abbrobotics productmanual irb2400 -...

ABB Robotics

Product manualIRB 2400

Trace back information:Workspace R13-1 version a6Checked in 2013-03-31Skribenta version 1184

Product manualIRB 2400/L

IRB 2400/10IRB 2400/16

M2000, M2000A, M2004

Document ID: 3HAC022031-001Revision: H

© Copyright 2004-2013 ABB. All rights reserved.

The information in this manual is subject to change without notice and should notbe construed as a commitment by ABB. ABB assumes no responsibility for any errorsthat may appear in this manual.Except as may be expressly stated anywhere in this manual, nothing herein shall beconstrued as any kind of guarantee or warranty by ABB for losses, damages topersons or property, fitness for a specific purpose or the like.In no event shall ABB be liable for incidental or consequential damages arising fromuse of this manual and products described herein.This manual and parts thereof must not be reproduced or copied without ABB'swritten permission.Additional copies of this manual may be obtained from ABB.The original language for this publication is English. Any other languages that aresupplied have been translated from English.

© Copyright 2004-2013 ABB. All rights reserved.ABB AB

Robotics ProductsSE-721 68 Västerås

Sweden

Table of contents9Overview of this manual ...................................................................................................................

13How to read the product manual ......................................................................................................14Product documentation, M2000/M2000A ........................................................................................15Product documentation, M2004 .......................................................................................................

171 Safety171.1 Introduction to safety information .........................................................................181.2 General safety information ..................................................................................181.2.1 Introduction to general safety information ....................................................191.2.2 Safety in the manipulator system ...............................................................201.2.3 Safety risks ............................................................................................201.2.3.1 Safety risks during installation and service work on manipulators .........231.2.3.2 CAUTION - Hot parts may cause burns! ...........................................241.2.3.3 Safety risks related to tools/work pieces ..........................................251.2.3.4 Safety risks related to pneumatic/hydraulic systems ..........................261.2.3.5 Safety risks during operational disturbances .....................................271.2.3.6 Risks associated with live electric parts ...........................................291.2.4 Safety actions .........................................................................................291.2.4.1 Safety fence dimensions ...............................................................301.2.4.2 Fire extinguishing ........................................................................311.2.4.3 Emergency release of the manipulator’s arm ....................................321.2.4.4 Brake testing ..............................................................................331.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" ........................341.2.4.6 Safe use of the FlexPendant ..........................................................351.2.4.7 Work inside the manipulator's working range ...................................361.2.5 Safety stops ...........................................................................................361.2.5.1 What is an emergency stop? ..........................................................381.3 Safety related instructions ..................................................................................381.3.1 Safety signals in the manual ......................................................................401.3.2 Safety symbols on manipulator labels .........................................................451.3.3 DANGER - Moving manipulators are potentially lethal! ...................................461.3.4 DANGER - First test run may cause injury or damage! ...................................471.3.5 DANGER - Make sure that the main power has been switched off! ....................491.3.6 WARNING - The unit is sensitive to ESD! .....................................................511.3.7 WARNING - Safety risks during handling of batteries .....................................521.3.8 WARNING - Safety risks during work with gearbox lubricants (oil or grease) ......

552 Installation and commissioning552.1 Introduction ......................................................................................................562.2 Unpacking .......................................................................................................562.2.1 Pre-installation procedure .........................................................................602.2.2 Working range ........................................................................................632.2.3 Risk of tipping/stability .............................................................................642.3 On-site installation ............................................................................................642.3.1 Lifting robot with lifting slings ....................................................................652.3.2 Manually releasing the brakes ...................................................................672.3.3 Orienting and securing the robot ................................................................702.3.4 Mounting the robot in suspended position ....................................................722.3.5 Loads ....................................................................................................732.3.6 Installation of signal lamp (option) ..............................................................742.3.7 Setting the system parameters for a suspended robot ....................................762.4 Restricting the working range ..............................................................................762.4.1 Introduction ............................................................................................772.4.2 Mechanically restricting the working range of axis 1 ......................................832.4.3 Mechanically restricting the working range of axis 2 ......................................

3HAC022031-001 Revision: H 5© Copyright 2004-2013 ABB. All rights reserved.

Table of contents

852.4.4 Installation of limit switch, axis 3 ................................................................862.5 Electrical connections ........................................................................................862.5.1 Connectors on robot ................................................................................872.5.2 Robot cabling and connection points ..........................................................

893 Maintenance893.1 Introduction ......................................................................................................903.2 Maintenance schedule .......................................................................................903.2.1 Specification of maintenance intervals ........................................................913.2.2 Maintenance schedule .............................................................................923.3 Changing activities ............................................................................................923.3.1 Type of lubrication in gearboxes ................................................................933.3.2 Oil change, gearbox axes 5-6 (wrist unit) .....................................................963.3.3 Replacement of SMB battery .....................................................................

1013.4 Cleaning activities .............................................................................................1013.4.1 Cleaning, robot ......................................................................................1033.5 Service Information System, M2000 ......................................................................1033.5.1 Using the SIS system ...............................................................................1043.5.2 Description of Service Information System (SIS) ...........................................1073.5.3 SIS system parameters ............................................................................1093.5.4 Setting the SIS parameters .......................................................................1113.5.5 Reading the SIS output logs ......................................................................1123.5.6 Exporting the SIS data .............................................................................

1134 Repair1134.1 Introduction ......................................................................................................1144.2 General procedures ...........................................................................................1144.2.1 Performing a leak-down test .....................................................................1154.2.2 Mounting instructions for bearings .............................................................1174.2.3 Mounting instructions for seals ..................................................................1194.2.4 Replacing parts on Clean Room robots .......................................................1214.3 Complete robot ................................................................................................1214.3.1 Replacement of cable unit, axes 1-3 ...........................................................1274.3.2 Replacement of cable harness, axes 4-6 ......................................................1354.4 Upper arm .......................................................................................................1354.4.1 Replacement of wrist IRB 2400/10/16 ..........................................................1394.4.2 Replacement of wrist IRB 2400L ................................................................1424.4.3 Replacement of complete upper arm ...........................................................1464.5 Lower arm .......................................................................................................1464.5.1 Replacement of complete lower arm ...........................................................1504.5.2 Replacement of tie rod .............................................................................1544.6 Frame and base ...............................................................................................1544.6.1 Replacement of SMB unit .........................................................................1604.6.2 Replacement of brake release unit .............................................................1624.6.3 Replacement of parallel arm ......................................................................1664.7 Motors ............................................................................................................1664.7.1 Replacement of motor, axis 1 ....................................................................1714.7.2 Replacement of motor, axis 2 ....................................................................1764.7.3 Replacement of motor, axis 3 ....................................................................1814.7.4 Replacement of motors, axes 4-6, IRB 2400L ................................................1884.7.5 Replacement of motors, axes 4-6, IRB 2400/10/16 .........................................1954.8 Gearboxes .......................................................................................................1954.8.1 Replacement of gearbox, axis 1-3 ...............................................................1984.8.2 Replacement of drive shaft unit, IRB 2400L ..................................................

2015 Calibration information2015.1 Introduction .....................................................................................................2025.2 Calibration methods ...........................................................................................

6 3HAC022031-001 Revision: H© Copyright 2004-2013 ABB. All rights reserved.

Table of contents

2045.3 Calibration scale and correct axis position .............................................................2055.4 Calibration movement directions for all axes ..........................................................2065.5 Updating revolution counters ...............................................................................2105.6 Checking the calibration position ..........................................................................

2136 Decommissioning2136.1 Environmental information ..................................................................................

2157 Reference information2157.1 Introduction ......................................................................................................2167.2 Applicable safety standards ................................................................................2187.3 Unit conversion .................................................................................................2197.4 Screw joints ....................................................................................................2227.5 Weight specifications .........................................................................................2237.6 Standard tools ..................................................................................................2247.7 Special tools ....................................................................................................2257.8 Lifting equipment and lifting instructions ................................................................

2278 Spare parts2278.1 Introduction ......................................................................................................2288.2 Spare parts - base .............................................................................................2308.3 Spare parts - lower arm ......................................................................................2428.4 Spare parts - upper arm, IRB 2400/10/16 ...............................................................2468.5 Spare parts - upper arm, IRB 2400/L .....................................................................2508.6 Spare parts - drive unit, IRB 2400/L ......................................................................2528.7 Spare parts - customer cable, axis 4 .....................................................................2538.8 Spare parts - limit switch ....................................................................................2548.9 Spare parts - customer connection kits ..................................................................

2559 Circuit diagram2559.1 About circuit diagrams .......................................................................................

257Index


Table of contents

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Overview of this manualAbout this manual

This manual contains instructions for• mechanical and electrical installation of the robot• maintenance of the robot• mechanical and electrical repair of the robot.

UsageThis manual should be used during

• installation, from lifting the robot to its work site and securing it to thefoundation to making it ready for operation

• maintenance work• repair work.

Who should read this manual?This manual is intended for:

• installation personnel• maintenance personnel• repair personnel.

PrerequisitesA maintenance/repair/installation craftsman working with an ABB Robot must:

• be trained by ABB and have the required knowledge of mechanical andelectrical installation/repair/maintenance work.

Organization of chaptersThe manual is organized in the following chapters:

ContentsChapter

Safety information that must be read through before performingany installation or service work on robot. Contains general safetyaspects as well as more specific information about how to avoidpersonal injuries and damage to the product.

Safety, service

Required information about lifting and installation of the robot.Installation and commis-sioning

Step-by-step procedures that describe how to perform mainten-ance of the robot. Based on a maintenance schedule that maybe used in the work of planning periodical maintenance.

Maintenance

Step-by-step procedures that describe how to perform repairactivities of the robot. Based on available spare parts.

Repair

Procedures that does not require specific calibration equipment.Calibration information

Environmental information about the robot and its components.Decommissioning

Useful information when performing installation, maintenanceor repair work (lists of necessary tools, reference documents,safety standards).

Reference information

Continues on next page3HAC022031-001 Revision: H 9


Overview of this manual

ContentsChapter

Complete list of robot parts, shown in the exploded views orfoldouts.

Part list

Detailed illustrations of the robot with reference numbers to thepart list.

Exploded views / Foldouts

References to the circuit diagram for the robot.Circuit diagram

ReferencesProcedures in this product manual contain references to the following manuals:

NoteDocument IDDocument name

3HAC042195-001Product specification - IRB 2400

Circuit diagram IRB 2400

3HAC021313-001Product manual - IRC5

3HAC021333-001Product manual - S4Cplus M2000

3HAC022419-001Product manual - S4Cplus M2000A

3HAC16590-1Operating manual - IRC5 with FlexPendant

3HAC7793-1User’s guide - S4Cplus (BaseWare OS 4.0)

M20043HAC025709-001Operating manual - Service Information System

3HAC16578-1Operating manual - Calibration Pendulum

M2000/M2000A3HAC022907-001Operating manual - Levelmeter Calibration

3HAC042927-001Technical reference manual - Lubrication in gear-boxes

3HAC17076-1Technical reference manual - System parameters

M20043HAC021395-001Application manual - Additional axes and standalone controller

M20003HAC9299-1Application manual - External axes

3HAC032104-001Operating manual - RobotStudio

Additional document references

Document IDDocument name

3HAC030421-001Application manual - CalibWare Field 5.0

Revisions

DescriptionRevision

First edition.-Replaces previous manuals:

• Installation and Commssioning Manual• Maintenance Manual• Repair Manual, part 1• Repair Manual, part 2.

Changes made in the material from the previous manuals:• Model M2004 implemented.

Continues on next page10 3HAC022031-001 Revision: H



Continued

DescriptionRevision• Chapter“ Calibration” replaced with chapter “Calibration information”.• Safety chapter rewritten.• Section Document references is completed with article numbers for

calibration manuals.

A

• Sections are restructured into Replacement procedures, instead of re-moval/refitting procedures.

• Procedure for refitting the motor of axis 1 is completed.• Correction made in Protection classes, robot on page 59.• Various corrections due to technical revisions etc.

B

Changes made in:• Prerequisites in section Overview• Oil change in section Maintenance

C

Content updated in chapter/section:• Section What is an emergency stop? added to chapter Safety.• Maintenance/Maintenance schedule: Interval for replacement of battery

pack changed.

D

Content updated in chapter/section:• Decommissioning chapter added.• Sealing compound updated in Replacing parts on Clean Room robots

on page 119.• Circuit diagrams are not included in this document but delivered as

separate files. See Circuit diagram on page 255.• List of standards updated, seeApplicable safety standards on page216.• Corrected spare part number for upper arm, see Spare parts - upper

arm, IRB 2400/10/16 on page 242.Updates in the chapter Safety:

• Updated safety signal graphics for the levels Danger and Warning, seeSafety signals in the manual on page 38.

• New safety labels on the manipulators, see Safety symbols on manipu-lator labels on page 40.

• Revised terminology: robot replaced with manipulator.

E

Content updated in chapter/section:• Corrected spare part number for gasket in Spare parts - upper arm, IRB

2400/L on page 246.

F




Continued

DescriptionRevision

This revision includes the following updates:• A new block, about general illustrations, added in section How to read

the product manual on page 13.• Added Setting the system parameters for a suspended robot on page74.• Corrections and changes in spare parts lists:

- Item 27, 29, 34, 35, 39, 51, 57, 58 and 59 are corrected in Spareparts - upper arm, IRB 2400/10/16 on page242. The exploded viewfor the upper arm spare parts is updated so that item 44 (bearingfor the upper and lower tie rod) is now shown, item 45 is movedand 61 is deleted, see Spare part view 7 on page 245.

- Item 16, 32, 35, 48, 56 and 134 are corrected and item 63 is re-moved in Spare parts - lower arm on page230. The exploded viewfor the lower arm spare parts is updated so that the sealings areshown for the upper and lower tie rod, see Spare part view 1 onpage 231.

• Some general tightening torques have been changed/added, see updatedvalues in Screw joints on page 219.

• Added WARNING - Safety risks during handling of batteries on page51.• Added Risk of tipping/stability on page 63.• AddedService Information System,M2000 on page103 (information only

valid for M2000 systems).• Touch-up paint added to Replacing parts on Clean Room robots on

page 119.• Added Installation of signal lamp (option) on page 73.

G

This revision includes the following updates:• All data about type of lubrication in gearboxes is moved from the

manual to a separate lubrication manual, see Type and amount of oil ingearboxes on page 92.

• A new SMB unit and battery is introduced, with longer battery lifetime.

H



Continued

How to read the product manualReading the procedures

The procedures contain references to figures, tools, material, and so on. Thereferences are read as described below.

References to figuresThe procedures often include references to components or attachment pointslocated on the manipulator/controller. The components or attachment points aremarked with italic text in the procedures and completed with a reference to thefigure where the current component or attachment point is shown.The denomination in the procedure for the component or attachment pointcorresponds to the denomination in the referenced figure.The table below shows an example of a reference to a figure from a step in aprocedure.

Note/IllustrationAction

Shown in the figure Location ofgearbox on page xx.

Remove the rear attachment screws, gearbox.8.

References to required equipmentThe procedures often include references to equipment (spare parts, tools, etc.)required for the different actions in the procedure. The equipment is marked withitalic text in the procedures and completed with a reference to the section wherethe equipment is listed with further information, that is article number anddimensions.The designation in the procedure for the component or attachment pointcorresponds to the designation in the referenced list.The table below shows an example of a reference to a list of required equipmentfrom a step in a procedure.


Art. no. is specified in Requiredequipment on page xx.

Fit a new sealing, axis 2 to the gearbox.3.

Safety informationThe manual includes a separate safety chapter that must be read through beforeproceeding with any service or installation procedures. All procedures also includespecific safety information when dangerous steps are to be performed.Read more in the chapter Safety on page 17.

IllustrationsThe robot is illustrated with general figures that does not take painting or protectiontype in consideration.Likewise certain work methods or general information, that is valid for several robotmodels, can be illustrated with pictures that show a different robot model that theone described in the current manual.


