ABB IRB 1510 Product Manual
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ABB IRB 1510 Product Manual

ABB IRB 1510 Product Manual

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IRB 1510

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Summary of Contents for ABB IRB 1510

  • Page 1 ROBOTICS Product manual IRB 1510...
  • Page 2 Trace back information: Workspace 24A version a16 Checked in 2024-03-07 Skribenta version 5.5.019...

  • Page 3: Product Manual

    Product manual IRB 1510ID - 4/1.5 IRC5, IRC5C Document ID: 3HAC087870-001 Revision: B © Copyright 2023-2024 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

    4.2.3 Expected component life ................Inspection activities ................... 4.3.1 Inspecting the oil level, axis-1 gearbox ............4.3.2 Inspecting the oil level, axis 2 gearbox ............Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 6 Service work on axes 4, 5 and 6 gearboxes ..........Calibration information When to calibrate ..................... Calibration methods ................... Synchronization marks and synchronization position for axes ........Calibration movement directions for all axes ............Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 7 Screw joints ....................Weight specifications ..................Standard tools ....................Special tools ....................Lifting accessories and lifting instructions .............. Spare parts Spare part lists and illustrations ................Index Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
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  • 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 1510. Some variants and designs may have been removed from the business offer and are no longer available for purchase.
  • Page 10 Documentation referred to in the manual, is listed in the table below. General Document name Document ID Product manual, spare parts - IRB 1510 3HAC087872-001 Circuit diagram - IRB 1510 3HAC087368-003 Safety manual for robot - Manipulator and IRC5 or OmniCore con-...

  • Page 11: 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 12 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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 13: How To Read The Product Manual

    Likewise, certain work methods or general information that is valid for several robot models, can be illustrated with illustrations that show a different robot model than the one that is described in the current manual. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
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  • Page 15: Safety

    Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. The information does not cover how to design, install and operate a robot system, nor does it cover all peripheral equipment that can influence the safety of the robot system.

  • Page 16: 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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 17: Safety Signals And Symbols

    NOTE Signal word used to indicate important facts and conditions. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 18 1.2.1 Safety signals in the manual Continued 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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 19: Safety Symbols On Manipulator Labels

    Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 20 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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 21 Tip risk when loosening bolts 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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 22 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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 23 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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 24 Shut off with handle 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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 25: Robot Stopping Functions

    The protective stops and emergency stops are described in the product manual for the controller. For more information see: • Product manual - IRC5 • Product manual - IRC5 Compact Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 26: Safety During 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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 27 Water • 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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 28 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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 29: Safety During Operation

    Hazards due to the use of brake release devices and/or gravity beneath the manipulator shall be considered. A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 30: Safety During Maintenance And Repair

    90 °C. Hot oil or grease Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 31 Specified amount de- on how much has previously pends on drained been drained from the gearbox. volume Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 32 WARNING 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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 33: 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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 34: 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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 35: Safety During 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 36: Safety During Decommissioning

    Hazards due to the use of brake release devices and/or gravity beneath the manipulator shall be considered. A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 37: Manipulator Description

    2 Manipulator description About IRB 1510 IRB 1510 is a 6-axis industrial robot, designed specifically for manufacturing industries that use flexible robot-based automation. The robot has an open structure that is specially adapted for flexible use, and can communicate extensively with external systems.
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  • Page 39: Installation And Commissioning

    Safety on page 15 before performing any installation work. Note Always connect the IRB 1510 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 40: Unpacking

    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 41: Technical Data

    The actual mounting angle must always be configured in the system parameters, otherwise the performance and lifetime is affected. See Setting the system parameters for a suspended or tilted robot on page Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 42 1850 ±900 N 1850 ±2350 N Torque xy ± 1550 Nm ± 3900 Nm Torque z ± 390 Nm ± 1200 Nm Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 43 Maximum ambient temperature +55° C Maximum ambient temperature (less than 24 hrs) +75° C Maximum ambient humidity 95% at constant temperature (gaseous only) Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 44 The table shows the available protection types of the robot, with the corresponding protection class. Protection type Protection class Manipulator, protection type Standard IP40 According to IEC 60529. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 45: Working Range

    494.4 1500 xx1100000306 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 46 (restricted 1073.2 -482.8 +150º -100º working range) pos4 (unrestric- 636.2 -192.3 +150º -180º ted working range) pos5 -163.1 366.8 +150º +80º Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 47: Turning Radius

    Minimum turning radius of axis 1 Working range Axis IRB 1510ID - 4/1.5 Note Axis 1 +170º to -170º Axis 2 +150º to -90º Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 48 Default value. +288 to -288 revolutions Maximum value. The default working range for axis 6 can be extended by changing parameter values in the software. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 49: Risk Of Tipping/Stability

