ABB IRB 8700 Series User manual

ROBOTICS
Product manual
IRB 8700

Trace back information:
Workspace R18-1 version a12
Checked in 2018-03-27
Skribenta version 5.2.025

Product manual
IRB 8700 - 550/4.20
IRB 8700 - 800/3.50
IRC5
Document ID: 3HAC052853-001
Revision: F
© Copyright 2015-2018 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 2015-2018 ABB. All rights reserved.
ABB AB, Robotics
Robotics and Motion
Se-721 68 Västerås
Sweden

Table of contents
9Overview of this manual ...................................................................................................................
13Product documentation ....................................................................................................................
15How to read the product manual ......................................................................................................
171 Safety
171.1 General safety information ..................................................................................
171.1.1 Limitation of liability .................................................................................
201.1.2 Protective stop and emergency stop ...........................................................
211.2 Safety actions ...................................................................................................
211.2.1 Fire extinguishing ....................................................................................
221.2.2 Emergency release of the robot axes ..........................................................
231.2.3 Make sure that the main power has been switched off ....................................
241.3 Safety risks ......................................................................................................
241.3.1 Safety risks during installation and service work on robots ..............................
261.3.2 Moving robots are potentially lethal ............................................................
271.3.3 First test run may cause injury or damage ....................................................
281.3.4 Work inside the working range of the robot ..................................................
291.3.5 Enabling device and hold-to-run functionality ...............................................
301.3.6 Risks associated with live electric parts .......................................................
321.3.7 The unit is sensitive to ESD .......................................................................
331.3.8 Hot parts may cause burns .......................................................................
341.3.9 Safety risks related to pneumatic/hydraulic systems ......................................
351.3.10 Brake testing ..........................................................................................
361.3.11 Safety risks during handling of batteries ......................................................
371.3.12 Safety risks during work with gearbox lubricants (oil or grease) .......................
391.4 Safety signals and symbols .................................................................................
391.4.1 Safety signals in the manual ......................................................................
411.4.2 Safety symbols on product labels ...............................................................
472 Installation and commissioning
472.1 Introduction ......................................................................................................
482.2 Unpacking .......................................................................................................
482.2.1 Pre-installation procedure .........................................................................
522.2.2 Working range ........................................................................................
552.2.3 Risk of tipping/stability .............................................................................
562.2.4 Main dimensions .....................................................................................
572.3 On-site installation ............................................................................................
572.3.1 Lifting the robot with fork lift accessory set installed ......................................
652.3.2 Attaching the robot and removing the fork lift accessory set ............................
672.3.3 Lifting the base plate ................................................................................
692.3.4 Securing the base plate ............................................................................
732.3.5 Lifting the robot with roundslings ...............................................................
762.3.6 Returning of the ABB pallet .......................................................................
772.3.7 Manually releasing the brakes ...................................................................
802.3.8 Orienting and securing the robot ................................................................
832.3.9 Loads fitted to the robot, stopping time and braking distances .........................
842.3.10 Fitting equipment ....................................................................................
902.4 Restricting the working range ..............................................................................
902.4.1 Axes with restricted working range .............................................................
912.4.2 Mechanically restricting the working range of axis 1 ......................................
942.5 Electrical connections ........................................................................................
942.5.1 Robot cabling and connection points ..........................................................
962.6 Installation of options .........................................................................................
962.6.1 Signal lamp (option) .................................................................................
972.6.2 Installing the motor cooling fans ................................................................
982.7 Start of robot in cold environments ......................................................................
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993 Maintenance
993.1 Introduction ......................................................................................................
1003.2 Maintenance schedule and expected component life ...............................................
1003.2.1 Specification of maintenance intervals ........................................................
1013.2.2 Maintenance schedule .............................................................................
1033.2.3 Expected component life .........................................................................
1043.3 Inspection activities ...........................................................................................
1043.3.1 Inspecting the oil level in axis-1 gearbox ......................................................
1073.3.2 Inspecting the oil level in axis-2 and 3 gearboxes ..........................................
1103.3.3 Inspecting the oil level in axis-4 primary gearbox ..........................................
1133.3.4 Inspecting the oil level in axis-4 secondary gearbox .......................................
1153.3.5 Inspecting the oil level in axis-5 gearbox ......................................................
1183.3.6 Inspecting the oil level in axis-6 gearbox ......................................................
1213.3.7 Inspecting the transparent plugs ................................................................
1233.3.8 Inspecting the balancing devices ...............................................................
1263.3.9 Inspecting the cable harness .....................................................................
1283.3.10 Inspecting the information labels ................................................................
1323.3.11 Inspecting the axis-1 mechanical stop pin ...................................................
1343.3.12 Inspecting the additional mechanical stops .................................................
1363.3.13 Inspecting the fork lift accessories ..............................................................
1383.3.14 Inspecting the signal lamp (option) .............................................................
1393.3.15 Inspecting dampers .................................................................................
1403.4 Replacement/changing activities ..........................................................................
1403.4.1 Type of lubrication in gearboxes ................................................................
1413.4.2 Changing oil, axis-1 gearbox .....................................................................
1473.4.3 Changing oil in axis-2 and axis-3 gearbox ....................................................
1533.4.4 Changing oil, axis-4 primary gearbox ..........................................................
1593.4.5 Changing oil, axis-4 secondary gearbox ......................................................
1643.4.6 Changing oil, axis-5 gearbox .....................................................................
1683.4.7 Changing oil, axis-6 gearbox .....................................................................
1733.4.8 Replacing the SMB battery ........................................................................
1763.5 Lubrication activities ..........................................................................................
1763.5.1 Lubricating the spherical roller bearings, balancing device ..............................
1783.5.2 Lubricating the cross roller bearing .............................................................
1803.6 Cleaning activities .............................................................................................
1803.6.1 Cleaning the IRB 8700 ..............................................................................
1834 Repair
1834.1 Introduction ......................................................................................................
1844.2 General procedures ...........................................................................................
