3HAC077389 PM CRB 15000-En
3HAC077389 PM CRB 15000-En
Product manual
CRB 15000
Trace back information:
Workspace Main version a525
Checked in 2023-06-30
Skribenta version 5.5.019
Product manual
CRB 15000
OmniCore
Table of contents
Overview of this manual ................................................................................................................... 9
Product documentation .................................................................................................................... 13
How to read the product manual ...................................................................................................... 15
1 Safety 17
1.1 Safety information ............................................................................................. 17
1.1.1 Limitation of liability ................................................................................. 17
1.1.2 Requirements on personnel ...................................................................... 19
1.2 Safety signals and symbols ................................................................................. 20
1.2.1 Safety signals in the manual ...................................................................... 20
1.2.2 Safety symbols on manipulator labels ......................................................... 22
1.3 Robot stopping functions .................................................................................... 28
1.4 Safety during installation and commissioning ......................................................... 29
1.5 Safety during operation ...................................................................................... 31
1.6 Safety during maintenance and repair ................................................................... 33
1.6.1 Safety during maintenance and repair ......................................................... 33
1.6.2 Emergency release of the robot axes .......................................................... 34
1.6.3 Brake testing .......................................................................................... 35
1.7 Safety during troubleshooting .............................................................................. 36
1.8 Safety during decommissioning ........................................................................... 37
2 Manipulator description 39
2.1 About CRB 15000 .............................................................................................. 39
2.2 Technical data .................................................................................................. 40
2.3 Safety data ....................................................................................................... 45
2.4 Working range ................................................................................................. 47
2.5 The unit is sensitive to ESD ................................................................................. 53
4 Maintenance 183
4.1 Introduction ...................................................................................................... 183
4.2 Maintenance schedule and expected component life ............................................... 184
4.2.1 Specification of maintenance intervals ........................................................ 184
4.2.2 Maintenance schedule ............................................................................. 185
4.3 Inspection activities ........................................................................................... 186
4.3.1 Inspecting the robot ................................................................................. 186
4.3.2 Inspecting the cable harness .................................................................... 190
4.4 Cleaning activities ............................................................................................. 195
4.4.1 Cleaning the CRB 15000 ........................................................................... 195
4.5 Testing activities ............................................................................................... 196
4.5.1 Testing the brake release functionality ........................................................ 196
4.5.2 Running the Cyclic Brake Check routine ...................................................... 198
4.5.3 Testing the functionality of the joint electronics ............................................. 199
5 Repair 201
5.1 Introduction ...................................................................................................... 201
5.2 General procedures ........................................................................................... 202
5.2.1 Mounting instructions for sealings .............................................................. 202
5.3 Cable harness .................................................................................................. 205
5.3.1 Replacing the base cabling ...................................................................... 205
5.3.2 Replacing the axis-1 cabling ...................................................................... 221
5.3.3 Replacing the axis-2 cabling ...................................................................... 293
5.3.4 Replacing the axis-3 cabling ..................................................................... 347
5.3.5 Replacing the axis-4 cabling ..................................................................... 382
5.3.6 Replacing the axis-5 cabling ..................................................................... 420
5.3.7 Replacing the axis-6 cabling ..................................................................... 466
5.3.8 Replacing the axis-5 to axis-6 transition cabling ........................................... 490
5.3.9 Replacing the brake release unit ............................................................... 491
5.4 Upper and lower arms ........................................................................................ 509
5.4.1 Replacing the lower arm .......................................................................... 509
5.4.2 Replacing the housing ............................................................................. 528
5.4.3 Replacing the tubular .............................................................................. 565
5.4.4 Replacing the wrist housing ...................................................................... 599
5.4.5 Replacing the tool flange and axis-6 inner flange .......................................... 638
5.4.6 Replacing the arm-side interface ............................................................... 645
6 Calibration 1063
6.1 Calibration methods ........................................................................................... 1063
6.2 Calibrating the torque sensors ............................................................................. 1065
6.3 Jogging directions ............................................................................................ 1067
6.4 Calibrating with Wrist Optimization method ........................................................... 1068
7 Troubleshooting 1071
7.1 Introduction to troubleshooting ............................................................................ 1071
7.2 Mechanical noise or dissonance .......................................................................... 1073
7.3 Manipulator collapses on power down ................................................................... 1074
7.4 Brake release tool does not work ......................................................................... 1075
7.5 Drive system communication link and DC link are both down during robot running ........ 1077
7.6 Communication failure between PROFIsafe-based laser scanner, PLC, and controller ....1078
7.7 Communication failure between PLC and controller ................................................. 1079
7.8 Communication failure between scalable I/O device and controller ............................. 1081
7.9 System failure when changing PROFINET-based laser scanner to SafetyIO-based laser
scanner ........................................................................................................... 1082
7.10 Movement in Safe area not in full speed or at zero speed ......................................... 1083
7.11 Unable to remove or reselect installed options in Collaborative Speed Control add-in .... 1084
7.12 Unexpected robot movement when starting the program in Protecting Area ................. 1085
7.13 Diagnostic LEDs on joint unit drive board .............................................................. 1086
8 Decommissioning 1089
8.1 Introduction to decommissioning ......................................................................... 1089
8.2 Environmental information .................................................................................. 1090
8.3 Scrapping of robot ............................................................................................. 1092
Index 1103
Usage
This manual should be used during:
• installation and commissioning, from lifting the product to its work site and
securing it to the foundation, to making it ready for operation
• maintenance work
• repair work
• decommissioning work
Note
Note
Significant potential hazards for robot systems are listed in ISO 10218-2. ISO
12100 provides examples of the hazards associated with machines.
Prerequisites
A maintenance/repair/installation craftsman working with an ABB robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
• be trained to respond to emergencies or abnormal situations.
References
Documentation referred to in the manual, is listed in the table below.
Document name Document ID
Product manual, spare parts - CRB 15000 3HAC079469-001
Product specification - CRB 15000 3HAC077390-001
Product manual - OmniCore C30 3HAC060860-001
Circuit diagram - CRB 15000 3HAC081041-003
Operating manual - Integrator's guide OmniCore 3HAC065037-001
Technical reference manual - System parameters 3HAC065041-001
Application manual - Functional safety and SafeMove 3HAC066559-001
Application manual - PROFINET Controller/Device 3HAC066558-001
Application manual - Force control Standard for GoFa 3HAC083267-001
Technical reference manual - Event logs for RobotWare 7 3HAC066553-001
Tip
Revisions
Revision Description
A First edition.
B Published in release 21B. The following updates are made in this revision:
• Added procedure for refitting the axis-4 cover in the replacement
procedure for the axis-5 joint unit.
• Changed the tightening torque for the axis-4 and axis-5 covers.
• Added procedure for refitting the swing in the replacement proced-
ure for the base.
• Added step for removing and refitting cable bracket in replacement
procedure for the lower arm.
• Corrected safety data.
• Updated information about SafeMove for the CRB 15000.
• Updated information about the arm-side interface, see Working
closely with the robot in a safe way on page 111.
• Added information about how to calibrate the robot, see Calibration
on page 1063.
• Updated spare part number for axis-3 joint unit.
Revision Description
C Published in release 21C. The following updates are made in this revision:
• Updated information related to the safety data, and the brake
closing time is updated.
• Updated how to initiate the calibration service routine.
• Updated information about Cyclic Brake Check in the maintenance
section.
• Updated article number for brake release tool.
• Added information about rotating connector at the manipulator
base, see Connectors at the base on page 102.
D Published in release 21D. The following updates are made in this revision:
• Added information about laser scanner.
• Added tip in section Calibration methods on page 1063.
• Updated working range for axis 6, see Working range on page 52.
E Published in release 22A. The following updates are made in this revision:
• Updated information about ASI buttons.
• Added tips about the calibration features, see Features in the
routine on page 1065.
• Updated information for the SafeMove function Human Contact
Supervision.
• Updated information for lead-through, see Lead-through on
page 117.
• Added information about length of thread engagement for attach-
ment screws.
• Added foundation material yield strength data.
• Updated information about response times in section Safety data
on page 45.
• Updated information about Gleitmo treated screws, see Screw
joints on page 1097.
• Updated replacement procedures for axis-2, axis-3, axis-4, axis-
5 and axis-6 cabling.
• Information about online user guide added in section The Safe-
Move configurator app on FlexPendant on page 120.
• Added more information for laser scanners.
F Published in release 22B. The following updates are made in this revision:
• Corrected wire rating for customer cabling.
• Added diagnostic data for drive board LEDs.
• Updated operating conditions regarding ambient humidity.
• Updated information regarding the torque sensor calibration
routine.
• Added connector designations to drive board images in replace-
ment procedures.
• Added information about changing laser scanner type.
G Published in release 22C. The following updates are made in this revision:
• Added pin specification for the customer connectors at the tool
flange.
• Added usable detergents to the cleaning section.
• Added protection class for clean room suitability.
• Changed tool designation and article number for cable tie gun.
• Minor corrections.
• Updated the connection figures and configuration procedure of
the safetyIO-based laser scanners.
• Removed the troubleshooting for issue of RED flashing status on
Scalable I/O device and failure to move the robot.
Revision Description
H Published in release 22D. The following updates are made in this revision:
• Added support for wrist optimization.
J Published in release 23A. The following updates are made in this revision:
• Added information for new brake release functionality using the
FlexPendant.
• Added support for the option Absolute Accuracy.
• Added information about releasing the brakes by using the Flex-
Pendant.
K Published in release 23A. The following updates are made in this revision:
• Updated requirement and procedure descriptions for manually
releasing the brakes.
L Published in release 23B. The following updates are made in this revision:
• Added new variants CRB 15000-10/1.52 and CRB 15000-12/1.27.
• Added pin assignment on XG1 connector of SafetyIO-based laser
scanner.
• Updated the logical expressions for SafeMove configuration using
Visual SafeMove, see Configuring pre logic on page 135.
Product documentation
Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories.
This listing is based on the type of information in the documents, regardless of
whether the products are standard or optional.
Tip
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Troubleshooting.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
• What is included (for example cables, I/O boards, RAPID instructions, system
parameters, software).
• How to install included or required hardware.
• How to use the application.
Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 17.
Illustrations
The product is illustrated with general figures that does not take painting or
protection type in consideration.
Likewise, certain work methods or general information that is valid for several
product models, can be illustrated with illustrations that show a different product
model than the one that is described in the current manual.
1 Safety
1.1 Safety information
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial robot will not cause injury or damage even if
all safety instructions are complied with.
The information does not cover how to design, install and operate a robot system,
nor does it cover all peripheral equipment that can influence the safety of the robot
system.
In particular, liability cannot be accepted if injury or damage has been caused for
any of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed as
intended.
• Non-authorized design modifications of the robot.
• Repairs on the robot and its spare parts carried out by in-experienced or
non-qualified personnel.
• Foreign objects.
• Force majeure.
Intended use
The ABB robot is intended for automation of different tasks including
moving/handling parts and production equipment or carrying sensors etc.
Application ranges from traditional manufacturing to services.
The integrator of the robot system is required to perform an assessment of the
hazards and risks.
The CRB 15000-5/0.95 can only be used with the ABB OmniCore C30 controller
with Drive system 7, and the CRB 15000-10/1.52 and CRB 15000-12/1.27 can only
be used with the ABB OmniCore C30 controller with Drive system 10.
Note
The type of drive system installed in the controller can be found on the drive
label on the controller cabinet. Always verify the drive label before connecting
the controller to the manipulator.
Controllers delivered in RobotWare versions earlier than 7.10 may not have a
Drive label attached. Then the integrator must clearly mark an observed symbol
on the controller to avoid incorrect connections.
For more information see:
• Product manual - OmniCore C30
General
Only personnel with appropriate training are allowed to install, maintain, service,
repair, and use the robot. This includes electrical, mechanical, hydraulics,
pneumatics, and other hazards identified in the risk assessment.
Persons who are under the influence of alcohol, drugs or any other intoxicating
substances are not allowed to install, maintain, service, repair, or use the robot.
The plant liable must make sure that the personnel is trained on the robot, and on
responding to emergency or abnormal situations.
Risk of entanglement
Loose clothing should not be worn and long hair should be tied up to reduce the
risk for entanglement.
Hazard levels
The table below defines the captions specifying the hazard levels used throughout
this manual.
Symbol Designation Significance
DANGER Signal word used to indicate an imminently hazard-
ous situation which, if not avoided, will result in ser-
ious injury.
Introduction to symbols
This section describes safety symbols used on labels (stickers) on the manipulator.
Symbols are used in combinations on the labels, describing each specific warning.
The descriptions in this section are generic, the labels can contain additional
information such as values.
Note
The symbols on the labels on the product must be observed. Additional symbols
added by the integrator must also be observed.
Types of symbols
Both the manipulator and the controller are marked with symbols, containing
important information about the product. This is important for all personnel handling
the robot, for example during installation, service, or operation.
The safety labels are language independent, they only use graphics. See Symbols
on safety labels on page 22.
The information labels can contain information in text.
Symbol Description
Warning!
Warns that an accident may occur if the instructions are not
followed that can lead to serious injury, possibly fatal, and/or
great damage to the product. It applies to warnings that apply
xx0900000812
to danger with, for example, contact with high voltage electrical
units, explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height, etc.
Caution!
Warns that an accident may occur if the instructions are not
followed that can result in injury and/or damage to the product.
It also applies to warnings of risks that include burns, eye injury,
skin injury, hearing damage, crushing or slipping, tripping, im-
xx0900000811 pact, fall from height, etc. Furthermore, it applies to warnings
that include function requirements when fitting and removing
equipment where there is a risk of damaging the product or
causing a breakdown.
Prohibition
Used in combinations with other symbols.
xx0900000839
Symbol Description
See user documentation
Read user documentation for details.
Which manual to read is defined by the symbol:
• No text: Product manual.
xx0900000813
xx0900000816
Do not disassemble
Disassembling this part can cause injury.
xx0900000815
Extended rotation
This axis has extended rotation (working area) compared to
standard.
xx0900000814
Brake release
Using the brake release tool will release the brakes. This means
that the robot arm can fall down.
xx0900000808
Symbol Description
Tip risk when loosening bolts
The robot can tip over if the bolts are not securely fastened.
xx0900000810
xx1500002402
Crush
Risk of crush injuries.
xx0900000817
Symbol Description
Heat
Risk of heat that can cause burns. (Both signs are used)
xx0900000818
!
3HAC 4431-1/06
xx1300001087
Moving robot
4 6 The robot can move unexpectedly.
3 5
1
xx0900000819
xx1000001141
2 3
xx1500002616
Lifting bolt
xx0900000821
Symbol Description
Adjustable chain sling with shortener
xx1000001242
Lifting of robot
xx0900000822
Oil
Can be used in combination with prohibition if oil is not allowed.
xx0900000823
Mechanical stop
xx0900000824
No mechanical stop
xx1000001144
Stored energy
Warns that this part contains stored energy.
Used in combination with Do not disassemble symbol.
xx0900000825
Symbol Description
Pressure
Warns that this part is pressurized. Usually contains additional
text with the pressure level.
xx0900000826
xx0900000827
Do not step
Warns that stepping on these parts can cause damage to the
parts.
xx1400002648
Layout
The robot integrated to a robot system shall be designed to allow safe access to
all spaces during installation, operation, maintenance, and repair.
If robot movement can be initiated from an external control panel then an emergency
stop must also be available.
Consider exposure to hazards, such as slipping, tripping, and falling.
Hazards due to the working position and posture for a person working with or near
the robot shall be considered.
Hazards due to noise emission from the robot needs to be considered.
Allergenic material
See Environmental information on page 1090 for specification of allergenic materials
in the product, if any.
Electrical safety
Incoming mains must be installed to fulfill national regulations.
The power supply wiring to the robot must be sufficiently fused and if necessary,
it must be possible to disconnect it manually from the mains power.
The power to the robot must be turned off with the main switch and the mains
power disconnected when performing work inside the controller cabinet. Lock and
tag shall be considered.
Harnesses between controller and manipulator shall be fixed and protected to
avoid tripping and wear.
Wherever possible, power on/off or rebooting the robot controller shall be performed
with all persons outside the safeguarded space.
Note
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot.
Safety devices
The integrator is responsible for that the safety devices necessary to protect people
working with the robot system are designed and installed correctly.
When integrating the robot with external devices to a robot system:
• The integrator of the robot system must ensure that emergency stop functions
are interlocked in accordance with applicable standards.
• The integrator of the robot system must ensure that safety functions are
interlocked in accordance with applicable standards.
Other hazards
The risk assessment should also consider other hazards arising from the
application, such as, but not limited to:
• Water
• Compressed air
• Hydraulics
End-effector hazards require particular attention for applications which involve
close human collaboration with the robot.
Automatic operation
Verify the application in the operating mode manual reduced speed, before changing
mode to automatic and initiating automatic operation.
WARNING
Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.
Hot surfaces
Touch surface temperatures shall be verified when running demanding motion
cycles at high ambient temperatures. If necessary, to prevent burns, allow touch
surfaces to cool down before working closely with the robot.
The following figure takes the CRB 15000-12/1.27 as an example to show the
locations of touch surfaces. All the other surfaces are considered as non-touch
surfaces.
xx2300000975
A Wrist housing
B Axis-5 cover
General
Corrective maintenance must only be carried out by personnel trained on the robot.
Maintenance or repair must be done with all electrical, pneumatic, and hydraulic
power switched off, that is, no remaining hazards.
Make sure that there are no loose screws, turnings, or other unexpected parts
remaining after work on the robot has been performed.
When the work is completed, verify that the safety functions are working as
intended.
Hot surfaces
Surfaces can be hot after running the robot, and touching these may result in burns.
Allow the surfaces to cool down before maintenance or repair.
Allergic reaction
Allergic reaction
Note
Related information
See also the safety information related to installation and operation.
Description
How to release the brakes is described in the section:
• Manually releasing the brakes on page 69.
When to test
During operation, the holding brake of each axis normally wears down. A test can
be performed to determine whether the brake can still perform its function.
How to test
The function of the holding brake of each axis motor may be verified as described
below:
1 Run each axis to a position where the combined weight of the manipulator
and any load is maximized (maximum static load).
2 Switch the motor to the MOTORS OFF.
3 Inspect and verify that the axis maintains its position.
If the manipulator does not change position as the motors are switched off,
then the brake function is adequate.
Note
General
When troubleshooting requires work with power switched on, special considerations
must be taken:
• Safety circuits might be muted or disconnected.
• Electrical parts must be considered as live.
• The manipulator can move unexpectedly at any time.
DANGER
Related information
See also the safety information related to installation, operation, maintenance, and
repair.
General
See section Decommissioning on page 1089.
If the robot is decommissioned for storage, take extra precaution to reset safety
devices to delivery status.
2 Manipulator description
2.1 About CRB 15000
Introduction
The CRB 15000 robot is a flexible, agile 6-axis articulated robot, available in three
variants spanning various options for payload from 5 kg to 12 kg, wrist reach from
0.95 m to 1.52 m (flange reach from 1.05 m to 1.62 m), and designed specifically
for manufacturing industries that use flexible robot-based automation. The robot
has an open structure that is especially adapted for flexible use, and can
communicate extensively with external systems.
Note
The CRB 15000-5/0.95 can only be used with the ABB OmniCore C30 controller
with Drive system 7, and the CRB 15000-10/1.52 and CRB 15000-12/1.27 can
only be used with the ABB OmniCore C30 controller with Drive system 10.
The type of drive system installed in the controller can be found on the Drive
label on the controller cabinet. Always verify the Drive label before connecting
the controller to the manipulator.
Controllers delivered in RobotWare versions earlier than 7.10 may not have a
Drive label attached. Then the integrator must clearly mark an observed symbol
on the controller to avoid incorrect connections.
For more information see:
• Product manual - OmniCore C30
Weight, robot
The table shows the weight of the robot.
Note
The weight does not include additional options, tools and other equipment fitted
on the robot.
Mounting positions
The table shows valid mounting positions and the installation (mounting) angle for
the manipulator.
Mounting position Installation angle
Floor mounted 0°
Wall mounted Any angle
Suspended 180°
Note
The actual mounting angle must always be configured in the system parameters,
otherwise the performance and lifetime is affected. See Setting the system
parameters for an inverted or a tilted robot on page 77.
The directions are valid for all floor mounted, table mounted, wall mounted and
suspended robots.
Txy
Fz
Fxy
Tz
xx1100000521
The table shows the various forces and torques working on the robot during different
kinds of operation.
Note
These forces and torques are extreme values that are rarely encountered during
operation. The values also never reach their maximum at the same time!
WARNING
The robot installation is restricted to the mounting options given in following load
table(s).
Floor mounted
Wall mounted
Suspended
Requirements, foundation
The table shows the requirements for the foundation where the weight of the
installed robot is included:
Requirement Value Note
Flatness of foundation 0.1/500 mm The value for levelness aims at the circum-
surface stance of the anchoring points in the robot
base.
In order to compensate for an uneven sur-
face, the robot can be recalibrated during in-
stallation. If resolver/encoder calibration is
changed this will influence the absolute ac-
curacy.
Minimum resonance 22Hz The value is recommended for optimal per-
frequency formance.
Note Due to foundation stiffness, consider robot
mass including equipment. i
It may affect the ma- For information about compensating for
nipulator lifetime to foundation flexibility, see the description of
have a lower reson- Motion Process Mode in the manual that de-
ance frequency than scribes the controller software option, see
recommended. References on page 10.
Harsh environment
The manipulator complies with the following harsh environment.
Parameter According to
Flowing, mixed gas corrosion test ISA–71.04-2013 G3
Harsh Group A
DIN EN 60068-2-60
Environmental information
The product complies with IEC 63000. Technical documentation for the assessment
of electrical and electronic products with respect to the restriction of hazardous
substances.
Joint torques
The following table shows the maximum torque for each joint. The maximum value
can be achieved on one axis at a time.
Axis Maximum joint torque
1 175.44 Nm i / 450 Nm ii / 390 Nm iii
2 175.44 Nm i / 400 Nm ii / 400 Nm iii
3 90.6 Nm i / 160 Nm ii / 160 Nm iii
4 18.72 Nm i / 60 Nm ii / 60 Nm iii
5 21.44 Nm i / 60 Nm ii / 60 Nm iii
6 9.2 Nm i / 60 Nm ii / 60 Nm iii
i Valid for CRB 15000-5/0.95.
ii Valid for CRB 15000-10/1.52.
iii Valid for CRB 15000-12/1.27.
Risk assessment
The results of a risk assessment performed on the robot and its intended application
may determine that a safety-related control system performance other than that
stated in ISO 10218 is warranted for the application.
The SISTEMA/ABB FSDT libraries contains details for the safety functions.
Safety data for SafeMove function - OmniCore C30 for CRB 15000
Note
All safety functions comply with ISO 10218-1: the SRP/CS achieves Category 3,
PL d.
The Cyclic Brake Check must be run every 8-48 hours. For more details see
Running the Cyclic Brake Check routine on page 198.
Note
For the manipulator, all the safety functionality is included in the joint units. These
are only designed to be replaced as complete units (see section Repair on
page 201). Individual subcomponents shall not be exchanged.
The maximum communication and manipulator reaction times must be added
to the reaction times from SafeMove (see Application manual - Functional safety
and SafeMove).
• For stopping functions: 4 ms
• For position and torque monitoring functions: 6 ms
• Brake closing time <110 ms
Note
A violation of the standstill monitoring will result in a Category 0 stop (see ISO
10218-1 §5.5.3). Due to the brake closing time, the robot can fall some distance
before it stops. Sufficient space must be provided around the robot to prevent
an operator from being trapped. The falling distance and maximum speed are
dependent on the robot pose, so this must be validated.
Pos 0
899
R951 R230.3
R199.4
287.6
Pos 6 Pos 8
Pos 4 272.7
Pos 2 265
0
X
Pos 5 179
Pos 7
Pos 3
686
0
951
507
470
507
951
230.2
198.1
xx2000002410
1882.3
Pos1
R1482.3 Z
Pos0 1297
R452.9
R202.6
0
X
307
Pos5 Pos7
0
48
150
888
625.3
596.9
925.3
1332.3
1632.3
1082.3
Pos3
xx2300000575
Pos1
1719
1235
R1381
R397.6
R202.5
Pos2
Pos4
338
Pos6
Pos8 276.8
194
369
Pos5 Pos7
0
674
193
635
674
1381
1381
370.6
1043
Pos3
xx2300000576
+180°
R199.4
R173.1
-180°
R951
xx2100000122
CRB 15000-10/1.52
+180°
R352.6
Y
R1632.3
R296.3(A)
-180°
xx2300000577
CRB 15000-12/1.27
R1381
+180°
Y
R202.5
R205(A)
-180°
xx2300000578
Working range
Description
ESD (electrostatic discharge) is the transfer of electrical static charge between two
bodies at different potentials, either through direct contact or through an induced
electrical field. When handling parts or their containers, personnel not grounded
may potentially transfer high static charges. This discharge may destroy sensitive
electronics.
Safe handling
Use one of the following alternatives:
• Use a wrist strap.
Wrist straps must be tested frequently to ensure that they are not damaged
and are operating correctly.
• Use an ESD protective floor mat.
The mat must be grounded through a current-limiting resistor.
• Use a dissipative table mat.
The mat should provide a controlled discharge of static voltages and must
be grounded.
General
This chapter contains assembly instructions and information for installing the CRB
15000 at the working site.
See also the product manual for the robot controller.
The installation must be done by qualified installation personnel in accordance
with the safety requirements set forth in the applicable national and regional
standards and regulations.
The technical data is detailed in section Technical data on page 40.
Safety information
Before any installation work is commenced, all safety information must be observed.
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 17 before performing any installation
work.
Note
Always connect the CRB 15000 and the robot to protective earth and residual
current device (RCD) before connecting to power and starting any installation
work.
For more information see:
• Product manual - OmniCore C30
3.2 Unpacking
Introduction
This section is intended for use when unpacking and installing the robot for the
first time. It also contains information useful during later re-installation of the robot.
Action
1 Make a visual inspection of the packaging and make sure that nothing is damaged.
2 Remove the packaging.
3 Check for any visible transport damage.
Note
Risk of tipping
CRB 15000-5/0.95 is delivered lying flat in the delivery package, while CRB
15000-10/1.52 and CRB 15000-12/1.27 are delivered in standing position in the
package. The robot cannot stand on its own without being secured to the foundation.
If the robot can not be fastened to the foundation directly, store it in the delivery
package.
Do not change the robot position before securing it to the foundation!
CRB 15000-5/0.95
xx2100000115
Axis 1 0°
Axis 2 0°
Axis 3 +85°
Axis 4 0°
Axis 5 0°
Axis 6 0°
CRB 15000-10/1.52
xx2300000380
Axis 1 0°
Axis 2 -15°
Axis 3 -225°
Axis 4 0°
Axis 5 -30°
Axis 6 0°
CRB 15000-12/1.27
xx2300000381
Axis 1 0°
Axis 2 -10°
Axis 3 +85°
Axis 4 0°
Axis 5 +15°
Axis 6 0°
WARNING
Introduction
This procedure is a brief guide when installing the robot for the first time. Also see
Pre-installation procedure on page 56.
First installation
Use these procedures to install the CRB 15000.
Action Note
1 Transport the manipulator to its intended location.
2 Install the valid platform or prepare the foundation
for the manipulator.
3 Lift and secure the manipulator to the plat- See Lifting the robot on page 61.
form/foundation. See Orienting and securing the ro-
bot on page 61.
4 Connect the manipulator to the controller. See
• Product manual - OmniCore
C30
5 Configure the safety settings. See
• Product manual - OmniCore
C30
6 How to start and run the robot is described in the See
product manual for the controller. • Product manual - OmniCore
C30
7 Install required equipment, if any.
• Installation of brake release tool on page 75
8
DANGER
Note
Wait till the robot has reached room temperature before switching on the mains
power. Otherwise there might be a risk of condensation on internal components
such as electronics.
Introduction
This section describes how to lift the robot and transport it to the installation site.
For CRB 15000-5/0.95, two persons are always required when lifting and securing
the robot. For CRB 15000-10/1.52 and CRB 15000-12/1.27, lifting accessories, such
as lifting roundslings, shall be prepared for the lifting and securing.
Do not leave the robot standing unfastened to the foundation, it is not stable on
its own.
CAUTION
The manipulator must not be connected to power during lifting and securing it
to the foundation.
Attachment screws
The table below specifies the type of securing screws and washers to be used for
securing the robot to the base plate/foundation.
All hardware is enclosed in the robot delivery.
Suitable screws M10x35
Quantity 4 pcs
Quality 8.8
Suitable washer 23/10.5/2.5 mm Steel
Guide pins DIN6325, hardened steel Ø6x24 mm, 2 pcs
Tightening torque 32 Nm ±10%
Length of thread engagement Minimum 15 mm for ground with material
yield strength 150 MPa
Level surface requirements 0.1/500 mm
B B
+0,012 6.4
6 H7 0 7.5
135 4x 12
73 C
D
(214.8)
56
135
0 .018
C (2
)
+0
56
73
6
B-B
6.
D
xx2000002366
CRB 15000-10/1.52
This illustration shows the hole configuration used when securing CRB
15000-10/1.52.
H7 +0.012 6.4
6 0 7.5
B B
C
170
90
0 .018
4x 12 (2
)
+0
D
(243.9)
6
72
170
85
4
6.
90 C
B-B D
xx2300000382
CRB 15000-12/1.27
This illustration shows the hole configuration used when securing CRB
15000-12/1.27.
B B
H7 +0.012 6.4
6 0 7.5
170
4x 12
90 C
D
(243.9)
(2
0 .018
72
)
170
+0
85
C
90
4
6.
B-B D
xx2300000383
Action Note
1 Make sure the installation site for the robot con-
forms to the specifications in section Technical
data on page 40.
Action Note
2 Prepare the installation site with attachment holes. The hole configuration of the base
is shown in Hole configuration,
base on page 62.
3 Valid for CRB 15000-10/1.52 and CRB 15000- Length: 2 m
12/1.27 Lifting capacity: >100 kg
Prepare the lifting roundsling.
Action Note
1
CAUTION
xx2100000118
CAUTION
4 Fit two pins to the holes in the base. Centering pins: DIN6325, hardened
steel Ø6x24 mm, 2 pcs .
5 Raise the robot to standing and secure to Screws: M10x35, 4 pcs, quality 8.8
foundation, paying attention to the centering Washers: 23/10.5/2.5 mm Steel
holes at the bottom of the robot base.
• Person 1: keep holding the robot stable.
• Person 2: secure the robot base to the
foundation with the securing screws and
washers.
6 Tighten the bolts in a crosswise pattern to en- Tightening torque: 32 Nm ±10%
sure that the base is not distorted.
Action Note
1 Make sure the robot is positioned in the recom- Recommended position for transport-
mended position for transportation and lifting. ation and lifting is shown in Transport-
ation and shipping position on
page 57.
WARNING
2
CAUTION
Action Note
3 Attach the roundslings to the robot according CRB 15000-10/1.52
to the figure.
Make sure the roundslings do not rub against
any sharp edges.
xx2300000384
CRB 15000-12/1.27
xx2300000385
4
WARNING
Action Note
6 Move the robot to the installation site.
CAUTION
7 Fit two pins to the holes in the base. Centering pins: DIN6325, hardened
steel Ø6x24 mm, 2 pcs .
8 Guide the robot gently, using the attachment Make sure the robot base is correctly
screws while lowering it into its mounting pos- fitted onto the pins.
ition.
9 Fit the securing screws and washers in the at- Screws: M10x35, 4 pcs, quality 8.8
tachment holes of the base. Washers: 23/10.5/2.5 mm Steel
10 Tighten the bolts in a crosswise pattern to en- Tightening torque: 32 Nm ±10%
sure that the base is not distorted.
CAUTION
On robots with RobotWare earlier than 7.10, the brakes are released using an
external brake release tool, see Manually releasing the brakes with the external
tool on page 71.
DANGER
CAUTION
Note
Action Note
1 Press the emergency stop.
On the FlexPendant, a tab appears, Brake Release.
2 Open the brake release window and select which See Arm-side interface on
brakes to release. Tap Request Brake Release. page 105.
The LEDs on the arm-side interface starts blinking
yellow.
3
DANGER
Action Note
4 Press the enabling device halfway in within 30 If the enabling device is not
seconds. This releases the brakes. pressed in within 30 seconds, the
brake release function will be can-
celled.
5 Move the robot arm to a desired position.
6 The brake will function again as soon as the en- When the enabling device is re-
abling device is released. leased or pressed fully in, then the
brakes are activated immediately.
To continue moving the arm freely,
the brake release function must be
restarted.
CAUTION
The external brake release tool works on robots with RobotWare earlier than
7.10. On robots with RobotWare 7.10 or later, the tool does not work.
How to release the brakes using the FlexPendant is described in section Manually
releasing the brakes on page 69.
CAUTION
Required equipment
Note
xx2000002539 xx2000002540
Note
The manipulator needs to be powered and motors in state Motors OFF. Do not
release the brakes in automatic operating mode.
Action Note
1 Take out the tool from its holder. Brake release tool: 3HAC079146-
001
xx2000002542
2
DANGER
xx2000002538
+48VDC (A)
0V (B)
xx2100000124
CAUTION
The external brake release tool works on robots with RobotWare earlier than
7.10. On robots with RobotWare 7.10 or later, the tool does not work.
How to release the brakes using the FlexPendant is described in section Manually
releasing the brakes on page 69.
xx2000002541
xx2100000403
xx2100000404
General
The robot is configured for mounting parallel to the floor, without tilting, on delivery.
If the robot is mounted in any other angle than 0°, then the system parameters
that describe the mounting angle (how the robot is oriented relative to the gravity)
must be re-defined.
Note
With inverted installation, make sure that the gantry or corresponding structure
is rigid enough to prevent unacceptable vibrations and deflections, so that
optimum performance can be achieved.
Note
The mounting positions are described in Mounting positions on page 40, and
the requirements on the foundation are described in Requirements, foundation
on page 42.
System parameters
Note
Gravity Beta
When the robot is mounted other than floor-standing (rotated around the y-axis),
the robot base frame and the system parameter Gravity Beta must be redefined.
If the robot is mounted upside down (inverted), then Gravity Beta should be π
(+3.141593).
If the robot is mounted on a wall, then Gravity Beta should be ±π/2 (±1.570796).
The Gravity Beta is a positive rotation direction around the y-axis in the base
coordinate system. The value is set in radians.
Gravity Alpha
If the robot is mounted on a wall (rotated around the x-axis), then the robot base
frame and the system parameter Gravity Alpha must be redefined. The value of
Gravity Alpha should then be ±π/2 (±1.570796).
The Gravity Alpha is a positive rotation direction around the x-axis in the base
coordinate system. The value is set in radians.
Note
The system parameter Gravity Alpha is not supported for all robot types.
If the robot does not support Gravity Alpha, then use Gravity Beta along with the
re-calibration of axis 1 to define the rotation of the robot around the x-axis.
Note
The parameter is supported for all robots on track when the system parameter
7 axes high performance motion is set, see Technical reference manual - System
parameters.
Gamma Rotation
Gamma Rotation defines the orientation of the robot foot on the travel carriage
(track motion).
0°
xx2100000297
xx2100000299 xx2100000300
Note
3.3.7 Loads fitted to the robot, stopping time and braking distances
CAUTION
Incorrectly defined loads may result in operational stops or major damage to the
robot.
Load diagrams, permitted extra loads (equipment) and their positions are specified
in the product specification. The loads must be defined in the software.
Note
Even after the robot is secured to the foundation, do not lean on it or place loads
on it, except what is permitted on the tool flange.
Robot dimensions
The figure shows the dimension of the robot.
CRB 15000-5/0.95
470 101
80
110
444
265
xx2000002368
CRB 15000-10/1.52
1297
1217
1107
400
218
0
0
150
787
888
xx2300000646
534
635
0
1235
1155
1045
338
xx2300000647
ELECTRICAL SHOCK
Upper arm
The robot upper arm is not designed with attachment holes for any arm load.
However, for light loads such as cables, it is possible to mount them directly on
the arm, or to replace the four screws on the upper arm cover with hex spacers,
as shown in the following figure (taking CRB 15000-5/0.95 as an example).
xx2300001024
Definitions of dimensions and masses are shown in Holes for fitting extra equipment
on page 85. Requirements on hex spacers are shown in Fastener quality for hex
spacers on page 88.
Note
Sharp edges or other hazards related to the hex spacers or fitted equipment
must be taken into consideration.
Note
If the gasket screws on the upper arm cover of CRB 15000-5/0.95 are replaced
with hex spacers, then the IP54 is no longer fulfilled.
Before fitting equipment to the robot upper arm, special considerations must be
taken:
• Any external cable routing along the robot arm shall be done in a flexible
way allowing for robot motion and taking hazards associated with
entanglement into account.
• The brake release points on each axis must be accessible in the end
application using the external brake release tool.
Brake release points are shown in Manually releasing the brakes on page 69.
CAUTION
The external brake release tool works on robots with RobotWare earlier
than 7.10. On robots with RobotWare 7.10 or later, the tool does not work.
• The armload interface can handle loads up to 1 kg. This includes the weight
of the cabling, tools, and workpiece (if lifted).
Note
When the arm load is defined, the maximum payload capacity may be
reduced in certain poses. A simulation in RobotStudio shall be performed
to verify that the combination of arm load and payload works in the intended
application.
4 x M3
41.2
5 (7)
80
A A
110
41.2
SECTION A-A
xx2300000988
5.6
101 56 311 270
3.6
4 x M3
42.5
(5.3)
80
A A
6
110
42.5
6
SECTION A-A
xx2300000989
5.6
101 56 208 270
3.6
4 x M3
42.5
(5.3)
80
A A
6
110
6
42.5
SECTION A-A
xx2300000990
2 x M4 8
4xM4 11
80
80
96
380
110
80
89
82
0
96
172
150 637
2 x R10
13 38 DETAIL G
2 x M4 8
400
G
F
20
DETAIL F
xx2300000754
2 x M4 8
80
4xM4 11
96
110
80
89
80 82
0
380
96
534
2 x R10
13 38
172
DETAIL G
2 x M4 8
F
G
338
20
DETAIL F
xx2300000755
xx2300000930
Tool flange
10.7
+0.015
6 H7 0 8 6.2
6.5 x 90
0.04
J
45° 7 x M6 9
0.2
+0.025
63 h7 -0.03
8x
0
31.5 H7
50
37
J J-J
xx2000002367
Safe handling
Use the following procedure after installation, maintenance, or repair, before
initiating motion.
DANGER
Initiating motion without fulfilling the following aspects, may increase the risk for
injury or cause damage to the robot.
Action
1 Remove all tools and foreign objects from the robot and its working area.
2 Verify that the robot is properly secured to its position by all screws, before it is powered
up.
3 Verify that any safety equipment installed to secure the position or restrict the robot
motion during service activity is removed.
4 Verify that the fixture and work piece are well secured, if applicable.
5 Verify that the brake release tool is in its intended place.
6 Verify that no personnel is leaning on, or have their head or neck close to the robot.
7 Verify that all arm covers and paddings, if any, are properly secured to the robot.
8 If maintenance or repair has been done, verify the function of the part that was main-
tained.
9 Verify the application in the operating mode manual reduced speed.
Overview
The safety separation technology and speed control for CRB 15000 is based on
the connection and communication of one or two safety laser scanners in the robot.
Laser scanner(s) provides a timely and continuous monitor on the activities within
its scanning area and forms a protective field. One laser scanner can provide a
scanning range of approximately 275°. The system integrator shall investigate the
site environment and place the laser scanner to a suitable location according to
the actual requirements.
CAUTION
Safety in the area that not in the scanning range must always be considered.
The system integrator shall assess the potential risks within this area and make
sure that proper measures have been applied to reduce risks.
275°
xx2100000168
Note
External 24V power supply shall be prepared for power connection of laser
scanners.
white blue
black
brown
24V + 0V
PROFIsafe PROFIsafe
xx2100000160
white blue
black
brown
24V + 0V
PROFIsafe
xx2300000226
white blue
black
brown
PROFIsafe PROFIsafe
24V+ 0V
Laser Scanner2
XF1 XD1
white blue
black
brown
PROFIsafe
24V+ 0V
xx2200000298
black
brown
PROFIsafe PROFIsafe
24V+ 0V
Laser Scanner2
XF1 XD1
white blue
black
brown
PROFIsafe
24V+ 0V
xx2300000227
Power
DSQC 1042
X1 X19
X2
Laser Scanner
XG1 XD1
OmniCore
controller white blue
black
brown
24V+ 0V
xx2200000299
Power
DSQC 1042
X1 X19
X2
Laser Scanner
XG1 XD1
OmniCore
controller white blue
black
brown
24V+ 0V
Laser Scanner 2
XG1 XD1
white blue
black
brown
24V+ 0V
xx2200000300
Note
If there are additional scalable I/O devices available, install and configure the
additional devices by following the detailed procedures in Application
manual - Scalable I/O.
Connector information
Pin assignment on XG1 of SafetyIO-based laser scanners
XG1 connector on SafetyIO-based laser scanner is a 17-pin, A-coded M12 female
connector. Pins 1-4 and pin 17 on XG1 are occupied for connecting the laser
scanner and scalable I/O device, while other 12 pins can be used for local inputs
and outputs.
xx2300000750
Number of connected
scanners
Scalable I/O
trol add-in
SafeMove
PLC
The following table lists the required actions for specific scenarios such as
RobotWare upgrade or rollback.
Scenario Actions
RobotWare 7.5 or an earlier ver-
sion upgraded to RobotWare 7.6 Note
or a later version
Applicable only when using PROFIsafe-based laser scanners
1 Install the Collaborative Speed Control add-in. See Information about Col-
laborative Speed Control add-in on page 141.
2 Reconfigure the PLC and laser scanner. See Configuration of one
PROFIsafe-based laser scanner (RobotWare 7.6 or later and PLC acting
as Master) on page 148.
RobotWare 7.6 or a later version
rolled back to RobotWare 7.5 or Note
an earlier version
Applicable only when using PROFIsafe-based laser scanners
Reconfigure the PLC and laser scanner. See Configuration of one PROFINET-
base laser scanner (RobotWare 7.5 or earlier) on page 142.
Adding a new laser scanner 1 Connect the new laser scanner in the same type as the one existing in the
system. See Connecting the laser scanner(s) on page 92.
2 Configure the new laser scanner. See Configuration of two PROFIsafe-
based laser scanners (RobotWare 7.6 or later and PLC acting as Master)
on page 152 or Configuration of two SafetyIO-base laser scanners (Robot-
Ware 7.6 or later) on page 169.
PROFIsafe-based laser scan-
ner(s) changed to Note
SafetyIO-based laser scanner(s)
Applicable only for RobotWare 7.6 or later
1 Reset the SafeMove configurations to factory settings by choosing Control-
ler > Reset to factory settings in the Visual SafeMove ribbon tab in Robot-
Studio.
2 Update the system using Installation Manager.
a. Unselect the installed profisafe package option(s) and select the required
IO package option(s).
b. Make sure option 3020-2 PROFINET Device and option 3023-2 PROFIsafe
Device under PROFINET group are selected in the System Option tab
page.
3 Configure the new laser scanner. See Configuration of one SafetyIO-base
laser scanner (RobotWare 7.6 or later) on page 164 or Configuration of two
SafetyIO-base laser scanners (RobotWare 7.6 or later) on page 169.
Connection via a PLC changed
to direct connection with the Note
OmniCore Controller
Applicable only when using PROFIsafe-based laser scanners
1 Upgrade the robot system to RobotWare 7.10 or later, and install the options
[3020-1] PROFINET Controller and [3023-1] PROFIsafe Controller to the
system.
2 Reconfigure the laser scanner. See Configuration of one PROFIsafe-based
laser scanner (RobotWare 7.10 or later and OmniCore acting as Master)
on page 156 or Configuration of two PROFIsafe-based laser scanners (Ro-
botWare 7.10 or later and OmniCore acting as Master) on page 160.
Introduction
Connect the robot and controller to each other after securing them to the foundation.
The lists below specify which cables to use for each respective application.
DANGER
CAUTION
Verify that the robot serial number is according to the number(s) in the Declaration
of Incorporation (DoI).
Robot cables
These cables are included in the standard delivery. They are completely
pre-manufactured and ready to plug in.
Cable sub-category Description Connection Connection
point, cabinet point, robot
Robot cable (combined Transfers DC bus power from X2 R1.MP
power and control cable power supply in the control
+ CP/CS) cabinet to the drive units in the
robot.
Robot cable
A
B
xx1600002016
A Diameter
B Diameter x10
Introduction
The customer cables are routed internally with the manipulator cable harness.
Customer cabling
xx2100000228
xx2100002065
M23 x 1
3 6
D A
C B
PE
xx2100000221
28
A D
B C
PE
xx2100000229
xx2100000125
CAUTION
Note
Always inspect the connector for dirt or damage before connecting it. Clean or
replace any damaged parts.
Introduction
The arm-side interface is located on axis 5, opposite to the tool flange. The
configuration of the arm-side interface is done using the application ASI Setting
on the FlexPendant.
xx2000002420
Prerequisites
A validated safety configuration must be set up before using the arm-side interface.
This must be based on a risk assessment of the application. Particular attention
should be paid to the risks of impact, crushing and shearing. See The SafeMove
configurator app on FlexPendant on page 120, and Application manual - Functional
safety and SafeMove.
