ABB IRB 760-450/3.2 User manual

Category
Robotics
Type
User manual

This manual is also suitable for

ROBOTICS
Product manual
IRB 760
Trace back information:
Workspace R18-2 version a18
Checked in 2018-11-20
Skribenta version 5.3.012
Product manual
IRB 760 - 450/3.2
IRC5
Document ID: 3HAC039838-001
Revision: M
© Copyright 2011-2018 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, 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 2011-2018 ABB. All rights reserved.
Specifications subject to change without notice.
ABB AB, Robotics
Robotics and Motion
Se-721 68 Västerås
Sweden
Table of contents
9Overview of this manual ...................................................................................................................
14How to read the product manual ......................................................................................................
15Product documentation ....................................................................................................................
171 Safety
171.1 General safety information ..................................................................................
171.1.1 Limitation of liability .................................................................................
191.1.2 Protective stop and emergency stop ...........................................................
201.2 Safety actions ...................................................................................................
201.2.1 Fire extinguishing ....................................................................................
211.2.2 Emergency release of the robot axes ..........................................................
221.2.3 Make sure that the main power has been switched off ....................................
231.3 Safety risks ......................................................................................................
231.3.1 Safety risks during installation and service work on robots ..............................
251.3.2 Moving robots are potentially lethal ............................................................
261.3.3 First test run may cause injury or damage ....................................................
271.3.4 Work inside the working range of the robot ..................................................
281.3.5 Enabling device and hold-to-run functionality ...............................................
291.3.6 Risks associated with live electric parts .......................................................
311.3.7 The unit is sensitive to ESD .......................................................................
321.3.8 Hot parts may cause burns .......................................................................
331.3.9 Safety risks related to pneumatic/hydraulic systems ......................................
341.3.10 Brake testing ..........................................................................................
351.3.11 Safety risks during handling of batteries ......................................................
361.3.12 Safety risks during work with gearbox lubricants (oil or grease) .......................
381.4 Safety signals and symbols .................................................................................
381.4.1 Safety signals in the manual ......................................................................
401.4.2 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 and type of motion ..............................................................
552.2.3 Risk of tipping/stability .............................................................................
562.3 On-site installation ............................................................................................
562.3.1 Lifting robot with fork lift ...........................................................................
622.3.2 Lifting robot with roundslings ....................................................................
642.3.3 Lifting robot with lifting slings ....................................................................
672.3.4 Manually releasing the brakes ...................................................................
692.3.5 Lifting the base plate ................................................................................
702.3.6 Securing the base plate ............................................................................
752.3.7 Orienting and securing the robot ................................................................
792.3.8 Fitting equipment on robot .......................................................................
842.3.9 Installation of signal lamp, upper arm (option) ..............................................
882.3.10 Loads fitted to the robot, stopping time and braking distances .........................
892.4 Restricting the working range ..............................................................................
892.4.1 Axes with restricted working range .............................................................
902.4.2 Mechanically restricting the working range of axis 1 ......................................
922.4.3 Extended working range, axis 1 (option 561-1) .............................................
932.5 Robot in cold environments .................................................................................
932.5.1 Start of robot in cold environments ............................................................
942.6 Electrical connections ........................................................................................
942.6.1 Robot cabling and connection points ..........................................................
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Table of contents
973 Maintenance
973.1 Introduction ......................................................................................................
983.2 Maintenance schedule and expected component life ...............................................
983.2.1 Specification of maintenance intervals ........................................................
993.2.2 Maintenance schedule .............................................................................
1013.2.3 Expected component life .........................................................................
1023.3 Inspection activities ...........................................................................................
1023.3.1 Inspecting the oil level in axis-1 gearbox .....................................................
1043.3.2 Inspecting, oil level gearbox axes 2 - 3 .......................................................
1073.3.3 Inspecting, oil level gearbox axis 6 ............................................................
1093.3.4 Inspecting, balancing device bearings and piston rod guide ring ......................
1123.3.5 Inspecting, cable harness ........................................................................
1143.3.6 Inspecting the information labels ................................................................
1163.3.7 Inspecting the axis-1 mechanical stop pin ...................................................
1183.3.8 Inspecting the additional mechanical stops .................................................
1203.3.9 Inspection, dampers ................................................................................
1223.3.10 Inspecting the signal lamp (option) .............................................................
1243.4 Replacement/changing activities ..........................................................................
1243.4.1 Type of lubrication in gearboxes ................................................................
1263.4.2 Changing oil, axis-1 gearbox .....................................................................
1293.4.3 Changing oil, gearbox axes 2 and 3 ...........................................................
1333.4.4 Changing oil, gearbox axis 6 .....................................................................
1353.4.5 Replacing the SMB battery ........................................................................
1393.5 Lubrication activities ..........................................................................................
1393.5.1 Lubricating balancing device bearings and piston rod ....................................
1423.6 Cleaning activities .............................................................................................
1423.6.1 Cleaning the IRB 760 ...............................................................................
1454 Repair
1454.1 Introduction ......................................................................................................