1844.2.1 Performing a leak-down test ......................................................................
1854.2.2 Mounting instructions for bearings .............................................................
1874.2.3 Mounting instructions for seals ..................................................................
1894.2.4 Cut the paint or surface on the robot before replacing parts ............................
1904.2.5 The brake release buttons may be jammed after service work .........................
1914.3 Attaching lifting accessories ................................................................................
1914.3.1 Attaching lifting accessories to the upper arm ...............................................
1954.3.2 Attaching lifting accessories to the wrist ......................................................
1984.4 Cable harness ..................................................................................................
1984.4.1 Removing the cable harness .....................................................................
2154.4.2 Refitting the cable harness ........................................................................
2354.4.3 Replacing the SMB ..................................................................................
2424.4.4 Replacing the brake release unit ................................................................
2484.5 Upper and lower arms ........................................................................................
2484.5.1 Replacing the upper arm ..........................................................................
3034.5.2 Replacing the wrist ..................................................................................
3224.5.3 Replacing the axis-6 unit ..........................................................................
3424.5.4 Replacing the turning disc ........................................................................
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3464.5.5 Replacing the process turning disc .............................................................
3494.5.6 Replacing the complete lower arm ..............................................................
4324.5.7 Replacing the parallel arm ........................................................................
5184.6 Frame and base ................................................................................................
5184.6.1 Replacing the counterweight ....................................................................
5244.6.2 Replacing the mechanical stop pin ............................................................
5304.6.3 Replacing the parallel rod .........................................................................
5474.6.4 Unloading and restoring the balancing device ...............................................
5524.6.5 Replacing the balancing devices ................................................................
5634.7 Motors ............................................................................................................
5634.7.1 Replacing the axis-1 motor .......................................................................
5754.7.2 Replacing the axis-2 and axis-3 motors ......................................................
5904.7.3 Replacing the axis-4 motor .......................................................................
6014.7.4 Replacing the axis-5 motor .......................................................................
6154.7.5 Replacing the axis-6 motor ........................................................................
6304.8 Gearboxes .......................................................................................................
6304.8.1 Replacing the hub ...................................................................................
6374.8.2 Replacing the axis-1 gearbox ....................................................................
6794.8.3 Replacing the axis-2 gearbox ....................................................................
7184.8.4 Replacing the axis-3 gearbox ....................................................................
7604.8.5 Replacing the axis-4 primary gearbox .........................................................
7864.8.6 Replacing the axis-6 gearbox ....................................................................
7955 Calibration
7955.1 Introduction to calibration ...................................................................................
7955.1.1 Introduction and calibration terminology ......................................................
7965.1.2 Calibration methods .................................................................................
7985.1.3 When to calibrate ...................................................................................
7995.2 Synchronization marks and axis movement directions .............................................
7995.2.1 Synchronization marks and synchronization position for axes .........................
8005.2.2 Calibration movement directions for all axes ................................................
8015.3 Updating revolution counters ...............................................................................
8055.4 Calibrating with Axis Calibration method ...............................................................
8055.4.1 Description of Axis Calibration ..................................................................
8075.4.2 Calibration tools for Axis Calibration ...........................................................
8095.4.3 Installation locations for the calibration tools ...............................................
8115.4.4 Axis Calibration - Running the calibration procedure ......................................
8175.5 Verifying the calibration ......................................................................................
8185.6 Checking the synchronization position ..................................................................
8196 Decommissioning
8196.1 Environmental information ..................................................................................
8216.2 Scrapping of robot .............................................................................................
8226.3 Decommissioning of balancing device ...................................................................
8257 Reference information
8257.1 Introduction ......................................................................................................
8267.2 Applicable standards .........................................................................................
8287.3 Unit conversion .................................................................................................
8297.4 Screw joints ....................................................................................................
8327.5 Weight specifications .........................................................................................
8337.6 Standard toolkit ................................................................................................
8347.7 Special tools ....................................................................................................
8377.8 Lifting accessories and lifting instructions ..............................................................
8398 Spare parts
8398.1 Spare part lists and illustrations ...........................................................................
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8419 Circuit diagrams
8419.1 Circuit diagrams ................................................................................................
843Index
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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.
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
A 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 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
Calibration procedures and general information about calibration.Calibration
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
Reference to the spare part list for the robot.Spare parts
Reference to the circuit diagram for the robot.Circuit diagram
References
Documentation referred to in the manual, is listed in the table below.
Document IDDocument name
3HAC052854-001Product manual, spare parts - IRB 8700
3HAC052852-001Product specification - IRB 8700
3HAC055802-001Product manual - DressPack/SpotPack IRB 8700
3HAC051028-002Circuit diagram - IRB 8700
3HAC047136-001Product manual - IRC5
3HAC050941-001Operating manual - IRC5 with FlexPendant
3HAC042927-001Technical reference manual - Lubrication in gearboxes
3HAC050948-001Technical reference manual - System parameters
Revisions
DescriptionRevision
First edition.-
The following updates are made in this revision:A
• Repair chapter added
• Edited information regarding deciding calibration routine in each
repair section.
• Added a warning that calibration pin must be inserted in the calib-
ration bushing until it snaps, see Description of Axis Calibration
on page 805.
• Added warning regarding risk of pinching, in Description of Axis
Calibration on page 805.
• Added information about inspection of calibration tool prior to
usage, see Examining the calibration tool on page 807.
• Added information about the calibration procedure, see Overview
of the calibration procedure on the FlexPendant on page 811,Re-
starting an interrupted calibration procedure on page 813.
• Added information about Axis Calibration when SafeMove is in-
stalled, see Axis Calibration with SafeMove option on page 814.
• Turn motion axis-6 updated to ±360°, see Working range on
page 52.
The following updates are made in this revision:B
• Illustrations added throughout the manual.
• Minor updates throughout the manual.
Published in release R16.2. The following updates are made in this revi-
sion:
C
• Drawing of the base plate is updated.
• Drawing of base plate is not available for purchase, faulty inform-
ation removed in Securing the base plate on page 69.
• Bearing grease 3HAC9408-1 changed name from Longtime PD2
to Tribol GR 100-2 PD
• Fork lift accessory descriptions updated.
Continues on next page
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Continued

