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Product manual (part 2 of 2), reference information IRB 7600 - 500/2.3 IRB 7600 - 400/2.55 IRB 7600 - 340/2.8 IRB 7600 - 150/3.5

M2000

M2000A

M2004

Document ID: 3HAC 022033-001 Revision: B

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, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted.

Additional copies of this manual may be obtained from ABB at its then current charge.

© Copyright 2004 ABB All right reserved.

ABB Automation Technologies AB Robotics SE-721 68 V‰sterÂs Sweden

Table of Contents

. Product documentation, M2000/M2000A Product documentation, M2004

Overview

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. 5

. 7

 

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. 8

1 Reference information

 

11

1.1 Introduction

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11

1.2 Applicable Safety

 

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1.3 Unit

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13

Screw joints

1.4 .

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14

1.5 Weight specifications

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. 17

1.6 Standard

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. 18

Special tools

1.7 .

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. 19

1.8 Document references

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22

1.9 Lifting equipment and lifting instructions

 

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2 Part list

25

2.1

Introduction

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25

2.2 Rebuilding parts

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26

2.2.1

Overview

 

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26

2.3 Part List

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27

2.3.1 Part list,

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27

2.3.2 Mechanical stop ax 1, 3HAC 12812-2 .

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. 29

2.3.3 Base incl frame ax 1, 3HAC 12304-1

 

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30

2.3.4 Axis 3-4 400kg, 3HAC 13063-1 (IRB 7600 - 400/2.55, -340/2.8, 150/3.5)

 

31

2.3.5 Axis 3-4 500kg, 3HAC 13063-2 (IRB 7600 - 500/2.3)

 

32

2.3.6 Axis 3-4 400kg Foundry, 3HAC 13063-4 (IRB 7600 - 400/2.55, -340/2.8, 150/3.5)

 

33

2.3.7 Axis 3-4 500kg Foundry, 3HAC 13063-5 (IRB 7600 - 500/2.3)

 

34

2.3.8 Wrist, 3HAC 10503-1 (Std) / 3HAC 15992-1 (Foundry)

 

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38

2.3.9 Material set manipulator, 3HAC 13079-1

 

44

2.3.10 Material set ax 1-2, 3HAC 13077-1

 

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45

2.3.11 Mtrl.set balancing device, 3HAC

 

48

2.3.12 Arm extension set, 956 mm, 3HAC 12311-1 (IRB 7600 - 150/3.5)

 

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49

2.3.13 Arm extension set, 250 mm, 3HAC 12311-2 (IRB 7600 - 340/2.8)

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50

3 Exploded views

51

3.1 Introduction

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51

3.2 Base incl. Frame

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52

3.3 Frame-Lower arm 1

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53

3.4 Frame-Lower arm 2

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54

3.5 Upper arm

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55

3.6 Wrist complete

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56

4 Circuit Diagram

57

4.1

Introduction

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57

Table of Contents

Overview

Overview

About this manual

This manual contains reference information for all procedures described in the Product manual, procedures .

Usage

This manual should be used during

ï installation

ï maintenance work

ï repair work.

Who should read this manual?

This manual is intended for:

ï installation personnel

ï maintenance personnel

ï repair personnel.

Prerequisites

The reader should

ï be a trained maintenance/repair craftsman

ï have the required knowledge of mechanical and electrical installation/repair/ maintenance work.

Overview

Organization of chapters The manual is organized in the following chapters:

Chapter

Contents

Reference information

Useful information when performing installation, maintenance or repair work (lists of necessary tools, reference documents, safety standards).

Part list

Complete list of manipulator parts, shown in the exploded views or foldouts.

Exploded views / Foldouts

Detailed illustrations of the manipulator with reference numbers to the part list.

Circuit Diagram

Circuit Diagram of the manipulator.

Revisions

Revision

Description

-

First edition. Replaces previous manuals:

ï Installation and Commssioning Manual

ï Maintenance Manual

ï Repair Manual, part 1

ï Repair Manual, part 2.