The tool and payload must be configured before configuring the arm-side interface.
See Operating manual - OmniCore.
WARNING
When using the lead-through function from the arm-side interface, make sure
that no one else can take control of the robot.
• In manual mode, by having a FlexPendant connected to the controller.
• In automatic mode, by setting up the system with caution regarding who
has the user grant UAS_REMOTE_START_STOP_IN_AUTO. This grant is
required to start or stop program execution in automatic mode. Any user
with this grant should be located within eyesight of the robot. The
FlexPendant can always be used to start or stop program execution.
See also Working closely with the robot in a safe way on page 111.
CAUTION
The robot is delivered with the buttons and LED lights pre-configured. During
installation this configuration must be verified before commissioning the
application.
CAUTION
When using the arm-side interface, make sure to use zone limits or physical
barriers to prevent contact between the manipulator and the human head. This
applies both to commissioning and automatic operation.
CAUTION
During fine tuning of positions, make sure not to place your head too close to
the manipulator.
Note
The buttons are deactivated until there is a valid safety configuration in the robot
controller.
The buttons on the arm-side interface are configured with RAPID routines in the
module GOFA_ASI_Procedures, located in the task T_ROB1.
On delivery, a number of pre-configured routines are available. These can be
customized as needed, and more routines can be added. All routine names must
start with ASI_
For the default configuration of the arm-side interface, no hazards can arise if both
buttons are pressed simultaneously. Consequently, the ASI application does not
trap or prevent this situation. Should the button configuration be changed, it must
be checked whether hazards could arise if the buttons are pressed at the same
time. If necessary, mitigations must be provided in the RAPID code. Simultaneous
pressing of both ASI buttons shall be considered in the application risk assessment.
To change what routine to run when pressing a button, use the FlexPendant app
ASI Setting.
xx2100000080
Gripper
There is a routine available for the up button that can open and close a gripper.
The function is toggled by each press of the button. To enable the gripper routine,
open the Wizard web app.
CAUTION
Note
In RobotWare 7.2, the light ring configuration cannot be changed, only disabled.
WARNING
When using the lead-through function from the arm-side interface, make sure
that no one else can take control of the robot. See recommendations in
Configuring the arm-side interface on page 105.
Prerequisites
A validated safety configuration must be set up before using the arm-side interface.
This must be based on a risk assessment of the application. Particular attention
should be paid to the risks of impact, crushing and shearing. See The SafeMove
configurator app on FlexPendant on page 120, and Application manual - Functional
safety and SafeMove.
The tool and payload must be configured before configuring the arm-side interface.
See Operating manual - OmniCore.
Note
The application ASI Setting on the FlexPendant must be open when using the
buttons, if the buttons are configured differently than default.
Tip
If the buttons are not responding, close the ASI Setting app and reopen it.
Introduction
The ASI Setting application can be used to verify to which robot the FlexPendant
is connected.
1 In the ASI Setting application, select Light indicator.
2 Toggle the Enabled switch to turn on or off the light ring on the robot.
3 Inspect on which robot the light ring is affected.
Note
This technique should also be used to verify a Robot Control Mate connection
before starting work.
Unconstrained collisions
An unconstrained collision is one where the body part involved is not trapped.
Under these circumstances, only transient collisions are possible.
The risks from unconstrained collisions can be reduced by creating a zone to
implement Cartesian speed limits, set by the safety function Tool Speed Supervision
(see Application manual - Functional safety and SafeMove). Assistance with setting
the limits is provided by the supporting function Human Interaction Supervision.
Guidance and biomechanical limits are provided in ISO/TS 15066.
Constrained collisions
A constrained collision is one where the body part involved is trapped between
the robot and another fixed object, or two parts of the robot. Constrained collisions
can be either transient, if the robot can give way (at least partially), or quasi-static.
If additional clients are needed, ensure that their interaction with the
controller can be disabled. Disable them while using the arm-side
interface.
Introduce organizational measures to prevent start of the programmed
motion while someone is using the arm-side interface. For example: it
shall be possible to visually confirm that the area around the robot is
clear.
Finally, if risks in automatic mode cannot be sufficiently reduced by these or other
means, use of the arm-side interface shall be restricted to manual mode.
Overview
CRB 15000 is designed to simplify collaborative applications. Therefore some
software features work somewhat different compared with standard industrial
robots. Some of them are listed in this section.
How to configure RobotWare is described in Operating manual - Integrator's guide
OmniCore.
Emergency stops
The configuration of emergency stops is stop category 1 and cannot be changed.
Collision detection
As default CRB 15000 will have collision detection active at stand still. It also has
another stop ramp compared to other robots to be able to release clamping forces.
Note
If the tool data is wrong, false collisions might be triggered and the robot arm
might drop a short distance during the stop ramp.
With the FlexPendant, a user can verify local presence with the three-position
enabling device. For robots without a connected FlexPendant, system input signals
can be used to verify local presence.
CAUTION
SafeMove
The functional safety and SafeMove configuration can be done in RobotStudio or
on the FlexPendant. The functionality in RobotStudio is more extensive. Both
interfaces are described in detail in Application manual - Functional safety and
SafeMove. The FlexPendant user interface is also described in this manual, see
The SafeMove configurator app on FlexPendant on page 120.
Singularities
Some positions in the robot working space can be attained using an infinite number
of robot configurations to position and orient the tool. These positions, known as
singular points (singularities), constitute a problem when calculating the robot arm
angles based on the position and orientation of the tool.
Generally speaking, a robot has two types of singularities; arm singularities or
wrist singularities.
The wrist singularities for the GoFa robot are different from other robots, due to
the design.
Note
The singularities can, in combination with large tools, require thorough validation
of forces if there is a risk of clamping situations.
Some typical examples of singularity positions for GoFa are shown here.
Typical arm singularities Typical wrist singularities
xx2300000098 xx2300000099
xx2300000101 xx2300000100
For more information about singularity, see Technical reference manual - RAPID
Overview, section Singularities.
3.6.2 Lead-through
What is lead-through?
The lead-through functionality is available for robots designed for collaborative
applications. If lead-through is available, this is shown on the FlexPendant.
Using lead-through, you can grab the robot arm and move it manually to a desired
position, as an alternative to jogging.
Using lead-through
Use the following procedure to jog the robot using the lead-through functionality:
1 Enable lead-through in one of the following ways:
• Press the thumb button on the FlexPendant.
xx2100000331
• On the start screen, tap Jog and select the Lead-through menu.
• In the QuickSet menu, select the Lead-through tab.
Note
Note
The Lead-through lock section is disabled for the Axis 1-6 mode.
The robot moves to the selected position. If the Lead-through lock option is
selected, the robot moves in such a way that the movement is restricted in
the locked direction.
Note
You can feel if an axis reaches its end position. Do not try to force the axis
beyond this position.
Note
The speed at which the robot moves when using the Lead-through functionality
is managed using the horizontal scroll bar available in the Lead-through Speed
section.
Lead-through can also be enabled using the RAPID instruction SetLeadThrough,
or a button on the arm side interface, see Arm-side interface on page 105. If the
lead-through button is pressed but the arm is not moved, then the lead-through
functionality is switched off after 10 seconds.
Lead-through is possible in both manual and automatic mode.
Note
Note
When using lead-through, it is important that the load is correctly defined. If the
load is heavier than defined, the effect will be the same as if you are pulling the
robot arm downwards. If the load is lighter than the defined load, the effect will
be the same as if you are pulling the robot arm upwards.
For the CRB 15000, there is a button for updating/refreshing the load while
lead-through is active.
For the CRB 15000, if varying loads from cables and other disturbances are
causing the robot to drift during lead-through, this can often be improved by
setting the system parameter Lead through load compensation to Always. See
Technical reference manual - System parameters, section Motion, type Robot.
Note
For collaborative robots, the motors are on by default unless extra safety
options are selected in the system.
Introduction
The application SafeMove on the FlexPendant offers an intuitive way to visualize
and configure a safety configuration for systems with the option SafeMove
Collaborative. This includes stop functions and Cyclic Brake Check. To get started,
see Use cases on page 123.
Tip
Use the online user guide tool, included in the SafeMove configurator app, for
help with the SafeMove configuration setup process.
Note
Prerequisites
• The option SafeMove Collaborative is required.
• To edit a configuration, the grant Safety Services is required. A user without
this grant can view a configuration, but not modify, write it to the controller,
or apply it to the controller.
Template configurations
The template configuration is adapted for the specific manipulator, and typically
contains one or two encapsulations of the arm, one encapsulation of the wrist
(intended for the tool), one or two safe zones, and a Cyclic Brake Check setting.
This configuration is typically a good start for a generic application with a smaller
tool.
The factory setting is an empty safety configuration. A loaded configuration can
be removed and the system is then reset to the factory setting.
Encapsulations
The encapsulations are geometries that can be in the shape of a sphere, capsule,
or lozenge. A sphere or capsule encapsulation can be modified in dimension and
position. A lozenge capsule can be modified in dimension, position, and rotation.
xx2100000712
Safe zones
The default safe zone is a rectangular box with four vertices. The vertices defines
the shape of the safe zone, and the position in space. More vertices can be added
to define the safe zone. The minimum number of vertices is 4, and the maximum
is 24.
Each vertex can be edited in x and y values.
xx2100000714
Each vertex is numbered, from 1 and up. When a new vertex is added between
two existing vertices the vertex numbers will be automatically adjusted so that they
come in order. For example, if a new vertex is added between vertices 2 and 3, the
vertex with index 3 will change to 4 and the new vertex will be indexed 3.
Supervision functions
The global supervision functions are not connected to a specific safe zone or safe
range. They can be added, modified, and deactivated.
For more information about the global supervision functions, see Application
manual - Functional safety and SafeMove.
Synchronization
The Synchronization tab is used to manually set the current joint positions for the
robot.
For more information about synchronization, see Application manual - Functional
safety and SafeMove.
Use cases
Starting the SafeMove configurator app
The SafeMove configurator app is available on the home screen of the FlexPendant
for systems with the option SafeMove Collaborative. If the app is not shown, then
review the system settings in RobotStudio Installation Manager and add the option.
The first time that the app is opened, a default factory setting is loaded. This
contains only the manipulator with Cyclic Brake Check activated. There are no
encapsulations, safe zones, or tool data defined.
The factory setting can always be resumed, if needed.
To continue and create a safety configuration, see Use the template configuration
on page 123.
xx2100000715
3 Review that the template configuration is suitable for the intended application.
If modifications are needed, see Modify a configuration on page 124.
Note
Modify a configuration
Use the following procedure to modify a loaded configuration and apply it to the
robot controller.
1 Select Enable Edit Mode to edit the safety configuration.
2 If no configuration is loaded, load an empty configuration or a template
configuration.
3 To add or modify an encapsulation, tap Add and select a geometry for Robot
Encapsulation or Tool Encapsulation.
To modify the encapsulation, select it and modify the attributes.
4 To add or modify a zone, tap Add and Add Zone.
Select the safe zone and modify the attributes. See Modify a safe zone on
page 125.
5 To add or modify a global setting, tap Add and select which supervision to
modify.
6 When the configuration is done, select Write to controller.
The safety report is presented on the screen.
Note
7 Save the safety report. Print out and sign this safety report.
The safety report and how to validate is described in detail in Application
manual - Functional safety and SafeMove.
8 Apply the configuration to the controller.
The controller is automatically restarted when applying the configuration.
xx2100000710
4 To add a supervision to a safe zone, tap to select the safe zone in the 3D
view, then tap Add.
5 Select a supervision function or guide.
xx2100000713
6 For supervision functions, select stop category, signal, and any other available
setting applicable for the function.
7 For the guide Human Contact Supervision, select contact type, tooling
properties, and body contact areas.
See Use the Human Contact Supervision settings on page 127.
Tip
xx2100000251
xx2100000717
DANGER
• All safety zones with connected supervision functions and signals used for
safety interlocking
• All global supervision functions
• All tools with corresponding supervision functions
Note
Concluding steps
After the validation is concluded, turn on the the SafeMove Assistant functionality,
with the system parameter Disable SafeMove Assistant.
xx2100000711
Body model
As defined in ISO/TS 15066, the body model is a representation of the human body
consisting of individual body segments characterized by biomechanical properties.
The segments of the body model has different sensitivity. In general, the application
should be designed so that the human head and neck is never exposed to hazards.
xx2100000709
Conclusion
The values calculated in the Human Contact Supervision function are conservative.
However, if the risk assessment for the final application shows that these values
can be changed to a higher value, for example, by using padding on the arm, then
the values can be changed in the settings for the tool force supervision and tool
speed supervision.
CAUTION
General
This section describes SafeMove configuration using Visual SafeMove for scenarios
with PROFIsafe-based laser scanners connected and OmniCore controller acting
as master.
Action
1 Start RobotStudio with a virtual controller (with or without a station) or connect a real
controller.
• The user account logging in the controller must be granted with the Safety
Services permission.
• The write access to the controller is also requested
2 In the Controller tab, click Online Monitor.
(Not needed when running a RobotStudio station.)
3 In the Controller tab, click Safety, then select Visual SafeMove.
Configuring SafeMove
Configuring pre logic
1 On the Visual SafeMove tab page, click Safe IO Configurator in the
Configuration group.
2 Click Pre Logic view in the Safe IO Configuration page.
3 Click New expression and create the following expressions.
• ISH_Activate_SST
• ISH_Activate_TSP
• ISH_Delay_SST
• ISH_Delay_TSP
• ISH_EnableDelay_Protecting
• ISH_EnableDelay_Warning
• ISH_Combination_Protecting
• ISH_Combination_Waning
In which, the expressions ISH_Combination_Protecting and
ISH_Combination_Waning are required only when two PROFIsafe-based
laser scanners are connected.
4 At the bottom of the Safe IO Configuration page, type the corresponding
logical expression in the text box for each expression and click Create
signals.
Expression Logic
ISH_Activate_SST Valid for scenarios with 1 PROFIsafe-based laser
scanner connected
ISH_Supervise_SST := ((NOT EDGE((NOT Protect-
ingArea1),ISH_Delayed_SST)) OR (NOT ISH_Ena-
bler_Delay_SST))
Valid for scenarios with 2 PROFIsafe-based laser
scanners connected
ISH_Supervise_SST := ((NOT EDGE((NOT Protect-
ingAreaSM),ISH_Delayed_SST)) OR (NOT ISH_Ena-
bler_Delay_SST))
ISH_Activate_TSP Valid for scenarios with 1 PROFIsafe-based laser
scanner connected
ISH_Supervise_TSP := ((NOT EDGE((NOT
WarningArea1),ISH_Delayed_TSP)) OR (NOT ISH_Ena-
bler_Delay_TSP))
Valid for scenarios with 2 PROFIsafe-based laser
scanners connected
ISH_Supervise_TSP := ((NOT EDGE((NOT
WarningAreaSM),ISH_Delayed_TSP)) OR (NOT
ISH_Enabler_Delay_TSP))
ISH_Delay_SST Valid for scenarios with 1 PROFIsafe-based laser
scanner connected
DELAY(ISH_Enabler_Delay_SST,Protect-
ingArea1,(ISH_AtUser_Period_ms_Until_SST /
ISH_SMctrl_Frequency),ISH_Count-
Delay_SST,ISH_Delayed_SST)
Valid for scenarios with 2 PROFIsafe-based laser
scanners connected
DELAY(ISH_Enabler_Delay_SST,Protect-
ingAreaSM,(ISH_AtUser_Period_ms_Until_SST /
ISH_SMctrl_Frequency),ISH_Count-
Delay_SST,ISH_Delayed_SST)
Expression Logic
ISH_Delay_TSP Valid for scenarios with 1 PROFIsafe-based laser
scanner connected
DELAY(ISH_Ena-
bler_Delay_TSP,WarningArea1,(ISH_AtUser_Peri-
od_ms_Until_TSP / ISH_SMctrl_Frequency),ISH_Count-
Delay_TSP,ISH_Delayed_TSP)
Valid for scenarios with 2 PROFIsafe-based laser
scanners connected
DELAY(ISH_Ena-
bler_Delay_TSP,WarningAreaSM,(ISH_AtUser_Peri-
od_ms_Until_TSP / ISH_SMctrl_Frequency),ISH_Count-
Delay_TSP,ISH_Delayed_TSP)
ISH_EnableDelay_Protect- ISH_Enabler_Delay_SST := (NOT ISH_User-
ing i MODE_bNot_IntermitCollab)
ISH_EnableDelay_Warning ISH_Enabler_Delay_TSP := ((NOT ISH_User-
i MODE_bNot_Cooperation) OR (NOT ISH_User-
MODE_bNot_IntermitCollab))
ISH_Combination_Protect- ProtectingAreaSM := (ProtectingArea1 AND Protect-
ing ii ingArea2)
ISH_Combination_Waning WarningAreaSM := (WarningArea1 AND WarningArea2)
ii
5 Click Signals view in the Safe IO Configuration page and then click Global
signals to expand the signal list.
6 Click on the Create new signal row and create the following signals.
• ISH_TFO_Active
• ISH_TSP_Active
• ISH_TSP_Viol
• ISH_SST_Active
• ISH_SST_Viol
7 Change the default value of following signals.
Signal Default value
ISH_AtUser_Period_ms_Until_SST 650
ISH_AtUser_Period_ms_Until_TSP 550
ISH_SMctrl_Frequency 4
ISH_UserMODE_bNot_Cooperation 1
Creating encapsulation
1 In the Visual SafeMove browser on the left pane of the window, select the
robot (ROB_1) and click Capsule in the Visual SafeMove ribbon tab to create
two capsule geometries for the robot.
3 In the Visual SafeMove browser, select the tool and click Capsule in the
Visual SafeMove ribbon tab.
4 Set capsule properties for the tool.
Parameter Value
Radius (mm) 75
Length (mm) 250
Start (Flange coordinates) (mm) X value 0
Y value 0
Z value 0
End (Flange coordinates) (mm) X value 0
Y value 250
Z value 250
• Quasi_Static_Contact_Zone_2
3 Set zone properties.
Note
All the parameter values provided in this section are for reference only.
The values shall be modified according to actual requirements and based
on risk assessment of the final application.
Parameter Value i
Transi- Quasi_Stat- Quasi_Stat-
ent_Con- ic_Con- ic_Con-
tact_Zone tact_Zone_1 tact_Zone_2
Tool Speed Supervision Priority BASE BASE BASE
Reference Task frame Task frame Task frame
Botton, Top (mm) Bottom value 50.000 -100.000 0.000
Top value 2000.000 50.000 350.000
Vertices X, Y X and Y values for ver- -1500, -1500 -1600, -1600 -100, -200
(mm) tices 1
X and Y values for ver- 1500, -1500 1600, -1600 100, -200
tices 2
X and Y values for ver- 1500, 1500 1600, 1600 100, 150
tices 3
X and Y values for ver- -1500, 1500 -1600, 1600 -100, 150
tices 4
i Values for safe zone dimension are for reference only. It is allowed to customize the safe
zone scope according to actual requirements. All the changes should be based on risk
assessment of the final application.
4 Right click the three zones respectively in the left navigation tree and choose
Tool Speed Supervision. Set following parameters.
Parameter Value
Transi- Quasi_Stat- Quasi_Stat-
ent_Con- ic_Con- ic_Con-
tact_Zone tact_Zone_1 tact_Zone_2
Violation action Stop category Cat- Cat- Cat-
egory1Stop egory1Stop egory1Stop
Speed limits Max speed (mm/s) 434.000 20.000 20.000
6 Click Tool Position Supervision in the Modify ribbon tab and set the
properties.
Parameter Value
Activation PermanentlyActive
Function active status No signal
Violation action Stop category Category1Stop
Signal No signal
Settings Checked the Include upper arm
geometry and Allow inside
check boxes.
Overview
Note
The Collaborative Speed Control add-in is required only for robots operating in
RobotWare 7.6 or later.
The Collaborative Speed Control add-in is integrated in the robot system at delivery
if any of laser scanner options 3351-X are ordered. It is also available separately
in the add-ins section in RobotStudio. To add it to an existing controller or do an
update, see the installation procedure to install and add it to the robot.
With the Collaborative Speed Control add-in installed, the speed control
configuration is activated for the robot.
For PROFIsafe-based scenarios where a PLC is connected to act as a master and
SafetyIO-based scenarios, after the add-in is installed, a predefined template
SafeMove configuration file is also available for easy configuration of basic
SafeMove functions.
Tip
GSD file
The GSD file, GSDML-V2.xx-ABB-Robotics-OmniCore-YYYYMMDD.xml, can be
obtained from the RobotStudio or the OmniCore controller.
• In the RobotWare installation folder in RobotStudio:
...\DistributionPackages\ABB.RobotWare-x.x.x-xxx\RobotPackages
\RobotControl_x.x.xxx\utility\service\GSDML\
• On the OmniCore Controller:
...\products\RobotControl_x.x.x\utility\service\GSDML\
A
B
C
D
xx2100000165
Configuration procedure
Before starting the configuration, obtain the microScan 3 Core - PROFINET GSDML
file and the software tool Safety Designer® from SICK's website first. Make sure
both the file and the software tool are in the latest versions.
Detailed procedures about how to configure the laser scanner are detailed in SICK
microScan3 Siemens PLC integration instruction manual - TIA Portal and SICK
microScan3 Siemens PLC integration instruction manual - SIMATIC Step 7.
Following described roughly:
1 Connect the laser scanner to the PLC and controller.
See the physical connection in Connecting the laser scanner(s) on page 92.
2 Open configuration software tool Safety Designer®.
3 Set IP address and PROFINET name in Configuration > Addressing.
• The scanner IP address must be in the same network segment with
the PLC and controller, that is, 192.168.10.XXX.
• The PROFINET name must be the same in the PLC configuration.
4 Set F-destination address to 12 in PROFINET area in Configuration >
Protocol Settings.
5 Define the four protection fields in Configuration > Fields.
6 Define the source for input signals of the scanner and configure basic settings
for the inputs and outputs in Configuration > Inputs and outputs.
The Use one input source checkbox must be selected and choose Rx:
Process image (6 Bytes) from the drop-down list.
7 Create monitoring cases and assign the fields that are to be monitored to
each monitoring cases in Configuration > Monitoring cases.
• Check the communication between the PLC and controller is well and activate
the laser scanner; set up the communication between the laser scanner, PLC
and OmniCore controller.
Configuring SafeMove
With RobotStudio
Basic steps for configuring SafeMove are as follows:
1 Make some initial preparations.
2 Configure system parameters.
3 Set the input and output size and name of the PROFINET internal device.
For CRB 15000, required settings for communication between laser scanner,
PLC and OmniCore controller are predefined in the configuration file.
4 Set up safety user grants.
Users must have access grants to lock safety controller configurations, safety
services and software synchronization.
5 Configure robot properties.
6 Configure the synchronization position.
7 Configure the SafeMove tool definitions.
8 Configure safe I/O signals.
Note
For the first time configuring safe I/O signals using Visual SafeMove, make
sure the I/O Engineering Tool is opened first. In this case, the configured
safe I/O signals can be displayed in the Visual SafeMove window.
With FlexPendant
1 Log in the FlexPendant.
The user logging in must have access grants to lock safety controller
configurations, safety services and software synchronization.
2 Tap Settings on the home page.
3 Tap Safety Controller.
4 Tap Synchronization in the left pane.
5 Jog the robot to match the Actual Positions values with the Sync Positions
values. Make sure they are the same.
6 Tap Synchronize.
GSD file
The GSD file, GSDML-V2.xx-ABB-Robotics-OmniCore-YYYYMMDD.xml, can be
obtained from the RobotStudio or the OmniCore controller.
• In the RobotWare installation folder in RobotStudio:
...\DistributionPackages\ABB.RobotWare-x.x.x-xxx\RobotPackages
\RobotControl_x.x.xxx\utility\service\GSDML\
• On the OmniCore Controller:
...\products\RobotControl_x.x.x\utility\service\GSDML\
xx2200000301
Configuration procedure
Before starting the configuration, obtain the microScan 3 Core - PROFINET GSDML
file and the software tool Safety Designer® from SICK's website first. Make sure
both the file and the software tool are in the latest versions.
Detailed procedures about how to configure the laser scanner are detailed in SICK
microScan3 Siemens PLC integration instruction manual - TIA Portal and SICK
microScan3 Siemens PLC integration instruction manual - SIMATIC Step 7.
Following described roughly:
1 Connect the laser scanner to the PLC and controller.
See the physical connection in Connecting the laser scanner(s) on page 92.
2 Open configuration software tool Safety Designer®.
3 Set IP address and PROFINET name in Configuration > Addressing.
• The scanner IP address must be in the same network segment with
the PLC and controller, that is, 192.168.10.XXX.
• The PROFINET name must be the same in the PLC configuration.
4 Set F-destination address to 12 in PROFINET area in Configuration >
Protocol Settings.
5 Define the two protection fields in Configuration > Fields.
6 Define the source for input signals of the scanner and configure basic settings
for the inputs and outputs in Configuration > Inputs and outputs.
The Use one input source checkbox must be selected and choose Rx:
Process image (6 Bytes) from the drop-down list.
7 Create monitoring cases and assign the fields that are to be monitored to
each monitoring cases in Configuration > Monitoring cases.
• Create variables.
Name Type Example address i
ProtectingTrigger Bool %I3.0
WarningTrigger Bool %I4.1
ProtectingArea Bool %Q68.0
WarningArea Bool %Q68.1
SafetyCommunicationEnable Bool %Q68.2
ActivateScanner Bool %Q3.0
i %I3.X and %I4.X are the addresses of the laser scanner; %Q68.X is the address of the
OmniCore controller.
%Q3.0 is for activating the monitoring cases of the laser scanner.
• Check the communication between the PLC and controller is well and activate
the laser scanner; set up the communication between the laser scanner, PLC
and OmniCore controller.
Configuring SafeMove
To enable SafeMove, perform the following procedure:
1 Log in the FlexPendant.
Make sure the user logged in have access grants to lock safety controller
configurations, safety services and software synchronization.
2 Tap SafeMove on the home page.
3 Tap Load in the pop-up message box to confirm loading of template SafeMove
configuration files.
The controller restarts.
4 After the controller is restarted, tap Settings on the home page.
5 Tap Safety Controller.
6 Tap Synchronization in the left pane.
7 Jog the robot to match the Actual Positions values with the Sync Positions
values.
Make sure the values are the same.
8 Tap Synchronize.
GSD file
The GSD file, GSDML-V2.xx-ABB-Robotics-OmniCore-YYYYMMDD.xml, can be
obtained from the RobotStudio or the OmniCore controller.
• In the RobotWare installation folder in RobotStudio:
...\DistributionPackages\ABB.RobotWare-x.x.x-xxx\RobotPackages
\RobotControl_x.x.xxx\utility\service\GSDML\
• On the OmniCore Controller:
...\products\RobotControl_x.x.x\utility\service\GSDML\
xx2200000301
Configuration procedure
Before starting the configuration, obtain the microScan 3 Core - PROFINET GSDML
file and the software tool Safety Designer® from SICK's website first. Make sure
both the file and the software tool are in the latest versions.
Detailed procedures about how to configure the laser scanners are detailed in
SICK microScan3 Siemens PLC integration instruction manual - TIA Portal and
SICK microScan3 Siemens PLC integration instruction manual - SIMATIC Step 7.
Following described roughly:
1 Connect the laser scanners to the PLC and controller.
See the physical connection in Connecting the laser scanner(s) on page 92.
2 Open configuration software tool Safety Designer®.
3 Set IP address, F-destination and PROFINET name in Configuration >
Addressing.
• The scanner IP address must be in the same network segment with
the PLC and controller, that is, 192.168.10.XXX.
• The PROFINET name must be the same in the PLC configuration.
• The two scanners must be set to different IP address, F-destination
and PROFINET name.
4 Set F-destination address to 12 for the first scanner and to 13 for the second
scanner, in PROFINET area in Configuration > Protocol Settings.
5 Define the two protection fields for each scanners in Configuration > Fields.
6 Define the source for input signals of each scanner and configure basic
settings for the inputs and outputs in Configuration > Inputs and outputs.
The Use one input source checkbox must be selected and choose Rx:
Process image (6 Bytes) from the drop-down list.
7 Create monitoring cases and assign the fields that are to be monitored to
each monitoring cases in Configuration > Monitoring cases.
The parameters f_dest_address and f_source_address for the SDI are set to
3 and 2, respectively, and for the SDO are set to 5 and 4, respectively.
• Make sure the address for the SDO signal is the first address of SDO 8 bytes
slot.
• Create variables.
Name Type Example address i
ProtectingTrigger Bool %I3.0
WarningTrigger Bool %I4.1
ProtectingTrigger1 Bool %I14.0
WarningTrigger1 Bool %I15.1
ProtectingArea ii Bool %Q68.0
WarningArea iii Bool %Q68.1
SafetyCommunicationEnable Bool %Q68.2
ActivateScanner Bool %Q3.0
ActivateScanner1 Bool %Q14.0
i %I3.X, %I4.X, %I14.X and %I15.X are the addresses of laser scanners; %Q68.X is the address
of the OmniCore controller.
%Q3.0 and %Q14.0 are for activating the monitoring cases of the laser scanners.
ii Value of ProtectingArea depends on logic AND value of ProtectingTrigger and
ProtectingTrigger1.
iii Value of WarningArea depends on logic AND value of WarningTrigger and WarningTrigger1.
• Check the communication between the PLC and controller is well and activate
the laser scanner; set up the communication between the laser scanner, PLC
and OmniCore controller.
Configuring SafeMove
To enable SafeMove, perform the following procedure:
1 Log in the FlexPendant.
Make sure the user logged in have access grants to lock safety controller
configurations, safety services and software synchronization.
2 Tap SafeMove on the home page.
3 Tap Load in the pop-up message box to confirm loading of template SafeMove
configuration files.
The controller restarts.
4 After the controller is restarted, tap Settings on the home page.
5 Tap Safety Controller.
6 Tap Synchronization in the left pane.
7 Jog the robot to match the Actual Positions values with the Sync Positions
values.
Make sure the values are the same.
8 Tap Synchronize.
Note
Two device names are displayed in the list by default. You shall right-click
on the device name mS3 12Byte In/Out PROFIsafe V2.6.1 and choose
Delete to delete it. The name may vary according to the actual laser scanner
connected.
5 Click the laser scanner with the asterisk(*) mark, and then in the Device
Catalog tab page on the right pane of the window, double-click mS3 6Byte
In/Out PROFIsafe V2.6.1.
6 In the displayed Signal Editor tab page, add signals with following settings.
Name Type of Signal Device Mapping i Default value
ActiveDevice1 Digital Output 8 1
ProtectingArea1 Digital Input 17 0
WarningArea1 Digital Input 8 0
i The mappings are only for examples. Refer to the cut-off setting defined in the Safety
Designer software and enter the actual value.
A new device name mS3 6Byte In/Out PROFIsafe V2.6.1 is displayed under
the scanner in the Configuration tab page.
7 Click the new device name and check the settings in the Properties tab page
on the right pane of the window.
Make sure the Destination value is the same as the F-Destination address
value for the scanner in the Safety Designer software.
8 In the I/O Engineering tab, click Cross Connections in the Configuration
group, and check the created signals.
Make sure the created signals are in the same name as the displayed signals.
9 In the I/O Engineering tab, click Write Config to write the configurations to
the controller.
10 Restart the controller.
11 After the controller is restarted, check the laser scanner name in the RAPID
program InternalSpeedHandling_User in task T_ROB1, and make sure it is
consistent with the name that the user defines for the laser scanner.
If the names are inconsistent, use the following steps to modify:
a In the Controller pane, double-click the RAPID program
InternalSpeedHandling_User in task T_ROB1.
The RAPID program is displayed in the right pane.
b Find the parameter Scanner1 and modify its value to the user-defined
laser scanner name.
xx2200000301
Configuration procedure
Before starting the configuration, obtain the microScan 3 Core - PROFINET GSDML
file and the software tool Safety Designer® from SICK's website first. Make sure
both the file and the software tool are in the latest versions.
Detailed procedures about how to configure the laser scanner are detailed in
Operating instructions microScan3 - PROFINET. Following described roughly:
1 Connect the laser scanner to the PC using a network cable.
See the physical connection in Connecting the laser scanner(s) on page 92.
Configuring SafeMove
To enable SafeMove, perform the following procedure:
1 Start RobotStudio and connect the controller.
• The user account logging in the controller must be granted with the
Safety Services permission.
• The write access to the controller is requested.
2 In the Controller tab, click Safety, then select Visual SafeMove.
3 In the Visual SafeMove window, configure SafeMove function as instructed
in Configuration of SafeMove using Visual SafeMove in RobotStudio on
page 135.
Note
Two device names are displayed in the list by default. You shall right-click
on the device name mS3 12Byte In/Out PROFIsafe V2.6.1 and choose
Delete to delete it. The name may vary according to the actual laser scanner
connected.
5 Click the laser scanner with the asterisk(*) mark, and then in the Device
Catalog tab page on the right pane of the window, double-click mS3 6Byte
In/Out PROFIsafe V2.6.1.
6 In the displayed Signal Editor tab page, add signals with following settings.
Name Type of Signal Device Mapping i Default value
ActiveDevice1 Digital Output 8 1
ProtectingArea1 Digital Input 17 0
WarningArea1 Digital Input 8 0
i The mappings are only for examples. Refer to the cut-off setting defined in the Safety
Designer software and enter the actual value.
A new device name mS3 6Byte In/Out PROFIsafe V2.6.1 is displayed under
the scanner in the Configuration tab page.
7 Click the new device name and check the settings in the Properties tab page
on the right pane of the window.
Make sure the Destination value is the same as the F-Destination address
value for the scanner in the Safety Designer software.
8 In the I/O Engineering tab, click Cross Connections in the Configuration
group, and check the created signals.
Make sure the created signals are in the same name as the displayed signals.
9 Repeat steps 4 to 8 to add the other laser scanner, for which the signal
settings shall be as follows.
Name Type of Signal Device Mapping i Default value
ActiveDevice2 Digital Output 8 1
ProtectingArea2 Digital Input 17 0
WarningArea2 Digital Input 8 0
i The mappings are only for examples. Refer to the cut-off setting defined in the Safety
Designer software and enter the actual value.
10 In the I/O Engineering tab, click Write Config to write the configurations to
the controller.
11 Restart the controller.
12 After the controller is restarted, check the laser scanner name in RAPID
program InternalSpeedHandling_User in task T_ROB1, and make sure it is
consistent with the name that the user defines for the laser scanner.
If the names are inconsistent, use the following steps to modify:
a In the Controller pane, double-click the RAPID program
InternalSpeedHandling_User in task T_ROB1.
The RAPID program is displayed in the right pane.
b Find the parameters Scanner1 and Scanner2, and modify their values
to the user-defined laser scanner names.
xx2200000301
Configuration procedure
Before starting the configuration, obtain the microScan 3 Core - PROFINET GSDML
file and the software tool Safety Designer® from SICK's website first. Make sure
both the file and the software tool are in the latest versions.
Detailed procedures about how to configure the laser scanner are detailed in
Operating instructions microScan3 - PROFINET . Following described roughly:
1 Connect the laser scanner to the controller using a network cable.
See the physical connection in Connecting the laser scanner(s) on page 92.
Configuring SafeMove
To enable SafeMove, perform the following procedure:
1 Start RobotStudio and connect the controller.
• The user account logging in the controller must be granted with the
Safety Services permission.
• The write access to the controller is requested.
2 In the Controller tab, click Safety, then select Visual SafeMove.
3 In the Visual SafeMove window, configure SafeMove function as instructed
in Configuration of SafeMove using Visual SafeMove in RobotStudio on
page 135.
xx2200000301
Configuration procedure
Before starting the configuration, obtain the software tool Safety Designer® from
SICK's website first. Make sure the software tool is in the latest version.
Detailed procedures about how to configure the laser scanner are detailed in
Operating instructions microScan3 - Pro I/O from the vendor. Following described
the procedure roughly:
1 Open configuration software tool Safety Designer®.
2 Set IP address in Configuration > Addressing.
Make sure the scanner IP address is in the same network segment with the
PC used for configuring the scanner.
3 Define the two protection fields for the scanner in Configuration > Fields.
4 Define the source for input signals of the scanner and configure basic settings
for the inputs and outputs in Configuration > Inputs and outputs.
5 Select one OSSD pair from the Signals panel to pin1 and pin2, and select
another OSSD pair to pin3 and pin4.
The two OSSD pairs will be used for defining the monitoring cases.
6 Create monitoring cases and assign the fields that are to be monitored to
each monitoring cases in Configuration > Monitoring cases.
7 Refer to the following table to obtain the pins defined to OSSD pairs. The
pins are from a 17-pin cable that will be used to connect the laser scanner
and scalable I/O device.
Pin Wiring color Name Function
1 Brown OSSD1A OSSD pair 1, OSSD A
2 Blue OSSD1B OSSD pair 1, OSSD B
3 White OSSD2A OSSD pair 2, OSSD A
4 Green OSSD2B OSSD pair 2, OSSD B
17 White with grey 0 V DC 0 DC
8 Connect the laser scanner to scalable I/O device with the defined pins.
Pin in cable Pin position number in X2 connector of
the device i
Pin1 (OSSD1A) D101+
Pin2 (OSSD1B) DI02+
Pin3 (OSSD2A) DI03+
Pin4 (OSSD2B) DI04+
Pin17 Circuit of D101-, D102-, D103- and D104-
i For detailed information of pin definitions in connector X2 Digital inputs of the scalable I/O
device DSQC1042, see the product specification of the controller and Application
manual - Scalable I/O.
5 Log in the RobotStudio using the admin use account and configure the device
to make sure the device communication works.
a Click the Controller tab and, in the Controller pane, choose I/O System
> EtherNetIP.
Information of three devices can be observed:
- CabinetIO is used for the I/O device DSQC1030, and the
communication status is normal.
- ABB_Scalable_IO and ABB_Scalable_IO1 are used for the I/O device
DSQC1042, and the communication status is abnormal.
b Check the IP address and serial numbers associated with
ABB_Scalable_IO and ABB_Scalable_IO1, which will display as follows.
Device name IP address Serial number
ABB_Scalable_IO 192.168.125.130 0
ABB_Scalable_IO1 192.168.125.131 Actual serial number of
the device
Note
Note
If there are additional scalable I/O devices available, install and configure the
additional devices by following the detailed procedures in Application
manual - Scalable I/O.
Configuring SafeMove
To enable SafeMove, perform the following procedure:
1 Log in the FlexPendant.
Make sure the user logged in have access grants to lock safety controller
configurations, safety services and software synchronization.
2 Tap SafeMove on the home page.
3 Tap Load in the pop-up message box to confirm loading of template SafeMove
configuration files.
The controller restarts.
4 After the controller is restarted, tap Settings on the home page.
5 Tap Safety Controller.
6 Tap Synchronization in the left pane.
7 Jog the robot to match the Actual Positions values with the Sync Positions
values.
Make sure the values are the same.
8 Tap Synchronize.
xx2200000301
Configuration procedure
Before starting the configuration, obtain the software tool Safety Designer® from
SICK's website first. Make sure the software tool is in the latest version.
Detailed procedures about how to configure the laser scanners are detailed in
Operating instructions microScan3 - Pro I/O from the vendor. Following described
the procedure roughly:
1 Open configuration software tool Safety Designer®.
2 Set IP address in Configuration > Addressing.
• Make sure the scanner IP addresses are in the same network segment
with the PC used for configuring the scanner.
8 Connect the laser scanners to safety module with the defined pins.
Scanner Pin in cable Pin position number in X2
connector of the device i
Scanner 1 Pin1 (OSSD1A) D101+
Pin2 (OSSD1B) DI02+
Pin3 (OSSD2A) DI03+
Pin4 (OSSD2B) DI04+
Pin17 Circuit of D101-, D102-, D103-
and D104-
Scanner 2 Pin1 (OSSD1A) D105+
Pin2 (OSSD1B) DI06+
Pin3 (OSSD2A) DI07+
Pin4 (OSSD2B) DI08+
Pin17 Circuit of D105-, D106-, D107-
and D108-
i For detailed information of pin definitions in connector X2 Digital inputs of the scalable I/O
device DSQC1042, see the product specification of the controller and Application
manual - Scalable I/O.
2 Connect the process power supply to connector X1 of the scalable I/O device
via pin locations PWR DO and GND DO.
3 Connect the logic power supply to connector X4 of the scalable I/O device
via pin locations PWR and GND.
4 Connect the Ethernet cable from the robot controller to connector X5.
5 Log in the RobotStudio using the admin use account and configure the device
to make sure the device communication works.
a Click the Controller tab and, in the Controller pane, choose I/O System
> EtherNetIP.
Information of three devices can be observed:
- CabinetIO is used for the I/O device DSQC1030, and the
communication status is normal.
- ABB_Scalable_IO and ABB_Scalable_IO1 are used for the I/O device
DSQC1042, and the communication status is abnormal.
b Check the IP address and serial numbers associated with
ABB_Scalable_IO and ABB_Scalable_IO1, which will display as follows.
Device name IP address Serial number
ABB_Scalable_IO 192.168.125.130 0
ABB_Scalable_IO1 192.168.125.131 Actual serial number of
the device
Note
Note
If there are additional scalable I/O devices available, install and configure the
additional devices by following the detailed procedures in Application
manual - Scalable I/O.
Configuring SafeMove
To enable SafeMove, perform the following procedure:
1 Log in the FlexPendant.
Make sure the user logged in have access grants to lock safety controller
configurations, safety services and software synchronization.
2 Tap SafeMove on the home page.
3 Tap Load in the pop-up message box to confirm loading of template SafeMove
configuration files.
The controller restarts.
4 After the controller is restarted, tap Settings on the home page.
5 Tap Safety Controller.
6 Tap Synchronization in the left pane.
7 Jog the robot to match the Actual Positions values with the Sync Positions
values.
Make sure the values are the same.
8 Tap Synchronize.
General
The speed control of CRB 15000 is affected by several factors, such as, the
RobotWare version, the speed setting in the FlexPendant, the speed setting in
motion instruction and the SpeedRefresh value. Users in different protection
fields defined for laser scanner to monitor and perform different program execution
actions may result in different movement speed. This section describes the speed
control strategies for typical scenarios.
xx2100000512
xx2100000513
xx2100000514
xx2200000302
xx2200000303
General
Configurations of speed control are allowed to be modified in RAPID programs,
which are loaded to the system after the Collaborative Speed Control add-in is
installed.
Note
Safety configurations can only be modified for robots running in RobotWare 7.6
and later versions.
Modified configuration must always be validated to verify that the desired safety
is achieved. If no validation is performed, or the validation is inadequate, the
configuration cannot be relied on for personal safety.
Note
Modified configuration must always be validated to verify that the desired safety
is achieved. If no validation is performed, or the validation is inadequate, the
configuration cannot be relied on for personal safety.
The SpeedHandling function is activated by default after the Collaborative Speed
Control add-in is installed and the SafeMove template is loaded. The function is
used to enable or disable speed-related actions for speed control.
It is possible to use the following procedure to deactivate the SpeedHandling
function based on risk assessment of the final application:
1 In RobotStudio, open the RAPID program InternalSpeedHandling_User in
task T_ROB1.
2 Navigate to the function ISH_b_FunctionlityIsUsed and set its value from
default TRUE to FALSE.
xx2200000435
Use the following procedure to disable the speed control function provided by
SafeMove:
1 Open the RobotStudio.
2 Log in the controller using the Admin account and request the write access.
3 In the Controller tab, choose Visual SafeMove from the Safety group in the
Configuration category.
4 In the Visual SafeMove tab, click Safe IO Configurator in the Configuration
group.
5 In the displayed Safe IO Configuration window, go to the signal
ISH_UserMODE_bNot_IntemitCollab in the global signal list and set the
value to 1.
xx2200000436
xx2200000437
xx2200000438
5 In the Visual SafeMove Properties window, set the Max speed (mm/s) in
the Speed limits area to a required value.
xx2200000439
3 In the Controller tab, choose Visual SafeMove from the Safety group in the
Configuration category.
4 In the Visual SafeMove tab, click Safe IO Configurator in the Configuration
group.
5 In the displayed Safe IO Configuration window, go to the signals
ISH_AtUser_Period_ms_Until_SST and ISH_AtUser_Period_ms_Until_TSP
in the global signal list and reset the value as required.
xx2200000440
4 Maintenance
4.1 Introduction
Safety information
Observe all safety information before conducting any service work.
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 17 before performing any service
work.
The maintenance must be done by qualified personnel in accordance with the
safety requirements set forth in the applicable national and regional standards and
regulations.
Note
If the CRB 15000 is connected to power, always make sure that the CRB 15000
is connected to protective earth and a residual current device (RCD) before
starting any maintenance work.
For more information see:
• Product manual - OmniCore C30
• Robot cabling and connection points on page 99.
Introduction
The intervals are specified in different ways depending on the type of maintenance
activity to be carried out and the working conditions of the CRB 15000:
• Calendar time: specified in months regardless of whether the system is
running or not.
• Operating time: specified in operating hours. More frequent running means
more frequent maintenance activities.
• SIS: specified by the robot's SIS (Service Information System). A typical
value is given for a typical work cycle, but the value will differ depending on
how hard each part is run.
The SIS used in OmniCore is further described in the Operating
manual - OmniCore.
