ABB Robotics IRB 1520 User manual

ROBOTICS
Product manual
IRB 1520

Trace back information:
Workspace 20B version a12
Checked in 2020-05-28
Skribenta version 5.3.033

Product manual
IRB 1520ID - 4/1.5
IRC5
Document ID: 3HAC043435-001
Revision: L
© Copyright 2012-2020 ABB. All rights reserved.
Specifications subject to change without notice.

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damage to persons
or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.
© Copyright 2012-2020 ABB. All rights reserved.
Specifications subject to change without notice.

Table of contents
9Overview of this manual ...................................................................................................................
13Product documentation ....................................................................................................................
15How to read the product manual ......................................................................................................
171 Safety
171.1 Safety information .............................................................................................
171.1.1 Limitation of liability .................................................................................
181.1.2 Requirements on personnel ......................................................................
191.2 Safety signals and symbols .................................................................................
191.2.1 Safety signals in the manual ......................................................................
211.2.2 Safety symbols on manipulator labels .........................................................
271.3 Robot stopping functions ....................................................................................
281.4 Installation and commissioning ............................................................................
311.5 Operation ........................................................................................................
311.5.1 Unexpected movement of robot arm ...........................................................
321.6 Maintenance and repair ......................................................................................
321.6.1 Maintenance and repair ............................................................................
351.6.2 Emergency release of the robot axes ..........................................................
361.6.3 Brake testing ..........................................................................................
371.7 Troubleshooting ................................................................................................
381.8 Decommissioning ..............................................................................................
392 Installation and commissioning
392.1 Introduction to installation and commissioning .......................................................
402.2 Unpacking .......................................................................................................
402.2.1 Pre-installation procedure .........................................................................
442.2.2 Working range ........................................................................................
482.2.3 Risk of tipping/stability .............................................................................
492.2.4 The unit is sensitive to ESD .......................................................................
502.3 On-site installation ............................................................................................
502.3.1 Lifting robot with roundslings ....................................................................
522.3.2 Lifting and turning a suspended mounted robot ............................................
532.3.3 Manually releasing the brakes ...................................................................
552.3.4 Orienting and securing the robot ................................................................
582.3.5 Setting the system parameters for a suspended or tilted robot .........................
632.3.6 Loads fitted to the robot, stopping time and braking distances .........................
642.3.7 Fitting equipment on the robot (robot dimensions) .........................................
682.4 Restricting the working range ..............................................................................
682.4.1 Axes with restricted working range .............................................................
692.4.2 Installation of additional mechanical stops on axis 3 ......................................
712.5 Electrical connections ........................................................................................
712.5.1 Robot cabling and connection points ..........................................................
732.6 Start of robot in cold environments ......................................................................
753 Maintenance
753.1 Introduction ......................................................................................................
763.2 Maintenance schedule and expected component life ...............................................
763.2.1 Specification of maintenance intervals ........................................................
773.2.2 Maintenance schedule .............................................................................
793.2.3 Expected component life ..........................................................................
803.3 Inspection activities ...........................................................................................
803.3.1 Inspecting the oil level, axis-1 gearbox ........................................................
833.3.2 Inspecting the oil level, axis 2 gearbox ........................................................
853.3.3 Inspecting the oil level, axis 3 gearbox ........................................................
883.3.4 Inspecting the oil level, axis 4 gearbox ........................................................
903.3.5 Inspecting the oil level, axis 5 gearbox ........................................................
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923.3.6 Inspecting the oil level, axis 5-6 gearbox ......................................................
943.3.7 Inspecting the cable harness .....................................................................
963.3.8 Inspecting information labels .....................................................................
983.3.9 Inspecting the mechanical stop pin, axis 1 ...................................................
1003.3.10 Inspecting, additional mechanical stops ......................................................
1033.3.11 Inspecting dampers .................................................................................
1063.4 Replacement activities .......................................................................................
1063.4.1 Type of lubrication in gearboxes ................................................................
1083.4.2 Changing the oil, axis 1 gearbox ................................................................
1133.4.3 Changing the oil, axis-2 gearbox ................................................................
1173.4.4 Changing the oil, axis-3 gearbox ................................................................
1223.4.5 Changing the oil in axes 5 and axis 5 and 6 gearboxes, IRB 1520ID ..................
1253.4.6 Replacing the battery pack ........................................................................
1303.5 Cleaning activities .............................................................................................
