ABB CRB 15000 User manual

ROBOTICS
Product manual
CRB 15000

Trace back information:
Workspace 22A version a16
Checked in 2022-03-11
Skribenta version 5.4.005

Product manual
CRB 15000
OmniCore
Document ID: 3HAC077389-001
Revision: E
© Copyright 20212022 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 20212022 ABB. All rights reserved.
Specifications subject to change without notice.

Table of contents
9Overview of this manual ...................................................................................................................
12Product documentation ....................................................................................................................
14How to read the product manual ......................................................................................................
151 Safety
151.1 Safety information .............................................................................................
151.1.1 Limitation of liability .................................................................................
161.1.2 Requirements on personnel ......................................................................
171.2 Safety signals and symbols .................................................................................
171.2.1 Safety signals in the manual ......................................................................
191.2.2 Safety symbols on manipulator labels .........................................................
251.3 Robot stopping functions ....................................................................................
261.4 Safety during installation and commissioning .........................................................
281.5 Safety during operation ......................................................................................
291.6 Safety during maintenance and repair ...................................................................
291.6.1 Safety during maintenance and repair .........................................................
301.6.2 Emergency release of the robot axes ..........................................................
311.6.3 Brake testing ..........................................................................................
321.7 Safety during troubleshooting ..............................................................................
331.8 Safety during decommissioning ...........................................................................
352 Manipulator description
352.1 About CRB 15000 ..............................................................................................
362.2 Technical data ..................................................................................................
402.3 Safety data .......................................................................................................
422.4 Working range .................................................................................................
442.5 The unit is sensitive to ESD .................................................................................
453 Installation and commissioning
453.1 Introduction to installation and commissioning .......................................................
463.2 Unpacking .......................................................................................................
463.2.1 Pre-installation procedure .........................................................................
473.2.2 Risk of tipping/stability .............................................................................
483.3 On-site installation ............................................................................................
483.3.1 Brief installation procedure .......................................................................
493.3.2 Lifting the robot ......................................................................................
493.3.2.1 Orienting and securing the robot ...................................................
523.3.3 Manually releasing the brakes ...................................................................
553.3.4 Installation of brake release tool .................................................................
573.3.5 Setting the system parameters for an inverted or a tilted robot .........................
603.3.6 Loads fitted to the robot, stopping time and braking distances .........................
613.3.7 Fitting equipment on the robot (robot dimensions) .........................................
633.3.8 Test run after installation, maintenance, or repair ..........................................
643.3.9 Installation of laser scanner ......................................................................
693.4 Electrical connections ........................................................................................
693.4.1 Robot cabling and connection points ..........................................................
713.4.2 Customer connections on the manipulator ...................................................
743.5 Arm-side interface .............................................................................................
743.5.1 Configuring the arm-side interface ..............................................................
783.5.2 Using the arm-side interface ......................................................................
793.5.3 Working closely with the robot in a safe way ................................................
823.6 Configuring the software .....................................................................................
823.6.1 Information about software for the CRB 15000 ..............................................
843.6.2 Lead-through ..........................................................................................
863.6.3 The SafeMove configurator app on FlexPendant ...........................................
973.6.4 Guidelines for transient and quasi-static contact, CRB 15000 ..........................
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1003.6.5 Information about Collaborative Speed Control add-in ....................................
1013.6.6 Speed control .........................................................................................
101
3.6.6.1 Configuration of one PROFINET-base laser scanner (RobotWare 7.5 or
earlier) .......................................................................................
107
3.6.6.2 Configuration of one PROFINET-base laser scanner (RobotWare 7.6 or
later) .........................................................................................
111
3.6.6.3 Configuration of two PROFINET-base laser scanners (RobotWare 7.6 or
later) .........................................................................................
115
3.6.6.4 Configuration of one SafetyIO-base laser scanner (RobotWare 7.6 or
later) .........................................................................................
119
3.6.6.5 Configuration of two SafetyIO-base laser scanners (RobotWare 7.6 or
later) .........................................................................................
1233.6.6.6 Speed control strategies ...............................................................
1263.6.7 Use cases of safety configurations .............................................................
1314 Maintenance
1314.1 Introduction ......................................................................................................
1324.2 Maintenance schedule and expected component life ...............................................
1324.2.1 Specification of maintenance intervals ........................................................
1334.2.2 Maintenance schedule .............................................................................
1344.3 Inspection activities ...........................................................................................
1344.3.1 Inspecting the robot .................................................................................
1374.3.2 Inspecting the cable harness ....................................................................
1404.4 Cleaning activities .............................................................................................
1404.4.1 Cleaning the CRB 15000 ...........................................................................
1414.5 Testing activities ...............................................................................................
1414.5.1 Testing the brake release functionality ........................................................
1424.5.2 Running the Cyclic Brake Check routine ......................................................
1434.5.3 Testing the functionality of the joint electronics .............................................
1455 Repair
1455.1 Introduction ......................................................................................................
1465.2 General procedures ...........................................................................................
1465.2.1 Mounting instructions for sealings ..............................................................
1495.3 Cable harness ..................................................................................................
1495.3.1 Replacing the base cabling ......................................................................
1595.3.2 Replacing the axis-1 cabling .....................................................................
1935.3.3 Replacing the axis-2 cabling .....................................................................
2215.3.4 Replacing the axis-3 cabling .....................................................................
2475.3.5 Replacing the axis-4 cabling .....................................................................
2775.3.6 Replacing the axis-5 cabling .....................................................................
3175.3.7 Replacing the axis-6 cabling .....................................................................
3395.3.8 Replacing the axis-5 to axis-6 transition cabling ...........................................
3405.3.9 Replacing the brake release unit ...............................................................
3575.4 Upper and lower arms ........................................................................................
3575.4.1 Replacing the lower arm ..........................................................................
3725.4.2 Replacing the housing .............................................................................
3995.4.3 Replacing the tubular ..............................................................................
4265.4.4 Replacing the wrist housing ......................................................................
4615.4.5 Replacing the tool flange and axis-6 inner flange ..........................................
4695.4.6 Replacing the arm-side interface ...............................................................
4735.5 Swing and base ................................................................................................
4735.5.1 Replacing the base .................................................................................
5085.5.2 Replacing the swing ................................................................................
5325.6 Joint units ........................................................................................................
5325.6.1 Replacing the axis-1 joint unit ...................................................................
5705.6.2 Replacing the axis-2 joint unit ...................................................................
5985.6.3 Replacing the axis-3 joint unit ...................................................................
6245.6.4 Replacing the axis-4 joint unit ...................................................................
6 Product manual - CRB 15000
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© Copyright 20212022 ABB. All rights reserved.
Table of contents

