ABB IRB 260 User manual

ABB Robotics
Product manual
IRB 260

Trace back information:
Workspace R13-1 version a6
Checked in 2013-03-31
Skribenta version 1184

Product manual
IRB 260
M2004
Document ID: 3HAC026048-001
Revision: E
© Copyright 2006-2013 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.
Additional copies of this manual may be obtained from ABB.
The original language for this publication is English. Any other languages that are
supplied have been translated from English.
© Copyright 2006-2013 ABB. All rights reserved.
ABB AB
Robotics Products
SE-721 68 Västerås
Sweden

Table of contents
9Overview of this manual ...................................................................................................................
12Product documentation, M2004 .......................................................................................................
14How to read the product manual ......................................................................................................
151 Safety
151.1 Introduction to safety information ......................................................................... 161.2 General safety information .................................................................................. 161.2.1 Introduction to general safety information .................................................... 171.2.2 Safety in the manipulator system ............................................................... 181.2.3 Safety risks ............................................................................................ 181.2.3.1 Safety risks during installation and service work on manipulators ......... 211.2.3.2 CAUTION - Hot parts may cause burns! ........................................... 221.2.3.3 Safety risks related to tools/work pieces .......................................... 231.2.3.4 Safety risks related to pneumatic/hydraulic systems .......................... 241.2.3.5 Safety risks during operational disturbances ..................................... 251.2.3.6 Risks associated with live electric parts ........................................... 271.2.4 Safety actions ......................................................................................... 271.2.4.1 Safety fence dimensions ............................................................... 281.2.4.2 Fire extinguishing ........................................................................ 291.2.4.3 Emergency release of the manipulator’s arm .................................... 301.2.4.4 Brake testing .............................................................................. 311.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" ........................ 321.2.4.6 Safe use of the FlexPendant .......................................................... 331.2.4.7 Work inside the manipulator's working range ................................... 341.2.5 Safety stops ........................................................................................... 341.2.5.1 What is an emergency stop? .......................................................... 361.3 Safety related instructions .................................................................................. 361.3.1 Safety signals in the manual ...................................................................... 381.3.2 Safety symbols on manipulator labels ......................................................... 431.3.3 DANGER - Moving manipulators are potentially lethal! ................................... 441.3.4 DANGER - First test run may cause injury or damage! ................................... 451.3.5 DANGER - Make sure that the main power has been switched off! .................... 471.3.6 WARNING - The unit is sensitive to ESD! ..................................................... 491.3.7 WARNING - Safety risks during handling of batteries ..................................... 501.3.8 WARNING - Safety risks during work with gearbox lubricants (oil or grease) ......
532 Installation and commissioning
532.1 Introduction ...................................................................................................... 542.2 Unpacking ....................................................................................................... 542.2.1 Pre-installation procedure ......................................................................... 572.2.2 Working range ........................................................................................ 592.2.3 Risk of tipping/stability ............................................................................. 602.3 On-site installation ............................................................................................ 602.3.1 Lifting of robot ........................................................................................ 642.3.2 Manually releasing the brakes ................................................................... 662.3.3 Orienting and securing the robot ................................................................ 692.3.4 Fitting equipment on the robot and robot dimensions ..................................... 732.3.5 Loads .................................................................................................... 742.3.6 Load diagram ......................................................................................... 752.3.7 Installation of signal lamp (option) .............................................................. 772.4 Restricting the working range .............................................................................. 772.4.1 Introduction ............................................................................................ 782.4.2 Mechanically restricting the working range of axis 1 ...................................... 842.4.3 Installation of position switch, axis 1 ........................................................... 872.4.4 Mechanically restricting the working range of axis 2 ...................................... 902.4.5 Mechanically restricting the working range of axis 3 ......................................
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Table of contents