Robots with the functionality Service Information System activated can show active
counters in the device browser in RobotStudio, or on the FlexPendant.
Maintenance schedule
Every 12 months
Every 6 months
Regularly
Required equipment
Action Note
1 Turn on the power supply on the controller.
2 Check the lights of the arm-side interface. A description of the LED output indicators
If the lights do not work as configured, is found in Arm-side interface on page 105.
contact your local ABB office.
Action Note
1 Look for abnormal wear or contamination. Clean as necessary.
See Cleaning the CRB 15000 on page 195.
2 Check for loose hardware at robot arms, Tighten loose hardware at base (foundation
base (foundation screws), and tool flange. screws tightening torque: 32 Nm ±10%)
and tool flange, if any.
3 Check for seepage of lubricants. If any seepage is found, contact ABB.
Action Note
1 Visually inspect all outer covers for dam- Spare part numbers are found in Product
age. manual, spare parts - CRB 15000.
If any cover is damaged or cannot perform
its protective function for other reasons, it
must be replaced.
2 Make sure that all covers are fully fastened. Tightening torques specified in Tightening
Manually check that the parts are not loose. torques to be inspected on page 187.
Tighten, if needed.
Note
This inspection is only needed for robots using the external brake release tool,
see Installation of brake release tool on page 75.
Action Note
1 Check that the brake release tool is avail- Brake release tool: 3HAC079146-001.
able at its storage location close to the ro- See Installation of brake release tool on
bot. page 75.
xx2000002566
xx2000002565
xx2300000758
xx2300000757
xx2100000056 xx2100000057
C D
xx2100000058
xx2100000059
A B
xx2100000060
xx2100000061
C D
xx2100000062 xx2100000091
A B,C
xx2300000530
xx2300000531
D E
xx2300000532
xx2300000533
A B,C
xx2300000534 xx2300000535
D E
xx2300000536 xx2300000537
Required equipment
2
ELECTROSTATIC DISCHARGE (ESD)
General
Different cleaning methods are allowed depending on the type of protection of the
CRB 15000.
Note
WARNING
Turn off all electrical power supplies to the robot before starting the cleaning.
Cleaning methods
This following table defines what cleaning methods are allowed for ABB
manipulators depending on the protection type.
Protection Cleaning method
type
Vacuum Wipe with cloth Rinse with water High pressure water,
cleaner steam or spray
Standard Yes Yes. With light No No
cleaning deter-
gent.
Usable detergents
This table specifies approved light cleaning detergents according to methods in
the table Cleaning methods on page 195.
Detergent i Concentration
Isopropyl Alcohol 70%
Ethanol 75%, 99.7%
i The manipulator can be cleaned (wiped with cloth) occasionally with specified detergents. Long
term use may lead to surface/apperance deterioration.
CAUTION
CAUTION
Action Note
1 Test the brake release functionality on each axis, See Manually releasing the brakes
by using the FlexPendant. on page 69.
2 If the holding brake does not release, check fol- All event logs can be seen on the
lowing: FlexPendant, or in Technical refer-
• Check for event log messages on the ence manual - Event logs for Robot-
FlexPendant. Ware 7.
Note
Action Note
1 Test the brake release functionality on each axis, See Manually releasing the brakes
by using the brake release tool. on page 69.
2 If the holding brake does not release, check fol- For OmniCore, all event logs from
lowing: the software can be seen on the
• Check for event log messages on the FlexPendant, or in Technical refer-
FlexPendant. ence manual - Event logs for Robot-
• Look for damage to the magnet. Ware 7.
Replace the tool if damaged.
• See troubleshooting section Brake release
tool does not work on page 1075.
Required equipment
No special equipment is required.
Action Note
1 Turn off power to the controller and then turn the
power on again.
2 Verify that the robot starts as expected.
5 Repair
5.1 Introduction
WARNING
Repair activities not described in this chapter must only be carried out by ABB.
Individual subcomponents shall not be exchanged.
Note
Unless otherwise specified, the repair activities are available for all the robot
variants, but only the CRB 15000-5/0.95 is illustrated.
Note
When replacing a part on the CRB 15000, report to your local ABB the serial
number, the article number, and the revision of both the replaced unit and the
replacement unit.
This is particularly important for safety equipment to maintain the safety integrity
of the installation.
Safety information
Make sure to read through the chapter Safety on page 17 before commencing any
service work.
Note
If the CRB 15000 is connected to power, always make sure that the CRB 15000
is connected to protective earth and a residual current device (RCD) before
starting any repair work.
For more information see:
• Product manual - OmniCore C30
General
This section describes how to mount different types of sealings.
Equipment
Rotating sealings
The following procedures describe how to fit rotating sealings.
CAUTION
Radial sealings
A radial sealing consists of a flexible rubber lip bonded to a rigid metal case. Only
one side of the sealing is static with a metal insert.
xx2300000433
Action Note
1 Check the sealing to ensure that:
• The sealing is of the correct type.
• There is no damage on the main lip.
Action Note
2 Inspect the shaft surface before mounting. If scratches
or damage are found, the shaft must be replaced since
it may result in future leakage. Do not try to grind or
polish the shaft surface to get rid of the defect.
3 Lubricate the sealing with grease just before fitting. Article number is specified in
(Not too early - there is a risk of dirt and foreign Equipment on page 202.
particles adhering to the sealing.)
Fill 2/3 of the space between the dust lip and the main
lip with grease. If the sealing is without dust lip, just
lubricate the main lip with a thin layer of grease.
A B C
xx2000000071
A Main lip
B Grease
C Dust lip
4 Mount the sealing correctly with a mounting tool. A
Never hammer directly on the sealing as this may
result in leakage.
xx2000000072
A Gap
O-rings
The following procedure describes how to fit o-rings.
Action Note
1 Ensure that the correct o-ring size is used.
2 Check the o-ring for surface defects, burrs, Defective o-rings, including damaged
shape accuracy, or deformation. or deformed o-rings, may not be used.
3 Check the o-ring grooves and mating surfaces.
They should be free of pores, contamination
and obvious scratches/damage.
4 Lubricate the o-ring with grease.
5 Tighten the screws evenly while assembling.
6 Check that the o-ring is not squashed outside
the o-ring groove.
xx2100000056
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the CRB 15000 via myABB Business Portal,
www.abb.com/myABB.
Required consumables
Action Note
1 Jog the robot to the specified position.
Valid for CRB 15000-5/0.95
• Axis 1: 0°
• Axis 2: 0°
• Axis 3: +85°
• Axis 4: 0°
• Axis 5: 0°
• Axis 6: 0°
xx2100000113
Action Note
Valid for CRB 15000-10/1.52
• Axis 1: 0°
• Axis 2: -15°
• Axis 3: -225°
• Axis 4: 0°
• Axis 5: -30°
• Axis 6: 0°
xx2300000380
xx2300000381
2
CAUTION
xx2100000414
Action Note
1
CAUTION
Action Note
2 Loosen the robot from the foundation.
• Person 1: keep holding the robot stable.
• Person 2: loosen the robot base from the
foundation by removing the attachment
screws and washers.
• Both persons: grasp the robot at appropri-
ate locations and lay it down on its back on
a working bench. Do not damage the base
socket.
CAUTION
xx2100000414
Action Note
1
CAUTION
Action Note
2 Attach the roundslings to the robot according CRB 15000-10/1.52
to the figure.
Make sure the roundslings do not rub against
any sharp edges.
xx2300000384
CRB 15000-12/1.27
xx2300000385
Note
Action Note
4 Loosen the robot base from the foundation by
removing the foundation attachment screws.
xx2300001060
5
WARNING
xx2300001061
Action Note
1 Remove the bottom cover by removing the attach- Valid for CRB 15000-5/0.95
ment screws.
xx2000002007
xx2300000760
Action Note
1 Cut the cable ties. Valid for CRB 15000-5/0.95
xx2100000424
xx2300000761
Action Note
2 Remove the functional and protective earth cables
by removing the screw.
xx2100000425
xx2100000426
xx2100000405
Action Note
1 Remove the attachment screws.
xx2100000406
Action Note
2 Pull out the cabling from the base.
xx2100000407
Action Note
1 Insert the cabling into the base.
xx2100000408
xx2100000409
Action Note
3 Secure the base connector with the attachment Hex socket head cap screw: M3x8
screws. 12.9 Lafre 2C2B/FC6.9 (4 pcs).
Tightening torque: 0.8 Nm.
xx2100000406
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2100000405
xx2100000426
Action Note
4 Secure the cables for functional earth and protect- Hex socket head cap screw: M3x6
ive earth with a screw. (1 pcs).
Tightening torque: 0.8 Nm.
xx2100000425
5 Secure the cabling with cable ties. Valid for CRB 15000-5/0.95
Cable ties (4 pcs)
xx2100000424
xx2300000761
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAB3772-64
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000002016
2 Refit the bottom cover with the attachment screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (8 pcs)
Note Tightening torque: 1.2 Nm.
xx2000002007
xx2100000268
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. 3HAC061327-072
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000002016
2 Refit the bottom cover with the attachment screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (8 pcs)
Note Tightening torque: 1.4 Nm.
xx2300000760
Action Note
1
CAUTION
xx2100000118
Action Note
3 Carry the robot to the installation site.
CAUTION
4 Fit two pins to the holes in the base. Centering pins: DIN6325, hardened
steel Ø6x24 mm, 2 pcs .
5 Raise the robot to standing and secure to Screws: M10x35, 4 pcs, quality 8.8
foundation, paying attention to the centering Washers: 23/10.5/2.5 mm Steel
holes at the bottom of the robot base.
• Person 1: keep holding the robot stable.
• Person 2: secure the robot base to the
foundation with the securing screws and
washers.
6 Tighten the bolts in a crosswise pattern to en- Tightening torque: 32 Nm ±10%
sure that the base is not distorted.
Action Note
1 Make sure the robot is positioned in the recom- Recommended position for transport-
mended position for transportation and lifting. ation and lifting is shown in Transport-
ation and shipping position on
page 57.
WARNING
2
CAUTION
Action Note
3 Attach the roundslings to the robot according CRB 15000-10/1.52
to the figure.
Make sure the roundslings do not rub against
any sharp edges.
xx2300000384
CRB 15000-12/1.27
xx2300000385
4
WARNING
Action Note
6 Move the robot to the installation site.
CAUTION
7 Fit two pins to the holes in the base. Centering pins: DIN6325, hardened
steel Ø6x24 mm, 2 pcs .
8 Guide the robot gently, using the attachment Make sure the robot base is correctly
screws while lowering it into its mounting pos- fitted onto the pins.
ition.
9 Fit the securing screws and washers in the at- Screws: M10x35, 4 pcs, quality 8.8
tachment holes of the base. Washers: 23/10.5/2.5 mm Steel
10 Tighten the bolts in a crosswise pattern to en- Tightening torque: 32 Nm ±10%
sure that the base is not distorted.
Concluding procedure
Action Note
1
DANGER
xx2100000057
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the CRB 15000 via myABB Business Portal,
www.abb.com/myABB.
Required consumables
Action Note
1 Jog the robot to the specified position:
• Axis 1: 0°
• Axis 2: 0°
• Axis 3: +60°
• Axis 4: 0°
• Axis 5: -90°
• Axis 6: No significance.
xx2100000044
2
CAUTION
Action Note
1
CAUTION
Action Note
2 Remove the four lower arm cover screws.
xx2000001929
xx2100000267
xx2000001930
Disconnecting the cabling between the lower arm and the swing
Action Note
1 Remove the functional earth cable by removing
the screw.
xx2000001936
xx2000001937
xx2000001938
Action Note
1 Remove the cable bracket by removing the four
screws.
xx2000001939
2 Secure the weight of the upper and lower arm. Suggestion with lifting sling and an
overhead crane.
CAUTION Example of CRB 15000-5/0.95,
similar to CRB 15000-10/1.52 and
The weight of the complete upper and lower arm CRB 15000-12/1.27.
together is 18 kg
xx2100000294
Action Note
3 Remove two attachment screws and fit two guide Guide pin, M4x120: 3HAC077786-
pins to the axis-2 joint unit. 001
Always use guide pins in pairs.
CAUTION
xx2000001951
xx2000001960
CAUTION
xx2000002151
Action Note
6 Remove the complete arm system from the swing.
xx2000001941
xx2000002432
Action Note
1
CAUTION
xx2000001935
Action Note
3
CAUTION
xx2000001931
xx2000001932
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
Action Note
2 Cut the cable ties.
xx2000001946
xx2000001945
xx2000001944
CAUTION
Action Note
1 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC077788-001
sensor side. Screws: M4x35 (4 pcs)
CAUTION
xx2000001956
xx2100000295
3 Fit two guide pins to the axis-2 joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
For joint units on axes 1, 2 and 3
of CRB 15000-5/0.95 and axis 3 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2000002433
xx2000001943
Action Note
5 Put the cabling at the slot in order not to squeeze
it during removal of joint unit.
xx2100000045
xx2000002434
CAUTION
xx2000001957
Action Note
1 Remove the swing attachment screws.
CAUTION
xx2000001987
CAUTION
xx2000002152
CAUTION
Action Note
1 Loosen the base from the foundation by removing
the attachment screws and washers.
xx2000002006
Action Note
2 Tilt the base on to its side and remove the bottom
cover by removing the attachment screws.
xx2000002007
Action Note
1 Cut the cable ties.
xx2000002012
xx2000002011
xx2000002010
Action Note
4 Disconnect the connectors from the drive board.
• D1.X1 from X1
• D1.DC+ from DC+
• D1.DC- from ground
• D1.X4 from X4
• D1.X2 from X2
• D1.X5 from X5
• DR.X8 from X8
CAUTION
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
Tip 10/1.52 and CRB 15000-12/1.27)
xx2000002057
Action Note
3 Cut the cable tie at the drive board.
xx2000002058
xx2100000301
xx2000002055
xx2000002053
Action Note
7 Remove the cable plate by removing the attach-
ment screws.
xx2000002049
CAUTION
Action Note
1 Jog the robot to the specified position: Valid for CRB 15000-10/1.52
• Axis 1: 0°
• Axis 2: 0°
• Axis 3: +60°
• Axis 4: 0°
• Axis 5: -90°
• Axis 6: No significance.
xx2300001062
xx2300001063
2
CAUTION
Action Note
1
CAUTION
xx2300000812
xx2300000813
Disconnecting the cabling between the lower arm and the swing
Action Note
1 Remove the functional earth cable by removing
the screw.
xx2000001936
Action Note
2 Cut the cable ties.
xx2000001937
xx2000001938
Action Note
1 Remove the cable bracket by removing the four
screws.
xx2000001939
Action Note
2 Secure the weight of the upper and lower arm. Suggestion with lifting sling and an
overhead crane.
CAUTION Example of CRB 15000-5/0.95,
similar to CRB 15000-10/1.52 and
The weight of the complete upper and lower arm CRB 15000-12/1.27.
together is up to 26 kg
xx2100000294
Action Note
3 Remove two attachment screws and fit two guide Guide pin, M5x125: 3HAC087786-
pins to the axis-2 joint unit. 001
Always use guide pins in pairs.
CAUTION
xx2000001951
xx2000001960
CAUTION
xx2000002151
Action Note
6 Remove the complete arm system from the swing.
xx2000001941
xx2000002432
Action Note
1
CAUTION
xx2300000814
Action Note
3
CAUTION
xx2300000815
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2000001946
Action Note
3 Remove the functional and protective earth cables
by removing the screw.
xx2000001945
xx2000001944
CAUTION
Action Note
1
CAUTION
2
WARNING
Action Note
3 Loosen the robot base from the foundation by
removing the foundation attachment screws.
xx2300001060
CAUTION
Action Note
1 Removing the attachment screws.
xx2300000786
Action Note
2 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC087787-001
sensor side. Screws: M5x30 (4 pcs for plate and
2 pcs for beam)
CAUTION
xx2300000787
xx2300000788
xx2300000789
CAUTION
xx2300000790
Action Note
5 Remove the lifting aid.
xx2300000778
xx2300000776
Action Note
1 Lift the base to standing and secure it to the Attachment screws: M10x35 8.8 (4
foundation with the attachment screws and pcs).
washers. Washers: 23/10.5/2.5 mm Steel (4 pcs).
Tightening torque: 32 Nm ±10%.
xx2300001060
Action Note
1 Valid for CRB 15000-10/1.52
Remove the swing transition.
xx2300000817
xx2300000818
CAUTION
xx2000001987
Action Note
4 Use two fully threaded attachment screws as re- Valid for CRB 15000-10/1.52
moval tools to press the swing out of position.
CAUTION
xx2000002152
CAUTION
Action Note
1 Loosen the base from the foundation by removing
the attachment screws and washers.
xx2300001060
Action Note
2 Tilt the base on to its side and remove the bottom
cover by removing the attachment screws.
xx2300000760
Action Note
1 Cut the cable ties.
xx2000002012
xx2000002011
xx2000002010
Action Note
4 Disconnect the connectors from the drive board.
• D1.X1 from X1
• D1.DC+ from DC+
• D1.DC- from ground
• D1.X4 from X4
• D1.X2 from X2
• D1.X5 from X5
• DR.X8 from X8
CAUTION
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
Tip 10/1.52 and CRB 15000-12/1.27)
xx2000002057
Action Note
3 Cut the cable tie at the drive board.
xx2000002058
xx2100000301
xx2000002055
xx2000002053
Action Note
7 Remove the cable plate by removing the attach-
ment screws.
xx2000002049
CAUTION
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
CAUTION
xx2000002051
Action Note
4 Secure the cable plate to the joint unit with the Hex socket head cap screw:
attachment screws. M2.5x6 12.9 Lafre 2C2B/FC6.9 (4
pcs)
Tightening torque: 0.45 Nm.
xx2000002049
xx2000002053
xx2000002056
xx2000002055
Action Note
7 Keep the cabling loose, making sure not to twist
or strain it.
Use the cable tie to pre-fix the cable by hand.
xx2100000507
8 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
10/1.52 and CRB 15000-12/1.27)
xx2000002057
Action Note
9 Secure the cables to the cable support with a Cable tie: 3HAC075545-001. For
cable tie, using a cable tie gun. securing joint unit cable.
Assembly direction for the cable tie is shown in Cable tie gun EVO 7i
the figure. Settiing for cable tie gun: 6.75.
xx2000002058
xx2000002059
xx2100000301
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2000002009
xx2000002010
4 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000002011
Action Note
5 Secure the cabling with cable ties. Cable ties (4 pcs)
xx2000002012
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAB3772-64
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000002016
Action Note
2 Refit the bottom cover with the attachment screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (8 pcs)
Note Tightening torque: 1.2 Nm.
xx2000002007
xx2100000268
Action Note
1 Lift the base to standing and secure it to the Attachment screws: M10x35 8.8 (4
foundation with the attachment screws and pcs).
washers. Washers: 23/10.5/2.5 mm Steel (4
pcs).
Tightening torque: 32 Nm ±10%.
xx2000002006
Action Note
1 Clean the mounting surface with isopropanol. Cleaning agent: Isopropanol
Apply flange sealant to the corner of the base Flange sealant: Loctite 574
mounting surface, as pointed out in the figure.
xx2000001990
CAUTION
xx2000001989
4 Secure the swing with the attachment screws. Hex socket head cap flange screw:
Pre-tighten the screws crosswise firstly. M4x25 12.9 Lafre
2C2B/FC6.9+PrO-COat111 (16 pcs)
CAUTION
xx2000001987
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Clean the mounting surface of the joint unit and Cleaning agent: Isopropanol
the mating surface on the casting with isopropan- Flange sealant: Loctite 574
ol.
Joint unit mounting surface is pointed out in the
figure.
3 Apply a thin layer of flange sealant to the mount-
ing surface. Do not contaminate the radial sealing
with sealant.
CAUTION xx2000001860
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Fit the lifting aid to the joint unit. Joint unit: 3HAC079141-001
Lifting aid: 3HAC077788-001
CAUTION Screws: M4x35 (4 pcs)
xx2000001957
Action Note
3 Fit two guide pins to the joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
For joint units on axes 1, 2 and 3
of CRB 15000-5/0.95 and axis 3 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2000002438
CAUTION
xx2000002153
5 Fit the joint unit to the swing, aligning the pin with
the pin hole.
CAUTION
xx2000001959
The connectors and the joint unit cables are
sensitive to mechanical damage. Handle the as-
sembly with care.
xx2000001961
Action Note
6 Secure the joint unit with new attachment screws. Flange socket head screw with
glue: 3HAB3413-435
M4x35 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue , 12 pcs
Used for joint unit of CRB 15000-
5/0.95.
Always use new screws when refit-
ting a joint unit. If ordering a new
joint unit spare part, new screws
are included.
xx2000001943
xx2100000295
xx2000001956
Action Note
1 Fit two guide pins to the axis-2 joint unit. Guide pin, M4x120: 3HAC077786-
001
xx2000001949
2 Remove any old residuals of flange sealant from Cleaning agent: Isopropanol
the lower arm mounting surface and clean with Flange sealant: Loctite 574
isopropanol.
Apply new flange sealant to the corner of the
lower arm mounting surface, as pointed out in the
figure.
xx2000001963
3
CAUTION
xx2000001941
Action Note
5 Secure the lower arm to the swing with all attach- Hex socket head cap flange screw:
ment screws but two. M4x25 12.9 Lafre
Pre-tighten the screws crosswise firstly. 2C2B/FC6.9+PrO-COat111 (16 pcs)
CAUTION
xx2000001940
6 Remove the guide pins and fasten the remaining Hex socket head cap flange screw:
two screws. M4x25 12.9 Lafre
2C2B/FC6.9+PrO-COat111 (16 pcs)
CAUTION
xx2000001951
xx2000001939
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2000002013
xx2000001944
4 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000001945
Action Note
5 Secure the cabling with cable ties. Cable ties (3 pcs)
xx2000001946
Action Note
1 Connect the connectors to each other and snap
them to the cable holders.
xx2000001938
xx2000001937
Action Note
3 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (1 pcs).
Tightening torque: 0.8 Nm
xx2000001936
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-044
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000001954
2 Refit the inner cover with four screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 1.4 Nm.
xx2000001930
Action Note
3 Snap the lower arm cover into place. Hex socket head cap screw: M3x16
12.9 Lafre 2C2B/FC6.9 (4 pcs)
4 Secure the cover with four screws.
Tightening torque: 0.45 Nm.
xx2000001929
Action Note
1 Fit the o-ring to cover groove. O-ring: 3HAC061327-047 (for CRB
Replace if damaged. 15000-5/0.95)
xx2000001962
xx2000001932
Action Note
3 For robots with RobotWare earlier than 7.10 Cable ties
Secure the brake release cable with a cable tie.
xx2000001931
4 Refit the cover with the four screws. Hex socket head cap screw: M3x30
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm
xx2000001935
Concluding procedure
Action Note
1 Calibrate the joint unit torque sensor. See Calibration on page 1063
1 On the FlexPendant, go to the Code app
and call the calibration procedure using PP
to Routine, not by using Call Routine.
2 Select the Joint Unit Replacement feature
and then select the axis to calibrate.
3 The controller is now restarted. Once the
home screen of the FlexPendant is shown,
press the Play button to continue the calib-
ration routine.
4 The robot moves to a position or positions
where measurements are performed.
5 The results of the measurements are
presented together with the current values
in the controller. Choose whether to save
the calibration data or not.
6 If new calibration data is saved you will be
asked to do a test with the lead-through
functionality active to verify that the
sensors work correctly.
7 Finally the robot is moved back to the ori-
ginal position.
8 Test the brake release (movement without
drive power) functionality, see Testing the
brake release functionality on page 196.
2
DANGER
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
CAUTION
Action Note
3 Orient the cable plate according to the figure.
The circle on the cable plate should point towards
the guide pin on the torque sensor.
xx2000002051
4 Secure the cable plate to the joint unit with the Hex socket head cap screw:
attachment screws. M2.5x6 12.9 Lafre 2C2B/FC6.9 (4
pcs)
Tightening torque: 0.45 Nm.
xx2000002049
xx2000002053
Action Note
6 Insert the cabling through the cable support and
fit the support to the drive board with the attach-
ment screws.
xx2000002056
xx2000002055
xx2100000507
Action Note
8 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
10/1.52 and CRB 15000-12/1.27)
xx2000002057
9 Secure the cables to the cable support with a Cable tie: 3HAC075545-001. For
cable tie, using a cable tie gun. securing joint unit cable.
Assembly direction for the cable tie is shown in Cable tie gun EVO 7i
the figure. Settiing for cable tie gun: 6.75.
xx2000002058
xx2000002059
Action Note
10 Remove the protection plate.
xx2100000301
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2000002009
Action Note
3 Connect the connectors to each other and snap
them to the cable holders.
• J1.DC+ to J1.DC+
• J1.DC- to J1.DC-
• J1.CS to J1.CS
• J1.CP to J1.CP
xx2000002010
4 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000002011
xx2000002012
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. 3HAC061327-072
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000002016
2 Refit the bottom cover with the attachment screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (8 pcs)
Note Tightening torque: 1.4 Nm.
xx2300000760
Action Note
1 Lift the base to standing and secure it to the Attachment screws: M10x35 8.8 (4
foundation with the attachment screws and pcs).
washers. Washers: 23/10.5/2.5 mm Steel (4
pcs).
Tightening torque: 32 Nm ±10%.
xx2000002006
Action Note
1 Fit two guide pins on the base unit for position Valid for CRB 15000-10/1.52
guidance. Guide pin, M5x75, 3HAC087786-
Always use guide pins in pairs. 002
Valid for CRB 15000-12/1.27
Guide pin, M5x125: 3HAC087786-
001
2 Refit the swing to the base unit, aligning the pin Example of CRB 15000-12/1.27,
with the pin hole. similar to CRB 15000-10/1.52.
CAUTION
xx2000001989
Action Note
3 Secure the swing with the attachment screws. Hex socket head cap screw: M5x30
12.9 Lafre 2C2B/FC6.9 (16 pcs)
CAUTION Tightening torque: 8.2 Nm
Valid for CRB 15000-12/1.27
Do not mix the flange screws used for CRB 15000-
5/0.95 and the threaded screws used for CRB
15000-10/1.52 and CRB 15000-12/1.27. Always
use washers together with the threaded screws
for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Illustration is for reference only.
xx2000001987
xx2300000819
xx2300000821
5 Valid for CRB 15000-10/1.52 Hex socket head cap screw: M5x25
Refit the swing flange with the attachment screws. 12.9 Lafre 2C2B/FC6.9 (16 pcs)
Always check the serial number printed on the Tightening torque: 8.2 Nm
swing parts and use the parts in the same number
for refitting.
CAUTION
xx2300000818
Action Note
6 Valid for CRB 15000-10/1.52 Guide pin, M5x75, 3HAC087786-
Fit two guide pins on the swing flange for position 002
guidance.
Always use guide pins in pairs.
7 Valid for CRB 15000-10/1.52
Refit the swing transition to the swing flange,
aligning the pin with the pin hole.
Always check the serial number printed on the
swing parts and use the parts in the same number
for refitting.
xx2300000820
8 Valid for CRB 15000-10/1.52 Hex socket head cap screw: M5x25
Secure the swing transition with the attachment 12.9 Lafre 2C2B/FC6.9 (16 pcs)
screws. Tightening torque: 8.2 Nm
CAUTION
xx2300000817
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2300000823
Action Note
3 Fit two guide pins to the swing. Guide pin, M5x125: 3HAC087786-
001
Always use guide pins in pairs.
For joint units on axes 1 and 2 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2300000791
4 Fit the lifting aid to the joint unit, aligning the pin Joint unit: 3HAC087472-001
with the pin hole. Lifting aid: 3HAC087787-001
Screws: M5x30 (4 pcs for plate and
CAUTION 2 pcs for beam)
xx2300000778
xx2300000777
xx2300000776
CAUTION
Action Note
6 Fit the joint unit to the swing, aligning the pin with
the pin hole.
CAUTION
xx2300000792
xx2300000780
xx2300000794
xx2300000795
Action Note
9 Secure with four attachment screws and pre-
tighten the screws crosswise.
xx2300000796
xx2300000797
11 Secure the joint unit with the remaining attach- Hex socket head cap screw:
ment screws. 3HAB3409-20
xx2300000798
Action Note
1 Lift the base to standing and secure it to the Attachment screws: M10x35 8.8 (4
foundation with the attachment screws and pcs).
washers. Washers: 23/10.5/2.5 mm Steel (4 pcs).
Tightening torque: 32 Nm ±10%.
xx2300001060
Refitting the lower and upper arm assembled (-10/1.52 and -12/1.27)
Action Note
1 Fit three guide pins to the axis-2 joint unit. Guide pin, M5x125: 3HAC087786-
001
xx2300001021
2
CAUTION
Action Note
3 Lift the upper and lower arm assembly to mount- Example of CRB 15000-5/0.95,
ing position and slide it onto the guide pins. similar to CRB 15000-10/1.52 and
CRB 15000-12/1.27.
xx2000001941
4 Secure the lower arm to the swing with all screws Hex socket head cap screw: M5x30
and washers but two. 12.9 Lafre 2C2B/FC6.9, 16 pcs
Pre-tighten the screws crosswise firstly.
CAUTION
5 Remove the guide pins and fasten the remaining Hex socket head cap screw: M5x30
two screws and washers. 12.9 Lafre 2C2B/FC6.9, 16 pcs
CAUTION
xx2300001023
Action Note
7 Refit the cable bracket with four screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs).
Tightening torque: 0.8 Nm
xx2000001939
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2000002013
xx2000001944
Action Note
4 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000001945
xx2000001946
Action Note
1 Connect the connectors to each other and snap
them to the cable holders.
xx2000001938
Action Note
2 Secure the cabling with cable ties. Cable ties (3 pcs)
xx2000001937
3 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (1 pcs).
Tightening torque: 0.8 Nm
xx2000001936
Action Note
1
CAUTION
xx2300000812
Action Note
3 Remove the lower inner cover by removing the
screws.
xx2300000813
Action Note
1 Refit the insert. Insert: 3HAC084002-001
Hex socket head cap screw: M3x10
12.9 Lafre 2C2B/FC6.9 (3 pcs)
Tightening torque: 1.4 Nm
xx2300000815
xx2300000816
3 Refit the cover with the four screws. Hex socket head cap screw: M3x12
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 1.4 Nm
xx2300000814
Concluding procedure
Action Note
1 Calibrate the joint unit torque sensor. See Calibration on page 1063
1 On the FlexPendant, go to the Code app
and call the calibration procedure using PP
to Routine, not by using Call Routine.
2 Select the Joint Unit Replacement feature
and then select the axis to calibrate.
3 The controller is now restarted. Once the
home screen of the FlexPendant is shown,
press the Play button to continue the calib-
ration routine.
4 The robot moves to a position or positions
where measurements are performed.
5 The results of the measurements are
presented together with the current values
in the controller. Choose whether to save
the calibration data or not.
6 If new calibration data is saved you will be
asked to do a test with the lead-through
functionality active to verify that the
sensors work correctly.
7 Finally the robot is moved back to the ori-
ginal position.
8 Test the brake release (movement without
drive power) functionality, see Testing the
brake release functionality on page 196.
2
DANGER
xx2100000058
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the CRB 15000 via myABB Business Portal,
www.abb.com/myABB.
Required consumables
Action Note
1 Jog the robot to the specified position:
• Axis 1: 0°
• Axis 2: 0° (home position)
• Axis 3: +60°
• Axis 4: 0°
• Axis 5: -90°
• Axis 6: No significance.
CAUTION
xx2100000044
2
CAUTION
Action Note
1
CAUTION
xx2000001929
xx2100000267
xx2000001930
Disconnecting the cabling between the lower arm and the swing
Action Note
1 Remove the functional earth cable by removing
the screw.
xx2000001936
xx2000001937
xx2000001938
Action Note
1 Remove the cable bracket by removing the four
screws.
xx2000001939
2 Secure the weight of the upper and lower arm. Suggestion with lifting sling and an
overhead crane.
CAUTION Example of CRB 15000-5/0.95,
similar to CRB 15000-10/1.52 and
The weight of the complete upper and lower arm CRB 15000-12/1.27.
together is 18 kg
xx2100000294
Action Note
3 Remove two attachment screws and fit two guide Guide pin, M4x120: 3HAC077786-
pins to the axis-2 joint unit. 001
Always use guide pins in pairs.
CAUTION
xx2000001951
xx2000001960
CAUTION
xx2000002151
Action Note
6 Remove the complete arm system from the swing.
xx2000001941
xx2000002432
Action Note
1
CAUTION
xx2000001935
Action Note
3
CAUTION
xx2000001931
xx2000001932
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
Action Note
2 Cut the cable ties.
xx2000001946
xx2000001945
xx2000001944
CAUTION
Action Note
1 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC077788-001
sensor side. Screws: M4x35 (4 pcs)
CAUTION
xx2000001956
xx2100000295
3 Fit two guide pins to the axis-2 joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
For joint units on axes 1, 2 and 3
of CRB 15000-5/0.95 and axis 3 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2000002433
xx2000001943
Action Note
5 Put the cabling at the slot in order not to squeeze
it during removal of joint unit.
xx2100000045
xx2000002434
CAUTION
xx2000001957
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
Action Note
2 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
Tip 10/1.52 and CRB 15000-12/1.27)
xx2000002057
xx2000002058
xx2100000301
Action Note
5 Remove the cable support from the drive board
by removing the attachment screws.
xx2000002055
xx2000002053
xx2000002049
CAUTION
Action Note
1 Jog the robot to the specified position: Valid for CRB 15000-10/1.52
• Axis 1: 0°
• Axis 2: 0° (home position)
• Axis 3: +60°
• Axis 4: 0°
• Axis 5: -90°
• Axis 6: No significance.
CAUTION
xx2300001062
xx2300001063
2
CAUTION
Action Note
1
CAUTION
xx2300000812
xx2300000813
Disconnecting the cabling between the lower arm and the swing
Action Note
1 Remove the functional earth cable by removing
the screw.
xx2000001936
Action Note
2 Cut the cable ties.
xx2000001937
xx2000001938
Action Note
1 Remove the cable bracket by removing the four
screws.
xx2000001939
Action Note
2 Secure the weight of the upper and lower arm. Suggestion with lifting sling and an
overhead crane.
CAUTION Example of CRB 15000-5/0.95,
similar to CRB 15000-10/1.52 and
The weight of the complete upper and lower arm CRB 15000-12/1.27.
together is up to 26 kg
xx2100000294
Action Note
3 Remove two attachment screws and fit two guide Guide pin, M5x125: 3HAC087786-
pins to the axis-2 joint unit. 001
Always use guide pins in pairs.
CAUTION
xx2000001951
xx2000001960
CAUTION
xx2000002151
Action Note
6 Remove the complete arm system from the swing.
xx2000001941
xx2000002432
Action Note
1
CAUTION
xx2300000814
Action Note
3
CAUTION
xx2300000815
Action Note
1
CAUTION
2
WARNING
xx2300001060
Action Note
4 Lay the robot down with the torque sensor side
upwards on a working bench. Do not damage
the base socket. Caution with the cabling.
CAUTION
Action Note
1 Removing the attachment screws.
xx2300000786
2 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC087787-001
sensor side. Screws: M5x30 (4 pcs for plate and
2 pcs for beam)
CAUTION
xx2300000787
xx2300000788
Action Note
3 Place the two semicircular blocks surrounding the
joint unit, and use two fully threaded attachment
screws as removal tools to press the joint unit out
of position.
xx2300000789
CAUTION
xx2300000790
xx2300000778
xx2300000776
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
Tip 10/1.52 and CRB 15000-12/1.27)
xx2000002057
xx2000002058
Action Note
4 Remove the protection plate.
xx2100000301
xx2000002055
xx2000002053
xx2000002049
Action Note
8 Remove the joint cable from the hollow shaft from
the torque sensor side.
CAUTION
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
CAUTION
xx2000002051
Action Note
4 Secure the cable plate to the joint unit with the Hex socket head cap screw:
attachment screws. M2.5x6 12.9 Lafre 2C2B/FC6.9 (4
pcs)
Tightening torque: 0.45 Nm.
xx2000002049
xx2000002053
xx2000002056
xx2000002055
Action Note
7 Keep the cabling loose, making sure not to twist
or strain it.
Use the cable tie to pre-fix the cable by hand.
xx2100000507
8 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
10/1.52 and CRB 15000-12/1.27)
xx2000002057
Action Note
9 Secure the cables to the cable support with a Cable tie: 3HAC075545-001. For
cable tie, using a cable tie gun. securing joint unit cable.
Assembly direction for the cable tie is shown in Cable tie gun EVO 7i
the figure. Settiing for cable tie gun: 6.75.
xx2000002058
xx2000002059
xx2100000301
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Clean the mounting surface of the joint unit and Cleaning agent: Isopropanol
the mating surface on the casting with isopropan- Flange sealant: Loctite 574
ol.
Joint unit mounting surface is pointed out in the
figure.
3 Apply a thin layer of flange sealant to the mount-
ing surface. Do not contaminate the radial sealing
with sealant.
CAUTION xx2000001860
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Fit the lifting aid to the joint unit. Joint unit: 3HAC079141-001
Lifting aid: 3HAC077788-001
CAUTION Screws: M4x35 (4 pcs)
xx2000001957
Action Note
3 Fit two guide pins to the joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
For joint units on axes 1, 2 and 3
of CRB 15000-5/0.95 and axis 3 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2000002438
CAUTION
xx2000002153
5 Fit the joint unit to the swing, aligning the pin with
the pin hole.
CAUTION
xx2000001959
The connectors and the joint unit cables are
sensitive to mechanical damage. Handle the as-
sembly with care.
xx2000001961
Action Note
6 Secure the joint unit with new attachment screws. Flange socket head screw with
glue: 3HAB3413-435
M4x35 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue , 12 pcs
Used for joint unit of CRB 15000-
5/0.95.
Always use new screws when refit-
ting a joint unit. If ordering a new
joint unit spare part, new screws
are included.
xx2000001943
xx2100000295
xx2000001956
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2000002013
xx2000001944
4 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000001945
Action Note
5 Secure the cabling with cable ties. Cable ties (3 pcs)
xx2000001946
Action Note
1 Fit the o-ring to cover groove. O-ring: 3HAC061327-047 (for CRB
Replace if damaged. 15000-5/0.95)
xx2000001962
xx2000001932
Action Note
3 For robots with RobotWare earlier than 7.10 Cable ties
Secure the brake release cable with a cable tie.
xx2000001931
4 Refit the cover with the four screws. Hex socket head cap screw: M3x30
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm
xx2000001935
Action Note
1 Fit two guide pins to the axis-2 joint unit. Guide pin, M4x120: 3HAC077786-
001
xx2000001949
Action Note
2 Remove any old residuals of flange sealant from Cleaning agent: Isopropanol
the lower arm mounting surface and clean with Flange sealant: Loctite 574
isopropanol.
Apply new flange sealant to the corner of the
lower arm mounting surface, as pointed out in the
figure.
xx2000001963
3
CAUTION
xx2000001941
5 Secure the lower arm to the swing with all attach- Hex socket head cap flange screw:
ment screws but two. M4x25 12.9 Lafre
Pre-tighten the screws crosswise firstly. 2C2B/FC6.9+PrO-COat111 (16 pcs)
CAUTION
xx2000001940
Action Note
6 Remove the guide pins and fasten the remaining Hex socket head cap flange screw:
two screws. M4x25 12.9 Lafre
2C2B/FC6.9+PrO-COat111 (16 pcs)
CAUTION
xx2000001951
xx2000001939
Action Note
1 Connect the connectors to each other and snap
them to the cable holders.
xx2000001938
Action Note
2 Secure the cabling with cable ties. Cable ties (3 pcs)
xx2000001937
3 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (1 pcs).
Tightening torque: 0.8 Nm
xx2000001936
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-044
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000001954
Action Note
2 Refit the inner cover with four screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 1.4 Nm.
xx2000001930
3 Snap the lower arm cover into place. Hex socket head cap screw: M3x16
12.9 Lafre 2C2B/FC6.9 (4 pcs)
4 Secure the cover with four screws.
Tightening torque: 0.45 Nm.
xx2000001929
Concluding procedure
Action Note
1 Calibrate the joint unit torque sensor. See Calibration on page 1063
1 On the FlexPendant, go to the Code app
and call the calibration procedure using PP
to Routine, not by using Call Routine.
2 Select the Joint Unit Replacement feature
and then select the axis to calibrate.
3 The controller is now restarted. Once the
home screen of the FlexPendant is shown,
press the Play button to continue the calib-
ration routine.
4 The robot moves to a position or positions
where measurements are performed.
5 The results of the measurements are
presented together with the current values
in the controller. Choose whether to save
the calibration data or not.
6 If new calibration data is saved you will be
asked to do a test with the lead-through
functionality active to verify that the
sensors work correctly.
7 Finally the robot is moved back to the ori-
ginal position.
8 Test the brake release (movement without
drive power) functionality, see Testing the
brake release functionality on page 196.
2
DANGER
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
CAUTION
Action Note
3 Orient the cable plate according to the figure.
The circle on the cable plate should point towards
the guide pin on the torque sensor.
xx2000002051
4 Secure the cable plate to the joint unit with the Hex socket head cap screw:
attachment screws. M2.5x6 12.9 Lafre 2C2B/FC6.9 (4
pcs)
Tightening torque: 0.45 Nm.
xx2000002049
xx2000002053
Action Note
6 Insert the cabling through the cable support and
fit the support to the drive board with the attach-
ment screws.
xx2000002056
xx2000002055
xx2100000507
Action Note
8 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
10/1.52 and CRB 15000-12/1.27)
xx2000002057
9 Secure the cables to the cable support with a Cable tie: 3HAC075545-001. For
cable tie, using a cable tie gun. securing joint unit cable.
Assembly direction for the cable tie is shown in Cable tie gun EVO 7i
the figure. Settiing for cable tie gun: 6.75.
xx2000002058
xx2000002059
Action Note
10 Remove the protection plate.
xx2100000301
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2300000823
3 Fit two guide pins to the swing. Guide pin, M5x125: 3HAC087786-
001
Always use guide pins in pairs.
For joint units on axes 1 and 2 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2300000791
Action Note
4 Fit the lifting aid to the joint unit, aligning the pin Joint unit: 3HAC087472-001
with the pin hole. Lifting aid: 3HAC087787-001
Screws: M5x30 (4 pcs for plate and
CAUTION 2 pcs for beam)
xx2300000778
xx2300000777
xx2300000776
CAUTION
Action Note
6 Fit the joint unit to the swing, aligning the pin with
the pin hole.
CAUTION
xx2300000792
xx2300000780
xx2300000794
xx2300000795
Action Note
9 Secure with four attachment screws and pre-
tighten the screws crosswise.
xx2300000796
xx2300000797
11 Secure the joint unit with the remaining attach- Hex socket head cap screw:
ment screws. 3HAB3409-20
xx2300000798
Action Note
1 Lift the base to standing and secure it to the Attachment screws: M10x35 8.8 (4
foundation with the attachment screws and pcs).
washers. Washers: 23/10.5/2.5 mm Steel (4 pcs).
Tightening torque: 32 Nm ±10%.
xx2300001060
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2000002013
xx2000001944
Action Note
4 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000001945
xx2000001946
Action Note
1 Refit the insert. Insert: 3HAC084002-001
Hex socket head cap screw: M3x10
12.9 Lafre 2C2B/FC6.9 (3 pcs)
Tightening torque: 1.4 Nm
xx2300000815
Action Note
2 Fit the o-ring to cover groove. O-ring: 3HAC061327-074 (for CRB
Replace if damaged. 15000-10/1.52 and CRB 15000-
12/1.27)
xx2300000816
3 Refit the cover with the four screws. Hex socket head cap screw: M3x12
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 1.4 Nm
xx2300000814
Refitting the lower and upper arm assembled (-10/1.52 and -12/1.27)
Action Note
1 Fit three guide pins to the axis-2 joint unit. Guide pin, M5x125: 3HAC087786-
001
xx2300001021
2
CAUTION
Action Note
3 Lift the upper and lower arm assembly to mount- Example of CRB 15000-5/0.95,
ing position and slide it onto the guide pins. similar to CRB 15000-10/1.52 and
CRB 15000-12/1.27.
xx2000001941
4 Secure the lower arm to the swing with all screws Hex socket head cap screw: M5x30
and washers but two. 12.9 Lafre 2C2B/FC6.9, 16 pcs
Pre-tighten the screws crosswise firstly.
CAUTION
5 Remove the guide pins and fasten the remaining Hex socket head cap screw: M5x30
two screws and washers. 12.9 Lafre 2C2B/FC6.9, 16 pcs
CAUTION
xx2300001023
Action Note
7 Refit the cable bracket with four screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs).
Tightening torque: 0.8 Nm
xx2000001939
Action Note
1 Connect the connectors to each other and snap
them to the cable holders.
xx2000001938
xx2000001937
Action Note
3 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (1 pcs).
Tightening torque: 0.8 Nm
xx2000001936
Action Note
1
CAUTION
xx2300000812
xx2300000813
Concluding procedure
Action Note
1 Calibrate the joint unit torque sensor. See Calibration on page 1063
1 On the FlexPendant, go to the Code app
and call the calibration procedure using PP
to Routine, not by using Call Routine.
2 Select the Joint Unit Replacement feature
and then select the axis to calibrate.