6545.6.5 Replacing the axis-5 joint unit and the axis-5 to axis-6 transition cabling ...........
6965.6.6 Replacing the axis-6 joint unit ...................................................................
7196 Calibration
7196.1 Calibration method and when to calibrate .............................................................
7206.2 Calibrating the robot .........................................................................................
7226.3 Jogging directions ............................................................................................
7237 Troubleshooting
7237.1 Introduction to troubleshooting ............................................................................
7257.2 Mechanical noise or dissonance ..........................................................................
7277.3 Manipulator collapses on power down ...................................................................
7287.4 Brake release tool does not work .........................................................................
7307.5 Communication failure between PROFINET-based laser scanner, PLC, and controller ....
7317.6 Communication failure between PLC and controller .................................................
7337.7 Communication failure between scalable I/O device and controller .............................
7347.8 Movement in Safe area not in full speed or at zero speed .........................................
7357.9 Unable to remove or change installed options in Collaborative Speed Control add-in .....
7367.10 RED flashing status on Scalable I/O device and unable to move the robot ...................
7377.11 Unexpected robot movement when starting the program in Protecting Area .................
7398 Decommissioning
7398.1 Environmental information ..................................................................................
7418.2 Scrapping of robot .............................................................................................
7439 Reference information
7439.1 Introduction ......................................................................................................
7449.2 Applicable standards .........................................................................................
7469.3 Unit conversion .................................................................................................
7479.4 Screw joints ....................................................................................................
7489.5 Weight specifications .........................................................................................
7499.6 Standard toolkit ................................................................................................
7509.7 Special tools ....................................................................................................
753Index
Product manual - CRB 15000 7
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© Copyright 20212022 ABB. All rights reserved.
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Overview of this manual
About this manual
This manual contains instructions for:
• mechanical and electrical installation of the CRB 15000
• maintenance of the CRB 15000
• mechanical and electrical repair of the CRB 15000
The robot described in this manual has the following protection types:
•Standard
Product manual scope
The manual covers all variants and designs of the CRB 15000. Some variants and
designs may have been removed from the business offer and are no longer available
for purchase.
Usage
This manual should be used during:
• installation and commissioning, from lifting the product to its work site and
securing it to the foundation, to making it ready for operation
• maintenance work
• repair work
• decommissioning work
Note
It is the responsibility of the integrator to conduct a risk assessment of the final
application.
It is the responsibility of the integrator to provide safety and user guides for the
robot system.
Who should read this manual?
This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
A maintenance/repair/installation craftsman working with an ABB robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
• be trained to respond to emergencies or abnormal situations.
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Overview of this manual

References
Documentation referred to in the manual, is listed in the table below.
Document IDDocument name
3HAC079469-001Product manual, spare parts - CRB 15000
3HAC077390-001Product specification - CRB 15000
3HAC060860-001Product manual - OmniCore C30
3HAC074304-003Circuit diagram - CRB 15000
3HAC065037-001Operating manual - Integrator's guide OmniCore
3HAC065041-001Technical reference manual - System parameters
3HAC066559-001Application manual - Functional safety and SafeMove
3HAC083267-001Application manual - Force Control Standard for GoFa
3HAC066553-001Technical reference manual - Event logs for RobotWare 7
Tip
All documents can be found via myABB Business Portal, www.abb.com/myABB.
Revisions
DescriptionRevision
First edition.A
Published in release 21B. The following updates are made in this revision:
• Added procedure for refitting the axis-4 cover in the replacement
procedure for the axis-5 joint unit.
• Changed the tightening torque for the axis-4 and axis-5 covers.
•Added procedure for refitting the swing in the replacement proced-
ure for the base.
•Added step for removing and refitting cable bracket in replacement
procedure for the lower arm.
• Corrected safety data.
• Updated information about SafeMove for the CRB 15000.
• Updated information about the arm-side interface, see Working
closely with the robot in a safe way on page 79.
•Added information about how to calibrate the robot, see Calibration
on page 719.
• Updated spare part number for axis-3 joint unit.
B
Published in release 21C. The following updates are made in this revision:
• Updated information related to the safety data, and the brake
closing time is updated.
• Updated how to initiate the calibration service routine.
•Updated information about Cyclic Brake Check in the maintenance
section.
• Updated article number for brake release tool.
• Added information about rotating connector at the manipulator
base, see Connectors at the base on page 71.
C
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Continued