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Pneumatic or hydraulic related hazards

Note

The pressure in the complete pneumatic or hydraulic systems must be released
before service and maintenance.

All components in the robot system that remain pressurized after switching off
the power to the robot must be marked with clearly visible drain facilities and a
warning sign that indicates the hazard of stored energy.

Loss of pressure in the robot system may cause parts or objects to drop.

Dump valves should be used in case of emergency.

Shot bolts should be used to prevent tools, etc., from falling due to gravity.

All pipes, hoses, and connections have to be inspected regularly for leaks and
damage. Damage must be repaired immediately.

Safety measures for arc welding

The following points should be observed:

•

Consider the welding robot equipment as a single unit.

•

Do not mix up the phase and grounding conductors when connecting the
equipment to the main supply.

•

The workpiece, fixtures, and positioner are usually in direct contact with the
welding circuit, and should therefore be regarded as live.

•

Do not touch live parts of the equipment with your bare hands or with damp
gloves.

•

The welding circuit shall not be grounded without necessary measures being
taken to ensure proper functioning of the grounding conductor.

•

The welding circuit must not be broken during the welding process.

WARNING

The welding wire is live during the welding process even before the arc is ignited.

Personal protective equipment

Use personal protective equipment, based on the risk assessment for the robot
system.

Do not wear loose-fitting garments or belts, bracelets, etc., that can become
entangled in the robot or positioner. Always use the prescribed personal protective
equipment.

Welding fumes and any gases formed or used when welding can be dangerous to
inhale.

Verify the safety functions

Before the robot system is put into operation, verify that the safety functions are
working as intended and that any remaining hazards identified in the risk
assessment are mitigated to an acceptable level.

30

Product manual - IRB 1520

3HAC043435-001 Revision: L

© Copyright 2012-2020 ABB. All rights reserved.

1 Safety

1.4 Installation and commissioning

Continued

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Summary of Contents for IRB 1520

Page 1: ...ROBOTICS Product manual IRB 1520 ...

Page 2: ...Trace back information Workspace 20B version a12 Checked in 2020 05 28 Skribenta version 5 3 033 ...

Page 3: ...Product manual IRB 1520ID 4 1 5 IRC5 Document ID 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved Specifications subject to change without notice ...

Page 4: ...ty by ABB for losses damage 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 f...

Page 5: ...ning a suspended mounted robot 53 2 3 3 Manually releasing the brakes 55 2 3 4 Orienting and securing the robot 58 2 3 5 Setting the system parameters for a suspended or tilted robot 63 2 3 6 Loads fitted to the robot stopping time and braking distances 64 2 3 7 Fitting equipment on the robot robot dimensions 68 2 4 Restricting the working range 68 2 4 1 Axes with restricted working range 69 2 4 2...

Page 6: ...rm system 183 4 4 Upper and lower arm 183 4 4 1 Replacing the complete upper arm IRB 1520ID 191 4 4 2 Replacing the complete lower arm 195 4 4 3 Replacing the wrist unit IRB 1600ID 201 4 4 4 Replacing the damper axis 2 203 4 4 5 Replacing the damper axis 3 205 4 4 6 Replacing the mechanical stop axis 3 IRB 1520ID 207 4 5 Frame and base 207 4 5 1 Replacing the base 214 4 5 2 Replacing the serial me...

Page 7: ...it conversion 293 7 4 Screw joints 296 7 5 Weight specifications 297 7 6 Standard tools 298 7 7 Special tools 299 7 8 Lifting accessories and lifting instructions 301 8 Spare parts 301 8 1 Spare part lists and illustrations 303 9 Circuit diagram 303 9 1 Circuit diagrams 305 Index Product manual IRB 1520 7 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved Table of contents ...

Page 8: ...This page is intentionally left blank ...

Page 9: ...of the IRB 1520 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 Contents Chapter 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 on ho...

Page 10: ...ain computer DSQC 639 3HAC047136 001 Product manual IRC5 IRC5 with main computer DSQC1000 3HAC050941 001 Operating manual IRC5 with FlexPendant 3HAC050944 001 Operating manual Service Information System 3HAC16578 1 Operating manual Calibration Pendulum 3HAC051016 001 Application manual Additional axes and stand alone controller 3HAC030421 001 Application manual CalibWare Field 3HAC042927 001 Techn...

Page 11: ...tion Start of robot in cold environments on page 73 added Updated information regarding replacement of brake release board Updated information regarding disconnecting and reconnecting battery cable to serial measurement board E Published in release R18 1 The following updates are made in this revi sion Added sections in General procedures on page 134 Safety restructured Updated spare parts number ...

Page 12: ...rotat ing sealings see Mounting instructions for sealings on page 137 Added information about Wrist Optimization and Wrist Optimization in calibration chapter Replaced article number and name of grease previously 3HAB3537 1 L 12 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved Overview of this manual Continued ...

Page 13: ...ioning 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 ...

Page 14: ...s The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters 14 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved Product documentation Continued ...

Page 15: ...ompleted 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 Illustration Action Art no is...

Page 16: ...This page is intentionally left blank ...

Page 17: ...ration 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 of the robot Repairs on the robot and its spare parts carried out by in experienced or non qualified personnel Foreign objects Force majeure Spare parts and equipment ABB supplie...

Page 18: ...ence of alcohol drugs or any other intoxicating substances are not allowed to install maintain service repair or use the robot The plant liable must make sure that the personnel is trained on the robot and on responding to emergency or abnormal situations Personal protective equipment Use personal protective equipment as stated in the product manual 18 Product manual IRB 1520 3HAC043435 001 Revisi...

Page 19: ...on which if not avoided will result in ser ious injury DANGER Signal word used to indicate a potentially hazardous situation which if not avoided could result in serious injury WARNING Signal word used to indicate a potentially hazardous situation related to electrical hazards which if not avoided could result in serious injury ELECTRICAL SHOCK Signal word used to indicate a potentially hazardous ...

Page 20: ...d to indicate where to find additional information or how to do an operation in an easier way TIP 20 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 1 Safety 1 2 1 Safety signals in the manual Continued ...

Page 21: ...ription Symbol Warning xx0900000812 Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc Caution xx090000...

Page 22: ...o not disassemble xx0900000815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the robot arm can fall down Continues on next page 22 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights rese...

Page 23: ... over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page Product manual IRB 1520 23 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 24: ...1 06 xx1300001087 Moving robot 1 2 3 4 5 6 xx0900000819 The robot can move unexpectedly xx1000001141 1 2 3 4 xx1500002616 Continues on next page 24 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 25: ...01242 Lifting of robot xx0900000822 Oil xx0900000823 Can be used in combination with prohibition if oil is not allowed Mechanical stop xx0900000824 Continues on next page Product manual IRB 1520 25 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 26: ...t this part is pressurized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller Do not step xx1400002648 Warns that stepping on these parts can cause damage to the parts 26 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Cont...

Page 27: ...rotective stops and emergency stops are described in the product manual for the controller For more information see Product manual IRC5 Product manual IRB 1520 27 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 1 Safety 1 3 Robot stopping functions ...

Page 28: ...t if dropped or released at maximum speed The maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot The maximum TCP speed and the maximum velocity of the robot axes are detailed in the section Robot motion in the product specification for the respective manipulator Consider exposure to hazards such as slipping tripping and falling Consider...

Page 29: ...When integrating the robot with external devices to a robot system The integrator of the robot system must ensure that emergency stop functions are interlocked in accordance with applicable standards The integrator of the robot system must ensure that safety functions are interlocked in accordance with applicable standards Other hazards WARNING Never stay beneath a robot arm Gravity and the releas...

Page 30: ...he welding circuit and should therefore be regarded as live Do not touch live parts of the equipment with your bare hands or with damp gloves The welding circuit shall not be grounded without necessary measures being taken to ensure proper functioning of the grounding conductor The welding circuit must not be broken during the welding process WARNING The welding wire is live during the welding pro...

Page 31: ... release of braking devices can create additional hazards A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment Product manual IRB 1520 31 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 1 Safety 1 5 1 Unexpected movement of robot arm ...

Page 32: ...ubricants oil or grease When handling oil grease or other chemical substances the safety information of the respective manufacturer must be observed Note Take special care when handling hot lubricants Elimination Action Description Warning Make sure that protective gear like goggles and gloves are al ways worn during this activity Changing and draining gearbox oil or grease may require hand ling h...

Page 33: ...ecified amount de pends on drained volume For lifetime reasons always drain as much oil as possible from the gearbox The magnetic oil plugs will gather residual metal chips Contaminated oil in gearboxes Hazards related to batteries Under rated conditions the electrode materials and liquid electrolyte in the batteries are sealed and not exposed to the outside There is a hazard in case of abuse mech...

Page 34: ...erform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment Related information See also the safety information related to installation and operation 34 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 1 Safety 1 6 1 Maintenance and repair Continued ...

Page 35: ...ire using an overhead crane or similar equipment Increased injury Before releasing the brakes make sure that the weight of the manipulator does not result in additional hazards for example even more severe injuries on a trapped person DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unexpected ways Make sure no personnel is near or beneath the robot Pr...

Page 36: ...s described below 1 Run each axis to a position where the combined weight of the manipulator and any load is maximized maximum static load 2 Switch the motor to the MOTORS OFF 3 Inspect and verify that the axis maintains its position If the manipulator does not change position as the motors are switched off then the brake function is adequate 36 Product manual IRB 1520 3HAC043435 001 Revision L Co...

Page 37: ...d engineers A risk assessment must be done to address both robot and robot system specific hazards WARNING Never stay beneath a robot arm Gravity and the release of braking devices can create additional hazards A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment Related information See also the safety informatio...

Page 38: ...m Gravity and the release of braking devices can create additional hazards A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment 38 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 1 Safety 1 8 Decommissioning ...

Page 39: ... extremely important that all safety information is observed There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page17 before performing any installation work Note If the IRB 1520 is connected to power always make sure that the robot is connected ...

Page 40: ...sory used if required is suitable to handle the weight of the robot as specified in Weight robot on page 41 5 If the robot is not installed directly it must be stored as described in Storage condi tions robot on page 43 6 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 43 7 Before taking the robot to i...

Page 41: ...robots xy xy z z T F F T xx1100000521 Force in any direction in the XY plane Fxy Force in the Z plane Fz Bending torque in any direction in the XY plane Txy Bending torque in the Z plane Tz The table shows the various forces and torques working on the robot during different kinds of operation Note These forces and torques are extreme values that are rarely encountered during operation The values a...

Page 42: ...uence the absolute accuracy 15 Maximum tilt The value is recommended for optimal perform ance 22 Hz Note It may affect the manipulator life time to have a lower resonance frequency than recommended Minimum resonance frequency Due to foundation stiffness consider robot mass including equipment i For information about compensating for founda tion flexibility see Application manual Control ler softwa...

Page 43: ...ent temperature 75 C Maximum ambient temperature less than 24 hrs 95 at constant temperature gaseous only Maximum ambient humidity Operating conditions robot The table shows the allowed operating conditions for the robot Value Parameter 5 Minimum ambient temperature 45 Maximum ambient temperature 95 at constant temperature gaseous only Maximum ambient humidity Protection classes robot The table sh...

Page 44: ...ding package This illustration shows the restricted working range of the robot 808 1500 295 494 4 2601 160 pos7 pos8 Z X pos6 pos2 pos4 pos3 pos0 pos1 pos5 xx1100000306 Continues on next page 44 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range ...

