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Product manual

CRB 15000

OmniCore

Document ID: 3HAC077389-001

Revision: L

Specifications subject to change without notice.

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Table of Contents5
Overview of this Manual9
Product Documentation13
How to Read the Product Manual15
Safety17
Safety Information17
Limitation of Liability17
Requirements on Personnel19
Safety Signals and Symbols20
Safety Signals in the Manual20
Safety Symbols on Manipulator Labels22
Robot Stopping Functions28
Safety During Installation and Commissioning29
Safety During Operation31
Safety During Maintenance and Repair33
Emergency Release of the Robot Axes34
Brake Testing35
Safety During Troubleshooting36
Safety During Decommissioning37
Manipulator Description39
About CRB 1500039
Technical Data40
Safety Data45
Working Range47
The Unit Is Sensitive to ESD53
Installation and Commissioning55
Introduction to Installation and Commissioning55
Unpacking56
Pre-Installation Procedure56
Risk of Tipping/Stability57
On-Site Installation60
Brief Installation Procedure60
Lifting the Robot61
Orienting and Securing the Robot61
Manually Releasing the Brakes69
Manually Releasing the Brakes with the External Tool71
Installation of Brake Release Tool75
Setting the System Parameters for an Inverted or a Tilted Robot77
Loads Fitted to the Robot, Stopping Time and Braking Distances80
Fitting Equipment on the Robot (Robot Dimensions)81
Test Run after Installation, Maintenance, or Repair90
Installation of Laser Scanner91
Electrical Connections99
Robot Cabling and Connection Points99
Customer Connections on the Manipulator101
Arm-Side Interface105
Configuring the Arm-Side Interface105
Using the Arm-Side Interface109
Testing the Flexpendant Connection110
Working Closely with the Robot in a Safe Way111
Configuring the Software114
Information about Software for the CRB 15000114
Lead-Through117
The Safemove Configurator App on Flexpendant120
Guidelines for Transient and Quasi-Static Contact, CRB 15000132
Configuration of Safemove Using Visual Safemove in Robotstudio135
Information about Collaborative Speed Control Add-In141
Speed Control142
Configuration of One PROFINET-Base Laser Scanner (Robotware 7.5 or Earlier)142
Configuration of One Profisafe-Based Laser Scanner (Robotware 7.6 or Later and PLC Acting as Master)148
Configuration of Two Profisafe-Based Laser Scanners (Robotware 7.6 or Later and PLC Acting as Master)152
Configuration of One Profisafe-Based Laser Scanner (Robotware 7.10 or Later and Omnicore Acting as Master)156
Configuration of Two Profisafe-Based Laser Scanners160
Or Later and Omnicore Acting as Master)160
Configuration of One Safetyio-Base Laser Scanner (Robotware 7.6 or Later)164
Configuration of Two Safetyio-Base Laser Scanners (Robotware 7.6 or Later)169
Speed Control Strategies174
Use Cases of Safety Configurations177
Maintenance183
Introduction183
Maintenance Schedule and Expected Component Life184
Specification of Maintenance Intervals184
Maintenance Schedule185
Inspection Activities186
Inspecting the Robot186
Inspecting the Cable Harness190
Cleaning Activities195
Cleaning the CRB 15000195
Testing Activities196
Testing the Brake Release Functionality196
Running the Cyclic Brake Check Routine198
Testing the Functionality of the Joint Electronics199
Repair201
Introduction201
General Procedures202
Mounting Instructions for Sealings202
Cable Harness205
Replacing the Base Cabling205
Replacing the Axis-1 Cabling221
Replacing the Axis-2 Cabling291
Replacing the Axis-3 Cabling343
Replacing the Axis-4 Cabling378
Replacing the Axis-5 Cabling417
Replacing the Axis-6 Cabling463
Replacing the Axis-5 to Axis-6 Transition Cabling487
Replacing the Brake Release Unit488
Upper and Lower Arms506
Replacing the Lower Arm506
Replacing the Housing541
Replacing the Tubular562
Replacing the Wrist Housing597
Replacing the Tool Flange and Axis-6 Inner Flange636
Replacing the Arm-Side Interface643
Swing and Base647
Replacing the Base647
Replacing the Swing718
Joint Units768
Replacing the Axis-1 Joint Unit (CRB 15000-5/0.95)768
Replacing the Axis-1 Joint Unit (CRB 15000-10/1.52 and CRB 15000-12/1.27)808
Replacing the Axis-2 Joint Unit (CRB 15000-5/0.95)848
Replacing the Axis-2 Joint Unit (CRB 15000-10/1.52 and CRB 15000-12/1.27)876
Replacing the Axis-3 Joint Unit904
Replacing the Axis-4 Joint Unit941
Replacing the Axis-5 Joint Unit and the Axis-5 to Axis-6 Transition Cabling980
Replacing the Axis-6 Joint Unit1027
Calibration1051
Calibration Methods1051
Calibrating the Torque Sensors1053
Jogging Directions1055
Calibrating with Wrist Optimization Method1056
Troubleshooting1059
Introduction to Troubleshooting1059
Mechanical Noise or Dissonance1061
Manipulator Collapses on Power down1062
Brake Release Tool Does Not Work1063
Drive System Communication Link and DC Link Are both down During Robot Running1065
Communication Failure between Profisafe-Based Laser Scanner, PLC, and Controller1066
Communication Failure between PLC and Controller1067
Communication Failure between Scalable I/O Device and Controller1069
System Failure When Changing PROFINET-Based Laser Scanner to Safetyio-Based Laser1070
Scanner1070
Movement in Safe Area Not in Full Speed or at Zero Speed1071
Unable to Remove or Reselect Installed Options in Collaborative Speed Control Add-In1072
Unexpected Robot Movement When Starting the Program in Protecting Area1073
Diagnostic Leds on Joint Unit Drive Board1074
Decommissioning1077
Introduction to Decommissioning1077
Environmental Information1078
Scrapping of Robot1080
Reference Information1081
Introduction1081
Applicable Standards1082
Unit Conversion1084
Screw Joints1085
Weight Specifications1086
Standard Toolkit1087
Special Tools1088
Index1091

ABB CRB 15000 - Page 3

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