ABB IRB 120 Bedienungsanleitung

ROBOTICS

Product manual

IRB 120

Trace back information:

Workspace R17-2 version a11

Checked in 2017-09-20

Skribenta version 5.1.011

Product manual

IRB 120 - 3/0.6

IRB 120T - 3/0.6

IRC5

Document ID: 3HAC035728-001

Revision: N

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.

ABB AB, Robotics

Robotics and Motion

Se-721 68 Västerås

Sweden

Table of contents
9Overview of this manual ...................................................................................................................
14Product documentation, IRC5 ..........................................................................................................
16How to read the product manual ......................................................................................................
171 Safety
171.1 Introduction to safety information ......................................................................... 181.2 General safety information .................................................................................. 181.2.1 Introduction to general safety information .................................................... 191.2.2 Safety in the robot system ........................................................................ 211.2.3 Protective stop and emergency stop ........................................................... 221.2.4 Safety risks ............................................................................................ 221.2.4.1 Safety risks during installation and service work on manipulators ......... 251.2.4.2 CAUTION - Hot parts may cause burns! ........................................... 261.2.4.3 Safety risks related to tools/work pieces .......................................... 271.2.4.4 Safety risks related to pneumatic/hydraulic systems .......................... 281.2.4.5 Safety risks during operational disturbances ..................................... 291.2.4.6 Risks associated with live electric parts ........................................... 311.2.5 Safety actions ......................................................................................... 311.2.5.1 Safety fence dimensions ............................................................... 321.2.5.2 Fire extinguishing ........................................................................ 331.2.5.3 Emergency release of the robot arm ............................................... 341.2.5.4 Brake testing .............................................................................. 351.2.5.5 Risk of disabling function "Reduced speed 250 mm/s" ........................ 361.2.5.6 Enabling device and hold-to-run functionality .................................... 371.2.5.7 Work inside the working range of the robot ....................................... 381.3 Safety signals and symbols ................................................................................. 381.3.1 Safety signals in the manual ...................................................................... 401.3.2 Safety symbols on product labels ............................................................... 461.4 Safety related instructions .................................................................................. 461.4.1 DANGER - Moving robots are potentially lethal! ............................................ 471.4.2 DANGER - First test run may cause injury or damage! ................................... 481.4.3 DANGER - Make sure that the main power has been switched off! .................... 501.4.4 WARNING - The unit is sensitive to ESD! ..................................................... 521.4.5 WARNING - Safety risks during handling of batteries ..................................... 531.4.6 WARNING - Safety risks during work with gearbox lubricants (oil or grease) ......
552 Installation and commissioning
552.1 Introduction ...................................................................................................... 562.2 Unpacking ....................................................................................................... 562.2.1 Pre-installation procedure ......................................................................... 602.2.2 Working range and type of motion .............................................................. 622.2.3 Risk of tipping/stability ............................................................................. 632.3 On-site installation ............................................................................................ 632.3.1 Lifting the robot with roundslings ............................................................... 662.3.2 Manually releasing the brakes ................................................................... 702.3.3 Orienting and securing the robot ............................................................... 722.3.4 Fitting equipment on robot ........................................................................ 752.3.5 Setting the system parameters for a suspended or tilted robot ......................... 802.3.6 Loads fitted to the robot, stopping time and braking distances ......................... 812.4 Restricting the working range .............................................................................. 812.4.1 Axes with restricted working range ............................................................. 822.4.2 Mechanically restricting the working range ................................................... 842.5 Making robot ready for operation .......................................................................... 842.5.1 Additional installation procedure, Clean Room .............................................. 852.6 Electrical connections ........................................................................................ 852.6.1 Robot cabling and connection points ..........................................................
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Table of contents