    The robot might be positioned in a different position at delivery, due to actual configurations and options (for example DressPack). WARNING The robot will be mechanically unstable if not properly secured to the foundation. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 50: 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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 51: On-Site Installation

    Equipment Art. no. Note Overhead crane Lifting capacity: 1,000 kg. Roundsling Length: 2 m. Quantity: 2 pcs. Lifting capacity: 1,000 kg. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 52 All lifting accessories used must be sized ac- cordingly! WARNING Personnel must not, under any circumstances, be present under the suspended load! Raise the overhead crane to lift the robot. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 53: Lifting And Turning A Suspended Mounted Robot

    Special tools on page 304. Any additional equipment required is specified in the instruction for the lifting accessory. Contact ABB for more information. Illustration xx1100000382 Product manual - IRB 1510 3HAC087870-001 Revision: B ©...

  • Page 54: Manually Releasing The Brakes

    The brake will function again as soon as the button is released. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 55 • 0V on pin 12 • 24V on pin 11 Push the brake release button to release the holding brakes, according to the previous procedure. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 56: Orienting And Securing The Robot

    Attachment bolts, specification Attachment bolts 4 pcs M16 x 45 Washers 30 x 17 x 3 Quality Tightening torque 200 Nm Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 57 Attachment point, front (no guide sleeve) Manipulator base Screw M16x120 Plain washer Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 58 3 Installation and commissioning 3.3.4 Orienting and securing the robot Continued Guide sleeve Isolator Nut M16 Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 59: Setting The System Parameters For A Suspended Or Tilted Robot

    The Gravity Beta is a positive rotation direction around the y-axis in the base coordinate system. The value is set in radians. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 60 B is the mounting angle in radians. Example of position Mounting angle (A°) Gravity Beta Floor mounted 0° 0.000000 (Default) Suspended mounting 180° 3.141593 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 61 3.3.5 Setting the system parameters for a suspended or tilted robot Continued Examples of mounting angles tilted around the Y axis (Gravity Beta) xx1100000373 Suspended mounting, mounting angle 180º Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 62 90° (Wall) 1.570796 -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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 63 Mounting angles and values on page 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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 64: 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 listed in References on page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 65: Fitting Equipment On The Robot (Robot Dimensions)

    3.3.7 Fitting equipment on the robot (robot dimensions) Robot dimensions The figure shows the dimension of the robot. 222.5 (63) xx1100000295 Minimum turning radius R=307 mm Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 66 The attachment holes are shown in the figures in this section. xx1100000302 Figure 3.2: Overview of attachment holes and dimensions Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 67 3 Installation and commissioning 3.3.7 Fitting equipment on the robot (robot dimensions) Continued xx1100000303 Figure 3.3: Detailed illustrations of attachment holes on the robot Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 68 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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 69: Restricting The Working Range

    This section describes how to install hardware that restricts 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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 70: Installation Of Additional Mechanical Stops On Axis 3

    Mechanical stop, axis 3 Spare parts on page 307. Technical reference manual - System Art. no. is specified in Refer- parameters ences on page Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 71 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 72: Electrical Connections

    Robot cable, signals Transfers resolver data from R1.SMB and power supply to the serial measurement board. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 73 Bending radius for static floor cables The minimum bending radius is 10 times the cable diameter for static floor cables. xx1600002016 Diameter Diameter x10 Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 74: 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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 75: Test Run After Installation, Maintenance, Or Repair

    Verify the application in the operating mode manual reduced speed. Collision risks CAUTION When programming the movements of the robot, always identify potential collision risks before initiating motion. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
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  • Page 77: Maintenance

    Note If the IRB 1510 is connected to power, always make sure that the IRB 1510 is connected to protective earth and a residual current device (RCD) before starting any maintenance work.

  • Page 78: Maintenance Schedule And Expected Component Life

    40000 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 79: Maintenance Schedule

    The following table specifies the required maintenance activities and intervals. Maintenance activity Equipment Interval Cleaning Robot Cleaning the IRB 1510 on page 133 Inspection Oil level in axis-1 gearbox Every 12 months. Inspection Oil level in axis-2 gearbox Every 12 months.
  • Page 80 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime can be extended with a battery shutdown service routine. See the operating manual for the robot controller for instructions. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 81: Expected Component Life

    The life expectancy is based on a test cycle that for every axis goes from the calibration position to minimum angle, to maximum angle and back to the calibration position. Deviations from this test cycle will result in differences in expected life! Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 82: Inspection Activities

    Other tools and procedures may be required. These procedures include references to the See references to these procedures in the tools required. step-by-step instructions below. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 83 How to fill oil is described in section: • Changing the oil, axis 1 gearbox on page 111 Refit the oil plug, inspection. Tightening torque: • 10 Nm Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 84 How to fill oil is described in section: • Changing the oil, axis 1 gearbox on page 111 Refit the oil plug. Tightening torque: • 10 Nm Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 85: Inspecting The Oil Level, Axis 2 Gearbox