922.5 Electrical connections ........................................................................................ 922.5.1 Connectors on robot ................................................................................ 932.5.2 Robot cabling and connection points ..........................................................
953 Maintenance
953.1 Introduction ...................................................................................................... 963.2 Maintenance schedule ....................................................................................... 963.2.1 Specification of maintenance intervals ........................................................ 973.2.2 Maintenance schedule ............................................................................. 983.3 Inspection activities ........................................................................................... 983.3.1 Inspection of information labels ................................................................. 1003.4 Changing activities ............................................................................................ 1003.4.1 Type of lubrication in gearboxes ................................................................ 1023.4.2 Oil change, gearbox axis 6 (wrist unit) ......................................................... 1043.4.3 Replacement of SMB battery ..................................................................... 1083.5 Cleaning activities ............................................................................................. 1083.5.1 Cleaning, robot ......................................................................................
1114 Repair
1114.1 Introduction ...................................................................................................... 1124.2 General procedures ........................................................................................... 1124.2.1 Performing a leak-down test ..................................................................... 1134.2.2 Mounting instructions for bearings ............................................................. 1154.2.3 Mounting instructions for seals .................................................................. 1174.3 Complete robot ................................................................................................ 1174.3.1 Replacement of cable unit, axes 1-3 ........................................................... 1234.3.2 Replacement of cable unit, axis 6 ............................................................... 1284.4 Upper arm ....................................................................................................... 1284.4.1 Replacement of shaft and bearings, tilthouse ............................................... 1404.4.2 Replacement of turning disk ...................................................................... 1434.4.3 Replacement of complete upper arm ........................................................... 1504.4.4 Replacement of linkage - upper rod ............................................................ 1534.4.5 Replacing the linkage - lower rod ............................................................... 1574.4.6 Replacement of linkage - link ..................................................................... 1624.5 Lower arm ....................................................................................................... 1624.5.1 Replacement of complete lower arm ........................................................... 1664.5.2 Replacement of parallel bar ....................................................................... 1704.6 Frame and base ............................................................................................... 1704.6.1 Replacement of SMB unit ......................................................................... 1764.6.2 Replacement of brake release unit ............................................................. 1784.6.3 Replacement of parallel arm ...................................................................... 1824.7 Motors ............................................................................................................ 1824.7.1 Replacement of motor, axis 1 .................................................................... 1874.7.2 Replacement of motor, axis 2 .................................................................... 1924.7.3 Replacement of motor, axis 3 .................................................................... 1974.7.4 Replacement of motor, axis 6 .................................................................... 2004.8 Gearboxes ....................................................................................................... 2004.8.1 Replacement of gearbox, axis 1-3 ............................................................... 2034.8.2 Replacement of gearbox, axis 6 .................................................................
2075 Calibration information
2075.1 Introduction ..................................................................................................... 2085.2 Calibration methods ........................................................................................... 2095.3 Calibration scale and correct axis position ............................................................. 2105.4 Calibration movement directions for all axes .......................................................... 2115.5 Updating revolution counters ............................................................................... 2135.6 Checking the calibration position ..........................................................................
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2156 Decommissioning
2156.1 Environmental information ..................................................................................
2177 Reference information
2177.1 Introduction ...................................................................................................... 2187.2 Applicable safety standards ................................................................................ 2207.3 Unit conversion ................................................................................................. 2217.4 Screw joints .................................................................................................... 2247.5 Weight specifications ......................................................................................... 2257.6 Standard tools .................................................................................................. 2267.7 Special tools .................................................................................................... 2367.8 Lifting accessories and lifting instructions ..............................................................
2378 Spare part lists and exploded views
2378.1 Introduction ...................................................................................................... 2388.2 Spare parts - overview ....................................................................................... 2398.3 Spare parts - cover ............................................................................................ 2418.4 Spare parts - robot IRB 260 ................................................................................. 2448.5 Spare parts - axes 1-3 ........................................................................................ 2538.6 Spare parts - upper arm ...................................................................................... 2558.7 Spare parts - tilthouse ........................................................................................ 2578.8 Spare parts - linkage .......................................................................................... 2588.9 Spare parts - material set cabling axis 6 ................................................................
2619 Circuit diagram
2619.1 About circuit diagrams .......................................................................................
263Index
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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.
The manual also contains reference information for all procedures detailed in the
manual.
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.
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.
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 about 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 in the work of planning 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 does not require specific calibration equipment.
General information about calibration.
Calibration information
Environmental information about the robot and its components.Decommissioning
Continues on next page
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Overview of this manual

ContentsChapter
Useful information when performing installation, maintenance
or repair work. Includes lists of necessary tools, additional
documents, safety standards, etc.
Reference information
Complete spare part list and complete list of robot components,
shown in the exploded views.
Spare parts and exploded
views
Reference to the circuit diagram for the robot.Circuit diagram
References
Procedures in this product manual contain references to the following manuals:
Document IDDocument name
3HAC025046-001Product specification - IRB 260
3HAC025611-001Circuit diagram IRB 260
3HAC021313-001Product manual - IRC5
3HAC16590-1Operating manual - IRC5 with FlexPendant
3HAC16578-1Operating manual - Calibration Pendulum
3HAC025709-001Operating manual - Service Information System
3HAC021395-001Application manual - Additional axes and stand alone controller
3HAC042927-001Technical reference manual - Lubrication in gearboxes
3HAC17076-1Technical reference manual - System parameters
3HAC030421-001Application manual - CalibWare Field 5.0
Revisions
DescriptionRevision
First edition-
Changes made in:
• Prerequisites in section Overview
• Oil change in section Maintenance
A
Content updated in chapter/section:
•Maintenance chapter, section Maintenance schedule : Interval for
replacement of battery pack changed.
• Section What is an emergency stop? added to chapter Safety
• The oil Shell Tivela S 150 in gearbox axis 6 has been replaced by
Kyodo Yushi TMO 150.
B
Content updated in chapter/section:
• Decommissioning chapter added.
• Circuit diagrams are not included in this document but delivered
as separate files. See Circuit diagram on page 261.
• List of standards updated, see Applicable safety standards on
page 218.
The chapter Safety updated with:
•Updated safety signal graphics for the levels Danger and Warning,
see Safety signals in the manual on page 36.
• New safety labels on the manipulators, see Safety symbols on
manipulator labels on page 38.
• Revised terminology: robot replaced with manipulator.
C
Continues on next page
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Overview of this manual
Continued