How to read the product manual

Product documentation, M2000/M2000AGeneral

The complete product documentation kit for the M2000 robot system, includingcontroller, robot and any hardware option, consists of the manuals listed below:

Product manualsManipulators, controllers, DressPack/SpotPack, and most other hardware will bedelivered 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.• Decommissioning.• Reference information (safety standards, unit conversions, screw joints, lists

of tools ).• Spare parts list with exploded views (or references to separate spare parts

lists).• Circuit diagrams (or references to circuit diagrams).

Software manualsThe software documentation consists of a wide range of manuals, ranging frommanuals for basic understanding of the operating system to manuals for enteringparameters during operation.A complete listing of all available software manuals is available from ABB.

Controller hardware option manualEach hardware option for the controller is supplied with its own documentation.Each document set contains the types of information specified below:

• Installation information• Repair information• Maintenance information

In addition, spare part information is supplied for the entire option.


Product documentation, M2000/M2000A

Product documentation, M2004Categories for manipulator documentation

The manipulator documentation is divided into a number of categories. This listingis based on the type of information in the documents, regardless of whether theproducts are standard or optional.All documents listed can be ordered from ABB on a DVD. The documents listedare valid for M2004 manipulator systems.

Product manualsManipulators, controllers, DressPack/SpotPack, and most other hardware will bedelivered 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.• Decommissioning.• Reference information (safety standards, unit conversions, screw joints, lists

of tools ).• Spare parts list with exploded views (or references to separate spare parts

lists).• Circuit diagrams (or references to circuit diagrams).

Technical reference manualsThe technical reference manuals describe reference information for roboticsproducts.

• Technical reference manual - Lubrication in gearboxes: Description of typesand volumes of lubrication for the manipulator gearboxes.

• Technical reference manual - RAPID overview: An overview of the RAPIDprogramming language.

• Technical referencemanual - RAPID Instructions, Functions and Data types:Description and syntax for all RAPID instructions, functions, and data types.

• Technical reference manual - RAPID kernel: A formal description of theRAPID programming language.

• Technical reference manual - System parameters: Description of systemparameters and configuration workflows.

Application manualsSpecific applications (for example software or hardware options) are described inApplication manuals. An application manual can describe one or severalapplications.



Product documentation, M2004

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, DVD with PC software).• How to install included or required hardware.• How to use the application.• Examples of how to use the application.

Operating manualsThe operating manuals describe hands-on handling of the products. The manualsare aimed at those having first-hand operational contact with the product, that isproduction cell operators, programmers, and trouble shooters.The group of manuals includes (among others):

• Operating manual - Emergency safety information• Operating manual - General safety information• Operating manual - Getting started, IRC5 and RobotStudio• Operating manual - Introduction to RAPID• Operating manual - IRC5 with FlexPendant• Operating manual - RobotStudio• Operatingmanual - Trouble shooting IRC5, for the controller and manipulator.


Product documentation, M2004

Continued

1 Safety1.1 Introduction to safety information

OverviewThe safety information in this manual is divided into two categories:

• General safety aspects, important to attend to before performing any servicework on the robot. These are applicable for all service work and are foundin General safety information on page 18.

• Specific safety information, pointed out in the procedures. How to avoid andeliminate the danger is either described directly in the procedure, or in specificinstructions in the section Safety related instructions on page 38.


1 Safety1.1 Introduction to safety information

1.2 General safety information

1.2.1 Introduction to general safety information

DefinitionsThis section details general safety information for personnel performing installation,repair and maintenance work.

SectionsThe general safety information is divided into the following sections.

ContainingContents• safety, service• limitation of liability• related information

General information

• safety risks during installation or service• risks associated with live electrical parts

Safety risks lists dangers relevant whenworking with the product. The dangers aresplit into different categories.

• fire extinguishing• safe use of the FlexPendant

Safety actions describes actions whichmay be taken to remedy or avoid dangers.

• stopping functions• description of emergency stop• description of safety stop• description of safeguarding

Safety stops describes different types ofstops.


1 Safety1.2.1 Introduction to general safety information

1.2.2 Safety in the manipulator system

Validity and responsibilityThe information does not cover how to design, install and operate a completesystem, nor does it cover all peripheral equipment that can influence the safety ofthe entire system. To protect personnel, the complete system must be designedand installed in accordance with the safety requirements set forth in the standardsand regulations of the country where the manipulator is installed.The users of ABB industrial manipulators are responsible for ensuring that theapplicable safety laws and regulations in the country concerned are observed andthat the safety devices necessary to protect people working with the manipulatorsystem are designed and installed correctly. Personnel working with manipulatorsmust be familiar with the operation and handling of the industrial manipulator asdescribed in the applicable documents, for example:

• Operating manual - IRC5 with FlexPendant• Product manual

Connection of external safety devicesApart from the built-in safety functions, the manipulator is also supplied with aninterface for the connection of external safety devices. An external safety functioncan interact with other machines and peripheral equipment via this interface. Thismeans that control signals can act on safety signals received from the peripheralequipment as well as from the manipulator.

Limitation of liabilityAny information given in this manual regarding safety must not be construed as awarranty by ABB that the industrial manipulator will not cause injury or damageeven if all safety instructions are complied with.

Related information

SectionDetailed in documentType of information

Installation andcommissioning

Product manual for the manipulatorInstallation of safety devices

Operating modesOperatingmanual - IRC5with FlexPend-ant

Changing operating modes

Installation andcommissioning

Product manual for the manipulatorRestricting the working space


1 Safety1.2.2 Safety in the manipulator system

1.2.3 Safety risks

1.2.3.1 Safety risks during installation and service work on manipulators

OverviewThis section includes information on general safety risks to be considered whenperforming installation and service work on the manipulator.These safety instructions have to be read and followed by any person who dealswith the installation and maintenance of the manipulator. Only persons who knowthe manipulator and are trained in the operation and handling of the manipulatorare allowed to maintain the manipulator. Persons who are under the influence ofalcohol, drugs or any other intoxicating substances are not allowed to maintain,repair, or use the manipulator.

General risks during installation and service• The instructions in the product manual in the chapter Installation and

commissioning must always be followed.• Emergency stop buttons must be positioned in easily accessible places so

that the manipulator can be stopped quickly.• Those in charge of operations must make sure that safety instructions are

available for the installation in question.• Those who install the manipulator must have the appropriate training for the

equipment in question and in any safety matters associated with it.

Spare parts and special equipmentABB does not supply spare parts and special equipment which have not beentested and approved by ABB. The installation and/or use of such products couldnegatively affect the structural properties of the manipulator and as a result of thataffect the active or passive safety operation. ABB is not liable for damages causedby the use of non-original spare parts and special equipment. ABB is not liable fordamages or injuries caused by unauthorized modifications to the manipulatorsystem.

Nation/region specific regulationsTo prevent injuries and damages during the installation of the manipulator, theregulations applicable in the country concerned and the instructions of ABBRobotics must be complied with.

Non-voltage related risks• Safety zones, which must be crossed before admittance, must be set up in

front of the manipulator's working space. Light beams or sensitive mats aresuitable devices.

• Turntables or the like should be used to keep the operator out of themanipulator's working space.



1 Safety1.2.3.1 Safety risks during installation and service work on manipulators

• The axes are affected by the force of gravity when the brakes are released.In addition to the risk of being hit by moving manipulator parts, there is a riskof being crushed by the parallel arm (if there is one).

• Energy stored in the manipulator for the purpose of counterbalancing certainaxes may be released if the manipulator, or parts thereof, are dismantled.

• When dismantling/assembling mechanical units, watch out for falling objects.• Be aware of stored heat energy in the controller.• Never use the manipulator as a ladder, which means, do not climb on the

manipulator motors or other parts during service work. There is a seriousrisk of slipping because of the high temperature of the motors and oil spillsthat can occur on the manipulator.

To be observed by the supplier of the complete system• The supplier of the complete system must ensure that all circuits used in the

safety function are interlocked in accordance with the applicable standardsfor that function.

• The supplier of the complete system must ensure that all circuits used in theemergency stop function are interlocked in a safe manner, in accordancewith the applicable standards for the emergency stop function.

Complete manipulator

DescriptionSafety risk

CAUTION

Motors and gears are HOT after running themanipulator! Touching motors and gears mayresult in burns!With a higher environment temperature, moresurfaces on the manipulator will get HOT andmay also result in burns.

Hot components!

WARNING

Take any necessary measures to ensure thatthe manipulator does not collapse as partsare removed, e.g. secure the lower arm ac-cording to repair instruction if removing mo-tor, axis 2.

Removed parts may result in collapse ofmanipulator!

WARNING

If the internal cables for the measurementsystem have been disconnected during repairor maintenance, then the revolution countersmust be updated.

Removed cables to the measurement sys-tem




Continued

Cabling


CAUTION

The cable packs are sensitive to mechanicaldamage! They must be handled with care,especially the connectors, in order to avoiddamaging them!

Cable packs are sensitive to mechanicaldamage!

Gearboxes and motors


CAUTION

Whenever parting/mating motor and gearbox,the gears may be damaged if excessive forceis used!

Gears may be damaged if excessive forceis used!


WARNING

Do not under any circumstances, deal withthe balancing device in any other way thanthat detailed in the product documentation!For example, attempting to open the balan-cing device is potentially lethal!

Dangerous balancing device!



Continued

1.2.3.2 CAUTION - Hot parts may cause burns!

DescriptionDuring normal operation, many manipulator parts become hot, especially the drivemotors and gears. Sometimes areas around these parts also become hot. Touchingthese may cause burns of various severity.Because of a higher environment temperature, more surfaces on the manipulatorget hot and may result in burns.

EliminationThe instructions below detail how to avoid the dangers specified above:

InfoAction

Always use your hand, at some distance, tofeel if heat is radiating from the potentiallyhot component before actually touching it.

1

Wait until the potentially hot component hascooled if it is to be removed or handled in anyother way.

2


1 Safety1.2.3.2 CAUTION - Hot parts may cause burns!

1.2.3.3 Safety risks related to tools/work pieces

Safe handlingIt must be possible to safely turn off tools, such as milling cutters, etc. Make surethat guards remain closed until the cutters stop rotating.It should be possible to release parts by manual operation (valves).

Safe designGrippers/end effectors must be designed so that they retain work pieces in theevent of a power failure or a disturbance to the controller.Unauthorized modifications of the originally delivered manipulator are prohibited.Without the consent of ABB it is forbidden to attach additional parts through welding,riveting, or drilling of new holes into the castings. The strength could be affected.

CAUTION

Ensure that a gripper is prevented from dropping a work piece, if such is used.


1 Safety1.2.3.3 Safety risks related to tools/work pieces

1.2.3.4 Safety risks related to pneumatic/hydraulic systems

GeneralSpecial safety regulations apply to pneumatic and hydraulic systems.

Note

All components that remain pressurized after separating the machine from thepower supply must be provided with clearly visible drain facilities and a warningsign that indicates the need for pressure relief before adjustments or performingany maintenance on the manipulator system.

Residual energy• Residual energy can be present in these systems. After shutdown, particular

care must be taken.• The pressure must be released in the complete pneumatic or hydraulic

systems before starting to repair them.• Work on hydraulic equipment may only be performed by persons with special

knowledge and experience of hydraulics.• All pipes, hoses, and connections have to be checked regularly for leaks and

damage. Damage must be repaired immediately.• Splashed oil may cause injury or fire.

Safe design• Gravity may cause any parts or objects held by these systems to drop.• Dump valves should be used in case of emergency.• Shot bolts should be used to prevent tools, etc., from falling due to gravity.


1 Safety1.2.3.4 Safety risks related to pneumatic/hydraulic systems

1.2.3.5 Safety risks during operational disturbances

General• The industrial manipulator is a flexible tool that can be used in many different

industrial applications.• All work must be carried out professionally and in accordance with the

applicable safety regulations.• Care must be taken at all times.

Qualified personnelCorrective maintenance must only be carried out by qualified personnel who arefamiliar with the entire installation as well as the special risks associated with itsdifferent parts.

Extraordinary risksIf the working process is interrupted, extra care must be taken due to risks otherthan those associated with regular operation. Such an interruption may have to berectified manually.


1 Safety1.2.3.5 Safety risks during operational disturbances

1.2.3.6 Risks associated with live electric parts

Voltage related risks, generalWork on the electrical equipment of the manipulator must be performed by aqualified electrician in accordance with electrical regulations.

• Although troubleshooting may, on occasion, need to be carried out while thepower supply is turned on, the robot must be turned off (by setting the mainsswitch to OFF) when repairing faults, disconnecting electric leads anddisconnecting or connecting units.

• The mains supply to the robot must be connected in such a way that it canbe turned off from outside the robot’s working space.

The necessary protection for the electrical equipment and manipulator systemduring construction, commissioning, and maintenance is guaranteed if the validregulations are followed.All work must be performed:

• by qualified personnel• on machine/manipulator system in deadlock• in an isolated state, disconnected from power supply, and protected against

reconnection

Voltage related risks, IRC5 controllerA danger of high voltage is associated with, for example, the following parts:

• Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) inthe controller.

• Units such as I/O modules, can be supplied with power from an externalsource.

• The mains supply/mains switch• The transformers• The power unit• The control power supply (230 VAC)• The rectifier unit (262/400-480 VAC and 400/700 VDC. Note: Capacitors!)• The drive unit (400/700 VDC)• The drive system power supply (230 VAC)• The service outlets (115/230 VAC)• The customer power supply (230 VAC)• The power supply unit for additional tools, or special power supply units for

the machining process.• The external voltage connected to the controller remains live even when the

robot is disconnected from the mains.• Additional connections.



1 Safety1.2.3.6 Risks associated with live electric parts

Voltage related risks, manipulatorA danger of high voltage is associated with the manipulator in:

• The power supply for the motors (up to 800 VDC).• The user connections for tools or other parts of the installation (max. 230

VAC).See chapter Installation and commissioning on page 55.

Voltage related risks, tools, material handling devices, etc.Tools, material handling devices, etc., may be live even if the robot system is inthe OFF position. Power supply cables which are in motion during the workingprocess may be damaged.


1 Safety1.2.3.6 Risks associated with live electric parts

Continued

1.2.4 Safety actions

1.2.4.1 Safety fence dimensions

GeneralInstall a safety cell around the manipulator to ensure safe manipulator installationand operation.

DimensioningDimension the fence or enclosure to enable it to withstand the force created if theload being handled by the manipulator is dropped or released at maximum speed.Determine the maximum speed from the maximum velocities of the manipulatoraxes and from the position at which the manipulator is working in the work cell(see the section Robot motion in the Product specification).Also consider the maximum possible impact caused by a breaking or malfunctioningrotating tool or other device fitted to the manipulator.


1 Safety1.2.4.1 Safety fence dimensions

1.2.4.2 Fire extinguishing

Note

Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in themanipulator system (manipulator or controller)!


1 Safety1.2.4.2 Fire extinguishing

1.2.4.3 Emergency release of the manipulator’s arm

DescriptionIn an emergency situation, any of the manipulator's axes may be released manuallyby pushing the brake release buttons on the manipulator.How to release the brakes is detailed in the section:

• Manually releasing the brakes on page 65.The manipulator arm may be moved manually on smaller manipulator models, butlarger models may require using an overhead crane or similar equipment.

Increased injuryBefore releasing the brakes, make sure that the weight of the arms does notincrease the pressure on the trapped person, further increasing any injury!


1 Safety1.2.4.3 Emergency release of the manipulator’s arm

1.2.4.4 Brake testing

When to testDuring operation, the holding brake of each axis normally wears down. A test canbe performed to determine whether the brake can still perform its function.

How to testThe function of the holding brake of each axis motor may be checked as describedbelow:

1 Run each manipulator axis to a position where the combined weight of themanipulator arm and any load is maximized (max. static load).