    Other tools and procedures may be required. These procedures include references to the See references to these procedures in the tools required. step-by-step instructions below. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 86: Inspecting Oil Level, Axis 2 Gearbox

    Before refitting the oil plug in the gearbox, always replace the oil plug sealing washer with a new one. If not there is a risk of leakage. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 87: Inspecting The Oil Level, Axis 3 Gearbox

    Other tools and procedures may be required. These procedures include references to the See references to these procedures in the tools required. step-by-step instructions below. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 88 Add oil if required. How to fill oil is described in section: • Changing the oil, axis-3 gearbox on page 120 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 89 4 Maintenance 4.3.3 Inspecting the oil level, axis 3 gearbox Continued Action Note Refit the oil plug. Tightening torque: • 10 Nm Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 90: Inspecting The Oil Level, Axis 4 Gearbox

    Action Note WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 91 Measure the oil level at the oil plug hole. Required oil level: • 35 mm ± 3 mm Add oil if required. Refit the oil plug, filling. Tightening torque: • 3 Nm Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 92: Inspecting The Oil Level, Axis 5 Gearbox

    Action Note WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 93 30 mm ± 3 mm below the lower edge of the oil plug hole. Add oil if required. Refit the oil plug, filling. Tightening torque: • 3 Nm Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 94: Inspecting The Oil Level, Axis 5-6 Gearbox

    Action Note WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 95 How to fill oil is described in section • Changing the oil in axis 5-6 gear- box, IRB 1510ID on page 125 Refit the oil plug, filling. Tightening torque: • 3 Nm Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 96: Inspecting The Cable Harness

    Hole in lower arm Bracket, lower arm Cable straps steel (One not visible here) Bracket, frame Cable strap plastic, lower arm Bracket, armhouse Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 97 These procedures include references to the See references to these procedures in the tools required. step-by-step instructions below. Circuit diagram See Circuit diagram - IRB 1510. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 98 Replace the cable harness if wear, cracks or How to replace the cable harness is de- damage is detected. scribed in Repair on page 135. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 99: Inspecting Information Labels

    Oil quantity label Instruction plate - Lifting of robot Required equipment Equipment Spare part number Note Labels Spare parts on page 307. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 100 Check all labels. See the figure in Location of information labels on page Replace any missing or damaged labels. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 101: Inspecting The Mechanical Stop Pin, Axis 1

    These procedures include may be required. See refer- references to the tools re- ences to these procedures in quired. the step-by-step instructions below. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 102 Note If the mechanical stop pin has been deformed or damaged, it must be replaced. Check that the mechanical stop pin is prop- erly attached. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 103: Inspecting, Additional Mechanical Stops

    Location of additional mechanical stops Additional mechanical stops are provided for axes 3 and 4. xx1100000351 Additional mechanical stop, axis 3 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 104 Check additional stops on axes 3 and 4 for damage. Location of additional mechanical stops on page 103. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 105 104. Correct attachment screws: • Axis 3: M6 x 40, quality 12.9 (2 pcs) • Axis 4: M6 x 8, quality 8.8 (3 pcs) Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 106: Inspecting Dampers

    4.3.11 Inspecting dampers Location of dampers The figure shows the location of all dampers to be inspected. xx1100000356 Dampers, axis 2 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 107 Spare part no. Note Damper Spare parts on page 307. Standard toolkit Content is defined in section Standard tools on page 303. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 108 Check all dampers for existing impressions larger than 2-3 mm. Check attachment screws for deformation. If any damage is detected the damper must be replaced. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 109: Replacement Activities

    Business Portal, www.abb.com/myABB. Location of gearboxes The figure shows the location of the gearboxes. xx1100000336 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 110 Includes pump with outlet pipe. Use the suggested dispenser or a similar one: • Orion OriCan article number 22590 (pneumatic) Nipple for quick connect fitting, with o-ring Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 111: Changing The Oil, Axis 1 Gearbox

    The axis 1 gearbox is located between the frame and base of the robot. The oil plug is shown in the figure. xx1100000339 Oil plug for filling Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 112 Standard tools on page 303. Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 113 Cut the straps that hold the oil draining hose fastened inside the robot base. Pull out the oil draining hose so that it reaches the oil collecting vessel. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 114 Refit the base cover. Refit the centering piece to the push button unit. Refit the push button guard to the base. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 115: Filling Oil, Axis 1 Gearbox

    How to inspect the oil level is de- scribed in Inspecting the oil level, axis- 1 gearbox on page Refit the oil plug. Tightening torque: 10 Nm. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 116: Changing The Oil, Axis-2 Gearbox

