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IRB 2600 Series
ABB IRB 2600 Series User Manual
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IRB
2600
Standard,
motor
type
A
xx0900000367
Continues
on
next
page
Product
manual
-
IRB
2600
305
3HAC035504-001
Revision:
Q
©
Copyright
2009-2018
ABB.
All
rights
reserved.
4
Repair
4.7.1
Removing
motors
Continued
304
306
Table of Contents
Default Chapter
5
Table of Contents
5
Overview of this Manual
9
Product Manual, Spare Parts - IRB
14
Product Documentation
16
How to Read the Product Manual
18
General Safety Information
19
Limitation of Liability
19
Protective Stop and Emergency Stop
21
Safety Actions
22
Fire Extinguishing
22
Emergency Release of the Robot Axes
23
Make Sure that the Main Power Has Been Switched off
24
Safety Risks During Installation and Service Work on Robots
25
Moving Robots Are Potentially Lethal
27
First Test Run May Cause Injury or Damage
28
Work Inside the Working Range of the Robot
29
Enabling Device and Hold-To-Run Functionality
30
Risks Associated with Live Electric Parts
31
The Unit Is Sensitive to ESD
33
Hot Parts May Cause Burns
34
Safety Risks Related to Pneumatic/Hydraulic Systems
35
Safety Risks with Pressure Relief Valve
36
Brake Testing
37
Safety Risks During Handling of Batteries
38
Safety Risks During Work with Gearbox Lubricants (Oil or Grease)
39
Safety Signals in the Manual
41
Safety Symbols on Product Labels
43
2 Installation and Commissioning
49
Introduction
49
Pre-Installation Procedure
50
Unpacking
50
Requirements, Foundation
52
Operating Conditions, Robot
53
Storage Conditions, Robot
53
Working Range and Type of Motion
54
Risk of Tipping/Stability
59
On-Site Installation
60
Lifting Robot with Roundslings
60
Lifting and Turning a Suspended Mounted Robot
63
Setting the System Parameters for a Suspended or Tilted Robot
64
Mounting Angles and Values
65
Manually Releasing the Brakes
68
Orienting and Securing the Robot
71
Fitting Equipment on Robot
75
Robot Dimensions
75
Load Areas
79
Fitting Equipment on Lower and Upper Arm
82
Loads Fitted to the Robot, Stopping Time and Braking Distances
88
Restricting the Working Range
89
Axes with Restricted Working Range
89
Mechanically Restricting the Working Range of Axis 1
90
Additional Stops
91
Installing Options
93
Installation of Cooling Fan for Motors (Option)
93
Installing an Expansion Container
97
Mounted Robot on
98
Installation of Foundry Plus Cable Guard (Option No. 908-1)
100
Signal Lamp (Option)
101
Start of Robot in Hot Environments
102
Start of Robot in Cold Environments
103
Electrical Connections
104
Robot Cabling and Connection Points
104
Customer Connection on Robot
108
Customer Connections on Upper Arm
111
3 Maintenance
113
Introduction
113
Maintenance Schedule and Expected Component Life
114
Specification of Maintenance Intervals
114
Maintenance Schedule
115
Expected Component Life
118
Inspection Activities
119
Inspecting Oil Level, Axis-1 Gearbox
119
Gearbox on
122
Gearbox on
123
Inspecting the Oil Level, Axis 2 Gearbox
124
Inspecting the Oil Level, Axis 3 Gearbox
127
Inspecting the Oil Level, Axis 4 Gearbox
129
Inspecting Oil Level, Gearbox Axes 5 - 6
131
Inspecting the Cable Harness
133
Inspecting Information Labels
135
Inspecting the Mechanical Stop Pin, Axis 1
137
Inspecting Additional Mechanical Stops
140
Inspecting Dampers
142
Inspecting the Pressure Relief Valve
144
Inspecting Signal Lamp (Option)
146
Replacement / Changing Activities
148
Type of Lubrication in Gearboxes
148
Changing the Oil, Axis 1 Gearbox on Floor Mounted Robots
150
Changing the Oil, Axis-1 Gearbox on Suspended Robots
158
Changing the Oil, Axis-2 Gearbox
163
Filling Oil, Axis-2 Gearbox
165