DescriptionRevision
• Working range updated.
• Main dimensions updated.
• Updated spare parts due to sealing upgrade in the motors:
- Motors
- Upper arm excluding wrist
- Wrist
- Axis 6 complete
Published in release R17.1. The following updates are made in this revi-
sion:
D
• Updates in procedure Replacing the axis-1 gearbox, Replacing
the axis-1 gearbox on page 637
• Figures in Filling oil into axis-1 gearbox updated.
• Caution with figures to ensure relieving pressure on the correct
balancing device added.
• Grease for cross roller bearing changed (from Tribol GR 100-0
PD to Mobilux EP2).
• Bending radius for static floor cables added.
• Motors updated, M12 instead of M14 holes for removal tool on
motors axis 1-3.
• Removal tool changed from 14 to 12 in required tools on axis 4
and 5.
• Added information that re-calibration is needed after replacement
of hub.
• Added replacement information in Replacing the hub, Replacing
the hub on page 630.
Published in release R17.2. The following updates are made in this revi-
sion:
E
• Caution about removing metal residues added in sections about
SMB boards.
• Information about minimum resonance frequency added.
• Base plate article number updated. (Is 3HAC053772-003, was
3HAC053772-002)
• Orange spare parts added.
• Installation drawing updated.
•Replacement methods for following spare parts are updated/com-
pleted:
- axis-1 gearbox
- axis-2 gearbox
- axis-3 gearbox
- axis-6 gearbox
- upper arm
- brake release board
- balancing device
- cable harness
- lower arm
- hub
• Illustrations and data for information labels corrected.
•Added text regarding overhaul in section specification of mainten-
ance intervals.
• Added article number for Grease Castrol Molub-Alloy 777-1 (used
with Hub splines).
• Section Start of robot in cold environments on page 98 added.
• Updated information regarding disconnecting and reconnecting
battery cable to serial measurement board.
Continues on next page
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Overview of this manual
Continued