3 The controller is now restarted. Once the
home screen of the FlexPendant is shown,
press the Play button to continue the calib-
ration routine.
4 The robot moves to a position or positions
where measurements are performed.
5 The results of the measurements are
presented together with the current values
in the controller. Choose whether to save
the calibration data or not.
6 If new calibration data is saved you will be
asked to do a test with the lead-through
functionality active to verify that the
sensors work correctly.
7 Finally the robot is moved back to the ori-
ginal position.
8 Test the brake release (movement without
drive power) functionality, see Testing the
brake release functionality on page 196.
2
DANGER
xx2100000059
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the CRB 15000 via myABB Business Portal,
www.abb.com/myABB.
Required consumables
Action Note
1 Jog the robot to the specified position: Example of CRB 15000-5/0.95,
• Axis 1: 0° similar to CRB 15000-10/1.52 and
• Axis 2: +90° (suggested position for con- CRB 15000-12/1.27.
venient working position)
• Axis 3: -80° (home position)
• Axis 4: 0°
• Axis 5: 0°
• Axis 6: 0°
CAUTION
2
CAUTION
Action Note
1
CAUTION
Action Note
2 Remove the four lower arm cover screws.
xx2000001929
xx2100000267
xx2000001947
xx2000001930
Action Note
1
CAUTION
xx2300000812
xx2300000829
xx2300000813
xx2300000830
Action Note
1 Cut the cable ties.
xx2000001937
xx2000001938
Action Note
1 Remove the functional earth cable by removing
the screw.
xx2000001964
xx2000001965
Action Note
1 Remove the cable bracket by removing the four
screws.
xx2000001966
CAUTION
xx2000001967
4 Fit two guide pins to the axis-3 joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
xx2000001968
xx2000001969
Action Note
6 Press the upper arm out of position by using two
fully threaded attachment screws as removal
tools.
xx2100000001
xx2000001970
Action Note
1
CAUTION
xx2000002021
3
CAUTION
Action Note
4 For robots with RobotWare earlier than 7.10
Open the cover and cut the cable tie that holds
the brake release cable.
xx2000002022
xx2000002023
Action Note
1
CAUTION
xx2300000833
3
CAUTION
Action Note
4 Remove the insert.
xx2300000834
Action Note
1 Cut the cable ties.
xx2000002066
xx2000001945
Action Note
3 Snap loose and disconnect the connectors:
• J4.DC+
• J4.DC-
• J4.CS
• J4.CP
xx2000002067
CAUTION
xx2000002068
Action Note
1 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC077788-001
sensor side. Screws: M4x35 (4 pcs)
CAUTION
xx2000002069
xx2000002070
Action Note
3 Fit two guide pins to the axis-3 joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
For joint units on axes 1, 2 and 3
of CRB 15000-5/0.95 and axis 3 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2000002576
xx2100000320
xx2100000003
xx2000002577
Action Note
7 Remove the joint unit from the housing.
CAUTION
xx2000002071
xx2000001957
Action Note
1 Remove the attachment screws.
xx2300000799
2 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC087788-001
sensor side. Screws: M4x30 (4 pcs)
CAUTION
xx2300000800
xx2300000801
Action Note
4 Remove the joint unit from the housing.
CAUTION
xx2300000802
xx2300000804
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
Tip 10/1.52 and CRB 15000-12/1.27)
xx2000002057
Action Note
3 Cut the cable tie at the drive board.
xx2000002058
xx2100000301
xx2000002055
xx2000002053
Action Note
7 Remove the cable plate by removing the attach-
ment screws.
xx2000002049
CAUTION
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
CAUTION
xx2000002051
Action Note
4 Secure the cable plate to the joint unit with the Hex socket head cap screw:
attachment screws. M2.5x6 12.9 Lafre 2C2B/FC6.9 (4
pcs)
Tightening torque: 0.45 Nm.
xx2000002049
xx2000002053
xx2000002056
xx2000002055
Action Note
7 Keep the cabling loose, making sure not to twist
or strain it.
Use the cable tie to pre-fix the cable by hand.
xx2100000507
8 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
10/1.52 and CRB 15000-12/1.27)
xx2000002057
Action Note
9 Secure the cables to the cable support with a Cable tie: 3HAC075545-001. For
cable tie, using a cable tie gun. securing joint unit cable.
Assembly direction for the cable tie is shown in Cable tie gun EVO 7i
the figure. Settiing for cable tie gun: 6.75.
xx2000002058
xx2000002059
xx2100000301
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Clean the mounting surface of the joint unit and Cleaning agent: Isopropanol
the mating surface on the casting with isopropan- Flange sealant: Loctite 574
ol.
Joint unit mounting surface is pointed out in the
figure.
3 Apply a thin layer of flange sealant to the mount-
ing surface. Do not contaminate the radial sealing
with sealant.
CAUTION xx2000001860
Action Note
1 Fit the lifting aid to the joint unit. Joint unit: 3HAC079141-001
Lifting aid: 3HAC077788-001
CAUTION Screws: M4x35 (4 pcs)
xx2000001957
Action Note
2 Fit two guide pins to the joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
For joint units on axes 1, 2 and 3
of CRB 15000-5/0.95 and axis 3 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2000002438
xx2100000004
CAUTION
Action Note
5 Secure the joint unit with new attachment screws. Flange socket head screw with
glue: 3HAB3413-435
M4x35 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue , 12 pcs
Used for joint unit of CRB 15000-
5/0.95.
Always use new screws when refit-
ting a joint unit. If ordering a new
joint unit spare part, new screws
are included.
xx2100000320
xx2000002070
xx2000002069
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
Action Note
2 Check the o-ring. O-ring: 3HAC061327-036
Replace if damaged.
xx2300000836
3 Fit two guide pins to the housing. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
For joint units on axes 1, 2 and 3
of CRB 15000-5/0.95 and axis 3 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2300000803
4 Fit the lifting aid to the joint unit, aligning the pin Joint unit: 3HAC087474-001
with the pin hole. Lifting aid: 3HAC087788-001
Screws: M4x30 (4 pcs)
CAUTION
xx2300000804
xx2300000777
Action Note
5 Fit the joint unit to the housing, aligning the pin
with the pin hole.
CAUTION
xx2300000806
xx2300000780
xx2300000808
xx2300000809
xx2300000810
Action Note
9 Remove the lifting aid by removing the screws.
xx2300000800
10 Secure the joint unit with the remaining attach- Hex socket head cap screw:
ment screws. 3HAB3409-262
xx2300000811
Action Note
1 Reconnect the connectors to the drive board.
• D3.X1 to X1
• D3/4.DC+ to DC+
• D3/4.DC- to Ground
• D3.X4 to X4
• D3/4.X2 to X2
• D3.X5 to X5
xx2000002068
Action Note
2 Connect the connectors to each other and snap
them to the cable holders.
• J4.DC+ to J4/5.DC+
• J4.DC- to J4/5.DC-
• J4.CS to J4/5.CS
• J4.CP to J4/5.CP
xx2000002067
3 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000001945
xx2000002066
Action Note
1 Fit the o-ring to its groove. O-ring: 3HAC061327-047
Replace if damaged.
xx2000001962
xx2000002023
xx2000002022
Action Note
4 Refit the cover with the four screws. Hex socket head cap screw: M3x30
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm
xx2000002021
Action Note
1
CAUTION
xx2300000833
3
CAUTION
xx2300000834
Action Note
1 Fit two guide pins to the axis-3 joint. Guide pin, M4x120: 3HAC077786-
001
xx2000001971
xx2000001973
xx2000001970
5 Secure the upper arm to the lower arm with all Hex socket head cap flange screw:
attachment screws but two. M4x25 12.9 Lafre
Pre-tighten the screws crosswise firstly. 2C2B/FC6.9+PrO-COat111 (16 pcs)
xx2000001969
Action Note
6 Remove the guide pins and fasten the remaining Hex socket head cap flange screw:
two screws. M4x25 12.9 Lafre
2C2B/FC6.9+PrO-COat111 (16 pcs)
xx2000001967
xx2000001966
Action Note
1 Secure the cabling with the cable tie. Cable ties
xx2000001965
2 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (1 pcs).
Tightening torque: 0.8 Nm
xx2000001964
Action Note
1 Connect the connectors to each other and snap
them to the cable holders.
xx2000001938
xx2000001937
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-044
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000001955
xx2000001954
2 Refit the inner covers with four screws each. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (8 pcs)
Tightening torque: 1.4 Nm.
xx2000001947
xx2000001930
Action Note
3 Snap the lower arm cover into place. Hex socket head cap screw: M3x16
12.9 Lafre 2C2B/FC6.9 (4 pcs)
4 Secure the cover with four screws.
Tightening torque: 0.45 Nm.
xx2000001929
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-075
Replace if damaged. O-ring: 3HAC061327-044
Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2300000832
xx2300000831
Action Note
2 Refit the inner covers with eight screws each. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (8 pcs) x 2
Tightening torque: 1.4 Nm.
xx2300000813
xx2300000830
3 Snap the lower arm cover into place. Hex socket head cap screw: M3x12
12.9 Lafre 2C2B/FC6.9 (3 pcs) x 2
4 Secure the cover with three screws.
Tightening torque: 1.4 Nm.
xx2300000812
xx2300000829
Concluding procedure
Action Note
1 Calibrate the joint unit torque sensor. See Calibration on page 1063
1 On the FlexPendant, go to the Code app
and call the calibration procedure using PP
to Routine, not by using Call Routine.
2 Select the Joint Unit Replacement feature
and then select the axis to calibrate.
3 The controller is now restarted. Once the
home screen of the FlexPendant is shown,
press the Play button to continue the calib-
ration routine.
4 The robot moves to a position or positions
where measurements are performed.
5 The results of the measurements are
presented together with the current values
in the controller. Choose whether to save
the calibration data or not.
6 If new calibration data is saved you will be
asked to do a test with the lead-through
functionality active to verify that the
sensors work correctly.
7 Finally the robot is moved back to the ori-
ginal position.
8 Test the brake release (movement without
drive power) functionality, see Testing the
brake release functionality on page 196.
2
DANGER
xx2100000060
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the CRB 15000 via myABB Business Portal,
www.abb.com/myABB.
Required consumables
Action Note
1 Jog the robot to the specified position: Example of CRB 15000-5/0.95,
• Axis 1: No significance. similar to CRB 15000-10/1.52 and
• Axis 2: 0° CRB 15000-12/1.27.
• Axis 3: 0°
• Axis 4: 0° (home position)
• Axis 5: +90°
• Axis 6: No significance.
CAUTION
xx2100000005
Action Note
2
CAUTION
Action Note
1
CAUTION
xx2000002021
3
CAUTION
xx2000002022
Action Note
5 For robots with RobotWare earlier than 7.10
Disconnect the brake release connector DR.X8
from the drive board.
Remove the cover.
xx2000002023
Action Note
1
CAUTION
xx2300000833
3
CAUTION
xx2300000834
Action Note
1 Cut the cable ties.
xx2000002066
xx2000001945
xx2000002067
Action Note
4 Disconnect the connectors from the drive board.
• D3/4.X2
• D3/4.DC+
• D3/4.DC-
xx2000002120
Action Note
1 Remove the cover by removing the four screws.
xx2000002075
xx2000002076
Action Note
1 Cut the cable tie. Valid for CRB 15000-5/0.95
xx2000002077
xx2300000839
2 Remove the cable bracket by removing the two Valid for CRB 15000-5/0.95
screws.
xx2000002078
xx2300000840
Action Note
3 Remove two attachment screws and fit two guide Guide pin, M3x110: 3HAC077787-
pins to the axis-4 joint unit. 001
Always use guide pins in pairs.
xx2000002079
xx2000002080
xx2000002081
xx2000002127
Action Note
6 Use two fully threaded attachment screws as re-
moval tools to press the housing out of position.
xx2100000006
xx2000002082
Action Note
1 Remove the cover screws.
xx2000002083
2
CAUTION
Action Note
3 For robots with RobotWare earlier than 7.10
Open the cover and cut the cable tie that holds
the brake release cable.
xx2000002084
xx2000002085
Action Note
1 Valid for CRB 15000-5/0.95
Remove the cover by removing the six screws.
Dispose the screws. New screws must be used
when refitting the cover.
New screws are included in the spare part delivery
of the joint unit.
xx2000002123
xx2300000841
Action Note
1 Cut the cable ties on joint unit.
xx2000002086
2 Cut the cable ties on tubular, if needed. Valid for CRB 15000-5/0.95
xx2000002124
xx2300000842
xx2300000843
Action Note
4 Remove the functional and protective earth cables
by removing the screw.
xx2000002087
xx2000002089
xx2000002125
Action Note
7 Pull out the cabling carefully from the tubular. Valid for CRB 15000-5/0.95
xx2000002126
xx2300000844
Action Note
1 Disconnect the connectors from the drive board. Tweezers
CAUTION
xx2000002088
Action Note
1 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC077789-001
sensor side. Screws: M3x12 (4 pcs)
CAUTION
xx2000002090
Action Note
2 Remove two attachment screws.
Dispose the screws.
New screws are included in the spare part delivery
of the joint unit.
xx2000002091
3 Fit two guide pins to the axis-4 joint unit. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
For joint units on axes 4, 5 and 6.
xx2000002578
xx2100000326
xx2100000327
CAUTION
Action Note
7 Remove the lifting aid and guide pins.
xx2000001957
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
Tip 10/1.52 and CRB 15000-12/1.27)
xx2000002057
xx2000002058
Action Note
4 Remove the protection plate.
xx2100000301
xx2000002055
xx2000002053
xx2000002049
Action Note
8 Remove the joint cable from the hollow shaft from
the torque sensor side.
CAUTION
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
CAUTION
xx2000002051
Action Note
4 Secure the cable plate to the joint unit with the Hex socket head cap screw:
attachment screws. M2.5x6 12.9 Lafre 2C2B/FC6.9 (4
pcs)
Tightening torque: 0.45 Nm.
xx2000002049
xx2000002053
xx2000002056
xx2000002055
Action Note
7 Keep the cabling loose, making sure not to twist
or strain it.
Use the cable tie to pre-fix the cable by hand.
xx2100000507
8 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
10/1.52 and CRB 15000-12/1.27)
xx2000002057
Action Note
9 Secure the cables to the cable support with a Cable tie: 3HAC075545-001. For
cable tie, using a cable tie gun. securing joint unit cable.
Assembly direction for the cable tie is shown in Cable tie gun EVO 7i
the figure. Settiing for cable tie gun: 6.75.
xx2000002058
xx2000002059
xx2100000301
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Clean the mounting surface of the joint unit and Cleaning agent: Isopropanol
the mating surface on the casting with isopropan- Flange sealant: Loctite 574
ol.
Joint unit mounting surface is pointed out in the
figure.
3 Apply a thin layer of flange sealant to the mount-
ing surface. Do not contaminate the radial sealing
with sealant.
CAUTION xx2000001860
Action Note
1
CAUTION
Action Note
2 Fit the lifting aid to the joint unit. Joint unit: 3HAC079143-001 (for
CRB 15000-5/0.95) / 3HAC087546-
CAUTION 001 (for CRB 15000-10/1.52 and
CRB 15000-12/1.27)
The connectors and the joint unit cables are Lifting aid: 3HAC077789-001
sensitive to mechanical damage. Handle the as- Screws: M3x12 (4 pcs)
sembly with care.
xx2000001957
3 Fit two guide pins to the joint unit. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
For joint units on axes 4, 5 and 6.
xx2000002438
CAUTION
5 Secure the joint unit with new attachment screws. Flange socket head screw with
glue: 3HAB3413-330
M3x30 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue , 12 pcs
Always use new screws when refit-
ting a joint unit. If ordering a new
joint unit spare part, new screws
are included.
xx2100000326
Action Note
6 Remove the guide pins and secure the remaining
two attachment screws.
xx2000002091
xx2000002090
Action Note
1 Reconnect the connectors to the drive board.
• D4/5.X1 to X1
• D4/5.X4 to X4
• D4/5.X5 to X5
xx2000002088
Action Note
1 Insert the cabling into the tubular. Valid for CRB 15000-5/0.95
xx2000002148
xx2300000845
xx2000002125
xx2000002089
Action Note
4 Secure the cables for functional earth and protect- Hex socket head cap screw: M3x6
ive earth with a screw. (1 pcs).
Tightening torque: 0.8 Nm.
xx2000002087
5 Secure the cabling to joint unit with cable ties. Cable ties (3 pcs)
xx2000002086
6 Secure the cabling to tubular with cable ties. Cable ties (2 pcs)
Valid for CRB 15000-5/0.95
xx2000002124
xx2300000842
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-043
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000002149
2 Refit the cover with new attachment screws. Flange socket head screw with
glue: 3HAB3413-312
M3x12 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue
For tubular cover of CRB 15000-
5/0.95.
Always use new screws.
If ordering a new axis-4 or axis-5
joint unit spare part, new screws
for the tubular cover are included.
Tightening torque: 1.6 Nm.
xx2000002123
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-076
Replace if damaged. O-ring: 3HAB3772-166
Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2300000846
xx2300000847
2 Refit the covers with new attachment screws. Hex socket head cap screw:
3HAB3409-224
M3x12 12.9 Lafre 2C2B/FC6.9 (3
pcs)
Tightening torque: 1.4 Nm.
xx2000002123
Action Note
1 Fit the o-ring to its groove. Valid for CRB 15000-5/0.95
Replace if damaged. O-ring: 3HAC061327-051
xx2000002092
xx2300000848
xx2000002085
xx2000002084
Action Note
4 Refit the cover with the four screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.2 Nm (for CRB
15000-5/0.95) / 0.9 Nm (for CRB
15000-10/1.52 and CRB 15000-
12/1.27)
Tightening torque: 0.9 Nm
xx2000002083
Action Note
1 Fit two guide pins to the axis-4 joint. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
xx2000002093
xx2000002094
Action Note
3 Lift the tubular into mounting position while insert-
ing the cabling into the housing.
4 Slide the tubular into place on the guide pins.
xx2000002082
5 Secure the tubular to the housing with all attach- Flange socket head screw: M3x20
ment screws but two. 12.9 Lafre 2C2B/FC6.9+PrO-
Pre-tighten the screws crosswise firstly. COat111
xx2000002081
6 Remove the guide pins and fasten the remaining Flange socket head screw: M3x20
two screws. 12.9 Lafre 2C2B/FC6.9+PrO-
COat111
xx2000002079
Action Note
8 Refit the cable bracket with the two screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs).
Tightening torque: 0.8 Nm
Valid for CRB 15000-5/0.95
xx2000002078
xx2300000840
xx2000002077
xx2300000839
Action Note
1 Check the inner plate gasket. Gasket: 3HAC075056-001
Replace if damaged.
xx2000002095
2 Refit the inner plate with the screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs).
Tightening torque: 1.4 Nm
xx2000002076
3 Refit the cover with the four screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs).
Tightening torque: 0.45 Nm
xx2000002075
Action Note
1 Reconnect the connectors to the drive board.
• D3/4.DC+ to DC+
• D3/4.DC- to Ground
• D3/4.X2 to X2
xx2000002120
xx2000002067
3 Secure the cables for functional earth and protect- Hex socket head cap screw: M3x6
ive earth with a screw. (1 pcs).
Tightening torque: 0.8 Nm.
xx2000001945
Action Note
4 Secure the cabling with cable ties. Cable ties (3 pcs)
xx2000002066
Action Note
1 Fit the o-ring to its groove. O-ring: 3HAC061327-047
Replace if damaged.
xx2000001962
xx2000002023
Action Note
3 For robots with RobotWare earlier than 7.10 Cable ties
Secure the brake release cable with a cable tie.
xx2000002022
4 Refit the cover with the four screws. Hex socket head cap screw: M3x30
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm
xx2000002021
Action Note
1 Refit the insert. Insert: 3HAC084002-001
Hex socket head cap screw: M3x10
12.9 Lafre 2C2B/FC6.9 (3 pcs)
Tightening torque: 1.4 Nm
xx2300000834
Action Note
2 Fit the o-ring to its groove. O-ring: 3HAC061327-047
Replace if damaged.
xx2300000835
3 Refit the cover with the four screws. Hex socket head cap screw: M3x30
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 1.4 Nm
xx2300000833
Concluding procedure
Action Note
1 Calibrate the joint unit torque sensor. See Calibration on page 1063
1 On the FlexPendant, go to the Code app
and call the calibration procedure using PP
to Routine, not by using Call Routine.
2 Select the Joint Unit Replacement feature
and then select the axis to calibrate.
3 The controller is now restarted. Once the
home screen of the FlexPendant is shown,
press the Play button to continue the calib-
ration routine.
4 The robot moves to a position or positions
where measurements are performed.
5 The results of the measurements are
presented together with the current values
in the controller. Choose whether to save
the calibration data or not.
6 If new calibration data is saved you will be
asked to do a test with the lead-through
functionality active to verify that the
sensors work correctly.
7 Finally the robot is moved back to the ori-
ginal position.
8 Test the brake release (movement without
drive power) functionality, see Testing the
brake release functionality on page 196.
Action Note
2
DANGER
xx2100000061
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the CRB 15000 via myABB Business Portal,
www.abb.com/myABB.
Required consumables
Action Note
1 Jog the robot to the specified position:
• Axis 1: No significance.
• Axis 2: No significance.
• Axis 3: No significance.
• Axis 4: No significance.
• Axis 5: 0° (home position)
• Axis 6: No significance.
2
CAUTION
Action Note
1 Valid for CRB 15000-5/0.95
Remove the cover by removing the six screws.
Dispose the screws. New screws must be used
when refitting the cover.
New screws are included in the spare part delivery
of the joint unit.
xx2000002123
xx2300000841
Action Note
1 Remove the cover screws.
xx2000002083
2
CAUTION
Action Note
3 For robots with RobotWare earlier than 7.10
Open the cover and cut the cable tie that holds
the brake release cable.
xx2000002084
xx2000002085
Action Note
1 Cut the cable ties on joint unit.
xx2000002086
Action Note
2 Cut the cable ties on tubular, if needed. Valid for CRB 15000-5/0.95
xx2000002124
xx2300000842
xx2300000843
xx2000002087
xx2000002089
Action Note
6 Disconnect the connectors that belongs to the Tweezers
axis-5 cabling, from the axis-4 drive board:
• D3/4.X2
• D3/4.DC-
• D3/4.DC+
Use tweezers, if needed.
xx2000002125
7 Pull out the cabling carefully from the tubular. Valid for CRB 15000-5/0.95
xx2000002126
xx2300000844
Action Note
1 Remove two attachment screws and fit two guide Guide pin, M3x110: 3HAC077787-
pins to the axis-5 joint unit. 001
Always use guide pins in pairs.
xx2000002128
xx2000002129
xx2000002130
xx2000002131
Action Note
1 Remove the tool flange screws and washers.
xx2000002155
2
CAUTION
xx2000002157
xx2000002158
Action Note
1 Remove the functional earth cable by removing
the screw.
xx2000002159
Action Note
1 Remove the tool flange adapter screws.
xx2000002165
xx2000002166
xx2000002167
Action Note
1
CAUTION
2
CAUTION
xx2000002550
xx2100000335
Action Note
1 Cut the cable ties.
xx2000002161
Action Note
2 Remove the functional and protective earth cables
by removing the screw.
xx2000002162
xx2000002163
CAUTION
xx2000002164
Action Note
1 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC077789-001
sensor side. Screws: M3x12 (4 pcs)
CAUTION
xx2000002168
xx2000002170
xx2100000328
Action Note
4 Remove the remaining attachment screws.
Use two screws as press out screws in the upcom-
ing step, then dispose all screws.
New screws are included in the spare part delivery
of the joint unit.
xx2100000329
xx2100000330
CAUTION
xx2000002169
xx2000001957
Action Note
1 Remove the cover by removing the four screws.
xx2000002132
2
CAUTION
xx2000002133
xx2000002134
Action Note
1 Cut the cable ties.
xx2000002135
xx2000002136
xx2000002137
CAUTION
Action Note
1 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC077789-001
sensor side. Screws: M3x12 (4 pcs)
CAUTION
xx2000002139
xx2000002140
xx2100000284
4 Fit two guide pins to the axis-5 joint unit. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
For joint units on axes 4, 5 and 6.
xx2100000332
xx2100000333
Action Note
6 Press the joint unit out of position using two of
the previous attachment screws as removal tools.
xx2100000334
CAUTION
xx2000001957
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
Tip 10/1.52 and CRB 15000-12/1.27)
xx2000002057
Action Note
3 Cut the cable tie at the drive board.
xx2000002058
xx2100000301
xx2000002055
xx2000002053
Action Note
7 Remove the cable plate by removing the attach-
ment screws.
xx2000002049
CAUTION
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
CAUTION
xx2000002051
Action Note
4 Secure the cable plate to the joint unit with the Hex socket head cap screw:
attachment screws. M2.5x6 12.9 Lafre 2C2B/FC6.9 (4
pcs)
Tightening torque: 0.45 Nm.
xx2000002049
xx2000002053
xx2000002056
xx2000002055
Action Note
7 Keep the cabling loose, making sure not to twist
or strain it.
Use the cable tie to pre-fix the cable by hand.
xx2100000507
8 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
10/1.52 and CRB 15000-12/1.27)
xx2000002057
Action Note
9 Secure the cables to the cable support with a Cable tie: 3HAC075545-001. For
cable tie, using a cable tie gun. securing joint unit cable.
Assembly direction for the cable tie is shown in Cable tie gun EVO 7i
the figure. Settiing for cable tie gun: 6.75.
xx2000002058
xx2000002059
xx2100000301
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Clean the mounting surface of the joint unit and Cleaning agent: Isopropanol
the mating surface on the casting with isopropan- Flange sealant: Loctite 574
ol.
Joint unit mounting surface is pointed out in the
figure.
3 Apply a thin layer of flange sealant to the mount-
ing surface. Do not contaminate the radial sealing
with sealant.
CAUTION xx2000001860
Action Note
1
CAUTION
Action Note
2 Fit the lifting aid to the joint unit. Joint unit: 3HAC079143-001 (for
CRB 15000-5/0.95) / 3HAC087546-
CAUTION 001 (for CRB 15000-10/1.52 and
CRB 15000-12/1.27)
The connectors and the joint unit cables are Lifting aid: 3HAC077789-001
sensitive to mechanical damage. Handle the as- Screws: M3x12 (4 pcs)
sembly with care.
xx2000001957
3 Fit two guide pins to the joint unit. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
For joint units on axes 4, 5 and 6.
xx2000002438
4 Fit the transition cable between axis-5 and axis-6 Cable harness, transition joint-5
joint units into the tilt. and joint-6: 3HAC083726-001
xx2100000040
Action Note
5 Place the cabling at the slot before refitting the
joint unit.
xx2100000041
xx2100000285
6 Fit the joint unit to the tilt, aligning the pin with the
pin hole.
CAUTION
Action Note
7 Secure the joint unit with new attachment screws. Flange socket head screw with
glue: 3HAB3413-330
M3x30 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue , 12 pcs
Used for joint unit of CRB 15000-
5/0.95.
Always use new screws when refit-
ting a joint unit. If ordering a new
joint unit spare part, new screws
are included.
xx2100000333
xx2000002140
xx2000002139
Action Note
1 Reconnect the connectors to the drive board.
• D4/5.X1 to X1
• D5.DC+ to +DC
• D5.DC- to Ground
• D4/5.X4 to X4
• D5/4.X2 to X2
• D4/5.X5 to X5
xx2000002138
xx2000002137
3 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000002136
Action Note
4 Secure the cabling with cable ties. Cable ties (3 pcs)
xx2000002135
Action Note
1 Fit the o-ring to its groove. Valid for CRB 15000-5/0.95
Replace if damaged. O-ring: 3HAC061327-051
xx2000001962
xx2300000849
Action Note
2 For robots with RobotWare earlier than 7.10
Place the cover at mounting position and recon-
nect the brake release connector DR.X8 to the
drive board.
xx2000002134
xx2000002133
4 Refit the cover with the four screws. Valid for CRB 15000-5/0.95
Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.2 Nm
Valid for CRB 15000-10/1.52 and
CRB 15000-12/1.27
Hex socket head cap screw: M3x12
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 1.4 Nm
xx2000002132
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Clean the mounting surface of the joint unit and Cleaning agent: Isopropanol
the mating surface on the casting with isopropan- Flange sealant: Loctite 574
ol.
Joint unit mounting surface is pointed out in the
figure.
3 Apply a thin layer of flange sealant to the mount-
ing surface. Do not contaminate the radial sealing
with sealant.
CAUTION xx2000001860
Action Note
1
CAUTION
Action Note
2 Fit the lifting aid to the joint unit. Joint unit: 3HAC079143-001 (for
CRB 15000-5/0.95) / 3HAC087546-
CAUTION 001 (for CRB 15000-10/1.52 and
CRB 15000-12/1.27)
The connectors and the joint unit cables are Lifting aid: 3HAC077789-001
sensitive to mechanical damage. Handle the as- Screws: M3x12 (4 pcs)
sembly with care.
xx2000001957
3 Fit two guide pins to the joint unit. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
For joint units on axes 4, 5 and 6.
xx2000002438
xx2100000041
Action Note
5 Fit the joint unit to the tilt, aligning the pin with the
pin hole.
CAUTION
xx2000002195
6 Secure the joint unit with new attachment screws. Flange socket head screw with
glue: 3HAB3413-330
M3x30 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue , 12 pcs
Used for joint unit of CRB 15000-
5/0.95.
Always use new screws when refit-
ting a joint unit. If ordering a new
joint unit spare part, new screws
are included.
xx2100000329
xx2000002170
Action Note
10 Remove the lifting aid by removing the screws.
xx2000002168
Action Note
1 Reconnect the connectors to the drive board.
• D6.X1 to X1
• D6.DC+ to +DC
• D6.DC- to Ground
• D6.X4 to X4
• D6.X2 to X2
• D6.X5 to X5
xx2000002164
xx2000002163
Action Note
3 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000002162
xx2000002161
Action Note
1 Fit the o-ring to its groove. O-ring: 3HAC061327-051
Replace if damaged.
xx2000002551
Action Note
2 Place the arm-side interface at mounting position
and reconnect the connectors.
• ASI.DC+
• ASI.DC-
• ASI.X1
The correct orientation of the arm-side interface
is with the convex button in upper position.
Note
xx2100000336
3 Refit the arm-side interface with four screws. Valid for CRB 15000-5/0.95
Hex socket head cap screw: M3x30
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm
Valid for CRB 15000-10/1.52 and
CRB 15000-12/1.27
Hex socket head cap screw: M3x20
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm
xx2000002550
Action Note
1 Clean the mounting surface with isopropanol. Cleaning agent: Isopropanol
Apply flange sealant to the corner of the adapter Flange sealant: Loctite 574
mounting surface, as pointed out in the figure.
xx2000002196
2 Refit the tool flange adapter, aligning the pin with Axis-6 inner flange: 3HAC073952-
the pin hole. 001
xx2000002167
xx2000002165
Action Note
1 Secure the cable for functional earth to the tool
flange adapter with a screw.
xx2000002159
Action Note
1 Check the o-ring on the tool flange and lubricate Axis-6 flange: 3HAC073953-001
with grease. O-ring: 3HAB3772-182
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000002197
xx2000002158
Action Note
3 Fit the connectors to the cable bracket and secure Cable ties (2 pcs)
the connectors with two cable ties.
xx2000002157
4 Refit and secure the tool flange with screws and Hex socket head cap screw: M3x12
washers. 12.9 Lafre 2C2B/FC6.9 (10 pcs)
Spring washer: 7x3.2x0.6 Steel (10
pcs)
Tightening torque: 1.8 Nm.
xx2000002155
Action Note
1 Fit two guide pins to the axis-5 joint. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
xx2000002146
Action Note
2 Clean the mounting surface with isopropanol. Cleaning agent: Isopropanol
Apply flange sealant to the corner of the tubular Flange sealant: Loctite 574
mounting surface, as pointed out in the figure.
xx2000002147
xx2000002131
5 Secure the tilt to the tubular with all attachment Flange socket head screw: M3x20
screws but two. 12.9 Lafre 2C2B/FC6.9+PrO-
Pre-tighten the screws crosswise firstly. COat111 (14 pcs)
xx2000002130
6 Remove the guide pins and fasten the remaining Flange socket head screw: M3x20
two screws. 12.9 Lafre 2C2B/FC6.9+PrO-
COat111 (2 pcs)
xx2000002128
Action Note
1 Insert the cabling into the tubular. Valid for CRB 15000-5/0.95
xx2000002148
xx2300000845
xx2000002125
xx2000002089
Action Note
4 Secure the cables for functional earth and protect- Hex socket head cap screw: M3x6
ive earth with a screw. (1 pcs).
Tightening torque: 0.8 Nm.
xx2000002087
5 Secure the cabling to joint unit with cable ties. Cable ties (3 pcs)
xx2000002086
6 Secure the cabling to tubular with cable ties. Cable ties (2 pcs)
Valid for CRB 15000-5/0.95
xx2000002124
xx2300000842
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-043
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000002149
2 Refit the cover with new attachment screws. Flange socket head screw with
glue: 3HAB3413-312
M3x12 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue
For tubular cover of CRB 15000-
5/0.95.
Always use new screws.
If ordering a new axis-4 or axis-5
joint unit spare part, new screws
for the tubular cover are included.
Tightening torque: 1.6 Nm.
xx2000002123
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-076
Replace if damaged. O-ring: 3HAB3772-166
Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2300000846
xx2300000847
2 Refit the covers with new attachment screws. Hex socket head cap screw:
3HAB3409-224
M3x12 12.9 Lafre 2C2B/FC6.9 (3
pcs)
Tightening torque: 1.4 Nm.
xx2000002123
Action Note
1 Fit the o-ring to its groove. Valid for CRB 15000-5/0.95
Replace if damaged. O-ring: 3HAC061327-051
xx2000002092
xx2300000848
xx2000002085
xx2000002084
Action Note
4 Refit the cover with the four screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.2 Nm (for CRB
15000-5/0.95) / 0.9 Nm (for CRB
15000-10/1.52 and CRB 15000-
12/1.27)
Tightening torque: 0.9 Nm
xx2000002083
Concluding procedure
Action Note
1 Calibrate the joint unit torque sensor. See Calibration on page 1063
1 On the FlexPendant, go to the Code app
and call the calibration procedure using PP
to Routine, not by using Call Routine.
2 Select the Joint Unit Replacement feature
and then select the axis to calibrate.
3 The controller is now restarted. Once the
home screen of the FlexPendant is shown,
press the Play button to continue the calib-
ration routine.
4 The robot moves to a position or positions
where measurements are performed.
5 The results of the measurements are
presented together with the current values
in the controller. Choose whether to save
the calibration data or not.
6 If new calibration data is saved you will be
asked to do a test with the lead-through
functionality active to verify that the
sensors work correctly.
7 Finally the robot is moved back to the ori-
ginal position.
8 Test the brake release (movement without
drive power) functionality, see Testing the
brake release functionality on page 196.
2
DANGER
xx2100000062
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the CRB 15000 via myABB Business Portal,
www.abb.com/myABB.
Required consumables
Action Note
1 Jog the robot to the specified position: Example of CRB 15000-5/0.95,
• Axis 1: No significance. similar to CRB 15000-10/1.52 and
• Axis 2: No significance. CRB 15000-12/1.27.
• Axis 3: No significance.
• Axis 4: No significance.
• Axis 5: approximately +20°
• Axis 6: 0° (home position)
CAUTION
Action Note
2
CAUTION
Action Note
1 Remove the tool flange screws and washers.
xx2000002155
2
CAUTION
xx2000002157
xx2000002158
Action Note
1 Remove the functional earth cable by removing
the screw.
xx2000002159
Action Note
1 Remove the tool flange adapter screws.
xx2000002165
xx2000002166
xx2000002167
Action Note
1
CAUTION
2
CAUTION
xx2000002550
xx2100000335
Action Note
1 Cut the cable ties.
xx2000002161
Action Note
2 Remove the functional and protective earth cables
by removing the screw.
xx2000002162
xx2000002163
CAUTION
xx2000002164
Action Note
1 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC077789-001
sensor side. Screws: M3x12 (4 pcs)
CAUTION
xx2000002168
xx2000002170
xx2100000328
Action Note
4 Remove the remaining attachment screws.
Use two screws as press out screws in the upcom-
ing step, then dispose all screws.
New screws are included in the spare part delivery
of the joint unit.
xx2100000329
xx2100000330
CAUTION
xx2000002169
xx2000001957
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
Tip 10/1.52 and CRB 15000-12/1.27)
xx2000002057
xx2000002058
Action Note
4 Remove the protection plate.
xx2100000301
xx2000002055
xx2000002053
xx2000002049
Action Note
8 Remove the joint cable from the hollow shaft from
the torque sensor side.
CAUTION
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
CAUTION
xx2000002051
Action Note
4 Secure the cable plate to the joint unit with the Hex socket head cap screw:
attachment screws. M2.5x6 12.9 Lafre 2C2B/FC6.9 (4
pcs)
Tightening torque: 0.45 Nm.
xx2000002049
xx2000002053
xx2000002056
xx2000002055
Action Note
7 Keep the cabling loose, making sure not to twist
or strain it.
Use the cable tie to pre-fix the cable by hand.
xx2100000507
8 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
10/1.52 and CRB 15000-12/1.27)
xx2000002057
Action Note
9 Secure the cables to the cable support with a Cable tie: 3HAC075545-001. For
cable tie, using a cable tie gun. securing joint unit cable.
Assembly direction for the cable tie is shown in Cable tie gun EVO 7i
the figure. Settiing for cable tie gun: 6.75.
xx2000002058
xx2000002059
xx2100000301
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Clean the mounting surface of the joint unit and Cleaning agent: Isopropanol
the mating surface on the casting with isopropan- Flange sealant: Loctite 574
ol.
Joint unit mounting surface is pointed out in the
figure.
3 Apply a thin layer of flange sealant to the mount-
ing surface. Do not contaminate the radial sealing
with sealant.
CAUTION xx2000001860
Action Note
1
CAUTION
Action Note
2 Fit the lifting aid to the joint unit. Joint unit: 3HAC079143-001 (for
CRB 15000-5/0.95) / 3HAC087546-
CAUTION 001 (for CRB 15000-10/1.52 and
CRB 15000-12/1.27)
The connectors and the joint unit cables are Lifting aid: 3HAC077789-001
sensitive to mechanical damage. Handle the as- Screws: M3x12 (4 pcs)
sembly with care.
xx2000001957
3 Fit two guide pins to the joint unit. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
For joint units on axes 4, 5 and 6.
xx2000002438
xx2100000041
Action Note
5 Fit the joint unit to the tilt, aligning the pin with the
pin hole.
CAUTION
xx2000002195
6 Secure the joint unit with new attachment screws. Flange socket head screw with
glue: 3HAB3413-330
M3x30 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue , 12 pcs
Used for joint unit of CRB 15000-
5/0.95.
Always use new screws when refit-
ting a joint unit. If ordering a new
joint unit spare part, new screws
are included.
xx2100000329
xx2000002170
Action Note
10 Remove the lifting aid by removing the screws.
xx2000002168
Action Note
1 Reconnect the connectors to the drive board.
• D6.X1 to X1
• D6.DC+ to +DC
• D6.DC- to Ground
• D6.X4 to X4
• D6.X2 to X2
• D6.X5 to X5
xx2000002164
xx2000002163
Action Note
3 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000002162
xx2000002161
Action Note
1 Fit the o-ring to its groove. O-ring: 3HAC061327-051
Replace if damaged.
xx2000002551
Action Note
2 Place the arm-side interface at mounting position
and reconnect the connectors.
• ASI.DC+
• ASI.DC-
• ASI.X1
The correct orientation of the arm-side interface
is with the convex button in upper position.
Note
xx2100000336
3 Refit the arm-side interface with four screws. Valid for CRB 15000-5/0.95
Hex socket head cap screw: M3x30
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm
Valid for CRB 15000-10/1.52 and
CRB 15000-12/1.27
Hex socket head cap screw: M3x20
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm
xx2000002550
Action Note
1 Clean the mounting surface with isopropanol. Cleaning agent: Isopropanol
Apply flange sealant to the corner of the adapter Flange sealant: Loctite 574
mounting surface, as pointed out in the figure.
xx2000002196
2 Refit the tool flange adapter, aligning the pin with Axis-6 inner flange: 3HAC073952-
the pin hole. 001
xx2000002167
xx2000002165
Action Note
1 Secure the cable for functional earth to the tool
flange adapter with a screw.
xx2000002159
Action Note
1 Check the o-ring on the tool flange and lubricate Axis-6 flange: 3HAC073953-001
with grease. O-ring: 3HAB3772-182
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000002197
xx2000002158
Action Note
3 Fit the connectors to the cable bracket and secure Cable ties (2 pcs)
the connectors with two cable ties.
xx2000002157
4 Refit and secure the tool flange with screws and Hex socket head cap screw: M3x12
washers. 12.9 Lafre 2C2B/FC6.9 (10 pcs)
Spring washer: 7x3.2x0.6 Steel (10
pcs)
Tightening torque: 1.8 Nm.
xx2000002155
Concluding procedure
Action Note
1 Calibrate the joint unit torque sensor. See Calibration on page 1063
1 On the FlexPendant, go to the Code app
and call the calibration procedure using PP
to Routine, not by using Call Routine.
2 Select the Joint Unit Replacement feature
and then select the axis to calibrate.
3 The controller is now restarted. Once the
home screen of the FlexPendant is shown,
press the Play button to continue the calib-
ration routine.
4 The robot moves to a position or positions
where measurements are performed.
5 The results of the measurements are
presented together with the current values
in the controller. Choose whether to save
the calibration data or not.
6 If new calibration data is saved you will be
asked to do a test with the lead-through
functionality active to verify that the
sensors work correctly.
7 Finally the robot is moved back to the ori-
ginal position.
8 Test the brake release (movement without
drive power) functionality, see Testing the
brake release functionality on page 196.
2
DANGER
xx2100000091
CAUTION
Brake release units exist only on robots with RobotWare earlier than 7.10. On
robots with RobotWare 7.10 or later, brake release units are unavailable.
The brake release units are located as shown in the figure.
xx2100000099 xx2100000100
Note
The spare parts related to the brake release function using the external tool are
discontinued from Q2 2023.
Note
Note
Required consumables
Note
The spare parts related to the brake release function using the external tool are
discontinued from Q2 2023.
Action Note
1 Jog the robot to the specified position:
• Axis 1: 0°
• Axis 2: 0°
• Axis 3: +85°
• Axis 4: 0°
• Axis 5: 0°
• Axis 6: 0°
xx2100000113
2
CAUTION
xx2100000414
Action Note
1
CAUTION
CAUTION
xx2100000414
Action Note
1 Remove the bottom cover by removing the attach- Valid for CRB 15000-5/0.95
ment screws.
xx2000002007
xx2300000760
Action Note
1 Cut the cable tie.
xx2100000410
Action Note
2 Disconnect the brake release cable from the
board.
xx2100000411
xx2100000413
xx2100000416
xx2100000418
Action Note
6 Disconnect the brake release cable from the
board.
xx2100000417
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAB3772-119
Replace if damaged. Grease: 3HAC031695-001
Harmonic Grease 4B No.2
Used to lubricate the seals.
xx2100000419
xx2100000420
Action Note
3 Connect the brake release cable to the board. Brake release unit: 3HAC079144-
001
xx2100000417
xx2100000418
5 Fit the brake release cover and secure with two Screws: M2x6 12.9 Gleitmo 605 (2
screws. pcs)
Tightening torque: 0.2 Nm.
xx2100000416
Action Note
6 Secure the brake release cable with a cable tie.
xx2100000421
7 Refit the brake release unit with the screws. Screws: M3x5 12.9 Lafre
2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm.
xx2100000413
xx2100000411
Action Note
9 Secure the brake release cable with a cable tie.
xx2100000410
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAB3772-64
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000002016
Action Note
2 Refit the bottom cover with the attachment screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (8 pcs)
Note Tightening torque: 1.2 Nm.
xx2000002007
xx2100000268
Action Note
1
CAUTION
xx2100000118
CAUTION
4 Fit two pins to the holes in the base. Centering pins: DIN6325, hardened
steel Ø6x24 mm, 2 pcs .
Action Note
5 Raise the robot to standing and secure to Screws: M10x35, 4 pcs, quality 8.8
foundation, paying attention to the centering Washers: 23/10.5/2.5 mm Steel
holes at the bottom of the robot base.
• Person 1: keep holding the robot stable.
• Person 2: secure the robot base to the
foundation with the securing screws and
washers.
6 Tighten the bolts in a crosswise pattern to en- Tightening torque: 32 Nm ±10%
sure that the base is not distorted.
Concluding procedure
Action Note
1
DANGER
Action Note
1
CAUTION
xx2000001935
3
CAUTION
Action Note
4 For robots with RobotWare earlier than 7.10
Open the cover and cut the cable tie that holds
the brake release cable.
xx2000001931
xx2000001932
Action Note
1 Cut the cable tie.
xx2100000096
Action Note
2 Remove the brake release cover by removing the
two screws.
xx2100000095
xx2100000094
xx2100000093
Action Note
1 If not already fitted, place the sheet metal inside
the cover.
xx2100000092
xx2100000093
xx2100000094
Action Note
4 Fit the brake release cover and secure with two Screws: M2x6 12.9 Gleitmo 605 (2
screws. pcs)
Tightening torque: 0.2 Nm.
xx2100000095
xx2100000096
Action Note
1 Fit the o-ring to its groove. O-ring: 3HAC061327-047
Replace if damaged.
xx2000001962
Action Note
2 Place the cover at mounting position and recon- Axis 2:
nect the brake release connector DR.X8 to the
drive board.
