ABB IRB 1200-7/0.7

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Table of Contents5
Overview of this Manual9
Product Documentation16
How to Read the Product Manual18
Safety19
Safety Information19
Limitation of Liability19
Requirements on Personnel20
Safety Signals and Symbols21
Safety Signals in the Manual21
Safety Symbols on Manipulator Labels23
Robot Stopping Functions29
Installation and Commissioning30
Operation33
Maintenance and Repair34
Emergency Release of the Robot Axes37
Brake Testing38
Troubleshooting39
Decommissioning40
Installation and Commissioning41
Introduction to Installation and Commissioning41
Unpacking42
Extra O-Rings42
Protection Covers44
Transportation Bracket45
Pre-Installation Procedure49
Dimensions55
Working Range59
Risk of Tipping/Stability62
The Unit Is Sensitive to ESD64
On-Site Installation65
Lifting Robot with Roundslings65
Lifting and Turning a Suspended Mounted Robot70
Manually Releasing the Brakes71
Orienting and Securing the Robot74
Setting the System Parameters for a Suspended or Tilted Robot78
Loads Fitted to the Robot, Stopping Time and Braking Distances83
Fitting of Equipment on the Robot84
Introduction to Fitting of Equipment84
Holes for Fitting Extra Equipment85
Fitting Tools on Hygienic Robots92
Installation of Options94
Installing the Signal Lamp on IRC5 Robots94
Installing the Signal Lamp for Omnicore Robots97
Restricting the Working Range99
Axes with Restricted Working Range99
Mechanically Restricting the Working Range100
Making Robot Ready for Operation105
Additional Installation Procedure, Clean Room105
Electrical Connections106
Robot Cabling and Connection Points106
Customer Connections111
Start of Robot in Cold Environments114
Maintenance115
Introduction115
Maintenance Schedule116
Specification of Maintenance Intervals116
Maintenance Schedule117
Inspection Activities119
Inspecting the Robot Paint119
Inspecting the Robot Cabling120
Inspecting the Information Labels121
Inspecting Mechanical Stops126
Inspecting Timing Belts129
Inspecting the Signal Lamp (Option)132
Replacement/Changing Activities134
Replacing the Battery Pack134
Replacing the Sealing Set on Tool Flange of Hygienic Robots144
Cleaning Activities149
Cleaning the IRB 1200149
Cleaning the IRB 1200 with Protection Type Hygienic152
Repair157
Introduction157
General Procedures158
Cut the Paint or Surface on the Robot before Replacing Parts158
Mounting Instructions for Sealings161
Sealing Differences Depending on Protection Class164
Swing Sealing Plug for Clean Room, Food Grade Lubrication and Hygienic Robots165
Cable Harness169
Replacing the Main Cable Package169
Replacing the Axis-4 FPC Unit, Housing Extender Unit and Housing Extender Sealings245
Replacing the Axis-5 FPC Unit277
Replacing the EIB/SMB Unit291
Upper and Lower Arms308
Replacing the Lower Arm308
Replacing the Signal Lamp377
Replacing the Tubular Spare Parts380
Replacing the Axis-3 Radial Sealing and Sealing Ring418
Replacing the Axis-2 Mechanical Stop454
Replacing the Axis-3 Mechanical Stop457
Replacing the Axis-4 Mechanical Stop460
Swing and Base492
Replacing the Base Spare Parts (Base, Axis-1 Radial Sealing, Protection Sleeve)492
Replacing the Swing Spare Parts (Swing, Axis-2 Radial Sealing)572
Replacing the Axis-1 Mechanical Stop638
Motors and Gearboxes641
Replacing the Axis-1 Gear Unit641
Replacing the Axis-2 Drive Unit642
Replacing the Axis-3 Drive Unit664
Replacing the Axis-4 Gearbox, Drive Shaft and Pulley686
Replacing the Axis-4 Motor with Pulley728
Replacing the Axis-4 Timing Belt740
Replacing the Axis-5 Motor with Pulley758
Replacing the Axis-5 Timing Belt771
Replacing the Axis-5 and Axis-6 Drive Unit778
Calibration805
Introduction to Calibration805
Introduction and Calibration Terminology805
Calibration Methods806
When to Calibrate809
Synchronization Marks and Axis Movement Directions810
Synchronization Marks and Synchronization Position for Axes810
Calibration Movement Directions for All Axes812
Updating Revolution Counters813
Updating Revolution Counters on IRC5 Robots813
Updating Revolution Counters on Omnicore Robots816
Calibrating with Axis Calibration Method818
Description of Axis Calibration818
Calibration Tools for Axis Calibration821
Installation Locations for the Calibration Tools824
Axis Calibration - Running the Calibration Procedure826
Reference Calibration832
Calibrating with Wrist Optimization Method834
Calibrating with Manual Calibration Method836
Manual Calibration Method - Calibration Position836
Manual Calibration Method - Content of Calibration Toolkit 3HAC051256-001837
Manual Calibration Method - Calibrating Axis 1838
Manual Calibration Method - Calibrating Axis 2845
Manual Calibration Method - Calibrating Axis 3849
Manual Calibration Method - Calibrating Axis 4854
Manual Calibration Method - Calibrating Axis 5 and Axis 6860
Verifying the Calibration864
Checking the Synchronization Position865
Decommissioning867
Introduction867
Environmental Information868
Scrapping of Robot870
Robot Description871
Introduction871
Type a of IRB 1200872
Type B of IRB 1200873
Description of Spare Part Versions874
Spare Part Versions for the Base on IP40/IP67 Robots874
Spare Part Versions for the Swing on IP40/IP67 Robots876
Spare Part Versions for the Axis-1 Sealing Ring on IP40/IP67 Robots878
Spare Part Versions for the Housing on Type a Robots880
Spare Part Versions for the Tubular on Type a Robots881
Spare Part Versions for the Tubular Cover on Clean Room Robots882
Reference Information883
Introduction883
Applicable Standards884
Unit Conversion885
Screw Joints886
Weight Specifications889
Standard Toolkit890
Special Tools891
Lifting Accessories and Lifting Instructions895
Spare Parts897
Spare Part Lists and Illustrations897
Circuit Diagrams899

ABB IRB 1200-7/0.7 - Page 905

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