Page 45: ...res Angle degrees Positions at wrist center mm Position in the figure axis 3 axis 2 Z X 0º 0º 1243 883 pos0 74 5º 0º 1793 160 pos1 80º 0º 365 4 482 7 pos2 74 5º 90º 453 1500 pos3 100º 150º 482 8 1073 2 pos4 restricted working range 180º 150º 192 3 636 2 pos4 unrestric ted working range 80º 150º 366 8 163 1 pos5 Continues on next page Product manual IRB 1520 45 3HAC043435 001 Revision L Copyright 2...

Page 46: ...90º 938 9 574 1 pos8 unrestric ted working range Turning radius xx1100000308 Minimum turning radius of axis 1 A Working range Note IRB 1520ID 4 1 5 Axis 170º to 170º Axis 1 150º to 90º Axis 2 Continues on next page 46 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range Continued ...

Page 47: ... value 155º to 155º Axis 4 135º to 135º Axis 5 Default value 200º to 200º Axis 6 Maximum value 288 to 288 revolutions The default working range for axis 6 can be extended by changing parameter values in the software Product manual IRB 1520 47 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range Continued ...

Page 48: ...ansportation position This figure shows the robot in its shipping position and transportation position 45 1 0 Axis 4 90 xx1100000309 WARNING The robot will be mechanically unstable if not properly secured to the foundation 48 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 2 Installation and commissioning 2 2 3 Risk of tipping stability ...

Page 49: ...ndling Note Action Wrist straps must be tested frequently to ensure that they are not damaged and are operating cor rectly Product manual IRC5 Use a wrist strap The wrist strap button is located inside the control ler 1 The mat must be grounded through a current limit ing resistor Use an ESD protective floor mat 2 The mat should provide a controlled discharge of static voltages and must be grounde...

Page 50: ... in U shape and put around the axis 3 gearbox B Required equipment Note Art no Equipment Lifting capacity 1 000 kg Overhead crane Length 2 m Roundsling Quantity 2 pcs Lifting capacity 1 000 kg Continues on next page 50 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 2 Installation and commissioning 2 3 1 Lifting robot with roundslings ...

Page 51: ...head crane put the other roundsling around the axis 3 gearbox and secure it safely at the overhead crane 2 Capacity for the roundslings are spe cified in Required equipment on page 50 See attachment in Attaching the roundslings on page 50 CAUTION The robot weighs 170 kg All lifting accessories used must be sized ac cordingly 3 WARNING Personnel must not under any circumstances be present under the...

Page 52: ...rticle numbers for the accessory and the instruction is specified in Special tools on page 298 Any additional equipment required is specified in the instruction for the lifting accessory Contact ABB for more information Illustration xx1100000382 52 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 2 Installation and commissioning 2 3 2 Lifting and turnin...

Page 53: ...on xx1100000312 Figure 2 1 Brake release buttons The internal brake release unit is located at the base of the robot and equipped with six buttons for con trolling the axes brakes The buttons are numbered according to the numbers of the axes 1 DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unexpected ways Make sure no personnel is near or beneath the...

Page 54: ...aused to a resistor di ode and to the system board DANGER Incorrect connections such as supplying power to the wrong pin may cause all brakes to be released simultaneously 1 xx1100000390 Supply 0V on pin 12 24V on pin 11 Connect an external power supply to connect or R1 MP 2 Push the brake release button to release the holding brakes according to the previous procedure 3 54 Product manual IRB 1520...

Page 55: ...iew G G are designed to include a guiding sleeve 150 150 150 150 4 5 F F G G F F G G G G F F 0 5 A 2 32 2 2 18 A 2 32 2 2X45 10 2 25 H8 0 0 033 2 18 xx1100000293 Attachment bolts specification 4 pcs Attachment bolts M16 x 45 30 x 17 x 3 Washers 8 8 Quality 200 Nm Tightening torque Continues on next page Product manual IRB 1520 55 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserve...

Page 56: ...obot to the installation site 3 Guide the robot gently using two of the attach ment bolts while lowering it into its mounting position 4 Specified in section Attachment bolts specification on page 55 Fit and tighten the bolts and washers in the base attachment holes 5 Isolating AW manipulator CAUTION If the manipulator is used for arc welding and is mounted on a pedestal make sure that the manipul...

Page 57: ...sleeve E Isolator F Nut M16 G Product manual IRB 1520 57 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 2 Installation and commissioning 2 3 4 Orienting and securing the robot Continued ...

Page 58: ...e mounting angle must be configured correctly in the system parameters so that the robot system can control the movements in the best possible way An incorrect definition of the mounting angle will result in Overloading the mechanical structure Lower path performance and path accuracy Some functions will not work properly for example Load Identification and Collision detection Gravity Beta If the ...

Page 59: ...n the system parameter 7 axes high performance motion is set see Technical reference manual System parameters Gamma Rotation Gamma Rotation defines the orientation of the robot foot on the travel carriage track motion Mounting angles and values The parameter Gravity Beta or Gravity Alpha specifies the mounting angle of the robot in radians It is calculated in the following way Gravity Beta A x 3 1...

Page 60: ...00373 Suspended mounting mounting angle 180º Continues on next page 60 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 2 Installation and commissioning 2 3 5 Setting the system parameters for a suspended or tilted robot Continued ...

Page 61: ...s 0 0 Floor mounted 1 0 785398 45 Tilted 2 1 570796 90 Wall 3 1 570796 90 Wall 4 Note For suspended robots 180 it is recommended to use Gravity Beta instead of Gravity Alpha Continues on next page Product manual IRB 1520 61 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 2 Installation and commissioning 2 3 5 Setting the system parameters for a suspended or tilted robot Conti...

Page 62: ...o calculate a new value is detailed in Mounting angles and values on page59 The system parameters are described in Technical reference manual System parameters The system parameters are configured in RobotStudio or on the FlexPendant 62 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 2 Installation and commissioning 2 3 5 Setting the system parameters ...

Page 63: ... robot References Load diagrams permitted extra loads equipment and their positions are specified in the product specification The loads must be defined in the software Operating manual IRC5 with FlexPendant Stopping time and braking distances The performance of the motor brake depends on if there are any loads attached to the robot For more information see product specification for the robot Prod...

Page 64: ... 63 125 160 394 177 723 590 1338 5 200 453 200 222 5 220 167 191 xx1100000295 Minimum turning radius R 307 mm A Continues on next page 64 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 2 Installation and commissioning 2 3 7 Fitting equipment on the robot robot dimensions ...

Page 65: ...holes are shown in the figures in this section xx1100000302 Figure 2 2 Overview of attachment holes and dimensions Continues on next page Product manual IRB 1520 65 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 2 Installation and commissioning 2 3 7 Fitting equipment on the robot robot dimensions Continued ...

Page 66: ...of attachment holes on the robot Continues on next page 66 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 2 Installation and commissioning 2 3 7 Fitting equipment on the robot robot dimensions Continued ...

Page 67: ...ng disk use only screws with quality 12 9 When fitting equipment on other places standard screws with quality 8 8 can be used Product manual IRB 1520 67 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 2 Installation and commissioning 2 3 7 Fitting equipment on the robot robot dimensions Continued ...

Page 68: ...3 hardware mechanical stop The mechanical stop must be installed on axis 3 if the robot features an Arc Welding package This section describes how to install hardware that restricts the working range Note Adjustments must also be made in the robot configuration software system parameters References to relevant manuals are included in the installation procedures 68 Product manual IRB 1520 3HAC04343...

Page 69: ...ration mechanical stop axis 3 The mechanical stop is installed at the upper arm housing as shown in the figure below xx1100000351 Additional mechanical stop axis 3 A Required equipment Note Art no Equipment See Spare parts on page 301 Mechanical stop axis 3 Art no is specified in Refer ences on page 10 Technical reference manual System parameters Continues on next page Product manual IRB 1520 69 3...

Page 70: ...que 14 Nm The system parameters that must be changed Upper joint bound and Lower joint bound are described in Technical reference manual Sys tem parameters Adjust the software working range limitations system parameter configuration to correspond to the mechanical limitations 3 WARNING If the mechanical stop pin is deformed after a hard collision it must be replaced Deformed movable stops and or a...

Page 71: ...rom the servo system External axes cables option See the Application manual Additional axes and stand alone controller M2004 see document number in Refer ences on page 10 Handles signals process media and power feeding for customer use regarding material handling or spot welding DressPack cables option See the Product manual Arc welding equipment for IRB 1520ID see document number in References on...

Page 72: ...radius for static floor cables The minimum bending radius is 10 times the cable diameter for static floor cables A B xx1600002016 Diameter A Diameter x10 B 72 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 2 Installation and commissioning 2 5 1 Robot cabling and connection points Continued ...

Page 73: ...regulated with the RAPID instruction VelSet Start the robot with its normal program but with reduced speed 1 Adjusting the speed and acceleration during warm up Depending on how cold the environment is and what program is being used the speed might need to be ramped up until reached maximum The table shows examples of how to adjust the speed Speed velocity AccSet Work cycles v100 100 mm s 20 20 3 ...

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Page 75: ...ided according to the maintenance activity Safety information Observe all safety information before conducting any service work There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page 17 before performing any service work Note If the IRB 1520 is c...

Page 76: ...ing on how hard each part is run The SIS used in M2004 is further described in the Operating manual Service Information System Robots with the functionality Service Information System activated can show active counters in the device browser in RobotStudio or on the FlexPendant Overhaul Depending on application and operational environment a complete overhaul may be necessary in average around 40000...

Page 77: ...Cleaning Every 12 months Oil level in axis 1 gearbox Inspection Every 12 months Oil level in axis 2 gearbox Inspection Every 12 months Oil level in axis 3 gearbox Inspection Every 48 months Oil level in axis 4 gearbox Inspection Every 48 months Oil level in axis 5 gearbox Inspection Every 12 months Oil level in axis 5 6 gearbox ID Inspection No inspection needed Oil level in axis 6 gearbox Inspect...

Page 78: ...or life limit is approaching that specified in section Expected component life on page 79 ii DTC Duty Time Counter Shows the operational time of the robot iii The battery low alert 38213 Battery charge low is displayed when the battery needs to be replaced The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned on until the battery is to be replaced See th...

Page 79: ...n also be affected by grouping harnesses cables other than standard options The life expectancy is based on a test cycle that for every axis goes from the calibration position to minimum angle to maximum angle and back to the calibration position Deviations from this test cycle will result in differences in expected life Product manual IRB 1520 79 3HAC043435 001 Revision L Copyright 2012 2020 ABB ...

Page 80: ...ion Type of lubrication in gearboxes on page 106 Lubrication oil Content is defined in section Standard tools on page 297 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page 80 Product manual IRB 1520 3HAC043435 001 Revision L Copyright ...

Page 81: ...x cess pressure 3 See Location of oil plugs on page 80 Open the oil plug inspection 4 xx1000000824 Measure the oil level at the oil plug hole Required oil level 39 mm 3 mm below the surface for the motor flange The oil level shall only just start to be ob served when looking through the oil filling hole See figure 5 Parts A 39 mm 3 mm B Surface for motor flange C Filling hole D Oil level How to fi...

Page 82: ...d pos ition and secure it on the floor 3 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 4 See the figure in Location of oil plugs on page 80 Open the oil plug inspection on the axis 1 gearbox 5 Required oil level 22 mm 3 mm below the surface for the motor flange 6 How to fill oil is described in secti...