Orient the cover for proper arrangement of the
brake release cable.
xx2000001932
Axis 3:
xx2000002023
Axis 4:
Tweezers
xx2000002085
Axis 5:
xx2000002134
Action Note
3 Secure the brake release cable with a cable tie. Cable ties
xx2000001931
4 Refit the cover with the four screws. Hex socket head cap screw: M3x30
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque:
Axis 2: 0.45 Nm
Axis 3: 0.45 Nm
Axis 4: 0.2 Nm
Axis 5: 0.2 Nm
xx2000001935
Concluding procedure
Action Note
1
DANGER
xx2000001928
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the CRB 15000 via myABB Business Portal,
www.abb.com/myABB.
Required consumables
Action Note
1 Jog the robot to the synchronization position.
2
CAUTION
Action Note
1
CAUTION
xx2000001929
xx2100000267
Action Note
4 Remove the inner covers by removing the screws.
xx2000001947
xx2000001930
Action Note
1
CAUTION
xx2300000812
xx2300000829
Action Note
3 Remove the inner covers by removing the screws.
xx2300000813
xx2300000830
Disconnecting the cabling between the lower arm and the swing
Action Note
1 Remove the functional earth cable by removing
the screw.
xx2000001936
xx2000001937
Action Note
3 Snap loose and disconnect all connectors.
xx2000001938
Action Note
1 Remove the functional earth cable by removing
the screw.
xx2000001964
xx2000001965
Action Note
1 Remove the cable bracket by removing the four
screws.
xx2000001966
Action Note
2 Secure the weight of the upper arm.
CAUTION
xx2000001967
4 Fit two guide pins to the axis-3 joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
xx2000001968
xx2000001969
xx2100000001
Action Note
7 Remove the upper arm from the lower arm.
Assist the cabling to be removed from the lower
arm while lifting away the complete upper arm.
Place the upper arm on a workbench.
xx2000001970
Action Note
1 Remove the cable bracket by removing the four
screws.
xx2000001939
Action Note
3 Remove two attachment screws and fit two guide Valid for CRB 15000-5/0.95
pins to the axis-2 joint unit. Guide pin, M4x120: 3HAC077786-
001
Valid for CRB 15000-10/1.52 and
CRB 15000-12/1.27
Guide pin, M5x125: 3HAC087786-
001
Always use guide pins in pairs.
xx2000001951
xx2000001960
xx2000001940
xx2000002151
Action Note
6 Remove the lower arm from the swing.
xx2000001952
Action Note
1 Fit two guide pins to the axis-2 joint unit. Valid for CRB 15000-5/0.95
Guide pin, M4x120: 3HAC077786-
001
Valid for CRB 15000-10/1.52 and
CRB 15000-12/1.27
Guide pin, M5x125: 3HAC087786-
001
xx2000001949
Action Note
2 Valid for CRB 15000-5/0.95 Cleaning agent: Isopropanol
Clean the mounting surface with isopropanol. Flange sealant: Loctite 574
Apply flange sealant to the corner of the lower
arm mounting surface, as pointed out in the figure.
xx2000001963
xx2000001952
4 Secure the lower arm to the swing with all attach- Valid for CRB 15000-5/0.95
ment screws but two. Hex socket head cap flange screw:
Pre-tighten the screws crosswise firstly. M4x25 12.9 Lafre
2C2B/FC6.9+PrO-COat111 (16 pcs)
CAUTION Valid for CRB 15000-10/1.52 and
CRB 15000-12/1.27
Do not mix the flange screws used for CRB 15000- Hex socket head cap screw: M5x30
5/0.95 and the threaded screws used for CRB 12.9 Lafre 2C2B/FC6.9, 16 pcs
15000-10/1.52 and CRB 15000-12/1.27. Always
use washers together with the threaded screws
for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Illustration is for reference only.
xx2000001940
Action Note
5 Remove the guide pins and fasten the remaining Valid for CRB 15000-5/0.95
two screws. Hex socket head cap flange screw:
M4x25 12.9 Lafre
2C2B/FC6.9+PrO-COat111 (16 pcs)
Valid for CRB 15000-10/1.52 and
CRB 15000-12/1.27
Hex socket head cap screw: M5x30
12.9 Lafre 2C2B/FC6.9, 16 pcs
xx2000001951
6 Torque tighten all screws crosswise. Tightening torque: 4.6 Nm (for CRB
15000-5/0.95) / 8.2 Nm (for CRB
15000-10/1.52 and CRB 15000-
12/1.27)
7 Refit the cable bracket with four screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs).
Tightening torque: 0.8 Nm
xx2000001939
Action Note
1 Fit two guide pins to the axis-3 joint. Guide pin, M4x120: 3HAC077786-
001
xx2000001971
xx2000001973
xx2000001970
5 Secure the upper arm to the lower arm with all Hex socket head cap flange screw:
attachment screws but two. M4x25 12.9 Lafre
Pre-tighten the screws crosswise firstly. 2C2B/FC6.9+PrO-COat111 (16 pcs)
xx2000001969
Action Note
6 Remove the guide pins and fasten the remaining Hex socket head cap flange screw:
two screws. M4x25 12.9 Lafre
2C2B/FC6.9+PrO-COat111 (16 pcs)
xx2000001967
xx2000001966
Action Note
1 Connect the connectors to each other and snap
them to the cable holders.
xx2000001938
Action Note
2 Secure the cabling with cable ties. Cable ties (3 pcs)
xx2000001937
3 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (1 pcs).
Tightening torque: 0.8 Nm
xx2000001936
Action Note
1 Secure the cabling with the cable tie. Cable ties
xx2000001965
2 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (1 pcs).
Tightening torque: 0.8 Nm
xx2000001964
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-044
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000001955
xx2000001954
2 Refit the inner covers with four screws each. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (8 pcs)
Tightening torque: 1.4 Nm.
xx2000001947
xx2000001930
Action Note
3 Snap the lower arm cover into place. Hex socket head cap screw: M3x16
12.9 Lafre 2C2B/FC6.9 (4 pcs)
4 Secure the cover with four screws.
Tightening torque: 0.45 Nm.
xx2000001929
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-075
Replace if damaged. O-ring: 3HAC061327-044
Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2300000832
xx2300000831
Action Note
2 Refit the inner covers with eight screws each. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (8 pcs) x 2
Tightening torque: 1.4 Nm.
xx2300000813
xx2300000830
3 Snap the lower arm cover into place. Hex socket head cap screw: M3x12
12.9 Lafre 2C2B/FC6.9 (3 pcs) x 2
4 Secure the cover with three screws.
Tightening torque: 1.4 Nm.
xx2300000812
xx2300000829
Concluding procedure
Action Note
1
DANGER
xx2000002019
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the CRB 15000 via myABB Business Portal,
www.abb.com/myABB.
Required consumables
Action Note
1 Jog the robot to the specified position: Example of CRB 15000-5/0.95,
• Axis 1: 0° similar to CRB 15000-10/1.52 and
• Axis 2: +90° (suggested position for con- CRB 15000-12/1.27.
venient working position)
• Axis 3: -80°
• Axis 4: 0°
• Axis 5: 0°
• Axis 6: 0°
xx2100000002
2
CAUTION
Action Note
1
CAUTION
xx2000001929
xx2100000267
Action Note
4 Remove the inner covers by removing the screws.
xx2000001947
xx2000001930
Action Note
1
CAUTION
xx2300000812
xx2300000829
Action Note
3 Remove the inner covers by removing the screws.
xx2300000813
xx2300000830
Action Note
1 Cut the cable ties.
xx2000001937
xx2000001938
Action Note
1 Remove the functional earth cable by removing
the screw.
xx2000001964
xx2000001965
Action Note
1 Remove the cable bracket by removing the four
screws.
xx2000001966
CAUTION
xx2000001967
Action Note
4 Fit two guide pins to the axis-3 joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
xx2000001968
xx2000001969
xx2100000001
xx2000001970
Action Note
1
CAUTION
Action Note
2 Remove the cover screws.
xx2000002021
3
CAUTION
xx2000002022
xx2000002023
Action Note
1
CAUTION
xx2300000833
3
CAUTION
xx2300000834
Action Note
1 Cut the cable ties.
xx2000002066
xx2000001945
xx2000002067
Action Note
4 Disconnect the connectors from the drive board.
• D3.X1
• D3/4.DC+
• D3/4.DC-
• D3.X4
• D3/4.X2
• D3.X5
CAUTION
xx2000002068
Action Note
1 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC077788-001
sensor side. Screws: M4x35 (4 pcs)
CAUTION
xx2000002069
xx2000002070
3 Fit two guide pins to the axis-3 joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
For joint units on axes 1, 2 and 3
of CRB 15000-5/0.95 and axis 3 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2000002576
Action Note
4 Remove the remaining attachment screws.
Use two screws as press out screws in the upcom-
ing step, then dispose all screws.
New screws are included in the spare part delivery
of the joint unit.
xx2100000320
xx2100000003
xx2000002577
CAUTION
xx2000002071
xx2000001957
Action Note
1 Remove the attachment screws.
xx2300000799
2 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC087788-001
sensor side. Screws: M4x30 (4 pcs)
CAUTION
xx2300000800
xx2300000801
CAUTION
xx2300000802
xx2300000804
Action Note
1 Remove the cover by removing the four screws.
xx2000002075
xx2000002076
Action Note
1 Cut the cable tie. Valid for CRB 15000-5/0.95
xx2000002077
xx2300000839
Action Note
2 Remove the cable bracket by removing the two Valid for CRB 15000-5/0.95
screws.
xx2000002078
xx2300000840
3 Remove two attachment screws and fit two guide Guide pin, M3x110: 3HAC077787-
pins to the axis-4 joint unit. 001
Always use guide pins in pairs.
xx2000002079
xx2000002080
Action Note
4 Remove the remaining attachment screws.
xx2000002081
xx2000002127
xx2100000006
xx2000002082
Action Note
1 Replace the housing. Housing: 3HAC073949-001 (for
CRB 15000-5/0.95) / 3HAC087550-
001 (for CRB 15000-10/1.52 and
CRB 15000-12/1.27)
Action Note
1 Fit two guide pins to the axis-4 joint. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
xx2000002093
xx2000002094
xx2000002082
Action Note
5 Secure the tubular to the housing with all attach- Flange socket head screw: M3x20
ment screws but two. 12.9 Lafre 2C2B/FC6.9+PrO-
Pre-tighten the screws crosswise firstly. COat111
xx2000002081
6 Remove the guide pins and fasten the remaining Flange socket head screw: M3x20
two screws. 12.9 Lafre 2C2B/FC6.9+PrO-
COat111
xx2000002079
Action Note
8 Refit the cable bracket with the two screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs).
Tightening torque: 0.8 Nm
Valid for CRB 15000-5/0.95
xx2000002078
xx2300000840
xx2000002077
xx2300000839
Action Note
1 Check the inner plate gasket. Gasket: 3HAC075056-001
Replace if damaged.
xx2000002095
2 Refit the inner plate with the screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs).
Tightening torque: 1.4 Nm
xx2000002076
3 Refit the cover with the four screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs).
Tightening torque: 0.45 Nm
xx2000002075
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
Action Note
2 Clean the mounting surface of the joint unit and Cleaning agent: Isopropanol
the mating surface on the casting with isopropan- Flange sealant: Loctite 574
ol.
Joint unit mounting surface is pointed out in the
figure.
3 Apply a thin layer of flange sealant to the mount-
ing surface. Do not contaminate the radial sealing
with sealant.
CAUTION xx2000001860
Action Note
1 Fit the lifting aid to the joint unit. Joint unit: 3HAC079141-001
Lifting aid: 3HAC077788-001
CAUTION Screws: M4x35 (4 pcs)
xx2000001957
2 Fit two guide pins to the joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
For joint units on axes 1, 2 and 3
of CRB 15000-5/0.95 and axis 3 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2000002438
Action Note
3 Place the cabling at the slot before refitting the
joint unit.
xx2100000004
CAUTION
5 Secure the joint unit with new attachment screws. Flange socket head screw with
glue: 3HAB3413-435
M4x35 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue , 12 pcs
Used for joint unit of CRB 15000-
5/0.95.
Always use new screws when refit-
ting a joint unit. If ordering a new
joint unit spare part, new screws
are included.
xx2100000320
xx2000002070
Action Note
9 Remove the lifting aid by removing the screws.
xx2000002069
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2300000836
3 Fit two guide pins to the housing. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
For joint units on axes 1, 2 and 3
of CRB 15000-5/0.95 and axis 3 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2300000803
Action Note
4 Fit the lifting aid to the joint unit, aligning the pin Joint unit: 3HAC087474-001
with the pin hole. Lifting aid: 3HAC087788-001
Screws: M4x30 (4 pcs)
CAUTION
xx2300000804
xx2300000777
CAUTION
xx2300000806
xx2300000780
xx2300000808
Action Note
7 Remove the guide pins.
xx2300000809
xx2300000810
xx2300000800
10 Secure the joint unit with the remaining attach- Hex socket head cap screw:
ment screws. 3HAB3409-262
xx2300000811
Action Note
1 Reconnect the connectors to the drive board.
• D3.X1 to X1
• D3/4.DC+ to DC+
• D3/4.DC- to Ground
• D3.X4 to X4
• D3/4.X2 to X2
• D3.X5 to X5
xx2000002068
xx2000002067
3 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000001945
Action Note
4 Secure the cabling with cable ties. Cable ties (3 pcs)
xx2000002066
Action Note
1 Fit the o-ring to its groove. O-ring: 3HAC061327-047
Replace if damaged.
xx2000001962
xx2000002023
Action Note
3 For robots with RobotWare earlier than 7.10 Cable ties
Secure the brake release cable with a cable tie.
xx2000002022
4 Refit the cover with the four screws. Hex socket head cap screw: M3x30
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm
xx2000002021
Action Note
1 Refit the insert. Insert: 3HAC084002-001
Hex socket head cap screw: M3x10
12.9 Lafre 2C2B/FC6.9 (3 pcs)
Tightening torque: 1.4 Nm
xx2300000834
Action Note
2 Fit the o-ring to its groove. O-ring: 3HAC061327-047
Replace if damaged.
xx2300000835
3 Refit the cover with the four screws. Hex socket head cap screw: M3x30
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 1.4 Nm
xx2300000833
Action Note
1 Fit two guide pins to the axis-3 joint. Guide pin, M4x120: 3HAC077786-
001
xx2000001971
Action Note
2 Valid for CRB 15000-5/0.95 Cleaning agent: Isopropanol
Clean the mounting surface with isopropanol. Flange sealant: Loctite 574
Apply flange sealant to the corner of the lower
arm mounting surface, as pointed out in the figure.
xx2000001973
xx2000001970
5 Secure the upper arm to the lower arm with all Hex socket head cap flange screw:
attachment screws but two. M4x25 12.9 Lafre
Pre-tighten the screws crosswise firstly. 2C2B/FC6.9+PrO-COat111 (16 pcs)
xx2000001969
6 Remove the guide pins and fasten the remaining Hex socket head cap flange screw:
two screws. M4x25 12.9 Lafre
2C2B/FC6.9+PrO-COat111 (16 pcs)
xx2000001967
Action Note
8 Refit the cable bracket with the four screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs).
Tightening torque: 0.8 Nm
xx2000001966
Action Note
1 Secure the cabling with the cable tie. Cable ties
xx2000001965
2 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (1 pcs).
Tightening torque: 0.8 Nm
xx2000001964
Action Note
1 Connect the connectors to each other and snap
them to the cable holders.
xx2000001938
xx2000001937
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-044
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000001955
xx2000001954
2 Refit the inner covers with four screws each. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (8 pcs)
Tightening torque: 1.4 Nm.
xx2000001947
xx2000001930
Action Note
3 Snap the lower arm cover into place. Hex socket head cap screw: M3x16
12.9 Lafre 2C2B/FC6.9 (4 pcs)
4 Secure the cover with four screws.
Tightening torque: 0.45 Nm.
xx2000001929
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-075
Replace if damaged. O-ring: 3HAC061327-044
Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2300000832
xx2300000831
Action Note
2 Refit the inner covers with eight screws each. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (8 pcs) x 2
Tightening torque: 1.4 Nm.
xx2300000813
xx2300000830
3 Snap the lower arm cover into place. Hex socket head cap screw: M3x12
12.9 Lafre 2C2B/FC6.9 (3 pcs) x 2
4 Secure the cover with three screws.
Tightening torque: 1.4 Nm.
xx2300000812
xx2300000829
Concluding procedure
Action Note
1 Calibrate the axis-3 joint unit torque sensor. See Calibration on page 1063
Action Note
2
DANGER
xx2100000052
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the CRB 15000 via myABB Business Portal,
www.abb.com/myABB.
Required consumables
Action Note
1 Jog the robot to the specified position: Example of CRB 15000-5/0.95,
• Axis 1: No significance. similar to CRB 15000-10/1.52 and
• Axis 2: 0° CRB 15000-12/1.27.
• Axis 3: 0°
• Axis 4: 0°
• Axis 5: +90°
• Axis 6: No significance.
xx2100000005
2
CAUTION
Action Note
1
CAUTION
xx2000002021
Action Note
3
CAUTION
xx2000002022
xx2000002023
Action Note
1
CAUTION
xx2300000833
Action Note
3
CAUTION
xx2300000834
Action Note
1 Cut the cable ties.
xx2000002066
xx2000001945
Action Note
3 Snap loose and disconnect the connectors:
• J4/5.DC+
• J4/5.DC-
• J4/5.CS
• J4/5.CP
xx2000002067
xx2000002120
Action Note
1 Remove the cover by removing the four screws.
xx2000002075
Action Note
2 Remove the inner plate by removing the screws.
xx2000002076
Action Note
1 Cut the cable tie. Valid for CRB 15000-5/0.95
xx2000002077
xx2300000839
Action Note
2 Remove the cable bracket by removing the two Valid for CRB 15000-5/0.95
screws.
xx2000002078
xx2300000840
3 Remove two attachment screws and fit two guide Guide pin, M3x110: 3HAC077787-
pins to the axis-4 joint unit. 001
Always use guide pins in pairs.
xx2000002079
xx2000002080
Action Note
4 Remove the remaining attachment screws.
xx2000002081
xx2000002127
xx2100000006
xx2000002082
Action Note
1 Remove the cover screws.
xx2000002083
2
CAUTION
xx2000002084
xx2000002085
Action Note
1 Valid for CRB 15000-5/0.95
Remove the cover by removing the six screws.
Dispose the screws. New screws must be used
when refitting the cover.
New screws are included in the spare part delivery
of the joint unit.
xx2000002123
xx2300000841
Action Note
1 Cut the cable ties on joint unit.
xx2000002086
Action Note
2 Cut the cable ties on tubular, if needed. Valid for CRB 15000-5/0.95
xx2000002124
xx2300000842
xx2300000843
xx2000002087
xx2000002089
Action Note
6 Disconnect the connectors that belongs to the Tweezers
axis-5 cabling, from the axis-4 drive board:
• D3/4.X2
• D3/4.DC-
• D3/4.DC+
Use tweezers, if needed.
xx2000002125
7 Pull out the cabling carefully from the tubular. Valid for CRB 15000-5/0.95
xx2000002126
xx2300000844
Action Note
1 Disconnect the connectors from the drive board. Tweezers
CAUTION
xx2000002088
Action Note
1 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC077789-001
sensor side. Screws: M3x12 (4 pcs)
CAUTION
xx2000002090
xx2000002091
3 Fit two guide pins to the axis-4 joint unit. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
For joint units on axes 4, 5 and 6.
xx2000002578
xx2100000326
xx2100000327
Action Note
6 Remove the joint unit from the tubular.
CAUTION
xx2000001957
Action Note
1 Remove two attachment screws and fit two guide Guide pin, M3x110: 3HAC077787-
pins to the axis-5 joint unit. 001
Always use guide pins in pairs.
xx2000002128
xx2000002129
xx2000002130
Action Note
3 Press the tilt out of position using two of the pre-
vious attachment screws as removal tools.
4 Remove the tilt from the tubular.
Assist the cabling to be removed while lifting away
the complete tilt.
Place the tilt on a workbench.
xx2000002131
Action Note
1 Replace the tubular. Tubular: 3HAC074509-001 (for
CRB 15000-5/0.95)
Tubular: 3HAC083685-001 (for
CRB 15000-10/1.52)
Tubular: 3HAC081054-001 (for
CRB 15000-12/1.27)
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
Action Note
2 Clean the mounting surface of the joint unit and Cleaning agent: Isopropanol
the mating surface on the casting with isopropan- Flange sealant: Loctite 574
ol.
Joint unit mounting surface is pointed out in the
figure.
3 Apply a thin layer of flange sealant to the mount-
ing surface. Do not contaminate the radial sealing
with sealant.
CAUTION xx2000001860
Action Note
1
CAUTION
2 Fit the lifting aid to the joint unit. Joint unit: 3HAC079143-001 (for
CRB 15000-5/0.95) / 3HAC087546-
CAUTION 001 (for CRB 15000-10/1.52 and
CRB 15000-12/1.27)
The connectors and the joint unit cables are Lifting aid: 3HAC077789-001
sensitive to mechanical damage. Handle the as- Screws: M3x12 (4 pcs)
sembly with care.
xx2000001957
Action Note
3 Fit two guide pins to the joint unit. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
For joint units on axes 4, 5 and 6.
xx2000002438
CAUTION
5 Secure the joint unit with new attachment screws. Flange socket head screw with
glue: 3HAB3413-330
M3x30 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue , 12 pcs
Always use new screws when refit-
ting a joint unit. If ordering a new
joint unit spare part, new screws
are included.
xx2100000326
xx2000002091
Action Note
8 Torque tighten all screws crosswise. Tightening torque: 1.4 Nm (for CRB
15000-5/0.95) / 1.9 Nm (for CRB
15000-10/1.52 and CRB 15000-
12/1.27)
9 Remove the lifting aid by removing the screws.
xx2000002090
Action Note
1 Reconnect the connectors to the drive board.
• D4/5.X1 to X1
• D4/5.X4 to X4
• D4/5.X5 to X5
xx2000002088
Action Note
1 Fit two guide pins to the axis-5 joint. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
xx2000002146
Action Note
2 Clean the mounting surface with isopropanol. Cleaning agent: Isopropanol
Apply flange sealant to the corner of the tubular Flange sealant: Loctite 574
mounting surface, as pointed out in the figure.
xx2000002147
xx2000002131
5 Secure the tilt to the tubular with all attachment Flange socket head screw: M3x20
screws but two. 12.9 Lafre 2C2B/FC6.9+PrO-
Pre-tighten the screws crosswise firstly. COat111 (14 pcs)
xx2000002130
6 Remove the guide pins and fasten the remaining Flange socket head screw: M3x20
two screws. 12.9 Lafre 2C2B/FC6.9+PrO-
COat111 (2 pcs)
xx2000002128
Action Note
1 Insert the cabling into the tubular. Valid for CRB 15000-5/0.95
xx2000002148
xx2300000845
xx2000002125
xx2000002089
Action Note
4 Secure the cables for functional earth and protect- Hex socket head cap screw: M3x6
ive earth with a screw. (1 pcs).
Tightening torque: 0.8 Nm.
xx2000002087
5 Secure the cabling to joint unit with cable ties. Cable ties (3 pcs)
xx2000002086
6 Secure the cabling to tubular with cable ties. Cable ties (2 pcs)
Valid for CRB 15000-5/0.95
xx2000002124
xx2300000842
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-043
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000002149
2 Refit the cover with new attachment screws. Flange socket head screw with
glue: 3HAB3413-312
M3x12 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue
For tubular cover of CRB 15000-
5/0.95.
Always use new screws.
If ordering a new axis-4 or axis-5
joint unit spare part, new screws
for the tubular cover are included.
Tightening torque: 1.6 Nm.
xx2000002123
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-076
Replace if damaged. O-ring: 3HAB3772-166
Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2300000846
xx2300000847
2 Refit the covers with new attachment screws. Hex socket head cap screw:
3HAB3409-224
M3x12 12.9 Lafre 2C2B/FC6.9 (3
pcs)
Tightening torque: 1.4 Nm.
xx2000002123
Action Note
1 Fit the o-ring to its groove. Valid for CRB 15000-5/0.95
Replace if damaged. O-ring: 3HAC061327-051
xx2000002092
xx2300000848
xx2000002085
xx2000002084
Action Note
4 Refit the cover with the four screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.2 Nm (for CRB
15000-5/0.95) / 0.9 Nm (for CRB
15000-10/1.52 and CRB 15000-
12/1.27)
Tightening torque: 0.9 Nm
xx2000002083
Action Note
1 Fit two guide pins to the axis-4 joint. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
xx2000002093
xx2000002094
Action Note
3 Lift the tubular into mounting position while insert-
ing the cabling into the housing.
4 Slide the tubular into place on the guide pins.
xx2000002082
5 Secure the tubular to the housing with all attach- Flange socket head screw: M3x20
ment screws but two. 12.9 Lafre 2C2B/FC6.9+PrO-
Pre-tighten the screws crosswise firstly. COat111
xx2000002081
6 Remove the guide pins and fasten the remaining Flange socket head screw: M3x20
two screws. 12.9 Lafre 2C2B/FC6.9+PrO-
COat111
xx2000002079
Action Note
8 Refit the cable bracket with the two screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs).
Tightening torque: 0.8 Nm
Valid for CRB 15000-5/0.95
xx2000002078
xx2300000840
xx2000002077
xx2300000839
Action Note
1 Check the inner plate gasket. Gasket: 3HAC075056-001
Replace if damaged.
xx2000002095
2 Refit the inner plate with the screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs).
Tightening torque: 1.4 Nm
xx2000002076
3 Refit the cover with the four screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs).
Tightening torque: 0.45 Nm
xx2000002075
Action Note
1 Reconnect the connectors to the drive board.
• D3/4.DC+ to DC+
• D3/4.DC- to Ground
• D3/4.X2 to X2
xx2000002120
xx2000002067
3 Secure the cables for functional earth and protect- Hex socket head cap screw: M3x6
ive earth with a screw. (1 pcs).
Tightening torque: 0.8 Nm.
xx2000001945
Action Note
4 Secure the cabling with cable ties. Cable ties (3 pcs)
xx2000002066
Action Note
1 Fit the o-ring to its groove. O-ring: 3HAC061327-047
Replace if damaged.
xx2000001962
xx2000002023
Action Note
3 For robots with RobotWare earlier than 7.10 Cable ties
Secure the brake release cable with a cable tie.
xx2000002022
4 Refit the cover with the four screws. Hex socket head cap screw: M3x30
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm
xx2000002021
Action Note
1 Refit the insert. Insert: 3HAC084002-001
Hex socket head cap screw: M3x10
12.9 Lafre 2C2B/FC6.9 (3 pcs)
Tightening torque: 1.4 Nm
xx2300000834
Action Note
2 Fit the o-ring to its groove. O-ring: 3HAC061327-047
Replace if damaged.
xx2300000835
3 Refit the cover with the four screws. Hex socket head cap screw: M3x30
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 1.4 Nm
xx2300000833
Concluding procedure
Action Note
1 Calibrate the axis-4 joint unit torque sensor. See Calibration on page 1063
2
DANGER
xx2100000053
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the CRB 15000 via myABB Business Portal,
www.abb.com/myABB.
Required consumables
Action Note
1 Jog the robot to the synchronization position.
Action Note
2
CAUTION
Action Note
1 Valid for CRB 15000-5/0.95
Remove the cover by removing the six screws.
Dispose the screws. New screws must be used
when refitting the cover.
New screws are included in the spare part delivery
of the joint unit.
xx2000002123
xx2300000841
Action Note
1 Remove the cover screws.
xx2000002083
2
CAUTION
Action Note
3 For robots with RobotWare earlier than 7.10
Open the cover and cut the cable tie that holds
the brake release cable.
xx2000002084
xx2000002085
Action Note
1 Cut the cable ties on joint unit.
xx2000002086
Action Note
2 Cut the cable ties on tubular, if needed. Valid for CRB 15000-5/0.95
xx2000002124
xx2300000842
xx2300000843
xx2000002087
xx2000002089
Action Note
6 Disconnect the connectors that belongs to the Tweezers
axis-5 cabling, from the axis-4 drive board:
• D3/4.X2
• D3/4.DC-
• D3/4.DC+
Use tweezers, if needed.
xx2000002125
7 Pull out the cabling carefully from the tubular. Valid for CRB 15000-5/0.95
xx2000002126
xx2300000844
Action Note
1 Remove two attachment screws and fit two guide Guide pin, M3x110: 3HAC077787-
pins to the axis-5 joint unit. 001
Always use guide pins in pairs.
xx2000002128
xx2000002129
xx2000002130
xx2000002131
Action Note
1 Remove the tool flange screws and washers.
xx2000002155
2
CAUTION
xx2000002157
xx2000002158
Action Note
1 Remove the functional earth cable by removing
the screw.
xx2000002159
Action Note
1 Remove the tool flange adapter screws.
xx2000002165
xx2000002166
xx2000002167
Action Note
1
CAUTION
2
CAUTION
xx2000002550
xx2100000335
Action Note
1 Cut the cable ties.
xx2000002161
Action Note
2 Remove the functional and protective earth cables
by removing the screw.
xx2000002162
xx2000002163
CAUTION
xx2000002164
Action Note
1 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC077789-001
sensor side. Screws: M3x12 (4 pcs)
CAUTION
xx2000002168
xx2000002170
xx2100000328
Action Note
4 Remove the remaining attachment screws.
Use two screws as press out screws in the upcom-
ing step, then dispose all screws.
New screws are included in the spare part delivery
of the joint unit.
xx2100000329
xx2100000330
CAUTION
xx2000002169
xx2000001957
Action Note
1 Remove the cover by removing the four screws.
xx2000002132
2
CAUTION
xx2000002133
xx2000002134
Action Note
1 Cut the cable ties.
xx2000002135
xx2000002136
xx2000002137
CAUTION
Action Note
1 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC077789-001
sensor side. Screws: M3x12 (4 pcs)
CAUTION
xx2000002139
xx2000002140
xx2100000284
4 Fit two guide pins to the axis-5 joint unit. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
For joint units on axes 4, 5 and 6.
xx2100000332
xx2100000333
Action Note
6 Press the joint unit out of position using two of
the previous attachment screws as removal tools.
xx2100000334
CAUTION
xx2000001957
Action Note
1 Replace the writ unit. Wrist housing: 3HAC073951-001
(for CRB 15000-5/0.95) /
3HAC073951-001 (for CRB 15000-
10/1.52 and CRB 15000-12/1.27)
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
Action Note
2 Clean the mounting surface of the joint unit and Cleaning agent: Isopropanol
the mating surface on the casting with isopropan- Flange sealant: Loctite 574
ol.
Joint unit mounting surface is pointed out in the
figure.
3 Apply a thin layer of flange sealant to the mount-
ing surface. Do not contaminate the radial sealing
with sealant.
CAUTION xx2000001860
Action Note
1
CAUTION
2 Fit the lifting aid to the joint unit. Joint unit: 3HAC079143-001 (for
CRB 15000-5/0.95) / 3HAC087546-
CAUTION 001 (for CRB 15000-10/1.52 and
CRB 15000-12/1.27)
The connectors and the joint unit cables are Lifting aid: 3HAC077789-001
sensitive to mechanical damage. Handle the as- Screws: M3x12 (4 pcs)
sembly with care.
xx2000001957
Action Note
3 Fit two guide pins to the joint unit. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
For joint units on axes 4, 5 and 6.
xx2000002438
4 Fit the transition cable between axis-5 and axis-6 Cable harness, transition joint-5
joint units into the tilt. and joint-6: 3HAC083726-001
xx2100000040
Action Note
5 Place the cabling at the slot before refitting the
joint unit.
xx2100000041
xx2100000285
6 Fit the joint unit to the tilt, aligning the pin with the
pin hole.
CAUTION
Action Note
7 Secure the joint unit with new attachment screws. Flange socket head screw with
glue: 3HAB3413-330
M3x30 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue , 12 pcs
Used for joint unit of CRB 15000-
5/0.95.
Always use new screws when refit-
ting a joint unit. If ordering a new
joint unit spare part, new screws
are included.
xx2100000333
xx2000002140
xx2000002139
Action Note
1 Reconnect the connectors to the drive board.
• D4/5.X1 to X1
• D5.DC+ to +DC
• D5.DC- to Ground
• D4/5.X4 to X4
• D5/4.X2 to X2
• D4/5.X5 to X5
xx2000002138
xx2000002137
3 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000002136
Action Note
4 Secure the cabling with cable ties. Cable ties (3 pcs)
xx2000002135
Action Note
1 Fit the o-ring to its groove. Valid for CRB 15000-5/0.95
Replace if damaged. O-ring: 3HAC061327-051
xx2000001962
xx2300000849
Action Note
2 For robots with RobotWare earlier than 7.10
Place the cover at mounting position and recon-
nect the brake release connector DR.X8 to the
drive board.
xx2000002134
xx2000002133
4 Refit the cover with the four screws. Valid for CRB 15000-5/0.95
Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.2 Nm
Valid for CRB 15000-10/1.52 and
CRB 15000-12/1.27
Hex socket head cap screw: M3x12
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 1.4 Nm
xx2000002132
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Clean the mounting surface of the joint unit and Cleaning agent: Isopropanol
the mating surface on the casting with isopropan- Flange sealant: Loctite 574
ol.
Joint unit mounting surface is pointed out in the
figure.
3 Apply a thin layer of flange sealant to the mount-
ing surface. Do not contaminate the radial sealing
with sealant.
CAUTION xx2000001860
Action Note
1
CAUTION
Action Note
2 Fit the lifting aid to the joint unit. Joint unit: 3HAC079143-001 (for
CRB 15000-5/0.95) / 3HAC087546-
CAUTION 001 (for CRB 15000-10/1.52 and
CRB 15000-12/1.27)
The connectors and the joint unit cables are Lifting aid: 3HAC077789-001
sensitive to mechanical damage. Handle the as- Screws: M3x12 (4 pcs)
sembly with care.
xx2000001957
3 Fit two guide pins to the joint unit. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
For joint units on axes 4, 5 and 6.
xx2000002438
xx2100000041
Action Note
5 Fit the joint unit to the tilt, aligning the pin with the
pin hole.
CAUTION
xx2000002195
6 Secure the joint unit with new attachment screws. Flange socket head screw with
glue: 3HAB3413-330
M3x30 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue , 12 pcs
Used for joint unit of CRB 15000-
5/0.95.
Always use new screws when refit-
ting a joint unit. If ordering a new
joint unit spare part, new screws
are included.
xx2100000329
xx2000002170
Action Note
10 Remove the lifting aid by removing the screws.
xx2000002168
Action Note
1 Reconnect the connectors to the drive board.
• D6.X1 to X1
• D6.DC+ to +DC
• D6.DC- to Ground
• D6.X4 to X4
• D6.X2 to X2
• D6.X5 to X5
xx2000002164
xx2000002163
Action Note
3 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000002162
xx2000002161
Action Note
1 Fit the o-ring to its groove. O-ring: 3HAC061327-051
Replace if damaged.
xx2000002551
Action Note
2 Place the arm-side interface at mounting position
and reconnect the connectors.
• ASI.DC+
• ASI.DC-
• ASI.X1
The correct orientation of the arm-side interface
is with the convex button in upper position.
Note
xx2100000336
3 Refit the arm-side interface with four screws. Valid for CRB 15000-5/0.95
Hex socket head cap screw: M3x30
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm
Valid for CRB 15000-10/1.52 and
CRB 15000-12/1.27
Hex socket head cap screw: M3x20
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm
xx2000002550
Action Note
1 Clean the mounting surface with isopropanol. Cleaning agent: Isopropanol
Apply flange sealant to the corner of the adapter Flange sealant: Loctite 574
mounting surface, as pointed out in the figure.
xx2000002196
2 Refit the tool flange adapter, aligning the pin with Axis-6 inner flange: 3HAC073952-
the pin hole. 001
xx2000002167
xx2000002165
Action Note
1 Secure the cable for functional earth to the tool
flange adapter with a screw.
xx2000002159
Action Note
1 Check the o-ring on the tool flange and lubricate Axis-6 flange: 3HAC073953-001
with grease. O-ring: 3HAB3772-182
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000002197
xx2000002158
Action Note
3 Fit the connectors to the cable bracket and secure Cable ties (2 pcs)
the connectors with two cable ties.
xx2000002157
4 Refit and secure the tool flange with screws and Hex socket head cap screw: M3x12
washers. 12.9 Lafre 2C2B/FC6.9 (10 pcs)
Spring washer: 7x3.2x0.6 Steel (10
pcs)
Tightening torque: 1.8 Nm.
xx2000002155
Action Note
1 Fit two guide pins to the axis-5 joint. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
xx2000002146
Action Note
2 Clean the mounting surface with isopropanol. Cleaning agent: Isopropanol
Apply flange sealant to the corner of the tubular Flange sealant: Loctite 574
mounting surface, as pointed out in the figure.
xx2000002147
xx2000002131
5 Secure the tilt to the tubular with all attachment Flange socket head screw: M3x20
screws but two. 12.9 Lafre 2C2B/FC6.9+PrO-
Pre-tighten the screws crosswise firstly. COat111 (14 pcs)
xx2000002130
6 Remove the guide pins and fasten the remaining Flange socket head screw: M3x20
two screws. 12.9 Lafre 2C2B/FC6.9+PrO-
COat111 (2 pcs)
xx2000002128
Action Note
1 Insert the cabling into the tubular. Valid for CRB 15000-5/0.95
xx2000002148
xx2300000845
xx2000002125
xx2000002089
Action Note
4 Secure the cables for functional earth and protect- Hex socket head cap screw: M3x6
ive earth with a screw. (1 pcs).
Tightening torque: 0.8 Nm.
xx2000002087
5 Secure the cabling to joint unit with cable ties. Cable ties (3 pcs)
xx2000002086
6 Secure the cabling to tubular with cable ties. Cable ties (2 pcs)
Valid for CRB 15000-5/0.95
xx2000002124
xx2300000842
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-043
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000002149
2 Refit the cover with new attachment screws. Flange socket head screw with
glue: 3HAB3413-312
M3x12 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue
For tubular cover of CRB 15000-
5/0.95.
Always use new screws.
If ordering a new axis-4 or axis-5
joint unit spare part, new screws
for the tubular cover are included.
Tightening torque: 1.6 Nm.
xx2000002123
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-076
Replace if damaged. O-ring: 3HAB3772-166
Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2300000846
xx2300000847
2 Refit the covers with new attachment screws. Hex socket head cap screw:
3HAB3409-224
M3x12 12.9 Lafre 2C2B/FC6.9 (3
pcs)
Tightening torque: 1.4 Nm.
xx2000002123
Concluding procedure
Action Note
1 Calibrate the axis-5 and axis-6 joint unit torque See Calibration on page 1063
sensor.
2
DANGER
xx2100000054
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the CRB 15000 via myABB Business Portal,
www.abb.com/myABB.
Required consumables
Action Note
1 Decide which calibration routine to use, and take
actions accordingly prior to beginning the repair
procedure.
2 Jog the robot to the specified position:
• Axis 1: No significance.
• Axis 2: No significance.
• Axis 3: No significance.
• Axis 4: No significance.
• Axis 5: No significance.
• Axis 6: 0°
3
CAUTION
Action Note
1 Remove the tool flange screws and washers.
xx2000002155
2
CAUTION
xx2000002157
xx2000002158
Action Note
1 Remove the functional earth cable by removing
the screw.
xx2000002159
Action Note
1 Remove the tool flange adapter screws.
xx2000002165
xx2000002166
xx2000002167
Action Note
1 Clean the mounting surface with isopropanol. Cleaning agent: Isopropanol
Apply flange sealant to the corner of the adapter Flange sealant: Loctite 574
mounting surface, as pointed out in the figure.
xx2000002196
2 Refit the tool flange adapter, aligning the pin with Axis-6 inner flange: 3HAC073952-
the pin hole. 001
xx2000002167
xx2000002165
Action Note
1 Secure the cable for functional earth to the tool
flange adapter with a screw.
xx2000002159
Action Note
1 Check the o-ring on the tool flange and lubricate Axis-6 flange: 3HAC073953-001
with grease. O-ring: 3HAB3772-182
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000002197
xx2000002158
Action Note
3 Fit the connectors to the cable bracket and secure Cable ties (2 pcs)
the connectors with two cable ties.
xx2000002157
4 Refit and secure the tool flange with screws and Hex socket head cap screw: M3x12
washers. 12.9 Lafre 2C2B/FC6.9 (10 pcs)
Spring washer: 7x3.2x0.6 Steel (10
pcs)
Tightening torque: 1.8 Nm.
xx2000002155
Concluding procedure
Action Note
1
DANGER
xx2000002549
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the CRB 15000 via myABB Business Portal,
www.abb.com/myABB.
Required consumables
Action Note
1 Jog the robot to a position where the arm side in-
terface is easily accessed.
2
CAUTION
Action Note
1
CAUTION
2
CAUTION
xx2000002550
xx2100000335
Action Note
1 Fit the o-ring to its groove. O-ring: 3HAC061327-051
Replace if damaged.
xx2000002551
Note
xx2100000336
Action Note
3 Refit the arm-side interface with four screws. Valid for CRB 15000-5/0.95
Hex socket head cap screw: M3x30
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm
Valid for CRB 15000-10/1.52 and
CRB 15000-12/1.27
Hex socket head cap screw: M3x20
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm
xx2000002550
Concluding procedure
Action Note
1
DANGER
xx2100000422
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the CRB 15000 via myABB Business Portal,
www.abb.com/myABB.
Required consumables
Action Note
1 Jog the robot to the specified position:
• Axis 1: 0°
• Axis 2: 0°
• Axis 3: +60°
• Axis 4: 0°
• Axis 5: -90°
• Axis 6: No significance.
CAUTION
xx2100000044
2
CAUTION
Action Note
1
CAUTION
xx2000001929
xx2100000267
xx2000001930
Disconnecting the cabling between the lower arm and the swing
Action Note
1 Remove the functional earth cable by removing
the screw.
xx2000001936
xx2000001937
xx2000001938
Action Note
1 Remove the cable bracket by removing the four
screws.
xx2000001939
2 Secure the weight of the upper and lower arm. Suggestion with lifting sling and an
overhead crane.
CAUTION Example of CRB 15000-5/0.95,
similar to CRB 15000-10/1.52 and
The weight of the complete upper and lower arm CRB 15000-12/1.27.
together is 18 kg
xx2100000294
Action Note
3 Remove two attachment screws and fit two guide Guide pin, M4x120: 3HAC077786-
pins to the axis-2 joint unit. 001
Always use guide pins in pairs.
CAUTION
xx2000001951
xx2000001960
CAUTION
xx2000002151
Action Note
6 Remove the complete arm system from the swing.
xx2000001941
xx2000002432
Action Note
1
CAUTION
xx2000001935
Action Note
3
CAUTION
xx2000001931
xx2000001932
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
Action Note
2 Cut the cable ties.
xx2000001946
xx2000001945
xx2000001944
CAUTION
Action Note
1 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC077788-001
sensor side. Screws: M4x35 (4 pcs)
CAUTION
xx2000001956
xx2100000295
3 Fit two guide pins to the axis-2 joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
For joint units on axes 1, 2 and 3
of CRB 15000-5/0.95 and axis 3 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2000002433
xx2000001943
Action Note
5 Put the cabling at the slot in order not to squeeze
it during removal of joint unit.
xx2100000045
xx2000002434
CAUTION
xx2000001957
Action Note
1 Remove the swing attachment screws.
CAUTION
xx2000001987
CAUTION
xx2000002152
CAUTION
Action Note
1 Loosen the base from the foundation by removing
the attachment screws and washers.
xx2000002006
Action Note
2 Tilt the base on to its side and remove the bottom
cover by removing the attachment screws.
xx2000002007
Action Note
1 Cut the cable ties.
xx2000002012
xx2000002011
xx2000002010
Action Note
4 Disconnect the connectors from the drive board.
• D1.X1 from X1
• D1.DC+ from DC+
• D1.DC- from ground
• D1.X4 from X4
• D1.X2 from X2
• D1.X5 from X5
• DR.X8 from X8
CAUTION
Action Note
1 Fit the lifting aid to the joint unit. Lifting aid: 3HAC077788-001
Screws: M4x35 (4 pcs)
CAUTION
xx2000001994
xx2100000296
Action Note
3 Fit two guide pins to the axis-1 joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
For joint units on axes 1, 2 and 3
of CRB 15000-5/0.95 and axis 3 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2000002435
xx2000002008
xx2000002436
CAUTION
xx2000002014
Action Note
7 Remove the lifting aid and guide pins.
xx2000001957
Action Note
1 Remove the attachment screws.
xx2100000406
xx2100000407
Action Note
1 Remove the brake release unit by removing the
screws.
xx2100000413
Action Note
1 Jog the robot to the specified position: Valid for CRB 15000-10/1.52
• Axis 1: 0°
• Axis 2: 0°
• Axis 3: +60°
• Axis 4: 0°
• Axis 5: -90°
• Axis 6: No significance.
