Contents - Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Overview
- Product documentation, M2000/M2000A
- 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
- Robot transportation precautions
- Securing the robot
- Unpacking
- Working range, IRB 7600 - 150/3.5
- Working range, IRB 7600 - 325/3.1
- Working range, IRB 7600 - 340/2.8
- Working range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55
- Working range, IRB 7600 - 500/2.3
- Risk of tipping / stability
- On-site Installation
- Lifting robot with lifting slings
- Lifting robot with roundslings
- Manually releasing the brakes
- Manually releasing the brakes, external brake release unit
- Lifting the base plate
- Securing the base plate
- Orienting and securing the robot
- Fitting equipment on robot
- Installation of base spacers (option)
- Installation of cooling fan for motors, axes 1-3 (option)
- Loads
- Restricting the working range
- Mechanically restricting the working range of axis 1
- Mechanically restricting the working range of axis 2
- Mechanically restricting the working range of axis 3
- Installation of position switches (option)
- Electrical connections
- Making robot ready for operation (Foundry Prime)
- Commissioning (Foundry Prime)
- Maintenance
- Maintenance schedule and expected life
- Maintenance schedule
- Expected component life
- Inspection activities
- Inspection, oil level gearbox axis 2
- Inspection, oil level gearbox axis 3
- Inspection, oil level gearbox axis 4
- Inspection, oil level, gearbox axis 5
- Inspection, oil level gearbox axis 6
- Inspection, balancing device
- Inspection, cable harness
- Inspection, mechanical stop, axis 1
- Inspection, mechanical stop, axes 1, 2 and 3
- Inspection, damper axes 2-5
- Inspection, position switch axes 1, 2 and 3
- Inspection, information labels
- Inspection, UL-lamp
- Inspection of air hoses (Foundry Prime)
- Changing/replacement activities
- Oil change, gearbox axis 1
- Oil change, gearbox axis 2
- Oil change, gearbox, axis 3
- Oil change, gearbox, axis 4
- Oil change, gearbox, axis 5
- Oil change, gearbox axis 6
- Replacement of SMB battery
- Lubrication activities
- Rust preventive measures, bearing axis 1 (Foundry Prime)
- Rust preventive measures, bearing axis 4 (Foundry Prime)
- Rust preventive measures, support bearing in wrist (Foundry Prime)
- Cleaning activities
- Cleaning, robot
- Repair
- General procedures
- Mounting instructions for bearings
- Mounting instructions for seals
- Complete robot
- Replacement of cable harness, axes 5-6
- Replacement of complete arm system
- Replacement of air nipple and hose (Foundry Prime)
- Upper and lower arm
- Replacement of complete wrist unit
- Replacement of complete upper arm
- Replacement of complete lower arm
- Frame and base
- Replacement of brake release unit
- Replacement of balancing device
- Replacement of spherical roller bearing, balancing device
- Unloading the balancing device
- Restoring the balancing device
- Motors
- Replacement of motor axis 2
- Replacement of motor, axis 3
- Replacement of motor, axis 4
- Replacement of motor, axis 5
- Replacement of motor, axis 6
- Gearboxes
- Replacement of gearbox, axis 2
- Replacement of gearbox, axis 3
- Replacement of gearbox, axis 4
- Replacement of gearbox, axis 5
- Replacement of gearbox, axis 6
- Calibration information
- Calibration methods
- Calibration scales and correct axis position
- Calibration movement directions for all axes
- Updating revolution counters
- Checking the calibration position
- Decommissioning
- Decommissioning of balancing device
- Reference information
- Applicable Safety Standards
- Unit conversion
- Screw joints
- Weight specifications
- Standard toolkit
- Special tools
- Lifting equipment and lifting instructions
- Spare part / part list
- Spare parts
- Spare part list
- Part list
- Rebuilding parts
- Part list, overview
- Mechanical stop axis 1, 3HAC12812-2
- Base incl frame axis 1, 3HAC12304-1
- Axis 3-4, 3HAC13063-1 (IRB 7600 - 150/3.5, - 325/3.1, -340/2.8, -400/2.55, -500/2.55)
- Axis 3-4, 3HAC13063-2 (IRB 7600 - 500/2.3)
- Axis 3-4 Foundry, 3HAC13063-5 (IRB 7600 - 500/2.3)
- Wrist, 3HAC16628-4 / 3HAC16628-3
- Material set robot, 3HAC13079-1
- Material set axis 1-2, 3HAC13077-1
- Material set balancing device, 3HAC13082-1
- Arm extension set, 956 mm, 3HAC12311-1 (IRB 7600 - 150/3.5)
- Arm extension set, 250 mm, 3HAC12311-2 (IRB 7600 - 340/2,8)
- Arm extension set, 500 mm, 3HAC12311-3 (IRB 7600 - 325/3,1)
- Exploded views
- Base incl. Frame
- Frame-Lower arm 1
- Frame-Lower arm 2
- Upper arm
- Wrist complete
- Circuit Diagram
- Circuit diagram 3HAC025744-001
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2 Installation and commissioning2.8.1. Additional installation procedure3HAC022033-001 Revision: E122© Copyright 2004 - 2008 ABB. All rights reserved.2.8 Making robot ready for operation (Foundry Prime)2.8.1. Additional installation procedureGeneralRobots delivered with the Foundry Prime protection are specially designed to work in waterjet cleaning cells with 100% humidity and alkaline detergent. To ensure that the protectionoffers the best reliability, some measures are needed during installation of the robot accordingto the procedures below.NOTE!For best reliability, it is of highest importance that the special maintenance instructions forthe Foundry Prime robot are followed and documented.Commissioning• Never switch off the overpressure in motors and serial measurement compartmentduring cooling down of robot after it has been switched off.• When turning off a cleaning cell we recommend that the humid air inside a cell isventilated out, to avoid that the humid air is sucked into gearboxes for example, dueto the raised vacuum when cooled down.Environmental conditionsThe table below details the environmental conditions.Air specification for pressurizing of robotThe air must be dry and clean, such as instrument air. The table below details the airspecifications.Parameter ValueHumidity 100%Washing detergent with pH <9.0Washing detergent must contain rust inhibitorand be approved by ABBCleaning bath temperature <60°C, used in a typical waterjet cleaningapplication at suitable speed.Parameter ValueDew point <+2°C at 6 barSolid particle size <5 micronsOil content <1 ppm (1 mg/m3)Pressure to robot 0.2 - 0.3 barContinues on next page
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