ABB IRB 120 User manual

ROBOTICS
Product manual
IRB 120

Trace back information:
Workspace R17-2 version a11
Checked in 2017-09-20
Skribenta version 5.1.011

Product manual
IRB 120 - 3/0.6
IRB 120T - 3/0.6
IRC5
Document ID: 3HAC035728-001
Revision: N
© Copyright 2009-2017 ABB. All rights reserved.

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, damages 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 2009-2017 ABB. All rights reserved.
ABB AB, Robotics
Robotics and Motion
Se-721 68 Västerås
Sweden

Table of contents
9Overview of this manual ...................................................................................................................
14Product documentation, IRC5 ..........................................................................................................
16How to read the product manual ......................................................................................................
171 Safety
171.1 Introduction to safety information ......................................................................... 181.2 General safety information .................................................................................. 181.2.1 Introduction to general safety information .................................................... 191.2.2 Safety in the robot system ........................................................................ 211.2.3 Protective stop and emergency stop ........................................................... 221.2.4 Safety risks ............................................................................................ 221.2.4.1 Safety risks during installation and service work on manipulators ......... 251.2.4.2 CAUTION - Hot parts may cause burns! ........................................... 261.2.4.3 Safety risks related to tools/work pieces .......................................... 271.2.4.4 Safety risks related to pneumatic/hydraulic systems .......................... 281.2.4.5 Safety risks during operational disturbances ..................................... 291.2.4.6 Risks associated with live electric parts ........................................... 311.2.5 Safety actions ......................................................................................... 311.2.5.1 Safety fence dimensions ............................................................... 321.2.5.2 Fire extinguishing ........................................................................ 331.2.5.3 Emergency release of the robot arm ............................................... 341.2.5.4 Brake testing .............................................................................. 351.2.5.5 Risk of disabling function "Reduced speed 250 mm/s" ........................ 361.2.5.6 Enabling device and hold-to-run functionality .................................... 371.2.5.7 Work inside the working range of the robot ....................................... 381.3 Safety signals and symbols ................................................................................. 381.3.1 Safety signals in the manual ...................................................................... 401.3.2 Safety symbols on product labels ............................................................... 461.4 Safety related instructions .................................................................................. 461.4.1 DANGER - Moving robots are potentially lethal! ............................................ 471.4.2 DANGER - First test run may cause injury or damage! ................................... 481.4.3 DANGER - Make sure that the main power has been switched off! .................... 501.4.4 WARNING - The unit is sensitive to ESD! ..................................................... 521.4.5 WARNING - Safety risks during handling of batteries ..................................... 531.4.6 WARNING - Safety risks during work with gearbox lubricants (oil or grease) ......
552 Installation and commissioning
552.1 Introduction ...................................................................................................... 562.2 Unpacking ....................................................................................................... 562.2.1 Pre-installation procedure ......................................................................... 602.2.2 Working range and type of motion .............................................................. 622.2.3 Risk of tipping/stability ............................................................................. 632.3 On-site installation ............................................................................................ 632.3.1 Lifting the robot with roundslings ............................................................... 662.3.2 Manually releasing the brakes ................................................................... 702.3.3 Orienting and securing the robot ............................................................... 722.3.4 Fitting equipment on robot ........................................................................ 752.3.5 Setting the system parameters for a suspended or tilted robot ......................... 802.3.6 Loads fitted to the robot, stopping time and braking distances ......................... 812.4 Restricting the working range .............................................................................. 812.4.1 Axes with restricted working range ............................................................. 822.4.2 Mechanically restricting the working range ................................................... 842.5 Making robot ready for operation .......................................................................... 842.5.1 Additional installation procedure, Clean Room .............................................. 852.6 Electrical connections ........................................................................................ 852.6.1 Robot cabling and connection points ..........................................................
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Table of contents