Changing the Oil, Axis-3 Gearbox
167
Filling Oil, Axis-3 Gearbox
169
Changing the Oil, Axis-4 Gearbox
171
Changing Oil, Axes-5 and -6 Gearboxes
175
Replacing SMB Battery
179
Cleaning
184
Cleaning the IRB 2600/IRB 2600 ID
184
4 Repair
187
Introduction
187
Performing a Leak-Down Test
188
General Procedures
188
Mounting Instructions for Bearings
189
Mounting Instructions for Seals
191
Cut the Paint or Surface on the Robot before Replacing Parts
193
The Brake Release Buttons May be Jammed after Service Work
194
Complete Robot
195
Removing the Complete Cable Harness
195
Removing Cable Harness in Frame
203
Removing Cable Harness in Lower Arm and Armhouse
204
Refitting the Complete Cable Harness
207
Refitting the Cable Harness in the Base
213
Refitting the Cable Harness in the Lower Arm and Armhouse
219
Replacing the Cable Harness in the Upper Arm - IRB 2600ID
222
Replacing SMB Unit
234
Refitting the SMB Unit
238
Replacing the Brake Release Board
240
Replacing the Complete Upper Arm
245
Attaching the Lifting Accessories to the Upper Arm
250
Attaching the Roundslings to the Upper Arm
251
Refitting the Complete Upper Arm
252
Replacing Complete Tubular Shaft Unit
255
Replacing Wrist Unit
262
Measuring the Play, Axis 5
268
Measuring the Play, Axis 6
270
Measuring the Play, Axis 5 (ID Upper Arm)
272
Measuring the Play, Axis 6 (ID Upper Arm)
275
Product Manual - IRB
276
Replacing the Lower Arm
278
Refitting the Lower Arm
283
Frame and Base Repair
286
Replacing Stop Pin Axis 1
286
Replacing the Base
289
Refitting the Base
296
Removing Motors
301
Position of Robot
308
Draining Gearbox
308
Refitting Motors
313
Filling Oil in Gearbox
320
Replacing Motor Axis 5 - IRB 2600ID
329
Refitting Motor Axis 5
335
Replacing Motor Axis 6 and Wrist Unit - IRB 2600ID
341
Refitting Axis-6 Motor and Wrist Unit
347
Adjusting the Play
352
Replacing Gearbox Axis 1
357
Gearboxes
357
Removing Gearbox Axis 1
361
Refitting Gearbox Axis 1
364
Refitting the Arm System to the Base
368
Replacing Gearbox Axis 2
370
Refitting Gearbox Axis 2
378
Replacing Gearbox Axis 3
383
Introduction and Calibration Terminology
391
Calibration Methods
392
When to Calibrate
394
Synchronization Marks and Axis Movement Directions
395
Synchronization Marks and Synchronization Position for Axes
395
Calibration Movement Directions for All Axes
398
Updating Revolution Counters
399
Calibrating with Axis Calibration Method
403
Description of Axis Calibration
403
Calibration Tools for Axis Calibration
406
Installation Locations for the Calibration Tools
408
Axis Calibration - Running the Calibration Procedure
412
Axis Calibration with Safemove Option
416
Unsynchronized Speed Exceeded
417
Unsynchronized Time Limit Expired
417
Calibrating with Calibration Pendulum Method
420
Verifying the Calibration
421
Checking the Synchronization Position
422
6 Decommissioning
423
Introduction
423
Environmental Information
424
Scrapping of Robot
426
7 Robot Description
427
Robot Types
427
Non-Compatible Versions of Axis-1 and Axis-2 Gearboxes
428
Identifying the Gearbox Version Visually
430
Identifying the Gearbox Version by Article Number
431
8 Reference Information
433
Introduction
433
Applicable Standards
434
Unit Conversion
436
Screw Joints
437
Weight Specifications
440
Standard Tools
441
Special Tools
442
Lifting Accessories and Lifting Instructions
444
9 Spare Part Lists
445
Spare Part Lists and Illustrations
445
Circuit Diagram
447
Index
449
4
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ABB IRB 2600 Series Specifications
General
Number of Axes
6
Robot Control
IRC5
Mounting
wall
Protection
IP67
Max Speed
Axis 1: 180°/s
Reach
1.65 m / 1.85 m
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