CAUTION
xx2300001062
xx2300001063
2
CAUTION
Action Note
1
CAUTION
xx2300000812
xx2300000813
Disconnecting the cabling between the lower arm and the swing
Action Note
1 Remove the functional earth cable by removing
the screw.
xx2000001936
Action Note
2 Cut the cable ties.
xx2000001937
xx2000001938
Action Note
1 Remove the cable bracket by removing the four
screws.
xx2000001939
Action Note
2 Secure the weight of the upper and lower arm. Suggestion with lifting sling and an
overhead crane.
CAUTION Example of CRB 15000-5/0.95,
similar to CRB 15000-10/1.52 and
The weight of the complete upper and lower arm CRB 15000-12/1.27.
together is up to 26 kg
xx2100000294
Action Note
3 Remove two attachment screws and fit two guide Guide pin, M5x125: 3HAC087786-
pins to the axis-2 joint unit. 001
Always use guide pins in pairs.
CAUTION
xx2000001951
xx2000001960
CAUTION
xx2000002151
Action Note
6 Remove the complete arm system from the swing.
xx2000001941
xx2000002432
Action Note
1
CAUTION
xx2300000814
Action Note
3
CAUTION
xx2300000815
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2000001946
Action Note
3 Remove the functional and protective earth cables
by removing the screw.
xx2000001945
xx2000001944
CAUTION
Action Note
1
CAUTION
2
WARNING
Action Note
3 Loosen the robot base from the foundation by
removing the foundation attachment screws.
xx2300001060
CAUTION
Action Note
1 Removing the attachment screws.
xx2300000786
Action Note
2 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC087787-001
sensor side. Screws: M5x30 (4 pcs for plate and
2 pcs for beam)
CAUTION
xx2300000787
xx2300000788
xx2300000789
CAUTION
xx2300000790
Action Note
5 Remove the lifting aid.
xx2300000778
xx2300000776
Action Note
1 Lift the base to standing and secure it to the Attachment screws: M10x35 8.8 (4
foundation with the attachment screws and pcs).
washers. Washers: 23/10.5/2.5 mm Steel (4 pcs).
Tightening torque: 32 Nm ±10%.
xx2300001060
Action Note
1 Valid for CRB 15000-10/1.52
Remove the swing transition.
xx2300000817
xx2300000818
CAUTION
xx2000001987
Action Note
4 Use two fully threaded attachment screws as re- Valid for CRB 15000-10/1.52
moval tools to press the swing out of position.
CAUTION
xx2000002152
CAUTION
Action Note
1 Loosen the base from the foundation by removing
the attachment screws and washers.
xx2300001060
Action Note
2 Tilt the base on to its side and remove the bottom
cover by removing the attachment screws.
xx2300000760
Action Note
1 Cut the cable ties.
xx2000002012
xx2000002011
xx2000002010
Action Note
4 Disconnect the connectors from the drive board.
• D1.X1 from X1
• D1.DC+ from DC+
• D1.DC- from ground
• D1.X4 from X4
• D1.X2 from X2
• D1.X5 from X5
• DR.X8 from X8
CAUTION
Action Note
1 Removing the attachment screws.
xx2300000770
Action Note
2 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC087787-001
sensor side. Screws: M5x30 (4 pcs for plate and
2 pcs for beam)
CAUTION
xx2300000771
xx2300000772
xx2300000773
CAUTION
xx2300000774
Action Note
5 Remove the lifting aid.
xx2300000778
xx2300000776
Action Note
1 Remove the attachment screws.
xx2100000406
xx2100000407
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAB3772-119
Replace if damaged. Grease: 3HAC031695-001
Harmonic Grease 4B No.2
Used to lubricate the seals.
xx2100000423
2 Refit the brake release unit to the new base with Base: 3HAC073922-001
the screws. Screws: M3x5 12.9 Lafre
2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm.
xx2100000413
Action Note
1 Insert the cabling into the base.
xx2100000408
Action Note
2 Orient the base connector so that it points to the
right, seen from back of the robot.
xx2100000409
3 Secure the base connector with the attachment Hex socket head cap screw: M3x8
screws. 12.9 Lafre 2C2B/FC6.9 (4 pcs).
Tightening torque: 0.8 Nm.
xx2100000406
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
Action Note
2 Clean the mounting surface of the joint unit and Cleaning agent: Isopropanol
the mating surface on the casting with isopropan- Flange sealant: Loctite 574
ol.
Joint unit mounting surface is pointed out in the
figure.
3 Apply a thin layer of flange sealant to the mount-
ing surface. Do not contaminate the radial sealing
with sealant.
CAUTION xx2000001860
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Fit the lifting aid to the joint unit. Joint unit: 3HAC079141-001
Lifting aid: 3HAC077788-001
CAUTION Screws: M4x35 (4 pcs)
xx2000001957
Action Note
3 Fit two guide pins to the joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
For joint units on axes 1, 2 and 3
of CRB 15000-5/0.95 and axis 3 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2000002438
4 Fit the joint unit to the base, aligning the pin with
the pin hole.
CAUTION
5 Secure the joint unit with new attachment screws. Flange socket head screw with
glue: 3HAB3413-435
M4x35 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue , 12 pcs
Used for joint unit of CRB 15000-
5/0.95.
Always use new screws when refit-
ting a joint unit. If ordering a new
joint unit spare part, new screws
are included.
xx2000002008
Action Note
6 Remove the guide pins and secure the remaining
two attachment screws.
xx2100000296
xx2000001994
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2000002009
Action Note
3 Connect the connectors to each other and snap
them to the cable holders.
• J1.DC+ to J1.DC+
• J1.DC- to J1.DC-
• J1.CS to J1.CS
• J1.CP to J1.CP
xx2000002010
4 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000002011
xx2000002012
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAB3772-64
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000002016
2 Refit the bottom cover with the attachment screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (8 pcs)
Note Tightening torque: 1.2 Nm.
xx2000002007
xx2100000268
Action Note
1 Lift the base to standing and secure it to the Attachment screws: M10x35 8.8 (4
foundation with the attachment screws and pcs).
washers. Washers: 23/10.5/2.5 mm Steel (4
pcs).
Tightening torque: 32 Nm ±10%.
xx2000002006
Action Note
1 Clean the mounting surface with isopropanol. Cleaning agent: Isopropanol
Apply flange sealant to the corner of the base Flange sealant: Loctite 574
mounting surface, as pointed out in the figure.
xx2000001990
Action Note
3 Refit the swing to the base unit, aligning the pin
with the pin hole.
CAUTION
xx2000001989
4 Secure the swing with the attachment screws. Hex socket head cap flange screw:
Pre-tighten the screws crosswise firstly. M4x25 12.9 Lafre
2C2B/FC6.9+PrO-COat111 (16 pcs)
CAUTION
xx2000001987
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
Action Note
2 Clean the mounting surface of the joint unit and Cleaning agent: Isopropanol
the mating surface on the casting with isopropan- Flange sealant: Loctite 574
ol.
Joint unit mounting surface is pointed out in the
figure.
3 Apply a thin layer of flange sealant to the mount-
ing surface. Do not contaminate the radial sealing
with sealant.
CAUTION xx2000001860
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Fit the lifting aid to the joint unit. Joint unit: 3HAC079141-001
Lifting aid: 3HAC077788-001
CAUTION Screws: M4x35 (4 pcs)
xx2000001957
Action Note
3 Fit two guide pins to the joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
For joint units on axes 1, 2 and 3
of CRB 15000-5/0.95 and axis 3 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2000002438
CAUTION
xx2000002153
5 Fit the joint unit to the swing, aligning the pin with
the pin hole.
CAUTION
xx2000001959
The connectors and the joint unit cables are
sensitive to mechanical damage. Handle the as-
sembly with care.
xx2000001961
Action Note
6 Secure the joint unit with new attachment screws. Flange socket head screw with
glue: 3HAB3413-435
M4x35 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue , 12 pcs
Used for joint unit of CRB 15000-
5/0.95.
Always use new screws when refit-
ting a joint unit. If ordering a new
joint unit spare part, new screws
are included.
xx2000001943
xx2100000295
xx2000001956
Action Note
1 Fit two guide pins to the axis-2 joint unit. Guide pin, M4x120: 3HAC077786-
001
xx2000001949
2 Remove any old residuals of flange sealant from Cleaning agent: Isopropanol
the lower arm mounting surface and clean with Flange sealant: Loctite 574
isopropanol.
Apply new flange sealant to the corner of the
lower arm mounting surface, as pointed out in the
figure.
xx2000001963
3
CAUTION
xx2000001941
Action Note
5 Secure the lower arm to the swing with all attach- Hex socket head cap flange screw:
ment screws but two. M4x25 12.9 Lafre
Pre-tighten the screws crosswise firstly. 2C2B/FC6.9+PrO-COat111 (16 pcs)
CAUTION
xx2000001940
6 Remove the guide pins and fasten the remaining Hex socket head cap flange screw:
two screws. M4x25 12.9 Lafre
2C2B/FC6.9+PrO-COat111 (16 pcs)
CAUTION
xx2000001951
xx2000001939
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2000002013
xx2000001944
4 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000001945
Action Note
5 Secure the cabling with cable ties. Cable ties (3 pcs)
xx2000001946
Action Note
1 Connect the connectors to each other and snap
them to the cable holders.
xx2000001938
xx2000001937
Action Note
3 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (1 pcs).
Tightening torque: 0.8 Nm
xx2000001936
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-044
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000001954
2 Refit the inner cover with four screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 1.4 Nm.
xx2000001930
Action Note
3 Snap the lower arm cover into place. Hex socket head cap screw: M3x16
12.9 Lafre 2C2B/FC6.9 (4 pcs)
4 Secure the cover with four screws.
Tightening torque: 0.45 Nm.
xx2000001929
Action Note
1 Fit the o-ring to cover groove. O-ring: 3HAC061327-047 (for CRB
Replace if damaged. 15000-5/0.95)
xx2000001962
xx2000001932
Action Note
3 For robots with RobotWare earlier than 7.10 Cable ties
Secure the brake release cable with a cable tie.
xx2000001931
4 Refit the cover with the four screws. Hex socket head cap screw: M3x30
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm
xx2000001935
Concluding procedure
Action Note
1 Calibrate the joint unit torque sensor for the axis-1 See Calibration on page 1063
and axis-2 joint units.
2
DANGER
Action Note
1 Insert the cabling into the base.
xx2100000408
xx2100000409
3 Secure the base connector with the attachment Hex socket head cap screw: M3x8
screws. 12.9 Lafre 2C2B/FC6.9 (4 pcs).
Tightening torque: 0.8 Nm.
xx2100000406
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2300000823
3 Fit two guide pins to the base. Guide pin, M5x125: 3HAC087786-
001
Always use guide pins in pairs.
For joint units on axes 1 and 2 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2300000775
Action Note
4 Fit the lifting aid to the joint unit, aligning the pin Joint unit: 3HAC087472-001
with the pin hole. Lifting aid: 3HAC087787-001
Screws: M5x30 (4 pcs for plate and
CAUTION 2 pcs for beam)
xx2300000778
xx2300000777
xx2300000776
5 Fit the joint unit to the base, aligning the pin with
the pin hole.
CAUTION
xx2300000779
xx2300000780
Action Note
6 Check the joint unit position by placing the lower
boss of one semicircular block between the lifting
aid and base.
The joint unit is properly placed when no gaps
between the block and both lifting aid and base
xx2300000781
xx2300000782
xx2300000783
xx2300000784
Action Note
10 Secure the joint unit with the remaining attach- Hex socket head cap screw:
ment screws. 3HAB3409-20
xx2300000785
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2000002009
Action Note
3 Connect the connectors to each other and snap
them to the cable holders.
• J1.DC+ to J1.DC+
• J1.DC- to J1.DC-
• J1.CS to J1.CS
• J1.CP to J1.CP
xx2000002010
4 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000002011
xx2000002012
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. 3HAC061327-072
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000002016
2 Refit the bottom cover with the attachment screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (8 pcs)
Note Tightening torque: 1.4 Nm.
xx2300000760
Action Note
1 Lift the base to standing and secure it to the Attachment screws: M10x35 8.8 (4
foundation with the attachment screws and pcs).
washers. Washers: 23/10.5/2.5 mm Steel (4
pcs).
Tightening torque: 32 Nm ±10%.
xx2000002006
Action Note
1 Fit two guide pins on the base unit for position Valid for CRB 15000-10/1.52
guidance. Guide pin, M5x75, 3HAC087786-
Always use guide pins in pairs. 002
Valid for CRB 15000-12/1.27
Guide pin, M5x125: 3HAC087786-
001
2 Refit the swing to the base unit, aligning the pin Example of CRB 15000-12/1.27,
with the pin hole. similar to CRB 15000-10/1.52.
CAUTION
xx2000001989
Action Note
3 Secure the swing with the attachment screws. Hex socket head cap screw: M5x30
12.9 Lafre 2C2B/FC6.9 (16 pcs)
CAUTION Tightening torque: 8.2 Nm
Valid for CRB 15000-12/1.27
Do not mix the flange screws used for CRB 15000-
5/0.95 and the threaded screws used for CRB
15000-10/1.52 and CRB 15000-12/1.27. Always
use washers together with the threaded screws
for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Illustration is for reference only.
xx2000001987
xx2300000819
xx2300000821
5 Valid for CRB 15000-10/1.52 Hex socket head cap screw: M5x25
Refit the swing flange with the attachment screws. 12.9 Lafre 2C2B/FC6.9 (16 pcs)
Always check the serial number printed on the Tightening torque: 8.2 Nm
swing parts and use the parts in the same number
for refitting.
CAUTION
xx2300000818
Action Note
6 Valid for CRB 15000-10/1.52 Guide pin, M5x75, 3HAC087786-
Fit two guide pins on the swing flange for position 002
guidance.
Always use guide pins in pairs.
7 Valid for CRB 15000-10/1.52
Refit the swing transition to the swing flange,
aligning the pin with the pin hole.
Always check the serial number printed on the
swing parts and use the parts in the same number
for refitting.
xx2300000820
8 Valid for CRB 15000-10/1.52 Hex socket head cap screw: M5x25
Secure the swing transition with the attachment 12.9 Lafre 2C2B/FC6.9 (16 pcs)
screws. Tightening torque: 8.2 Nm
CAUTION
xx2300000817
Action Note
1
CAUTION
2
WARNING
xx2300001060
Action Note
4 Lay the robot down with the torque sensor side
upwards on a working bench. Do not damage
the base socket. Caution with the cabling.
CAUTION
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2300000823
3 Fit two guide pins to the swing. Guide pin, M5x125: 3HAC087786-
001
Always use guide pins in pairs.
For joint units on axes 1 and 2 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2300000791
Action Note
4 Fit the lifting aid to the joint unit, aligning the pin Joint unit: 3HAC087472-001
with the pin hole. Lifting aid: 3HAC087787-001
Screws: M5x30 (4 pcs for plate and
CAUTION 2 pcs for beam)
xx2300000778
xx2300000777
xx2300000776
CAUTION
Action Note
6 Fit the joint unit to the swing, aligning the pin with
the pin hole.
CAUTION
xx2300000792
xx2300000780
xx2300000794
xx2300000795
Action Note
9 Secure with four attachment screws and pre-
tighten the screws crosswise.
xx2300000796
xx2300000797
11 Secure the joint unit with the remaining attach- Hex socket head cap screw:
ment screws. 3HAB3409-20
xx2300000798
Action Note
1 Lift the base to standing and secure it to the Attachment screws: M10x35 8.8 (4
foundation with the attachment screws and pcs).
washers. Washers: 23/10.5/2.5 mm Steel (4 pcs).
Tightening torque: 32 Nm ±10%.
xx2300001060
Refitting the lower and upper arm assembled (-10/1.52 and -12/1.27)
Action Note
1 Fit three guide pins to the axis-2 joint unit. Guide pin, M5x125: 3HAC087786-
001
xx2300001021
2
CAUTION
Action Note
3 Lift the upper and lower arm assembly to mount- Example of CRB 15000-5/0.95,
ing position and slide it onto the guide pins. similar to CRB 15000-10/1.52 and
CRB 15000-12/1.27.
xx2000001941
4 Secure the lower arm to the swing with all screws Hex socket head cap screw: M5x30
and washers but two. 12.9 Lafre 2C2B/FC6.9, 16 pcs
Pre-tighten the screws crosswise firstly.
CAUTION
5 Remove the guide pins and fasten the remaining Hex socket head cap screw: M5x30
two screws and washers. 12.9 Lafre 2C2B/FC6.9, 16 pcs
CAUTION
xx2300001023
Action Note
7 Refit the cable bracket with four screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs).
Tightening torque: 0.8 Nm
xx2000001939
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2000002013
xx2000001944
Action Note
4 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000001945
xx2000001946
Action Note
1 Connect the connectors to each other and snap
them to the cable holders.
xx2000001938
Action Note
2 Secure the cabling with cable ties. Cable ties (3 pcs)
xx2000001937
3 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (1 pcs).
Tightening torque: 0.8 Nm
xx2000001936
Action Note
1
CAUTION
xx2300000812
Action Note
3 Remove the lower inner cover by removing the
screws.
xx2300000813
Action Note
1 Refit the insert. Insert: 3HAC084002-001
Hex socket head cap screw: M3x10
12.9 Lafre 2C2B/FC6.9 (3 pcs)
Tightening torque: 1.4 Nm
xx2300000815
xx2300000816
3 Refit the cover with the four screws. Hex socket head cap screw: M3x12
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 1.4 Nm
xx2300000814
Concluding procedure
Action Note
1 Calibrate the joint unit torque sensor for the axis-1 See Calibration on page 1063
and axis-2 joint units.
2
DANGER
xx2000001986
xx2300000766
xx2300000769
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the CRB 15000 via myABB Business Portal,
www.abb.com/myABB.
Required consumables
Action Note
1 Jog the robot to the specified position:
• Axis 1: 0°
• Axis 2: 0° (home position)
• Axis 3: +60°
• Axis 4: 0°
• Axis 5: -90°
• Axis 6: No significance.
CAUTION
xx2100000044
2
DANGER
Action Note
1
CAUTION
Action Note
2 Remove the four lower arm cover screws.
xx2000001929
xx2100000267
xx2000001930
Disconnecting the cabling between the lower arm and the swing
Action Note
1 Remove the functional earth cable by removing
the screw.
xx2000001936
xx2000001937
xx2000001938
Action Note
1 Remove the cable bracket by removing the four
screws.
xx2000001939
2 Secure the weight of the upper and lower arm. Suggestion with lifting sling and an
overhead crane.
CAUTION Example of CRB 15000-5/0.95,
similar to CRB 15000-10/1.52 and
The weight of the complete upper and lower arm CRB 15000-12/1.27.
together is 18 kg
xx2100000294
Action Note
3 Remove two attachment screws and fit two guide Guide pin, M4x120: 3HAC077786-
pins to the axis-2 joint unit. 001
Always use guide pins in pairs.
CAUTION
xx2000001951
xx2000001960
CAUTION
xx2000002151
Action Note
6 Remove the complete arm system from the swing.
xx2000001941
xx2000002432
Action Note
1
CAUTION
xx2000001935
Action Note
3
CAUTION
xx2000001931
xx2000001932
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
Action Note
2 Cut the cable ties.
xx2000001946
xx2000001945
xx2000001944
CAUTION
Action Note
1 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC077788-001
sensor side. Screws: M4x35 (4 pcs)
CAUTION
xx2000001956
xx2100000295
3 Fit two guide pins to the axis-2 joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
For joint units on axes 1, 2 and 3
of CRB 15000-5/0.95 and axis 3 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2000002433
xx2000001943
Action Note
5 Put the cabling at the slot in order not to squeeze
it during removal of joint unit.
xx2100000045
xx2000002434
CAUTION
xx2000001957
Action Note
1 Remove the swing attachment screws.
CAUTION
xx2000001987
CAUTION
xx2000002152
CAUTION
Action Note
1 Jog the robot to the specified position: Valid for CRB 15000-10/1.52
• Axis 1: 0°
• Axis 2: 0° (home position)
• Axis 3: +60°
• Axis 4: 0°
• Axis 5: -90°
• Axis 6: No significance.
CAUTION
xx2300001062
xx2300001063
2
DANGER
Action Note
1
CAUTION
xx2300000812
xx2300000813
Disconnecting the cabling between the lower arm and the swing
Action Note
1 Remove the functional earth cable by removing
the screw.
xx2000001936
Action Note
2 Cut the cable ties.
xx2000001937
xx2000001938
Action Note
1 Remove the cable bracket by removing the four
screws.
xx2000001939
Action Note
2 Secure the weight of the upper and lower arm. Suggestion with lifting sling and an
overhead crane.
CAUTION Example of CRB 15000-5/0.95,
similar to CRB 15000-10/1.52 and
The weight of the complete upper and lower arm CRB 15000-12/1.27.
together is up to 26 kg
xx2100000294
Action Note
3 Remove two attachment screws and fit two guide Guide pin, M5x125: 3HAC087786-
pins to the axis-2 joint unit. 001
Always use guide pins in pairs.
CAUTION
xx2000001951
xx2000001960
CAUTION
xx2000002151
Action Note
6 Remove the complete arm system from the swing.
xx2000001941
xx2000002432
Action Note
1
CAUTION
xx2300000814
Action Note
3
CAUTION
xx2300000815
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2000001946
Action Note
3 Remove the functional and protective earth cables
by removing the screw.
xx2000001945
xx2000001944
CAUTION
Action Note
1
CAUTION
2
WARNING
Action Note
3 Loosen the robot base from the foundation by
removing the foundation attachment screws.
xx2300001060
CAUTION
Action Note
1 Removing the attachment screws.
xx2300000786
Action Note
2 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC087787-001
sensor side. Screws: M5x30 (4 pcs for plate and
2 pcs for beam)
CAUTION
xx2300000787
xx2300000788
xx2300000789
CAUTION
xx2300000790
Action Note
5 Remove the lifting aid.
xx2300000778
xx2300000776
Action Note
1 Lift the base to standing and secure it to the Attachment screws: M10x35 8.8 (4
foundation with the attachment screws and pcs).
washers. Washers: 23/10.5/2.5 mm Steel (4 pcs).
Tightening torque: 32 Nm ±10%.
xx2300001060
Action Note
1 Valid for CRB 15000-10/1.52
Remove the swing transition.
xx2300000817
xx2300000818
CAUTION
xx2000001987
Action Note
4 Use two fully threaded attachment screws as re- Valid for CRB 15000-10/1.52
moval tools to press the swing out of position.
CAUTION
xx2000002152
CAUTION
Action Note
1 Clean the mounting surface with isopropanol. Cleaning agent: Isopropanol
Apply flange sealant to the corner of the base Flange sealant: Loctite 574
mounting surface, as pointed out in the figure.
xx2000001990
Action Note
2 Separate the new swing parts by removing the
pre-assembling screws.
3 Refit the swing to the base unit, aligning the pin
with the pin hole.
CAUTION
xx2000001989
4 Secure the swing with the attachment screws. Hex socket head cap flange screw:
Pre-tighten the screws crosswise firstly. M4x25 12.9 Lafre
2C2B/FC6.9+PrO-COat111 (16 pcs)
CAUTION
xx2000001987
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
Action Note
2 Clean the mounting surface of the joint unit and Cleaning agent: Isopropanol
the mating surface on the casting with isopropan- Flange sealant: Loctite 574
ol.
Joint unit mounting surface is pointed out in the
figure.
3 Apply a thin layer of flange sealant to the mount-
ing surface. Do not contaminate the radial sealing
with sealant.
CAUTION xx2000001860
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Fit the lifting aid to the joint unit. Joint unit: 3HAC079141-001
Lifting aid: 3HAC077788-001
CAUTION Screws: M4x35 (4 pcs)
xx2000001957
Action Note
3 Fit two guide pins to the joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
For joint units on axes 1, 2 and 3
of CRB 15000-5/0.95 and axis 3 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2000002438
CAUTION
xx2000002153
5 Fit the joint unit to the swing, aligning the pin with
the pin hole.
CAUTION
xx2000001959
The connectors and the joint unit cables are
sensitive to mechanical damage. Handle the as-
sembly with care.
xx2000001961
Action Note
6 Secure the joint unit with new attachment screws. Flange socket head screw with
glue: 3HAB3413-435
M4x35 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue , 12 pcs
Used for joint unit of CRB 15000-
5/0.95.
Always use new screws when refit-
ting a joint unit. If ordering a new
joint unit spare part, new screws
are included.
xx2000001943
xx2100000295
xx2000001956
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2000002013
xx2000001944
4 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000001945
Action Note
5 Secure the cabling with cable ties. Cable ties (3 pcs)
xx2000001946
Action Note
1 Fit the o-ring to cover groove. O-ring: 3HAC061327-047 (for CRB
Replace if damaged. 15000-5/0.95)
xx2000001962
xx2000001932
Action Note
3 For robots with RobotWare earlier than 7.10 Cable ties
Secure the brake release cable with a cable tie.
xx2000001931
4 Refit the cover with the four screws. Hex socket head cap screw: M3x30
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm
xx2000001935
Action Note
1 Fit two guide pins to the axis-2 joint unit. Guide pin, M4x120: 3HAC077786-
001
xx2000001949
Action Note
2 Remove any old residuals of flange sealant from Cleaning agent: Isopropanol
the lower arm mounting surface and clean with Flange sealant: Loctite 574
isopropanol.
Apply new flange sealant to the corner of the
lower arm mounting surface, as pointed out in the
figure.
xx2000001963
3
CAUTION
xx2000001941
5 Secure the lower arm to the swing with all attach- Hex socket head cap flange screw:
ment screws but two. M4x25 12.9 Lafre
Pre-tighten the screws crosswise firstly. 2C2B/FC6.9+PrO-COat111 (16 pcs)
CAUTION
xx2000001940
Action Note
6 Remove the guide pins and fasten the remaining Hex socket head cap flange screw:
two screws. M4x25 12.9 Lafre
2C2B/FC6.9+PrO-COat111 (16 pcs)
CAUTION
xx2000001951
xx2000001939
Action Note
1 Connect the connectors to each other and snap
them to the cable holders.
xx2000001938
Action Note
2 Secure the cabling with cable ties. Cable ties (3 pcs)
xx2000001937
3 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (1 pcs).
Tightening torque: 0.8 Nm
xx2000001936
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-044
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000001954
Action Note
2 Refit the inner cover with four screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 1.4 Nm.
xx2000001930
3 Snap the lower arm cover into place. Hex socket head cap screw: M3x16
12.9 Lafre 2C2B/FC6.9 (4 pcs)
4 Secure the cover with four screws.
Tightening torque: 0.45 Nm.
xx2000001929
Concluding procedure
Action Note
1 Calibrate the joint unit torque sensor for the axis-2 See Calibration on page 1063
joint unit.
2
DANGER
Action Note
1 Fit two guide pins on the base unit for position Valid for CRB 15000-10/1.52
guidance. Guide pin, M5x75, 3HAC087786-
Always use guide pins in pairs. 002
Valid for CRB 15000-12/1.27
Guide pin, M5x125: 3HAC087786-
001
2 Refit the swing to the base unit, aligning the pin Example of CRB 15000-12/1.27,
with the pin hole. similar to CRB 15000-10/1.52.
CAUTION
xx2000001989
Action Note
3 Secure the swing with the attachment screws. Hex socket head cap screw: M5x30
12.9 Lafre 2C2B/FC6.9 (16 pcs)
CAUTION Tightening torque: 8.2 Nm
Valid for CRB 15000-12/1.27
Do not mix the flange screws used for CRB 15000-
5/0.95 and the threaded screws used for CRB
15000-10/1.52 and CRB 15000-12/1.27. Always
use washers together with the threaded screws
for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Illustration is for reference only.
xx2000001987
xx2300000819
xx2300000821
5 Valid for CRB 15000-10/1.52 Hex socket head cap screw: M5x25
Refit the swing flange with the attachment screws. 12.9 Lafre 2C2B/FC6.9 (16 pcs)
Always check the serial number printed on the Tightening torque: 8.2 Nm
swing parts and use the parts in the same number
for refitting.
CAUTION
xx2300000818
Action Note
6 Valid for CRB 15000-10/1.52 Guide pin, M5x75, 3HAC087786-
Fit two guide pins on the swing flange for position 002
guidance.
Always use guide pins in pairs.
7 Valid for CRB 15000-10/1.52
Refit the swing transition to the swing flange,
aligning the pin with the pin hole.
Always check the serial number printed on the
swing parts and use the parts in the same number
for refitting.
xx2300000820
8 Valid for CRB 15000-10/1.52 Hex socket head cap screw: M5x25
Secure the swing transition with the attachment 12.9 Lafre 2C2B/FC6.9 (16 pcs)
screws. Tightening torque: 8.2 Nm
CAUTION
xx2300000817
Action Note
1
CAUTION
2
WARNING
xx2300001060
Action Note
4 Lay the robot down with the side that axis-2
torque sensor will be upwards on a working
bench. Do not damage the base socket. Cau-
tion with the cabling.
CAUTION
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2300000823
3 Fit two guide pins to the swing. Guide pin, M5x125: 3HAC087786-
001
Always use guide pins in pairs.
For joint units on axes 1 and 2 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2300000791
Action Note
4 Fit the lifting aid to the joint unit, aligning the pin Joint unit: 3HAC087472-001
with the pin hole. Lifting aid: 3HAC087787-001
Screws: M5x30 (4 pcs for plate and
CAUTION 2 pcs for beam)
xx2300000778
xx2300000777
xx2300000776
CAUTION
Action Note
6 Fit the joint unit to the swing, aligning the pin with
the pin hole.
CAUTION
xx2300000792
xx2300000780
xx2300000794
xx2300000795
Action Note
9 Secure with four attachment screws and pre-
tighten the screws crosswise.
xx2300000796
xx2300000797
11 Secure the joint unit with the remaining attach- Hex socket head cap screw:
ment screws. 3HAB3409-20
xx2300000798
Action Note
1 Lift the base to standing and secure it to the Attachment screws: M10x35 8.8 (4
foundation with the attachment screws and pcs).
washers. Washers: 23/10.5/2.5 mm Steel (4 pcs).
Tightening torque: 32 Nm ±10%.
xx2300001060
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2000002013
xx2000001944
Action Note
4 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000001945
xx2000001946
Action Note
1 Refit the insert. Insert: 3HAC084002-001
Hex socket head cap screw: M3x10
12.9 Lafre 2C2B/FC6.9 (3 pcs)
Tightening torque: 1.4 Nm
xx2300000815
Action Note
2 Fit the o-ring to cover groove. O-ring: 3HAC061327-074 (for CRB
Replace if damaged. 15000-10/1.52 and CRB 15000-
12/1.27)
xx2300000816
3 Refit the cover with the four screws. Hex socket head cap screw: M3x12
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 1.4 Nm
xx2300000814
Refitting the lower and upper arm assembled (-10/1.52 and -12/1.27)
Action Note
1 Fit three guide pins to the axis-2 joint unit. Guide pin, M5x125: 3HAC087786-
001
xx2300001021
2
CAUTION
Action Note
3 Lift the upper and lower arm assembly to mount- Example of CRB 15000-5/0.95,
ing position and slide it onto the guide pins. similar to CRB 15000-10/1.52 and
CRB 15000-12/1.27.
xx2000001941
4 Secure the lower arm to the swing with all screws Hex socket head cap screw: M5x30
and washers but two. 12.9 Lafre 2C2B/FC6.9, 16 pcs
Pre-tighten the screws crosswise firstly.
CAUTION
5 Remove the guide pins and fasten the remaining Hex socket head cap screw: M5x30
two screws and washers. 12.9 Lafre 2C2B/FC6.9, 16 pcs
CAUTION
xx2300001023
Action Note
7 Refit the cable bracket with four screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs).
Tightening torque: 0.8 Nm
xx2000001939
Action Note
1 Connect the connectors to each other and snap
them to the cable holders.
xx2000001938
xx2000001937
Action Note
3 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (1 pcs).
Tightening torque: 0.8 Nm
xx2000001936
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-075
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000001954
2 Refit the inner cover with four screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 1.4 Nm.
xx2300000813
Action Note
3 Refit the lower cover of lower arm with three Lower arm cover, lower: Lower
screws. arm, used for CRB 15000-10/1.52
and CRB 15000-12/1.27.
Tightening torque: 1.4 Nm.
xx2300000812
Concluding procedure
Action Note
1 Calibrate the joint unit torque sensor for the axis-2 See Calibration on page 1063
joint unit.
2
DANGER
xx2000002018
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the CRB 15000 via myABB Business Portal,
www.abb.com/myABB.
Required consumables
Action Note
1 Jog the robot to the specified position:
• Axis 1: 0° (home position)
• Axis 2: 0°
• Axis 3: +60°
• Axis 4: 0°
• Axis 5: -90°
• Axis 6: No significance.
CAUTION
xx2100000044
2
CAUTION
Action Note
1
CAUTION
Action Note
2 Remove the four lower arm cover screws.
xx2000001929
xx2100000267
xx2000001930
Disconnecting the cabling between the lower arm and the swing
Action Note
1 Remove the functional earth cable by removing
the screw.
xx2000001936
xx2000001937
xx2000001938
Action Note
1 Remove the cable bracket by removing the four
screws.
xx2000001939
2 Secure the weight of the upper and lower arm. Suggestion with lifting sling and an
overhead crane.
CAUTION Example of CRB 15000-5/0.95,
similar to CRB 15000-10/1.52 and
The weight of the complete upper and lower arm CRB 15000-12/1.27.
together is 18 kg
xx2100000294
Action Note
3 Remove two attachment screws and fit two guide Guide pin, M4x120: 3HAC077786-
pins to the axis-2 joint unit. 001
Always use guide pins in pairs.
CAUTION
xx2000001951
xx2000001960
CAUTION
xx2000002151
Action Note
6 Remove the complete arm system from the swing.
xx2000001941
xx2000002432
Action Note
1
CAUTION
xx2000001935
Action Note
3
CAUTION
xx2000001931
xx2000001932
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
Action Note
2 Cut the cable ties.
xx2000001946
xx2000001945
xx2000001944
CAUTION
Action Note
1 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC077788-001
sensor side. Screws: M4x35 (4 pcs)
CAUTION
xx2000001956
xx2100000295
3 Fit two guide pins to the axis-2 joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
For joint units on axes 1, 2 and 3
of CRB 15000-5/0.95 and axis 3 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2000002433
xx2000001943
Action Note
5 Put the cabling at the slot in order not to squeeze
it during removal of joint unit.
xx2100000045
xx2000002434
CAUTION
xx2000001957
Action Note
1 Remove the swing attachment screws.
CAUTION
xx2000001987
CAUTION
xx2000002152
CAUTION
Action Note
1 Loosen the base from the foundation by removing
the attachment screws and washers.
xx2000002006
Action Note
2 Tilt the base on to its side and remove the bottom
cover by removing the attachment screws.
xx2000002007
Action Note
1 Cut the cable ties.
xx2000002012
xx2000002011
xx2000002010
Action Note
4 Disconnect the connectors from the drive board.
• D1.X1 from X1
• D1.DC+ from DC+
• D1.DC- from ground
• D1.X4 from X4
• D1.X2 from X2
• D1.X5 from X5
• DR.X8 from X8
CAUTION
Action Note
1 Fit the lifting aid to the joint unit. Lifting aid: 3HAC077788-001
Screws: M4x35 (4 pcs)
CAUTION
xx2000001994
xx2100000296
Action Note
3 Fit two guide pins to the axis-1 joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
For joint units on axes 1, 2 and 3
of CRB 15000-5/0.95 and axis 3 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2000002435
xx2000002008
xx2000002436
CAUTION
xx2000002014
Action Note
7 Remove the lifting aid and guide pins.
xx2000001957
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
Tip 10/1.52 and CRB 15000-12/1.27)
xx2000002057
xx2000002058
Action Note
4 Remove the protection plate.
xx2100000301
xx2000002055
xx2000002053
xx2000002049
Action Note
8 Remove the joint cable from the hollow shaft from
the torque sensor side.
CAUTION
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
CAUTION
xx2000002051
Action Note
4 Secure the cable plate to the joint unit with the Hex socket head cap screw:
attachment screws. M2.5x6 12.9 Lafre 2C2B/FC6.9 (4
pcs)
Tightening torque: 0.45 Nm.
xx2000002049
xx2000002053
xx2000002056
xx2000002055
Action Note
7 Keep the cabling loose, making sure not to twist
or strain it.
Use the cable tie to pre-fix the cable by hand.
xx2100000507
8 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
10/1.52 and CRB 15000-12/1.27)
xx2000002057
Action Note
9 Secure the cables to the cable support with a Cable tie: 3HAC075545-001. For
cable tie, using a cable tie gun. securing joint unit cable.
Assembly direction for the cable tie is shown in Cable tie gun EVO 7i
the figure. Settiing for cable tie gun: 6.75.
xx2000002058
xx2000002059
xx2100000301
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Clean the mounting surface of the joint unit and Cleaning agent: Isopropanol
the mating surface on the casting with isopropan- Flange sealant: Loctite 574
ol.
Joint unit mounting surface is pointed out in the
figure.
3 Apply a thin layer of flange sealant to the mount-
ing surface. Do not contaminate the radial sealing
with sealant.
CAUTION xx2000001860
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Fit the lifting aid to the joint unit. Joint unit: 3HAC079141-001
Lifting aid: 3HAC077788-001
CAUTION Screws: M4x35 (4 pcs)
xx2000001957
Action Note
3 Fit two guide pins to the joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
For joint units on axes 1, 2 and 3
of CRB 15000-5/0.95 and axis 3 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2000002438
4 Fit the joint unit to the base, aligning the pin with
the pin hole.
CAUTION
5 Secure the joint unit with new attachment screws. Flange socket head screw with
glue: 3HAB3413-435
M4x35 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue , 12 pcs
Used for joint unit of CRB 15000-
5/0.95.
Always use new screws when refit-
ting a joint unit. If ordering a new
joint unit spare part, new screws
are included.
xx2000002008
Action Note
6 Remove the guide pins and secure the remaining
two attachment screws.
xx2100000296
xx2000001994
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2000002009
Action Note
3 Connect the connectors to each other and snap
them to the cable holders.
• J1.DC+ to J1.DC+
• J1.DC- to J1.DC-
• J1.CS to J1.CS
• J1.CP to J1.CP
xx2000002010
4 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000002011
xx2000002012
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAB3772-64
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000002016
2 Refit the bottom cover with the attachment screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (8 pcs)
Note Tightening torque: 1.2 Nm.
xx2000002007
xx2100000268
Action Note
1 Lift the base to standing and secure it to the Attachment screws: M10x35 8.8 (4
foundation with the attachment screws and pcs).
washers. Washers: 23/10.5/2.5 mm Steel (4
pcs).
Tightening torque: 32 Nm ±10%.
xx2000002006
Action Note
1 Clean the mounting surface with isopropanol. Cleaning agent: Isopropanol
Apply flange sealant to the corner of the base Flange sealant: Loctite 574
mounting surface, as pointed out in the figure.
xx2000001990
Action Note
3 Refit the swing to the base unit, aligning the pin
with the pin hole.
CAUTION
xx2000001989
4 Secure the swing with the attachment screws. Hex socket head cap flange screw:
Pre-tighten the screws crosswise firstly. M4x25 12.9 Lafre
2C2B/FC6.9+PrO-COat111 (16 pcs)
CAUTION
xx2000001987
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
Action Note
2 Clean the mounting surface of the joint unit and Cleaning agent: Isopropanol
the mating surface on the casting with isopropan- Flange sealant: Loctite 574
ol.
Joint unit mounting surface is pointed out in the
figure.
3 Apply a thin layer of flange sealant to the mount-
ing surface. Do not contaminate the radial sealing
with sealant.
CAUTION xx2000001860
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Fit the lifting aid to the joint unit. Joint unit: 3HAC079141-001
Lifting aid: 3HAC077788-001
CAUTION Screws: M4x35 (4 pcs)
xx2000001957
Action Note
3 Fit two guide pins to the joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
For joint units on axes 1, 2 and 3
of CRB 15000-5/0.95 and axis 3 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2000002438
CAUTION
xx2000002153
5 Fit the joint unit to the swing, aligning the pin with
the pin hole.
CAUTION
xx2000001959
The connectors and the joint unit cables are
sensitive to mechanical damage. Handle the as-
sembly with care.
xx2000001961
Action Note
6 Secure the joint unit with new attachment screws. Flange socket head screw with
glue: 3HAB3413-435
M4x35 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue , 12 pcs
Used for joint unit of CRB 15000-
5/0.95.
Always use new screws when refit-
ting a joint unit. If ordering a new
joint unit spare part, new screws
are included.
xx2000001943
xx2100000295
xx2000001956
Action Note
1 Fit two guide pins to the axis-2 joint unit. Guide pin, M4x120: 3HAC077786-
001
xx2000001949
2 Remove any old residuals of flange sealant from Cleaning agent: Isopropanol
the lower arm mounting surface and clean with Flange sealant: Loctite 574
isopropanol.
Apply new flange sealant to the corner of the
lower arm mounting surface, as pointed out in the
figure.
xx2000001963
3
CAUTION
xx2000001941
Action Note
5 Secure the lower arm to the swing with all attach- Hex socket head cap flange screw:
ment screws but two. M4x25 12.9 Lafre
Pre-tighten the screws crosswise firstly. 2C2B/FC6.9+PrO-COat111 (16 pcs)
CAUTION
xx2000001940
6 Remove the guide pins and fasten the remaining Hex socket head cap flange screw:
two screws. M4x25 12.9 Lafre
2C2B/FC6.9+PrO-COat111 (16 pcs)
CAUTION
xx2000001951
xx2000001939
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2000002013
xx2000001944
4 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000001945
Action Note
5 Secure the cabling with cable ties. Cable ties (3 pcs)
xx2000001946
Action Note
1 Connect the connectors to each other and snap
them to the cable holders.
xx2000001938
xx2000001937
Action Note
3 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (1 pcs).
Tightening torque: 0.8 Nm
xx2000001936
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-044
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000001954
2 Refit the inner cover with four screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 1.4 Nm.
xx2000001930
Action Note
3 Snap the lower arm cover into place. Hex socket head cap screw: M3x16
12.9 Lafre 2C2B/FC6.9 (4 pcs)
4 Secure the cover with four screws.
Tightening torque: 0.45 Nm.
xx2000001929
Action Note
1 Fit the o-ring to cover groove. O-ring: 3HAC061327-047 (for CRB
Replace if damaged. 15000-5/0.95)
xx2000001962
xx2000001932
Action Note
3 For robots with RobotWare earlier than 7.10 Cable ties
Secure the brake release cable with a cable tie.
xx2000001931
4 Refit the cover with the four screws. Hex socket head cap screw: M3x30
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm
xx2000001935
Concluding procedure
Action Note
1 Calibrate the joint unit torque sensor. See Calibration on page 1063
1 On the FlexPendant, go to the Code app
and call the calibration procedure using PP
to Routine, not by using Call Routine.
2 Select the Joint Unit Replacement feature
and then select the axis to calibrate.
3 The controller is now restarted. Once the
home screen of the FlexPendant is shown,
press the Play button to continue the calib-
ration routine.
4 The robot moves to a position or positions
where measurements are performed.
5 The results of the measurements are
presented together with the current values
in the controller. Choose whether to save
the calibration data or not.
6 If new calibration data is saved you will be
asked to do a test with the lead-through
functionality active to verify that the
sensors work correctly.
7 Finally the robot is moved back to the ori-
ginal position.
8 Test the brake release (movement without
drive power) functionality, see Testing the
brake release functionality on page 196.
2
DANGER
5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27)
xx2300000764
xx2300000767
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the CRB 15000 via myABB Business Portal,
www.abb.com/myABB.
Required consumables
Action Note
1 Jog the robot to the specified position: Valid for CRB 15000-10/1.52
• Axis 1: 0° (home position)
• Axis 2: 0°
• Axis 3: +60°
• Axis 4: 0°
• Axis 5: -90°
• Axis 6: No significance.
CAUTION
xx2300001062
xx2300001063
2
CAUTION
Action Note
1
CAUTION
xx2300000812
xx2300000813
Disconnecting the cabling between the lower arm and the swing
Action Note
1 Remove the functional earth cable by removing
the screw.
xx2000001936
Action Note
2 Cut the cable ties.
xx2000001937
xx2000001938
Action Note
1 Remove the cable bracket by removing the four
screws.
xx2000001939
Action Note
2 Secure the weight of the upper and lower arm. Suggestion with lifting sling and an
overhead crane.
CAUTION Example of CRB 15000-5/0.95,
similar to CRB 15000-10/1.52 and
The weight of the complete upper and lower arm CRB 15000-12/1.27.
together is up to 26 kg
xx2100000294
Action Note
3 Remove two attachment screws and fit two guide Guide pin, M5x125: 3HAC087786-
pins to the axis-2 joint unit. 001
Always use guide pins in pairs.