1464.2 General procedures ...........................................................................................
1464.2.1 Performing a leak-down test ......................................................................
1474.2.2 Mounting instructions for bearings .............................................................
1494.2.3 Mounting instructions for seals ..................................................................
1514.2.4 Cut the paint or surface on the robot before replacing parts ............................
1524.2.5 The brake release buttons may be jammed after service work .........................
1534.3 Complete robot .................................................................................................
1534.3.1 Replacing cable harness, lower end (axes 1-3) .............................................
1634.3.2 Replacing the cable harness, upper end (incl. axis 6) .....................................
1714.3.3 Replacing the SMB unit ............................................................................
1744.3.4 Replacing the brake release board .............................................................
1784.3.5 Replacing the base, including axis 1 gearbox ...............................................
1864.4 Upper and lower arm .........................................................................................
1864.4.1 Replacing the turning disk ........................................................................
1914.4.2 Replacing the tilthouse unit .......................................................................
2114.4.3 Replacing the upper arm ..........................................................................
2284.4.4 Replacing linkage - upper link arm ..............................................................
2354.4.5 Replacing the linkage - lower link arm .........................................................
2424.4.6 Replacement of linkage - link .....................................................................
2534.4.7 Replacing the parallel rod .........................................................................
2614.4.8 Replacing the complete lower arm ..............................................................
2714.4.9 Replacement of parallel arm ......................................................................
2784.5 Frame and base ................................................................................................
2784.5.1 Replacing the balancing device ..................................................................
2874.5.2 Replacing the balancing weight ..................................................................
2914.6 Motors ............................................................................................................
2914.6.1 Replacing motor, axis 1 ............................................................................
2984.6.2 Replacing motors, axes 2 and 3 .................................................................
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Table of contents
3094.6.3 Replacing motor, axis 6 ............................................................................
3164.7 Gearboxes .......................................................................................................
3164.7.1 Replacing the axis 1 gearbox .....................................................................
3294.7.2 Replacing the gearbox, axes 2- 3 ...............................................................
3414.7.3 Replacing gearbox axis 6 ..........................................................................
3495 Calibration
3495.1 Introduction to calibration ...................................................................................
3495.1.1 Introduction and calibration terminology ......................................................
3505.1.2 Calibration methods .................................................................................
3525.1.3 When to calibrate ...................................................................................
3535.2 Synchronization marks and axis movement directions .............................................
3535.2.1 Synchronization marks and synchronization position for axes .........................
3555.2.2 Calibration movement directions for all axes ................................................
3565.3 Updating revolution counters ...............................................................................
3605.4 Calibrating with Axis Calibration method ...............................................................
3605.4.1 Description of Axis Calibration ..................................................................
3625.4.2 Calibration tools for Axis Calibration ...........................................................
3645.4.3 Installation locations for the calibration tools ...............................................
3665.4.4 Axis Calibration - Running the calibration procedure ......................................
3725.5 Calibrating with Calibration Pendulum method ........................................................
3735.6 Verifying the calibration ......................................................................................
3745.7 Checking the synchronization position ..................................................................
3756 Decommissioning
3756.1 Environmental information ..................................................................................
3776.2 Scrapping of robot .............................................................................................
3786.3 Decommissioning of balancing device ...................................................................
3817 Reference information
3817.1 Introduction ......................................................................................................
3827.2 Applicable standards .........................................................................................
3847.3 Unit conversion .................................................................................................
3857.4 Screw joints ....................................................................................................
3887.5 Weight specifications .........................................................................................
3897.6 Standard tools ..................................................................................................
3907.7 Special tools ....................................................................................................
3927.8 Lifting accessories and lifting instructions ..............................................................
3938 Spare parts
3938.1 Spare part lists and illustrations ...........................................................................
3959 Circuit diagrams
3959.1 Circuit diagrams ................................................................................................
397Index
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Table of contents
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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.