6.2 Customer connections on the robot ............................................................ 892.7 Start of robot in cold environments ......................................................................
Maintenance
1 Introduction ...................................................................................................... 923.2 Maintenance schedule ....................................................................................... 923.2.1 Specification of maintenance intervals ........................................................ 933.2.2 Maintenance schedule ............................................................................. 953.3 Inspection activities ........................................................................................... 953.3.1 Inspecting the robot cabling ..................................................................... 963.3.2 Inspecting mechanical stops .................................................................... 993.3.3 Inspecting dampers ................................................................................. 1013.3.4 Inspecting timing belts ............................................................................ 1053.3.5 Inspecting plastic covers .......................................................................... 1073.4 Replacement/changing activities .......................................................................... 1073.4.1 Type of lubrication in gearboxes ................................................................ 1093.4.2 Replacing the battery pack ........................................................................ 1123.5 Cleaning activities ............................................................................................. 1123.5.1 Cleaning the IRB 120 ...............................................................................
Repair
1 Introduction ...................................................................................................... 1164.2 General procedures ........................................................................................... 1164.2.1 Mounting instructions for seals .................................................................. 1184.2.2 Replacing parts on the robot ..................................................................... 1204.3 Cable harness .................................................................................................. 1204.3.1 Removing the cable harness ..................................................................... 1344.3.2 Refitting the cable harness ........................................................................ 1484.3.3 Replacing the Encoder Interface board ........................................................ 1514.4 Plastic covers ................................................................................................... 1514.4.1 Replacing plastic covers ........................................................................... 1554.5 Upper arm ....................................................................................................... 1554.5.1 Replacing the upper arm .......................................................................... 1644.6 Lower arm ....................................................................................................... 1644.6.1 Replacing the lower arm ........................................................................... 1694.7 Motors and motors with gearboxes ....................................................................... 1694.7.1 Replacing axis-1 motor with gearbox .......................................................... 1904.7.2 Replacing axis-2 motor with gearbox .......................................................... 2024.7.3 Replacing axis-3 motor with gearbox .......................................................... 2104.7.4 Replacing motor axis 4, with gearbox .......................................................... 2114.7.5 Replacing motor axis 5 ............................................................................. 2174.7.6 Replacing motor axis 6 ............................................................................. 2184.8 Gearboxes ....................................................................................................... 2184.8.1 Replacing gearbox axis 1 .......................................................................... 2194.8.2 Replacing gearbox axis 2 .......................................................................... 2204.8.3 Replacing gearbox axis 3 .......................................................................... 2214.8.4 Replacing gearbox axis 4 .......................................................................... 2224.8.5 Replacing gearbox axis 5 .......................................................................... 2234.8.6 Replacing gearbox axis 6 ..........................................................................
Calibration
1 Introduction to calibration ................................................................................... 2255.1.1 Introduction and calibration terminology ...................................................... 2265.1.2 Calibration methods ................................................................................. 2275.1.3 When to calibrate ................................................................................... 2285.2 Synchronization marks and axis movement directions ............................................. 2285.2.1 Synchronization marks and synchronization position for axes ......................... 2305.2.2 Calibration movement directions for all axes ................................................
Product manual - IRB 120
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© Copyright 2009-2017 ABB. All rights reserved.
Table of contents

2315.3 Updating revolution counters ............................................................................... 2355.4 Calibrating with Axis Calibration method ............................................................... 2355.4.1 Description of Axis Calibration .................................................................. 2375.4.2 Axis Calibration - Running the calibration procedure ...................................... 2425.5 Calibrating with manual calibration method ............................................................ 2485.6 Verifying the calibration ...................................................................................... 2495.7 Checking the synchronization position ..................................................................
2516 Decommissioning
2516.1 Introduction ...................................................................................................... 2526.2 Environmental information .................................................................................. 2536.3 Scrapping of robot .............................................................................................
2557 Reference information
2557.1 Introduction ...................................................................................................... 2567.2 Applicable standards ......................................................................................... 2577.3 Unit conversion ................................................................................................. 2587.4 Screw joints .................................................................................................... 2597.5 Weight specifications ......................................................................................... 2607.6 Standard toolkit ................................................................................................ 2617.7 Special tools .................................................................................................... 2627.8 Lifting equipment and lifting instructions ................................................................
2638 Spare parts
2638.1 Spare part lists and illustrations ...........................................................................
2659 Circuit diagrams
2659.1 Circuit diagrams ................................................................................................
267Index
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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.

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

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 the 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

Procedures that do not require specific calibration equipment.

General information about calibration.

Calibration information

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

Product manual - IRB 120 9

3HAC035728-001 Revision: N

Overview of this manual

ContentsChapter

Complete spare part list and complete list of robot components,

shown in exploded views.

Spare part / part list

Detailed illustrations of the robot with reference numbers to the

part list.

Exploded views

Reference to the circuit diagram for the robot.Circuit diagram

References

Document IDReference

3HAC035960-001Product specification - IRB 120

3HAC049098-001Product manual, spare parts - IRB 120

3HAC021313-001Product manual - IRC5

IRC5 with main computer DSQC 639.

3HAC047136-001Product manual - IRC5

IRC5 with main computer DSQC1000.

3HAC035738-001Product manual - IRC5 Compact

3HAC027707-001Product manual - IRC5 Panel Mounted Controller

3HAC042927-001Technical reference manual - Lubrication in gearboxes

3HAC050941-001Operating manual - IRC5 with FlexPendant

3HAC027098-001Operating manual - Emergency safety information

Same document num-

ber regardless of lan-

guage.

3HAC031045-001Operating manual - General safety information i

iThis manual contains all safety instructions from the product manuals for the manipulators and the

controllers.

Revisions

DescriptionRevision

First edition-

This revision includes the following additions and/or changes:A • Section "Product documentation, M2004" added.

• Section "How to read the product manual" added.

•Safety chapter- Updated safety signal graphics for levels Danger! and

Warning! See section Safety signals in the manual on page 38.

•Safety chapter - New safety labels on the manipulators, see Safety

symbols on product labels on page 40.

•Safety chapter- Revised terminology: robot replaced with manipulator.

•Safety chapter - Information not applicable to IRB 120 in WARNING

- Safety risks during work with gearbox lubricants (oil or grease) on

page 53 removed.

•Installation chapter- Illustration updated in Risk of tipping/stability

on page 62.

•Installation chapter- Attachment screws added in Lifting the robot

with roundslings on page 63.

•Installation chapter- Value in illustration updated in Orienting and

securing the robot on page 70.

Continues on next page

10 Product manual - IRB 120

3HAC035728-001 Revision: N

Overview of this manual

Continued

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