ABB IRB 7600 - 500/2.55 User manual

ABB Robotics
Product manual
IRB 7600

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

Product manual
IRB 7600 - 500/2.55
IRB 7600 - 500/2.3
IRB 7600 - 400/2.55
IRB 7600 - 340/2.8
IRB 7600 - 325/3.1
IRB 7600 - 150/3.5
M2000, M2000A, M2004
Document ID: 3HAC022033-001
Revision: M
© Copyright 2007-2013 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 2007-2013 ABB. All rights reserved.
ABB AB
Robotics Products
SE-721 68 Västerås
Sweden

Table of contents
9Overview of this manual ...................................................................................................................
15Product documentation, M2000/M2000A ........................................................................................
16Product documentation, M2004 .......................................................................................................
18How to read the product manual ......................................................................................................
191 Safety
191.1 Introduction to safety information ......................................................................... 201.2 General safety information .................................................................................. 201.2.1 Introduction to general safety information .................................................... 211.2.2 Safety in the manipulator system ............................................................... 221.2.3 Safety risks ............................................................................................ 221.2.3.1 Safety risks during installation and service work on manipulators ......... 251.2.3.2 CAUTION - Hot parts may cause burns! ........................................... 261.2.3.3 Safety risks related to tools/work pieces .......................................... 271.2.3.4 Safety risks related to pneumatic/hydraulic systems .......................... 281.2.3.5 Safety risks during operational disturbances ..................................... 291.2.3.6 Risks associated with live electric parts ........................................... 311.2.4 Safety actions ......................................................................................... 311.2.4.1 Safety fence dimensions ............................................................... 321.2.4.2 Fire extinguishing ........................................................................ 331.2.4.3 Emergency release of the manipulator’s arm .................................... 341.2.4.4 Brake testing .............................................................................. 351.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" ........................ 361.2.4.6 Safe use of the FlexPendant .......................................................... 371.2.4.7 Work inside the manipulator's working range ................................... 381.2.4.8 Signal lamp (optional) ................................................................... 391.2.5 Safety stops ........................................................................................... 391.2.5.1 What is an emergency stop? .......................................................... 411.3 Safety related instructions .................................................................................. 411.3.1 Safety signals in the manual ...................................................................... 431.3.2 Safety symbols on manipulator labels ......................................................... 481.3.3 DANGER - Moving manipulators are potentially lethal! ................................... 491.3.4 DANGER - First test run may cause injury or damage! ................................... 501.3.5 WARNING - The brake release buttons may be jammed after service work ........ 511.3.6 DANGER - Make sure that the main power has been switched off! .................... 521.3.7 WARNING - The unit is sensitive to ESD! ..................................................... 531.3.8 WARNING - Safety risks during handling of batteries ..................................... 541.3.9 WARNING - Safety risks during work with gearbox lubricants (oil or grease) ......
572 Installation and commissioning
572.1 Introduction ...................................................................................................... 582.2 Robot transportation precautions ......................................................................... 632.3 Securing the robot ............................................................................................ 652.4 Unpacking ....................................................................................................... 652.4.1 Pre-installation procedure ......................................................................... 682.4.2 Working range, IRB 7600 - 150/3.5 .............................................................. 692.4.3 Working range, IRB 7600 - 340/2.8 .............................................................. 702.4.4 Working range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55 ................................ 712.4.5 Working range, IRB 7600 - 500/2.3 .............................................................. 722.4.6 Risk of tipping/stability ............................................................................. 732.5 On-site installation ............................................................................................ 732.5.1 Lifting robot with fork lift ........................................................................... 812.5.2 Lifting robot with lifting slings .................................................................... 832.5.3 Lifting robot with roundslings .................................................................... 852.5.4 Manually releasing the brakes ...................................................................
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882.5.5 Manually releasing the brakes, external brake release unit .............................. 922.5.6 Lifting the base plate ............................................................................... 932.5.7 Securing the base plate ............................................................................ 972.5.8 Orienting and securing the robot ................................................................ 1002.5.9 Fitting equipment on robot ....................................................................... 1052.5.10 Installation of base spacers (option) ........................................................... 1072.5.11 Extended working range, axis 1 (option 561-1) ............................................. 1082.5.12 Installation of cooling fan for motors, axes 1-3 (option) ................................... 1172.5.13 Installation of Foundry Plus Cable guard (option no. 908-1) ............................. 1182.5.14 Loads .................................................................................................... 1192.5.15 Installation of signal lamp (option) .............................................................. 1202.6 Restricting the working range .............................................................................. 1202.6.1 Introduction ............................................................................................ 1212.6.2 Mechanically restricting the working range of axis 1 ...................................... 1232.6.3 Mechanically restricting the working range of axis 2 ...................................... 1252.6.4 Mechanically restricting the working range of axis 3 ...................................... 1282.6.5 Installation of position switches (option) ...................................................... 1402.7 Electrical connections ........................................................................................ 1402.7.1 Robot cabling and connection points ..........................................................
1453 Maintenance
1453.1 Introduction ...................................................................................................... 1463.2 Maintenance schedule and expected life ............................................................... 1463.2.1 Specification of maintenance intervals ........................................................ 1473.2.2 Maintenance schedule ............................................................................. 1513.2.3 Expected component life ......................................................................... 1523.3 Inspection activities .......................................................................................... 1523.3.1 Inspection, oil level gearbox axis 1 ............................................................. 1553.3.2 Inspection, oil level gearbox axis 2 ............................................................. 1583.3.3 Inspection, oil level gearbox axis 3 ............................................................. 1603.3.4 Inspection, oil level gearbox axis 4 ............................................................. 1633.3.5 Inspection, oil level, gearbox axis 5 ............................................................ 1663.3.6 Inspection, oil level gearbox axis 6 ............................................................. 1693.3.7 Inspection, balancing device ..................................................................... 1753.3.8 Inspection, cable harness ......................................................................... 1783.3.9 Inspecting, mechanical stop pin, axis 1 ....................................................... 1803.3.10 Inspection, mechanical stop, axes 1, 2 and 3 ............................................... 1823.3.11 Inspection, damper axes 2-5 ...................................................................... 1843.3.12 Inspection, position switch axes 1, 2 and 3 ................................................... 1883.3.13 Inspection, information labels .................................................................... 1913.3.14 Inspection, UL-lamp ................................................................................. 1933.4 Changing/replacement activities .......................................................................... 1933.4.1 Type of lubrication in gearboxes ................................................................ 1953.4.2 Oil change, gearbox axis 1 ........................................................................ 1993.4.3 Changing oil, axis-2 gearbox .................................................................... 2023.4.4 Changing oil, axis-3 gearbox .................................................................... 2053.4.5 Oil change, gearbox, axis 4 ....................................................................... 2083.4.6 Oil change, gearbox, axis 5 ....................................................................... 2113.4.7 Oil change, gearbox axis 6 ........................................................................ 2143.4.8 Replacing the SMB battery ........................................................................ 2193.5 Lubrication activities ......................................................................................... 2193.5.1 Cleaning activities .................................................................................. 2193.5.1.1 Flushing a contaminated gearbox ................................................... 2213.5.1.2 Cleaning, robot ........................................................................... 2233.5.2 Lubrication of spherical roller bearing, balancing device ................................. 2253.6 Service Information System, M2000 ...................................................................... 2253.6.1 Using the SIS system ............................................................................... 2263.6.2 Description of Service Information System (SIS) ........................................... 2293.6.3 SIS system parameters ............................................................................