DescriptionRevision
• Added figures and corrected information regarding inspection of
oil level and change of oil in axis-6 gearbox.
• Changed amount of screws and image for removal/refitting of
axis-6 unit support shaft.
• Definition of reference calibration clarified.
• Updated maintenance schedule.
Published in release R18.1. The following updates are made in this revi-
sion:
F
• Information added about fatigue to Axis Calibration tool, see Cal-
ibration tools for Axis Calibration on page 807.
• Added sections in General procedures on page 184.
• Added reference manual for DressPack.
• Safety restructured.
• Updated spare parts number brake release board unit (was
BRK001, is DSQC1052).
• Note added to calibration chapter to emphasize the requirement
of equally dressed robot when using previously created reference
calibration values.
• Information about myABB Business Portal added.
• Added Nickel in Environmental information.
•Added article numbers for cooling fan cabling between robot base
and control cabinet.
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Overview of this manual
Continued

Product documentation
Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories.
This listing is based on the type of information in the documents, regardless of
whether the products are standard or optional.
All documents can be found via myABB Business Portal, www.myportal.abb.com.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
•Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
•Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• Circuit diagrams (or references to circuit diagrams).
Technical reference manuals
The technical reference manuals describe reference information for robotics
products, for example lubrication, the RAPID language, and system parameters.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
•What is included (for example cables, I/O boards, RAPID instructions, system
parameters, software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
Continues on next page
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Product documentation

Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.
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Product documentation
Continued

How to read the product manual
Reading the procedures
The procedures contain all information required for the installation or service activity
and can be printed out separately when needed for a certain service procedure.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 17.
Illustrations
The product is illustrated with general figures that does not take painting or
protection type in consideration.
Likewise, certain work methods or general information that is valid for several
product models, can be illustrated with illustrations that show a different product
model than the one that is described in the current manual.
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How to read the product manual

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1 Safety
1.1 General safety information
1.1.1 Limitation of liability
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial robot will not cause injury or damage even if
all safety instructions are complied with.
The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment that can influence the safety of
the entire system.
In particular, liability cannot be accepted if injury/damage has been caused for any
of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed.
• Non-authorized design modifications made in or around the robot.
• Repairs carried out by in-experienced or non-qualified personnel.
• Foreign objects.
• Force majeure.
Nation/region specific regulations
To protect personnel, the complete system must be designed and installed in
accordance with the safety requirements set forth in the standards and regulations
of the country where the robot is installed.
To be observed by the supplier of the complete system
The integrator is responsible that the safety devices necessary to protect people
working with the robot system are designed and installed correctly.
When integrating the robot with external devices and machines:
• The supplier of the complete system must ensure that all circuits used in the
safety function are interlocked in accordance with the applicable standards
for that function.
• The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance
with the applicable standards for the emergency stop function.
Continues on next page
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1 Safety
1.1.1 Limitation of liability

The integrator of the final application is required to perform an assessment of the
hazards and risks (HRA).
Note
The integrator is responsible for the safety of the final application.
Safe access
The robot system shall be designed to allow safe access to all areas where
intervention is necessary during operation, adjustment, and maintenance.
Where it is necessary to perform tasks within the safeguarded space there shall
be safe and adequate access to the task locations.
Safety zones, which must be crossed before admittance, must be set up in front
of the robot's working space. Light beams or sensitive mats are suitable devices.
Turntables or the like should be used to keep the operator out of the robot's working
space.
A safety fence is recommended to ensure safeguarded space. Sufficient space
must be provided around the manipulator to protect those working with or on it
from hazards such as crushing.
The fence or enclosure must be dimensioned to withstand the force created if the
load being handled by the robot is dropped or released at maximum speed.
Determine the maximum speed from the maximum velocities of the robot axes and
from the position at which the robot is working in the work cell (see the section
Robot motion in the Product specification).
Also consider the maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the robot.
Safe handling
Users shall not be exposed to hazards, including slipping, tripping, and falling
hazards.
It must be possible to safely turn off tools, such as milling cutters, etc. Make sure
that guards remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
Emergency stop buttons must be positioned in easily accessible places so that
the robot can be stopped quickly. If any of the buttons do not stop all the robot
workcell motion, each emergency stop button must be marked, if more than one
is provided, to indicate its designated safety function.
Grippers/end effectors must be designed so that they retain work pieces in the
event of a power failure or a disturbance to the controller.
Continues on next page
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1 Safety
1.1.1 Limitation of liability
Continued

Unauthorized modifications of the originally delivered robot are prohibited. Without
the consent of ABB it is forbidden to attach additional parts through welding,
riveting, or drilling of new holes into the castings. The strength could be affected.
CAUTION
Ensure that a gripper is prevented from dropping a work piece, if such is used.
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1 Safety
1.1.1 Limitation of liability
Continued

1.1.2 Protective stop and emergency stop
Overview
The protective stops and emergency stops are described in the product manual
for the controller.
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1 Safety
1.1.2 Protective stop and emergency stop