2 Switch the motor to the MOTORS OFF position with the operating modeselector on the controller.

3 Check 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.


1 Safety1.2.4.4 Brake testing

1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s"

Note

Do not change Transm gear ratio or other kinematic system parameters fromthe FlexPendant or a PC. This will affect the safety function "Reduced speed 250mm/s".


1 Safety1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s"

1.2.4.6 Safe use of the FlexPendant

Enabling deviceThe enabling device is a manually operated, constant pressure push-button which,when continuously activated in one position only, allows potentially hazardousfunctions but does not initiate them. In any other position, hazardous functions arestopped safely.The enabling device is of a specific type where you must press the push-buttononly half-way to activate it. In the fully in and fully out positions, manipulatoroperation is impossible.

Note

The enabling device is a push-button located on the side of the FlexPendantwhich, when pressed halfway in, switches the system to MOTORS ON. Whenthe enabling device is released or pushed all the way in, the manipulator switchesto the MOTORS OFF state.To ensure safe use of the FlexPendant, the following must be implemented:

• The enabling device must never be rendered inoperational in any way.• During programming and testing, the enabling device must be released as

soon as there is no need for the manipulator to move.• Anyone entering the manipulator working space must always bring the

FlexPendant with him/her. This is to prevent anyone else from taking controlof the manipulator without his/her knowledge.

Hold-to-run functionThe hold-to-run function allows movement when a button connected to the functionis actuated manually and immediately stops any movement when released. Thehold-to-run function can only be used in manual mode.How to operate the hold-to-run function for IRC5 is described in Operatingmanual - IRC5 with FlexPendant.


1 Safety1.2.4.6 Safe use of the FlexPendant

1.2.4.7 Work inside the manipulator's working range

WARNING

If work must be carried out within the manipulator’s work area, the followingpoints must be observed:

• The operating mode selector on the controller must be in the manual modeposition to render the enabling device operational and to block operationfrom a computer link or remote control panel.

• The manipulator’s speed is limited to max. 250 mm/s when the operatingmode selector is in the position Manual mode with reduced speed. Thisshould be the normal position when entering the working space.The position Manual mode with full speed (100%) may only be used bytrained personnel who are aware of the risks that this entails. Manual modewith full speed (100%) is not available in USA or Canada.

• Pay attention to the rotating axes of the manipulator. Keep away from axesto not get entangled with hair or clothing. Also, be aware of any danger thatmay be caused by rotating tools or other devices mounted on the manipulatoror inside the cell.

• Test the motor brake on each axis, according to the section Brake testingon page 32.

WARNING

NEVER, under any circumstances, stay beneath any of the manipulator’s axes!There is always a risk that the manipulator will move unexpectedly whenmanipulator axes are moved using the enabling device or during other workinside the manipulator’s working range.


1 Safety1.2.4.7 Work inside the manipulator's working range

1.2.5 Safety stops

1.2.5.1 What is an emergency stop?

Definition of emergency stopAn emergency stop is a state that overrides any other manipulator control,disconnects drive power from the manipulator motors, stops all moving parts, anddisconnects power from any potentially dangerous functions controlled by themanipulator system.An emergency stop state means that all power is disconnected from the manipulatorexcept for the manual brake release circuits. You must perform a recoveryprocedure, i.e, resetting the emergency stop button and pressing the Motors Onbutton, in order to return to normal operation.The manipulator system can be configured so that the emergency stop results ineither:

• An uncontrolled stop, immediately stopping the manipulator actions bydisconnecting power from the motors.

• A controlled stop, stopping the manipulator actions with power available tothe motors so that the manipulator path can be maintained. When completed,power is disconnected from the motors.

The default setting is an uncontrolled stop. However, controlled stops are preferredsince they minimize extra, unnecessary wear on the manipulator and the actionsneeded to return the manipulator system back to production. Please consult yourplant or cell documentation to see how your manipulator system is configured.

Note

The emergency stop function may only be used for the purpose and under theconditions for which it is intended.

Note

The emergency stop function is intended for immediately stopping equipmentin the event of an emergency.

Note

Emergency stop should not be used for normal program stops as this causesextra, unnecessary wear on the manipulator.For how to perform normal program stops, see section Stopping programs inOperating manual - IRC5 with FlexPendant.



1 Safety1.2.5.1 What is an emergency stop?

Classification of stopsThe safety standards that regulate automation and manipulator equipment definecategories in which each type of stop applies:

... then it is classified as...If the stop is...

category 0 (zero)uncontrolled

category 1controlled

Emergency stop devicesIn a manipulator system there are several emergency stop devices that can beoperated in order to achieve an emergency stop. There are emergency stop buttonsavailable on the FlexPendant and on the controller cabinet (on the Control Moduleon a Dual Cabinet Controller). There can also be other types of emergency stopson your manipulator. Consult your plant or cell documentation to see how yourmanipulator system is configured.


1 Safety1.2.5.1 What is an emergency stop?

Continued

1.3 Safety related instructions

1.3.1 Safety signals in the manual

Introduction to safety signalsThis section specifies all dangers that can arise when doing the work describedin this manual. Each danger consists of:

• A caption specifying the danger level (DANGER, WARNING, or CAUTION)and the type of danger.

• A brief description of what will happen if the operator/service personnel donot eliminate the danger.

• Instruction about how to eliminate danger to simplify doing the work.

Danger levelsThe table below defines the captions specifying the danger levels used throughoutthis manual.

SignificanceDesignationSymbol

Warns that an accident will occur if the instructionsare not followed, resulting in a serious or fatal injuryand/or severe damage to the product. It applies towarnings that apply to danger with, for example,contact with high voltage electrical units, explosionor fire risk, risk of poisonous gases, risk of crushing,impact, fall from height, and so on.

DANGER

xx0200000022

Warns that an accident may occur if the instructionsare not followed that can lead to serious injury, pos-sibly fatal, and/or great damage to the product. Itapplies to warnings that apply to danger with, forexample, contact with high voltage electrical units,explosion or fire risk, risk of poisonous gases, riskof crushing, impact, fall from height, etc.

WARNING

xx0100000002

Warns for electrical hazards which could result insevere personal injury or death.

ELECTRICALSHOCK

xx0200000024

Warns that an accident may occur if the instructionsare not followed that can result in injury and/ordamage to the product. It also applies to warningsof risks that include burns, eye injury, skin injury,hearing damage, crushing or slipping, tripping, im-pact, fall from height, etc. Furthermore, it applies towarnings that include function requirements whenfitting and removing equipment where there is a riskof damaging the product or causing a breakdown.

CAUTION

xx0100000003

Warns for electrostatic hazards which could resultin severe damage to the product.

ELECTROSTATICDISCHARGE (ESD)

xx0200000023



1 Safety1.3.1 Safety signals in the manual

SignificanceDesignationSymbol

Describes important facts and conditions.NOTE

xx0100000004

Describes where to find additional information orhow to do an operation in an easier way.

TIP

xx0100000098


1 Safety1.3.1 Safety signals in the manual

Continued

1.3.2 Safety symbols on manipulator labels

Introduction to labelsThis 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 additionalinformation such as values.

Note

The safety and health symbols on the labels on the manipulator must be observed.Additional safety information given by the system builder or integrator must alsobe observed.

Types of labelsBoth the manipulator and the controller are marked with several safety andinformation labels, containing important information about the product. Theinformation is useful for all personnel handling the manipulator system, for exampleduring installation, service, or operation.The safety labels are language independent, they only use graphics. See Symbolson safety labels on page 40.The information labels can contain information in text (English, German, andFrench).

Symbols on safety labels

DescriptionSymbol

Warning!

xx0900000812

Warns that an accident may occur if the instructions are notfollowed that can lead to serious injury, possibly fatal, and/orgreat damage to the product. It applies to warnings that applyto danger with, for example, contact with high voltage electricalunits, explosion or fire risk, risk of poisonous gases, risk ofcrushing, impact, fall from height, etc.

Caution!

xx0900000811

Warns that an accident may occur if the instructions are notfollowed 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-pact, fall from height, etc. Furthermore, it applies to warningsthat include function requirements when fitting and removingequipment where there is a risk of damaging the product orcausing a breakdown.

Prohibition

xx0900000839

Used in combinations with other symbols.



1 Safety1.3.2 Safety symbols on manipulator labels

DescriptionSymbol

See user documentation

xx0900000813

Read user documentation for details.Which manual to read is defined by the symbol:

• No text: Product manual.• EPS: Application manual - Electronic Position Switches.

Before dismantling see product manual

xx0900000816

Do not dismantle

xx0900000815

Dismantling this part can cause injury.

Extended rotation

xx0900000814

This axis has extended rotation (working area) compared tostandard.

Brake release

xx0900000808

Pressing this button will release the brakes. This means thatthe manipulator arm can fall down.

Tip risk when loosening bolts

xx0900000810

The manipulator can tip over if the bolts are not securelyfastened.




Continued

DescriptionSymbol

Crush

xx0900000817

Risk of crush injuries.

Heat

xx0900000818

Risk of heat that can cause burns.

Moving robot

xx0900000819

The robot can move unexpectedly.

xx1000001141

Brake release buttons

xx0900000820

xx1000001140




Continued

DescriptionSymbol

Lifting bolt

xx0900000821

Chain sling with shortener

xx1000001242

Lifting of robot

xx0900000822

Oil

xx0900000823

Can be used in combination with prohibition if oil is not allowed.

Mechanical stop

xx0900000824

No mechanical stop

xx1000001144

Stored energy

xx0900000825

Warns that this part contains stored energy.Used in combination with Do not dismantle symbol.




Continued

DescriptionSymbol

Pressure

xx0900000826

Warns that this part is pressurized. Usually contains additionaltext with the pressure level.

Shut off with handle

xx0900000827

Use the power switch on the controller.



Continued

1.3.3 DANGER - Moving manipulators are potentially lethal!

DescriptionAny moving manipulator is a potentially lethal machine.When running, the manipulator may perform unexpected and sometimes irrationalmovements. Moreover, all movements are performed with great force and mayseriously injure any personnel and/or damage any piece of equipment locatedwithin the working range of the manipulator.

Elimination

NoteAction

Emergency stop equipment such as gates,tread mats, light curtains, etc.

Before attempting to run the manipulator,make sure all emergency stop equipmentis correctly installed and connected.

1

How to use the hold-to-run function is de-scribed in section How to use the hold-to-run function in theOperatingmanual - IRC5with FlexPendant.

Usually the hold-to-run function is activeonly in manual full speed mode. To in-crease safety it is also possible to activatehold-to-run for manual reduced speed witha system parameter.

2

The hold-to-run function is used in manualmode, not in automatic mode.

Make sure no personnel are present withinthe working range of the manipulator be-fore pressing the start button.

3


1 Safety1.3.3 DANGER - Moving manipulators are potentially lethal!

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

DescriptionSince performing a service activity often requires disassembly of the robot, thereare several safety risks to take into consideration before the first test run.

EliminationFollow the procedure below when performing the first test run after a serviceactivity, such as repair, installation, or maintenance.

Action

Remove all service tools and foreign objects from the robot and its working area1

Check that the fixture and workpiece are well secured, if applicable2

Install all safety equipment properly3

Make sure all personnel are standing at a safe distance from the robot, that is out ofits reach behind safety fences, and so on

4

Pay special attention to the function of the part previously serviced5

Collision risks

CAUTION

When programming the movements of the manipulator always check potentialcollision risks before the first test run.


1 Safety1.3.4 DANGER - First test run may cause injury or damage!

1.3.5 DANGER - Make sure that the main power has been switched off!

DescriptionWorking with high voltage is potentially lethal. Persons subjected to high voltagemay suffer cardiac arrest, burn injuries, or other severe injuries. To avoid thesedangers, do not proceed working before eliminating the danger as detailed below.

Elimination, Panel Mounted Controller

Note/illustrationAction

xx0600003255

Switch off the main switch for the controller.1

Elimination, Single Cabinet Controller


xx0600002782

Switch off the main switch on the controllercabinet.

1

A: Main switch



1 Safety1.3.5 DANGER - Make sure that the main power has been switched off!

Elimination, Dual Cabinet Controller


xx0600002783

Switch off the main switch on the DriveModule.

1

K: Main switch, Drive Module

A: Main switch, Control ModuleSwitch off the main switch on the ControlModule.

2


1 Safety1.3.5 DANGER - Make sure that the main power has been switched off!

Continued

1.3.6 WARNING - The unit is sensitive to ESD!

DescriptionESD (electrostatic discharge) is the transfer of electrical static charge between twobodies at different potentials, either through direct contact or through an inducedelectrical field. When handling parts or their containers, personnel not groundedmay potentially transfer high static charges. This discharge may destroy sensitiveelectronics.

Elimination

NoteAction

Wrist straps must be tested frequently to ensurethat they are not damaged and are operating cor-rectly.

Use a wrist strap1

The mat must be grounded through a current-limit-ing resistor.

Use an ESD protective floor mat.2

The mat should provide a controlled discharge ofstatic voltages and must be grounded.

Use a dissipative table mat.3

Location of wrist strap buttonThe location of the wrist strap button is shown in the following illustration.

IRC5The wrist strap button is located in the top right corner.

xx0500002171

Wrist strap buttonA



1 Safety1.3.6 WARNING - The unit is sensitive to ESD!

Panel Mounted Controller

xx0600003249

Panel Mounted Control ModuleA

Panel Mounted Drive ModuleB

Wrist strap button NOTE! When not used, the wrist strap must always be attachedto the wrist strap button.

C


1 Safety1.3.6 WARNING - The unit is sensitive to ESD!

Continued

1.3.7 WARNING - Safety risks during handling of batteries

DescriptionUnder normal conditions of use, the electrode materials and liquid electrolyte inthe batteries are not exposed to the outside, provided the battery integrity ismaintained and seals remain intact.There is a risk of exposure only in case of abuse (mechanical, thermal, electrical)which leads to the activation of safety valves and/or the rupture of the batterycontainer. Electrolyte leakage, electrode materials reaction with moisture/water orbattery vent/explosion/fire may follow, depending upon the circumstances.

Note

Appropriate disposal regulations must be observed.

Elimination

NoteAction

Operating temperaturesare listed in Pre-install-ation procedure onpage 56.

Do not short circuit, recharge, puncture, incinerate, crush,immerse, force discharge or expose to temperatures abovethe declared operating temperature range of the product.Risk of fire or explosion.

1

Use safety glasses when handling the batteries.2

In the event of leakage, wear gloves and chemical apron.3

In the event of fire, use self-contained breathing apparatus.4


1 Safety1.3.7 WARNING - Safety risks during handling of batteries

1.3.8 WARNING - Safety risks during work with gearbox lubricants (oil or grease)

DescriptionWhen handling gearbox lubricants, there is a risk of both personal injury andproduct damage occurring. The following safety information must be regardedbefore performing any work with lubricants in the gearboxes.

Note

When handling oil, grease, or other chemical substances the safety informationof the manufacturer must be observed.

Note

When aggressive media is handled, an appropriate skin protection must beprovided.

Note

Appropriate disposal regulations must be observed.

Note

Take special care when handling hot lubricants.

Warnings and elimination

Elimination/ActionDescriptionWarning

Make sure that protective gearlike goggles and gloves are al-ways worn during this activity.

Changing and draining gearboxoil or grease may require hand-ling hot lubricant heated up to90 °C.

xx0100000002

Hot oil or grease

Make sure that protective gearlike goggles and gloves are al-ways worn.

When working with gearbox lub-ricant there is a risk of an allergicreaction.

xx0100000002

Allergic reaction

Open the plug carefully and keepaway from the opening. Do notoverfill the gearbox when filling.

When opening the oil or greaseplug, there may be pressurepresent in the gearbox, causinglubricant to spray from theopening.xx0100000002

Possible pressurebuild-up in gearbox



1 Safety1.3.8 WARNING - Safety risks during work with gearbox lubricants (oil or grease)

Elimination/ActionDescriptionWarning

Make sure not to overfill thegearbox when filling it with oil orgrease!

