ABB IRB 760 Series Bedienungsanleitung

ABB Robotics

Product manual

IRB 760

Trace back information:

Workspace R13-1 version a6

Checked in 2013-03-31

Skribenta version 1184

Product manual

IRB 760 - 450/3.2

M2004

Document ID: 3HAC039838-001

Revision: C

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.

Additional copies of this manual may be obtained from ABB.

The original language for this publication is English. Any other languages that are

supplied have been translated from English.

ABB AB

Robotics Products

SE-721 68 Västerås

Sweden

Table of contents
9Overview of this manual ...................................................................................................................
12How to read the product manual ......................................................................................................
13Product documentation, M2004 .......................................................................................................
151 Safety
151.1 Introduction to safety information ......................................................................... 161.2 General safety information .................................................................................. 161.2.1 Introduction to general safety information .................................................... 171.2.2 Safety in the manipulator system ............................................................... 181.2.3 Safety risks ............................................................................................ 181.2.3.1 Safety risks during installation and service work on manipulators ......... 211.2.3.2 CAUTION - Hot parts may cause burns! ........................................... 221.2.3.3 Safety risks related to tools/work pieces .......................................... 231.2.3.4 Safety risks related to pneumatic/hydraulic systems .......................... 241.2.3.5 Safety risks during operational disturbances ..................................... 251.2.3.6 Risks associated with live electric parts ........................................... 271.2.4 Safety actions ......................................................................................... 271.2.4.1 Safety fence dimensions ............................................................... 281.2.4.2 Fire extinguishing ........................................................................ 291.2.4.3 Emergency release of the manipulator’s arm .................................... 301.2.4.4 Brake testing .............................................................................. 311.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" ........................ 321.2.4.6 Safe use of the FlexPendant .......................................................... 331.2.4.7 Work inside the manipulator's working range ................................... 341.2.4.8 Signal lamp (optional) ................................................................... 351.2.5 Safety stops ........................................................................................... 351.2.5.1 What is an emergency stop? .......................................................... 371.3 Safety related instructions .................................................................................. 371.3.1 Safety signals in the manual ...................................................................... 391.3.2 Safety symbols on manipulator labels ......................................................... 441.3.3 DANGER - Moving manipulators are potentially lethal! ................................... 451.3.4 DANGER - First test run may cause injury or damage! ................................... 461.3.5 WARNING - The brake release buttons may be jammed after service work ........ 471.3.6 DANGER - Make sure that the main power has been switched off! .................... 481.3.7 WARNING - The unit is sensitive to ESD! ..................................................... 491.3.8 WARNING - Safety risks during handling of batteries ..................................... 501.3.9 WARNING - Safety risks during work with gearbox lubricants (oil or grease) ......
532 Installation and commissioning
532.1 Introduction ...................................................................................................... 542.2 Unpacking ....................................................................................................... 542.2.1 Pre-installation procedure ......................................................................... 572.2.2 Working range and type of motion .............................................................. 602.2.3 Risk of tipping/stability ............................................................................. 622.3 On-site installation ............................................................................................ 622.3.1 Lifting robot with fork lift ........................................................................... 682.3.2 Lifting robot with roundslings .................................................................... 702.3.3 Lifting robot with lifting slings .................................................................... 732.3.4 Manually releasing the brakes ................................................................... 752.3.5 Lifting the base plate ............................................................................... 762.3.6 Securing the base plate ............................................................................ 802.3.7 Orienting and securing the robot ................................................................ 842.3.8 Fitting equipment on robot ....................................................................... 872.3.9 Installation of signal lamp, upper arm (option) .............................................. 912.3.10 Loads ....................................................................................................
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© Copyright 2013 ABB. All rights reserved.
Table of contents