1303.5.1 Cleaning the IRB 1520 ..............................................................................
1334 Repair
1334.1 Introduction ......................................................................................................
1344.2 General procedures ...........................................................................................
1344.2.1 Performing a leak-down test ......................................................................
1354.2.2 Mounting instructions for bearings .............................................................
1374.2.3 Mounting instructions for sealings ..............................................................
1404.2.4 Cut the paint or surface on the robot before replacing parts ............................
1414.2.5 The brake release buttons may be jammed after service work .........................
1424.3 Complete manipulator ........................................................................................
1424.3.1 Replacing the cable harness - lower end ......................................................
1624.3.2 Replacing the cable harness - upper end .....................................................
1784.3.3 Replacing the complete arm system ...........................................................
1834.4 Upper and lower arm .........................................................................................
1834.4.1 Replacing the complete upper arm, IRB 1520ID ............................................
1914.4.2 Replacing the complete lower arm ..............................................................
1954.4.3 Replacing the wrist unit, IRB 1600ID ...........................................................
2014.4.4 Replacing the damper, axis 2 .....................................................................
2034.4.5 Replacing the damper, axis 3 .....................................................................
2054.4.6 Replacing the mechanical stop axis 3, IRB 1520ID .........................................
2074.5 Frame and base ................................................................................................
2074.5.1 Replacing the base ..................................................................................
2144.5.2 Replacing the serial measurement unit ........................................................
2224.5.3 Replacing the push button unit ..................................................................
2294.6 Motors ............................................................................................................
2294.6.1 Replacing motors on axis 1 and 2 ...............................................................
2394.6.2 Replacing motors on axes 3 and 4 ..............................................................
2464.6.3 Replacing motor on axis 5 .........................................................................
2504.6.4 Replacing the axis 6 motor ........................................................................
2544.7 Gearboxes .......................................................................................................
2544.7.1 Replacing the axis 1 gearbox .....................................................................
2604.7.2 Replacing the axis 2 gearbox .....................................................................
2664.7.3 Replacing the axis 3 gearbox .....................................................................
2724.7.4 Service work on axes 4, 5 and 6 gearboxes ..................................................
2735 Calibration information
2735.1 When to calibrate .............................................................................................
2745.2 Calibration methods ...........................................................................................
2765.3 Synchronization marks and synchronization position for axes ...................................
2785.4 Calibration movement directions for all axes ..........................................................
2795.5 Updating revolution counters ...............................................................................
2825.6 Calibrating with Calibration Pendulum method .......................................................
2835.7 Calibrating with Wrist Optimization method ...........................................................
2845.8 Checking the synchronization position ..................................................................
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2856 Decommissioning
2856.1 Introduction ......................................................................................................
2866.2 Environmental information ..................................................................................
2876.3 Scrapping of robot .............................................................................................
2897 Reference information
2897.1 Introduction ......................................................................................................
2907.2 Applicable standards .........................................................................................
2927.3 Unit conversion .................................................................................................
2937.4 Screw joints ....................................................................................................
2967.5 Weight specifications .........................................................................................
2977.6 Standard tools ..................................................................................................
2987.7 Special tools ....................................................................................................
2997.8 Lifting accessories and lifting instructions ..............................................................
3018 Spare parts
3018.1 Spare part lists and illustrations ...........................................................................
3039 Circuit diagram
3039.1 Circuit diagrams ................................................................................................
305Index
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Overview of this manual
About this manual
This manual contains instructions for:
• mechanical and electrical installation of the robot
• maintenance of the robot
• mechanical and electrical repair of the robot.
Usage
This manual should be used during:
• installation, from lifting the robot to its work site and securing it to the
foundation, to making it ready for operation
• maintenance work
• repair work and calibration.
Who should read this manual?
This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
Maintenance/repair/installation personnel working with an ABB Robot must:
• be trained by 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 1520. Some variants
and designs may have been removed from the business offer and are no longer
available for purchase.
Organization of chapters
The manual is organized in the following chapters:
ContentsChapter
Safety information that must be read through before performing
any installation or service work on robot. Contains general safety
aspects as well as more specific information on how to avoid
personal injuries and damage to the product.
Safety, service
Required information about lifting and installation of the robot.Installation and commis-
sioning
Step-by-step procedures that describe how to perform mainten-
ance of the robot. Based on a maintenance schedule that may
be used to plan periodical maintenance.
Maintenance
Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.
Repair
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Overview of this manual