Page 83: ...her gearbox See section Type of lubrication in gearboxes on page 106 Lubrication oil Content is defined in section Standard tools on page 297 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page Product manual IRB 1520 83 3HAC043435 001 R...

Page 84: ...ting and turning a suspended mounted robot on page 52 If the robot is suspended lift it down from its suspended position and secure it on the floor 4 See Location of axis 2 gearbox on page 83 Then open the oil plug for inspection Measure the oil level at the oil plug hole 5 Required oil level 23 mm 3 mm below the lower edge of the oil plug hole How to fill oil is described in section Changing the ...

Page 85: ...ction Type of lubrication in gearboxes on page 106 Lubrication oil Content is defined in section Standard tools on page 297 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page Product manual IRB 1520 85 3HAC043435 001 Revision L Copyrigh...

Page 86: ...re supply air pressure supply to the robot before entering the robot work ing area 3 CAUTION The gearbox can contain an excess of pres sure that can be hazardous Open the oil plug carefully in order to let out the excess pres sure 4 See the figure in Location of axis 3 gearbox on page 85 Open the oil plug for inspection 5 Measure the oil level at the oil plug hole 6 Required oil level 42 mm from t...

Page 87: ... Tightening torque 10 Nm Refit the oil plug 8 Product manual IRB 1520 87 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 3 Maintenance 3 3 3 Inspecting the oil level axis 3 gearbox Continued ...

Page 88: ...ools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Inspecting the oil level axis 4 gearbox Use this procedure to inspect the oil level in the axis 4 gearbox A suspended robot must be taken down and secured standing on the floor for inspection Note Action WARNING Handling gearbox oil involves several safety risks see Ge...

Page 89: ...ain an excess of pres sure that can be hazardous Open the oil plug carefully in order to let out the excess pres sure 4 See the figure in Location of axis 4 gearbox on page 88 Open the oil plug 5 Measure the oil level at the oil plug hole 6 Required oil level 35 mm 3 mm Add oil if required 7 Tightening torque 3 Nm Refit the oil plug filling 8 Product manual IRB 1520 89 3HAC043435 001 Revision L Co...

Page 90: ...s and procedures may be required See references to these procedures in the step by step instructions below Inspecting oil level axis 5 gearbox Use this procedure to inspect the oil level in the axis 5 gearbox A suspended robot must be taken down and secured standing on the floor for inspection Note Action WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grea...

Page 91: ...n excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 4 See Location of axis 5 gearbox on page 90 Open the oil plug 5 Measure the oil level at the oil plug hole 6 Required oil level 30 mm 3 mm below the lower edge of the oil plug hole Add oil if required 7 Tightening torque 3 Nm Refit the oil plug filling 8 Product manual IRB 1520 91 3HAC04...

Page 92: ...oolkit These procedures include refer ences to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Inspecting oil level axis 5 6 gearbox Use this procedure to inspect the oil level in the axis 5 6 gearbox A suspended robot must be taken down and secured standing on the floor for inspection Note Action WARNING Handl...

Page 93: ...en the oil plug carefully in order to let out the ex cess pressure 4 Open the oil plug 5 Measure the oil level at the oil plug hole 6 Required oil level 25 mm 3 mm from the oil plug flange How to fill oil is described in section Changing the oil in axes 5 and axis 5 and 6 gearboxes IRB 1520ID on page 122 Add oil if required 7 Tightening torque 3 Nm Refit the oil plug filling 8 Product manual IRB 1...

Page 94: ... Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below See chapter Circuit diagram on page 303 Circuit diagram Continues on next page 94 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 3 Maintenance 3 3 7 Inspecting ...

Page 95: ...ke an overall visual inspection of the cable harness in order to detect wear or damage 2 Check the connectors at the base 3 Check the connectors at the armhouse 4 Check all brackets and straps are properly attached to the robot 5 How to replace the cable harness is de scribed in Repair on page 133 Replace the cable harness if wear cracks or damage is detected 6 Product manual IRB 1520 95 3HAC04343...

Page 96: ... B Instruction plate High temperature C Calibration label D Rating label E Instruction plate Brake release unit F Oil quantity label G Instruction plate Lifting of robot H Required equipment Note Spare part number Equipment See Spare parts on page 301 Labels Continues on next page 96 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 3 Maintenance 3 3 8 I...

Page 97: ...y air pressure supply to the robot before entering the robot work ing area 1 See the figure in Location of information labels on page 96 Check all labels 2 Replace any missing or damaged labels 3 Product manual IRB 1520 97 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 3 Maintenance 3 3 8 Inspecting information labels Continued ...

Page 98: ... on page301 Mechanical stop pin axis 1 Content is defined in section Standard tools on page 297 Standard toolkit These procedures include references to the tools re quired Other tools and procedures may be required See refer ences to these procedures in the step by step instructions below Continues on next page 98 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights...

Page 99: ... the figure in Location of mechanical stop pin axis 1 on page 98 Regularly check that the mechanical stop pin is not bent or damaged in any other way 2 Note If the mechanical stop pin has been deformed or damaged it must be replaced 3 Check that the mechanical stop pin is prop erly attached 4 Product manual IRB 1520 99 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 3 Mainten...

Page 100: ...Additional mechanical stops are provided for axes 3 and 4 xx1100000351 Additional mechanical stop axis 3 A Continues on next page 100 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 3 Maintenance 3 3 10 Inspecting additional mechanical stops ...

Page 101: ...ure to inspect additional mechanical stops on axes 3 and 4 Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 See Location of additional mechanical stops on page 100 Check additional stops on axes 3 and 4 for damage 2 Continues on next page Product manual IRB 1520 101 3HAC043435 001 Revision L Co...

Page 102: ...quipment on page 101 If any damage is detected the mechanical stops must be replaced Correct attachment screws Axis 3 M6 x 40 quality 12 9 2 pcs Axis 4 M6 x 8 quality 8 8 3 pcs 4 102 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 3 Maintenance 3 3 10 Inspecting additional mechanical stops Continued ...

Page 103: ...he figure shows the location of all dampers to be inspected xx1100000356 Dampers axis 2 Continues on next page Product manual IRB 1520 103 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 3 Maintenance 3 3 11 Inspecting dampers ...

Page 104: ...See Spare parts on page301 Damper Content is defined in section Standard tools on page 297 Standard toolkit Continues on next page 104 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 3 Maintenance 3 3 11 Inspecting dampers Continued ...

Page 105: ...g area 1 See the figure in Location of dampers on page 103 Check all dampers for damage or cracks 2 Check all dampers for existing impressions larger than 2 3 mm 3 Check attachment screws for deformation 4 If any damage is detected the damper must be replaced 5 Product manual IRB 1520 105 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 3 Maintenance 3 3 11 Inspecting dampers ...

Page 106: ...l in gearboxes Information about the type of lubrication article number as well as the amount in the specific gearbox can be found in Technical reference manual Lubrication in gearboxes available for registered users on myABB Business Portal www mypo rtal abb com Location of gearboxes The figure shows the location of the gearboxes xx1100000336 Continues on next page 106 Product manual IRB 1520 3HA...

Page 107: ...te Equipment Includes pump with outlet pipe Oil dispenser Use the suggested dispenser or a similar one Orion OriCan article number 22590 pneumatic Nipple for quick connect fitting with o ring Product manual IRB 1520 107 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 3 Maintenance 3 4 1 Type of lubrication in gearboxes Continued ...

Page 108: ...ted between the frame and base of the robot The oil plug is shown in the figure xx1100000339 Oil plug for filling A Continues on next page 108 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 3 Maintenance 3 4 2 Changing the oil axis 1 gearbox ...

Page 109: ...he complete amount of oil Oil collecting vessel Used to accelerate the draining procedure Compressed air Content is defined in section Standard tools on page 297 Standard toolkit See references to these procedures in the step by step instructions below Other tools and procedures may be required Continues on next page Product manual IRB 1520 109 3HAC043435 001 Revision L Copyright 2012 2020 ABB All...

Page 110: ... several safety risks see Gearbox lubricants oil or grease on page 32 2 Remove the push button guard from the base 3 Remove the centering piece from the push button unit 4 xx1100000315 Remove the base cover 5 Cut the straps that hold the oil draining hose fastened inside the robot base 6 Pull out the oil draining hose so that it reaches the oil collecting vessel 7 Continues on next page 110 Produc...

Page 111: ...x imum pressure allowed 10 kPa 10 WARNING Used oil is hazardous material and must be disposed of in a safe way See section De commissioning on page285 for more inform ation 11 Note There will be some oil left in the gearbox after draining 12 See Required equipment on page 109 Refit the oil plugs 13 Tightening torque 10 Nm Fasten the oil draining hose inside the base with straps 14 Refit the base c...

Page 112: ...us Open the oil plug care fully in order to let out the excess pressure 3 See Location of oil plugs on page108 Open the oil plug for filling 4 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 106 Refill the gearbox with lubricating oil Note The amount of oil to be filled depends on the amount previously being drained 5 How to inspect the oil lev...

Page 113: ...fitting B Required equipment Note Equipment 3HAC029646 001 Oil plug sealing washer gearbox Information about the oil is found in Technical reference manual Lubrication in gearboxes Lubricating oil See Type and amount of oil in gearboxes on page 106 The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel Continues on next page Product manual IRB 1520 1...

Page 114: ...N The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 3 See the figure in Location of oil plugs on page 113 Either connect a nipple to the quick connect fitting in the hole for draining or remove the quick connect fitting 4 See the figure in Location of oil plugs on page 113 Note Drainage will be quicker if the oi...

Page 115: ... oil Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 32 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex c...

Page 116: ...t the oil level is described in section Inspecting the oil level axis 2 gearbox on page 83 Inspect the oil level 6 Tightening torque 10 Nm Refit oil plug Note Before refitting the oil plug in the gearbox always replace the oil plug sealing washer with a new one If not there is a risk of leakage 7 116 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 3 Ma...

Page 117: ...upper arm rotational center Oil plugs are shown in the figure xx1100000341 Oil plug gearbox A xx1100000342 Oil plug armhouse A Continues on next page Product manual IRB 1520 117 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 3 Maintenance 3 4 4 Changing the oil axis 3 gearbox ...

Page 118: ...take the complete amount of oil Oil collecting vessel One example of oil dispenser can be found in section Type of lubrication in gearboxes on page 106 Oil dispenser xx1200000862 Funnel Content is defined in section Standard tools on page 297 Standard toolkit Continues on next page 118 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 3 Maintenance 3 4 4...

Page 119: ...ll electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 32 3 Continues on next page Product manual IRB 1520 119 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 3 Maintenance 3 4 4 Changing the oil axis 3 g...

Page 120: ...material and must be disposed of in a proper way See section De commissioning for more information 8 Tightening torque Refit oil plugs 9 10 Nm Filling oil axis 3 gearbox Use this procedure to fill the gearbox with oil Note Action xx0800000329 Move the upper arm to a position where the wrist is pointing towards the floor as shown in the figure 1 DANGER Turn off all electric power supply hydraulic p...

Page 121: ...ind type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 106 Refill the gearbox with lubricating oil Tip Use a funnel 6 Note The amount of oil to be filled depends on the amount previously being drained How to inspect oil is described in section Inspecting the oil level axis 3 gearbox on page 85 Inspect the oil level 7 Tightening torque Refit the oil plug 8 10 Nm...