Overfilling of gearbox lubricantcan lead to internal over-pres-sure inside the gearbox which inturn may:

• damage seals and gas-kets

• completely press outseals and gaskets

• prevent the robot frommoving freely.

xx0100000002

Do not overfill

After filling, check the correctlevel.

When filling gearbox oil, do notmix different types of oil unlessspecified in the instructions. Al-ways use the type of oil specifiedby the manufacturer!

Mixing types of oil may causesevere damage to the gearbox.

xx0100000002

Do not mix types of oil

When changing gearbox oil, firstrun the robot for a time to heatup the oil.

Warm oil drains quicker thancold oil.

xx0100000098

Heat up the oil

After refilling, check the lubricantlevel.

The specified amount of oil orgrease is based on the totalvolume of the gearbox. Whenchanging the lubricant, theamount refilled may differ fromthe specified amount, dependingon how much has previouslybeen drained from the gearbox.

xx0100000004

Specified amount de-pends on drainedvolume


1 Safety1.3.8 WARNING - Safety risks during work with gearbox lubricants (oil or grease)

Continued

2 Installation and commissioning2.1 Introduction

GeneralThis chapter contains information for installing the IRB 2400 at the working site.More detailed technical data can be found in the Product specification for the IRB2400, such as:

• Load diagram• Permitted extra loads (equipment)• Location of extra loads (equipment).

Safety informationBefore any installation work is commenced, it is extremely important that all safetyinformation is observed!There are general safety aspects that must be read through, as well as more specificsafety information that describes the danger and safety risks when performing theprocedures. Read the chapterSafety on page17 before performing any installationwork.

Note

If the IRB 2400 is connected to power, always make sure that the robot isconnected to protective earth before starting any installation work!For more information see:

• Product manual - IRC5• Product manual - IRC5 Panel Mounted Controller


2 Installation and commissioning2.1 Introduction

2.2 Unpacking

2.2.1 Pre-installation procedure

IntroductionThis section is intended for use when unpacking and installing the robot for thefirst time. It also contains information useful during later re-installation of the robot.

Checking the pre-requisites for installationInstallation craftsmen working with an ABB robot must:

• be trained by ABB and have the required knowledge of mechanical andelectrical installation/maintenance/repair work

• conform to all national and local codes.

Action

Visually inspect the robot to make sure that it is not damaged.1

Make sure that the lifting accessory used is suitable to handle the weight of the robotas specified in:

• Weight, robot on page 56

2

If the robot is not installed directly, it must be stored as described in:• Storage conditions, robot on page 58

3

Make sure that the expected operating environment of the robot conforms to thespecifications as described in:

• Operating conditions, robot on page 58

4

Before taking the robot to its installation site, make sure that the site conforms to:• Loads on foundation, robot on page 57• Protection classes, robot on page 59• Requirements, foundation on page 58

5

Before moving the robot, please observe the stability of the robot:• Risk of tipping/stability on page 63

6

When these prerequisites are met, the robot can be taken to its installation site asdescribed in section:

• On-site installation on page 64

7

Install required equipment, if any.• Installation of signal lamp (option) on page 73

8

Weight, robotThe table shows the weight of the robot.

WeightRobot model

380 kgIRB 2400

Note

The weight does not include tools and other equipment fitted on the robot!



2 Installation and commissioning2.2.1 Pre-installation procedure

Loads on foundation, robotThe illustration shows the directions of the robots stress forces. The directions arevalid for all floor mounted and suspended robots.

xy

xy

z

z

T

F

F

T

xx1100000521

Force in any direction in the XY planeFxy

Force in the Z planeFz

Bending torque in any direction in the XY planeTxy

Bending torque in the Z planeTz

The table shows the various forces and torques working on the robot during differentkinds of operation.

Note

These forces and torques are extreme values that are rarely encountered duringoperation. The values also never reach their maximum at the same time!

Floor mounted

Max. load (emergency stop)Endurance load (in operation)Force

IRB 2400 -10, -16: ± 2600NIRB 2400 -10, -16: ± 2000 NForce xyIRB 2400 -L: ± 2100 NIRB 2400 -L: ± 1700 N

IRB 2400 -10, -16: 4100 ± 1900 NIRB 2400 -10, -16: 4100 ± 1400 NForce zIRB 2400 -L: 4100 ± 1400 NIRB 2400 -L: 4100 ± 1100 N

IRB 2400 -10, -16: ± 4000 NmIRB 2400 -10, -16: ± 3400 NmTorque xyIRB 2400 -L: ± 3400 NmIRB 2400 -L: ± 3000 Nm

IRB 2400 -10, -16: ± 900 NmIRB 2400 -10, -16: ± 550 NmTorque zIRB 2400 -L: ± 900 NmIRB 2400 -L: ± 450 Nm




Continued

Suspended

Max. load (emergency stop)Endurance load (in operation)Force

IRB 2400 -10, -16: ± 2600 NIRB 2400 -10, -16: ± 2000 NForce xyIRB 2400 -L: ± 2100 NIRB 2400 -L: ± 1700 N

IRB 2400 -10, -16: - 4100 ± 1900 NIRB 2400 -10, -16: - 4100 ± 1400 NForce zIRB 2400 -L: - 4100 ± 1400 NIRB 2400 -L: - 4100 ± 1100 N

IRB 2400 -10, -16: ± 4000 NmIRB 2400 -10, -16: ± 3400 NmTorque xyIRB 2400 -L: ± 3400 NmIRB 2400 -L: ± 3000 Nm

IRB 2400 -10, -16: ± 900 NmIRB 2400 -10, -16: ± 550 NmTorque zIRB 2400 -L: ± 900 NmIRB 2400 -L: ± 450 Nm

Requirements, foundationThe table shows the requirements for the foundation where the weight of theinstalled robot is included:

NoteValueRequirement

Flat foundations give better repeatability of theresolver calibration compared to original settingson delivery from ABB.

0,5 mmMaximum deviationfrom levelness

The value for levelness aims at the circumstanceof the anchoring points in the robot base.In order to compensate for an uneven surface,the robot can be recalibrated during installation.If resolver calibration is changed this will influ-ence the absolute accuracy.

The limit for the maximum payload on the robotis reduced if the robot is tilted from 0°.

5°Maximum tilt

Contact ABB for further information about accept-able loads.

30 HzMinimum resonancefrequency

Storage conditions, robotThe table shows the allowed storage conditions for the robot:

ValueParameter

-25° CMinimum ambient temperature

+55° CMaximum ambient temperature

+70° CMaximum ambient temperature (less than 24 hrs)

Max. 95% at constant temperat-ure

Maximum ambient humidity

Operating conditions, robotThe table shows the allowed operating conditions for the robot:

ValueParameter

+5° CMinimum ambient temperature

+45° CMaximum ambient temperature




Continued

ValueParameter

Max. 95% at constant temperat-ure

Maximum ambient humidity

Protection classes, robotThe table shows the protection class of the robot:

Protection classEquipment

IP 54Manipulator, protection type Standard

IP 67Manipulator, protection type Foundry Plus

IP 54Manipulator, protection type Clean Room

IP 67Manipulator, protection type Wash



Continued

2.2.2 Working range

Working rangeThis section specifies the working areas of the robot models.

IRB 2400/LThe working area is the same for both floor and inverted (suspended). Positionsare located at wrist center.

xx0200000159

Angle axis 3Angle axis 2ZXPos.

0016209700

-60022984041

6507456022

-60110-24615773

24.5110-4034004

-60-100623-16115

65-1001088-1156



2 Installation and commissioning2.2.2 Working range

IRB 2400/10, /16The working area is the same for both floor and inverted (suspended). Positionsare located at wrist center.

xx0200000160

Angle axis 3Angle axis 2ZXPos.

0014558550

-60020413601

6506935412

-60110-11813513

18.3110-3024004

-60-100624-13505

65-1001036-536

Positions in the working rangeThe table below specifies the positions inside the working range, shown in thefigure above.

Angles (º)Position (mm)Position in figure

Axis 3Axis 2ZX

0011398701

-17-2812465102

31-287224463

119602185154




Continued

Angles (º)Position (mm)Position in figure

Axis 3Axis 2ZX

11985-736075

268521015066

-1742114813137



Continued

2.2.3 Risk of tipping/stability

Risk of tippingIf the robot is not fastened to the foundation and standing still, the robot is notstable in the whole working area. Moving the arms will displace the center of gravity,which may cause the robot to tip over.The shipping position is the most stable position.Do not change the robot position before securing it to the foundation!

WARNING

The robot is likely to be mechanically unstable if not secured to the foundation!


2 Installation and commissioning2.2.3 Risk of tipping/stability

2.3 On-site installation

2.3.1 Lifting robot with lifting slings

Required equipment

NoteEquipment

Length: 2 m. Load at 90°: 380 kg.Sling line Type: KDBK 7-8.

Illustration, attachment of lifting slingsThe figure below shows how to attach the lifting slings to the robot.

xx0200000164

Lifting of robot

NoteAction

If necessary, release the brakes asdetailed in section Manually releas-ing the brakes on page 65.

Move the robot to the lifting position shown inthe figure above.

1

Attach the straps to the special eye bolts on thegearboxes for axes 2 and 3.

2

Lift the robot carefully.3


2 Installation and commissioning2.3.1 Lifting robot with lifting slings

2.3.2 Manually releasing the brakes

GeneralThe holding brakes of each axis’ motor are of an electromechanical type and arereleased when voltage is applied. This section details how to release the brakes,using the internal brake release unit, in order to enable the axes to move manually.The brake of each motor can also be released by connecting an external voltagesupply directly on the motor connector, see the circuit diagram or the repairprocedures for each motor (section Motors on page 166).

Releasing the brakes using the brake release unitThe procedure below details how to release the holding brakes using the internalbrake release unit.


DANGER

When releasing the holding brakes, the robotaxes may move very quickly and sometimesin unexpected ways!Make sure no personnel is near or beneaththe robot arm!

1

Detailed in section Supplying powerto connector R1.MP on page 66.

If the robot is not connected to the controller,power must be supplied to the connectorR1.MP.

2

xx0600002697

The internal brake release unit is located atthe base of the robot and equipped with but-tons for controlling the holding brakes for eachaxis separately. The buttons are numberedaccording to the numbers of the axes.To release the brake on a particular robot axis,push the corresponding button on the internalbrake release panel and keep it depressed.The brake will function again as soon as thebutton is released.

3



2 Installation and commissioning2.3.2 Manually releasing the brakes

Supplying power to connector R1.MPIf the robot is not connected to the controller, power must be supplied to connectorR1.MP in the robot base in order to enable the brake release unit on the robot.


CAUTION

Be careful not to interchange the 24 VDC and 0Vpins! If they are mixed up, damage can be causedto a resistor diode and to the system board.

1

xx0200000167

Connect an external power supply to connectorR1.MP, at the robot base.Supply:

• +24 V on pin B8• 0 V on pin C10

2

Release the brakes with the brake release unit asdetailed in the previous procedure.

3


2 Installation and commissioning2.3.2 Manually releasing the brakes

Continued

2.3.3 Orienting and securing the robot

GeneralThis section details how to orient and secure the robot to the foundation in orderto safely run the robot. The requirements for the foundations are shown in thetables and figures below.

Bolting requirementsWhen bolting a base plate or the base to a concrete floor, follow the generalinstructions for expansion-shell bolts. The screw joint must be able to withstandthe stress loads defined in section Pre-installation procedure on page 56.

Note

When the robot is to be mounted in a tilted or a suspended position, the guidesleeves must be used to secure the bolted joint.

Attachment screwsThe table below specifies the type of securing screws and washers to be used forsecuring the robot to the base plate/foundation.

M16 x 50Suitable screws, lightly lubricated:

Quality 8.8Quality

Thickness: 3 mmSuitable washer:Outer diameter: 30 mmInner diameter: 17 mm

190 NmTightening torque:



2 Installation and commissioning2.3.3 Orienting and securing the robot

Hole configurationThe figure below shows the hole configuration of the robot base, used whensecuring the robot. Cross section is shown in the following figure.

xx0200000181

Cross section, guide sleeve holeThe figure below shows the cross section of the guide sleeve holes (from previousfigure):

xx0200000182




Continued

Guide sleevesTwo guide sleeves can be fitted to the two rear bolt holes to allow the same robotto be remounted without re-adjusting the program.

Art. no.Equipment

2151 0024-169Guide sleeves



Continued

2.3.4 Mounting the robot in suspended position

GeneralThe robot can be mounted in a suspended position. This section details how toturn the robot.How to change the system parameters is detailed in Setting the system parametersfor a suspended robot on page 74.

Turning the robot1 Use the special tool for inverted mounting, see following figure.

xx0200000212

Lifting beamA

Fork liftB

Inverted mounting tool 3HAB8961-1-



2 Installation and commissioning2.3.4 Mounting the robot in suspended position

2 Seal the eight holes in the bottom plate with plastic plugs, see followingfigure.

xx0200000215

Plastic plugs (x8)A


2 Installation and commissioning2.3.4 Mounting the robot in suspended position

Continued

2.3.5 Loads

GeneralAny loads mounted on the robot must be defined correctly and carefully (withregard to the position of center of gravity and mass moments of inertia) in orderto avoid jolting movements and overloading motors, gears and structure.

CAUTION

Incorrectly defined loads may result in operational stops or major damage to therobot.

ReferencesLoad diagrams, permitted extra loads (equipment) and their positions are specifiedin the product specification. The loads must also be defined in the software asdetailed in:

• User’s guide - S4Cplus (BaseWare OS 4.0) , (M2000, M2000A)• Operating manual - IRC5 with FlexPendant (M2004)

Stop time and braking distancesRobot motor brake performance depends on any loads attached. For informationabout brake performance, read the product specification for the robot.


2 Installation and commissioning2.3.5 Loads

2.3.6 Installation of signal lamp (option)

Note

Do not use the signal lamp in a Clean Room environment.

Signal lampSee the assembly instruction delivered with the signal lamp.


2 Installation and commissioning2.3.6 Installation of signal lamp (option)

2.3.7 Setting the system parameters for a suspended robot

GeneralInitially the system is configured for mounting on the floor, without leaning. Themethod for mounting the robot in a suspended position is basically the same asfor floor mounting.

Note

With suspended installation, make sure that the gantry or corresponding structureis rigid enough to prevent unacceptable vibrations and deflections, so thatoptimum performance can be achieved.

System parametersIf the robot is mounted at any other angle, the system parameterGravity Betamustbe updated.Gravity Beta specifies the robot’s mounting angle expressed in radians.

Note

Gravity Beta must be configured correctly so that the robot system can controlthe movements in the best possible way. An incorrect definition of the mountingangle (Gravity Beta) will result in:

• Overloading the mechanical structure.• Lower path performance and path accuracy.• Some functions will not work properly, for example Load Identification and

Collision detection.

Mounting angles and valuesThe parameter Gravity Beta specifies the robot’s mounting angle in radians. It iscalculated in the following way.Gravity Beta = A° x 3.141593/180 = B radians, where A is the mounting angle indegrees and B is the mounting angle in radians.

Gravity BetaMounting angle (A°)Example of position

0.000000 (Default)0°Floor (A)

3.141593180°Suspended (D)

Defining the parameter in the software, RobotWare 4.0Following steps describes how to enter the correct gravity beta values.


Choose Topics: Manipulator.1

Choose Types: Robot.2

xx0200000073

Select Master and press Enter.3



2 Installation and commissioning2.3.7 Setting the system parameters for a suspended robot


Select the desired parameter Gravity Beta and changeits value.

4

Press OK to confirm.5

Defining the parameter in the softwareThe value of the system parameter Gravity Beta must be redefined when changingthe mounting angle of the robot. The parameter belongs to the type Robot, in thetopic Motion.How to calculate a new value is detailed inMounting angles and values on page74.The parameter is described in Technical reference manual - System parameters.The parameter can be edited either with the FlexPendant or in RobotStudio. SeeOperating manual - IRC5 with FlexPendant or Operating manual - RobotStudio.Article numbers for the manuals are specified in References on page 10.


