ABB IRB 7600 User manual

ROBOTICS
Product manual
IRB 7600

Trace back information:
Workspace 23D version a13
Checked in 2023-12-07
Skribenta version 5.5.019

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
IRC5, OmniCore
Document ID: 3HAC022033-001
Revision: AH
© Copyright 2007 - 2023 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 2007 - 2023 ABB. All rights reserved.
Specifications subject to change without notice.

Table of contents
9Overview of this manual ...................................................................................................................
17Product documentation, IRC5, OmniCore .......................................................................................
19How to read the product manual ......................................................................................................
211 Safety
211.1 Safety information .............................................................................................
211.1.1 Limitation of liability .................................................................................
221.1.2 Requirements on personnel ......................................................................
231.2 Safety signals and symbols .................................................................................
231.2.1 Safety signals in the manual ......................................................................
251.2.2 Safety symbols on manipulator labels .........................................................
311.3 Robot stopping functions ....................................................................................
321.4 Safety during installation and commissioning .........................................................
351.5 Safety during operation ......................................................................................
361.6 Safety during maintenance and repair ...................................................................
361.6.1 Safety during maintenance and repair .........................................................
391.6.2 Emergency release of the robot axes ..........................................................
401.6.3 Brake testing ..........................................................................................
411.7 Safety during troubleshooting ..............................................................................
421.8 Safety during decommissioning ...........................................................................
432 Installation and commissioning
432.1 Introduction to installation and commissioning .......................................................
442.2 Robot transportation precautions .........................................................................
482.3 Securing the robot with a transport support ...........................................................
502.4 Unpacking .......................................................................................................
502.4.1 Pre-installation procedure .........................................................................
512.4.2 Technical data ........................................................................................
552.4.3 Working range, IRB 7600 - 150/3.5 ..............................................................
562.4.4 Working range, IRB 7600 - 340/2.8 ..............................................................
572.4.5 Working range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55 ................................
582.4.6 Working range, IRB 7600 - 500/2.3 ..............................................................
592.4.7 Risk of tipping/stability .............................................................................
602.4.8 The unit is sensitive to ESD .......................................................................
612.5 On-site installation ............................................................................................
612.5.1 Lifting robot with fork lift ...........................................................................
672.5.2 Lifting robot with lifting accessory (recommended lifting method) .....................
692.5.3 Lifting robot with roundslings ....................................................................
712.5.4 Manually releasing the brakes ...................................................................
732.5.5 Lifting the base plate ................................................................................
742.5.6 Securing the base plate ............................................................................
792.5.7 Orienting and securing the robot ................................................................
822.5.8 Fitting equipment on robot .......................................................................
872.5.9 Installation of base spacers (option) ...........................................................
892.5.10 Installation of cooling fan for motors (option) ................................................
962.5.11 Installation of Foundry Plus Cable guard (option) ..........................................
972.5.12 Loads fitted to the robot, stopping time and braking distances .........................
982.5.13 Safety lamp (option for IRC5) .....................................................................
992.5.14 Extended working range, axis 1 (option) .....................................................
1012.6 Restricting the working range ..............................................................................
1012.6.1 Axes with restricted working range .............................................................
1022.6.2 Mechanically restricting the working range of axis 1 ......................................
1042.6.3 Mechanically restricting the working range of axis 2 ......................................
1062.6.4 Mechanically restricting the working range of axis 3 ......................................
1092.7 Electrical connections ........................................................................................
1092.7.1 Robot cabling and connection points ..........................................................
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© Copyright 2007 - 2023 ABB. All rights reserved.
Table of contents

