushings for installation of calibration tools too. How to know which type the robot is? The type label on the base of the robot tells if the robot supports SafeMove 2.

  • Page 874: Description Of Spare Part Versions

    Spare part versions for the base on IP40/IP67 robots Note IRB 1200 has different base versions that are not compatible with each other. Always use the following list as a reference to check the base installed on robot and order the correct spare parts.
  • Page 875 3HAC059553-001 3HAC058386-001 Order: Base 3HAC059553-001 has a bushing • base 3HAC059553-001 for fitting calibration tool for Axis Calib- ration. xx1600001037 Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 876: Spare Part Versions For The Swing On Ip40/Ip67 Robots

    Spare part versions for the swing on IP40/IP67 robots Note IRB 1200 has different swing versions that are not compatible with each other. Always use the following list as a reference to check the swing installed on robot and order the correct spare parts.
  • Page 877 3HAC059554-001 3HAC058387-001 Order: The swing has a bushing for fitting • swing 3HAC059554-001 calibration tool for Axis Calibration. xx1600001038 Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 878: Spare Part Versions For The Axis-1 Sealing Ring On Ip40/Ip67 Robots

    Spare part versions for the axis-1 sealing ring on IP40/IP67 robots Note IRB 1200 has different axis-1 sealing ring versions that are not compatible with each other. Always use the following list as a reference to check the sealing ring installed on robot and order the correct spare parts.
  • Page 879 Order: • corresponding cable harness. See "Manipulator cable harness" in Product manual, spare parts - IRB 1200 for spare part numbers. xx1900001601 Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 880: Spare Part Versions For The Housing On Type A Robots

    Spare part versions for the housing on Type A robots Note IRB 1200 and IRB 1200 Type A have different housing versions that are not compatible with each other. Always use the following list as a reference to check the housing installed on robot and to order the correct spare parts.

  • Page 881: Spare Part Versions For The Tubular On Type A Robots

    Spare part versions for the tubular on Type A robots Note IRB 1200 and IRB 1200 Type A have different tubular versions that are not compatible with each other. Always use the following list as a reference to check the tubular installed on robot and to order the correct spare parts.

  • Page 882: Spare Part Versions For The Tubular Cover On Clean Room Robots

    Spare part versions for the tubular cover on Clean Room robots Note IRB 1200 with protection type Clean Room has different tubular cover versions that are not compatible with each other. Always use the following list as a reference to check the tubular cover installed on robot and to order the correct spare parts.

  • Page 883: Reference Information

    8 Reference information 8.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 884: Applicable Standards

    Safety requirements for industrial robots and robot systems ANSI/UL 1740 Safety standard for robots and robotic equipment CAN/CSA Z 434-03 Industrial robots and robot Systems - General safety require- ments Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 885: Unit Conversion

    2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 886: Screw Joints

    8.4 Screw joints 8.4 Screw joints General This section describes how to tighten the various types of screw joints on ABB robots. The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials.
  • Page 887 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 888 8.4 Screw joints Continued Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Lubricated with Molycote 1000, Gleitmo 603 or equivalent Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 889: Weight Specifications

    All components exceeding 22 kg (50 lbs) are highlighted in this way. To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.

  • Page 890: Standard Toolkit

    Hex socket head cap no. 2.5 socket 1/2" bit L=110 mm Small screwdriver T-handle with ball head Small cutting plier Plastic mallet Needle-nose plier Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 891: Special Tools

    Standard toolkit on page 890, and of special tools, listed directly in the instructions and also gathered in this section. Special tools Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 892 Press, puller and unloading tools Axis-1 sealing assembly tool set 3HAC049692-001 Used to refit the axis-1 radial sealing. xx1400000535 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 893 Used to refit the radial sealing, if replacement is needed. xx1400000540 Other tools 24 VDC power supply Calibration toolkit, manual 3HAC051256-001 calibration Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 894 Tools and equipment with spare part number: (These tools can be ordered from ABB) Calibration tool box, Axis 3HAC074119-001 Calibration 3HAC079686-001 Flange tightening tool xx2100001462 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.

  • Page 895: Lifting Accessories And Lifting Instructions

    The instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
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  • Page 897: Spare Parts

    Spare parts and exploded views are not included in the manual but delivered as a separate document for registered users on myABB Business Portal, www.abb.com/myABB. All documents can be found via myABB Business Portal, www.abb.com/myABB. Product manual - IRB 1200 3HAC046983-001 Revision: S...
  • Page 898 This page is intentionally left blank...

  • Page 899: Circuit Diagrams

    Circuit diagram - IRB 4600 3HAC029038-003 Circuit diagram - IRB 6620 3HAC025090-001 Circuit diagram - IRB 6620 / IRB 6620LX 3HAC025090-001 Continues on next page Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 900 Circuit diagram - IRB 6700 / IRB 6790 3HAC043446-005 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 14000 3HAC050778-003 Circuit diagram - IRB 910SC 3HAC056159-002 Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 901 84 batteries disposal, 868 battery fire extinguishing, 31 replacing, 134 fitting battery shutdown extra equipment, 85 service routine, 134 fitting, equipment, 84 Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 902 51 recycling, 868 lock and tag, 31 regional regulations, 30 lower arm release brakes, 37 replacing, 308 replacements, report, 157 lubricants, 34 replacing Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 903 37 type B, 873 signals, 21 signals in manual, 21 UL lamp symbols, 21 replacing, 377 symbols on robot, 23 Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 904 20 robot, 69 Wrist Optimization overview of method, 834 validity and responsibility, 19 velocity adjusting, 114 zero position verifying calibration, 864 checking, 865 Product manual - IRB 1200 3HAC046983-001 Revision: S © Copyright 2014 - 2021 ABB. All rights reserved.
  • Page 906 SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics & Discrete Automation 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2014 - 2021 ABB. All rights reserved. Specifications subject to change without notice.

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