CAUTION
xx2000001951
xx2000001960
CAUTION
xx2000002151
Action Note
6 Remove the complete arm system from the swing.
xx2000001941
xx2000002432
Action Note
1
CAUTION
xx2300000814
Action Note
3
CAUTION
xx2300000815
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2000001946
Action Note
3 Remove the functional and protective earth cables
by removing the screw.
xx2000001945
xx2000001944
CAUTION
Action Note
1
CAUTION
2
WARNING
Action Note
3 Loosen the robot base from the foundation by
removing the foundation attachment screws.
xx2300001060
CAUTION
Action Note
1 Removing the attachment screws.
xx2300000786
Action Note
2 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC087787-001
sensor side. Screws: M5x30 (4 pcs for plate and
2 pcs for beam)
CAUTION
xx2300000787
xx2300000788
xx2300000789
CAUTION
xx2300000790
Action Note
5 Remove the lifting aid.
xx2300000778
xx2300000776
Action Note
1 Lift the base to standing and secure it to the Attachment screws: M10x35 8.8 (4
foundation with the attachment screws and pcs).
washers. Washers: 23/10.5/2.5 mm Steel (4 pcs).
Tightening torque: 32 Nm ±10%.
xx2300001060
Action Note
1 Valid for CRB 15000-10/1.52
Remove the swing transition.
xx2300000817
xx2300000818
CAUTION
xx2000001987
Action Note
4 Use two fully threaded attachment screws as re- Valid for CRB 15000-10/1.52
moval tools to press the swing out of position.
CAUTION
xx2000002152
CAUTION
Action Note
1 Loosen the base from the foundation by removing
the attachment screws and washers.
xx2300001060
Action Note
2 Tilt the base on to its side and remove the bottom
cover by removing the attachment screws.
xx2300000760
Action Note
1 Cut the cable ties.
xx2000002012
xx2000002011
xx2000002010
Action Note
4 Disconnect the connectors from the drive board.
• D1.X1 from X1
• D1.DC+ from DC+
• D1.DC- from ground
• D1.X4 from X4
• D1.X2 from X2
• D1.X5 from X5
• DR.X8 from X8
CAUTION
Action Note
1 Removing the attachment screws.
xx2300000770
Action Note
2 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC087787-001
sensor side. Screws: M5x30 (4 pcs for plate and
2 pcs for beam)
CAUTION
xx2300000771
xx2300000772
xx2300000773
CAUTION
xx2300000774
Action Note
5 Remove the lifting aid.
xx2300000778
xx2300000776
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
Tip 10/1.52 and CRB 15000-12/1.27)
xx2000002057
Action Note
3 Cut the cable tie at the drive board.
xx2000002058
xx2100000301
xx2000002055
xx2000002053
Action Note
7 Remove the cable plate by removing the attach-
ment screws.
xx2000002049
CAUTION
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
CAUTION
xx2000002051
Action Note
4 Secure the cable plate to the joint unit with the Hex socket head cap screw:
attachment screws. M2.5x6 12.9 Lafre 2C2B/FC6.9 (4
pcs)
Tightening torque: 0.45 Nm.
xx2000002049
xx2000002053
xx2000002056
xx2000002055
Action Note
7 Keep the cabling loose, making sure not to twist
or strain it.
Use the cable tie to pre-fix the cable by hand.
xx2100000507
8 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
10/1.52 and CRB 15000-12/1.27)
xx2000002057
Action Note
9 Secure the cables to the cable support with a Cable tie: 3HAC075545-001. For
cable tie, using a cable tie gun. securing joint unit cable.
Assembly direction for the cable tie is shown in Cable tie gun EVO 7i
the figure. Settiing for cable tie gun: 6.75.
xx2000002058
xx2000002059
xx2100000301
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2300000823
3 Fit two guide pins to the base. Guide pin, M5x125: 3HAC087786-
001
Always use guide pins in pairs.
For joint units on axes 1 and 2 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2300000775
Action Note
4 Fit the lifting aid to the joint unit, aligning the pin Joint unit: 3HAC087472-001
with the pin hole. Lifting aid: 3HAC087787-001
Screws: M5x30 (4 pcs for plate and
CAUTION 2 pcs for beam)
xx2300000778
xx2300000777
xx2300000776
5 Fit the joint unit to the base, aligning the pin with
the pin hole.
CAUTION
xx2300000779
xx2300000780
Action Note
6 Check the joint unit position by placing the lower
boss of one semicircular block between the lifting
aid and base.
The joint unit is properly placed when no gaps
between the block and both lifting aid and base
xx2300000781
xx2300000782
xx2300000783
xx2300000784
Action Note
10 Secure the joint unit with the remaining attach- Hex socket head cap screw:
ment screws. 3HAB3409-20
xx2300000785
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2000002009
Action Note
3 Connect the connectors to each other and snap
them to the cable holders.
• J1.DC+ to J1.DC+
• J1.DC- to J1.DC-
• J1.CS to J1.CS
• J1.CP to J1.CP
xx2000002010
4 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000002011
xx2000002012
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. 3HAC061327-072
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000002016
2 Refit the bottom cover with the attachment screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (8 pcs)
Note Tightening torque: 1.4 Nm.
xx2300000760
Action Note
1 Lift the base to standing and secure it to the Attachment screws: M10x35 8.8 (4
foundation with the attachment screws and pcs).
washers. Washers: 23/10.5/2.5 mm Steel (4 pcs).
Tightening torque: 32 Nm ±10%.
xx2300001060
Action Note
1 Fit two guide pins on the base unit for position Valid for CRB 15000-10/1.52
guidance. Guide pin, M5x75, 3HAC087786-
Always use guide pins in pairs. 002
Valid for CRB 15000-12/1.27
Guide pin, M5x125: 3HAC087786-
001
2 Refit the swing to the base unit, aligning the pin Example of CRB 15000-12/1.27,
with the pin hole. similar to CRB 15000-10/1.52.
CAUTION
xx2000001989
Action Note
3 Secure the swing with the attachment screws. Hex socket head cap screw: M5x30
12.9 Lafre 2C2B/FC6.9 (16 pcs)
CAUTION Tightening torque: 8.2 Nm
Valid for CRB 15000-12/1.27
Do not mix the flange screws used for CRB 15000-
5/0.95 and the threaded screws used for CRB
15000-10/1.52 and CRB 15000-12/1.27. Always
use washers together with the threaded screws
for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Illustration is for reference only.
xx2000001987
xx2300000819
xx2300000821
5 Valid for CRB 15000-10/1.52 Hex socket head cap screw: M5x25
Refit the swing flange with the attachment screws. 12.9 Lafre 2C2B/FC6.9 (16 pcs)
Always check the serial number printed on the Tightening torque: 8.2 Nm
swing parts and use the parts in the same number
for refitting.
CAUTION
xx2300000818
Action Note
6 Valid for CRB 15000-10/1.52 Guide pin, M5x75, 3HAC087786-
Fit two guide pins on the swing flange for position 002
guidance.
Always use guide pins in pairs.
7 Valid for CRB 15000-10/1.52
Refit the swing transition to the swing flange,
aligning the pin with the pin hole.
Always check the serial number printed on the
swing parts and use the parts in the same number
for refitting.
xx2300000820
8 Valid for CRB 15000-10/1.52 Hex socket head cap screw: M5x25
Secure the swing transition with the attachment 12.9 Lafre 2C2B/FC6.9 (16 pcs)
screws. Tightening torque: 8.2 Nm
CAUTION
xx2300000817
Action Note
1
CAUTION
2
WARNING
xx2300001060
Action Note
4 Lay the robot down with the torque sensor side
upwards on a working bench. Do not damage
the base socket. Caution with the cabling.
CAUTION
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2300000823
3 Fit two guide pins to the swing. Guide pin, M5x125: 3HAC087786-
001
Always use guide pins in pairs.
For joint units on axes 1 and 2 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2300000791
Action Note
4 Fit the lifting aid to the joint unit, aligning the pin Joint unit: 3HAC087472-001
with the pin hole. Lifting aid: 3HAC087787-001
Screws: M5x30 (4 pcs for plate and
CAUTION 2 pcs for beam)
xx2300000778
xx2300000777
xx2300000776
CAUTION
Action Note
6 Fit the joint unit to the swing, aligning the pin with
the pin hole.
CAUTION
xx2300000792
xx2300000780
xx2300000794
xx2300000795
Action Note
9 Secure with four attachment screws and pre-
tighten the screws crosswise.
xx2300000796
xx2300000797
11 Secure the joint unit with the remaining attach- Hex socket head cap screw:
ment screws. 3HAB3409-20
xx2300000798
Action Note
1 Lift the base to standing and secure it to the Attachment screws: M10x35 8.8 (4
foundation with the attachment screws and pcs).
washers. Washers: 23/10.5/2.5 mm Steel (4 pcs).
Tightening torque: 32 Nm ±10%.
xx2300001060
Refitting the lower and upper arm assembled (-10/1.52 and -12/1.27)
Action Note
1 Fit three guide pins to the axis-2 joint unit. Guide pin, M5x125: 3HAC087786-
001
xx2300001021
2
CAUTION
Action Note
3 Lift the upper and lower arm assembly to mount- Example of CRB 15000-5/0.95,
ing position and slide it onto the guide pins. similar to CRB 15000-10/1.52 and
CRB 15000-12/1.27.
xx2000001941
4 Secure the lower arm to the swing with all screws Hex socket head cap screw: M5x30
and washers but two. 12.9 Lafre 2C2B/FC6.9, 16 pcs
Pre-tighten the screws crosswise firstly.
CAUTION
5 Remove the guide pins and fasten the remaining Hex socket head cap screw: M5x30
two screws and washers. 12.9 Lafre 2C2B/FC6.9, 16 pcs
CAUTION
xx2300001023
Action Note
7 Refit the cable bracket with four screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs).
Tightening torque: 0.8 Nm
xx2000001939
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2000002013
xx2000001944
Action Note
4 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000001945
xx2000001946
Action Note
1 Connect the connectors to each other and snap
them to the cable holders.
xx2000001938
Action Note
2 Secure the cabling with cable ties. Cable ties (3 pcs)
xx2000001937
3 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (1 pcs).
Tightening torque: 0.8 Nm
xx2000001936
Action Note
1
CAUTION
xx2300000812
Action Note
3 Remove the lower inner cover by removing the
screws.
xx2300000813
Action Note
1 Refit the insert. Insert: 3HAC084002-001
Hex socket head cap screw: M3x10
12.9 Lafre 2C2B/FC6.9 (3 pcs)
Tightening torque: 1.4 Nm
xx2300000815
xx2300000816
3 Refit the cover with the four screws. Hex socket head cap screw: M3x12
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 1.4 Nm
xx2300000814
Concluding procedure
Action Note
1 Calibrate the joint unit torque sensor. See Calibration on page 1063
1 On the FlexPendant, go to the Code app
and call the calibration procedure using PP
to Routine, not by using Call Routine.
2 Select the Joint Unit Replacement feature
and then select the axis to calibrate.
3 The controller is now restarted. Once the
home screen of the FlexPendant is shown,
press the Play button to continue the calib-
ration routine.
4 The robot moves to a position or positions
where measurements are performed.
5 The results of the measurements are
presented together with the current values
in the controller. Choose whether to save
the calibration data or not.
6 If new calibration data is saved you will be
asked to do a test with the lead-through
functionality active to verify that the
sensors work correctly.
7 Finally the robot is moved back to the ori-
ginal position.
8 Test the brake release (movement without
drive power) functionality, see Testing the
brake release functionality on page 196.
2
DANGER
xx2000001948
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the CRB 15000 via myABB Business Portal,
www.abb.com/myABB.
Required consumables
Action Note
1 Jog the robot to the specified position:
• Axis 1: 0°
• Axis 2: 0° (home position)
• Axis 3: +60°
• Axis 4: 0°
• Axis 5: -90°
• Axis 6: No significance.
CAUTION
xx2100000044
2
CAUTION
Action Note
1
CAUTION
Action Note
2 Remove the four lower arm cover screws.
xx2000001929
xx2100000267
xx2000001930
Disconnecting the cabling between the lower arm and the swing
Action Note
1 Remove the functional earth cable by removing
the screw.
xx2000001936
xx2000001937
xx2000001938
Action Note
1 Remove the cable bracket by removing the four
screws.
xx2000001939
2 Secure the weight of the upper and lower arm. Suggestion with lifting sling and an
overhead crane.
CAUTION Example of CRB 15000-5/0.95,
similar to CRB 15000-10/1.52 and
The weight of the complete upper and lower arm CRB 15000-12/1.27.
together is 18 kg
xx2100000294
Action Note
3 Remove two attachment screws and fit two guide Guide pin, M4x120: 3HAC077786-
pins to the axis-2 joint unit. 001
Always use guide pins in pairs.
CAUTION
xx2000001951
xx2000001960
CAUTION
xx2000002151
Action Note
6 Remove the complete arm system from the swing.
xx2000001941
xx2000002432
Action Note
1
CAUTION
xx2000001935
Action Note
3
CAUTION
xx2000001931
xx2000001932
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
Action Note
2 Cut the cable ties.
xx2000001946
xx2000001945
xx2000001944
CAUTION
Action Note
1 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC077788-001
sensor side. Screws: M4x35 (4 pcs)
CAUTION
xx2000001956
xx2100000295
3 Fit two guide pins to the axis-2 joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
For joint units on axes 1, 2 and 3
of CRB 15000-5/0.95 and axis 3 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2000002433
xx2000001943
Action Note
5 Put the cabling at the slot in order not to squeeze
it during removal of joint unit.
xx2100000045
xx2000002434
CAUTION
xx2000001957
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
Action Note
2 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
Tip 10/1.52 and CRB 15000-12/1.27)
xx2000002057
xx2000002058
xx2100000301
Action Note
5 Remove the cable support from the drive board
by removing the attachment screws.
xx2000002055
xx2000002053
xx2000002049
CAUTION
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
Action Note
2 Place the joint cable through the hollow shaft from
the torque sensor side.
CAUTION
xx2000002051
4 Secure the cable plate to the joint unit with the Hex socket head cap screw:
attachment screws. M2.5x6 12.9 Lafre 2C2B/FC6.9 (4
pcs)
Tightening torque: 0.45 Nm.
xx2000002049
xx2000002053
Action Note
6 Insert the cabling through the cable support and
fit the support to the drive board with the attach-
ment screws.
xx2000002056
xx2000002055
xx2100000507
Action Note
8 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
10/1.52 and CRB 15000-12/1.27)
xx2000002057
9 Secure the cables to the cable support with a Cable tie: 3HAC075545-001. For
cable tie, using a cable tie gun. securing joint unit cable.
Assembly direction for the cable tie is shown in Cable tie gun EVO 7i
the figure. Settiing for cable tie gun: 6.75.
xx2000002058
xx2000002059
Action Note
10 Remove the protection plate.
xx2100000301
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Clean the mounting surface of the joint unit and Cleaning agent: Isopropanol
the mating surface on the casting with isopropan- Flange sealant: Loctite 574
ol.
Joint unit mounting surface is pointed out in the
figure.
3 Apply a thin layer of flange sealant to the mount-
ing surface. Do not contaminate the radial sealing
with sealant.
CAUTION xx2000001860
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Fit the lifting aid to the joint unit. Joint unit: 3HAC079141-001
Lifting aid: 3HAC077788-001
CAUTION Screws: M4x35 (4 pcs)
xx2000001957
3 Fit two guide pins to the joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
For joint units on axes 1, 2 and 3
of CRB 15000-5/0.95 and axis 3 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2000002438
CAUTION
xx2000002153
Action Note
5 Fit the joint unit to the swing, aligning the pin with
the pin hole.
CAUTION
xx2000001959
The connectors and the joint unit cables are
sensitive to mechanical damage. Handle the as-
sembly with care.
xx2000001961
6 Secure the joint unit with new attachment screws. Flange socket head screw with
glue: 3HAB3413-435
M4x35 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue , 12 pcs
Used for joint unit of CRB 15000-
5/0.95.
Always use new screws when refit-
ting a joint unit. If ordering a new
joint unit spare part, new screws
are included.
xx2000001943
xx2100000295
Action Note
10 Remove the lifting aid by removing the screws.
xx2000001956
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2000002013
xx2000001944
Action Note
4 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000001945
xx2000001946
Action Note
1 Fit the o-ring to cover groove. O-ring: 3HAC061327-047 (for CRB
Replace if damaged. 15000-5/0.95)
xx2000001962
Action Note
2 For robots with RobotWare earlier than 7.10
Place the cover at mounting position and recon-
nect the brake release connector DR.X8 to the
drive board.
Orient the cover for proper arrangement of the
brake release cable.
xx2000001932
xx2000001931
4 Refit the cover with the four screws. Hex socket head cap screw: M3x30
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm
xx2000001935
Action Note
1 Fit two guide pins to the axis-2 joint unit. Guide pin, M4x120: 3HAC077786-
001
xx2000001949
2 Remove any old residuals of flange sealant from Cleaning agent: Isopropanol
the lower arm mounting surface and clean with Flange sealant: Loctite 574
isopropanol.
Apply new flange sealant to the corner of the
lower arm mounting surface, as pointed out in the
figure.
xx2000001963
3
CAUTION
xx2000001941
Action Note
5 Secure the lower arm to the swing with all attach- Hex socket head cap flange screw:
ment screws but two. M4x25 12.9 Lafre
Pre-tighten the screws crosswise firstly. 2C2B/FC6.9+PrO-COat111 (16 pcs)
CAUTION
xx2000001940
6 Remove the guide pins and fasten the remaining Hex socket head cap flange screw:
two screws. M4x25 12.9 Lafre
2C2B/FC6.9+PrO-COat111 (16 pcs)
CAUTION
xx2000001951
xx2000001939
Action Note
1 Connect the connectors to each other and snap
them to the cable holders.
xx2000001938
xx2000001937
3 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (1 pcs).
Tightening torque: 0.8 Nm
xx2000001936
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-044
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000001954
2 Refit the inner cover with four screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 1.4 Nm.
xx2000001930
3 Snap the lower arm cover into place. Hex socket head cap screw: M3x16
12.9 Lafre 2C2B/FC6.9 (4 pcs)
4 Secure the cover with four screws.
Tightening torque: 0.45 Nm.
xx2000001929
Concluding procedure
Action Note
1 Calibrate the joint unit torque sensor. See Calibration on page 1063
1 On the FlexPendant, go to the Code app
and call the calibration procedure using PP
to Routine, not by using Call Routine.
2 Select the Joint Unit Replacement feature
and then select the axis to calibrate.
3 The controller is now restarted. Once the
home screen of the FlexPendant is shown,
press the Play button to continue the calib-
ration routine.
4 The robot moves to a position or positions
where measurements are performed.
5 The results of the measurements are
presented together with the current values
in the controller. Choose whether to save
the calibration data or not.
6 If new calibration data is saved you will be
asked to do a test with the lead-through
functionality active to verify that the
sensors work correctly.
7 Finally the robot is moved back to the ori-
ginal position.
8 Test the brake release (movement without
drive power) functionality, see Testing the
brake release functionality on page 196.
2
DANGER
5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27)
xx2300000765 xx2300000768
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the CRB 15000 via myABB Business Portal,
www.abb.com/myABB.
Required consumables
Action Note
1 Jog the robot to the specified position: Valid for CRB 15000-10/1.52
• Axis 1: 0°
• Axis 2: 0° (home position)
• Axis 3: +60°
• Axis 4: 0°
• Axis 5: -90°
• Axis 6: No significance.
CAUTION
xx2300001062
xx2300001063
2
CAUTION
Action Note
1
CAUTION
xx2300000812
xx2300000813
Disconnecting the cabling between the lower arm and the swing
Action Note
1 Remove the functional earth cable by removing
the screw.
xx2000001936
Action Note
2 Cut the cable ties.
xx2000001937
xx2000001938
Action Note
1 Remove the cable bracket by removing the four
screws.
xx2000001939
Action Note
2 Secure the weight of the upper and lower arm. Suggestion with lifting sling and an
overhead crane.
CAUTION Example of CRB 15000-5/0.95,
similar to CRB 15000-10/1.52 and
The weight of the complete upper and lower arm CRB 15000-12/1.27.
together is up to 26 kg
xx2100000294
Action Note
3 Remove two attachment screws and fit two guide Guide pin, M5x125: 3HAC087786-
pins to the axis-2 joint unit. 001
Always use guide pins in pairs.
CAUTION
xx2000001951
xx2000001960
CAUTION
xx2000002151
Action Note
6 Remove the complete arm system from the swing.
xx2000001941
xx2000002432
Action Note
1
CAUTION
xx2300000814
Action Note
3
CAUTION
xx2300000815
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2000001946
Action Note
3 Remove the functional and protective earth cables
by removing the screw.
xx2000001945
xx2000001944
CAUTION
Action Note
1
CAUTION
2
WARNING
Action Note
3 Loosen the robot base from the foundation by
removing the foundation attachment screws.
xx2300001060
CAUTION
Action Note
1 Removing the attachment screws.
xx2300000786
Action Note
2 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC087787-001
sensor side. Screws: M5x30 (4 pcs for plate and
2 pcs for beam)
CAUTION
xx2300000787
xx2300000788
xx2300000789
CAUTION
xx2300000790
Action Note
5 Remove the lifting aid.
xx2300000778
xx2300000776
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
Tip 10/1.52 and CRB 15000-12/1.27)
xx2000002057
Action Note
3 Cut the cable tie at the drive board.
xx2000002058
xx2100000301
xx2000002055
xx2000002053
Action Note
7 Remove the cable plate by removing the attach-
ment screws.
xx2000002049
CAUTION
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
CAUTION
xx2000002051
Action Note
4 Secure the cable plate to the joint unit with the Hex socket head cap screw:
attachment screws. M2.5x6 12.9 Lafre 2C2B/FC6.9 (4
pcs)
Tightening torque: 0.45 Nm.
xx2000002049
xx2000002053
xx2000002056
xx2000002055
Action Note
7 Keep the cabling loose, making sure not to twist
or strain it.
Use the cable tie to pre-fix the cable by hand.
xx2100000507
8 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
10/1.52 and CRB 15000-12/1.27)
xx2000002057
Action Note
9 Secure the cables to the cable support with a Cable tie: 3HAC075545-001. For
cable tie, using a cable tie gun. securing joint unit cable.
Assembly direction for the cable tie is shown in Cable tie gun EVO 7i
the figure. Settiing for cable tie gun: 6.75.
xx2000002058
xx2000002059
xx2100000301
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2300000823
3 Fit two guide pins to the swing. Guide pin, M5x125: 3HAC087786-
001
Always use guide pins in pairs.
For joint units on axes 1 and 2 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2300000791
Action Note
4 Fit the lifting aid to the joint unit, aligning the pin Joint unit: 3HAC087472-001
with the pin hole. Lifting aid: 3HAC087787-001
Screws: M5x30 (4 pcs for plate and
CAUTION 2 pcs for beam)
xx2300000778
xx2300000777
xx2300000776
CAUTION
Action Note
6 Fit the joint unit to the swing, aligning the pin with
the pin hole.
CAUTION
xx2300000792
xx2300000780
xx2300000794
xx2300000795
Action Note
9 Secure with four attachment screws and pre-
tighten the screws crosswise.
xx2300000796
xx2300000797
11 Secure the joint unit with the remaining attach- Hex socket head cap screw:
ment screws. 3HAB3409-20
xx2300000798
Action Note
1 Lift the base to standing and secure it to the Attachment screws: M10x35 8.8 (4
foundation with the attachment screws and pcs).
washers. Washers: 23/10.5/2.5 mm Steel (4 pcs).
Tightening torque: 32 Nm ±10%.
xx2300001060
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx2000002013
xx2000001944
Action Note
4 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000001945
xx2000001946
Action Note
1 Refit the insert. Insert: 3HAC084002-001
Hex socket head cap screw: M3x10
12.9 Lafre 2C2B/FC6.9 (3 pcs)
Tightening torque: 1.4 Nm
xx2300000815
Action Note
2 Fit the o-ring to cover groove. O-ring: 3HAC061327-074 (for CRB
Replace if damaged. 15000-10/1.52 and CRB 15000-
12/1.27)
xx2300000816
3 Refit the cover with the four screws. Hex socket head cap screw: M3x12
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 1.4 Nm
xx2300000814
Refitting the lower and upper arm assembled (-10/1.52 and -12/1.27)
Action Note
1 Fit three guide pins to the axis-2 joint unit. Guide pin, M5x125: 3HAC087786-
001
xx2300001021
2
CAUTION
Action Note
3 Lift the upper and lower arm assembly to mount- Example of CRB 15000-5/0.95,
ing position and slide it onto the guide pins. similar to CRB 15000-10/1.52 and
CRB 15000-12/1.27.
xx2000001941
4 Secure the lower arm to the swing with all screws Hex socket head cap screw: M5x30
and washers but two. 12.9 Lafre 2C2B/FC6.9, 16 pcs
Pre-tighten the screws crosswise firstly.
CAUTION
5 Remove the guide pins and fasten the remaining Hex socket head cap screw: M5x30
two screws and washers. 12.9 Lafre 2C2B/FC6.9, 16 pcs
CAUTION
xx2300001023
Action Note
7 Refit the cable bracket with four screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs).
Tightening torque: 0.8 Nm
xx2000001939
Action Note
1 Connect the connectors to each other and snap
them to the cable holders.
xx2000001938
xx2000001937
Action Note
3 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (1 pcs).
Tightening torque: 0.8 Nm
xx2000001936
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-075
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000001954
2 Refit the inner cover with four screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 1.4 Nm.
xx2300000813
Action Note
3 Refit the lower cover of lower arm with three Lower arm cover, lower: Lower
screws. arm, used for CRB 15000-10/1.52
and CRB 15000-12/1.27.
Tightening torque: 1.4 Nm.
xx2300000812
Concluding procedure
Action Note
1 Calibrate the joint unit torque sensor. See Calibration on page 1063
1 On the FlexPendant, go to the Code app
and call the calibration procedure using PP
to Routine, not by using Call Routine.
2 Select the Joint Unit Replacement feature
and then select the axis to calibrate.
3 The controller is now restarted. Once the
home screen of the FlexPendant is shown,
press the Play button to continue the calib-
ration routine.
4 The robot moves to a position or positions
where measurements are performed.
5 The results of the measurements are
presented together with the current values
in the controller. Choose whether to save
the calibration data or not.
6 If new calibration data is saved you will be
asked to do a test with the lead-through
functionality active to verify that the
sensors work correctly.
7 Finally the robot is moved back to the ori-
ginal position.
8 Test the brake release (movement without
drive power) functionality, see Testing the
brake release functionality on page 196.
2
DANGER
xx2000002020
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the CRB 15000 via myABB Business Portal,
www.abb.com/myABB.
Required consumables
Action Note
1 Jog the robot to the specified position: Example of CRB 15000-5/0.95,
• Axis 1: 0° similar to CRB 15000-10/1.52 and
• Axis 2: +90° (suggested position for con- CRB 15000-12/1.27.
venient working position)
• Axis 3: -80° (home position)
• Axis 4: 0°
• Axis 5: 0°
• Axis 6: 0°
CAUTION
2
CAUTION
Action Note
1
CAUTION
xx2000001929
xx2100000267
Action Note
4 Remove the inner covers by removing the screws.
xx2000001947
xx2000001930
Action Note
1
CAUTION
xx2300000812
xx2300000829
Action Note
3 Remove the inner covers by removing the screws.
xx2300000813
xx2300000830
Action Note
1 Cut the cable ties.
xx2000001937
xx2000001938
Action Note
1 Remove the functional earth cable by removing
the screw.
xx2000001964
xx2000001965
Action Note
1 Remove the cable bracket by removing the four
screws.
xx2000001966
CAUTION
xx2000001967
Action Note
4 Fit two guide pins to the axis-3 joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
xx2000001968
xx2000001969
xx2100000001
xx2000001970
Action Note
1
CAUTION
Action Note
2 Remove the cover screws.
xx2000002021
3
CAUTION
xx2000002022
xx2000002023
Action Note
1
CAUTION
xx2300000833
3
CAUTION
xx2300000834
Action Note
1 Cut the cable ties.
xx2000002066
xx2000001945
xx2000002067
Action Note
4 Disconnect the connectors from the drive board.
• D3.X1
• D3/4.DC+
• D3/4.DC-
• D3.X4
• D3/4.X2
• D3.X5
CAUTION
xx2000002068
Action Note
1 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC077788-001
sensor side. Screws: M4x35 (4 pcs)
CAUTION
xx2000002069
xx2000002070
3 Fit two guide pins to the axis-3 joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
For joint units on axes 1, 2 and 3
of CRB 15000-5/0.95 and axis 3 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2000002576
Action Note
4 Remove the remaining attachment screws.
Use two screws as press out screws in the upcom-
ing step, then dispose all screws.
New screws are included in the spare part delivery
of the joint unit.
xx2100000320
xx2100000003
xx2000002577
CAUTION
xx2000002071
xx2000001957
Action Note
1 Remove the attachment screws.
xx2300000799
2 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC087788-001
sensor side. Screws: M4x30 (4 pcs)
CAUTION
xx2300000800
xx2300000801
CAUTION
xx2300000802
xx2300000804
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
Tip 10/1.52 and CRB 15000-12/1.27)
xx2000002057
xx2000002058
Action Note
4 Remove the protection plate.
xx2100000301
xx2000002055
xx2000002053
xx2000002049
Action Note
8 Remove the joint cable from the hollow shaft from
the torque sensor side.
CAUTION
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
CAUTION
xx2000002051
Action Note
4 Secure the cable plate to the joint unit with the Hex socket head cap screw:
attachment screws. M2.5x6 12.9 Lafre 2C2B/FC6.9 (4
pcs)
Tightening torque: 0.45 Nm.
xx2000002049
xx2000002053
xx2000002056
xx2000002055
Action Note
7 Keep the cabling loose, making sure not to twist
or strain it.
Use the cable tie to pre-fix the cable by hand.
xx2100000507
8 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
10/1.52 and CRB 15000-12/1.27)
xx2000002057
Action Note
9 Secure the cables to the cable support with a Cable tie: 3HAC075545-001. For
cable tie, using a cable tie gun. securing joint unit cable.
Assembly direction for the cable tie is shown in Cable tie gun EVO 7i
the figure. Settiing for cable tie gun: 6.75.
xx2000002058
xx2000002059
xx2100000301
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Clean the mounting surface of the joint unit and Cleaning agent: Isopropanol
the mating surface on the casting with isopropan- Flange sealant: Loctite 574
ol.
Joint unit mounting surface is pointed out in the
figure.
3 Apply a thin layer of flange sealant to the mount-
ing surface. Do not contaminate the radial sealing
with sealant.
CAUTION xx2000001860
Action Note
1 Fit the lifting aid to the joint unit. Joint unit: 3HAC079141-001
Lifting aid: 3HAC077788-001
CAUTION Screws: M4x35 (4 pcs)
xx2000001957
Action Note
2 Fit two guide pins to the joint unit. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
For joint units on axes 1, 2 and 3
of CRB 15000-5/0.95 and axis 3 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2000002438
xx2100000004
CAUTION
Action Note
5 Secure the joint unit with new attachment screws. Flange socket head screw with
glue: 3HAB3413-435
M4x35 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue , 12 pcs
Used for joint unit of CRB 15000-
5/0.95.
Always use new screws when refit-
ting a joint unit. If ordering a new
joint unit spare part, new screws
are included.
xx2100000320
xx2000002070
xx2000002069
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
Action Note
2 Check the o-ring. O-ring: 3HAC061327-036
Replace if damaged.
xx2300000836
3 Fit two guide pins to the housing. Guide pin, M4x120: 3HAC077786-
001
Always use guide pins in pairs.
For joint units on axes 1, 2 and 3
of CRB 15000-5/0.95 and axis 3 of
CRB 15000-10/1.52 and CRB
15000-12/1.27.
xx2300000803
4 Fit the lifting aid to the joint unit, aligning the pin Joint unit: 3HAC087474-001
with the pin hole. Lifting aid: 3HAC087788-001
Screws: M4x30 (4 pcs)
CAUTION
xx2300000804
xx2300000777
Action Note
5 Fit the joint unit to the housing, aligning the pin
with the pin hole.
CAUTION
xx2300000806
xx2300000780
xx2300000808
xx2300000809
xx2300000810
Action Note
9 Remove the lifting aid by removing the screws.
xx2300000800
10 Secure the joint unit with the remaining attach- Hex socket head cap screw:
ment screws. 3HAB3409-262
xx2300000811
Action Note
1 Reconnect the connectors to the drive board.
• D3.X1 to X1
• D3/4.DC+ to DC+
• D3/4.DC- to Ground
• D3.X4 to X4
• D3/4.X2 to X2
• D3.X5 to X5
xx2000002068
Action Note
2 Connect the connectors to each other and snap
them to the cable holders.
• J4.DC+ to J4/5.DC+
• J4.DC- to J4/5.DC-
• J4.CS to J4/5.CS
• J4.CP to J4/5.CP
xx2000002067
3 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000001945
xx2000002066
Action Note
1 Fit the o-ring to its groove. O-ring: 3HAC061327-047
Replace if damaged.
xx2000001962
xx2000002023
xx2000002022
Action Note
4 Refit the cover with the four screws. Hex socket head cap screw: M3x30
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm
xx2000002021
Action Note
1 Refit the insert. Insert: 3HAC084002-001
Hex socket head cap screw: M3x10
12.9 Lafre 2C2B/FC6.9 (3 pcs)
Tightening torque: 1.4 Nm
xx2300000834
xx2300000835
Action Note
3 Refit the cover with the four screws. Hex socket head cap screw: M3x30
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 1.4 Nm
xx2300000833
Action Note
1 Fit two guide pins to the axis-3 joint. Guide pin, M4x120: 3HAC077786-
001
xx2000001971
xx2000001973
Action Note
3 Lift the upper arm into mounting position while
inserting the cabling into the lower arm.
4 Slide the upper arm into place on the guide pins.
xx2000001970
5 Secure the upper arm to the lower arm with all Hex socket head cap flange screw:
attachment screws but two. M4x25 12.9 Lafre
Pre-tighten the screws crosswise firstly. 2C2B/FC6.9+PrO-COat111 (16 pcs)
xx2000001969
6 Remove the guide pins and fasten the remaining Hex socket head cap flange screw:
two screws. M4x25 12.9 Lafre
2C2B/FC6.9+PrO-COat111 (16 pcs)
xx2000001967
xx2000001966
Action Note
1 Secure the cabling with the cable tie. Cable ties
xx2000001965
2 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (1 pcs).
Tightening torque: 0.8 Nm
xx2000001964
Action Note
1 Connect the connectors to each other and snap
them to the cable holders.
xx2000001938
Action Note
2 Secure the cabling with cable ties. Cable ties (3 pcs)
xx2000001937
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-044
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000001955
xx2000001954
Action Note
2 Refit the inner covers with four screws each. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (8 pcs)
Tightening torque: 1.4 Nm.
xx2000001947
xx2000001930
3 Snap the lower arm cover into place. Hex socket head cap screw: M3x16
12.9 Lafre 2C2B/FC6.9 (4 pcs)
4 Secure the cover with four screws.
Tightening torque: 0.45 Nm.
xx2000001929
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-075
Replace if damaged. O-ring: 3HAC061327-044
Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2300000832
xx2300000831
2 Refit the inner covers with eight screws each. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (8 pcs) x 2
Tightening torque: 1.4 Nm.
xx2300000813
xx2300000830
Action Note
3 Snap the lower arm cover into place. Hex socket head cap screw: M3x12
12.9 Lafre 2C2B/FC6.9 (3 pcs) x 2
4 Secure the cover with three screws.
Tightening torque: 1.4 Nm.
xx2300000812
xx2300000829
Concluding procedure
Action Note
1 Calibrate the joint unit torque sensor. See Calibration on page 1063
1 On the FlexPendant, go to the Code app
and call the calibration procedure using PP
to Routine, not by using Call Routine.
2 Select the Joint Unit Replacement feature
and then select the axis to calibrate.
3 The controller is now restarted. Once the
home screen of the FlexPendant is shown,
press the Play button to continue the calib-
ration routine.
4 The robot moves to a position or positions
where measurements are performed.
5 The results of the measurements are
presented together with the current values
in the controller. Choose whether to save
the calibration data or not.
6 If new calibration data is saved you will be
asked to do a test with the lead-through
functionality active to verify that the
sensors work correctly.
7 Finally the robot is moved back to the ori-
ginal position.
8 Test the brake release (movement without
drive power) functionality, see Testing the
brake release functionality on page 196.
Action Note
2
DANGER
xx2000002119
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the CRB 15000 via myABB Business Portal,
www.abb.com/myABB.
Required consumables
Action Note
1 Jog the robot to the specified position: Example of CRB 15000-5/0.95,
• Axis 1: No significance. similar to CRB 15000-10/1.52 and
• Axis 2: 0° CRB 15000-12/1.27.
• Axis 3: 0°
• Axis 4: 0° (home position)
• Axis 5: +90°
• Axis 6: No significance.
CAUTION
xx2100000005
2
CAUTION
Action Note
1
CAUTION
xx2000002021
Action Note
3
CAUTION
xx2000002022
xx2000002023
Action Note
1
CAUTION
xx2300000833
Action Note
3
CAUTION
xx2300000834
Action Note
1 Cut the cable ties.
xx2000002066
xx2000001945
Action Note
3 Snap loose and disconnect the connectors:
• J4/5.DC+
• J4/5.DC-
• J4/5.CS
• J4/5.CP
xx2000002067
xx2000002120
Action Note
1 Remove the cover by removing the four screws.
xx2000002075
Action Note
2 Remove the inner plate by removing the screws.
xx2000002076
Action Note
1 Cut the cable tie. Valid for CRB 15000-5/0.95
xx2000002077
xx2300000839
Action Note
2 Remove the cable bracket by removing the two Valid for CRB 15000-5/0.95
screws.
xx2000002078
xx2300000840
3 Remove two attachment screws and fit two guide Guide pin, M3x110: 3HAC077787-
pins to the axis-4 joint unit. 001
Always use guide pins in pairs.
xx2000002079
xx2000002080
Action Note
4 Remove the remaining attachment screws.
xx2000002081
xx2000002127
xx2100000006
xx2000002082
Action Note
1 Remove the cover screws.
xx2000002083
2
CAUTION
xx2000002084
xx2000002085
Action Note
1 Valid for CRB 15000-5/0.95
Remove the cover by removing the six screws.
Dispose the screws. New screws must be used
when refitting the cover.
New screws are included in the spare part delivery
of the joint unit.
xx2000002123
xx2300000841
Action Note
1 Cut the cable ties on joint unit.
xx2000002086
Action Note
2 Cut the cable ties on tubular, if needed. Valid for CRB 15000-5/0.95
xx2000002124
xx2300000842
xx2300000843
xx2000002087
xx2000002089
Action Note
6 Disconnect the connectors that belongs to the Tweezers
axis-5 cabling, from the axis-4 drive board:
• D3/4.X2
• D3/4.DC-
• D3/4.DC+
Use tweezers, if needed.
xx2000002125
7 Pull out the cabling carefully from the tubular. Valid for CRB 15000-5/0.95
xx2000002126
xx2300000844
Action Note
1 Disconnect the connectors from the drive board. Tweezers
CAUTION
xx2000002088
Action Note
1 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC077789-001
sensor side. Screws: M3x12 (4 pcs)
CAUTION
xx2000002090
xx2000002091
3 Fit two guide pins to the axis-4 joint unit. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
For joint units on axes 4, 5 and 6.
xx2000002578
xx2100000326
xx2100000327
Action Note
6 Remove the joint unit from the tubular.
CAUTION
xx2000001957
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
Tip 10/1.52 and CRB 15000-12/1.27)
xx2000002057
Action Note
3 Cut the cable tie at the drive board.
xx2000002058
xx2100000301
xx2000002055
xx2000002053
Action Note
7 Remove the cable plate by removing the attach-
ment screws.
xx2000002049
CAUTION
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
CAUTION
xx2000002051
Action Note
4 Secure the cable plate to the joint unit with the Hex socket head cap screw:
attachment screws. M2.5x6 12.9 Lafre 2C2B/FC6.9 (4
pcs)
Tightening torque: 0.45 Nm.
xx2000002049
xx2000002053
xx2000002056
xx2000002055
Action Note
7 Keep the cabling loose, making sure not to twist
or strain it.
Use the cable tie to pre-fix the cable by hand.
xx2100000507
8 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
10/1.52 and CRB 15000-12/1.27)
xx2000002057
Action Note
9 Secure the cables to the cable support with a Cable tie: 3HAC075545-001. For
cable tie, using a cable tie gun. securing joint unit cable.
Assembly direction for the cable tie is shown in Cable tie gun EVO 7i
the figure. Settiing for cable tie gun: 6.75.
xx2000002058
xx2000002059
xx2100000301
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Clean the mounting surface of the joint unit and Cleaning agent: Isopropanol
the mating surface on the casting with isopropan- Flange sealant: Loctite 574
ol.
Joint unit mounting surface is pointed out in the
figure.
3 Apply a thin layer of flange sealant to the mount-
ing surface. Do not contaminate the radial sealing
with sealant.
CAUTION xx2000001860
Action Note
1
CAUTION
Action Note
2 Fit the lifting aid to the joint unit. Joint unit: 3HAC079143-001 (for
CRB 15000-5/0.95) / 3HAC087546-
CAUTION 001 (for CRB 15000-10/1.52 and
CRB 15000-12/1.27)
The connectors and the joint unit cables are Lifting aid: 3HAC077789-001
sensitive to mechanical damage. Handle the as- Screws: M3x12 (4 pcs)
sembly with care.
xx2000001957
3 Fit two guide pins to the joint unit. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
For joint units on axes 4, 5 and 6.
xx2000002438
CAUTION
5 Secure the joint unit with new attachment screws. Flange socket head screw with
glue: 3HAB3413-330
M3x30 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue , 12 pcs
Always use new screws when refit-
ting a joint unit. If ordering a new
joint unit spare part, new screws
are included.
xx2100000326
Action Note
6 Remove the guide pins and secure the remaining
two attachment screws.
xx2000002091
xx2000002090
Action Note
1 Reconnect the connectors to the drive board.
• D4/5.X1 to X1
• D4/5.X4 to X4
• D4/5.X5 to X5
xx2000002088
Action Note
1 Insert the cabling into the tubular. Valid for CRB 15000-5/0.95
xx2000002148
xx2300000845
xx2000002125
xx2000002089
Action Note
4 Secure the cables for functional earth and protect- Hex socket head cap screw: M3x6
ive earth with a screw. (1 pcs).
Tightening torque: 0.8 Nm.
xx2000002087
5 Secure the cabling to joint unit with cable ties. Cable ties (3 pcs)
xx2000002086
6 Secure the cabling to tubular with cable ties. Cable ties (2 pcs)
Valid for CRB 15000-5/0.95
xx2000002124
xx2300000842
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-043
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000002149
2 Refit the cover with new attachment screws. Flange socket head screw with
glue: 3HAB3413-312
M3x12 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue
For tubular cover of CRB 15000-
5/0.95.
Always use new screws.
If ordering a new axis-4 or axis-5
joint unit spare part, new screws
for the tubular cover are included.
Tightening torque: 1.6 Nm.
xx2000002123
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-076
Replace if damaged. O-ring: 3HAB3772-166
Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2300000846
xx2300000847
2 Refit the covers with new attachment screws. Hex socket head cap screw:
3HAB3409-224
M3x12 12.9 Lafre 2C2B/FC6.9 (3
pcs)
Tightening torque: 1.4 Nm.
xx2000002123
Action Note
1 Fit the o-ring to its groove. Valid for CRB 15000-5/0.95
Replace if damaged. O-ring: 3HAC061327-051
xx2000002092
xx2300000848
xx2000002085
xx2000002084
Action Note
4 Refit the cover with the four screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.2 Nm (for CRB
15000-5/0.95) / 0.9 Nm (for CRB
15000-10/1.52 and CRB 15000-
12/1.27)
Tightening torque: 0.9 Nm
xx2000002083
Action Note
1 Fit two guide pins to the axis-4 joint. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
xx2000002093
xx2000002094
Action Note
3 Lift the tubular into mounting position while insert-
ing the cabling into the housing.
4 Slide the tubular into place on the guide pins.
xx2000002082
5 Secure the tubular to the housing with all attach- Flange socket head screw: M3x20
ment screws but two. 12.9 Lafre 2C2B/FC6.9+PrO-
Pre-tighten the screws crosswise firstly. COat111
xx2000002081
6 Remove the guide pins and fasten the remaining Flange socket head screw: M3x20
two screws. 12.9 Lafre 2C2B/FC6.9+PrO-
COat111
xx2000002079
Action Note
8 Refit the cable bracket with the two screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs).
Tightening torque: 0.8 Nm
Valid for CRB 15000-5/0.95
xx2000002078
xx2300000840
xx2000002077
xx2300000839
Action Note
1 Check the inner plate gasket. Gasket: 3HAC075056-001
Replace if damaged.
xx2000002095
2 Refit the inner plate with the screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs).
Tightening torque: 1.4 Nm
xx2000002076
3 Refit the cover with the four screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs).
Tightening torque: 0.45 Nm
xx2000002075
Action Note
1 Reconnect the connectors to the drive board.
• D3/4.DC+ to DC+
• D3/4.DC- to Ground
• D3/4.X2 to X2
xx2000002120
xx2000002067
3 Secure the cables for functional earth and protect- Hex socket head cap screw: M3x6
ive earth with a screw. (1 pcs).