The manual also contains reference information for all procedures detailed in the
manual.
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.
Who should read this manual?
This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
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.
Product manual scope
The manual covers covers all variants and designs of the IRB 760. Some variants
and designs may have been removed from the business offer and are no longer
available for purchase.
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 about 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 main-
tenance of the robot. Based on a maintenance schedule that
may be used in the work of planning periodical maintenance.
Maintenance
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Overview of this manual
ContentsChapter
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 calibra-
tion.
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
documents, safety standards etc.
Reference information
Reference to the spare part list for the robot.Spare part / part list
Reference to the circuit diagram for the robot.Circuit diagram
References
Document IDReference
3HAC040446-001Product manual, spare parts - IRB 760
3HAC039612-001Product specification - IRB 760
3HAC031045-001Operating manual - General safety information
i
3HAC021313-001Product manual - IRC5
IRC5 with main computer DSQC 639.
3HAC047136-001Product manual - IRC5
IRC5 with main computer DSQC1000.
3HAC050941-001Operating manual - IRC5 with FlexPendant
3HAC050996-001Application manual - Electronic Position Switches
3HAC051016-001Application manual - Additional axes and stand alone control-
ler
3HAC042927-001Technical reference manual - Lubrication in gearboxes
3HAC050948-001Technical reference manual - System parameters
i
This manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Revisions
DescriptionRevision
First edition-
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Overview of this manual
Continued
DescriptionRevision
This revision includes the following updates:
• A new block, about general illustrations, added in section How to read
the product manual on page 14.
• Added information about balancing device, see Safety risks during
installation and service work on robots on page 23.
• Added an illustration that shows the directions of the robot stress
forces and changed the value for the force in the Z plane, see Loads
on foundation, robot on page 49.
• Added information about installing the signal lamp, see Pre-installation
procedure on page 48, and clarified the installation steps in Installation
of signal lamp, upper arm (option) on page 84.
• Added an assembly tool and a KM10 socket to the list of required
equipment and the instructions when replacing the upper and lower
link arms, see sections Replacing linkage - upper link arm on page 228
and Replacing the linkage - lower link arm on page 235. The tools are
also added to the list of Special tools in the Reference chapter.
• Added guide sleeves to hold the axes 2/3 sealing in place when refitting
the lower arm, see Replacing the complete lower arm on page 261.
• Added guide pins to the step that describes refitting of the axis 1
gearbox to the base, see Replacing the axis 1 gearbox on page 316.
Also made minor improvements in the working order in the step-by-
step instruction.
• Improved and corrected the instruction for how to remove and refit
the upper arm, see Replacing the upper arm on page 211.
• Improved and corrected the instruction for how to remove and refit
the tilthouse unit, see Replacing the tilthouse unit on page 191.
• Changed the instruction so that the weight of axis 3 is unloaded when
removing the axis 3 motor, instead of securing the upper arm with
roundslings, see Replacing motors, axes 2 and 3 on page 298. Other
minor improvements also made.
• Added information that the cable should be twisted one turn when
refitting it in the upper arm tube, see Replacing the cable harness,
upper end (incl. axis 6) on page 163.
• Clarified the importance of correct orientation of the turning disk when
removing and refitting it, see the refitting instruction in Replacing the
turning disk on page 186.
• Improved and corrected the instruction for how to remove and refit
the axis 2 and axis 3 gearbox, see Replacing the gearbox, axes 2- 3
on page 329.
A
This revision includes the following updates:
• Minor corrections and editorial changes made throughout the manual.
• Some general tightening torques have been changed/added, see up-
dated values in Screw joints on page 385.
• Added Safety risks during handling of batteries on page 35.
B
This revision includes the following updates:
• The maximum allowed deviation in levelness of the base plate is
changed, see Securing the base plate on page 70.
• Reference to Hilti standard added to the foundation recommendation
for the base plate and class designation for foundation is changed to
european standard C25/C30 (previously Swedish standard K25/K30),
see Securing the base plate on page 70.
• All data about type of lubrication in gearboxes is moved from the
manual to a separate lubrication manual, see Type and amount of oil
in gearboxes on page 124.
• A new SMB unit and battery is introduced, with longer battery lifetime.
C
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Overview of this manual
Continued
DescriptionRevision
This revision includes the following updates:
• Spare parts in general corrected.