    Type and amount of oil in gearboxes on page 109. Oil collecting vessel The capacity of the vessel must be sufficient to take the complete amount of oil. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 117 Drain the gearbox oil using an oil collecting vessel. Note Draining is time-consuming. Elapsed time varies depending on the temperature of the oil. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 118 Open oil plug, filling. See the figure in: • Location of oil plugs on page 116 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 119 Before refitting the oil plug in the gearbox, always replace the oil plug sealing washer with a new one. If not there is a risk of leakage. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 120: Changing The Oil, Axis-3 Gearbox

    The axis-3 gearbox is located in the upper arm rotational center. Oil plugs are shown in the figure. xx1100000341 Oil plug, gearbox xx1100000342 Oil plug, armhouse Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 121 Type of lubrication in gearboxes on page 109 Funnel xx1200000862 Standard toolkit Content is defined in section Standard tools on page 303. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 122 WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 123 • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 124 How to inspect oil is described in section: • Inspecting the oil level, axis 3 gearbox on page 87 Refit the oil plug. Tightening torque: 10 Nm Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 125: Changing The Oil In Axis 5-6 Gearbox, Irb 1510Id

    Standard tools on page 303. Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 126 The figure shows IRB 1600 but the upper arm ing robot. position is the same for the IRB 1510. • axis 4: - 90º, to a position where the oil plug (A) is faced down- wards.
  • Page 127 Position the robot as shown in the figure The figure shows IRB 1600 but the upper to the right: arm position is the same for the IRB 1510. • axis 4: + 90º, to a position where the oil plug (A) is faced upwards.

  • Page 128: Replacing The Battery Pack

    See the operating manual for the robot controller for instructions. WARNING Hazards related to batteries on page Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 129 The battery pack for the measurement system is located inside the base of the robot, as shown in the figure below. xx2300001176 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 130 307. Standard toolkit Content is defined in section Standard tools on page 303. Circuit diagram See Circuit diagram - IRB 1510. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 131 Close the velcro strap around the battery pack. Valid for battery pack with 3-pole battery contact. Secure the battery with a cable strap. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 132 Refit the base cover to the robot. Location of battery pack on page 129. Update the revolution counters. Detailed in section Updating revolution counters on page 283.. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 133: Cleaning Activities

    General To secure high uptime it is important that the IRB 1510 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 1510.
  • Page 134 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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 135: 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 1510, report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit.

  • Page 136: General Procedures

    Spray any suspected leak areas with the leak detec- tion spray. Bubbles indicate a leak. When the leak has been localized, take the necessary measures to correct the leak. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 137: Mounting Instructions For Bearings

    Make sure the bearing is properly aligned as this will directly affect the durab- ility of the bearing. Greasing of bearings Note This instruction is not valid for solid oil bearings. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 138 Grooved ball bearings must be filled with grease from both sides. • Tapered roller bearings and axial needle bearings must be greased in the split condition. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 139: Mounting Instructions For Sealings

    A radial sealing consists of a flexible rubber lip bonded to a rigid metal case. Only one side of the sealing is static with a metal insert. xx2300000433 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 140 A Main lip B Grease C Dust lip Note Ensure that no grease is ap- plied to the red marked surface. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 141 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. Tighten the screws evenly when fastening the flange joint.
  • Page 142 Lubricate the o-ring with grease. Tighten the screws evenly while assembling. Check that the o-ring is not squashed outside the o-ring groove. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 143: Cut The Paint Or Surface On The Robot Before Replacing Parts

    Carefully grind the paint edge that is left on the structure to a smooth surface. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 144: The Brake Release Buttons May Be Jammed After Service Work

    If a button gets jammed in the depressed position, the alignment of the brake release unit must be adjusted so that the buttons can move freely in their tubes. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 145: Complete Manipulator