Page 122: ...ication in gearboxes Lubricating oil See Type and amount of oil in gearboxes on page 106 The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel Content is defined in section Standard tools on page 297 Standard toolkit See references to these procedures in the step by step instructions below Other tools and procedures may be required Continues on next...

Page 123: ...position where the oil plug A is faced down wards Note The total amount of oil will not be drained There will remain approxim ately 20 ml in the wrist unit 3 The figure shows IRB 1600 but the upper arm position is the same for the IRB 1520 xx0700000033 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the excess pressure 4 S...

Page 124: ...same for the IRB 1520 xx0700000034 Position the robot as shown in the figure to the right axis 4 90º to a position where the oil plug A is faced upwards 1 A Oil plugs Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 106 Fill new oil in the wrist Check the oil level to make sure the filled amount of oil is correct 2 See Inspecting the oil level a...

Page 125: ...tery is typically 36 months For an SMB board with 2 pole battery contact the typical lifetime of a new battery is 36 months if the robot is powered off 2 days week or 18 months if the robot is powered off 16 h day The lifetime can be extended for longer production breaks with a battery shutdown service routine See Operating manual IRC5 with FlexPendant for instructions WARNING See Hazards related ...

Page 126: ...ystem is located inside the base of the robot as shown in the figure below xx1100000319 Continues on next page 126 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 3 Maintenance 3 4 6 Replacing the battery pack Continued ...

Page 127: ...tery pack battery 2 pole battery contact A Velcro strap B Connector X3 C RMU 101 F xx1300000330 Battery pack 3 pole battery contact B Serial measurement board RMU 101 C BU unit D Continues on next page Product manual IRB 1520 127 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 3 Maintenance 3 4 6 Replacing the battery pack Continued ...

Page 128: ...n page 297 Standard toolkit See chapter Circuit diagram on page303 Circuit diagram Replacement battery pack The procedure below details how to replace the battery pack Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 xx1100000315 Remove the base cover from the robot by unscrewing its attachment...

Page 129: ...onnect it to the serial measurement unit X3 6 Valid for battery pack with 2 pole battery contact 7 Close the velcro strap around the battery pack Valid for battery pack with 3 pole battery contact 8 Secure the battery with a cable strap See Location of battery pack on page 126 Refit the base cover to the robot 9 Detailed in section Updating revolution counters on page 279 Update the revolution cou...

Page 130: ...rbox is according to the recommendations see Inspection activities on page 80 2 Write down the oil level 3 Inspect the oil level again after for example 6 months 4 If the oil level is decreased then replace the gearbox Special cleaning considerations This section specifies some special considerations when cleaning the robot Always use cleaning equipment as specified Any other cleaning equipment ma...

Page 131: ...r No No Yes With light cleaning deter gent Yes Standard Cables Movable cables need to be able to move freely Remove waste material such as sand dust and chips if it prevents cable movement Clean the cables if they have a crusty surface for example from dry release agents Product manual IRB 1520 131 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 3 Maintenance 3 5 1 Cleaning t...

Page 132: ...This page is intentionally left blank ...

Page 133: ... the article number and the revision of both the replaced unit and the replacement unit This is particularly important for safety equipment to maintain the safety integrity of the installation Safety information Make sure to read through the chapter Safety on page 17 before commencing any service work Note If the IRB 1520 is connected to power always make sure that the IRB 1520 is connected to pro...

Page 134: ...he pressure must under no circumstance be higher than 0 25 bar 20 25 kPa Also during the time when the pressure is raised 3 0 2 0 25 bar 20 25 kPa Disconnect the compressed air supply 4 If the compressed air is signific antly colder or warmer than the gearbox to be tested a slight pressure increase or decrease may occur This is quite normal Wait for approximately 8 10 minutes and make sure that no...

Page 135: ...exposed to any stresses during the assembly work 3 Assembly of tapered bearings Follow the preceding instructions for the assembly of the bearings when mounting a tapered bearing on the robot In addition to those instructions the following procedure must be carried out to enable the roller elements to adjust to the correct position against the race flange Note Action Tension the bearing gradually ...

Page 136: ...arted During operation the bearing should be filled to 70 80 of the available volume Ensure that grease is handled and stored properly to avoid contamination Grease the different types of bearings as following description Grooved ball bearings must be filled with grease from both sides Tapered roller bearings and axial needle bearings must be greased in the split condition 136 Product manual IRB 1...

Page 137: ...ction Check the sealing to ensure that The sealing is of the correct type There is no damage on the main lip 1 Inspect the shaft surface before mounting If scratches or damage are found the shaft must be replaced since it may result in future leakage Do not try to grind or polish the shaft surface to get rid of the defect 2 Article number is specified in Equipment on page 137 A B C xx2000000071 A ...

Page 138: ...d because leakage could occur Clean the surfaces properly in accordance with the recommendations of ABB 2 Distribute the sealing compound evenly over the surface preferably with a brush 3 Tighten the screws evenly when fastening the flange joint 4 O rings The following procedure describes how to fit o rings Note Action Ensure that the correct o ring size is used 1 Defective o rings including damag...

Page 139: ...ontamination Lubricate the o ring with grease 4 Tighten the screws evenly while assembling 5 Check that the o ring is not squashed outside the o ring groove 6 Product manual IRB 1520 139 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 2 3 Mounting instructions for sealings Continued ...

Page 140: ...int Standard Foundry Plus ABB Orange 3HAC037052 001 Touch up paint Standard Foundry Plus Removing Description Action xx0900000121 Cut the paint with a knife in the joint between the part that will be removed and the struc ture to avoid that the paint cracks 1 Carefully grind the paint edge that is left on the structure to a smooth surface 2 140 Product manual IRB 1520 3HAC043435 001 Revision L Cop...

Page 141: ...e to the robot Elimination To eliminate the danger after service work has been performed inside the SMB recess follow the procedure below Action Make sure the power is turned off 1 Remove the push button guard if necessary 2 Verify that the push buttons of the brake release unit are working by pressing them down one by one 3 Make sure none of the buttons are jammed in the tube If a button gets jam...

Page 142: ...ess in the upper end is described in section Replacing the cable harness upper end on page 162 Location of cable harness lower end The lower end of the cable harness is located as shown in the figure xx1100000313 Continues on next page 142 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 1 Replacing the cable harness lower end ...

Page 143: ...y step instruc tions below Removing the cable harness lower end Use this procedure to remove the lower end of the cable harness Note Action Jog the robot to the calibra tion position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Continues on next page Product manual IRB 1520 143 3HAC043435 001 Revisio...

Page 144: ...nnectors inside the armhouse Note Make a note of how the cables are run on the brack et 4 Continues on next page 144 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 1 Replacing the cable harness lower end Continued ...

Page 145: ...cable harness in the arm house 5 xx1100000327 Unscrew the attachment screws 2 pcs that holds the bracket of the cable harness to the upper arm 6 Continues on next page Product manual IRB 1520 145 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 1 Replacing the cable harness lower end Continued ...

Page 146: ...ew the attachment screws 2 2 pcs that holds the cable harness to the lower arm just enough to be able to slide the brackets of the cable harness off the screws 8 Continues on next page 146 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 1 Replacing the cable harness lower end Continued ...

Page 147: ...arness below 9 xx1100000323 Unscrew the attachment screws 2 pcs of the brack et that holds the cable har ness inside the frame 10 Continues on next page Product manual IRB 1520 147 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 1 Replacing the cable harness lower end Continued ...

Page 148: ...covers by unscrewing its attachment screws 12 See Replacing motors on axis 1 and 2 on page 229 Remove the covers of the axes 1 and 2 motors and disconnect all connectors R2 MP1 R2 FB1 R2 MP2 and R2 FB2 13 Continues on next page 148 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 1 Replacing the cable harness lower end Continued ...

Page 149: ... in order to be able to refit the push buttons correctly later 14 xx1100000315 Remove the base cover 15 Continues on next page Product manual IRB 1520 149 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 1 Replacing the cable harness lower end Continued ...

Page 150: ...unit on page214 Disconnect all connectors to the SMB and push button units 17 See Replacing the push button unit on page 222 xx1100000317 Unscrew the two connectors on the plate for connector 18 Continues on next page 150 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 1 Replacing the cable harness lower end Continued ...

Page 151: ...22 Refitting the cable harness lower end Use this procedure to refit the lower end of the cable harness Note Action Apply cable grease on the plastic parts inside base and frame if needed 1 Connect the earth cable to the fastening plate 2 See Replacing the serial measurement unit on page 214 Reconnect all connectors to SMB and push button units 3 See Replacing the push button unit on page 222 Cont...

Page 152: ...e fastening plate in the base with its attachment screws 2 2 pcs 5 Refit all cable clamps and straps securing the cable harness to the fastening plate 6 Continues on next page 152 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 1 Replacing the cable harness lower end Continued ...

Page 153: ...e plate for connector and fastening plate in to the base Check that the cable har ness is placed correctly CAUTION Be careful not to damage the cable harness in the process The space is cramp 8 Continues on next page Product manual IRB 1520 153 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 1 Replacing the cable harness lower end Continued ...

Page 154: ...r with its attachment screws 4 pcs 9 xx1100000315 Refit the base cover 10 Continues on next page 154 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 1 Replacing the cable harness lower end Continued ...

Page 155: ... of the cable harness on the at tachment screws 2 2 pcs in the lower arm and secure the cable harness 12 Continues on next page Product manual IRB 1520 155 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 1 Replacing the cable harness lower end Continued ...

Page 156: ...ach the bracket of the cable harness with one screw Do not secure the screw at this point It must be possible to match the hole for the other screw 15 Fit the other of the two covers with its attachment screws 16 Continues on next page 156 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 1 Replacing the cable harness lower end Continued ...

Page 157: ...cable harness lower end on page 142 Check that the cable har ness is placed correctly in the base and frame 18 xx1100000322 Fit the cover on the frame 19 Continues on next page Product manual IRB 1520 157 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 1 Replacing the cable harness lower end Continued ...

Page 158: ...xx1100000328 Secure the cable harness to the armhouse by fitting the bracket with its attach ment screws 4 pcs 21 Continues on next page 158 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 1 Replacing the cable harness lower end Continued ...

Page 159: ... with its attachment screws 2 pcs 22 See on page Reconnect the connectors to motors axes 3 and 4 23 Continues on next page Product manual IRB 1520 159 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 1 Replacing the cable harness lower end Continued ...

Page 160: ...tion The brake release buttons may be jammed after service work on page 141 26 Calibration is described in a separate calibration manual enclosed with the calibration tools Recalibrate the robot 27 General calibration information is included in section Cal ibration information on page 273 Continues on next page 160 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All right...

Page 161: ...all safety re quirements are met when performing the first test run 28 Product manual IRB 1520 161 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 1 Replacing the cable harness lower end Continued ...

Page 162: ...e harness is located inside the armhouse and arm tube as shown in the figure The figure shows the IRB 1600ID but is also applicable to IRB 1520 B A F E R4 FB6 R4 FB5 R4 MP5 R4 MP6 R3 FB3 R3 FB4 R3 FB5 R3 FB6 R3 MP3 R3 MP4 R3 MP5 R3 MP6 xx0700000038 Required equipment Note Art no Equipment See Spare parts on page301 Cable harness Continues on next page 162 Product manual IRB 1520 3HAC043435 001 Rev...

