Contents - Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Overview of this manual
- Product documentation, M2000/M2000A
- Product documentation, M2004
- How to read the product manual
- Safety
- General safety information
- Safety in the manipulator system
- Safety risks
- CAUTION - Hot parts may cause burns
- Safety risks related to tools/work pieces
- 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 manipulator's arm
- Brake testing
- Risk of disabling function "Reduced speed 250 mm/s
- Safe use of the FlexPendant
- Work inside the manipulator's working range
- Signal lamp (optional)
- Safety stops
- Safety related instructions
- Safety symbols on manipulator labels
- DANGER - Moving manipulators are potentially lethal
- DANGER - First test run may cause injury or damage
- WARNING - The brake release buttons may be jammed after service work
- DANGER - Make sure that the main power has been switched off
- WARNING - The unit is sensitive to ESD
- WARNING - Safety risks during handling of batteries
- WARNING - Safety risks during work with gearbox lubricants (oil or grease)
- Installation and commissioning
- Robot transportation precautions
- Securing the robot
- Unpacking
- Working range, IRB 7600 - 150/3.5
- 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)
- Extended working range, axis 1 (option 561-1)
- Installation of cooling fan for motors, axes 1-3 (option)
- Installation of Foundry Plus Cable guard (option no. 908-1)
- Loads
- Installation of signal lamp (option)
- 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
- 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
- Inspecting, mechanical stop pin, 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
- Changing/replacement activities
- Oil change, gearbox axis 1
- Changing oil, axis-2 gearbox
- Changing oil, axis-3 gearbox
- Oil change, gearbox, axis 4
- Oil change, gearbox, axis 5
- Oil change, gearbox axis 6
- Replacing the SMB battery
- Lubrication activities
- Cleaning, robot
- Lubrication of spherical roller bearing, balancing device
- Service Information System, M2000
- Description of Service Information System (SIS)
- SIS system parameters
- Setting the SIS parameters
- Reading the SIS output logs
- Exporting the SIS data
- 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
- Upper and lower arm
- Replacement of complete wrist unit
- Replacement of complete upper arm
- Replacement of complete lower arm
- Replacement of lower arm shaft
- Frame and base
- Replacement of brake release unit
- Replacing the balancing device
- Replacement of spherical roller bearing, balancing device
- Unloading the balancing device using hydraulic press tool
- Restoring the balancing device using a hydraulic press tool
- 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 scale 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 tools
- Special tools
- Lifting accessories 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
- 8.3.6 Axis 3-4, 3HAC13063-1 (IRB 7600 - 150/3.5, - 325/3.1, -340/2.8, -400/2.55
- Axis 3-4, 3HAC13063-2 (IRB 7600 - 500/2.3)
- 8.3.8 Axis 3-4, Foundry, 3HAC13063-4 (IRB 7600 -150/3.5, - 325/3.1, - 340/2.8, - 400/2.55
- 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)
- Exploded views
- Base incl. Frame
- Frame-Lower arm 1
- Frame-Lower arm 2
- Upper arm
- Wrist complete
- Circuit diagram
- Validity of circuit diagram 3HAC025744-1
- Validity of circuit diagram 3HAC13347-1
- Index
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1.2.3.6 Risks associated with live electric partsVoltage related risks, generalWork on the electrical equipment of the manipulator must be performed by aqualified electrician in accordance with electrical regulations.• Although troubleshooting may, on occasion, need to be carried out while thepower supply is turned on, the robot must be turned off (by setting the mainsswitch to OFF) when repairing faults, disconnecting electric leads anddisconnecting or connecting units.• The mains supply to the robot must be connected in such a way that it canbe turned off from outside the robot’s working space.The necessary protection for the electrical equipment and manipulator systemduring construction, commissioning, and maintenance is guaranteed if the validregulations are followed.All work must be performed:• by qualified personnel• on machine/manipulator system in deadlock• in an isolated state, disconnected from power supply, and protected againstreconnectionVoltage related risks, IRC5 controllerA danger of high voltage is associated with, for example, the following parts:• Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) inthe controller.• Units such as I/O modules, can be supplied with power from an externalsource.• The mains supply/mains switch• The transformers• The power unit• The control power supply (230 VAC)• The rectifier unit (262/400-480 VAC and 400/700 VDC. Note: Capacitors!)• The drive unit (400/700 VDC)• The drive system power supply (230 VAC)• The service outlets (115/230 VAC)• The customer power supply (230 VAC)• The power supply unit for additional tools, or special power supply units forthe machining process.• The external voltage connected to the controller remains live even when therobot is disconnected from the mains.• Additional connections.Continues on next page3HAC022033-001 Revision: M 29© Copyright 2007-2013 ABB. All rights reserved.1 Safety1.2.3.6 Risks associated with live electric parts
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