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2313.6.4 Setting the SIS parameters ....................................................................... 2333.6.5 Reading the SIS output logs ...................................................................... 2343.6.6 Exporting the SIS data .............................................................................
2354 Repair
2354.1 Introduction ...................................................................................................... 2364.2 General procedures ........................................................................................... 2364.2.1 Performing a leak-down test ..................................................................... 2374.2.2 Mounting instructions for bearings ............................................................. 2394.2.3 Mounting instructions for seals .................................................................. 2414.3 Complete robot ................................................................................................. 2414.3.1 Replacement of cable harness, axes 1-4 ..................................................... 2504.3.2 Replacement of cable harness, axes 5-6 ...................................................... 2534.3.3 Replacement of complete arm system ......................................................... 2584.4 Upper and lower arm ......................................................................................... 2584.4.1 Replacing turning disk .............................................................................. 2624.4.2 Replacement of complete wrist unit ............................................................ 2664.4.3 Replacement of complete upper arm ........................................................... 2714.4.4 Replacement of complete lower arm ........................................................... 2794.4.5 Replacement of lower arm shaft ................................................................. 2894.5 Frame and base ................................................................................................ 2894.5.1 Replacing the SMB unit ............................................................................ 2924.5.2 Replacement of brake release unit ............................................................. 2984.5.3 Replacing the balancing device .................................................................. 3064.5.4 Replacement of spherical roller bearing, balancing device .............................. 3114.5.5 Unloading the balancing device using hydraulic press tool .............................. 3154.5.6 Restoring the balancing device using a hydraulic press tool ............................ 3184.6 Motors ............................................................................................................ 3184.6.1 Replacement of motor, axis 1 .................................................................... 3224.6.2 Replacement of motor axis 2 ..................................................................... 3274.6.3 Replacement of motor, axis 3 .................................................................... 3334.6.4 Replacement of motor, axis 4 .................................................................... 3384.6.5 Replacement of motor, axis 5 .................................................................... 3424.6.6 Replacement of motor, axis 6 .................................................................... 3484.7 Gearboxes ....................................................................................................... 3484.7.1 Replacing the axis 1 gearbox ..................................................................... 3584.7.2 Replacement of gearbox, axis 2 ................................................................. 3664.7.3 Replacement of gearbox, axis 3 ................................................................. 3724.7.4 Replacement of gearbox, axis 4 ................................................................. 3774.7.5 Replacement of gearbox, axis 5 ................................................................. 3834.7.6 Replacement of gearbox, axis 6 .................................................................
3875 Calibration information
3875.1 Introduction ..................................................................................................... 3885.2 Calibration methods ........................................................................................... 3905.3 Calibration scale and correct axis position ............................................................. 3915.4 Calibration movement directions for all axes .......................................................... 3925.5 Updating revolution counters ............................................................................... 3965.6 Checking the calibration position ..........................................................................
3996 Decommissioning
3996.1 Environmental information .................................................................................. 4006.2 Decommissioning of balancing device ...................................................................
4037 Reference information
4037.1 Introduction ...................................................................................................... 4047.2 Applicable safety standards ................................................................................ 4067.3 Unit conversion .................................................................................................
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4077.4 Screw joints .................................................................................................... 4107.5 Weight specifications ......................................................................................... 4117.6 Standard tools .................................................................................................. 4127.7 Special tools .................................................................................................... 4157.8 Lifting accessories and lifting instructions ..............................................................
4178 Spare part / part list
4178.1 Introduction ...................................................................................................... 4188.2 Spare parts ...................................................................................................... 4188.2.1 Introduction ............................................................................................ 4198.2.2 Spare part list ......................................................................................... 4228.3 Part list ............................................................................................................ 4228.3.1 Introduction ............................................................................................ 4238.3.2 Rebuilding parts ...................................................................................... 4258.3.3 Part list, overview .................................................................................... 4278.3.4 Mechanical stop axis 1, 3HAC12812-2 ......................................................... 4288.3.5 Base incl frame axis 1, 3HAC12304-1 ..........................................................
429
8.3.6 Axis 3-4, 3HAC13063-1 (IRB 7600 - 150/3.5, - 325/3.1, -340/2.8, -400/2.55,
-500/2.55) .............................................................................................. 4338.3.7 Axis 3-4, 3HAC13063-2 (IRB 7600 - 500/2.3) .................................................
434
8.3.8 Axis 3-4, Foundry, 3HAC13063-4 (IRB 7600 -150/3.5, - 325/3.1, - 340/2.8, - 400/2.55,
- 500/2.55) .............................................................................................. 4358.3.9 Axis 3-4 Foundry, 3HAC13063-5 (IRB 7600 - 500/2.3) ..................................... 4368.3.10 Wrist, 3HAC16628-4 / 3HAC16628-3 ........................................................... 4418.3.11 Material set robot, 3HAC13079-1 ................................................................ 4428.3.12 Material set axis 1-2, 3HAC13077-1 ............................................................ 4468.3.13 Material set balancing device, 3HAC13082-1 ................................................ 4478.3.14 Arm extension set, 956 mm, 3HAC12311-1 (IRB 7600 - 150/3.5) ....................... 4488.3.15 Arm extension set, 250 mm, 3HAC12311-2 (IRB 7600 - 340/2,8) .......................
4499 Exploded views
4499.1 Introduction ..................................................................................................... 4509.2 Base incl. Frame .............................................................................................. 4519.3 Frame-Lower arm 1 ........................................................................................... 4529.4 Frame-Lower arm 2 ........................................................................................... 4549.5 Upper arm ....................................................................................................... 4559.6 Wrist complete .................................................................................................
45710 Circuit diagram
45710.1 About circuit diagrams ....................................................................................... 45910.2 Validity of circuit diagram 3HAC025744-1 .............................................................. 46010.3 Validity of circuit diagram 3HAC13347-1 ................................................................
461Index
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Table of contents

