5 Installation and Commissioning 5.

5 Installation and Commissioning

5.11 Mechanical Dismounting of Manipulator
5.11.1 MechanicalDismounting of ManipulatorConfiguration A/B
Procedure
This section describes the mechanical dismounting of the manipulator. The
procedure may be required for performing possible repair procedures in the future.
The manipulator is lifted by using a lifting device installed on the manipulator and
an overhead crane or similar lifting equipment.

1. Place the robot in position for dismounting procedure, as shown inFigure 47.
2. Turn the electrical disconnect switch ‘off’ and lock switch in ‘off’ position.
WARNING!Make sure that the mains switch is ‘off’ and locked in ‘off’ positionbefore continuing. Also make sure that possible other connected systems are ‘off’.

WARNING!Brakes must under no circumstances be released unless specificallynoted. Releasing the brakes can cause severe injury. Disable the axis brake release
function and mark brake release function to prevent releasing the brakesaccidentally.

3.
Build a scaffold, so that the dismounting of the manipulator can be performedin a secure way.
4. Place transport pallet on a side on the floor beneath the manipulator.
WARNING!Make sure that thepallet is secured so that it can notdrop.

5.
Install lifting device (fig.47/2) with 2 e.a. screws (or lifting hooks) on top of
manipulator base unit (fig.47/5) and 2 e.a. screws (fig.47/3) on bottom of base
unit.(The illustration shows a manipulator configuration A. For a configuration
B, the lower end (fig.47/3) of the lifting device needs to be turned).
Figure 47 Lifting device

1
3
2
5
4
Product manual, IRB 5500
3HNA015911-001 en Rev.10


5 Installationand Commissioning

5.11 Mechanical Dismounting of Manipulator
6.
Attach lifting strap to lifting hook (fig.47/1) on lifting device (fig.47/2).
7. Tension the lifting strap. Check that strap is properly secured.
WARNING!Do not walk under the hanging load.
8.
Remove 4 e.a. M16 mounting screws (fig.47/4).
9.
Slowly lower the manipulator until it can be mounted to the transport pallet(fig.48/2).
Figure 48 Mounting manipulator to pallet

1
2
10. Install 4 attachment screws (fig.48/1).
11.
Slowly lower manipulatorsuch that thepallet andmanipulatorstart to rotate,asshown in Figure 37.
12. Lower the manipulator until it is resting on the floor.
13. Remove lifting equipment.
14. Remove lifting device from manipulator.
3HNA015911-001 en Rev.10
Product manual, IRB 5500


5 Installation and Commissioning

5.11 Mechanical Dismounting of Manipulator
5.11.2 MechanicalDismounting of Manipulator Vertical Configuration A/B
Procedure
This section describes the mechanical dismounting of the manipulator. The
procedure may be required for performing possible repair procedures in the future.
The manipulator is lifted by using a lifting device installed on the manipulator and
an overhead crane or similar lifting equipment.

1. Place the robot in position for dismounting procedure, as shown inFigure 49.
2. Turn the electrical disconnect switch ‘off’ and lock switch in ‘off’ position.
WARNING!Make sure that the mains switch is ‘off’ and locked in ‘off’ positionbefore continuing. Also make sure that possible other connected systems are ‘off’.

WARNING!Brakes must under no circumstances be released unless specificallynoted. Releasing the brakes can cause severe injury. Disable the axis brake release
function and mark brake release function to prevent releasing the brakesaccidentally.

3.
Build a scaffold, so that the dismounting of the manipulator can be performedin a secure way.
4. Place transport pallet on the floor beneath the manipulator.
5.
Install lifting device (fig.49/1) on manipulator as shown in following
illustration. (The illustration shows a manipulator configuration A. For a
configuration B, the lifting device needs to be turned).
Fit guide pins (fig.49/2 and 4) of support block (fig.49/6) into guide holes on
lifting device (fig.49/1). Instal the lifting device on top of manipulator base unitwith 2 e.a. screws (fig.49/5). Tighten screws with 20Nm. Tighten screw
(fig.49/3) such that the support block supports the vertical arm without any
slack.