2 Installation and commissioning2.3.7 Setting the system parameters for a suspended robot

Continued

2.4 Restricting the working range

2.4.1 Introduction

GeneralWhen installing the robot, make sure that it can move freely within its entire workingspace. If there is a risk that it may collide with other objects, its working spaceshould be limited.The working range of the following axes may be restricted:

• Axis 1, hardware (mechanical stop and position switch)• Axis 2, hardware (mechanical stop).• Axis 3, hardware (limit switch)

This section describes how to install hardware that restricts the working range.

Note

Adjustments must also be made in the robot configuration software (systemparameters). References to relevant manuals are included in the installationprocedures.


2 Installation and commissioning2.4.1 Introduction

2.4.2 Mechanically restricting the working range of axis 1

Restrictions in the working rangeThe working range of axis 1 can be restricted within the area from 50º to 140º asshown in the figure below. The restrictions are made by fitting two extra stops tothe robot base and adjusting the system parameter configuration.

xx0500002105



2 Installation and commissioning2.4.2 Mechanically restricting the working range of axis 1

Location of the mechanical stop, axis 1The extra mechanical stop is fitted to the robot base as shown in the figure below.Note! The stop must only be mounted in the direction shown below!

xx0200000205

Stop, axis 1, removable1

Plain washer2

Hex socket head cap screw3

Required equipment

NoteArt. no.Equipment

Includes:• removable stop (2 pcs)• plain washers (4 pcs)• hex socket head cap screw (4

pcs, M12x30)• drill template (1 pc)

3HAB 7298-1Stop, axis 1

Art. no. is specified in References onpage 10.

-User’s guide - S4Cplus (BaseWareOS 4.0) (RobotWare 4.0)Technical referencemanual - Systemparameters

Fitting, mechanical stop axis 1The procedure below details how to fit a mechanical stop to the robot base.

NoteAction

Decide where to fit the extra mechanical stops,according to the figure Location of where to drillholes for extra stops on page 80.

1

The template is also shown in thefigure Drill template on page 82 inscale 1:1.

Make a copy of the drill template, enclosed withthe mechanical stop.

2




Continued

NoteAction

Place the template edge edge withthe robot base, as shown in the figureLocation of where to drill holes forextra stops on page 80.

Use the template to mark the center of the twoholes on each stop.

3

Drill the holes through, Ø 10.2. Cut threads,M12.

4

Note! The stops must be mounted incorrect direction, as shown in the fig-ure Location of where to drill holesfor extra stops on page 80.

Fit the stops to the robot base, but withouttightening the screws.

5

If necessary; correct the angle of im-pact.

Turn axis 1 manually and check the workingrange between the stops.

6

Tighten the screws.7

How to define the range of movementin RobotWare 4.0 is detailed inUser’sguide - S4Cplus (BaseWare OS 4.0),chapter System Parameters - topicManipulator.

Adjust the software working range limitations(system parameter configuration) to correspondto the mechanical limitations.

8

The system parameters that must bechanged (Upper joint bound andLower joint bound) are described inTechnical referencemanual - Systemparameters.

WARNING

If the mechanical stop pin is deformed after ahard collision, it must be replaced!Deformedmovable stops and/or additional stopsas well as deformed attachment screws mustalso be replaced after a hard collision.

9




Continued

Location of where to drill holes for extra stopsThe figure below shows the drill pattern used when drilling for mechanical stopson axis 1.

xx0200000206

Maximum working range, axis 1A

Minimum working range, axis 1B

Drilling pattern enclosed with the mechanical stop.C

This mounting direction onlyD

The minimum and maximum measurement between the mechanical stops. Thedifference between the measurement and the minimum and maximum workingrange is 2 x 4º, which corresponds to the width of the stop pin (at the frame).

*




Continued

Hidden stiffening ribs and forbidden drilling sector

xx0600002647

Drilling not allowed inside this sector!C

Center lines for the hidden stiffening ribsD




Continued

Drill template

xx0200000207



Continued

2.4.3 Mechanically restricting the working range of axis 2

GeneralThe range of rotation for axis 2 can be limited mechanically by fitting extra stopson the lower arm.

Restrictions in working rangeThe figure below shows the mechanical stops available. The number of items thatare needed for different working ranges are specified in the following table.

xx0200000208

Qty. item 3Qty. item 2Qty. item 1Working range

---+110° / -100°

221+110° / -70°

422+110° / -40°

221+80° / -100°

422+80° / -70°

623+80° / -40°

422+50° / -100°

623+50° / -70°

824+50° / -40°

623+20° / -100°

824+20° / -70°

1025+20° / -40°

Required equipment


3HAC 2624-1Stop, axis 2





Art. no. is specified in sectionReferences on page 10.

-User’s guide - S4Cplus (BaseWareOS4.0) (RobotWare 4.0)Technical reference manual - Systemparameters

The content is defined in thesection Standard tools onpage 223.

-Standard toolkit



Continued

2.4.4 Installation of limit switch, axis 3

GeneralThe working range of axis 3 can be limited by fitting an electrical switch on thegearbox axis 3, which senses the position via a cam. The system parameterconfiguration must also be updated.

Mounting of eletrical stopFollowing illustration shows how to fit the electrical stop.

xx0200000211


2 Installation and commissioning2.4.4 Installation of limit switch, axis 3

2.5 Electrical connections

2.5.1 Connectors on robot

Connectors on the robotThe figure below shows all connections of the robot cabling, including the customerconnections.

xx0500002043


2 Installation and commissioning2.5.1 Connectors on robot

2.5.2 Robot cabling and connection points

IntroductionConnect 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.

Main cable categoriesAll cables between the robot and controller are divided into the following categories:

DescriptionCable category

Handles power supply to and control of the robot's motorsas well as feedback from the serial measurement board.

Robot cables

Specified in the table Robot cables on page 87.

Handles supply to and feedback from any position switcheson the robot.

Position switch cables (option)

Specified in the table Position switch cables, robot base tocontroller (option) on page 88.

Handles communication with equipment fitted on the robotby the customer, low voltage signals and high voltage powersupply + protective ground.

Customer cables (option)

See the product manual for the controller 1) .

Handles power supply to and control of the external axes'motors as well as feedback from the servo system.

External axes cables (option)

See the Application manual - Additional axes and standalone controller (M2004)or Application manual - Externalaxes (M2000) 1) .

Art. no. is specified in section References on page 10.1)

The cable categories are divided into sub-categories, specified below:

Robot cablesThese cables are included in the standard delivery. They are completelypre-manufactured and ready to plug in.

Connectionpoint, robot

Connectionpoint, cabinet

DescriptionCable sub-category

R1.MPXS1Transfers drive power from thedrive units in the control cabinetto the robot motors.

Robot cable, power

R1.SMBXS2Transfers resolver data fromand power supply to the serialmeasurement board.

Robot cable, signals

Robot cable, power

Art. no.Cable

3HAC9038-1Robot cable, power: 7 m






2 Installation and commissioning2.5.2 Robot cabling and connection points

Robot cable, signals

Art. no.Cable

3HAC7998-1Robot cable signal, shielded: 7 m




Position switch cables, robot base to controller (option)These cables are not included in the standard delivery, but are included in thedelivery if the position switch option is ordered. The position switches can also beordered without cables. The cables are completely pre-manufactured and readyto plug in.

Cabling between robot base and controller

Connectionpoint, cabinet

Connectionpoint, robot

Art. no.Cable

XS8R1.SW3HAC7997-1Position switch cable, axis 1, 7 m





2 Installation and commissioning2.5.2 Robot cabling and connection points

Continued

3 Maintenance3.1 Introduction

Structure of this chapterThis chapter describes all the maintenance activities recommended for the IRB2400.It is based on the maintenance schedule found at the beginning of the chapter.The schedule contains information about required maintenance activities includingintervals, and refers to procedures for the activities.Each procedure contains all the information required to perform the activity,including required tools and materials.The procedures are gathered in different sections and divided up according to themaintenance activity.

Safety informationObserve all safety information before conducting any service work!There are general safety aspects that must be read through, as well as more specificsafety information that describes the danger and safety risks when performing theprocedures. Read the chapter Safety on page 17 before performing any servicework!

Note

If the IRB 2400 is connected to power, always make sure that the IRB 2400 isconnected to protective earth before starting any maintenance work!For more information see:

• Product manual - IRC5• Product manual - IRC5 Panel Mounted Controller


3 Maintenance3.1 Introduction

3.2 Maintenance schedule

3.2.1 Specification of maintenance intervals

IntroductionThe intervals are specified in different ways depending on the type of maintenanceactivity to be carried out and the working conditions of the IRB 2400:

• Calendar time: specified in months regardless of whether the system isrunning or not.

• Operating time: specified in operating hours. More frequent running meansmore frequent maintenance activities.

• SIS: specified by the robot's SIS (Service Information System). A typicalvalue is given for a typical work cycle, but the value will differ depending onhow hard each part is run. The SIS used in M2000 and M2000A is furtherdescribed in the section Service Information System, M2000 on page 103.The SIS used in M2004 is further described in theOperatingmanual - ServiceInformation System.


3 Maintenance3.2.1 Specification of maintenance intervals

3.2.2 Maintenance schedule

GeneralThe robot must be maintained regularly to ensure proper function. The maintenanceactivities and intervals are specified in the table below.Non-predictable situations also give rise to inspections of the robot. Any damagesmust be attended to immediately!The inspection intervals do not specify the life of each component.

Activities and intervals, standard equipmentThe table below specifies the required maintenance activities and intervals andalso refers to the section where performing the activity is detailed.

Detailed in section:NoteIntervalMaintenance activity

Lubricated for life.Maintenance free units.

40000 hOil change in gearboxes,axes 1,2, 3 and 4

Oil change, gearboxaxes 5-6 (wrist unit) onpage 93.

After first 4000h, then every60 mth i

12000 h ii

Oil change in wrist unit

Replacement of SMBbattery on page 96.

Battery pack, measure-ment system with 2-pole battery contact,e.g. DSQC633A

Battery lowalert iii

Replacement of batterypack, SMB unit

Replacement of SMBbattery on page 96.

Battery pack, measure-ment system of typeRMU101 or RMU102 (3-pole battery contact)

36 months orbattery lowalert iv

Replacement of batterypack, SMB unit

Replace if required.36 mthsInspection of all signalcabling in lower and up-per arm

Replace if bent.60 mthsReplacement of mechan-ical stop axis 1i Change the oil for the first time after 4000 hours, then after every 60 months.ii Changing interval if the robot is working in an environment temperature over 40ºC.iii The battery low alert (38213 Battery charge low) is displayed when remaining backup capacity

(robot powered off) is less than 2 months. The typical lifetime of a new battery is 36 months if therobot is powered off 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetimecan be extended with a battery shutdown service routine. See Operating manual - IRC5 withFlexPendant for instructions.

iv The battery low alert (38213Battery charge low) is displayed when the battery needs to be replaced.The recommendation to avoid an unsynchronized robot is to keep the power to the controller turnedon until the battery is to be replaced.See the replacement instruction for more details.


3 Maintenance3.2.2 Maintenance schedule

3.3 Changing activities

3.3.1 Type of lubrication in gearboxes

IntroductionThis section describes where to find information about the type of lubrication,article number and the amount of lubrication in the specific gearbox. It alsodescribes the equipment needed when working with lubrication.

CAUTION

Always read the specific instructions for Clean Room robots before doing anyrepair work, see Replacing parts on Clean Room robots on page 119.

Location of gearboxesThe figure shows the location of the gearboxes.

Type and amount of oil in gearboxesInformation about the type of lubrication, article number as well as the amount inthe specific gearbox can be found in Technical reference manual - Lubrication ingearboxes. Document number is presented in References on page 10. In order toalways get the latest information of updates about lubrication in gearboxes, alwayscheck on ABB Library for the latest revision of the manual. A new revision will bepublished on ABB Library immediatly after any updates.Before starting any inspection, maintenance, or changing activities of lubrication,always check ABB Library for the latest revision of this manual. The revision ofthe manual published on the Documentation DVD (released twice a year) will onlycontain the latest updates when the Documentation DVD is released. Any updatesof the manual in between these releases will be published on ABB Library. Thereforethe manual published on the documentation DVD may not contain the latest updatesabout lubrication. If ABB Library cannot be reached, contact the local ABB Serviceorganisation for more information.

Equipment

NoteEquipment

Includes pump with outlet pipe.Oil dispenserUse the suggested dispenser or a similar one:

• Orion OriCan art. no. 22590 (pneumatic)

Nipple for quick connect fitting, with o-ring


3 Maintenance3.3.1 Type of lubrication in gearboxes

3.3.2 Oil change, gearbox axes 5-6 (wrist unit)

Location of oil plugs, gearbox axes 5-6The oil plugs are located at the wrist unit as shown in the figure below.

xx0300000118

Oil plugA

Oil plug (air inlet when draining from oil plug A)B

Required equipment

NoteEquipment

Information about the oil is found inTechnical referencemanual - Lubricationin gearboxes.

Lubricating oil

See Type and amount of oil in gearboxeson page 92.

The capacity of the vessel must be suffi-cient to take the complete amount of oil.

Oil collecting vessel

The content is defined in the sectionStandard tools on page 223.

Standard toolkit



3 Maintenance3.3.2 Oil change, gearbox axes 5-6 (wrist unit)

Draining the gearbox, axes 5-6 (IRB 2400/10/16)The procedure below details how to drain the oil from the wrist unit.


xx0300000120

Run the upper arm to a horizontal position andturn axis 4 to the calibration position.

1

DANGER

Turn off all electric power, hydraulic andpneumatic pressure supplies to the robot!

2

WARNING

Handling gearbox oil involves several safetyrisks. Before proceeding, please read thesafety information in the section WARNING -Safety risks during work with gearbox lubric-ants (oil or grease) on page 52.

3

Shown in the figure Location of oilplugs, gearbox axes 5-6 on page 93.

Remove the oil plugs in the wrist.4

xx0300000121

Turn axis 4 through 90° so that the oil plug onthe side of the wrist is pointing downwards.

5

Then turn axis 4 another 90°.6

Let the remaining oil run out through the holeon the tilt housing.

7




Continued

Refilling, gearbox axes 5-6The procedure below details how to refill oil to the wrist unit.

NoteAction

Run the upper arm to a horizontal position and turn axis4 to the calibration position.

1

DANGER

Turn off all electric power, hydraulic and pneumatic pres-sure supplies to the robot!

2

WARNING

Handling gearbox oil involves several safety risks. Beforeproceeding, please read the safety information in thesectionWARNING - Safety risks during work with gearboxlubricants (oil or grease) on page 52.

3

Fill oil in the hole located on the tilt housing (axis 5) untilthe oil reaches up to the hole located on the side of thewrist.

4

Note

If the robot is mounted in suspension, the wrist should beturned 180°.

5

Refit the oil plugs to the wrist.6



Continued

3.3.3 Replacement of SMB battery

Note

The battery low alert (38213 Battery charge low) is displayed when the batteryneeds to be replaced. The recommendation to avoid an unsynchronized robotis to keep the power to the controller turned on until the battery is to be replaced.For an SMB board with 3-pole battery contact (RMU101 3HAC044168-001 orRMU102 3HAC043904-001), the lifetime of a new battery is typically 36 months.For an SMB board with 2-pole battery contact, the typical lifetime of a new batteryis 36 months if the robot is powered off 2 days/week or 18 months if the robot ispowered off 16 h/day. The lifetime can be extended for longer production breakswith a battery shutdown service routine. See Operating manual - IRC5 withFlexPendant for instructions.

WARNING

See instructions for batteries,WARNING - Safety risks during handling of batterieson page 51.