Tightening torque: 0.8 Nm.
xx2000001945
Action Note
4 Secure the cabling with cable ties. Cable ties (3 pcs)
xx2000002066
Action Note
1 Fit the o-ring to its groove. O-ring: 3HAC061327-047
Replace if damaged.
xx2000001962
xx2000002023
Action Note
3 For robots with RobotWare earlier than 7.10 Cable ties
Secure the brake release cable with a cable tie.
xx2000002022
4 Refit the cover with the four screws. Hex socket head cap screw: M3x30
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm
xx2000002021
Action Note
1 Refit the insert. Insert: 3HAC084002-001
Hex socket head cap screw: M3x10
12.9 Lafre 2C2B/FC6.9 (3 pcs)
Tightening torque: 1.4 Nm
xx2300000834
Action Note
2 Fit the o-ring to its groove. O-ring: 3HAC061327-047
Replace if damaged.
xx2300000835
3 Refit the cover with the four screws. Hex socket head cap screw: M3x30
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 1.4 Nm
xx2300000833
Concluding procedure
Action Note
1 Calibrate the joint unit torque sensor. See Calibration on page 1063
1 On the FlexPendant, go to the Code app
and call the calibration procedure using PP
to Routine, not by using Call Routine.
2 Select the Joint Unit Replacement feature
and then select the axis to calibrate.
3 The controller is now restarted. Once the
home screen of the FlexPendant is shown,
press the Play button to continue the calib-
ration routine.
4 The robot moves to a position or positions
where measurements are performed.
5 The results of the measurements are
presented together with the current values
in the controller. Choose whether to save
the calibration data or not.
6 If new calibration data is saved you will be
asked to do a test with the lead-through
functionality active to verify that the
sensors work correctly.
7 Finally the robot is moved back to the ori-
ginal position.
8 Test the brake release (movement without
drive power) functionality, see Testing the
brake release functionality on page 196.
Action Note
2
DANGER
5.6.7 Replacing the axis-5 joint unit and the axis-5 to axis-6 transition cabling
xx2000002121
xx2100000091
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the CRB 15000 via myABB Business Portal,
www.abb.com/myABB.
Required consumables
Action Note
1 Jog the robot to the specified position:
• Axis 1: No significance.
• Axis 2: No significance.
• Axis 3: No significance.
• Axis 4: No significance.
• Axis 5: 0° (home position)
• Axis 6: No significance.
CAUTION
2
CAUTION
Action Note
1 Valid for CRB 15000-5/0.95
Remove the cover by removing the six screws.
Dispose the screws. New screws must be used
when refitting the cover.
New screws are included in the spare part delivery
of the joint unit.
xx2000002123
Action Note
2 Valid for CRB 15000-10/1.52 and CRB 15000-
12/1.27
Remove the covers by removing the screws.
xx2300000841
Action Note
1 Remove the cover screws.
xx2000002083
2
CAUTION
xx2000002084
Action Note
4 For robots with RobotWare earlier than 7.10 Tweezers
Disconnect the brake release connector DR.X8
from the drive board.
Remove the cover.
xx2000002085
Action Note
1 Cut the cable ties on joint unit.
xx2000002086
2 Cut the cable ties on tubular, if needed. Valid for CRB 15000-5/0.95
xx2000002124
xx2300000842
Action Note
3 Valid for CRB 15000-10/1.52 and CRB 15000-
12/1.27
Remove the cable brackets.
xx2300000843
xx2000002087
xx2000002089
xx2000002125
Action Note
7 Pull out the cabling carefully from the tubular. Valid for CRB 15000-5/0.95
xx2000002126
xx2300000844
Action Note
1 Remove two attachment screws and fit two guide Guide pin, M3x110: 3HAC077787-
pins to the axis-5 joint unit. 001
Always use guide pins in pairs.
xx2000002128
xx2000002129
Action Note
2 Remove the remaining attachment screws.
xx2000002130
xx2000002131
Action Note
1 Remove the tool flange screws and washers.
xx2000002155
2
CAUTION
Action Note
3 Cut the cable ties.
xx2000002157
xx2000002158
Action Note
1 Remove the functional earth cable by removing
the screw.
xx2000002159
Action Note
1 Remove the tool flange adapter screws.
xx2000002165
Action Note
2 Press the adapter out of position by using two of
the attachment screws as removal tools.
xx2000002166
xx2000002167
Action Note
1
CAUTION
2
CAUTION
xx2000002550
Action Note
4 Loosen the arm-side interface carefully and dis-
connect the connectors from it.
• ASI.DC+
• ASI.DC-
• ASI.X1
xx2100000335
Action Note
1 Cut the cable ties.
xx2000002161
xx2000002162
xx2000002163
Action Note
4 Disconnect the connectors from the drive board. Tweezers
• D6.X1
• D6.DC+
• D6.DC-
• D6.X4
• D6.X2
• D6.X5
CAUTION
xx2000002164
Action Note
1 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC077789-001
sensor side. Screws: M3x12 (4 pcs)
CAUTION
xx2000002168
xx2000002170
Action Note
3 Fit two guide pins to the axis-6 joint unit. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
For joint units on axes 4, 5 and 6.
xx2100000328
xx2100000329
xx2100000330
Action Note
6 Remove the joint unit from the tubular.
CAUTION
xx2000002169
xx2000001957
Action Note
1 Remove the cover by removing the four screws.
xx2000002132
2
CAUTION
Action Note
3 For robots with RobotWare earlier than 7.10
Open the cover and cut the cable tie that holds
the brake release cable.
xx2000002133
xx2000002134
Action Note
1 Cut the cable ties.
xx2000002135
xx2000002136
Action Note
3 Snap loose and disconnect the connectors:
• J5/6.DC+
• J5/6.DC-
• J5/6.CS
• J5/6.CP
xx2000002137
CAUTION
Action Note
1 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC077789-001
sensor side. Screws: M3x12 (4 pcs)
CAUTION
xx2000002139
xx2000002140
Action Note
3 Put the cabling at the slot in order not to squeeze
it during removal of joint unit.
xx2100000284
4 Fit two guide pins to the axis-5 joint unit. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
For joint units on axes 4, 5 and 6.
xx2100000332
xx2100000333
xx2100000334
CAUTION
Action Note
8 Remove the lifting aid and guide pins.
xx2000001957
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
Tip 10/1.52 and CRB 15000-12/1.27)
xx2000002057
xx2000002058
Action Note
4 Remove the protection plate.
xx2100000301
xx2000002055
xx2000002053
xx2000002049
Action Note
8 Remove the joint cable from the hollow shaft from
the torque sensor side.
CAUTION
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
CAUTION
xx2000002051
Action Note
4 Secure the cable plate to the joint unit with the Hex socket head cap screw:
attachment screws. M2.5x6 12.9 Lafre 2C2B/FC6.9 (4
pcs)
Tightening torque: 0.45 Nm.
xx2000002049
xx2000002053
xx2000002056
xx2000002055
Action Note
7 Keep the cabling loose, making sure not to twist
or strain it.
Use the cable tie to pre-fix the cable by hand.
xx2100000507
8 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
10/1.52 and CRB 15000-12/1.27)
xx2000002057
Action Note
9 Secure the cables to the cable support with a Cable tie: 3HAC075545-001. For
cable tie, using a cable tie gun. securing joint unit cable.
Assembly direction for the cable tie is shown in Cable tie gun EVO 7i
the figure. Settiing for cable tie gun: 6.75.
xx2000002058
xx2000002059
xx2100000301
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Clean the mounting surface of the joint unit and Cleaning agent: Isopropanol
the mating surface on the casting with isopropan- Flange sealant: Loctite 574
ol.
Joint unit mounting surface is pointed out in the
figure.
3 Apply a thin layer of flange sealant to the mount-
ing surface. Do not contaminate the radial sealing
with sealant.
CAUTION xx2000001860
Action Note
1
CAUTION
Action Note
2 Fit the lifting aid to the joint unit. Joint unit: 3HAC079143-001 (for
CRB 15000-5/0.95) / 3HAC087546-
CAUTION 001 (for CRB 15000-10/1.52 and
CRB 15000-12/1.27)
The connectors and the joint unit cables are Lifting aid: 3HAC077789-001
sensitive to mechanical damage. Handle the as- Screws: M3x12 (4 pcs)
sembly with care.
xx2000001957
3 Fit two guide pins to the joint unit. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
For joint units on axes 4, 5 and 6.
xx2000002438
4 Fit the transition cable between axis-5 and axis-6 Cable harness, transition joint-5
joint units into the tilt. and joint-6: 3HAC083726-001
xx2100000040
Action Note
5 Place the cabling at the slot before refitting the
joint unit.
xx2100000041
xx2100000285
6 Fit the joint unit to the tilt, aligning the pin with the
pin hole.
CAUTION
Action Note
7 Secure the joint unit with new attachment screws. Flange socket head screw with
glue: 3HAB3413-330
M3x30 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue , 12 pcs
Used for joint unit of CRB 15000-
5/0.95.
Always use new screws when refit-
ting a joint unit. If ordering a new
joint unit spare part, new screws
are included.
xx2100000333
xx2000002140
xx2000002139
Action Note
1 Reconnect the connectors to the drive board.
• D4/5.X1 to X1
• D5.DC+ to +DC
• D5.DC- to Ground
• D4/5.X4 to X4
• D5/4.X2 to X2
• D4/5.X5 to X5
xx2000002138
xx2000002137
3 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000002136
Action Note
4 Secure the cabling with cable ties. Cable ties (3 pcs)
xx2000002135
Action Note
1 Fit the o-ring to its groove. Valid for CRB 15000-5/0.95
Replace if damaged. O-ring: 3HAC061327-051
xx2000001962
xx2300000849
Action Note
2 For robots with RobotWare earlier than 7.10
Place the cover at mounting position and recon-
nect the brake release connector DR.X8 to the
drive board.
xx2000002134
xx2000002133
4 Refit the cover with the four screws. Valid for CRB 15000-5/0.95
Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.2 Nm
Valid for CRB 15000-10/1.52 and
CRB 15000-12/1.27
Hex socket head cap screw: M3x12
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 1.4 Nm
xx2000002132
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Clean the mounting surface of the joint unit and Cleaning agent: Isopropanol
the mating surface on the casting with isopropan- Flange sealant: Loctite 574
ol.
Joint unit mounting surface is pointed out in the
figure.
3 Apply a thin layer of flange sealant to the mount-
ing surface. Do not contaminate the radial sealing
with sealant.
CAUTION xx2000001860
Action Note
1
CAUTION
Action Note
2 Fit the lifting aid to the joint unit. Joint unit: 3HAC079143-001 (for
CRB 15000-5/0.95) / 3HAC087546-
CAUTION 001 (for CRB 15000-10/1.52 and
CRB 15000-12/1.27)
The connectors and the joint unit cables are Lifting aid: 3HAC077789-001
sensitive to mechanical damage. Handle the as- Screws: M3x12 (4 pcs)
sembly with care.
xx2000001957
3 Fit two guide pins to the joint unit. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
For joint units on axes 4, 5 and 6.
xx2000002438
xx2100000041
Action Note
5 Fit the joint unit to the tilt, aligning the pin with the
pin hole.
CAUTION
xx2000002195
6 Secure the joint unit with new attachment screws. Flange socket head screw with
glue: 3HAB3413-330
M3x30 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue , 12 pcs
Used for joint unit of CRB 15000-
5/0.95.
Always use new screws when refit-
ting a joint unit. If ordering a new
joint unit spare part, new screws
are included.
xx2100000329
xx2000002170
Action Note
10 Remove the lifting aid by removing the screws.
xx2000002168
Action Note
1 Reconnect the connectors to the drive board.
• D6.X1 to X1
• D6.DC+ to +DC
• D6.DC- to Ground
• D6.X4 to X4
• D6.X2 to X2
• D6.X5 to X5
xx2000002164
xx2000002163
Action Note
3 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000002162
xx2000002161
Action Note
1 Fit the o-ring to its groove. O-ring: 3HAC061327-051
Replace if damaged.
xx2000002551
Action Note
2 Place the arm-side interface at mounting position
and reconnect the connectors.
• ASI.DC+
• ASI.DC-
• ASI.X1
The correct orientation of the arm-side interface
is with the convex button in upper position.
Note
xx2100000336
3 Refit the arm-side interface with four screws. Valid for CRB 15000-5/0.95
Hex socket head cap screw: M3x30
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm
Valid for CRB 15000-10/1.52 and
CRB 15000-12/1.27
Hex socket head cap screw: M3x20
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm
xx2000002550
Action Note
1 Clean the mounting surface with isopropanol. Cleaning agent: Isopropanol
Apply flange sealant to the corner of the adapter Flange sealant: Loctite 574
mounting surface, as pointed out in the figure.
xx2000002196
2 Refit the tool flange adapter, aligning the pin with Axis-6 inner flange: 3HAC073952-
the pin hole. 001
xx2000002167
xx2000002165
Action Note
1 Secure the cable for functional earth to the tool
flange adapter with a screw.
xx2000002159
Action Note
1 Check the o-ring on the tool flange and lubricate Axis-6 flange: 3HAC073953-001
with grease. O-ring: 3HAB3772-182
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000002197
xx2000002158
Action Note
3 Fit the connectors to the cable bracket and secure Cable ties (2 pcs)
the connectors with two cable ties.
xx2000002157
4 Refit and secure the tool flange with screws and Hex socket head cap screw: M3x12
washers. 12.9 Lafre 2C2B/FC6.9 (10 pcs)
Spring washer: 7x3.2x0.6 Steel (10
pcs)
Tightening torque: 1.8 Nm.
xx2000002155
Action Note
1 Fit two guide pins to the axis-5 joint. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
xx2000002146
Action Note
2 Clean the mounting surface with isopropanol. Cleaning agent: Isopropanol
Apply flange sealant to the corner of the tubular Flange sealant: Loctite 574
mounting surface, as pointed out in the figure.
xx2000002147
xx2000002131
5 Secure the tilt to the tubular with all attachment Flange socket head screw: M3x20
screws but two. 12.9 Lafre 2C2B/FC6.9+PrO-
Pre-tighten the screws crosswise firstly. COat111 (14 pcs)
xx2000002130
6 Remove the guide pins and fasten the remaining Flange socket head screw: M3x20
two screws. 12.9 Lafre 2C2B/FC6.9+PrO-
COat111 (2 pcs)
xx2000002128
Action Note
1 Insert the cabling into the tubular. Valid for CRB 15000-5/0.95
xx2000002148
xx2300000845
xx2000002125
xx2000002089
Action Note
4 Secure the cables for functional earth and protect- Hex socket head cap screw: M3x6
ive earth with a screw. (1 pcs).
Tightening torque: 0.8 Nm.
xx2000002087
5 Secure the cabling to joint unit with cable ties. Cable ties (3 pcs)
xx2000002086
6 Secure the cabling to tubular with cable ties. Cable ties (2 pcs)
Valid for CRB 15000-5/0.95
xx2000002124
xx2300000842
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-043
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000002149
2 Refit the cover with new attachment screws. Flange socket head screw with
glue: 3HAB3413-312
M3x12 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue
For tubular cover of CRB 15000-
5/0.95.
Always use new screws.
If ordering a new axis-4 or axis-5
joint unit spare part, new screws
for the tubular cover are included.
Tightening torque: 1.6 Nm.
xx2000002123
Action Note
1 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-076
Replace if damaged. O-ring: 3HAB3772-166
Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2300000846
xx2300000847
2 Refit the covers with new attachment screws. Hex socket head cap screw:
3HAB3409-224
M3x12 12.9 Lafre 2C2B/FC6.9 (3
pcs)
Tightening torque: 1.4 Nm.
xx2000002123
Action Note
1 Fit the o-ring to its groove. Valid for CRB 15000-5/0.95
Replace if damaged. O-ring: 3HAC061327-051
xx2000002092
xx2300000848
xx2000002085
xx2000002084
Action Note
4 Refit the cover with the four screws. Hex socket head cap screw: M3x8
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.2 Nm (for CRB
15000-5/0.95) / 0.9 Nm (for CRB
15000-10/1.52 and CRB 15000-
12/1.27)
Tightening torque: 0.9 Nm
xx2000002083
Concluding procedure
Action Note
1 Calibrate the joint unit torque sensor. See Calibration on page 1063
1 On the FlexPendant, go to the Code app
and call the calibration procedure using PP
to Routine, not by using Call Routine.
2 Select the Joint Unit Replacement feature
and then select the axis to calibrate.
3 The controller is now restarted. Once the
home screen of the FlexPendant is shown,
press the Play button to continue the calib-
ration routine.
4 The robot moves to a position or positions
where measurements are performed.
5 The results of the measurements are
presented together with the current values
in the controller. Choose whether to save
the calibration data or not.
6 If new calibration data is saved you will be
asked to do a test with the lead-through
functionality active to verify that the
sensors work correctly.
7 Finally the robot is moved back to the ori-
ginal position.
8 Test the brake release (movement without
drive power) functionality, see Testing the
brake release functionality on page 196.
2
DANGER
xx2000002122
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the CRB 15000 via myABB Business Portal,
www.abb.com/myABB.
Required consumables
Action Note
1 Jog the robot to the specified position: Example of CRB 15000-5/0.95,
• Axis 1: No significance. similar to CRB 15000-10/1.52 and
• Axis 2: No significance. CRB 15000-12/1.27.
• Axis 3: No significance.
• Axis 4: No significance.
• Axis 5: approximately +20°
• Axis 6: 0° (home position)
CAUTION
2
CAUTION
Action Note
1 Remove the tool flange screws and washers.
xx2000002155
2
CAUTION
Action Note
3 Cut the cable ties.
xx2000002157
xx2000002158
Action Note
1 Remove the functional earth cable by removing
the screw.
xx2000002159
Action Note
1 Remove the tool flange adapter screws.
xx2000002165
Action Note
2 Press the adapter out of position by using two of
the attachment screws as removal tools.
xx2000002166
xx2000002167
Action Note
1
CAUTION
2
CAUTION
xx2000002550
Action Note
4 Loosen the arm-side interface carefully and dis-
connect the connectors from it.
• ASI.DC+
• ASI.DC-
• ASI.X1
xx2100000335
Action Note
1 Cut the cable ties.
xx2000002161
xx2000002162
xx2000002163
Action Note
4 Disconnect the connectors from the drive board. Tweezers
• D6.X1
• D6.DC+
• D6.DC-
• D6.X4
• D6.X2
• D6.X5
CAUTION
xx2000002164
Action Note
1 Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC077789-001
sensor side. Screws: M3x12 (4 pcs)
CAUTION
xx2000002168
xx2000002170
Action Note
3 Fit two guide pins to the axis-6 joint unit. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
For joint units on axes 4, 5 and 6.
xx2100000328
xx2100000329
xx2100000330
Action Note
6 Remove the joint unit from the tubular.
CAUTION
xx2000002169
xx2000001957
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
Action Note
2 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
Tip 10/1.52 and CRB 15000-12/1.27)
xx2000002057
xx2000002058
xx2100000301
Action Note
5 Remove the cable support from the drive board
by removing the attachment screws.
xx2000002055
xx2000002053
xx2000002049
CAUTION
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
Action Note
2 Place the joint cable through the hollow shaft from
the torque sensor side.
CAUTION
xx2000002051
4 Secure the cable plate to the joint unit with the Hex socket head cap screw:
attachment screws. M2.5x6 12.9 Lafre 2C2B/FC6.9 (4
pcs)
Tightening torque: 0.45 Nm.
xx2000002049
xx2000002053
Action Note
6 Insert the cabling through the cable support and
fit the support to the drive board with the attach-
ment screws.
xx2000002056
xx2000002055
xx2100000507
Action Note
8 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001
(for CRB 15000-5/0.95) /
3HAC087789-001 (for CRB 15000-
10/1.52 and CRB 15000-12/1.27)
xx2000002057
9 Secure the cables to the cable support with a Cable tie: 3HAC075545-001. For
cable tie, using a cable tie gun. securing joint unit cable.
Assembly direction for the cable tie is shown in Cable tie gun EVO 7i
the figure. Settiing for cable tie gun: 6.75.
xx2000002058
xx2000002059
Action Note
10 Remove the protection plate.
xx2100000301
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2 Clean the mounting surface of the joint unit and Cleaning agent: Isopropanol
the mating surface on the casting with isopropan- Flange sealant: Loctite 574
ol.
Joint unit mounting surface is pointed out in the
figure.
3 Apply a thin layer of flange sealant to the mount-
ing surface. Do not contaminate the radial sealing
with sealant.
CAUTION xx2000001860
Action Note
1
CAUTION
2 Fit the lifting aid to the joint unit. Joint unit: 3HAC079143-001 (for
CRB 15000-5/0.95) / 3HAC087546-
CAUTION 001 (for CRB 15000-10/1.52 and
CRB 15000-12/1.27)
The connectors and the joint unit cables are Lifting aid: 3HAC077789-001
sensitive to mechanical damage. Handle the as- Screws: M3x12 (4 pcs)
sembly with care.
xx2000001957
3 Fit two guide pins to the joint unit. Guide pin, M3x110: 3HAC077787-
001
Always use guide pins in pairs.
For joint units on axes 4, 5 and 6.
xx2000002438
xx2100000041
Action Note
5 Fit the joint unit to the tilt, aligning the pin with the
pin hole.
CAUTION
xx2000002195
6 Secure the joint unit with new attachment screws. Flange socket head screw with
glue: 3HAB3413-330
M3x30 12.9 Lafre
2C2B/FC6.9+PrO-COat111, with
NYPLAS glue , 12 pcs
Used for joint unit of CRB 15000-
5/0.95.
Always use new screws when refit-
ting a joint unit. If ordering a new
joint unit spare part, new screws
are included.
xx2100000329
xx2000002170
Action Note
10 Remove the lifting aid by removing the screws.
xx2000002168
Action Note
1 Reconnect the connectors to the drive board.
• D6.X1 to X1
• D6.DC+ to +DC
• D6.DC- to Ground
• D6.X4 to X4
• D6.X2 to X2
• D6.X5 to X5
xx2000002164
xx2000002163
Action Note
3 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1
protective earth with a screw. pcs).
Tightening torque: 0.8 Nm.
xx2000002162
xx2000002161
Action Note
1 Fit the o-ring to its groove. O-ring: 3HAC061327-051
Replace if damaged.
xx2000002551
Action Note
2 Place the arm-side interface at mounting position
and reconnect the connectors.
• ASI.DC+
• ASI.DC-
• ASI.X1
The correct orientation of the arm-side interface
is with the convex button in upper position.
Note
xx2100000336
3 Refit the arm-side interface with four screws. Valid for CRB 15000-5/0.95
Hex socket head cap screw: M3x30
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm
Valid for CRB 15000-10/1.52 and
CRB 15000-12/1.27
Hex socket head cap screw: M3x20
12.9 Lafre 2C2B/FC6.9 (4 pcs)
Tightening torque: 0.45 Nm
xx2000002550
Action Note
1 Clean the mounting surface with isopropanol. Cleaning agent: Isopropanol
Apply flange sealant to the corner of the adapter Flange sealant: Loctite 574
mounting surface, as pointed out in the figure.
xx2000002196
2 Refit the tool flange adapter, aligning the pin with Axis-6 inner flange: 3HAC073952-
the pin hole. 001
xx2000002167
xx2000002165
Action Note
1 Secure the cable for functional earth to the tool
flange adapter with a screw.
xx2000002159
Action Note
1 Check the o-ring on the tool flange and lubricate Axis-6 flange: 3HAC073953-001
with grease. O-ring: 3HAB3772-182
Replace if damaged. Grease: 3HAC042536-001 (Shell
Gadus S2)
xx2000002197
xx2000002158
Action Note
3 Fit the connectors to the cable bracket and secure Cable ties (2 pcs)
the connectors with two cable ties.
xx2000002157
4 Refit and secure the tool flange with screws and Hex socket head cap screw: M3x12
washers. 12.9 Lafre 2C2B/FC6.9 (10 pcs)
Spring washer: 7x3.2x0.6 Steel (10
pcs)
Tightening torque: 1.8 Nm.
xx2000002155
Concluding procedure
Action Note
1 Calibrate the joint unit torque sensor. See Calibration on page 1063
1 On the FlexPendant, go to the Code app
and call the calibration procedure using PP
to Routine, not by using Call Routine.
2 Select the Joint Unit Replacement feature
and then select the axis to calibrate.
3 The controller is now restarted. Once the
home screen of the FlexPendant is shown,
press the Play button to continue the calib-
ration routine.
4 The robot moves to a position or positions
where measurements are performed.
5 The results of the measurements are
presented together with the current values
in the controller. Choose whether to save
the calibration data or not.
6 If new calibration data is saved you will be
asked to do a test with the lead-through
functionality active to verify that the
sensors work correctly.
7 Finally the robot is moved back to the ori-
ginal position.
8 Test the brake release (movement without
drive power) functionality, see Testing the
brake release functionality on page 196.
2
DANGER
6 Calibration
6.1 Calibration methods
Overview
This section specifies the different types of calibration and the calibration methods
that are supplied by ABB.
Types of calibration
This is shown on the FlexPendant as error code 90549 Torque sensor check
failure or 34334 Arm side torque sensor error.
• A joint unit has been replaced.
• Repair work that involves removal and refitting of the joint units, has been
performed.
• After heavy collisions or uncontrolled stops. This does not apply to collisions
or stops which may routinely be experienced as part of a power and force
limiting application.
No calibration is needed at site at robot installation.
The torque sensor routine only works on floor mounted robots.
Tip
When designing the robot cell, run the torque sensor routine in RobotStudio to
verify that the path and pose are obtainable in the planned design.
References
Article numbers for the calibration tools are listed in the section Special tools on
page 1100.
CAUTION
Keep a distance from the robot while the routine is running, until the calibration
data has been reviewed, accepted as reasonable, and stored.
1 On the FlexPendant, go to the Code app and call the calibration procedure
Torque Sensor Calib, using PP to Routine, not by using Call Routine. Press
Play.
2 Select which feature to run.
The features are described in Features in the routine on page 1065.
Only the feature Torque Sensor Check is shown for users without user grant
Safety Services.
The other features require a password. The password is 14775 (cannot be
changed).
3 Select which axis to calibrate.
Continues on next page
Product manual - CRB 15000 1065
3HAC077389-001 Revision: L
© Copyright 2021 - 2023 ABB. All rights reserved.
6 Calibration
6.2 Calibrating the torque sensors
Continued
4 For the Joint Unit Replacement feature, the controller will now restart. Once
the home screen of the FlexPendant is shown, press the Play button to
continue the calibration routine.
5 The robot moves to a position or positions where measurements are
performed.
6 The results of the measurements are presented together with the current
values in the controller. Choose whether to save the calibration data or not.
If the calibration data is saved, the new sensor offsets are saved in a file
called TSENS_LOG.TXT in the HOME directory.
7 If new calibration data is saved you will be asked to do a test with the
lead-through functionality active to verify that the sensors work correctly.
8 Finally the robot is moved back to the original position.
Tip
If the Joint Unit Replacement feature has been run, there is no need to run any
of the other features.
xx2000002400
Tip
Select positions with large reorientations around the TCP. For best results,
make sure that axis 4 and 5 have large movements.
a Jog the robot to an appropriate position,
A, for the first approach point.
Use small increments to accurately posi-
tion the tool tip as close to the reference
point as possible.
b Tap Modify Position to define the point.
c Repeat for each approach point to be
defined, positions B, C, and D.
Jog away from the fixed world point to
achieve the best result. Just changing the
tool orientation will not give as good a
result.
en0400000906
7 Troubleshooting
7.1 Introduction to troubleshooting
Introduction
The product manual and the circuit diagram contains information that can be good
when troubleshooting.
For OmniCore, all event logs from the software can be seen on the FlexPendant,
or in Technical reference manual - Event logs for RobotWare 7.
Make sure to read through the section Safety on page 17 before starting.
Troubleshooting strategies
1 Isolate the fault to pinpoint the cause of the problem from consequential
problems.
2 Divide the fault chain in two.
3 Check communication parameters and cables.
4 Check that the software version is compatible with the hardware.
Work systematically
1 Take a look around to make sure that all screws, connectors, and cables are
secured, and that the robot and other parts are clean, not damaged, and
correctly fitted.
2 Replace one thing at a time.
3 Do not replace units randomly.
4 Make sure that there are no loose screws, turnings, or other unexpected
parts remaining after work has been performed.
5 When the work is completed, verify that the safety functions are working as
intended.
Basic scenarios
What to look for during troubleshooting depends on when the fault occurred. Was
the robot recently installed or was it recently repaired? The following table gives
hints on what to look for in specific situations.
The robot has recently Check:
been installed • the configuration files
• connectors
• options and their configuration
• changes in the robot working space/movements.
Description
Mechanical noise or dissonance that has not been observed before can indicate
problems in bearings, motors, gearboxes, or similar. Be observant of changes over
time.
A faulty bearing often emits scraping, grinding, or clicking noises shortly before
failing.
Consequences
Failing bearings cause the path accuracy to become inconsistent, and in severe
cases, the joint can seize completely.
Possible causes
The symptom can be caused by:
• Worn bearings.
• Contaminations have entered the bearing grooves.
• Loss of lubrication in bearings.
• Loose heat sinks, fans, or metal parts.
If the noise is emitted from a gearbox, the following can also apply:
• Overheating.
Recommended actions
The following actions are recommended:
Action Information
1
CAUTION
Description
The manipulator is able to work correctly while Motors ON is active, but when
Motors OFF is active, one or more axes drops or collapses under its own weight.
The holding brakes (normally one in each motor), is not able to hold the weight of
the manipulator arm.
Consequences
For a heavy robot, the collapse can cause severe injury to personnel working in
the area or severe damage to the robot and/or surrounding equipment.
For a small robot, the collapse can cause injury to personnel working close to the
robot or damage to the robot and/or surrounding equipment.
Possible causes
The symptom can be caused by:
• Faulty brake.
• Faulty power supply to the brake.
Recommended actions
The following actions are recommended:
Action Information
1 Determine which motor(s) causes the robot
to collapse.
2 Check the brake power supply to the col- See the circuit diagram.
lapsing motor during the Motors OFF state. Check for any recorded fault status.
Description
The holding brake of a motor is not released using the brake release tool.
Consequences
The robot axis can not be manually moved.
Possible causes
The symptom can be caused by:
• The RobotWare version is 7.10 or higher. Then the brakes are released using
the FlexPendant, see Manually releasing the brakes on page 69.
• Damaged magnet on the brake release tool.
• Faulty power supply to the brake.
• Incorrect usage of the brake release tool:
- There has been an attempt to use the brake release mechanism while
the robot is in mode MOTORS ON.
- There has been an attempt to use the brake release mechanism in
automatic operating mode.
- There has been an attempt to use the brake release mechanism during
the startup phase of the controller, that is, before the controller is fully
operational.
- There has been an attempt to use the brake release mechanism while
the manipulator is moving.
- There has been a very brief application of the magnet to the brake
release points, for example, by accident.
• Faulty joint electronic hardware.
Recommended actions
The following actions are recommended:
Action Information
1 Look for damage to the magnet. Brake release tool: 3HAC079146-001
Replace the tool if damaged.
Note
2 Verify that the brake release tool is used See Manually releasing the brakes with
correctly. the external tool on page 71.
3 Check the brake power supply to the motor See the circuit diagram.
during the Motors OFF state. Check for any recorded fault status.
Action Information
4 Reset the brake release software as follows:
1 Turn off electrical power supply to the robot.
2 Turn on electrical power supply to the robot, without enabling the motors, and
perform following step within 30 minutes.
3 Wait for the controller to be fully operational, for example, verify that the Flex-
Pendant is restarted. Place the brake release tool against the brake release
point on the joint and hold for 2-10 seconds. Remove the brake release tool
and wait for at least 2 seconds.
Software is reset. Any error code is removed from the FlexPendant.
4 Test the brake release function using the brake release tool against the brake
release point on the joint.
If the brake still does not release, repeat the reset cycle steps 3 and 4.
Five (5) attempts are allowed in total to reset the brake release. If desired, the
process can be repeated from step 1. If the brake still does not release, contact
the local ABB customer service.
7.5 Drive system communication link and DC link are both down during robot running
Description
During robot running, the robot system enters system failure state with 34402 "DC
link voltage too low" and 39351 "The drive system communication link is down"
reported.
Consequence
No operation will be possible until the fault is corrected.
Possible causes
• The system power is derating when the robot system is running with incoming
mains lower than 180 VAC.
• The incoming mains voltage to the rectifier unit is out of specification.
• Cable between manipulator and controller is disconnected.
Recommended actions
1 Run warm-up cycles.
2 Reduce acceleration or speed.
3 Change to 230 VAC incoming mains, or add an external transformer to
upgrade the incoming mains to 230 VAC.
4 Check incoming mains voltage. Change the mains tolerance min so that the
mains voltage is inside the specified interval.
5 Check the cable connection between manipulator and controller.
6 Check for other hardware event log messages regarding connection problem.
Description
The ProfiNet LED on the laser scanner is not lit up, indicating that the profinet
communication between the laser scanner, PLC, and OmniCore controller fails to
be set up. However, the cable connection is properly connected and necessary
parameters are correctly set during the laser scanner configuration.
This issue may occur when PROFIsafe-based laser scanner(s) is connected.
Consequences
Communication fails to be set up between the laser scanner, PLC, and OmniCore.
The safety separation function with the laser scanner cannot be applied.
Possible causes
The firewall for the ProfiNet network is disabled.
Recommended actions
1 Open RobotStudio.
2 In the Controller tab page, choose Communication from the Configuration
group.
3 Select Firewall Manager in the Type pane.
4 Set Enable on Public Network to Yes for the network service ProfiNet.
Description
The OmniCore controller and PLC are configured with all parameters correctly set.
However, the communication between the OmniCore controller and PLC still fails.
This issue may occur when the PROFIsafe-based laser scanner(s) is connected.
Consequence
The safety configurations do not take effect.
Possible causes
During configuration of communication between the OmniCore controller and PLC,
the PROFIsafe device information must be configured on the OmniCore controller’s
side first. Otherwise, the configured signals will not be saved in the safety module
in the OmniCore controller.
Recommended actions
1 Open the RobotStudio.
2 In the Controller tab page, choose Visual SafeMove from Safety in the
Configuration group.
3 Check the Safe I/O configurations.
For robots running RobotWare 7.5 or earlier, the following signals can be
observed.
xx2100000511
For robots running RobotWare 7.6 or later, the following signals can be
observed.
xx2200000304
Description
The OmniCore controller and scalable I/O device DSQC1042 are configured with
all parameters correctly set. However, the communication between the OmniCore
controller and scalable I/O device still fails.
This issue may occur when the SafetyIO-based laser scanner(s) is connected.
Consequence
The safety configurations do not take effect.
Possible causes
During configuration of communication between the OmniCore controller and
scalable I/O device, the scalable I/O device information must be configured on the
OmniCore controller’s side first. Otherwise, the configured signals will not be saved
in the OmniCore controller.
Recommended actions
1 Open the RobotStudio.
2 In the Controller tab page, choose Visual SafeMove from Safety in the
Configuration group.
3 Check the Safe I/O configurations.
The following signals can be observed.
xx2200000305
Description
The robot configured with PROFINET-based laser scanner(s) needs to replace
with SafetyIO-based laser scanner. During system update using the Installation
Manager, system failure occurs after removing the profisafe package option(s)
and selecting required IO package option(s).
Consequence
The system cannot be successfully set up.
Possible causes
Option 3020-2 PROFINET Device and option 3023-2 PROFIsafe Device are removed
together with the profisafe package option(s), and the safety configurations become
invalid.
Recommended actions
1 On the home page of the FlexPendant, tap Settings.
2 Tap Backup & Recovery.
3 Tap Reset user data.
4 Select Reset safety settings.
5 Tap Reset.
6 Restart the controller.
If the problem persists, reinstall the system.
Description
The speed in the Safe area is not at the full speed specified in the motion instruction
or even at zero speed after the SST/TSP violation is triggered.
This issue may occur when robot is running in RobotWare 7.5 or an earlier version.
Consequences
Robot cannot move in the specified speed, that is, in slow speed, or even stops
movement in the Safe area.
Possible causes
Before the SST/TSP is triggered, the system triggers Protecting or Warning area
speed control first. In this case, the speed control module uses the value of
SpeedRefresh to control the robot movement speed. At the time that the SST/TSP
triggers the robot stopping, the speed control has already changed by the
SpeedRefresh value which is 0 in Protecting area and 20 in Warning area.
When users are back to the Safe area and restart or step the program after the
SST/TSP violation, the SpeedRefresh value that refresh the speed to 100 does
not take effect. That is, the speed is still controlled by the SpeedRefresh value 0
or 20. Although the speed shown in the FlexPendant is 100%, the actual speed is
still controlled by the combination of the SpeedRefresh value and the speed set
in motion instruction, which will result in the movement stopping or moving in slow
speed in the Safe area.
Furthermore, when the STT violation is triggered, the manipulator triggers Cat0 or
Cat1 emergency stop. If the user tries to start program in the Protecting area but
is not in the STT area, the robot will start moving a short path to regain the previous
point and then stop. In this case, the speed is restricted to 0.
For more details, see Strategies (RobotWare 7.5) on page 174.
Recommended actions
Users could perform either of the following solutions:
• Reset the program pointer and start the program in the Safe area again.
• Enter the Warning area but not trigger the TSP supervision violation and then
back to the Safe area again.
Description
The installed lead-through or laser scanner options fail to be removed or reselected
in the Collaborative Speed Control add-in using Installation Manager 7.
Consequence
• Modules of the SpeedHandling function remain in task T_ROB1 after the
installed options are removed.
• Existing template SafeMove configuration file is not removed after the installed
options are removed or not synchronized with new configuration file for the
new option after the installed options are reselected.
Recommended actions
1 Reset the template SafeMove configuration file to factory settings and apply
it to the controller.
2 For scenarios to remove options, de-select the checkboxes of the options
that require to be removed in the Collaborative Speed Control add-in and
apply it to the controller.
3 For scenarios to reselect options, de-select the checkboxes of the options
not required first and then select the required options in the Collaborative
Speed Control add-in and apply it to the controller.
4 Reset the RAPID programs and parameters in RobotStudio and restart the
controller.
5 Load the template SafeMove configuration file using the SafeMove
configurator app on FlexPendant.
7.12 Unexpected robot movement when starting the program in Protecting Area
Description
The robot moves unexpectedly in a speed not larger than 250 mm/sec when the
user starts the program in Protecting area, in which situation the robot should be
stopped and stand still.
Consequence
The unexpected robot movement may cause damages or injuries to objects or
persons within its movement range.
Possible causes
The robot moves in mentioned scenario only when all of the following conditions
are met:
• The function ISH_b_FunctionlityIsUsed in RAPID program
InternalSpeedHandling_User is set to TRUE.
• The template SafeMove configuration file provided with the Collaborative
Speed Control add-in is not loaded, or is loaded but Global_SST configuration
is removed or the ISH_UserMODE_bNot_IntemitCollab is set to 1.
• The system is in Auto mode or Manual Full Speed mode.
• The robot was stopped during running a program, and then manually moved
to another position which is within the range of the robot return path.
• The user stands in Protecting area and restarts the program using
FlexPendant.
Recommended actions
Reset the template SafeMove configuration file to factory setting and then load the
configuration file provided with the Collaborative Speed Control add-in. See detailed
procedures in The SafeMove configurator app on FlexPendant on page 120.
LED Error
LED PWR
LED Status
LED Safety
xx2200000706
Diagnostic codes
LED PWR
8 Decommissioning
8.1 Introduction to decommissioning
Introduction
This section contains information to consider when taking a product, robot or
controller, out of operation.
It deals with how to handle potentially dangerous components and potentially
hazardous materials.
Note
Transportation
Prepare the robot or parts before transport, this to avoid hazards.
Introduction
ABB robots contain components in different materials. During decommissioning,
all materials should be dismantled, recycled, or reused responsibly, according to
the relevant laws and industrial standards. Robots or parts that can be reused or
upcycled helps to reduce the usage of natural resources.
Symbol
The following symbol indicates that the product must not be disposed of as common
garbage. Handle each product according to local regulations for the respective
content (see table below).
xx1800000058
xx1900000803
Green symbol with "e" in it: The product does not contain any hazardous substances
exceeding concentration limits and is a green environmentally friendly product
which can be recycled.
Note
DANGER
9 Reference information
9.1 Introduction
General
This chapter includes general information, complementing the more specific
information in the different procedures in the manual.
General
The product is compliant with ISO 10218-1:2011, Robots for industrial environments
- Safety requirements - Part 1 Robots, and applicable parts in the normative
references, as referred to from ISO 10218-1:2011. In case of deviation from ISO
10218-1:2011, these are listed in the declaration of incorporation. The declaration
of incorporation is part of the delivery.
Robot standards
Standard Description
ISO 9283 Manipulating industrial robots – Performance criteria and re-
lated test methods
ISO 9787 Robots and robotic devices – Coordinate systems and motion
nomenclatures
ISO 9946 Manipulating industrial robots – Presentation of characteristics
Standard Description
IEC 60204-1 Safety of machinery - Electrical equipment of machines - Part
1: General requirements, normative reference from ISO 10218-
1
IEC 61000-6-2 Electromagnetic compatibility (EMC) – Part 6-2: Generic
standards – Immunity standard for industrial environments
IEC 61000-6-4 Electromagnetic compatibility (EMC) – Part 6-4: Generic
standards – Emission standard for industrial environments
ISO 13849-1:2006 Safety of machinery - Safety related parts of control systems
- Part 1: General principles for design, normative reference
from ISO 10218-1
ISO/TS 15066 Robots and robotic devices - Collaborative robots
This Technical Specification specifies safety requirements for
collaborative industrial robot systems and the work environ-
ment, and supplements the requirements and guidance on
collaborative industrial robot operation given in ISO 10218-1
and ISO 10218-2.
Standard Description
ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems
ANSI/UL 1740 Safety standard for robots and robotic equipment
CAN/CSA Z 434-03 Industrial robots and robot Systems - General safety require-
ments
EN ISO 10218-1 Robots and robotic devices — Safety requirements for indus-
trial robots — Part 1: Robots
Deviations
Deviations from ISO 10218-1:2011 for CRB 15000
The CRB 15000 is intended for collaborative operation. The integrator of the robot
system is required to perform an assessment of the hazards and risks.
Requirement Deviation for CRB Motivation
15000
§5.3.5 Single point of The arm side interface The CRB 15000 robot is intended for collab-
control. can be overridden in orative applications where contact between
automatic mode. robot and the operator is harmless.
Converter table
Use the following table to convert units used in this manual.
Quantity Units
Length 1m 3.28 ft. 39.37 in
Weight 1 kg 2.21 lb.
Weight 1g 0.035 ounces
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.225 lbf
Moment 1 Nm 0.738 lbf-ft
Volume 1L 0.264 US gal
General
This section describes how to tighten the various types of screw joints on ABB
robots.
The instructions and torque values are valid for screw joints comprised of metallic
materials and do not apply to soft or brittle materials.
Tightening torque
Before tightening any screw, note the following:
• Special torques are specified in the repair, maintenance or installation
procedure descriptions. Any special torque specified overrides a standard
torque!
• Use the correct tightening torque for each type of screw joint.
• Only use correctly calibrated torque keys.
• Always tighten the joint by hand, and never use pneumatic tools.
• Use the correct tightening technique, that is do not jerk. Tighten the screw
in a slow, flowing motion.
• Maximum allowed total deviation from the specified value is 10%!
Definition
In installation, repair, and maintenance procedures, weights of the components
handled are sometimes specified. All components exceeding 22 kg (50 lbs) are
highlighted in this way.
To avoid injury, ABB recommends the use of a lifting accessory when handling
components with a weight exceeding 22 kg. A wide range of lifting accessories
and devices are available for each manipulator model.
Example
Following is an example of a weight specification in a procedure:
Action Note
CAUTION
General
All service (repairs, maintenance, and installation) procedures contains lists of
tools required to perform the specified activity.
All special tools required are listed directly in the procedures while all the tools
that are considered standard are gathered in the standard toolkit and defined in
the following table.
This way, the tools required are the sum of the standard toolkit and any tools listed
in the instruction.
General
All service instructions contain lists of tools required to perform the specified
activity. The required tools are a sum of standard tools, defined in the section
Standard toolkit on page 1099, and of special tools, listed directly in the instructions
and also gathered in this section.
Special tools
Note
If the replacing procedure is not listed in the table below, only standard tools are
needed for the procedure.
Axis-2 cabling
Axis-3 cabling
Axis-4 cabling
Axis-5 cabling
Axis-6 cabling
Wrist housing
Lower arm
Housing
Tubular
cabling
Swing
Base
Tools and equipment with spare part number:
(These tools can be ordered from ABB)
Lifting accessories
xx2100000465
xx2100000464
xx2300000825
xx2300000826
Guiding tools
Axis-2 cabling
Axis-3 cabling
Axis-4 cabling
Axis-5 cabling
Axis-6 cabling
Wrist housing
Lower arm
Housing
Tubular
cabling
Swing
Base
Tools and equipment with spare part number:
(These tools can be ordered from ABB)
xx2300000824
xx2300000824
Other tools
Cable tie gun EVO 7i - 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
xx2100000461
xx2100000461
ABB AS
Robotics & Discrete Automation
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000
ABB Inc.
Robotics & Discrete Automation
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000
abb.com/robotics
3HAC077389-001, Rev L, en