Manipulator weight: Approx. 600kg

Product manual, IRB 5500
3HNA015911-001 en Rev.10


5 Installation and Commissioning
5.11 Mechanical Dismounting of Manipulator
92 3HNA015911-001 en Rev.10 Product manual, IRB 5500
Figure 49 Lifting device
6. Attach lifting strap (fig.49/7) to lifting hook (fig.49/8) on lifting device
(fig.49/9).
7. Tension the lifting strap. Check that strap is properly secured.
WARNING! Do not walk under the hanging load.
8. Remove 4 e.a. M16 mounting screws (fig.49/10).
9. Slowly lower the manipulator until the foot unit hits the transport pallet.
Carefully continue to lower the manipulator until it is horizontally and the foot
unit is resting completely in mounting position.
10. Install 4 attachment screws (fig.49/10).
11. Remove lifting equipment.
12. Remove lifting device from manipulator.
1
2
3
4
5
6
7
8
9
10

5 Installation and Commissioning

5.12 Manipulator Configuration Conversion
5.12Manipulator Configuration Conversion
Description
This section describes a procedure for changing a manipulator configuration A intoa configuration B.

1.
Invert the axis 1 stop devices. Not applicable for the manipulator vertical
configuration.
a.
Remove the axis 1 stop devices (fig.50/1,2) (configuration A) from the
base unit.
b.
Install the axis 1 stopdevices in inverted position,as shown in following
illustration (configuration B).
Figure 50 Axis 1 stop devices with base unit in center position, top view

Configuration A
Configuration B

Stop stud on Stop stud on
foot unit foot unit

Base unit in
center position
1
Base unit Foot unit


Base unit in
center position
1
2
Base unit Foot unit


2


Product manual, IRB 5500
3HNA015911-001 en Rev.10


5 Installationand Commissioning

5.12 Manipulator Configuration Conversion
2. Invert the axis 2 stop device.
a. Remove 2 e.a. attachment screws and remove the axis 2 stop device(fig.51/1) from the axis 2 arm.
b. Remove guide pin, the calibration mark, from stop device and install itagain on the other side.
c. Turn the stop device and install it in inverted position, as shown in
following illustration.

Figure 51 Axis 2 stop device with axis 2 arm in center position, front view

Configuration A Configuration B

Axis 2arm
in center position
Calibration mark
Attachment
screw
1
Stop device on
axis 2 arm
Axis 2 arm
in center position
Base unit Stop stud on base unit Base unit Stop stud on baseunit

3HNA015911-001 en Rev.10 Product manual, IRB 5500


5 Installation and Commissioning

5.12 Manipulator Configuration Conversion
3. Invert the axis 3 stop devices.
a. Remove the axis 3 stop devices (fig.52/1,2) (configuration A) from the
axis 3 arm (screws are located on rear side).
b. Release brakes for axis 3. For information on how to release the axisbrakes, see ’Releasing Axis Brakes’ on page 111.
c. Turn axis 3 arm 180°.
d. Turn stop devices (fig.52/1,2) and install them in inverted position, asshown in following illustration (configuration B).

Figure 52 Axis 3 stop devices with axis 3 arm in center position, front view

Configuration A Configuration B

1 2
Axis 2 arm
Stop stud on axis2 arm
1
Axis 3 arm
in center
position
Axis 2 arm
Stop stud on axis2 arm
2

Axis 3 arm
in center position

Product manual, IRB 5500 3HNA015911-001 en Rev.10


5 Installationand Commissioning

5.12 Manipulator Configuration Conversion
4.
Reinstall RobotWare software, as described in the ‘Operator’s Manual, IRC5P’/
Installation and Commissioning / Install/Update Controller Software.
3HNA015911-001 en Rev.10
Product manual, IRB 5500


6 Preventive Maintenance

6.1 Introduction
6
Preventive Maintenance

6.1Introduction
About this Chapter
This chapter provides instructions for performing scheduled preventivemaintenance on the manipulator.

The preventivemaintenance isbased on a maintenancechart with information about
required maintenance activities including intervals, and references to procedures forthe activities.

Note that the intervals described are recommended intervals. The intervals neededfor your installation may vary, depending on environmental conditions, number ofworking hours etc. The maintenance routines in this description must be seen inrelation to the plant’s own maintenance routines for the paint equipment.

Safety Information
Before any work described in this chapter is commenced, it is extremely important
that all information concerning safety is carefully studied.

There are general safety aspects that must be read through, as wellas more specificsafety information that describes danger and safety risks when performing the
procedures. Read the Safety Manual before performing any service work.


WARNING!No maintenance work must be performed on the robot before the safetyguidelines in the ‘Safety Manual’ have been read and understood. Work must only
be performed by skilled personnel with the proper training.

General Considerations
The prime objective ofany preventive maintenance program is to ensure maximumsystemavailability. Eachscheduled andproperly performed preventive maintenance
activity should assist in realizing this objective. Preventive maintenance that doesnot reduce system downtime is unnecessary and costly.

The robot and paint system is designed to be able to work under very demanding
conditions with a minimum of maintenance. Nevertheless, certain routine checks
and preventative maintenance must be carried out at given periodical intervals.