3 Maintenance3.3.3 Replacement of SMB battery

Location of SMB battery unitThe SMB battery unit is located inside the robot base, as shown in the figure below.

xx0300000067

SMB battery (2-pole battery contact)A

SMB battery cableB




Continued

A B C

xx1300000288

SMB battery cableA

Cable strapB

SMB battery RMU (3-pole battery contact)C

Required equipment

Note

There are two variants of SMB units and batteries. One with 2-pole battery contactand one with 3-pole battery contact. The variant with the 3-pole battery contacthas longer lifetime for the battery.It is important that the SMB unit uses the correct battery. Make sure to order thecorrect spare parts. Do not replace the battery contact!




Continued

NoteSpare part no.Equipment

Lithium battery.3HAC16831-1Battery unit (2-pole battery con-tact) This battery requires that the serial

measurement unit 3HAC17396-1 isinstalled. If instead serial measure-ment unit 3HAB 8413-1 is installed,the battery 4944 026-4 must beused!

RMU3HAC044075-001Battery unit (3-pole battery con-tact) Lithium battery.

Can only be used with SMB unit3HAC046277-001 containing SMBboard 3HAC044168-001.

Always replace with a new one!3HAC3200-1Gasket, cover


Standard toolkit

These procedures include refer-ences to the tools required.

Other tools and procedures maybe required. See references tothese procedures in the step-by-step instructions below.

Replacement, SMB batteryThe procedure below details how to replace the SMB battery.

NoteAction

DANGER


1

xx0200000023

2

WARNING

The unit is sensitive to ESD. Before handlingthe unit please read the safety information inthe section WARNING - The unit is sensitiveto ESD! on page 49

xx0200000399

Remove the rear cover plate (A) on the robotby unscrewing its attachment screws (B).

3

Remove the battery terminals from the serialmeasuring board and cut the clasp that keepsthe battery unit in place.

4

Shown in the figure Location of SMBbattery unit on page 97.

Fit the new battery and connect the terminalsto the serial measuring board.

5




Continued

NoteAction

Always replace a removed gasket witha new!

Refit the cover to the robot base, together witha new gasket.

6

Spare part no. is specified in Requiredequipment on page 98.

Detailed in the sectionUpdating revolu-tion counters on page 206.

Update the revolution counters!7



Continued

3.4 Cleaning activities

3.4.1 Cleaning, robot

WARNING

Turn off all electrical power supplies to the manipulator before entering its workspace.

GeneralTo secure high uptime it is important that the robot is cleaned regularly. Thefrequency of cleaning depends on the environment in which the robot works.Different cleaning methods are allowed depending on the type of protection of therobot.

Note

Always check the serial number label for verification of the robot protection type.

Cleaning activitiesThese instructions specify allowed cleaning methods for each type of protection.

Cleaning methodProtectiontype

High pressure water orsteam

Rinse with waterWipewith clothVacuumcleaner

NoYes. It is highly re-commended thatwater contain arust-preventionsolution and thatthe robot be driedafterwards.

Yes. With lightcleaning deter-gent.

YesStandard

Yes i . It is highly recom-mended that water andsteam contains rust pre-ventive, without cleaningdetergents.

Yes. It is highly re-commended thatwater contain arust-preventionsolution.

Yes. With lightcleaning deter-gent or spirit.

YesFoundry Plus

Yes i .It is highly recom-mended that water andsteam contains rust pre-ventive, without cleaningdetergents.

Yes. It is highly re-commended thatwater contain arust-preventionsolution.

Yes. With lightcleaning deter-gent or spirit.

YesWash

NoNoYes. With lightcleaning deter-gent, spirit orisopropyl alco-hol.

YesClean room

i Perform according to section Cleaning with water and steam on page 102.



3 Maintenance3.4.1 Cleaning, robot

Cleaning with water and steamCleaning methods that can be used for ABB robots with protection Standard,Foundry Plus, Wash and Foundry Prime.

NoteEquipment, etc.

Vacuum cleaner

Cloth with mild detergent• Max. water pressure at the nozzle: 700 kN/m2

(7 bar) i

• Fan jet nozzle should be used, min. 45° spread• Distance from nozzle to encapsulation: min. 0.4

m• Flow: max. 20 liters/min i .

Water cleaner

• Water pressure at nozzle: max. 2,500 kN/m2 (25bar)

• Type of nozzle: fan jet, min. 45° spread• Distance from nozzle to encapsulation: min. 0.4

m• Water temperature: max. 80° C

Steam cleaner

i Typical tap water pressure and flow

CablesMovable cables need to be able to move freely:

• Remove waste material, such as sand, dust and chips, if it prevents cablemovement.

• Clean the cables if they have a crusty surface, for example from dry releaseagents.

Dos and don'ts!The section below specifies some special considerations when cleaning the robot.Always!

• Always use cleaning equipment as specified above! Any other cleaningequipment may shorten the life of the robot.

• Always check that all protective covers are fitted to the robot before cleaning!Never!

• Never point the water jet at connectors, joints, sealings, or gaskets!• Never use compressed air to clean the robot!• Never use solvents that are not approved by ABB to clean the robot!• Never spray from a distance closer than 0.4 meters!• Never remove any covers or other protective devices before cleaning the

robot!


3 Maintenance3.4.1 Cleaning, robot

Continued

3.5 Service Information System, M2000

3.5.1 Using the SIS system

GeneralThis is a brief description of how to use the Service Information System, SIS forM2000 robot systems. Details may be found in:

• Service Information System, SIS• Defining the SIS input parameters• Setting the SIS parameters• Importing/exporting SIS data• Reading the SIS output logs

The section is only valid for M2000 systems. For information regarding M2004robot systems, see additional documentation, Operating manual - ServiceInformation System. Article number is specified in section References on page10.

Basic procedure

ReferenceAction

These are described in Description ofService Information System (SIS) onpage 104.

Determine which of the system functionsyou require.

1

Recommendations on how to define theseare given in SIS system parameters onpage 107.

Define what values are adequate and suit-able for your application in your productionenvironment.

2

How to do this is detailed in Setting theSIS parameters on page 109.

Enter these parameters in the system.3

Run the robot in normal operation.4

The TPU displays for resetting any SISvalue are shown inDescription of ServiceInformation System (SIS) on page 104.

Reset the counter if a repair is made, or if acounter for any other reason is restarted.

5

How to access this is detailed in Readingthe SIS output logs on page 111.

When a time limit, set in the parameters, isexceeded, a message may be read on theTech Pendant Unit (TPU).

6

These are described in Exporting the SISdata on page 112.

If the log containing the message is to beavailable from an external PC, or if the SISparameters are to be entered from an extern-al PC, a set of software tools are availableto build such an application.

7


3 Maintenance3.5.1 Using the SIS system

3.5.2 Description of Service Information System (SIS)

GeneralService Information System (SIS) is a software function within the robot controller,which simplifies maintenance of the robot system. It supervises the operating timeand mode of the robot, and alerts the operator when a maintenance activity isscheduled.Maintenance is scheduled by setting the system parameters of the type SISParameters, see section Setting the SIS parameters on page 109. All systemparameters are described in User´s Guide - System Parameters.

Supervised functionsThe following counters are available:

• Calendar time counter, a general alarm based on calendar time• Operation time counter, a general alarm based on operational time• Gearbox 1 operation time counter, based on percentage of the axis 1 gearbox

service interval• Gearbox 2 operation time counter, based on percentage of the axis 2 gearbox



service intervalCounters are reset when maintenance has been performed.The counter status is displayed after running the service routine for maintenance.Status “OK” indicates that no service interval limit has been exceeded by thatcounter.

Calendar timeThis is a clock within the control system that keeps track of the service interval,based on calendar time.When the calendar time limit for maintenance is reached, a message is displayedon the TPU. How to access this is detailed in section Reading the SIS output logson page 111.The following information is available about the calendar time in the service routine.

Date when the counter was reset last time, i.e. after the last service.Prev service

Elapsed time since the counter was reset the last time.Elapsed time

Date when next scheduled service is planned. This date is calcu-lated using system parameters, as detailed in section Setting theSIS parameters on page 109.

Next service

Remaining time to next scheduled service date.Remaining time



3 Maintenance3.5.2 Description of Service Information System (SIS)

Operation timeThis is a function within the control system that keeps track of the amount of timethe "MOTORS ON" signal is active, i.e. the amount of time the robot is in theoperating mode.When the operation time limit for maintenance is reached, a message is displayedon the TPU. How to access this is detailed in section Reading the SIS output logson page 111.The following information is available about the operation time in the service routine.

The specified service interval until another service will be required.This parameter was entered manually as detailed in section Settingthe SIS parameters on page 109.

Service interval

Operation time since the service interval was set the last time.Elapsed time

Remaining operation time until the time set in service interval hasexpired.

Remaining time

GearboxBased on measurements, torque and RPM, for example, the system calculates anexpected service interval for each gearbox. When service is due, a message willbe shown on the TPU. How to access this is detailed in section Reading the SISoutput logs on page 111.The following information is available about the joint service status in the serviceroutine.

Service status for axis x, i.e. the automatically calculated timeparameter has not been exceeded.

Joint x OK

The service interval for the axis in question has been reached.Joint x NOK

No service time parameter calculation available.Joint x N/AApplies to axes 4 and 5 (IRB 6600 and IRB 7600).

The following information is available for the axis service status in the serviceroutine.

The consumed time as a percentage of the total amount of time.Consumed time

Operation time for axis x since calculation began.Elapsed time

Remaining operation time for axis x until the service time parametervalue has been reached.

Remaining time

Reset valuesCounters may be reset at any time by running the service routine.When resetting, the counter variables are reset. The variables are described insection Exporting the SIS data on page 112!

Service interval exceededWhen the service time has been exceeded for the selection made, an error message(Service interval exceeded!) is displayed.




Continued

No data availableWhen no data is available for the selection made, a message (No data available!)is displayed when trying to display the data.



Continued

3.5.3 SIS system parameters

GeneralThis section details the system parameters that may be set with estimated values.The values can be defined by the operating organization as knowledge of therobot's working conditions are accumulated.Since the counters are to be used for purposes defined by the user, ABB cannotgive any recommendations regarding their definitions.The figures below shows the options of parameters to be set.

en0200000049

Operation time limit (service level)The number of operation hours selected as service interval.E.g. by setting the value "20,000", the SIS will save this as the nominal time foractivating the alarm, not counting the percentage described below.

Operation time warningA percentage of the "Operation time limit" specified above.E.g. by setting the value "90", the SIS will alert the operator 18,000 hours after anoperation time "Reset" was made the last time.

Calendar time limit (service level)The number of calendar years selected as service interval.E.g. by setting the value "2", the SIS will save this as the nominal time for activatingthe alarm, not counting the percentage described below.

Calendar time warningA percentage of the "Calendar time limit" specified above.E.g. by setting the value "90", the SIS will alert the operator after 90% of two years,i.e. 657 days after a calendar time "Reset" was made the last time.



3 Maintenance3.5.3 SIS system parameters

Gearbox warningA percentage of the gearbox service interval as calculated by the system. E.g. bysetting the value "90", the SIS will alert the operator after 90% of the expectedservice interval of each gearbox.The robot system automatically detects and stores all required variables to calculatethe expected service interval (estimated remaining lifetime) of each gearbox. Thisis done by extrapolating data from earlier operation into a function of time, usinga formula including:

• input and output torque• gearbox spindle speed• other variables


3 Maintenance3.5.3 SIS system parameters

Continued

3.5.4 Setting the SIS parameters

GeneralIf the SIS system is to function properly, a number of parameters must be set. Thisis detailed below.

Procedure M2000This is an instruction of how to enter SIS parameters to the M2000 robot system.

NoteAction

Detailed in the User's Guide.Open "System parameters"using the TPU.

1

xx0200000045

Go to "System paramet-ers/Manipulator/types 2".

2

en0200000046



3 Maintenance3.5.4 Setting the SIS parameters

NoteAction

en0200000047

Select "0 SIS parameters"and press "Enter".

3

xx0100000200

en0200000048

Select the required systemThe parameter list is dis-played.

4

en0200000049

Available parameters are described in section SIS systemparameters on page 107.

Select the required paramet-ers by stepping up anddown through the parameterlist.

5


3 Maintenance3.5.4 Setting the SIS parameters

Continued

3.5.5 Reading the SIS output logs

GeneralWhenever a set condition has expired (e.g. max allowed operation time beforeservice), a message to this effect will be shown in the Operational log.

Access to logsHow to open a log and show its contents is detailed in the User's Guide, chapterService.

Available messagesThe following messages may be shown:

Meaning:SIS message in thelog:

Available in:

The manually set calendar time limit has expired.How to set the limit is detailed in section Settingthe SIS parameters on page 109.

Service MessageService is due!X calendar dayssince last service.

Calendar time

Proceed with the required service as detailed inchapterRepair on page113 or chapterMaintenanceon page 89 depending on which type of service.

X number of calendar days remain until themanually set calendar time limit expires.

Service MessageX calendar days tonext service.

Calendar time

How to set the value determining when the mes-sage is to be shown, is detailed in section Settingthe SIS parameters on page 109.

The manually set operation time limit has expired.How to set the limit is detailed in section Settingthe SIS parameters on page 109.

Service MessageService is due!X production hourssince last service.

Operation time


X number of operation hours remain until themanually set operation time limit expires.

Service MessageX production hoursto next service.

Operation time


The automatically calculated gearbox time limithas expired.

Service MessageGearbox x requiresservice!

Gearbox time


X percent of gearbox hours remain until the auto-matically calculated gearbox time limit expires.

Service MessageX% of the service in-terval has expired forgearbox x!

Gearbox time



3 Maintenance3.5.5 Reading the SIS output logs

3.5.6 Exporting the SIS data

GeneralThis section describes the available variables for entering SIS parameters as wellas showing any values of exceeded time limits as detected by the SIS counters.In a M2000 robot system, the values can be read on a PC using "Webware SDK".How to access these variables and how to perform the actual programmingsequences are detailed in the robot system User's Guide.

DefinitionsThe table below defines the names and functions of all software variables availablefor communication between the SIS and an external computer.

FunctionCounter typeUnitSignal

The date on which the supervision was star-ted/reset last time.

Calendar timesecsisRestartDate

The number of hours since start/last reset.Calendar timesecsisCalendarT

Total number of operation hours since thesystem was started. Corresponds to the oper-ating time counter on the control cabinet.

Operation timesecsisTotRunT

The number of operation hours since start/lastreset of the operation time counter. Corres-ponds to the operating time counter on thecontrol cabinet.

Operation timesecsisRunT

Estimated life of gearbox axis 1Gearbox timehrssisL10h_1

Operation time of gearbox axis 1Gearbox timesecsisL10h_Time_1






Operation time of gearbox axis 6Gearbox timehrssisL10h_Time_6


3 Maintenance3.5.6 Exporting the SIS data

4 Repair4.1 Introduction

Structure of this chapterThis chapter details all repair activities recommended for the robot and any externalunits of the robot.It is made up of separate procedures, each detailing a specific repair activity. Eachprocedure contains all the information required to perform the activity, for examplespare parts numbers, required special tools and materials.The procedures are gathered in sections, divided according to the componentlocation on the robot.

Required equipmentThe details of the equipments required to perform a specific repair activity arelisted in the respective procedures.The details of equipments are also available in different lists in the chapterReferences on page 10.

Safety informationThere are general safety information and specific safety information. The specificsafety information describes the danger and safety risks while performing specificsteps in a procedure. Make sure to read through the chapter Safety on page 17before commencing any service work.

Note

If the robot is connected to power, always make sure that the robot is connectedto earth before starting any repair work.For more information see:

• Product manual - IRC5• Product manual - Panel Mounted Controller.


4 Repair4.1 Introduction

4.2 General procedures

4.2.1 Performing a leak-down test

GeneralAfter refitting any motor and gearbox, the integrity of all seals enclosing the gearboxoil must be tested. This is done in a leak-down test.