• Added information about risks when scrapping a decommissioned
robot, see Scrapping of robot on page 377.
D
This revision includes the following updates:
• Instruction regarding protection pipe in gearbox axis 1 added, see
Removal, gearbox axis 1 on page 318.
• The maximum allowed deviation in levelness of the base plate and
foundation is changed, see Securing the base plate on page 70.
• Added tightening torque for oil plug of axis-1 gearbox.
• Added tightening torque for R1.SMB and 7th axis connector, ses Re-
placing cable harness, lower end (axes 1-3) on page 153.
• Minor corrections.
E
Illustrations of SMB battery RMU improved.F
This revision includes the following updates:
• Updated article number for label; Combined warning label "Brake re-
lease", "Brake release buttons" and "Moving robot"
• Grease name change (Longtime PD 2 → Tribol GR 100-2 PD)
G
Published in release R16.2. The following updates are done in this revision:
• Drawing of base plate is not available for purchase, faulty information
removed in Securing the base plate on page 70.
• Corrections due to updates in terminology.
• New standard calibration method is introduced (Axis Calibration). See
Calibration on page 349.
• Information about grounding point added. See Robot cabling and
connection points on page 94.
• Replacement procedure for the upper arm is updated, see Replacing
the upper arm on page 211.
H
Published in release R17.2. The following updates are made in this revision:
• Caution about removing metal residues added in sections about SMB
boards.
• Information about minimum resonance frequency added.
• Bending radius for static floor cables added.
• Updated list of applicable standards.
• Added text regarding overhaul in section specification of maintenance
intervals.
• Updated the section Start of robot in cold environments on page 93.
• Updated information regarding replacement of brake release board.
• Updated information regarding disconnecting and reconnecting battery
cable to serial measurement board.
• Updated information regarding replacing the balancing device.
• Definition of reference calibration clarified.
J
Continues on next page
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Overview of this manual
Continued
DescriptionRevision
Published in release R18.1. The following updates are made in this revision:
• Information added about fatigue to Axis Calibration tool, see Calibration
tools for Axis Calibration on page 362.
• Added sections in General procedures on page 146.
• Safety restructured.
• Updated spare part number brake release board (was DSQC563, is
DSQC1050)
• Added spare part number for axis-2 and axis-3 gearbox o-ring in repair
procedures.
• Note added to calibration chapter to emphasize the requirement of
equally dressed robot when using previously created reference calib-
ration values.
• Information about myABB Business Portal added.
K
Published in release R18.2. The following updates are done in this revision:
• Added locating hole position in tool flange view.
L
Published in release R18.2. The following updates are made in this revision:
• Updated references.
M
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Overview of this manual
Continued
How to read the product manual
Reading the procedures
The procedures contain references to figures, tools, material, and so on. The
references are read as described below.
References to figures
The procedures often include references to components or attachment points
located on the manipulator/controller. The components or attachment points are
marked with italic text in the procedures and completed with a reference to the
figure where the current component or attachment point is shown.
The denomination in the procedure for the component or attachment point
corresponds to the denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a
procedure.
Note/IllustrationAction
Shown in the figure Location of
gearbox on page xx.
Remove the rear attachment screws, gearbox.8.
References to required equipment
The procedures often include references to equipment (spare parts, tools, etc.)
required for the different actions in the procedure. The equipment is marked with
italic text in the procedures and completed with a reference to the section where
the equipment is listed with further information, that is article number and
dimensions.
The designation in the procedure for the component or attachment point
corresponds to the designation in the referenced list.
The table below shows an example of a reference to a list of required equipment
from a step in a procedure.
Note/IllustrationAction
Art. no. is specified in Required
equipment on page xx.
Fit a new sealing, axis 2 to the gearbox.3.
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 robot 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 robot
models, can be illustrated with illustrations that show a different robot model than
the one that is described in the current manual.
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How to read the product manual
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).
• 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
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 do not drop work pieces/tools
in the event of a power failure or a disturbance to the controller.
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 of the robot could
be affected.
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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
1.2 Safety actions
1.2.1 Fire extinguishing
Note
Use a CARBON DIOXIDE (CO
2
) extinguisher in the event of a fire in the
manipulator or controller.
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1 Safety
1.2.1 Fire extinguishing
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ABB IRB 760-450/3.2 User manual

Category
Robotics
Type
User manual
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