1132.8 Start of robot in cold environments ......................................................................
1142.9 Test run after installation, maintenance, or repair ....................................................
1153 Maintenance
1153.1 Introduction ......................................................................................................
1163.2 Maintenance schedule and expected life ...............................................................
1163.2.1 Specification of maintenance intervals ........................................................
1173.2.2 Maintenance schedule .............................................................................
1213.2.3 Expected component life .........................................................................
1223.3 Inspection activities ...........................................................................................
1223.3.1 Inspecting the motor seal .........................................................................
1253.3.2 Inspecting the oil level in axis-1 gearbox .....................................................
1283.3.3 Inspecting the oil level in axis-2 gearbox .....................................................
1313.3.4 Inspecting the oil level in axis-3 gearbox .....................................................
1343.3.5 Inspecting the oil level in axis-4 gearbox .....................................................
1373.3.6 Inspecting the oil level in axis-5 gearbox .....................................................
1403.3.7 Inspecting the oil level in axis-6 gearbox .....................................................
1433.3.8 Inspecting the balancing device .................................................................
1493.3.9 Inspecting the cable harness .....................................................................
1523.3.10 Inspecting the axis-1 mechanical stop pin ...................................................
1543.3.11 Inspecting the mechanical stops on axes 1, 2, and 3 ......................................
1563.3.12 Inspecting the damper on axes 2 to 5 ..........................................................
1583.3.13 Inspecting the information labels ................................................................
1603.3.14 Inspecting the UL lamp .............................................................................
1623.4 Changing/replacement activities ..........................................................................
1623.4.1 Type of lubrication in gearboxes ................................................................
1643.4.2 Changing oil, axis-1 gearbox .....................................................................
1683.4.3 Changing oil, axis-2 gearbox .....................................................................
1713.4.4 Changing oil, axis-3 gearbox .....................................................................
1743.4.5 Changing oil, axis-4 gearbox .....................................................................
1773.4.6 Changing oil, axis-5 gearbox .....................................................................
1813.4.7 Changing oil, axis-6 gearbox .....................................................................
1843.4.8 Replacing the SMB battery ........................................................................
1893.5 Lubrication activities ..........................................................................................
1893.5.1 Lubrication of spherical roller bearing, balancing device .................................
1913.6 Cleaning activities .............................................................................................
1913.6.1 Flushing a contaminated gearbox ...............................................................
1933.6.2 Cleaning the IRB 7600 ..............................................................................
1973.7 Service Information System, M2000 ......................................................................
1973.7.1 Using the SIS system ...............................................................................
1983.7.2 Description of Service Information System (SIS) ...........................................
2013.7.3 SIS system parameters ............................................................................
2023.7.4 Setting the SIS parameters .......................................................................
2033.7.5 Reading the SIS output logs ......................................................................
2043.7.6 Exporting the SIS data .............................................................................
2054 Repair
2054.1 Introduction ......................................................................................................
2064.2 General procedures ...........................................................................................
2064.2.1 Performing a leak-down test ......................................................................
2074.2.2 Mounting instructions for bearings .............................................................
2094.2.3 Mounting instructions for sealings ..............................................................
2134.2.4 Cut the paint or surface on the robot before replacing parts ............................
2144.2.5 The brake release buttons may be jammed after service work .........................
2154.3 Complete robot .................................................................................................
2154.3.1 Replacement of cable harness, axes 1-4 .....................................................
2254.3.2 Replacement of cable harness, axes 5-6 ......................................................
2284.3.3 Replacement of complete arm system .........................................................
6 Product manual - IRB 7600
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© Copyright 2007 - 2023 ABB. All rights reserved.
Table of contents

2334.4 Upper and lower arm .........................................................................................
2334.4.1 Replacing turning disk ..............................................................................
2374.4.2 Replacement of complete wrist unit ............................................................
2424.4.3 Replacement of complete upper arm ...........................................................
2474.4.4 Replacement of complete lower arm ...........................................................
2574.4.5 Replacement of lower arm shaft .................................................................
2654.5 Frame and base ................................................................................................
2654.5.1 Replacing the SMB unit ............................................................................
2694.5.2 Replacement of brake release board ...........................................................
2754.5.3 Replacement of spherical roller bearing, balancing device ..............................
2804.5.4 Replacing the balancing device ..................................................................
2924.6 Motors ............................................................................................................
2924.6.1 Replacement of motor, axis 1 ....................................................................
2974.6.2 Replacement of motor axis 2 .....................................................................
3034.6.3 Replacement of motor, axis 3 ....................................................................
3104.6.4 Replacement of motor, axis 4 ....................................................................
3174.6.5 Replacement of motor, axis 5 ....................................................................
3224.6.6 Replacement of motor, axis 6 ....................................................................
3294.7 Gearboxes .......................................................................................................
3294.7.1 Replacing the axis 1 gearbox .....................................................................
3414.7.2 Replacement of gearbox, axis 2 .................................................................
3504.7.3 Replacement of gearbox, axis 3 .................................................................
3574.7.4 Replacement of gearbox, axis 4 .................................................................
3624.7.5 Replacement of gearbox, axis 5 .................................................................
3694.7.6 Replacement of gearbox, axis 6 .................................................................
3755 Calibration
3755.1 Introduction to calibration ...................................................................................
3755.1.1 Introduction and calibration terminology ......................................................
3765.1.2 Calibration methods .................................................................................
3795.1.3 When to calibrate ...................................................................................
3805.2 Synchronization marks and axis movement directions .............................................
3805.2.1 Synchronization marks and synchronization position for axes .........................
3815.2.2 Calibration movement directions for all axes ................................................
3825.3 Updating revolution counters ...............................................................................
3825.3.1 Updating revolution counters on IRC5 robots ...............................................
3875.3.2 Updating revolution counters on OmniCore robots ........................................
3895.4 Calibrating with Axis Calibration method ...............................................................
3895.4.1 Description of Axis Calibration ..................................................................
3925.4.2 Calibration tools for Axis Calibration ...........................................................
3945.4.3 Installation locations for the calibration tools ...............................................
3955.4.4 Axis Calibration - Running the calibration procedure ......................................
3995.4.5 Reference calibration ...............................................................................
4015.5 Calibrating with Calibration Pendulum method .......................................................
4025.6 Calibrating with Wrist Optimization method ...........................................................
4045.7 Verifying the calibration ......................................................................................
4055.8 Checking the synchronization position ..................................................................
4096 Decommissioning
4096.1 Introduction to decommissioning .........................................................................
4106.2 Environmental information ..................................................................................
4126.3 Scrapping of robot .............................................................................................
4136.4 Decommissioning of balancing device ...................................................................
4177 Robot description
4177.1 Type A vs type B motors ....................................................................................
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© Copyright 2007 - 2023 ABB. All rights reserved.
Table of contents

