ABB IRB 920 - User Manual

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ROBOTICS

Product manual

IRB 920

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Table of Contents5
Overview of this Manual9
Product Documentation11
How to Read the Product Manual13
Safety15
Safety Information15
Limitation of Liability15
Requirements on Personnel16
Safety Signals and Symbols17
Safety Signals in the Manual17
Safety Symbols on Manipulator Labels19
Robot Stopping Functions25
Safety During Installation and Commissioning26
Safety During Operation29
Safety During Maintenance and Repair30
Emergency Release of the Robot Axes33
Brake Testing34
Safety During Troubleshooting35
Safety During Decommissioning36
Manipulator Description37
About IRB 92037
Technical Data38
Robot Dimensions41
Working Range44
Information Labels48
The Unit Is Sensitive to ESD49
Installation and Commissioning51
Introduction to Installation and Commissioning51
Unpacking52
Pre-Installation Procedure52
Risk of Tipping/Stability53
Transportation Bracket54
On-Site Installation55
Brief Installation Procedure55
Test Run after Installation, Maintenance, or Repair56
Lifting the Robot57
Lifting the Robot by Two People57
Lifting Robot with Lifting Accessories59
Manually Releasing the Brakes63
Orienting and Securing the Robot65
Loads Fitted to the Robot, Stopping Time and Braking Distances68
Lamp69
Lamp on the Robot69
Installation of Signal Lamp (Option)70
Fitting Equipment on the Robot (Robot Dimensions)72
Restricting the Working Range75
Adjusting the Working Range75
Mechanically Restricting the Working Range76
Electrical Connections78
Robot Cabling and Connection Points78
Customer Connections81
Maintenance85
Introduction85
Service Information System (SIS)86
Maintenance Schedule and Expected Component Life87
Specification of Maintenance Intervals87
Maintenance Schedule88
Expected Component Life90
Inspection Activities91
Inspecting the Information Labels91
Inspecting the Robot Cabling93
Inspecting the Ball Screw Spline Unit94
Inspecting Axis-3 Mechanical Stops97
Inspecting Timing Belts100
Replacement/Changing Activities105
Lubrication Activities106
Lubricating the Ball Screw Spline Unit106
Cleaning Activities108
Cleaning the IRB108
Repair111
Introduction111
General Procedures112
Performing a Leak-Down Test112
Mounting Instructions for Bearings113
Mounting Instructions for Sealings115
Cut the Paint or Surface on the Robot before Replacing Parts118
Cable Harness120
Replacing the Main Harness120
Replacing the Process Hub175
Replacing the SMB Unit and Battery Unit193
Base203
Replacing the Base203
Replacing the Axis-1 Timing Belt266
Inner Arm325
Replacing the Inner Arm325
Outer Arm398
Replacing the Mechanical Stopper398
Replacing the Bellows421
Replacing the Pulley on the Ball Screw Upper Position436
Replacing the Pulley on the Ball Screw Lower Position454
Replacing the Ball Screw488
Replacing the Axis-2 Timing Belt534
Replacing the Axis-3 Timing Belt565
Replacing the Axis-4 Second Timing Belt579
Replacing the Axis-4 Timing Belt601
Replacing the Transmission Module626
Replacing the Outer Arm652
Motors712
Replacing the Axis-1 Motor Sub-Assembly712
Replacing the Axis-2 Motor Sub-Assembly771
Replacing the Axis-3 Motor Sub-Assembly802
Replacing the Axis-4 Motor Sub-Assembly819
Gearboxes843
Replacing the Axis-1 Gear Unit Sub-Assembly843
Replacing the Axis-2 Gear Unit Sub-Assembly906
Calibration945
Introduction to Calibration945
Introduction and Calibration Terminology945
Calibration Methods946
When to Calibrate948
Synchronization Marks and Axis Movement Directions949
Synchronization Marks and Synchronization Position for Axes949
Calibration Movement Directions for All Axes951
Updating Revolution Counters952
Updating Revolution Counters on Omnicore Robots952
Calibrating with Axis Calibration Method956
Description of Axis Calibration956
Calibration Tools for Axis Calibration959
Installation Locations for the Calibration Tools961
Axis Calibration - Running the Calibration Procedure962
Reference Calibration966
Calibrating the Robot968
Calibration Position968
Calibrating Axis 1 and Axis 2969
Calibrating Axis 3 and Axis 4970
Verifying the Calibration975
Checking the Synchronization Position976
Troubleshooting977
Introduction to Troubleshooting977
Oil and Grease Stains on Motors and Gearboxes979
Mechanical Noise or Dissonance980
Manipulator Collapses on Power down982
Motor Temperature too High983
Decommissioning985
Introduction985
Environmental Information986
Scrapping of Robot988
Reference Information989
Introduction989
Applicable Standards990
Unit Conversion991
Screw Joints992
Weight Specifications995
Standard Toolkit996
Special Tools997
Lifting Accessories and Lifting Instructions999
Spare Parts1001
Spare Part Lists and Illustrations1001

Brand	ABB
Model	IRB 920
Category	Robotics
Language	English

ABB IRB 920 - User Manual

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