Page 163: ...the upper end of the cable harness Preparations Note Action xx1100000439 Jog the upper arm to a vertical position with the wrist pointing at the floor 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 2 Remove all extra equipment fitted on the up per arm and wrist 3 Continues on next page Product manual IR...

Page 164: ...al to each other 4 xx1100000473 Fit two threaded bars M8 with nuts fitted at the bottom end Length 120 mm 5 Continues on next page 164 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 2 Replacing the cable harness upper end Continued ...

Page 165: ...ded bars until it rests on the nuts 6 xx1100000411 Unscrew the attachment screws 3 pcs holding the cover with mechanical stop and remove the cover 7 Continues on next page Product manual IRB 1520 165 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 2 Replacing the cable harness upper end Continued ...

Page 166: ...ectors of the axis 5 mo tor Note It is not needed to remove the motors 3 Carefully pull out the cables of the axes 5 and 6 motors from the arm tube 4 Remove the support ring and V ring from the arm tube and place them temporarily on the cable harness spiral 5 Continues on next page 166 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 2 Repl...

Page 167: ...ff the arm tube 7 Hold the arm tube and unscrew the two threaded bars M8 8 Carefully lower the arm tube without causing any damage to the cable harness and put it somewhere safe 9 Remove the support ring and V ring 10 Continues on next page Product manual IRB 1520 167 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 2 Replacing the cable harness upper end Continue...

Page 168: ...700000099 Cover plate A Clamp B R4 FB5 C R4 FB6 D R4 MP6 E R4 MP5 F R3 MP5 G R3 MP6 H R3 FB5 I R3 FB6 J Continues on next page 168 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 2 Replacing the cable harness upper end Continued ...

Page 169: ...he bracket of the cable harness 1 xx1000001004 A Cable strap Secure the spiral of the cable harness with a cable strap or similar as shown in the figure in order to keep the spiral in position 2 Continues on next page Product manual IRB 1520 169 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 2 Replacing the cable harness upper end Continued ...

Page 170: ...ness in the upper arm Note Make a note of how the cables are run on the bracket 4 Wrap the connectors with some plastic film and tape in order to protect them from con tamination 5 A xx0700000114 Pull the cable harness carefully out off the armhouse 6 Continues on next page 170 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 2 Replacing th...

Page 171: ... tape in order to protect them from con tamination 2 A xx0700000114 Run the cable harness into the armhouse through the passage A 3 Apply cable grease on the cables inside the armhouse 4 xx1000001004 Place the cover and the cable harness spiral into its position Note Do not remove the cable strap at this point 5 A Cable strap Continues on next page Product manual IRB 1520 171 3HAC043435 001 Revisi...

Page 172: ...Action Place the support ring and V ring temporarily on the cable harness spiral 1 Fit two threaded bars M8 in two of the attach ment holes diagonal to each other 2 Lift the arm tube on to the threaded bars and fit the nuts at the end of the bars 3 xx1100000474 Lower the arm tube carefully and let it rest on the nuts 4 Continues on next page 172 Product manual IRB 1520 3HAC043435 001 Revision L Co...

Page 173: ... cable strap CAUTION When the cable strap is cut the spiral of the cable harness can unwind and the cables can start to cross each other 6 Wind the cable harness spiral carefully in a tight fitting and then release it 3 4 of a revolu tion Note Check that the cable harness spiral is fitted correctly The two cables must not cross each other 7 Continues on next page Product manual IRB 1520 173 3HAC04...

Page 174: ...the connectors to the axis 5 mo tor 3 Reconnect the connectors to the axis 6 mo tor 4 Note When reconnecting the connectors R4 FB6 and R4 MP6 make sure to push the connectors towards the wrist as far away from the axis 5 6 cable spiral as possible to avoid grease to accumulate on the resolver connector Secure the FB connectors on the axes 5 and 6 motors with cable straps 5 Continues on next page 1...

Page 175: ... Lift the arm tube carefully while at the same time check that the position of the cable har ness is correct 1 Check that the sealing ring and V ring are in the correct position in the arm tube 2 Tightening torque 24 Nm Secure the arm tube with the attachment screws possible to fit at this point 3 In order to release the brakes for axis 4 see Manually releasing the brakes on page 53 4 Continues on...

Page 176: ...ot stretched to much If stretched too much there is a risk of damage to the cable harness Note If axis 4 is not running correctly the spiral of the cable harness must be refitted 6 Concluding refitting Note Action R3 FB3 R3 FB4 R3 FB5 R3 FB6 R3 MP3 R3 MP4 R3 MP5 R3 MP6 xx0700000105 Reconnect the connectors in the armhouse 1 Continues on next page 176 Product manual IRB 1520 3HAC043435 001 Revision...

Page 177: ...ools Recalibrate the robot 3 General calibration information is included in section Calibration information on page 273 DANGER Make sure all safety requirements are met when performing the first test run 4 Product manual IRB 1520 177 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 2 Replacing the cable harness upper end Continued ...

Page 178: ...em The complete armsystem is located as shown in the figure xx1100000438 Required equipment Note Art no Equipment Content is defined in section Standard tools on page 297 Standard toolkit Continues on next page 178 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 3 Replacing the complete arm system ...

Page 179: ...shall be placed with the wrist pointing at the floor 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 2 See Replacing the cable harness lower end on page 142 Remove the cable harness from armhouse and lower arm 3 CAUTION The robot arm system weighs 55 kg All lifting accessories used must be sized accordin...

Page 180: ...40 Unscrew the attachment screws 18 pcs and washers holding the lower arm to gearbox axis 2 6 xx1100000441 Carefully lift away the complete arm system and put it somewhere safe 7 Continues on next page 180 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 3 Replacing the complete arm system Continued ...

Page 181: ...rm sys tem with a roundsling in an overhead crane or similar as shown in the figure 3 xx1100000440 Secure the complete arm system to the gearbox axis 2 with its attachment screws and washers 4 Tightening torque 34 Nm M8x40 18 pcs See Replacing the cable harness lower end on page 142 Refit the cable harness in the lower arm and armhouse 5 Continues on next page Product manual IRB 1520 181 3HAC04343...

Page 182: ...General calibration information is included in section Calibration information on page 273 DANGER Make sure all safety requirements are met when performing the first test run 7 182 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 3 3 Replacing the complete arm system Continued ...

Page 183: ...ired after replacement of upper arm Location of the complete upper arm The complete upper arm is located as shown in the figure xx1100000347 Continues on next page Product manual IRB 1520 183 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 4 1 Replacing the complete upper arm IRB 1520ID ...

Page 184: ...mplete upper arm Note Action Jog the axis 3 to 90 1 See Changing the oil axis 3 gearbox on page 117 Drain the axis 3 gearbox 2 xx1100000348 Jog the robot to the synchronization position 3 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 4 Continues on next page 184 Product manual IRB 1520 3HAC043435 001 Rev...

Page 185: ...use and loosen the cabling from straps and brackets 6 xx1100000328 Remove the bracket holding the cable har ness to the armhouse and pull out the cable harness 7 Continues on next page Product manual IRB 1520 185 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 4 1 Replacing the complete upper arm IRB 1520ID Continued ...

Page 186: ...e weight of the upper arm with a roundsling Apply the roundsling through the hole in the upper arm See figure 10 The figure shows IRB 1600ID but the way to secure the upper arm with the round sling is the same on IRB 1520 Continues on next page 186 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 4 1 Replacing the complete upper arm IRB 1520I...

Page 187: ... to refit the complete upper arm Note Action Wipe the contact surfaces clean on both the up per and lower arm 1 CAUTION The robot upper arm weighs 35 kg All lifting accessories used must be sized accord ingly 2 Attach a roundsling to the upper arm and lift it 3 Move the upper arm to the mounting position 4 Continues on next page Product manual IRB 1520 187 3HAC043435 001 Revision L Copyright 2012 ...

Page 188: ...uality 12 9 Gleitmo 12 pcs See Replacing motors on axes 3 and 4 on page 239 Refit the motor 6 xx1100000330 Insert the cable harness through the hole and into the armhouse 7 Continues on next page 188 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 4 1 Replacing the complete upper arm IRB 1520ID Continued ...

Page 189: ... and Replacing the axis 6 motor on page 250 Connect all the connectors in the armhouse and secure the cabling with brackets and straps 10 Check the gaskets in the armhouse cover Re place if damaged 11 Continues on next page Product manual IRB 1520 189 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 4 1 Replacing the complete upper arm IRB 1520ID Continued ...

Page 190: ...ation Pendu lum enclosed with the calibration tools Recalibrate the robot 14 General calibration information is in cluded in section Calibration informa tion on page 273 DANGER Make sure all safety requirements are met when performing the first test run 15 190 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 4 1 Replacing the complete upper a...

Page 191: ...o Equipment See Spare parts on page301 Lower arm Used to clean the mating sur faces Isopropanol Loctite 574 Locking liquid Content is defined in section Standard tools on page 297 Standard toolkit Continues on next page Product manual IRB 1520 191 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 4 2 Replacing the complete lower arm ...

Page 192: ...t the connectors of the cable har ness to the lower end in the armhouse 2 Pull out the cable harness from the arm house 3 See Replacing the cable harness lower end on page 142 Remove the cable harness from the lower arm 4 See section Replacing the complete upper arm IRB 1520ID on page 183 Remove the complete upper arm 5 CAUTION The robot lower arm weighs 20 kg All lifting accessories used must be ...

Page 193: ...ion Wipe the contact surfaces clean on both the lower arm and gearboxes on axes 2 and 3 with isopropanol 1 CAUTION The robot lower arm weighs 20 kg All lifting accessories used must be sized accordingly 2 Secure the weight of the lower arm with a roundsling in an overhead crane or similar and lift it in position 3 Continues on next page Product manual IRB 1520 193 3HAC043435 001 Revision L Copyrig...

Page 194: ...e cable harness lower end on page 142 Refit the lower end of the cable harness in the armhouse and reconnect the connectors 7 Pendulum Calibration is described in Operating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 8 General calibration information is included in section Calibration information on page 273 DANGER Make sure all safety requirements are met...

Page 195: ... the wrist unit as shown is also valid for IRB 1520 Upper arm A Wrist B Motor axis 6 C Hexagon socket head screw M5x25 D Hexagon socket head screw M5X16 10 9 Short head E Hexagon socket head screw M5x25 F Hexagon socket head screw M8x35 G Required equipment Note Art No Equipment See Spare parts on page301 Wrist ID Continues on next page Product manual IRB 1520 195 3HAC043435 001 Revision L Copyrig...

Page 196: ... Removing the wrist unit Use this procedure to remove the complete wrist unit Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 1 Remove all extra equipment fitted on upper arm and wrist 2 xx1100000354 Remove the plug covering the attachment screw below 3 Continues on next page 196 Product manual...

Page 197: ...ing the attachment screw 4 xx1100000394 Remove the VK Cover 5 Gently pull the cables out through the hole for the VK cover in the armtube 6 Continues on next page Product manual IRB 1520 197 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 4 3 Replacing the wrist unit IRB 1600ID Continued ...

Page 198: ...l when handling the wrist Always hold on the casting do not hold on the wrist cover This can damage the sealing which will cause oil leakage 9 Refitting the wrist unit Use this procedure to refit the complete wrist unit Note Action Move the wrist with the axis 6 motor fitted to the mounting site 1 Apply a string or similar to the cable harness and run it out through the hole for the VK cover 2 Con...