4198 Reference information
4198.1 Introduction ......................................................................................................
4208.2 Applicable standards .........................................................................................
4218.3 Unit conversion .................................................................................................
4228.4 Screw joints ....................................................................................................
4258.5 Weight specifications .........................................................................................
4268.6 Standard tools ..................................................................................................
4278.7 Special tools ....................................................................................................
4318.8 Lifting accessories and lifting instructions ..............................................................
4339 Spare part lists
4339.1 Spare part lists and illustrations ...........................................................................
43510 Circuit diagram
43510.1 Circuit diagrams ................................................................................................
43710.2 Validity of circuit diagram 3HAC025744-1 ..............................................................
43810.3 Validity of circuit diagram 3HAC13347-1 ................................................................
439Index
8 Product manual - IRB 7600
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© Copyright 2007 - 2023 ABB. All rights reserved.
Table of contents

Overview of this manual
About this manual
This manual contains instructions for:
• mechanical and electrical installation of the IRB 7600
• maintenance of the IRB 7600
• mechanical and electrical repair of the IRB 7600
The robot described in this manual has the following protection types:
•Standard
•Foundry Plus
This manual describes the manipulator using either the IRC5 or the OmniCore
controller.
Product manual scope
The manual covers all variants and designs of the IRB 7600. 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.
Continues on next page
Product manual - IRB 7600 9
3HAC022033-001 Revision: AH
© Copyright 2007 - 2023 ABB. All rights reserved.
Overview of this manual

References
Procedures in this product manual contain references to the following manuals:
General
Document IDDocument name
3HAC049113-001Product manual, spare parts - IRB 7600
3HAC13347-1Circuit diagram - IRB 7600
3HAC025744-001
3HAC031045-001Safety manual for robot - Manipulator and IRC5 or OmniCore
controller i
3HAC16578-1Operating manual - Calibration Pendulum
3HAC042927-001Technical reference manual - Lubrication in gearboxes
iThis manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
OmniCore robots
Document IDDocument name
3HAC087209-001Product specification - IRB 7600
3HAC081697-001Product manual - OmniCore V400XT
3HAC065036-001Operating manual - OmniCore
3HAC065041-001Technical reference manual - System parameters
3HAC082287-001Application manual - Additional axes for OmniCore
IRC5 robots
Document IDDocument name
Document.ID-1Product specification - IRB 7600
3HAC047136-001Product manual - IRC5
IRC5 with main computer DSQC1000 or later.
3HAC050941-001Operating manual - IRC5 with FlexPendant
3HAC16578-1Operating manual - Calibration Pendulum
3HAC050944-001Operating manual - Service Information System
3HAC050948-001Technical reference manual - System parameters
3HAC051016-001Application manual - Additional axes and standalone controller
3HAC030421-001Application manual - CalibWare Field
Revisions
DescriptionRevision
First edition.-
Replaces previous manuals:
• Installation and Commissioning Manual
• Maintenance Manual
• Repair Manual, part 1
• Repair Manual, part 2.
Continues on next page
10 Product manual - IRB 7600
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© Copyright 2007 - 2023 ABB. All rights reserved.
Overview of this manual
Continued