    Location of cable harness - lower end The lower end of the cable harness is located as shown in the figure. xx1100000313 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 146 • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 147 Remove the armhouse cov- xx1100000349 Disconnect all connectors inside the armhouse. Note Make a note of how the cables are run on the brack- Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 148 R3.MP6 xx0700000105 Unscrew the attachment screws (2 pcs) that holds the bracket of the cable harness to the upper arm. xx1100000327 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 149 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 150 Unscrew the attachment screws (2 pcs) of the brack- et that holds the cable har- ness inside the frame. xx1100000323 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 151 Replacing motors on axis 1 and 2 on page 232. axes 1 and 2 motors and disconnect all connectors - R2.MP1, R2.FB1, R2.MP2 and R2.FB2, Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 152 This is done in order to be able to refit the push buttons correctly later. xx1100000314 Remove the base cover. xx1100000315 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 153 SMB and push button Replacing the push button unit on page 225. units. Unscrew the two connectors on the plate for connector. xx1100000317 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 154 Replacing the serial measurement unit on page 218. to SMB and push button Replacing the push button unit on page 225. units. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 155 (2 + 2 pcs). xx1100000321 Refit all cable clamps and straps securing the cable harness to the fastening plate. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 156 CAUTION Be careful not to damage the cable harness in the process. The space is cramp. xx1100000316 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 157 Continued Action Note Secure the plate for con- nector with its attachment screws (4 pcs). xx1100000329 Refit the base cover. xx1100000315 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 158 (2 + 2 pcs) in the lower arm and secure the cable harness. xx1100000326 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 159 Fit the other of the two covers with its attachment screws. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 160 Location of cable harness - lower end on ness is placed correctly in page 145. the base and frame. Fit the cover on the frame. xx1100000322 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 161 Secure the cable harness to the armhouse by fitting the bracket with its attach- ment screws (4 pcs). xx1100000328 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 162 (2 pcs). xx1100000327 Reconnect the connectors Replacing motors on axes 3 and 4 on page 242. to motors axes 3 and 4. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 163 Calibration is described in a separate calibration manual enclosed with the calibration tools. General calibration information is included in section Cal- ibration information on page 277. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 164 Make sure all safety re- quirements are met when performing the first test run. See Test run after in- stallation, maintenance, or repair on page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 165: Replacing The Cable Harness - Upper End

    R3.FB4 R3.FB5 R3.FB6 R3.MP3 R3.MP4 R3.MP5 R3.MP6 xx0700000038 Required equipment Equipment Art. no. Note Cable harness Spare parts on page 307. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 166 Remove all extra equipment fitted on the up- per arm and wrist. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 167 Fit two threaded bars (M8) with nuts fitted at the bottom end. Length: 120 mm xx1100000473 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 168 Unscrew the attachment screws (3 pcs) holding the cover with mechanical stop and remove the cover. xx1100000411 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 169 6 motors from the arm tube. Remove the support ring and V-ring from the arm tube and place them temporarily on the cable harness spiral. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 170 Carefully lower the arm tube without causing any damage to the cable harness and put it somewhere safe. Remove the support ring and V-ring. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 171 The cable harness spiral is shown in the figure: xx0700000099 Cover plate Clamp R4.FB5 R4.FB6 R4.MP6 R4.MP5 R3.MP5 R3.MP6 R3.FB5 R3.FB6 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 172 A: Cable strap Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 173 Wrap the connectors with some plastic film and tape in order to protect them from con- tamination. Pull the cable harness carefully out off the armhouse. xx0700000114 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 174 Place the cover and the cable harness spiral into its position. Note Do not remove the cable strap at this point! xx1000001004 A: Cable strap Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 175 Lower the arm tube carefully and let it rest on the nuts. xx1100000474 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 176 3/4 of a revolu- tion. Note Check that the cable harness spiral is fitted correctly. The two cables must not cross each other! Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 177 5-6 cable spiral as possible, to avoid grease to accumulate on the resolver connector. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 178 In order to release the brakes for axis 4 see Manually releasing the brakes on page Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 179 Concluding refitting Action Note Reconnect the connectors in the armhouse. R3.FB3 R3.FB4 R3.FB5 R3.FB6 R3.MP3 R3.MP4 R3.MP5 R3.MP6 xx0700000105 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 180 277. DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 181: Replacing The Complete Arm System

    The complete armsystem is located as shown in the figure. xx1100000438 Required equipment Equipment Art. no. Note Standard toolkit Content is defined in section Standard tools on page 303. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 182 145. CAUTION The robot arm system weighs 55 kg. All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 183 2. xx1100000440 Carefully lift away the complete arm system and put it somewhere safe. xx1100000441 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 184 M8x40 (18 pcs) Refit the cable harness in the lower arm and Replacing the cable harness - lower armhouse. end on page 145. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 185 277. DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 186: Upper And Lower Arm

    Recalibration of robot axis 3-6 is required after replacement of upper arm. Location of the complete upper arm The complete upper arm is located as shown in the figure. xx1100000347 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 187 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot work- ing area. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 188 165. and brackets. Remove the bracket holding the cable har- ness to the armhouse and pull out the cable harness. xx1100000328 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 189 See figure! xx0700000060 The figure shows IRB 1600ID but the way to secure the upper arm with the round- sling is the same on IRB 1510. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B...
  • Page 190 All lifting accessories used must be sized accord- ingly! Attach a roundsling to the upper arm and lift it. Move the upper arm to the mounting position. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 191 Replacing motors on axes 3 and 4 on page 242. Insert the cable harness through the hole and into the armhouse. xx1100000330 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 192 5 on page 249 Replacing the axis 6 motor on page 253. Check the gaskets in the armhouse cover. Re- place if damaged! Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 193 277. DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 194: Replacing The Complete Lower Arm