Required equipment

NoteArt. no.Equipment, etc.

3HAC0207-1Leakdown tester

-Leak detection spray

Procedure

NoteAction

Finish the refitting procedure of the motor or gear inquestion.

1

Art. no. is specified in Requiredequipment on page 114.

Remove the topmost oil plug on the gear in questionand replace it with the leakdown tester.Adapters, which are included in the leakdown testerkit, may be required.

2

Correct value:Apply compressed air and raise the pressure withthe knob until the correct value is shown on themanometer.

30.2 - 0.25 bar (20 - 25 kPa)

Disconnect the compressed air supply.4

If the compressed air is signific-antly colder or warmer than thegearbox to be tested, a slightpressure increase or decreasemay occur. This is quite normal.

Wait for approx. 8-10 minutes. No pressure loss maybe detected.

5

Was any pressure drop evident?6Localize the leak as detailed below.Remove the leakdown tester and refit the oil plug.The test is complete.

Spray suspected leak areas with leak detection spray.Bubbles indicate a leak.

7

When the leak has been localized, take the necessarymeasures to correct the leak.

8


4 Repair4.2.1 Performing a leak-down test

4.2.2 Mounting instructions for bearings

GeneralThis section describes how to mount and grease different types of bearings on therobot.

Equipment


Used to grease the bearings, if notspecified otherwise.

3HAB3537-1Grease

Assembly of all bearingsFollow the following instructions while mounting a bearing on the robot.

NoteAction

To avoid contamination, let a new bearing remain in its wrappinguntil it is time for fitting.

1

Ensure that the parts included in the bearing fitting are free fromburrs, grinding waste, and other contamination. Cast componentsmust be free of foundry sand.

2

Bearing rings, inner rings, and roller elements must not be subjec-ted to direct impact. The roller elements must not be exposed toany stresses during the assembly work.

3

Assembly of tapered bearingsFollow the preceding instructions for the assembly of the bearings when mountinga tapered bearing on the robot.In addition to those instructions, the following procedure must be carried out toenable the roller elements to adjust to the correct position against the race flange.

NoteAction

Tension the bearing gradually until the recommended pre-tension is achieved.

Note

The roller elements must be rotated a specified number of turns before pre-tensioning is carried out and also rotated during the pre-tensioning sequence.

1

Make sure the bearing is properly aligned as this will directly affect the durab-ility of the bearing.

2

Greasing of bearingsThe bearings must be greased after assembly according to the followinginstructions:

• The bearings must not be completely filled with grease. However, if spaceis available beside the bearing fitting, the bearing may be totally filled withgrease when mounted, as excessive grease will be pressed out from thebearing when the robot is started.

• During operation, the bearing should be filled to 70-80% of the availablevolume.



4 Repair4.2.2 Mounting instructions for bearings

• Ensure that grease is handled and stored properly to avoid contamination.Grease the different types of bearings as following description:

• Grooved ball bearings must be filled with grease from both sides.• Tapered roller bearings and axial needle bearings must be greased in the

split condition.


4 Repair4.2.2 Mounting instructions for bearings

Continued

4.2.3 Mounting instructions for seals

GeneralThis section describes how to mount different types of seals onto the robot.

Equipment


Used to lubricate the seals.3HAB3537-1Grease

Rotating sealsThe procedure below describes how to fit rotating seals.

CAUTION

Please observe the following before commencing any assembly of seals:• Protect the sealing surfaces during transport and mounting.• Keep the seal in its original wrappings or protect it well before actual

mounting.• The fitting of seals and gears must be carried out on clean workbenches.• Use a protective sleeve for the sealing lip during mounting, when sliding

over threads, keyways, etc.

NoteAction

Check the seal to ensure that:• The seal is of the correct type (provided with cutting

edge).• There is no damage to the sealing edge (feel with a

fingernail).

1

Inspect the sealing surface before mounting. If scratchesor damage are found, the seal must be replaced since itmay result in future leakage.

2

Art. no. is specified inEquipment on page 117.

Lubricate the seal with grease just before fitting. (Not tooearly - there is a risk of dirt and foreign particles adheringto the seal.)

3

Fill 2/3 of the space between the dust tongue and sealinglip with grease. The rubber coated external diameter mustalso be greased, unless otherwise specified.

Mount the seal correctly with a mounting tool.4Never hammer directly on the seal as this may result inleakage.



4 Repair4.2.3 Mounting instructions for seals

Flange seals and static sealsThe following procedure describes how to fit flange seals and static seals.

Action

Check the flange surfaces. They must be even and free from pores.1It is easy to check flatness using a gauge on the fastened joint (without sealing com-pound).If the flange surfaces are defective, the parts may not be used because leakage couldoccur.

Clean the surfaces properly in accordance with the recommendations of ABB.2

Distribute the sealing compound evenly over the surface, preferably with a brush.3

Tighten the screws evenly when fastening the flange joint.4

O-ringsThe following procedure describes how to fit o-rings.

NoteAction

Ensure that the correct o-ring size is used.1

Defective o-rings may not be used.Check the o-ring for surface defects, burrs,shape accuracy, and so on.

2

Defective o-rings may not be used.Check the o-ring grooves.3The grooves must be geometrically correct andshould be free of pores and contamination.

Lubricate the o-ring with grease.4

Tighten the screws evenly while assembling.5


4 Repair4.2.3 Mounting instructions for seals

Continued

4.2.4 Replacing parts on Clean Room robots

GeneralWhen replacing parts on a Clean Room robot, it is important to make sure thatafter the replacement, no particles will be emitted from the joint between thestructure and the new part, and that the easy cleaned surface is retained.

Required equipment

NoteSpare partsEquipment

Sikaflex 521 FC. Color white.Sealing compound

Width 6-9 mm, made of wood.Tooling pin

EthanolCleaning agent

Knife

Lint free cloth

3HAC036639-001Touch up paint Clean Room,White

RemovingUse this procedure when removing a part for replacement on a Clean Room robot.

DescriptionAction

xx0900000121

Cut the paint with a knife in the joint betweenthe part that will be removed and the struc-ture, to avoid that the paint cracks.

1

Carefully grind the paint edge that is left onthe structure to a smooth surface.

2

Refitting

DescriptionAction

Use ethanol on a lint free cloth.Before the parts are refitted, clean the jointso that it is free from oil and grease.

1

Place the tooling pin in hot water.2



4 Repair4.2.4 Replacing parts on Clean Room robots

DescriptionAction

xx0900000122

Seal all refitted joints with Sikaflex 521FC.3

xx0900000125

Use the tooling pin to even out the surfaceof the Sikaflex seal.

4

Sikaflex 521FC skin dry time (15 minutes).Wait 15 minutes.5

3HAC035355-001Note

Always read the instruction in the productdata sheet in the paint repair kit for FoundryPrime.

6

3HAC036639-001Use Touch up paint Clean Room, white topaint the joint.

Note

Always read the instruction in the productdata sheet in the paint repair kit for CleanRoom.

7

Note

After all repair work, wipe the robot free from particles with spirit on a lint freecloth.


4 Repair4.2.4 Replacing parts on Clean Room robots

Continued

4.3 Complete robot

4.3.1 Replacement of cable unit, axes 1-3

Location of cablingThe cable unit of axes 1-3 is run from the base of the robot to the motors, axes 1,2 and 3, as shown in the figure below.A more detailed view of the component and its position may be found in chapterSpare parts on page 227.

xx0500002541

Connectors behind the cover plate at the robot base; R1.MP1-3 and R2.BU1-3.At the serial measurement board; R2.G (battery), R2.FB1-3.

A

Connectors at motor 2; R3.MP2 and R3.FB2B

Connectors at motor 3; R3.MP3, R3.FB3,R3.LS1 and R3.LS2C

Connectors at motor 1; R3.MP1, R3.FB1D

Upper bracketE

Cable guide in the middle of the frameF

Required equipment

NoteArt. no.Spare part no.Equipment, etc.

Includes:• cabling• covers, motor 1-3• attachment screws• gaskets, motor axes

1-3

3HAC4791-1Cable unit axes 1-3,Standard



4 Repair4.3.1 Replacement of cable unit, axes 1-3


Sealing in the base for thecables. Always use a newsealing.

3HAC4113-1Sealing

3HAC3200-1Gasket, cover

2166 2055-3Cable straps, outdoor

Loctite 57412340011-116Flange sealing

See the chapter Circuit dia-gram on page 255.

Circuit diagram

The content is defined inthe section Standard toolson page 223.

Standard toolkit

These procedures includereferences to the tools re-quired.

Other tools and proced-ures may be required. Seereferences to these pro-cedures in the step-by-step instructions below.

Removal, cable unit, axes 1-3The procedure below details how to remove the cabling of axes 1-3.


Axes 2 and 3 may be tilted slightly to im-prove access.

In order to facilitate refitting of the cableharness, move the robot to the specifiedposition:

• Axis 1: 0°• Axis 2: 0°• Axis 3: 0°• Axis 4: 0°• Axis 5: +90°• Axis 6: no significance

1

DANGER


2

xx0200000399

Remove the rear cover plate (A) on the ro-bot by unscrewing its attachment screws(B).

3

Disconnect the connectors R1.MP1-3 andR2.BU1-3 inside the base.

4

Disconnect all the earth cables on theR1.M1-3 cable from the back of the cover.

5




Continued


xx0200000398

Loosen the nuts (D) and remove the SMBunit carefully from the bracket.The cable (A) between the battery (B) andthe SMB unit (C) may stay connected, inorder to avoid recalibration of the robot. Becareful not to let the weight of the SMB unitstrain the cable!In order to remove the SMB unit com-pletely, the connector R2.G must be discon-nected! This causes a necessary recalibra-tion of the robot!

6

xx0200000400

Disconnect the connector R2.FB 1-3 fromthe connection R2.SMB1-4 (C) on the SMBunit.

7

R2.SMBR2.SMB3-6R2.SMB1-4

This releases the cable harness from theframe.

Unscrew the four screws securing the cablegland.

8

xx0200000404

Remove the cable guide in the middle ofthe frame by removing the attachmentscrews of the holder (A).Remove the cables from the guide.

9

Note! Different robot versions are fittedwith different versions of the holder. Makesure the correct one is used to avoid cablefailure.

Note! Do not remove or loosen any of thecable brackets from the new harness, theangle of the brackets is factory optimized.

Remove the upper bracket securing thecables to the arm house by unscrewing itstwo attachment screws.

10

Remove the cover of the motors 1-3.11




Continued


xx0200000401

Disconnect all the connectors at the motorsof axes 1, 2 and 3.

12

R3.MP1-3R3.FB1-3Connection box

Remove the three screws of the connectionbox for the motors of axes 1, 2 and 3.

13

Gently pull the cable harness out.14

Refitting, cable unit, axes 1-3The procedure below details how to refit the cabling of axes 1-3 to the robot.


DANGER


1

Gently pull down the cable harness throughthe center hole of axis 1.

2

The gasket is included in the spare partof the cable unit, spare part no. is spe-cified in Required equipment onpage 121.

Fit a new gasket and fit the connection boxon motor 1, 2 and 3, using the three attach-ment screws.

3

xx0200000401

Reconnect all the connectors at motors 1, 2and 3.

4

R3.MP1-3R3.FB1-3Connection box

Refit the cover of the motors, axes 1, 2 and3, with the five attachment screws.

5

Refit the upper bracket securing the cablesto the arm house, using the two attachmentscrews.

6




Continued


xx0200000404

Fit the cable guide to the harness and securethe holder to the frame with its two attach-ment screws (A).

7

Note! Different robot versions are fittedwith different versions of the holder.Make sure the correct one is used toavoid cable failure.

xx0200000402

Secure the cabling inside the base.Insert the cables in the sealing:

Power cablePower cablePower cableCustomer cableSignal cableSignal cable

Note! Make sure that each cable is fitted inthe same position as the old one, otherwisethe conduit entry will not be watertight. Usesix cable straps.Note! Always use a new sealing, combinedwith a flange sealing (Loctite 574).

8

Art. numbers are specified in Requiredequipment on page 121.

xx0200000400

Connect the connectors R2.FB 1-3 to theconnection R2.SMB1-4 (C) on the SMB unit.

9

R2.SMBR2.SMB3-6R2.SMB1-4




Continued


xx0200000398

Refit the SMB unit to the bracket with thenuts (D). Be careful not to let the weight ofthe SMB-unit strain the cable! (A).

10

Note! The cable (A) between the battery(B) and the SMB-unit (C) may stay con-nected, in order to avoid recalibration ofthe robot.

xx0200000403

Connect all the earth cables on the R1.M1-3cable to the back of the cover.

11

Connect the connectors R1.MP1-3 andR2.BU1-3 inside the base.

12

xx0200000399

Refit the rear cover plate (A) on the robotwith its attachment screws (B), together witha new gasket.

13


Detailed in the section Updating revolu-tion counters on page 206.

If the battery has been disconnected fromthe SMB unit, the revolution counters mustbe updated!

14

DANGER

Make sure all safety requirements are metwhen performing the first test run. These arefurther detailed in the sectionDANGER - Firsttest run may cause injury or damage! onpage 46.

15



Continued

4.3.2 Replacement of cable harness, axes 4-6

Location of cable harnessThe cable harness runs throughout the robot as shown in the figure below.

xx0200000396

Connector at robot base, R1.MP, R1.SMB and R1.C/CSA

Electrical connectors rear of the cover plate at the robot base , R1.MP1-3,R1.MP4-6, R1.CS, R1.CP, R1.H1, R2.BU, R2.BU1-3, R2.BU4-6,

a1

Connectors at the serial mesurement board (SMB-unit), R2.SMB1-2 (empty),R2.G (bat), R2.FB1-3 and R2.FB4-6

a2

Connectors at motor 2, R3.MP2 and R3.FB2B

Connectors at motor 3, R3.MP3, R3.FB3,R3.LS1 and R3.LS2C

Connectors at motor 1, R3.MP1, R3.FB1D

Connectors at motor 4 (5 kg option), R3.MP4 and R3.FB4E

Connectors at motor 4 (15 kg option), R3.MP4 and R3.FB4e

Connectors at motor 5, R3.MP5 and R3.FB5F

Connectors at motor 6, R3.MP6 and R3.FB6G

Connectors R3.H1 and R3.H2 (5 kg option)H

Connectors R3.H1 and R3.H2 (15 kg option)h



4 Repair4.3.2 Replacement of cable harness, axes 4-6

Required equipment


IRB 2400/L3HAC 9330-1Cable unit axes 4-6 Stand-ard

IRB 2400 /10, /163HAC9328-1Cable unit axes 4-6 Stand-ard

IRB 2400/L Option 0433HAC 8520-1Cable unit, axes 4-6 Opt043

3HAC4429-1Gasket, motor axes 4-6

3HAB 5922-1Sealing

Loctite 57412340011-116Flange sealing

L=208mm21662055-1Cable straps, outdoor


Circuit Diagram


Standard toolkit


Other tools and proceduresmay be required. See refer-ences to these proceduresin the step-by-step instruc-tions below.

Removal, cable harness, axes 4-6The procedure below details how to remove the cable harness, axes 4-6.


DANGER


1

Axes 2 and 3 may be tilted slightly to im-prove access.

In order to facilitate refitting of the cableharness, run the robot to the specified pos-ition:

• Axis 1: 0 °• Axis 2: 0 °• Axis 3: 0 °• Axis 4: 0 °• Axis 5: +90 °• Axis 6: no significance

2

xx0200000399

Remove the rear cover plate (A) on the ro-bot by unscrewing its attachment screws(B).

3




Continued


Disconnect connectors R1.MP4-6 andR2.BU4-6.

4

xx0200000403

Disconnect all the earth cables on theR1.M4-6 cable from the back of the cover.