Page 199: ...rs R4 FB6 and R4 MP6 make sure to push the connectors towards the wrist as far away from the axis 5 6 cable spiral as possible to avoid grease to accumulate on the resolver connector Reconnect connectors R4 FB6 and R4 MP6 through the hole for the VK cover 5 Tightening torque 6 Nm xx1100000355 Secure the flexible coupling with the M5x16 screw 6 Continues on next page Product manual IRB 1520 199 3HA...

Page 200: ...ith the calibration tools Recalibrate the robot 9 General calibration information is included in section Calibration information on page 273 DANGER Make sure all safety requirements are met when performing the first test run 10 200 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 4 3 Replacing the wrist unit IRB 1600ID Continued ...

Page 201: ...tent is defined in section Standard tools on page 297 Standard toolkit These procedures include references to the tools re quired Other tools and procedures may be required See refer ences to these procedures in the step by step instructions below Continues on next page Product manual IRB 1520 201 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 4 4 Replacing the da...

Page 202: ...e this procedure to refit the damper Note Action Run the robot to a position where it is best to enable access to the attachment screw of the damper 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 2 M6x60 quality 8 8 A2F Secure the damper with the attachment screw and washer 3 DANGER Make sure all safety...

Page 203: ...equired equipment Note Art no Equipment etc See Spare parts on page 301 Damper axis 3 Content is defined in section Standard tools on page 297 Standard toolkit Continues on next page Product manual IRB 1520 203 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 4 5 Replacing the damper axis 3 ...

Page 204: ...is 3 Use this procedure to refit the damper Note Action Run the robot to a position where it is best to enable access to the attachment screw of the damper 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 2 M6x60 quality 8 8 A2F Secure the damper with the attachment screw and washer 3 DANGER Make sure all...

Page 205: ...e xx1100000358 Required equipment Note Art no Equipment See Spare parts on page301 Mechanical stop Content is defined in section Standard tools on page 297 Standard tools Continues on next page Product manual IRB 1520 205 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 4 6 Replacing the mechanical stop axis 3 IRB 1520ID ...

Page 206: ...work ing area 2 Remove the mechanical stop 3 Refitting the mechanical stop axis 3 Use this procedure to refit the mechanical stop Note Action Attachment screws M6x35 quality 8 8 A2F 2 pcs Refit the mechanical stop with its attachment screws 1 DANGER Make sure all safety requirements are met when performing the first test run 2 206 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 20...

Page 207: ...base Location of the base The location of the base is shown in the figure xx1100000437 Continues on next page Product manual IRB 1520 207 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the base ...

Page 208: ...ure supply to the robot before entering the robot work ing area 2 See Draining axis 1 gearbox on page110 Drain the axis 1 gearbox 3 See Replacing the cable harness lower end on page 142 Remove the cable harness in base and frame 4 Pull out the cable harness from the base and frame and place it in a way that it will not be damaged in the continued procedure 5 See Lifting robot with roundslings on p...

Page 209: ...The robot base weighs 42 kg All lifting accessories used must be sized accordingly 10 Secure the weight of the base in a roundsling in an overhead crane or similar 11 Unscrew the oil drain hose from the base 12 xx1100000389 Unscrew the attachment screws 6 pcs se curing the base to the axis 1 gearbox 13 Continues on next page Product manual IRB 1520 209 3HAC043435 001 Revision L Copyright 2012 2020...

Page 210: ... O ring 1 pc 131x2 Keep it in a clean place It will be refitted on the new base Unscrew the attachment screws holding the base cable protection and remove it 16 Continues on next page 210 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the base Continued ...

Page 211: ...cessories used must be sized accordingly 3 Secure the weight of the base with round slings and lift it to the mounting site 4 Lift up the base into a vertical position 5 xx1100000536 A O ring 6 pcs 15 5x1 5 B O ring 1 pc 131x2 Apply grease on the big o ring 131x2 and fit it in position to its groove in the base Replace if damaged 6 Continues on next page Product manual IRB 1520 211 3HAC043435 001 ...

Page 212: ...Fasten the four attachment screws carefully but do not tighten them yet It must still be possible to remove the guide pins and re place them with the remaining attachment screws 11 Remove the guide pins and replace them with the remaining attachment screws 12 Tightening torque 150 Nm Secure the base to gearbox axis 1 with its attachment screws 13 M14x25 6 pcs Refit the oil drain hose to the base 1...

Page 213: ...e 134 Perform a leak down test 21 See Filling oil axis 1 gearbox on page112 Fill axis 1 gearbox with oil 22 Calibration is described in a separate calibration manual enclosed with the cal ibration tools Recalibrate the robot 23 General calibration information is included in section Calibration information on page 273 DANGER Make sure all safety requirements are met when performing the first test r...

Page 214: ...t The serial measurement unit is located inside the base of the robot as shown in the figure xx1100000332 Continues on next page 214 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 5 2 Replacing the serial measurement unit ...

Page 215: ...tor SMB1 4 B Connector SMB 3 6 C Hexagon nuts totally 4 pcs D Hexagon nuts totally 2 pcs Only the outer nuts are used D Battery pack 2 pole battery contact E Battery cable connector F Continues on next page Product manual IRB 1520 215 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 5 2 Replacing the serial measurement unit Continued ...

Page 216: ...ace the battery contact Note Art no Equipment See Spare parts on page301 Serial measurement unit See Spare parts on page301 Battery pack See Spare parts on page301 Gasket base cover Fitted to the push button unit in order to align it correctly 3HAC025815 001 Centering piece Replace if damaged Content is defined in section Standard tools on page 297 Standard toolkit See chapter Circuit diagram on p...

Page 217: ...work ing area 1 The push button guard must be removed to ensure a correct refitting of the push buttons xx1100000314 Remove the push button guard from the base 2 xx0600002776 B Centering piece Remove the centering piece from the push button unit 3 Continues on next page Product manual IRB 1520 217 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 5 2 Replacing the se...

Page 218: ...ds the plate for connector with SMB and push button units and pull it carefully out approx imately 150 mm 5 xx1700000993 Disconnect the battery cable by pressing down the upper lip of the R2 G connector to release the lock while pulling the connector upwards 6 Continues on next page 218 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 5 2 Rep...

Page 219: ...00000335 Fit the SMB to the plate with its attachment screws 3 pcs 1 Secure the SMB fitted on the plate with its attachment screws 4 pcs 2 Make sure the unit is placed as straight as possible The push buttons can other wise get jammed Refit the push button unit with its nuts 2 pcs 3 Shown in the figure Serial measurement unit layout on page 215 Reconnect all the connectors Make sure the lock on th...

Page 220: ...ng piece is specified in Required equipment on page 216 xx1100000316 Push the plate for connector with SMB and push button units fitted carefully into the base Be careful not to damage any of the components or cable harness in the process 6 xx1100000329 Secure the plate for connector with its attach ment screws 7 Continues on next page 220 Product manual IRB 1520 3HAC043435 001 Revision L Copyrigh...

Page 221: ...after service work on page 141 10 xx1100000314 Refit the push button guard to the robot base 11 Press the push buttons 1 to 6 one at a time to make sure that the buttons are moving freely and do not stay in any locked position 12 Detailed in section Updating revolution counters on page 279 Update the revolution counters 13 Product manual IRB 1520 221 3HAC043435 001 Revision L Copyright 2012 2020 A...

Page 222: ...rement unit as shown in the figure xx0500001394 Push button unit A Hexagon nuts 2 pcs B Hexagon nuts SMB unit 4 pcs Only the outer ones are used C Required equipment Note Article number Equipment DSQC1054 3HAC064944 001 Brake release board Push button unit 3HAC022047 001 Gasket base cover Continues on next page 222 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All right...

Page 223: ...supply air pressure supply to the robot before entering the robot work ing area 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 49 2 The push button guard must be removed to ensure a correct refitting of the push button unit xx1100000314 Remove the push button guard from the base 3 Conti...

Page 224: ...use shortage on the boards which can result in hazardous failures 5 Take a picture or make notes of how the robot cabling is positioned in regard to the push button unit 6 xx1100000345 Unscrew the nuts securing the push button unit to the SMB unit 7 Continues on next page 224 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 5 3 Replacing the ...

Page 225: ...o refit the push button unit Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 49 2 Continues on next page Product manual IRB 1520 225 3H...

Page 226: ...wo hexagon nuts 4 Verify that the robot cabling is positioned correctly according to previously taken pic ture notes WARNING Screened cables must not get in contact with the brake release board after installation Eliminate all risks of contact between screened cables and the brake release board 5 Check the gasket of the base cover Replace it if damaged 6 Continues on next page 226 Product manual I...

Page 227: ...s x1 and x2 in the figure to the right should not differ more than 1 mm from each other 8 WARNING Before continuing any service work follow the safety procedure in section The brake release buttons may be jammed after service work on page 141 9 Continues on next page Product manual IRB 1520 227 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 5 3 Replacing the push ...

Page 228: ...o not stay in any locked position 11 Detailed in section Updating revolution counters on page 279 Update the revolution counters 12 DANGER Make sure all safety requirements are met when performing the first test run 13 228 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 5 3 Replacing the push button unit Continued ...

Page 229: ...on axis 5 see section Replacing motor on axis 5 on page 246 How to replace the motor on axis 6 see section Replacing the axis 6 motor on page 250 Location of motors on axes 1 and 2 The motors are located as shown in the figure xx1100000282 Continues on next page Product manual IRB 1520 229 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 6 1 Replacing motors on axis...

Page 230: ...n page 297 Standard toolkit Content is defined in section Special tools on page 298 Special toolkit These procedures include references to the tools re quired Other tools and procedures may be required See refer ences to these procedures in the step by step instructions below Position of the robot Place the robot in the recommended position in order to facilitate replacement of motors Position Mot...

Page 231: ...IRB 1520 Draining gearboxes The table specifies if the oil needs to be drained from the gearboxes Note These recommendations are valid if the method how to position the robot described above is followed Action Motor Draining is not needed provided that the re commended procedure for removal is fol lowed Axis 1 motor Drain the axis 2 gearbox as described in Changing the oil axis 2 gearbox on page11...

Page 232: ...2 xx0700000060 Only applicable to the axis 2 motor DANGER Secure the weight of the lower arm properly before releasing the brakes of motor axis 2 When releasing the holding brakes of the motor the lower arm will be movable and may fall down 3 See Changing the oil axis 2 gearbox on page 113 Only applicable to the axis 2 motor Drain the axis 2 gearbox 4 Continues on next page 232 Product manual IRB ...

Page 233: ...e connectors 5 Disconnect the connectors inside 6 xx1100000376 Unscrew the attachment screws that holds the motor plate 7 Continues on next page Product manual IRB 1520 233 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 6 1 Replacing motors on axis 1 and 2 Continued ...

Page 234: ...ment screws securing the motor Use a 300 mm extension for bits 1 2 10 Only applicable to the axis 2 motor 11 Fit two guide pins in opposite holes Continues on next page 234 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 6 1 Replacing motors on axis 1 and 2 Continued ...

Page 235: ... 2 motors Note Action Wipe clean all assembly surfaces 1 Only applicable to the axis 2 motor 2 Fit two guide pins in opposite holes Replace the o ring if damaged xx1100000380 Make sure the o ring on the circumference of the motor is seated properly 3 Continues on next page Product manual IRB 1520 235 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 6 1 Replacing mot...