When performing routine maintenance or repair work, a number of precautionsmust be kept in mind to avoid introducing additional errors into the system.

.
Do not perform more than recommended preventive maintenance on equipmen

結果 (中文) 1:

5 安装和调试5.11 机械拆装的机械手5.11.1 MechanicalDismounting 的 ManipulatorConfiguration A / B程序本节介绍了机械手的机械拆装。的程序可能需要在将来进行可能的修复程序。机械手使用安装在机械臂上的升降装置解除和桥式起重机或类似的起重设备。1.地方机器人位置的卸载程序，如图所示的图 47。2.关闭电器断开开关 '关闭' 和锁开关在 '' 位置。警告!请确保电源开关是 '关闭' 和 '关闭' 贴现继续锁定。此外确认可能其他连接的系统是 '小康'。警告!刹车必须在任何情况下被释放，除非 specificallynoted。在松刹车会造成严重伤害。禁用轴制动释放功能和马克制动释放功能，以防止释放 brakesaccidentally。3。建立一个支架，从而可拆卸机械手 performedin 以安全的方式。4.地方运输托盘一边透过机械手在地板上。警告!请确保该 thepallet 安全的它可以 notdrop。5。顶部安装升降装置 (fig.47/2) 与 2 e.a.螺钉 (或起吊挂钩)机械手基本单元 (fig.47/5) 和基底部 2 e.a.螺钉 (fig.47/3)unit.(The illustration shows a manipulator configuration A. For a configuration B, the lower end (fig.47/3) of the lifting device needs to be turned). Figure 47 Lifting device 1 3 2 5 4 Product manual, IRB 5500 3HNA015911-001 en Rev.10 5 Installationand Commissioning 5.11 Mechanical Dismounting of Manipulator 6. Attach lifting strap to lifting hook (fig.47/1) on lifting device (fig.47/2). 7. Tension the lifting strap. Check that strap is properly secured. WARNING!Do not walk under the hanging load. 8. Remove 4 e.a. M16 mounting screws (fig.47/4). 9. Slowly lower the manipulator until it can be mounted to the transport pallet(fig.48/2). Figure 48 Mounting manipulator to pallet 1 2 10. Install 4 attachment screws (fig.48/1). 11. Slowly lower manipulatorsuch that thepallet andmanipulatorstart to rotate,asshown in Figure 37. 12. Lower the manipulator until it is resting on the floor. 13. Remove lifting equipment. 14. Remove lifting device from manipulator. 3HNA015911-001 en Rev.10 Product manual, IRB 5500 5 Installation and Commissioning 5.11 Mechanical Dismounting of Manipulator 5.11.2 MechanicalDismounting of Manipulator Vertical Configuration A/B Procedure This section describes the mechanical dismounting of the manipulator. The procedure may be required for performing possible repair procedures in the future. The manipulator is lifted by using a lifting device installed on the manipulator and an overhead crane or similar lifting equipment. 1. Place the robot in position for dismounting procedure, as shown inFigure 49. 2. Turn the electrical disconnect switch ‘off’ and lock switch in ‘off’ position. WARNING!Make sure that the mains switch is ‘off’ and locked in ‘off’ positionbefore continuing. Also make sure that possible other connected systems are ‘off’. WARNING!Brakes must under no circumstances be released unless specificallynoted. Releasing the brakes can cause severe injury. Disable the axis brake release function and mark brake release function to prevent releasing the brakesaccidentally. 3. Build a scaffold, so that the dismounting of the manipulator can be performedin a secure way. 4. Place transport pallet on the floor beneath the manipulator. 5. Install lifting device (fig.49/1) on manipulator as shown in following illustration. (The illustration shows a manipulator configuration A. For a configuration B, the lifting device needs to be turned). Fit guide pins (fig.49/2 and 4) of support block (fig.49/6) into guide holes on lifting device (fig.49/1). Instal the lifting device on top of manipulator base unitwith 2 e.a. screws (fig.49/5). Tighten screws with 20Nm. Tighten screw (fig.49/3) such that the support block supports the vertical arm without any slack. Manipulator weight: Approx. 600kg Product manual, IRB 5500 3HNA015911-001 en Rev.10 5 Installation and Commissioning 5.11 Mechanical Dismounting of Manipulator 92 3HNA015911-001 en Rev.10 Product manual, IRB 5500 Figure 49 Lifting device 6. Attach lifting strap (fig.49/7) to lifting hook (fig.49/8) on lifting device (fig.49/9). 7. Tension the lifting strap. Check that strap is properly secured. WARNING! Do not walk under the hanging load. 8. Remove 4 e.a. M16 mounting screws (fig.49/10). 9. Slowly lower the manipulator until the foot unit hits the transport pallet. Carefully continue to lower the manipulator until it is horizontally and the foot unit is resting completely in mounting position. 10. Install 4 attachment screws (fig.49/10). 11. Remove lifting equipment. 12. Remove lifting device from manipulator. 12345 6 789105 Installation and Commissioning 5.12 Manipulator Configuration Conversion 5.12Manipulator Configuration Conversion Description This section describes a procedure for changing a manipulator configuration A intoa configuration B. 1. Invert the axis 1 stop devices. Not applicable for the manipulator vertical configuration. a. Remove the axis 1 stop devices (fig.50/1,2) (configuration A) from the base unit. b. Install the axis 1 stopdevices in inverted position,as shown in following illustration (configuration B). Figure 50 Axis 1 stop devices with base unit in center position, top view Configuration A Configuration B Stop stud on Stop stud on foot unit foot unit Base unit in center position 1 Base unit Foot unit Base unit in center position 1 2 Base unit Foot unit 2 Product manual, IRB 5500 3HNA015911-001 en Rev.10 5 Installationand Commissioning 5.12 Manipulator Configuration Conversion 2. Invert the axis 2 stop device. a. Remove 2 e.a. attachment screws and remove the axis 2 stop device(fig.51/1) from the axis 2 arm. b. Remove guide pin, the calibration mark, from stop device and install itagain on the other side. c. Turn the stop device and install it in inverted position, as shown in following illustration. Figure 51 Axis 2 stop device with axis 2 arm in center position, front view Configuration A Configuration B Axis 2arm in center position Calibration mark Attachment screw 1 Stop device on axis 2 arm Axis 2 arm in center position Base unit Stop stud on base unit Base unit Stop stud on baseunit 3HNA015911-001 en Rev.10 Product manual, IRB 5500 5 Installation and Commissioning 5.12 Manipulator Configuration Conversion 3. Invert the axis 3 stop devices. a. Remove the axis 3 stop devices (fig.52/1,2) (configuration A) from the axis 3 arm (screws are located on rear side). b. Release brakes for axis 3. For information on how to release the axisbrakes, see ’Releasing Axis Brakes’ on page 111. c. Turn axis 3 arm 180°. d. Turn stop devices (fig.52/1,2) and install them in inverted position, asshown in following illustration (configuration B).
Figure 52 Axis 3 stop devices with axis 3 arm in center position, front view

