ABB CRB 15000 User manual

ROBOTICS
Product manual
CRB 15000

Trace back information:
Workspace Main version a396
Checked in 2021-03-31
Skribenta version 5.4.005

Product manual
CRB 15000
OmniCore
Document ID: 3HAC077389-001
Revision: A
© Copyright 2021 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 2021 ABB. All rights reserved.
Specifications subject to change without notice.

Table of contents
9Overview of this manual ...................................................................................................................
11Product documentation ....................................................................................................................
13How to read the product manual ......................................................................................................
151 Safety
151.1 Safety information .............................................................................................
151.1.1 Limitation of liability .................................................................................
161.1.2 Safety data .............................................................................................
171.1.3 Requirements on personnel ......................................................................
181.2 Safety signals and symbols .................................................................................
181.2.1 Safety signals in the manual ......................................................................
201.2.2 Safety symbols on manipulator labels .........................................................
261.3 Robot stopping functions ....................................................................................
271.4 Installation and commissioning ............................................................................
291.5 Operation ........................................................................................................
291.5.1 Unexpected movement of robot arm ...........................................................
301.6 Maintenance and repair ......................................................................................
301.6.1 Maintenance and repair ............................................................................
311.6.2 Emergency release of the robot axes ..........................................................
321.6.3 Brake testing ..........................................................................................
331.7 Troubleshooting ................................................................................................
341.8 Decommissioning ..............................................................................................
352 Manipulator description
352.1 About CRB 15000 ..............................................................................................
362.2 Technical data ..................................................................................................
402.3 Working range .................................................................................................
422.4 The unit is sensitive to ESD .................................................................................
433 Installation and commissioning
433.1 Introduction to installation and commissioning .......................................................
443.2 Unpacking .......................................................................................................
443.2.1 Pre-installation procedure .........................................................................
453.2.2 Risk of tipping/stability .............................................................................
463.3 On-site installation ............................................................................................
463.3.1 Brief installation procedure .......................................................................
473.3.2 Lifting the robot ......................................................................................
473.3.2.1 Orienting and securing the robot ...................................................
503.3.3 Manually releasing the brakes ...................................................................
533.3.4 Installation of brake release tool .................................................................
553.3.5 Setting the system parameters for a suspended or a tilted robot ......................
583.3.6 Loads fitted to the robot, stopping time and braking distances .........................
593.3.7 Fitting equipment on the robot (robot dimensions) .........................................
613.3.8 First test run may cause injury or damage ....................................................
623.4 Electrical connections ........................................................................................
623.4.1 Robot cabling and connection points ..........................................................
643.4.2 Customer connections on the manipulator ...................................................
673.5 Arm-side interface .............................................................................................
673.5.1 Configuring the arm-side interface ..............................................................
713.5.2 Using the arm-side interface ......................................................................
723.6 Configuring the software .....................................................................................
723.6.1 Information about RobotWare and CRB 15000 ..............................................
733.6.2 Lead-through ..........................................................................................
753.6.3 CRB 15000 with SafeMove ........................................................................
Product manual - CRB 15000 5
3HAC077389-001 Revision: A
© Copyright 2021 ABB. All rights reserved.
Table of contents

774 Maintenance
774.1 Introduction ......................................................................................................
784.2 Maintenance schedule and expected component life ...............................................
784.2.1 Specification of maintenance intervals ........................................................
794.2.2 Maintenance schedule .............................................................................
804.3 Inspection activities ...........................................................................................
804.3.1 Inspecting the robot .................................................................................
834.3.2 Inspecting the cable harness ....................................................................
864.4 Cleaning activities .............................................................................................
864.4.1 Cleaning the CRB 15000 ...........................................................................
874.5 Testing activities ...............................................................................................
874.5.1 Testing the brake release functionality ........................................................
884.5.2 Testing the functionality of the joint electronics .............................................
895 Repair
895.1 Introduction ......................................................................................................
905.2 General procedures ...........................................................................................
905.2.1 Mounting instructions for sealings ..............................................................
935.3 Cable harness ..................................................................................................
935.3.1 Replacing the base cabling ......................................................................
1035.3.2 Replacing the axis-1 cabling .....................................................................
1375.3.3 Replacing the axis-2 cabling .....................................................................
1545.3.4 Replacing the axis-3 cabling .....................................................................
1725.3.5 Replacing the axis-4 cabling .....................................................................
1935.3.6 Replacing the axis-5 cabling .....................................................................
2125.3.7 Replacing the axis-6 cabling .....................................................................
2275.3.8 Replacing the axis-5 to axis-6 transition cabling ...........................................
2285.3.9 Replacing the brake release unit ...............................................................
2445.4 Upper and lower arms ........................................................................................
2445.4.1 Replacing the lower arm ..........................................................................
2585.4.2 Replacing the housing .............................................................................
2855.4.3 Replacing the tubular ..............................................................................
3125.4.4 Replacing the wrist housing ......................................................................
3505.4.5 Replacing the tool flange and axis-6 inner flange ..........................................
3585.4.6 Replacing the arm-side interface ...............................................................
3625.5 Swing and base ................................................................................................
3625.5.1 Replacing the base .................................................................................
3965.5.2 Replacing the swing ................................................................................
4205.6 Joint units ........................................................................................................
4205.6.1 Replacing the axis-1 joint unit ...................................................................
4585.6.2 Replacing the axis-2 joint unit ...................................................................
4865.6.3 Replacing the axis-3 joint unit ...................................................................
5125.6.4 Replacing the axis-4 joint unit ...................................................................
5425.6.5 Replacing the axis-5 joint unit and the axis-5 to axis-6 transition cabling ...........
5835.6.6 Replacing the axis-6 joint unit ...................................................................
6076 Calibration
6076.1 Calibrating the robot ..........................................................................................
6086.2 Jogging directions .............................................................................................
6097 Troubleshooting
6097.1 Introduction to troubleshooting ............................................................................
6117.2 Mechanical noise or dissonance ..........................................................................
6137.3 Manipulator collapses on power down ...................................................................
6147.4 Brake release tool does not work .........................................................................
6 Product manual - CRB 15000
3HAC077389-001 Revision: A
© Copyright 2021 ABB. All rights reserved.
Table of contents

6158 Decommissioning
6158.1 Environmental information ..................................................................................
6178.2 Scrapping of robot .............................................................................................
6199 Reference information
6199.1 Introduction ......................................................................................................
6209.2 Applicable standards .........................................................................................
6229.3 Unit conversion .................................................................................................
6239.4 Screw joints ....................................................................................................
6249.5 Weight specifications .........................................................................................
6259.6 Standard toolkit ................................................................................................
6269.7 Special tools ....................................................................................................
629Index
Product manual - CRB 15000 7
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© Copyright 2021 ABB. All rights reserved.
Table of contents

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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 hazard and risk analysis of
the final application and to ensure its safety.
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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Product manual - CRB 15000 9
3HAC077389-001 Revision: A
© Copyright 2021 ABB. All rights reserved.
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
Revisions
DescriptionRevision
First edition.A
10 Product manual - CRB 15000
3HAC077389-001 Revision: A
© Copyright 2021 ABB. All rights reserved.
Overview of this manual
Continued