    Used to clean the mating sur- faces. Locking liquid Loctite 574 Standard toolkit Content is defined in section Standard tools on page 303. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 195: Removing The Lower Arm

    All lifting accessories used must be sized accordingly! Secure the weight of the lower arm with a roundsling in an overhead crane or similar. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 196 Secure the weight of the lower arm with a roundsling in an overhead crane or similar and lift it in position. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 197 277. DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 198: Replacing The Wrist Unit, Irb 1600Id

    Hexagon socket head screw M5x25 Hexagon socket head screw M8x35 Required equipment Equipment Art. No. Note Wrist, ID Spare parts on page 307. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 199 Remove all extra equipment fitted on upper arm and wrist. Remove the plug covering the attachment screw below. xx1100000354 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 200 Remove the VK-Cover. xx1100000394 Gently pull the cables out through the hole for the VK- cover in the armtube. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 201: Refitting The Wrist Unit

    Apply a string or similar to the cable harness and run it out through the hole for the VK cover. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 202 Secure the flexible coupling with the M5x16 Tightening torque 6 Nm screw. xx1100000355 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 203 Operating manual - Calibration Pendulum, enclosed with the calibration tools. General calibration information is included in section Calibration information on page 277. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 204 Note DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 205: Replacing The Damper, Axis 2

    These procedures include may be required. See refer- references to the tools re- ences to these procedures in quired. the step-by-step instructions below. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 206 DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 207: Replacing The Damper, Axis 3

    Note Damper, axis 3 Spare parts on page 307. Standard toolkit Content is defined in section Standard tools on page 303. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 208 DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 209: Replacing The Mechanical Stop Axis 3, Irb 1510Id

    Art. no. Note Mechanical stop Spare parts on page 307. Standard tools Content is defined in section Standard tools on page 303. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 210 A2F (2 pcs) DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 211: Frame And Base

    5.5 Frame and base 5.5.1 Replacing the base Location of the base The location of the base is shown in the figure. xx1100000437 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 212 Lifting robot with roundslings on page CAUTION The IRB 1510 robot weighs 170 kg. All lifting accessories used must be sized accordingly! Secure the weight of the robot with a round- sling in an overhead crane or similar.
  • Page 213 Note The figure shows IRB 4600 but the prin- Lift the robot and put it safely on its side on ciple is the same for IRB 1510. some pallets or similar. Let it rest on the lower arm. See figure! xx0800000352 •...
  • Page 214 Unscrew the attachment screws holding the Keep it in a clean place. It will be refitted base cable protection and remove it. on the new base. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 215 Replace if damaged! xx1100000536 • A: O-ring, 6 pcs (15.5x1.5) • B: O-ring, 1 pc (131x2) Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 216 Refit the oil drain hose to the base. Secure the oil tube with cable straps inside the base. CAUTION The IRB 1510 robot weighs 170 kg. All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B ©...
  • Page 217 277. DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 218: Replacing The Serial Measurement Unit

    Location of serial measurement unit The serial measurement unit is located inside the base of the robot, as shown in the figure. xx1100000332 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 219 Replace if damaged. Standard toolkit Content is defined in section Standard tools on page 303. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 220 Remove the centering piece from the push button unit. xx0600002776 • B: Centering piece Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 221 Disconnect the battery cable by pressing down the upper lip of the R2.G connector to release the lock while pulling the connector upwards. xx1700000993 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 222 219. Make sure the lock on the battery cable con- nector R2.G snaps into place during refitting. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 223 Be careful not to damage any of the components or cable harness in the process! xx1100000316 Secure the plate for connector with its attach- ment screws. xx1100000329 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 224 Update the revolution counters! Detailed in section Updating revolution counters on page 283.. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 225: Replacing The Push Button Unit

    Hexagon nuts, SMB unit (4 pcs). Only the outer ones are used. Required equipment Equipment Article number Note Brake release board/Push 3HAC064944-001 DSQC1054 button unit Gasket, base cover 3HAC022047-001 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 226 Remove the push button guard from the base. The push button guard must be removed to ensure a correct refitting of the push button unit. xx1100000314 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 227 Unscrew the nuts securing the push button unit to the SMB unit. xx1100000345 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 228 The unit is sensitive to ESD. Before handling the unit read the safety information in section The unit is sensitive to ESD on page Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 229 Eliminate all risks of contact between screened cables and the brake release board. Check the gasket of the base cover. Replace it if damaged. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 230 Before continuing any service work, follow the safety procedure in section The brake release buttons may be jammed after service work on page 144! Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 231 283.. DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 232: Replacing Motors On Axis 1 And 2 ............................................................... Replacing Motors On Axes 3 And