Page 236: ...00375 A Axis 1 motor B Axis 2 motor Secure the motor with its attachment screws Use a 300 mm extension for bits 1 2 Tightening torque axis 1 motor 20 Nm Tightening torque axis 2 motor 20 Nm 8 xx1100000377 Carefully insert the motor cables through the connection box of the motor 9 Continues on next page 236 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserve...

Page 237: ... Only applicable to the axis 2 motor Perform a leak down test of the axis 2 gear box 13 See Changing the oil axis 2 gearbox on page 113 Only applicable to the axis 2 motor Refill the axis 2 gearbox with oil 14 Refit the motor cover 15 Continues on next page Product manual IRB 1520 237 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 6 1 Replacing motors on axis 1 an...

Page 238: ...General calibration information is included in section Calibration information on page 273 DANGER Make sure all safety requirements are met when performing the first test run 17 238 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 6 1 Replacing motors on axis 1 and 2 Continued ...

Page 239: ...ce the motor on axis 5 see section Replacing motor on axis 5 on page 246 How to replace the motor on axis 6 see section Replacing the axis 6 motor on page 250 Location of motors on axes 3 and 4 The motors are located as shown in the figure xx1100000282 Continues on next page Product manual IRB 1520 239 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 6 2 Replacing m...

Page 240: ...nded in order to fascilitate replacing of motors DANGER Secure the arm system before removing any motor The brake is located in the motor and is therefore released when the motor is removed Position Motor Jog the upper arm to a vertical position with the wrist pointing at the floor after the oil is drained Axis 3 motor Jog the upper arm to a vertical position with the wrist pointing at the floor A...

Page 241: ... described in Changing the oil axis 3 gearbox on page 117 Only applicable to the axis 3 motor Drain the oil from the gearbox 1 xx1100000439 Jog the upper arm to vertical position with the wrist pointing at the floor 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 3 Continues on next page Product manual I...

Page 242: ...isconnect the motor connectors 6 Unscrew the attachment screws securing the motor 7 Use a 300 mm extension for bits 3 8 Remove the motor by lifting it carefully straight out making sure the motor pinion is not damaged while moving it away from the gear 8 Continues on next page 242 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 6 2 Replacing...

Page 243: ...re that motor pinion is not damaged or scratched 2 xx1100000479 Make sure the o ring on the circumference of the motor is seated properly Replace if damaged 3 Lubricate the o ring with grease 4 Continues on next page Product manual IRB 1520 243 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 6 2 Replacing motors on axes 3 and 4 Continued ...

Page 244: ...ent screws and plain washers 3 M6x25 4 pcs Use a 300 mm extension for bits 3 8 Tightening torque motor axis 4 10 Nm M6x20 4 pcs Reconnect the connectors 4 Refit the cables inside the armhouse 5 See Performing a leak down test on page 134 Only applicable to the axis 3 motor Perform a leak down test of the axis 3 gear box 6 See Changing the oil axis 3 gearbox on page 117 Only applicable to the axis ...

Page 245: ...n tools Recalibrate the robot 9 General calibration information is included in section Calibration information on page 273 DANGER Make sure all safety requirements are met when performing the first test run 10 Product manual IRB 1520 245 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 6 2 Replacing motors on axes 3 and 4 Continued ...

Page 246: ... replace the motors on axes 3 and 4 see section on page How to replace the motor on axis 6 see section Replacing the axis 6 motor on page 250 Location of the axis 5 motor The motors are located as shown in the figure xx1100000282 Axis 1 motor A Continues on next page 246 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 6 3 Replacing motor on ...

Page 247: ...ecommended in order to fascilitate replacing of motors Position Motor Jog the upper arm to a vertical position with the wrist pointing at the floor Axis 5 motor Draining gearbox The table specifies if the oil needs to be drained from the gearbox Note These recommendations are valid if the method how to position the robot described above is followed Action Motor Draining is not needed provided that...

Page 248: ...e o ring on the circumfer ence is seated properly 3 Replace if damaged Lubricate the o ring with some grease 4 Make sure that the motor will be fitted in the correct position 5 Refitting the axis 5 motor Note Action Place the motor carefully in its mounting po sition 1 Tightening torque 10 Nm Secure the motor with its attachment screws 2 Follow the instructions in section Repla cing the cable harn...

Page 249: ...e sure all safety requirements are met when performing the first test run 5 Product manual IRB 1520 249 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 6 3 Replacing motor on axis 5 Continued ...

Page 250: ... replace the motors on axes 3 and 4 see section on page How to replace the motor on axis 5 see section Replacing the axis 6 motor on page 250 Location of the axis 6 motor The motors are located as shown in the figure xx1100000282 Axis 1 motor A Continues on next page 250 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 6 4 Replacing the axis ...

Page 251: ...commended in order to fascilitate replacing of motors Position Motor Jog the robot the the calibration position Axis 6 motor Draining gearbox The table specifies if the oil needs to be drained from the gearboxes Note These recommendations are valid if the method how to position the robot described above is followed Action Motor Draining is not needed provided that the re commended procedure for re...

Page 252: ... Note Do not move the gears in the wrist when the motor is removed When refitting the motor the gears in the wrist shall be in the same position as they were before the removal 6 Open the flexible coupling securing the mo tor 7 Unscrew the attachment screws securing the motor Note Do not remove the attachment screws secur ing the bracket 8 Remove the motor by lifting it out carefully making sure t...

Page 253: ...r to release the brakes connect the 24VDC power supply to the motor 2 Tightening torque 6 Nm Secure the motor with its attachment screws 3 M5x25 Refit the flexible coupling securing the axes 6 motor to the rod 4 See Replacing the wrist unit IRB 1600ID on page 195 Refit the wrist 5 Calibration is described in a separate calibration manual enclosed with the cal ibration tools Recalibrate the robot 6...

Page 254: ...re parts on page301 O rings See Spare parts on page301 Base M8 x 100 3HAC15520 1 Guide pins Always use guide pins in pairs Lifting accessories Content is defined in section Standard tools on page 297 Standard toolkit Continues on next page 254 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 gearbox ...

Page 255: ... off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 3 CAUTION The IRB 1520 robot weighs 170 kg All lifting accessories used must be sized accordingly 4 See Replacing the base on page 207 Remove the base Note The referred instructions for how to replace the base includes how to put the robot in a position best suited to f...

Page 256: ...00000450 Unscrew two attachment screws securing the gearbox and fit two guide pins in opposite holes 7 Always use guide pins in pairs Unscrew the remaining attachment screws securing the gearbox 8 Continues on next page 256 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 gearbox Continued ...

Page 257: ...e gears may be damaged if excessive force is used xx1100000452 Remove the gearbox carefully in order not to damage the motor pinion 10 Continues on next page Product manual IRB 1520 257 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 gearbox Continued ...

Page 258: ...1100000453 Fit two guide pins in opposite holes in the frame 2 xx1100000451 Fit two M14 screws diagonally in the gearbox screw holes to be used as handles 3 CAUTION Whenever parting mating motor and gearbox the gears may be damaged if excessive force is used 4 Continues on next page 258 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 7 1 Rep...

Page 259: ...ak down test on page 134 Perform a leak down test 10 See Changing the oil axis 1 gearbox on page 108 Refill gearbox with oil 11 Calibration is described in a separate calibration manual enclosed with the cal ibration tools Recalibrate the robot 12 General calibration information is included in section Calibration information on page 273 DANGER Make sure all safety requirements are met when perform...

Page 260: ... in section Standard tools on page 297 Standard toolkit These procedures include references to the tools re quired Other tools and procedures may be required See refer ences to these procedures in the step by step instructions below Continues on next page 260 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 7 2 Replacing the axis 2 gearbox ...

Page 261: ...s 2 gearbox of oil 3 CAUTION Whenever parting mating motor and gearbox the gears may be damaged if excessive force is used 4 See Removing the axes 1 and 2 motors on page 232 Remove the axis 2 motor 5 See Replacing the cable harness lower end on page 142 Remove the cable harness from base and frame 6 See Replacing the complete arm system on page 178 Remove the complete arm system 7 Continues on nex...

Page 262: ...nscrew the remaining attachment screws securing the gearbox 9 If needed use the threaded holes on the gearbox and press out the gearbox 10 Continues on next page 262 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 7 2 Replacing the axis 2 gearbox Continued ...

Page 263: ...procedure to refit the axis 2 gearbox Note Action Wipe all contact surfaces clean on gearbox and robot 1 xx1100000459 Check the cable protection 2 Continues on next page Product manual IRB 1520 263 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 7 2 Replacing the axis 2 gearbox Continued ...

Page 264: ...n the guide pins and slide it in position 6 Tightening torque 17 Nm Secure the gearbox with its attachment screws 7 M6x40 16 pcs Tightening torque 17 Nm Remove the guide pins and fit the two remain ing attachments screws 8 Continues on next page 264 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 7 2 Replacing the axis 2 gearbox Continued ...

Page 265: ...me 12 See Performing a leak down test on page 134 Perform a leak down test 13 See Changing the oil axis 2 gearbox on page 113 Refill oil in the gearbox 14 Calibration is described in a separate calibration manual enclosed with the cal ibration tools Recalibrate the robot 15 General calibration information is included in section Calibration information on page 273 DANGER Make sure all safety requir...

Page 266: ... in section Standard tools on page 297 Standard toolkit These procedures include references to the tools re quired Other tools and procedures may be required See refer ences to these procedures in the step by step instructions below Continues on next page 266 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 7 3 Replacing the axis 3 gearbox ...

Page 267: ...amaged if excessive force is used 4 See on page Remove the axis 3 motor 5 See Replacing the cable harness upper end on page 162 Remove the cable harness in the upper arm 6 See Replacing the complete upper arm IRB 1520ID on page 183 Remove the complete upper arm 7 Place the complete upper arm on a work bench some pallets or similar 8 xx1100000463 Remove two of the attachment screws and fit two guid...

Page 268: ...the gearbox out on the guide pins and remove it 12 Refitting the axis 3 gearbox Use this procedure to refit the axis 3 gearbox Note Action Wipe clean all mating surfaces on lower arm and frame with isopropanol 1 Continues on next page 268 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 7 3 Replacing the axis 3 gearbox Continued ...

Page 269: ...x1100000458 Check the o ring Replace if damaged 3 Put some grease on the o ring 4 Continues on next page Product manual IRB 1520 269 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 7 3 Replacing the axis 3 gearbox Continued ...

Page 270: ...e guide pins and slide it in position 6 xx1100000464 Secure the gearbox with its attachment screws 7 Tightening torque 14 Nm M6x40 16 pcs Continues on next page 270 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 4 Repair 4 7 3 Replacing the axis 3 gearbox Continued ...

Page 271: ...age 162 Refit the cable harness 12 See Performing a leak down test on page 134 Perform a leak down test 13 See Changing the oil axis 3 gearbox on page 117 Refill the gearbox with oil 14 Calibration is described in a separate calibration manual enclosed with the cal ibration tools Recalibrate the robot 15 General calibration information is included in section Calibration information on page 273 DAN...

Page 272: ...xes require replacement axis 4 the complete upper arm is to be replaced This procedure is detailed in section Replacing the complete upper arm IRB 1520ID on page 183 axes 5 and 6 the complete wrist unit is to be replaced This procedure is detailed in section Replacing the wrist unit IRB 1600ID on page 195 272 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights rese...