Configuration A Configuration B

1 2
Axis 2 arm
Stop stud on axis2 arm
1
Axis 3 arm
in center
position
Axis 2 arm
Stop stud on axis2 arm
2

Axis 3 arm
in center position

Product manual, IRB 5500 3HNA015911-001 en Rev.10


5 Installationand Commissioning

5.12 Manipulator Configuration Conversion
4.
Reinstall RobotWare software, as described in the ‘Operator’s Manual, IRC5P’/
Installation and Commissioning / Install/Update Controller Software.
3HNA015911-001 en Rev.10
Product manual, IRB 5500


6 Preventive Maintenance

6.1 Introduction
6
Preventive Maintenance

6.1Introduction
About this Chapter
This chapter provides instructions for performing scheduled preventivemaintenance on the manipulator.

The preventivemaintenance isbased on a maintenancechart with information about
required maintenance activities including intervals, and references to procedures forthe activities.

Note that the intervals described are recommended intervals. The intervals neededfor your installation may vary, depending on environmental conditions, number ofworking hours etc. The maintenance routines in this description must be seen inrelation to the plant’s own maintenance routines for the paint equipment.

Safety Information
Before any work described in this chapter is commenced, it is extremely important
that all information concerning safety is carefully studied.

There are general safety aspects that must be read through, as wellas more specificsafety information that describes danger and safety risks when performing the
procedures. Read the Safety Manual before performing any service work.


WARNING!No maintenance work must be performed on the robot before the safetyguidelines in the ‘Safety Manual’ have been read and understood. Work must only
be performed by skilled personnel with the proper training.

General Considerations
The prime objective ofany preventive maintenance program is to ensure maximumsystemavailability. Eachscheduled andproperly performed preventive maintenance
activity should assist in realizing this objective. Preventive maintenance that doesnot reduce system downtime is unnecessary and costly.

The robot and paint system is designed to be able to work under very demanding
conditions with a minimum of maintenance. Nevertheless, certain routine checks
and preventative maintenance must be carried out at given periodical intervals.

When performing routine maintenance or repair work, a number of precautionsmust be kept in mind to avoid introducing additional errors into the system.

.
Do not perform more than recommended preventive maintenance on equipmen