    Replacing motor on axis 5 on page 249. How to replace the motor on axis 6 see section Replacing the axis 6 motor on page 253. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 233 Motor axis 5 (inside upper arm) Motor axis 6 (inside upper arm) Required equipment Equipment Art. no. Note Motor Spare parts on page 307. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 234 The figure shows the IRB 4600 but the prin- ciple is the same for IRB 1510. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B...
  • Page 235 2! When releasing the holding brakes of the motor, the lower arm will be movable and may fall down! xx0700000060 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 236 A: Axis 1 motor • B: Axis 2 motor Disconnect the connectors inside. Unscrew the attachment screws that holds the motor plate. xx1100000376 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 237 Use a 300 mm extension for bits 1/2". xx1100000378 Only applicable to the axis 2 motor! Fit two guide pins in opposite holes. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 238 Fit two guide pins in opposite holes. Make sure the o-ring on the circumference Replace the o-ring if damaged! of the motor is seated properly. xx1100000380 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 239 A: Axis 1 motor • B: Axis 2 motor Carefully insert the motor cables through the connection box of the motor. xx1100000377 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 240 Only applicable to the axis 2 motor! Changing the oil, axis-2 gearbox on page 116. Refill the axis 2 gearbox with oil. Refit the motor cover. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 241 277. DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 242 Replacing the axis 6 motor on page 253. Location of motors on axes 3 and 4 The motors are located as shown in the figure. xx1100000282 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 243 The table specifies if the oil needs to be drained from the gearboxes. Note These recommendations are valid if the method how to position the robot described above, is followed. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 244 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot work- ing area. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 245 Remove the motor by lifting it carefully straight out, making sure the motor pinion is not damaged while moving it away from the gear. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 246 Make sure the o-ring on the circumference of the motor is seated properly. Replace if damaged! xx1100000479 Lubricate the o-ring with grease. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 247 Only applicable to the axis 3 motor! Changing the oil, axis-3 gearbox on page 120. Refill the axis 3 gearbox with oil. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 248 277. DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 249: Replacing Motor On Axis

    Replacing the axis 6 motor on page 253. Location of the axis 5 motor The motors are located as shown in the figure. xx1100000282 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 250 Removing the axis 5 motor Use this procedure to remove the axis 5 motor. Action Note Jog the robot to the recommended position. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 251 Calibration is described in a separate calibration manual enclosed with the cal- ibration tools. General calibration information is included in section Calibration information on page 277. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 252 Note DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 253: Replacing The Axis 6 Motor

    Replacing the axis 6 motor on page 253. Location of the axis 6 motor The motors are located as shown in the figure. xx1100000282 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 254 Releasing the brakes Connect the 24 VDC power supply for brake release to R1.MP. Connect to pins: Pin 12 Pin 13 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 255 Use this procedure to refit the axis 6 motor. Preparations Action Note Wipe clean all assembly surfaces. Make sure that the pinion is not damaged or scratched. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 256 277. DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 257: Gearboxes

    M8 x 100 Always use guide pins in pairs! Lifting accessories Standard toolkit Content is defined in section Standard tools on page 303. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 258 • air pressure supply to the robot, before entering the robot work- ing area. CAUTION The IRB 1510 robot weighs 170 kg. All lifting accessories used must be sized accordingly! Remove the base. Replacing the base on page 211.
  • Page 259 257. holes. xx1100000450 Always use guide pins in pairs! Unscrew the remaining attachment screws securing the gearbox. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 260 Remove the gearbox carefully in order not to damage the motor pinion. xx1100000452 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 261 CAUTION Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 262 277. DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 263: Replacing The Axis 2 Gearbox

    These procedures include may be required. See refer- references to the tools re- ences to these procedures in quired. the step-by-step instructions below. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 264 Replacing the cable harness - lower frame. end on page 145. Remove the complete arm system. Replacing the complete arm system on page 181. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 265 Unscrew the remaining attachment screws securing the gearbox. xx1100000456 If needed use the threaded holes on the gearbox and press out the gearbox. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 266 Use this procedure to refit the axis 2 gearbox. Action Note Wipe all contact surfaces clean on gearbox and robot. Check the cable protection. xx1100000459 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 267 Tightening torque: 17 Nm. screws. M6x40 (16 pcs) Remove the guide pins and fit the two remain- Tightening torque: 17 Nm. ing attachments screws. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 268 277. DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 269: Replacing The Axis 3 Gearbox

    These procedures include may be required. See refer- references to the tools re- ences to these procedures in quired. the step-by-step instructions below. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 270 Remove two of the attachment screws and fit two guide pins in opposite holes. xx1100000463 Always use guide pins in pairs. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 271 Use this procedure to refit the axis 3 gearbox. Action Note Wipe clean all mating surfaces on lower arm and frame with isopropanol. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 272 Continued Action Note Check the protection ring. xx1100000459 Check the o-ring. Replace if damaged! xx1100000458 Put some grease on the o-ring. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 273 Place the gearbox on the guide pins and slide it in position. Secure the gearbox with its attachment screws. xx1100000464 Tightening torque: 14 Nm. M6x40 (16 pcs) Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 274 277. DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 275: Service Work On Axes 4, 5 And 6 Gearboxes

    5 and 6: the complete wrist unit is to be replaced. This procedure is detailed in section Replacing the wrist unit, IRB 1600ID on page 198. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 276 This page is intentionally left blank...

