Contents - Table Of Contents
- Table Of Contents
- Table Of Contents
- Overview
- Product documentation, M2004
- How to read the product manual
- Safety
- General safety information
- Safety risks
- Safety risks related to tools/workpieces
- Safety risks related to pneumatic/hydraulic systems
- Safety risks during operational disturbances
- Risks associated with live electric parts
- Safety actions
- Fire extinguishing
- Emergency release of the robot's arm
- Brake testing
- Risk of disabling function "Reduced speed 250 mm/s
- Safe use of the FlexPendant
- Work inside the robot's working range
- Signal lamp (optional)
- Translate the information on safety and information labels
- Safety related instructions
- DANGER - Moving robots are potentially lethal
- DANGER - First test run may cause injury or damage
- WARNING - The brake release buttons may be jammed after service work
- WARNING - The unit is sensitive to ESD
- WARNING - Safety risks during work with gearbox oil
- Installation and commissioning
- Unpacking
- Working range
- On-site installation
- Manually releasing the brakes
- Orienting and securing the robot
- Suspended mounting
- Loads
- Fitting equipment on the robot (robot dimensions)
- Installation of signal lamp for 1600 (option)
- Installation of signal lamp for 1600 ID (option)
- Restricting the working range
- Installation of additional mechanical stops on axis 1
- Installation of additional mechanical stop on axis 2
- Installation of additional mechanical stops on axis 3
- Installation of position switch, axis 1
- Electrical connections
- Robot cabling and connection points
- Customer connections on the robot
- Making robot ready for operation (Cleanroom)
- Maintenance
- Maintenance schedule and expected component life
- Maintenance schedule
- Expected component life
- Inspection activities
- Replacement activities
- Oil change, gearbox axes 5 and 6
- Oil change, gearbox axes 5- 6, IRB 1600ID
- Replacement of measurement system battery pack
- Cleaning activities
- Repair
- General procedures
- Mounting instructions for bearings
- Mounting instructions for seals
- Complete manipulator
- Replacement of cable harness, IRB 1600ID
- Replacement of complete arm system
- Upper and lower arm
- Replacement of complete upper arm, IRB 1600ID
- Replacement of complete lower arm
- Replacement of wrist unit
- Replacement of wrist unit, IRB1600ID
- Replacement of damper, axis 2
- Replacement of damper, axis 3
- Replacement of Mechanical damper, axis 3, IRB 1600ID
- Replacement of damper, axis 5
- Remove upper arm AW Gun
- Fitting equipment on the robot, IRB 1600ID
- Frame and base
- Replacement of serial measurement unit
- Replacement of push button unit
- Motors
- Replacement of motor, axis 2
- Replacement of motor, axis 3
- Replacement of motor, axis 3, IRB 1600ID
- Replacement of motor, axis 4
- Replacement of motor, axis 4, 1600ID
- Replacement of motor and timing belt, axis 5
- Replacement of motor, axis 5, IRB 1600ID
- Replacement of motor and timing belt, axis 6
- Replacement of motor, axis 6 IRB 1600ID
- Gearboxes
- Service work on gearboxes, axes 3, 4, 5 and 6
- Calibration information
- Calibration methods
- Calibration scales and correct axis position
- Calibration movement directions for all axes
- Updating revolution counters
- Checking the calibration position
- Robot description
- Reference information
- Unit conversion
- Screw joints
- Weight specifications
- Standard toolkit
- Special tools
- Lifting equipment and lifting instructions
- Spare parts and exploded views
- Spare parts - base
- Spare parts - base connections
- Spare parts - frame
- Spare parts - lower arm
- Spare parts - upper arm
- Spare parts - options
- Spare parts - upper arm 1600ID
- Circuit diagram
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2 Installation and commissioning2.2.1. Pre-installation procedure3HAC026660-001 Revision: C38© Copyright 2006-2008 ABB. All rights reserved.2.2 Unpacking2.2.1. Pre-installation procedureGeneralThis instruction is primarily intended for use when unpacking and installing the robot for thefirst time. It also contains information useful during later re-installation of the robot.Checking the pre-requisites for installationThe check-list below details what must be observed before proceeding with the actualinstallation of the robot:WeightThe table below shows the weight of the robot model.Loads on foundationThe table below shows the various forces and torques working on the robot during differentkinds of operation. Note! These forces and torques are extreme values that are rarelyencountered during operation. The values also never reach their maximum at the same time!Action Detailed in section:1. Make sure only qualified installation personnelconforming to all national and local codes are allowedto perform the installation.2. Make sure the robot has not been damaged, byvisually inspecting its exterior.3. Make sure the lifting device to be used isdimensioned to handle the weight of the robot.Weight on page 38.4. If the robot is not to be installed directly, it must bestored.Storage conditions on page 39.5. Make sure the appointed operating environment ofthe robot conforms to the specifications.Operating conditions on page 39and Protection classes on page39.6. Before taking the robot to its installation site, makesure the site conforms to applicable requirements.Loads on foundation on page 38and Requirements, foundationon page 39.7. Before moving the robot, make sure it does not tipover!8. When these prerequisites have been met, the robotmay be taken to its installation site.Lifting robot with roundsling onpage 45.Robot model WeightIRB 1600 - x/1.2 247 kgIRB 1600 - x/1.45 250 kgForce Mounting Endurance load Max. load(emergency stop)Force XY Floor mountedSuspendedWall mounted± 1650 N± 1650 N± 3900 N± 31500 N± 3150 N± 5300 NContinues on next page
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