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.
The robot described in this manual has the protection type Standard and Foundry
Plus.
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 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 maintenance
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, tools, etc.
Repair
Procedures that do not require specific calibration equipment.
General information about calibration.
Calibration information
Continues on next page
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Overview of this manual

ContentsChapter
Environmental information about the robot and its components.Decommissioning
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 shown in exploded views.Spare 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
Procedures in this product manual contain references to the following manuals:
NoteDocument IDDocument name
3HAC044350-001Product manual - IRB 7600 Foundry Prime
3HAC023934-001Product specification - IRB 7600
3HAC13491-1Product specification - IRB 7600 M2000/M2000A
3HAC13347-1Circuit diagram - IRB 7600
3HAC025744-001
3HAC021313-001Product manual - IRC5
3HAC021333-001Product manual - S4Cplus M2000
3HAC022419-001Product manual - S4Cplus M2000A
3HAC16590-1Operating manual - IRC5 with FlexPendant
3HAC7793-1User’s guide - S4Cplus (BaseWare OS 4.0)
3HAC16578-1Operating manual - Calibration Pendulum
M20043HAC025709-001Operating manual - Service Information System
M2000/M2000A3HAC022907-001Operating manual - Levelmeter Calibration
3HAC042927-001Technical reference manual - Lubrication in gear-
boxes
3HAC17076-1Technical reference manual - System parameters
M20043HAC021395-001Application manual - Additional axes and stand
alone controller
M20003HAC9299-1Application manual - External axes
Additional document references
Document IDDocument name
3HAC030421-001Application manual - CalibWare Field 5.0
Continues on next page
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Overview of this manual
Continued