Page 273: ...rs on page 279 This will occur when The battery is discharged A resolver error occurs The signal between a resolver and measurement board is interrupted A robot axis is moved with the control system disconnected The revolution counters must also be updated after the robot and controller are connected at the first installation The robot is rebuilt If the robot is rebuilt for example after a crash o...

Page 274: ...n coordinate system for the robot Absolute accuracy calibration option al Absolute accuracy calibration data is found on the SMB serial measurement board in the robot For robots with RobotWare 5 05 or older the absolute accuracy calibration data is delivered in a file absacc cfg supplied with the robot at delivery The file replaces the calib cfg file and identifies motor positions as well as absol...

Page 275: ...re and what to do at each step is given on the FlexPendant You will be guided through the calibration procedure step by step CalibWare Absolute Accuracy calibration The CalibWare tool guides through the calibration process and calculates new compensation parameters This is further detailed in the Application manual CalibWare Field If a service operation is done to a robot with the option Absolute ...

Page 276: ...ition for each axis Synchronization marks IRB 1520ID xx1100000363 Figure 5 1 Calibration marks from bottom left to top right Axis 1 axis 4 axis 5 and axis 6 Continues on next page 276 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 5 Calibration information 5 3 Synchronization marks and synchronization position for axes ...

Page 277: ...arks from top to bottom Axis 3 and axis 2 Product manual IRB 1520 277 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 5 Calibration information 5 3 Synchronization marks and synchronization position for axes Continued ...

Page 278: ...ll handle the calibration movements automatically and these might be different from the positive directions shown below Manual movement directions 6 axes Note The graphic shows an IRB 7600 The positive direction is the same for all 6 axis robots except the positive direction of axis 3 for IRB 6400R which is in the opposite direction xx0200000089 278 Product manual IRB 1520 3HAC043435 001 Revision ...

Page 279: ... 2600ID IRB 2600 IRB 2400 IRB 910 SC IRB 1660ID IRB 1600ID IRB 1600 IRB 1520 IRB 1410 IRB 140 Coupled axes x x x x x x x Axis 4 5 6 x x x x x Axis 5 6 x Axis 4 3 Step 1 Manually running the manipulator to the synchronization position Use this procedure to manually run the manipulator to the synchronization position Note Action Select axis by axis motion mode 1 See Synchronization marks and synchro...

Page 280: ...nu tap Calibration xx1500000942 1 All mechanical units connected to the system are shown with their calibration status 2 Tap the mechanical unit in question xx1500000943 Continues on next page 280 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 5 Calibration information 5 5 Updating revolution counters Continued ...

Page 281: ...layed warning that the updating operation cannot be undone Tap Update to proceed with updating the revolution counters Tap Cancel to cancel updating the revolution counters Tapping Update updates the selected revolution counters and removes the tick from the list of axes 6 CAUTION If a revolution counter is incorrectly updated it will cause incorrect manipulator posi tioning which in turn may caus...

Page 282: ... Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools 282 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 5 Calibration information 5 6 Calibrating with Calibration Pendulum method ...

Page 283: ...be run 1 Choose calibration routine Wrist Optimization 2 Modify targets for 4 point tool frame definition in Wrist Optimization routine en0400000906 a Jog the robot to an appropriate position A for the first approach point Use small increments to accurately posi tion the tool tip as close to the reference point as possible b Tap Modify Position to define the point c Repeat for each approach point ...

Page 284: ...76 and Updating revolution counters on page 279 Check that the synchronization marks for the axes align correctly If they do not update the revolu tion counters 6 Using the jogging window Use this procedure to jog the robot to the synchronization position of all axes Note Action On the ABB menu tap Jogging 1 Tap Motion mode to select group of axes to jog 2 Tap to select the axis to jog axis 1 2 or...

Page 285: ... the country in which the robot and the control unit are installed If the robot or the control unit is partially or completely disposed of the various parts must be grouped together according to their nature which is all iron together and all plastic together and disposed of accordingly These parts must also be disposed of in accordance with the current legislation of the country in which the robo...

Page 286: ...d so on Steel Brakes motors Neodymium Cables connectors drive belts and so on Plastic rubber Gearboxes Oil grease Covers synchronization brackets Aluminium Oil and grease Where possible arrange for oil and grease to be recycled Dispose of via an authorized person contractor in accordance with local regulations Do not dispose of oil and grease near lakes ponds ditches down drains or onto soil Incin...

Page 287: ...attery is exposed to heat for example from a blow torch it will explode Always remove all oil grease in gearboxes If exposed to heat for example from a blow torch the oil grease will catch fire When motors are removed from the robot the robot will collapse if it is not properly supported before the motor is removed Product manual IRB 1520 287 3HAC043435 001 Revision L Copyright 2012 2020 ABB All r...

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Page 289: ...pter includes general information complementing the more specific information in the different procedures in the manual Product manual IRB 1520 289 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 7 Reference information 7 1 Introduction ...

Page 290: ...ices Coordinate systems and motion nomenclatures ISO 9787 2013 Manipulating industrial robots performance criteria and related test methods ISO 9283 1998 Classification of air cleanliness EN ISO 14644 1 2015i Ergonomics of the thermal environment Part 1 EN ISO 13732 1 2008 EMC Generic emission EN 61000 6 4 2007 A1 2011 IEC 61000 6 4 2006 A1 2010 option 129 1 EMC Generic immunity EN 61000 6 2 2005 ...

Page 291: ... principles Part 1 Terminology and general principles EN 614 1 2006 A1 2009 Safety of machinery Two hand control devices Functional aspects Principles for design EN 574 1996 A1 2008 Product manual IRB 1520 291 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 7 Reference information 7 2 Applicable standards Continued ...

Page 292: ...39 37 in 3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume 292 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 7 Reference information 7 3 Unit conversion ...

Page 293: ...d be used Screws lubricated in other ways Screws lubricated with Molycote 1000 should only be used when specified in the repair maintenance or installation procedure descriptions In such cases proceed as follows 1 Apply lubricant to the screw thread 2 Apply lubricant between the plain washer and screw head 3 Screw dimensions of M8 or larger must be tightened with a torque wrench Screw dimensions o...

Page 294: ...pair maintenance or installation procedure overrides the standard torque Tightening torque Nm Class 12 9 oil lubric ated Tightening torque Nm Class 10 9 oil lubric ated Tightening torque Nm Class 8 8 oil lubricated Dimension 6 M5 10 M6 40 34 24 M8 80 67 47 M10 140 115 82 M12 340 290 200 M16 670 560 400 M20 1150 960 680 M24 Lubricated screws Molycote Gleitmo or equivalent with allen head screws The...

Page 295: ...ning torque for water and air connectors when one or both connectors are made of brass Note A special torque specified in the repair maintenance or installation procedure overrides the standard torque Tightening torque Nm Max Tightening torque Nm Min Tightening torque Nm Nominal Dimension 15 8 12 1 8 20 10 15 1 4 25 15 20 3 8 50 30 40 1 2 90 55 70 3 4 Product manual IRB 1520 295 3HAC043435 001 Rev...

Page 296: ...essory when handling components with a weight exceeding 22 kg A wide range of lifting accessories and devices are available for each manipulator model Example Following is an example of a weight specification in a procedure Note Action CAUTION The arm weighs 25 kg All lifting accessories used must be sized accord ingly 296 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB A...

Page 297: ...ng open end spanner 8 19 mm 1 Socket head cap 2 5 17 mm 1 Torx socket no 20 60 1 Torque wrench 4 200 Nm 1 Small screwdriver 1 Plastic mallet 1 Ratchet head for torque wrench 1 2 1 Socket head cap no 5 socket 1 2 bit L 20 mm 1 Socket head cap no 6 socket 1 2 bit L 20 mm 1 Socket head cap no 8 socket 1 2 bit L 20 mm 1 Socket head cap no 10 socket 1 2 bit L 20 mm 1 Socket head cap no 12 socket 1 2 bi...

Page 298: ...truction 3HAC041419 002 Calibration equipment Calibration Pendulum The following table specifies the calibration equipment needed when calibrating the robot with the Calibration Pendulum method Note Art no Tools Complete kit that also in cludes operating manual 3HAC15716 1 Calibration Pendulum tool set Additional equipment to the Calibration Pendulum tool set required for calibration of axis 1 3HA...

Page 299: ...ting accessories is not detailed in the activity procedure but in the instruction delivered with each piece of lifting accessories This implies that the instructions delivered with the lifting accessories should be stored for later reference Product manual IRB 1520 299 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 7 Reference information 7 8 Lifting accessories and lifting ...

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Page 301: ...ews are not included in the manual but delivered as a separate document for registered users on myABB Business Portal www mypo rtal abb com Product manual IRB 1520 301 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 8 Spare parts 8 1 Spare part lists and illustrations ...

Page 302: ...This page is intentionally left blank ...

Page 303: ...B 140 type C 3HAC025611 001 Circuit diagram IRB 260 3HAC028647 009 Circuit diagram IRB 360 3HAC036446 005 Circuit diagram IRB 460 3HAC025691 001 Circuit diagram IRB 660 3HAC025691 001 Circuit diagram IRB 760 3HAC046307 003 Circuit diagram IRB 1200 3HAC2800 3 Circuit diagram IRB 1410 3HAC021351 003 Circuit diagram IRB 1600 1660 3HAC039498 007 Circuit diagram IRB 1520 3HAC6670 3 Circuit diagram IRB ...

Page 304: ...B 6650S 3HAC025744 001 3HAC025744 001 Circuit diagram IRB 6660 3HAC029940 001 3HAC043446 005 Circuit diagram IRB 6700 IRB 6790 3HAC13347 1 Circuit diagram IRB 7600 3HAC025744 001 3HAC050778 003 Circuit diagram IRB 14000 3HAC056159 002 Circuit diagram IRB 910SC 304 Product manual IRB 1520 3HAC043435 001 Revision L Copyright 2012 2020 ABB All rights reserved 9 Circuit diagram 9 1 Circuit diagrams Co...

Page 305: ...w of method 282 calibration position jogging to 284 scales 276 calibration scales 276 CalibWare 274 carbon dioxide extinguisher 29 cast iron disposal 286 cleaning 130 climbing on robot 32 Cold environments 73 connecting the robot and controller cabling 71 copper disposal 286 D damage to additional mechanical stop 100 damper axis 2 replacing 201 spare part number 201 damper axis 3 replacing 203 spa...

Page 306: ...5 original spare parts 17 P pedestal installed on pedestal 28 personnel requirements 18 plastic disposal 286 position robot when draining wrist unit 123 124 positive directions axes 278 PPE 18 30 product standards 290 protection classes 43 protection type 43 protective equipment 18 30 protective wear 18 30 push button unit releasing the brakes 53 replacing 222 spare part number 222 R regional regu...

Page 307: ...ks 276 system integrator requirements 28 system parameter Gravity Alpha 59 Gravity Beta 58 T temperatures operation 43 storage 43 testing brakes 36 tightening torques attachment screws robot to foundation attachment bolts 55 tools Calibration Pendulum equipment 298 torques on foundation 41 troubleshooting oil spills 130 safety 37 turning accessory 52 U updating revolution counters 279 users requir...

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Page 310: ...Telephone 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics and Motion No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics and Motion 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC043435 001 Rev L en Copyright 2012 2020 ABB All rights reserved Specifications subject to change without notice ...

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