Changes made in the material from the previous manuals:

ï Model M2004 implemented.

ï Various corrections due to technical revisions, changes in the toolkits etc.

A

Following updates are made:

ï Section Document references is completed with article numbers for calibration manuals.

ï Section Part list is completed with the spare part number for a variant of the cable harness/brake release unit.

B

New lubricating oil in the gearboxes. Changes are made in the section Part list.

Product documentation, M2000/M2000A

Product documentation, M2000/M2000A

General

The complete product documentation kit for the M2000 robot system, including controller, robot and any hardware option, consists of the manuals listed below:

Hardware manuals

All hardware, robots and controller cabinets, will be delivered with a Product manual which

is divided into two parts:

Product manual, procedures

ï Safety information

ï Installation and commissioning (descriptions of mechanical installation, electrical connections and loading system software)

ï Maintenance (descriptions of all required preventive maintenance procedures including intervals)

ï Repair (descriptions of all recommended repair procedures including spare parts)

ï Additional procedures, if any (calibration, decommissioning)

Product manual, reference information

ï Reference information (article numbers for documentation referred to in Product manual, procedures, lists of tools, safety standards)

ï Part list

ï Foldouts or exploded views

ï Circuit diagrams

Software manuals

The software documentation consists of a wide range of manuals, ranging from manuals for basic understanding of the operating system to manuals for entering parameters during operation.

A complete listing of all available software manuals is available from ABB.

Controller hardware option manual

Each hardware option for the controller is supplied with its own documentation. Each document set contains the types of information specified below:

ï Installation information

ï Repair information

ï Maintenance information

In addition, spare part information is supplied for the entire option.

Product documentation, M2004

Product documentation, M2004

General

The robot documentation may be divided into a number of categories. This listing is based on the type of information contained within the documents, regardless of whether the products are standard or optional. This means that any given delivery of robot products will not contain all documents listed, only the ones pertaining to the equipment delivered.

However, all documents listed may be ordered from ABB. The documents listed are valid for M2004 robot systems.

Hardware manuals

All hardware, robots and controller cabinets, will be delivered with a Product manual which is divided into two parts:

Product manual, procedures

ï Safety information

ï Installation and commissioning (descriptions of mechanical installation, electrical connections and loading system software)

ï Maintenance (descriptions of all required preventive maintenance procedures including intervals)

ï Repair (descriptions of all recommended repair procedures including spare parts)

ï Additional procedures, if any (calibration, decommissioning)

Product manual, reference information

ï Reference information (article numbers for documentation referred to in Product manual, procedures, lists of tools, safety standards)

ï Part list

ï Foldouts or exploded views

ï Circuit diagrams

RobotWare manuals

The following manuals describe the robot software in general and contain relevant reference information:

ï RAPID Overview: An overview of the RAPID programming language.

ï RAPID reference manual part 1: Description of all RAPID instructions.

ï RAPID reference manual part 2: Description of all RAPID functions and data types.

ï Technical reference manual - System parameters: Description of system parameters and configuration workflows.

Product documentation, M2004

Application manuals

Specific applications (e.g. 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:

ï The purpose of the application (what it does and when it is useful)

ï What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)

ï How to use the application

ï Examples of how to use the application

Operator's manuals

This group of manuals is aimed at those having first hand operational contact with the robot, i.e. production cell operators, programmers and trouble shooters. The group of manuals include:

ï Operator's manual - IRC5 with FlexPendant

ï Operator's manual - RobotStudio Online

ï Trouble shooting manual for the controller and robot

Miscellaneous

A number of manuals provide generic descriptions of the robot and robot system. These include:

ï Robot fundamentals (describing the fundamental aspects, functions, concept and similar, of a robot system to provide a basic understanding of the robot system)

Product documentation, M2004

1 Reference information

1 Reference information

1.1. Introduction