ContentsChapter
Procedures that do not require specific calibration equipment.
General information about calibration.
Calibration information
Environmental information about the robot and its components.Decommissioning
Useful information when performing installation, maintenance
or repair work. Includes lists of necessary tools, additional doc-
uments, safety standards, etc.
Reference information
Reference to the spare part list for the robot.Spare parts and exploded
views
Reference to the circuit diagram for the robot.Circuit diagram
References
Documentation referred to in the manual, is listed in the table below.
Document IDDocument name
3HAC043436-001Product manual, spare parts - IRB 1520
3HAC043438-001Product manual - Arc welding equipment for IRB 1520ID
3HAC039498-007Circuit diagram - IRB 1520
3HAC043437-001Product specification - IRB 1520
3HAC031045-001Safety manual for robot - Manipulator and IRC5 or OmniCore con-
troller i
3HAC021313-001Product manual - IRC5
IRC5 with main computer DSQC 639.
3HAC047136-001Product manual - IRC5
IRC5 with main computer DSQC1000.
3HAC050941-001Operating manual - IRC5 with FlexPendant
3HAC050944-001Operating manual - Service Information System
3HAC16578-1Operating manual - Calibration Pendulum
3HAC051016-001Application manual - Additional axes and stand alone controller
3HAC030421-001Application manual - CalibWare Field
3HAC042927-001Technical reference manual - Lubrication in gearboxes
3HAC050948-001Technical reference manual - System parameters
iThis manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Revisions
DescriptionRevision
First edition.-
This revision includes the following updates:
• All data about type of lubrication in gearboxes is moved from the
manual to a separate lubrication manual, see Type and amount
of oil in gearboxes on page 106.
• Changed pin number for 24V connection, see Manually releasing
the brakes on page 53.
• A new SMB unit and battery is introduced, with longer battery
lifetime.
A
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Continued

DescriptionRevision
This revision includes the following updates:
•Added information about risks when scrapping a decommissioned
robot, see Scrapping of robot on page 287.
• The working range for axis 5 is corrected.
• Note about the placement of connectors in ID-upper arm added
in Repair instructions. See Replacing the cable harness - upper
end on page 162 and Replacing the wrist unit, IRB 1600ID on
page 195.
• Note about handling the wrist during replacement added. See
Replacing the wrist unit, IRB 1600ID on page 195.
B
This revision includes the following updates:
• Minor corrections.
C
This revision includes the following updates:
• Updated section Setting the system parameters for a suspended
or tilted robot on page 58.
D
Published in release R17.2. The following updates are made in this revi-
sion:
• Information about coupled axes in Updating revolution counters
on page 279.
• Caution about removing metal residues added in sections about
SMB boards.
• Information about minimum resonance frequency added.
• Bending radius for static floor cables added.
• Updated list of applicable standards.
•Added text regarding overhaul in section specification of mainten-
ance intervals.
• Section Start of robot in cold environments on page 73 added.
• Updated information regarding replacement of brake release
board.
• Updated information regarding disconnecting and reconnecting
battery cable to serial measurement board.
E
Published in release R18.1. The following updates are made in this revi-
sion:
• Added sections in General procedures on page 134.
• Safety restructured.
• Updated spare parts number brake release board/push button
(was DSQC563, is DSQC1050)
• Information about myABB Business Portal added.
F
Published in release R18.2. The following updates are done in this revi-
sion:
• Updated spare parts number brake release board/push button
from 3HAC065022-001 to 3HAC064944-001.
G
Published in release R18.2. The following updates are done in this revi-
sion:
• Updated reference.
H
Published in release 19B. The following updates are made in this revision:
• New touch up color Graphite White available. See Cut the paint
or surface on the robot before replacing parts on page 140.
• New article numbers for manipulator cables in section Robot
cabling and connection points on page 71.
J
Published in release 19C. The following updates are done in this revision:
• Updated tightening torques of axis-3, -4, -5, 5-6 oil plugs.
K
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Continued