  • Page 277: Calibration Information

    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 278: Calibration Methods

    Wrist optimization will update standard calib- ration data for axes 4 and 5. Brief description of calibration methods Calibration Pendulum method Calibration Pendulum is a standard calibration method for calibration of some ABB robots. Two different routines are available for the Calibration Pendulum method: •...
  • Page 279 The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including the Operating manual - Calibration Pendulum, which describes the method and the different routines further. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 280: Synchronization Marks And Synchronization Position For Axes

    Synchronization marks, IRB 1510 xx1100000363 Figure 6.1: Calibration marks (from bottom left to top right): Axis 1, axis 4, axis 5 and axis 6. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 281 6 Calibration information 6.3 Synchronization marks and synchronization position for axes Continued xx1100000364 Figure 6.2: Calibration marks (from top to bottom): Axis 3 and axis 2. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 282: Calibration Movement Directions For All Axes

    Note! The graphic shows an IRB 7600. The positive direction is the same for all 6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in the opposite direction! xx0200000089 Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 283: Updating Revolution Counters

    When all axes are positioned, update the Step 2 - Updating the revolution counter revolution counter. with the FlexPendant on page 284. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 284 All mechanical units connected to the system are shown with their calibration status. Tap the mechanical unit in question. xx1500000943 Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 285 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 288. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 286: 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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 287 WARNING Robot moves automatically when pressing Calibrate. 6 Wrist optimization is finished. 7 Redefine / verify TCP for all tools. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 288: Checking The Synchronization Position

    This may be done: • Using a MoveAbsJ instruction with argument zero on all axes. • Using the Jogging window on the FlexPendant. Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 289: Checking The Synchronization Position On Irc5 Robots

    If they do not, up- ization position for axes on page 280 date the revolution counters. Updating revolution counters on page 283. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 290 This page is intentionally left blank...

  • Page 291: Decommissioning

    See also Environmental information on page 292. Transportation Prepare the robot or parts before transport, this to avoid hazards. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 292: Environmental Information

    7.2 Environmental information 7.2 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 293 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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 294: Scrapping Of Robot

    • A used robot does not have the same performance as on delivery. Springs, brakes, bearings, and other parts might be worn or broken. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 295: Reference Information

    8.1 Introduction 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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 296: Applicable Standards

    Arc welding equipment - Part 1: Welding power sources IEC 60974-10:2014 Arc welding equipment - Part 10: EMC requirements ISO 14644-1:2015 Classification of air cleanliness Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 297 Degrees of protection provided by enclosures (IP code) Only valid for arc welding robots. Replaces IEC 61000-6-4 for arc welding robots. Only robots with protection Clean Room. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 298: Unit Conversion

    1 kg 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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 299: 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 300 Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm) Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric- ated ated Continues on next page Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 301 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 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 302: 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 303: Standard Tools

    Socket head cap no: 12, socket 1/2" bit L 20 mm Socket head cap no: 14, socket 1/2" bit L 20 mm 100 mm extension, 1/2" square drive Small cutting plier T-handle with ball head Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 304: Special Tools

    3HAC041422-001 Additional equipment to the Calibration Pendulum tool set, required for calibration of axis Includes calibration tool block, parallel pins and a pro- tection screw. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.

  • Page 305: Lifting Accessories And Lifting Instructions

    The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting accessories. The instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 306 This page is intentionally left blank...

  • Page 307: 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 1510 3HAC087870-001 Revision: B...
  • Page 308 This page is intentionally left blank...
  • Page 309 30 scales, 280 HRA, 26 calibration scales, 280 humidity CalibWare, 278 operation, 44 carbon dioxide extinguisher, 27 storage, 43 cast iron disposal, 292 Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 310 19 axis 3, 120 test run, 75 operating conditions, 44 safety devices, 27 orienting, robot, 56 safety hazard original spare parts, 15 hydraulic system, 28 Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 311 Wrist Optimization sync marks, 280 overview of method, 286 system integrator requirements, 26 system parameter Gravity Alpha, 60 zero position Gravity Beta, 59 checking, 288 Product manual - IRB 1510 3HAC087870-001 Revision: B © Copyright 2023-2024 ABB. All rights reserved.
  • Page 314 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 2023-2024 ABB. All rights reserved. Specifications subject to change without notice.

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