ABB IRB 1600ID User Manual

Product manual
Articulated Robot
IRB 1600 - 5/1,2 type A
IRB 1600 - 5/1,45 type A
IRB 1600 - 6/1,2 type A
IRB 1600 - 6/1,45 type A
IRB 1600 - 7/1,2 type A
IRB 1600 - 7/1,45 type A
IRB 1600 - 8/1,2 type A
IRB 1600 - 8/1,45 type A
IRB 1600ID
M2004

ABB IRB 1600ID Specifications

General

Type	Industrial Robot
Model	IRB 1600ID
Manufacturer	ABB
Payload Capacity	4 kg
Degrees of Freedom	6
Protection	IP 67
Robot Control	IRC5
Mounting	Floor, Wall
Repeatability	±0.05 mm

Summary

1 Safety

1.2 General safety information

1.2.1 Safety in the robot system

1.2.2 Safety risks

Identifies and describes various safety risks associated with robot operation and maintenance.

1.2.3 Safety actions

Provides specific actions to mitigate identified safety risks during robot operation.

1.3 Safety related instructions

Details specific safety instructions, including danger and warning messages.

1.3.2 DANGER - Moving robots are potentially lethal!

Highlights the extreme danger posed by moving robot parts and the necessary precautions.

1.3.3 DANGER - First test run may cause injury or damage!

Warns about potential risks during the first test run after service and provides elimination steps.

1.3.4 WARNING - The brake release buttons may be jammed after service work

Alerts to a potential issue with jammed brake release buttons after service and its consequences.

1.3.5 WARNING - The unit is sensitive to ESD!

Warns about electrostatic discharge (ESD) sensitivity and provides protective measures.

1.3.6 WARNING - Safety risks during work with gearbox oil

Details safety risks associated with handling gearbox oil and necessary precautions.

2 Installation and commissioning

2.2.1 Pre-installation procedure

2.3.1 Lifting robot with roundsling

Provides recommended lifting positions and procedures using a roundsling for safe robot handling.

2.3.2 Manually releasing the brakes

2.3.3 Orienting and securing the robot

2.3.4 Suspended mounting

2.4.2 Installation of additional mechanical stops on axis 1

2.4.3 Installation of additional mechanical stop on axis 2

2.4.4 Installation of additional mechanical stops on axis 3

2.4.5 Installation of position switch, axis 1

2.5.1 Connectors on robot

2.5.2 Robot cabling and connection points

3 Maintenance

3.2 Maintenance schedule and expected component life

3.2.2 Maintenance schedule

3.3 Inspection activities

3.3.1 Inspection, damper axes 2, 3 and 5

3.4 Replacement activities

3.4.1 Oil in gearboxes

3.4.2 Oil change, gearbox axes 5 and 6

Provides instructions and required equipment for changing oil in gearboxes for axes 5 and 6.

3.4.3 Oil change, gearbox axes 5- 6, IRB 1600ID

Details the oil change procedure for gearboxes on axes 5-6 of the IRB 1600ID.

3.4.4 Replacement of measurement system battery pack

Explains how to replace the battery pack for the robot's measurement system.

3.5.1 Cleaning, complete robot

4 Repair

4.2.1 Performing a leak-down test

4.2.2 Mounting instructions for bearings

4.2.3 Mounting instructions for seals

4.3.1 Replacement of cable harness

Provides detailed steps for replacing the robot's cable harness.

4.3.2 Replacement of cable harness, IRB 1600ID

Details the procedure for replacing the cable harness specifically for the IRB 1600ID model.

4.3.3 Replacement of complete arm system

Explains the procedure for replacing the entire robot arm system.

4.4.1 Replacement of complete upper arm

Provides the procedure for replacing the complete upper arm assembly.

4.4.2 Replacement of complete upper arm, IRB 1600ID

Details the replacement procedure for the complete upper arm on the IRB 1600ID model.

4.4.3 Replacement of complete lower arm

Provides the procedure for replacing the complete lower arm assembly.

4.4.4 Replacement of wrist unit

Details the procedure for replacing the robot's wrist unit.

4.4.5 Replacement of wrist unit, IRB 1600ID

Explains the procedure for replacing the wrist unit on the IRB 1600ID model.

4.4.6 Replacement of damper, axis 2

4.4.7 Replacement of damper, axis 3

4.4.8 Replacement of Mechanical damper, axis 3, IRB 1600ID

4.4.9 Replacement of damper, axis 5

4.4.10 Remove upper arm AW Gun

4.4.11 Fitting equipment on the robot, IRB 1600ID

4.5.1 Replacement of base

Provides the procedure for replacing the robot's base assembly.

4.5.2 Replacement of serial measurement unit

Details the procedure for replacing the serial measurement unit located in the robot base.

4.5.3 Replacement of push button unit

Explains how to replace the push button unit for brake release.

4.6 Motors

4.6.1 Replacement of motor, axis 1

Provides the procedure for replacing the motor on axis 1.

4.6.2 Replacement of motor, axis 2

Details the procedure for replacing the motor on axis 2.

4.6.3 Replacement of motor, axis 3

Provides the procedure for replacing the motor on axis 3.

4.6.4 Replacement of motor, axis 3, IRB 1600ID

Details the procedure for replacing the motor on axis 3 for the IRB 1600ID model.

4.6.5 Replacement of motor, axis 4

Provides the procedure for replacing the motor on axis 4.

4.6.6 Replacement of motor, axis 4, 1600ID

Details the procedure for replacing the motor on axis 4 for the 1600ID model.

4.6.7 Replacement of motor and timing belt, axis 5

Provides the procedure for replacing the motor and timing belt on axis 5.

4.6.8 Replacement of motor, axis 5, IRB 1600ID

Details the procedure for replacing the motor on axis 5 for the IRB 1600ID.

4.6.9 Replacement of motor and timing belt, axis 6

Provides the procedure for replacing the motor and timing belt on axis 6.

4.6.10 Replacement of motor, axis 6 IRB 1600ID

Details the procedure for replacing the motor on axis 6 for the IRB 1600ID.

4.7 Gearboxes

4.7.1 Replacement of gearbox, axes 1-2

Provides the procedure for replacing the gearbox unit for axes 1 and 2.

4.7.2 Service work on gearboxes, axes 3, 4, 5 and 6

5 Calibration information

5.2 Calibration methods

5.3 Calibration scales and correct axis position

5.4 Calibration movement directions for all axes

5.5 Updating revolution counters

5.6 Checking the calibration position