DescriptionRevision
Published in release 20B. The following updates are made in this revision:
•Clarified and added information in mounting instructions for rotat-
ing sealings, see Mounting instructions for sealings on page 137.
•Added information about Wrist Optimization and Wrist Optimization
in calibration chapter.
• Replaced article number and name of grease, previously
3HAB3537-1.
L
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Continued

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.
All documents can be found via myABB Business Portal, www.myportal.abb.com.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
•Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
•Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.
Technical reference manuals
The technical reference manuals describe reference information for robotics
products, for example lubrication, the RAPID language, and system parameters.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
•What is included (for example cables, I/O boards, RAPID instructions, system
parameters, software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
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Product documentation

Operating manuals
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.
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Product documentation
Continued

How to read the product manual
Reading the procedures
The procedures contain references to figures, tools, material, and so on. The
references are read as described below.
References to figures
The procedures often include references to components or attachment points
located on the manipulator/controller. The components or attachment points are
marked with italic text in the procedures and completed with a reference to the
figure where the current component or attachment point is shown.
The denomination in the procedure for the component or attachment point
corresponds to the denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a
procedure.
Note/IllustrationAction
Shown in the figure Location of
gearbox on page xx.
Remove the rear attachment screws, gearbox.8.
References to required equipment
The procedures often include references to equipment (spare parts, tools, etc.)
required for the different actions in the procedure. The equipment is marked with
italic text in the procedures and completed with a reference to the section where
the equipment is listed with further information, that is article number and
dimensions.
The designation in the procedure for the component or attachment point
corresponds to the designation in the referenced list.
The table below shows an example of a reference to a list of required equipment
from a step in a procedure.
Note/IllustrationAction
Art. no. is specified in Required
equipment on page xx.
Fit a new sealing, axis 2 to the gearbox.3.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 17.
Illustrations
The robot is illustrated with general figures that does not take painting or protection
type in consideration.
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.
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1 Safety
1.1 Safety information
1.1.1 Limitation of liability
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.
In particular, liability cannot be accepted if injury or damage has been caused for
any of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed.
• Non-authorized design modifications of the robot.
• Repairs on the robot and its spare parts carried out by in-experienced or
non-qualified personnel.
• Foreign objects.
• Force majeure.
Spare parts and equipment
ABB supplies original spare parts and equipment which have been tested and
approved. 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.
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1 Safety
1.1.1 Limitation of liability

1.1.2 Requirements on personnel
General
Only personnel with appropriate training are allowed to install, maintain, service,
repair, and use the robot. This includes electrical, mechanical, hydraulics,
pneumatics, and other hazards identified in the risk assessment.
Persons who are under the influence of alcohol, drugs or any other intoxicating
substances are not allowed to install, maintain, service, repair, or use the robot.
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 product manual.
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1 Safety
1.1.2 Requirements on personnel

1.2 Safety signals and symbols
1.2.1 Safety signals in the manual
Introduction to safety signals
This section specifies all safety signals used in the user manuals. Each signal
consists of:
• A caption specifying the hazard level (DANGER, WARNING, or CAUTION)
and the type of hazard.
• Instruction about how to reduce the hazard to an acceptable level.
• A brief description of remaining hazards, if not adequately reduced.
Hazard levels
The table below defines the captions specifying the hazard levels used throughout
this manual.
For more information, see standard ISO 13849.
SignificanceDesignationSymbol
Signal word used to indicate an imminently hazard-
ous situation which, if not avoided, will result in ser-
ious injury.
DANGER
Signal word used to indicate a potentially hazardous
situation which, if not avoided, could result in serious
injury.
WARNING
Signal word used to indicate a potentially hazardous
situation related to electrical hazards which, if not
avoided, could result in serious injury.
ELECTRICAL
SHOCK
Signal word used to indicate a potentially hazardous
situation which, if not avoided, could result in slight
injury.
CAUTION
Signal word used to indicate a potentially hazardous
situation which, if not avoided, could result in severe
damage to the product.
ELECTROSTATIC
DISCHARGE (ESD)
Signal word used to indicate important facts and
conditions.
NOTE
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1 Safety
1.2.1 Safety signals in the manual

SignificanceDesignationSymbol
Signal word used to indicate where to find additional
information or how to do an operation in an easier
way.
TIP
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1 Safety
1.2.1 Safety signals in the manual
Continued