4 Restricting the working range .............................................................................. 922.4.1 Introduction ............................................................................................ 932.4.2 Mechanically restricting the working range of axis 1 ...................................... 952.4.3 Extended working range, axis 1 (option 561-1) ............................................. 962.5 Robot in cold environments ................................................................................. 962.5.1 Start of robot in cold environments ............................................................. 972.6 Electrical connections ........................................................................................ 972.6.1 Robot cabling and connection points ..........................................................
Maintenance
1 Introduction ...................................................................................................... 1003.2 Maintenance schedule and expected component life ............................................... 1003.2.1 Specification of maintenance intervals ........................................................ 1013.2.2 Maintenance schedule ............................................................................. 1033.2.3 Expected component life ......................................................................... 1043.3 Inspection activities ........................................................................................... 1043.3.1 Inspecting, oil level gearbox axis 1 ............................................................ 1063.3.2 Inspecting, oil level gearbox axes 2 - 3 ....................................................... 1093.3.3 Inspecting, oil level gearbox axis 6 ............................................................ 1113.3.4 Inspecting, balancing device bearings and piston rod guide ring ...................... 1143.3.5 Inspecting, cable harness ........................................................................ 1173.3.6 Inspection, information labels .................................................................... 1193.3.7 Inspecting, mechanical stop pin, axis 1 ....................................................... 1213.3.8 Inspecting, additional mechanical stops ...................................................... 1233.3.9 Inspection, dampers ................................................................................ 1253.3.10 Inspecting, signal lamp (option) ................................................................. 1273.4 Replacement/changing activities .......................................................................... 1273.4.1 Type of lubrication in gearboxes ................................................................ 1293.4.2 Changing oil, axis-1 gearbox ..................................................................... 1323.4.3 Changing oil, gearbox axes 2 and 3 ........................................................... 1353.4.4 Changing oil, gearbox axis 6 ..................................................................... 1373.4.5 Replacing the SMB battery ........................................................................ 1423.5 Lubrication activities .......................................................................................... 1423.5.1 Lubricating balancing device bearings and piston rod .................................... 1453.6 Cleaning activities ............................................................................................. 1453.6.1 Cleaning, robot ......................................................................................
Repair
1 Introduction ...................................................................................................... 1484.2 General procedures ........................................................................................... 1484.2.1 Performing a leak-down test ..................................................................... 1494.2.2 Mounting instructions for bearings ............................................................. 1514.2.3 Mounting instructions for seals .................................................................. 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 unit ................................................................ 1784.3.5 Replacing the base, including axis 1 gearbox .............................................. 1854.4 Upper and lower arm ......................................................................................... 1854.4.1 Replacing the turning disk ........................................................................ 1904.4.2 Replacing the tilthouse unit ....................................................................... 2094.4.3 Replacing the upper arm .......................................................................... 2214.4.4 Replacing linkage - upper link arm .............................................................. 2284.4.5 Replacing the linkage - lower link arm ......................................................... 2354.4.6 Replacement of linkage - link ..................................................................... 2444.4.7 Replacing the parallel rod ......................................................................... 2514.4.8 Replacing the complete lower arm .............................................................. 2594.4.9 Replacement of parallel arm ......................................................................
3HAC039838-001 Revision: C
© Copyright 2013 ABB. All rights reserved.
Table of contents

5 Frame and base ................................................................................................ 2654.5.1 Replacing the balancing device ................................................................. 2744.5.2 Replacing the balancing weight .................................................................. 2784.6 Motors ............................................................................................................ 2784.6.1 Replacing motor, axis 1 ............................................................................ 2844.6.2 Replacing motors, axes 2 and 3 ................................................................. 2944.6.3 Replacing motor, axis 6 ............................................................................ 3014.7 Gearboxes ....................................................................................................... 3014.7.1 Replacing the axis 1 gearbox ..................................................................... 3114.7.2 Replacing the gearbox, axes 2- 3 ............................................................... 3224.7.3 Replacing gearbox axis 6 ..........................................................................
Calibration information
1 Introduction ..................................................................................................... 3305.2 Calibration methods ........................................................................................... 3325.3 Calibration scale and correct axis position ............................................................. 3345.4 Calibration movement directions for all axes .......................................................... 3355.5 Updating revolution counters ............................................................................... 3375.6 Checking the calibration position ..........................................................................
Decommissioning
1 Environmental information .................................................................................. 3406.2 Decommissioning of balancing device ...................................................................
Reference information
1 Introduction ...................................................................................................... 3447.2 Applicable safety standards ................................................................................ 3467.3 Unit conversion ................................................................................................. 3477.4 Screw joints .................................................................................................... 3507.5 Weight specifications ......................................................................................... 3517.6 Standard tools .................................................................................................. 3527.7 Special tools .................................................................................................... 3547.8 Lifting accessories and lifting instructions ..............................................................
Spare parts
1 Spare part lists and illustrations ...........................................................................
Circuit diagrams
1 About circuit diagrams .......................................................................................
359Index
3HAC039838-001 Revision: C 7
© Copyright 2013 ABB. All rights reserved.
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

A maintenance/repair/installation craftsman 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 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

Step-by-step procedures that describe how to perform repair

activities of the robot. Based on available spare parts.

Repair

Procedures that does not require specific calibration equipment.Calibration Information

General information about calibration.

Environmental information about the robot and its components.Decommissioning

Continues on next page

3HAC039838-001 Revision: C 9

Overview of this manual

ContentsChapter

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

3HAC021313-001Product manual - IRC5

3HAC16590-1Operating manual - IRC5 with FlexPendant

3HAC027709-001Application manual - Electronic Position Switches

3HAC021395-001Application manual - Additional axes and stand alone control-

ler

3HAC042927-001Technical reference manual - Lubrication in gearboxes

3HAC17076-1Technical reference manual - System parameters

Revisions

DescriptionRevision

First edition-

Continues on next page

10 3HAC039838-001 Revision: C

Overview of this manual

Continued

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