872.6.2 Customer connections on the robot ............................................................ 892.7 Start of robot in cold environments ......................................................................
913 Maintenance
913.1 Introduction ...................................................................................................... 923.2 Maintenance schedule ....................................................................................... 923.2.1 Specification of maintenance intervals ........................................................ 933.2.2 Maintenance schedule ............................................................................. 953.3 Inspection activities ........................................................................................... 953.3.1 Inspecting the robot cabling ..................................................................... 963.3.2 Inspecting mechanical stops .................................................................... 993.3.3 Inspecting dampers ................................................................................. 1013.3.4 Inspecting timing belts ............................................................................ 1053.3.5 Inspecting plastic covers .......................................................................... 1073.4 Replacement/changing activities .......................................................................... 1073.4.1 Type of lubrication in gearboxes ................................................................ 1093.4.2 Replacing the battery pack ........................................................................ 1123.5 Cleaning activities ............................................................................................. 1123.5.1 Cleaning the IRB 120 ...............................................................................
1154 Repair
1154.1 Introduction ...................................................................................................... 1164.2 General procedures ........................................................................................... 1164.2.1 Mounting instructions for seals .................................................................. 1184.2.2 Replacing parts on the robot ..................................................................... 1204.3 Cable harness .................................................................................................. 1204.3.1 Removing the cable harness ..................................................................... 1344.3.2 Refitting the cable harness ........................................................................ 1484.3.3 Replacing the Encoder Interface board ........................................................ 1514.4 Plastic covers ................................................................................................... 1514.4.1 Replacing plastic covers ........................................................................... 1554.5 Upper arm ....................................................................................................... 1554.5.1 Replacing the upper arm .......................................................................... 1644.6 Lower arm ....................................................................................................... 1644.6.1 Replacing the lower arm ........................................................................... 1694.7 Motors and motors with gearboxes ....................................................................... 1694.7.1 Replacing axis-1 motor with gearbox .......................................................... 1904.7.2 Replacing axis-2 motor with gearbox .......................................................... 2024.7.3 Replacing axis-3 motor with gearbox .......................................................... 2104.7.4 Replacing motor axis 4, with gearbox .......................................................... 2114.7.5 Replacing motor axis 5 ............................................................................. 2174.7.6 Replacing motor axis 6 ............................................................................. 2184.8 Gearboxes ....................................................................................................... 2184.8.1 Replacing gearbox axis 1 .......................................................................... 2194.8.2 Replacing gearbox axis 2 .......................................................................... 2204.8.3 Replacing gearbox axis 3 .......................................................................... 2214.8.4 Replacing gearbox axis 4 .......................................................................... 2224.8.5 Replacing gearbox axis 5 .......................................................................... 2234.8.6 Replacing gearbox axis 6 ..........................................................................
2255 Calibration
2255.1 Introduction to calibration ................................................................................... 2255.1.1 Introduction and calibration terminology ...................................................... 2265.1.2 Calibration methods ................................................................................. 2275.1.3 When to calibrate ................................................................................... 2285.2 Synchronization marks and axis movement directions ............................................. 2285.2.1 Synchronization marks and synchronization position for axes ......................... 2305.2.2 Calibration movement directions for all axes ................................................
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2315.3 Updating revolution counters ............................................................................... 2355.4 Calibrating with Axis Calibration method ............................................................... 2355.4.1 Description of Axis Calibration .................................................................. 2375.4.2 Axis Calibration - Running the calibration procedure ...................................... 2425.5 Calibrating with manual calibration method ............................................................ 2485.6 Verifying the calibration ...................................................................................... 2495.7 Checking the synchronization position ..................................................................
2516 Decommissioning
2516.1 Introduction ...................................................................................................... 2526.2 Environmental information .................................................................................. 2536.3 Scrapping of robot .............................................................................................
2557 Reference information
2557.1 Introduction ...................................................................................................... 2567.2 Applicable standards ......................................................................................... 2577.3 Unit conversion ................................................................................................. 2587.4 Screw joints .................................................................................................... 2597.5 Weight specifications ......................................................................................... 2607.6 Standard toolkit ................................................................................................ 2617.7 Special tools .................................................................................................... 2627.8 Lifting equipment and lifting instructions ................................................................
2638 Spare parts
2638.1 Spare part lists and illustrations ...........................................................................
2659 Circuit diagrams
2659.1 Circuit diagrams ................................................................................................
267Index
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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.
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 the robot. Contains general
safety aspects as well as more specific information on how to
avoid personal injuries and damage to the product.
Safety
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
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
Continues on next page
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Overview of this manual

ContentsChapter
Complete spare part list and complete list of robot components,
shown in exploded views.
Spare part / part list
Detailed illustrations of the robot with reference numbers to the
part list.
Exploded views
Reference to the circuit diagram for the robot.Circuit diagram
References
Document IDReference
3HAC035960-001Product specification - IRB 120
3HAC049098-001Product manual, spare parts - IRB 120
3HAC021313-001Product manual - IRC5
IRC5 with main computer DSQC 639.
3HAC047136-001Product manual - IRC5
IRC5 with main computer DSQC1000.
3HAC035738-001Product manual - IRC5 Compact
3HAC027707-001Product manual - IRC5 Panel Mounted Controller
3HAC042927-001Technical reference manual - Lubrication in gearboxes
3HAC050941-001Operating manual - IRC5 with FlexPendant
3HAC027098-001Operating manual - Emergency safety information
Same document num-
ber regardless of lan-
guage.
3HAC031045-001Operating manual - General safety information i
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 additions and/or changes:A • Section "Product documentation, M2004" added.
• Section "How to read the product manual" added.
•Safety chapter- Updated safety signal graphics for levels Danger! and
Warning! See section Safety signals in the manual on page 38.
•Safety chapter - New safety labels on the manipulators, see Safety
symbols on product labels on page 40.
•Safety chapter- Revised terminology: robot replaced with manipulator.
•Safety chapter - Information not applicable to IRB 120 in WARNING
- Safety risks during work with gearbox lubricants (oil or grease) on
page 53 removed.
•Installation chapter- Illustration updated in Risk of tipping/stability
on page 62.
•Installation chapter- Attachment screws added in Lifting the robot
with roundslings on page 63.
•Installation chapter- Value in illustration updated in Orienting and
securing the robot on page 70.
Continues on next page
10 Product manual - IRB 120
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Overview of this manual
Continued