5

xx0200000398

Loosen the nuts (D) holding the SMB-unitslightly, then remove it carefully from thebracket.The cable (A) between the battery (B) andthe SMB-unit (C) may stay connected, inorder to avoid recalibration of the robot. Becareful not to let the weight of the SMB-unitstrain the cable!In order to remove the SMB-unit com-pletely, the connector R2.G must be discon-nected! This causes a necessary recalibra-tion of the robot!

6

xx0200000400

Disconnect connector R2.FB 4-6 from theconnection R2.SMB4-6 (B) on the SMB-unit.

7

This releases the cable harness from theframe.

Unscrew the four screws securing the cablegland.

8




Continued


xx0200000404

Remove the adapter plate from the harnessby removing its two attachment screws (A).

9

Note! Different robot versions are fittedwith different plate versions. Make surethe correct one is used to avoid cablefailure.

xx0200000405

Remove the upper bracket securing thecables to the arm house by unscrewing itstwo attachment screws (C).Cut the strip clamp (B).

10

Remove the back cover of the motors 4-6,fitted with torx screw.

11

xx0200000406

Disconnect all connectors at motor 4, 5 andmotor 6, R3.MP4-6 and R3.FB4-6:A - R3.MP5B - R3.MP6C - R3.MP4D - R3.FB5E - R3.FB6F - R3.FB4

12

Remove all screws holding the motor caseon motor 4-6.

13

Gently pull the cable harness out.14




Continued

Refitting, cable harness, axes 4-6The procedure below details how to refit the cable harness, axes 4-6.


DANGER

Turn off all electric power, hydraulic andpneumatic pressure supplies to the ro-bot!

1

Axes 2 and 3 may be tilted slightly to improveaccess.

In order to facilitate refitting of the cableharness, run the robot to the specifiedposition:

• Axis 1: 0 °• Axis 2: 0 °• Axis 3: 0 °• Axis 4: 0 °• Axis 5: +90 °• Axis 6: no significance

2

Gently pull down the cable harnessthrough the center of the lower arm andthrough the hole of axis 1.

3

Note! Always use a new gasket! Art. no. isspecified inRequired equipment on page128.

Fit a new gasket and fit the motor caseon motor 4-6 using the nine torx screws.

4




Continued


xx0200000406

Reconnect all connectors at motor 4, 5and 6. R3.MP 4-6 (A) and R3.FB 1-3 (B)A - R3.MP5B - R3.MP6C - R3.MP4D - R3.FB5E - R3.FB6F - R3.FB4

5

xx0300000063

xx0300000062

Fit the back cover of the motors 4-6.6




Continued


Fit the upper bracket securing the cablesto the arm house, using the two attach-ment screws.

7

xx0200000404

Fit the adapter plate to the harness byusing its two attachment screws (A).

8

Note! Different robot versions are fitted withdifferent plate versions. Make sure the cor-rect one is used to avoid cable failure.

xx0200000402

Fit all the screws securing the cablegland.This attaches the cable harness to theframe.Cables

• A - Power• B - Power• C - Power• D - Customer• E - Signal• F - Signal

Note! Make sure that each cable is fittedat the same position as the old ones,otherwise the conduit entry will not bewatertight.Note! Always use a new sealing andcombine it with a flange sealing (Loctite574).

9

Art. no:s.are specified inRequired equipmenton page 128.

xx0200000400

Connect connectors R2.FB 4-6 to theconnection R2.SMB4-6 (B) on the SMB-unit.

10




Continued


xx0200000398

Fit the SMB-unit to the bracket with thenuts (D), be careful not to let the weightof the SMB-unit strain the battery cable!(A).

11

Note! The cable (A) between the battery (B)and the SMB-unit (C) may stay connected,in order to avoid recalibration of the robot.

xx0200000403

Run all the earth cables on the R1.M4-6cable to the back of the cover.

12

Connect connectors R1.MP4-6 andR2.BU4-6.

13

xx0200000399

Refit the rear cover plate (A) on the robotwith its attachment screws (B).

14

DANGER

Make sure all safety requirements aremet when performing the first test run.These are further detailed in the sectionDANGER - First test run may cause in-jury or damage! on page 46.

15



Continued

4.4 Upper arm

4.4.1 Replacement of wrist IRB 2400/10/16

Location of wristThe wrist is defined as the axis 5 and 6 of the robot. This is shown in pos (A) inthe figure below.

xx0300000103

WristA

Upper armB

Lower armC

FrameD

BaseE



4 Repair4.4.1 Replacement of wrist IRB 2400/10/16

Wrist unit

xx0300000104

Attachment screws and washersA

Oil plugB

WristC

Required equipment


3HAB9398-1Wrist, Standard

Replace if damaged.3HAB3772-12O-ring

Shell Alvania WR23HAB3537-1Grease

M8, length = 70 mm-Guide pins

3HAB7887-1Measuring tool

24 VDC, 1.5 A.-Power supplyFor releasing the brakes.


-Standard toolkit






Continued

Removal, wrist unitThe procedure below details how to remove the wrist from the robot upper arm.The wrist, which includes axes 5 and 6, is a complete unit comprising drive unitsand gearboxes. It is a replacement unit of complex design and should not normallybe serviced on-site. Instead it should be sent to ABB for service etc.ABB recommends its customers to carry out only the following servicing and repairwork on the wrist.

NoteAction

DANGER

Turn off all electric power, hydraulic and pneumaticpressure supplies to the robot!

1

Shown in the figure Wrist uniton page 136.

Remove the oil plug on the wrist and drain it from allthe oil.

2

Shown in the figure Wrist uniton page 136.

Undo the attachment screws and remove the wrist.3

Refitting, wrist unitThe wrist, which includes axes 5 and 6, is a complete unit comprising drive unitsand gearboxes. It is a replacement unit of complex design and should not normallybe serviced on-site. Instead it should be sent to ABB for service.The procedure below details how to refitt the wrist to the robot upper arm.


DANGER


1

Clean the surface of the tubular shaft.2


Lubricate the o-ring with grease to be sure that itdoes not get displaced, and fit it in its position onthe upper arm tubular.

3

Specified inRequired equipmenton page 136.

xx0200000424

Fit the two guide pins (A) diagonally on the wrist.Carefully push the wrist against the tubular. Whenthe gears are meeting each other, they may need tobe rotated to mesh properly.

4

Fix the wrist with two screws and two washers. Re-move the M8 guide pins and fit the other two screwsand washers.

5




Continued


Connect to motor axis 5, connect-or R3.MP5:

• + :pin 7• - : pin 8

Connect to motor axis 6, connect-or R3.MP6:

• + : pin 7• - : pin 8

In order to release the brakes, connect the 24 VDCpower supply to the motor.Note!Release the brakes of the two motors, but oneat a time!

6


Fit the measuring tool at the rear of the motor.7

xx0200000425

Push the wrist, as shown in the figure to the right,to locate the smallest play in the same way as foradjustment of play when changing motors for axes5 and 6, detailed in section Replacement of motors,axes 4-6, IRB 2400/10/16 on page 188.

8

A Gears on drive shaft unit,axis 5-6

B Gears on the wrist

Tightening torque: 17 Nm.Tighten the attachment screws and washers.9

Check the play by moving axes 5 and 6 by hand.10

See the section Oil change,gearbox axes 5-6 (wrist unit) onpage 93.

Refill the wrist unit with oil.11

Calibration is detailed in a separ-ate calibration manual enclosedwith the calibration tools.

Recalibrate the robot.12

General calibration informationis included in the sectionCalibra-tion information on page 201.

DANGER

Make sure all safety requirements are met whenperforming the first test run. These are further de-tailed in the section DANGER - First test run maycause injury or damage! on page 46.

13



Continued

4.4.2 Replacement of wrist IRB 2400L

Location of wristThe wrist is defined as the axis 5 and 6 of the robot and shown in pos (A) in thefigure below.

xx0200000409

WristA

Upper armB

Lower armC

FrameD

BaseE



4 Repair4.4.2 Replacement of wrist IRB 2400L

Required equipment

NoteSpare part no.Equipment, etc.

Standard and Foundry.3HAC10814-1Wrist, 5 kg

Loctite 574-Locking liquid


-Standard toolkit

These procedures include referencesto the tools required.


Removal, wrist unitThe procedure below details how to remove the wrist from the robot upper arm.The wrist, which includes axes 5 and 6, is a complete unit comprising drive unitsand gearboxes. It is a replacement unit of complex design and should not normallybe serviced on-site. Instead it should be sent to ABB for service etc.ABB recommends its customers to carry out only the following servicing and repairwork on the wrist.


DANGER


1

xx0300000104

Remove the oil plug from the wrist anddrain it from all the oil.

2

A ScrewB Oil plug (air inlet)C Wrist unit

Undo the screws and remove the wrist.3




Continued

Refitting, wrist unitThe procedure below details how to refit the wrist unit to the robot.

NoteAction

DANGER


1

Clean the surface of the tubular shaft.2

Apply Loctite 574 all around.3

Tightening torque: 8.3 Nm +10%.Fit the wrist, tighten the attachment screws.4

Screw the clamping sleeves together using screwsto a torque of 5.7 Nm.

5

Refit the plugs.6

Refit the cover at the motor side of axis 5-6.7

Calibration is detailed in a separatecalibration manual enclosed withthe calibration tools.

Calibrate the robot!8

General calibration information isincluded in the section Calibrationinformation on page 201.

DANGER

Make sure all safety requirements are met whenperforming the first test run. These are furtherdetailed in the section DANGER - First test runmay cause injury or damage! on page 46.

9



Continued

4.4.3 Replacement of complete upper arm

Location of upper armThe upper arm is located on top of the robot as shown in (A) and (B) the figurebelow. The complete upper arm includes the wrist unit.

xx0200000409

Wrist axis 5-6A

Upper arm axis 3-4B

Lower arm axis 2C

Frame axis 1D

BaseE



4 Repair4.4.3 Replacement of complete upper arm

Required equipment


-Lifting device, upper arm

Used for removing the shafts from theupper arm.

3HAB9009-1Dismounting tool, shaft ends

3HAB6464-1Mounting tool, bearing

To be used together with lifting eye,M12 and lifting device, upper arm.

-Lifting tool (chain)


-Standard toolkit

These procedures include referencesto the tools required.


Upper arm attachment

xx0200000436

CoverA

KM nutsB

Attachment screwC

Sealing (insert a strap under the sealing to let the air go out when fitting thecover)

D




Continued

Removal, upper armThe procedure below details how to remove the complete upper arm.


DANGER


1

Detailed in section Replacementof tie rod on page 150.

Remove the tie rod.2

Detailed in section Replacementof motors, axes 4-6, IRB 2400L onpage 181.

Loosen the connectors of the motors of axes 4, 5and 6.

3

Disconnect the connection box from the motors.4

Shown in the figure Upper arm at-tachment on page 143.

Remove the covers (Left + Right).5


Undo the KM nuts (Left + Right).6


Remove the attachment screws (Left + Right).7

xx0200000435

Fit the lifting device to the upper arm, and liftenough for the strap to stretch without lifting therobot.

8

Lifting without lifting tool!


Pull out the shaft, using the dismounting tool forshaft ends. Mark the shafts (left, right).

9

Refitting, upper armThe procedure below details how to refit the complete upper arm.

NoteAction

DANGER


1

Fit sealings in the upper arm.2


Fit the inner ring of the bearings on shafts, usingthe mounting tool for bearings.

3

Raise the upper arm into the mounting position.4

Fit shaft spindles (both sides).5

Tightening torque: 90 Nm.Insert the screws and tighten.6Shown in the figure Upper armattachment on page 143.




Continued

NoteAction

Shown in the figure Upper armattachment on page 143.

The following procedure must be performed within10 minutes, before the Loctite starts to harden.

• Apply Loctite 243 on the KM-nuts.• Fit and tighten the KM-nut on the left side

first (robot seen from behind) so that thebearing comes against the collar.

• Unscrew the KM-nut and then retighten witha torque of 35 Nm.

• Tighten the KM-nut on the right side, movethe upper arm up and down at the same time,until there is no play.

• Unscrew the nut again.• Tighten the KM-nut with a torque of 35 Nm.• Push in a strap under the sealing to let the

air go out and then fit the covers.

7

Fit the calibration plate for axis 3.8

Reconnect the connection boxes and the cabling.9


Recalibrate the robot!10

General calibration information isincluded in the sectionCalibrationinformation on page 201.

DANGER


11



Continued

4.5 Lower arm

4.5.1 Replacement of complete lower arm

Location of lower armThe lower arm is located as shown in the figure below.A more detailed view of the component and its position may be found in chapterSpare parts on page 227.

xx0200000409

WristA

Upper armB

Lower armC

FrameD

BaseE



4 Repair4.5.1 Replacement of complete lower arm

Required equipment


2400/10, /163HAC4796-1Lower arm

2400L3HAC4797-1Lower arm

Replace if damaged.3HAB3732-13Sealing ring (V-ring)

Used to lubricate the sealingring.

3HAB3537-1Bearing grease

-Hoisting equipment


Standard toolkit

Complete kit that also includesoperating manual.

3HAC15716-1Calibration Pendulumtoolkit

These procedures include ref-erences to the tools required.

Other tools and proced-ures may be required.See references to theseprocedures in the step-by-step instructions be-low.

Removal, lower armThe procedure below details how to remove the complete lower arm.


DANGER


1

Detailed in sectionRemoval, upper arm onpage 144.

Remove the upper arm.2

CAUTION

The robot lower arm weighs 27 kg withoutany additional equipment fitted.All lifting accessories used must be sizedaccordingly!

3




Continued


xx0200000439

Fit the lifting equipment to the lower armto secure its weight.

4

Detailed in section Removal, tie rod onpage 152.


Detailed in section Removal, parallel armon page 163.

Remove the parallel arm.6

Pull down the cabling from inside thelower arm and remove any cable attach-ments.

7

xx0200000440

Remove the attachment screws and thespring tension plate.

8

Attachment screws

Remove the lower arm.9




Continued

Refitting, lower armThe procedure below details how to refit the complete lower arm.

NoteAction

DANGER


1

Move the damper and calibration marking tothe new lower arm.

2


Make sure that the sealing ring is fitted prop-erly to the gearbox, undamaged and properlylubricated with grease. If damaged, replacewith a new one.

3

Shown in the figure Location of lowerarm on page 146.

CAUTION

The robot lower arm weighs 27 kg without anyadditional equipment fitted.All lifting accessories used must be sized ac-cordingly!

4

Lift the lower arm into position.5

12 pcs; M10 x 40. Tightening torque:72 Nm.

Fit the spring tension plate to the lower armand secure the arm to the gearbox with the 12attachment screws.

6

Detailed in section Refitting, parallelarm on page 164.

Refit the parallel arm.7

Detailed in section Refitting, tie rod onpage 152.

Refit the tie rod.8

Detailed in sectionRefitting, upper armon page 144.

Refit the upper arm.9

Detailed in section Refitting, cableharness, axes 4-6 on page 131.

Refit the cabling.10

Calibration is detailed in a separatecalibration manual enclosed with thecalibration tools.


General calibration information is in-cluded in the sectionCalibration inform-ation on page 201.

DANGER

Make sure all safety requirements are metwhen performing the first test run. These arefurther detailed in the section DANGER - Firsttest run may cause injury or damage! onpage 46.

12



Continued

4.5.2 Replacement of tie rod

Location of tie rodThe tie rod is located as shown in the figure below.A more detailed view of the component and its position may be found in chapterSpare parts on page 227.

xx0200000444

Tie rodA

Parallel armB



4 Repair4.5.2 Replacement of tie rod

xx0200000443

Bearing sealingA

Back up ringB

Attachment screwC

Locking washerD

Spherical roller bearingE

Upper connection IRB 2400 5 kg

Bearing sealingF

Spherical roller bearingG

Bearing sealingH

ScrewI

Required equipment


Loctite 2433HAB7116-1Locking liquid

3HAB3537-1Grease

3HAB6324-1Press tool, parallel barbearing

Used to fit the tie rod.3HAB6331-1Mounting tool, parallel bar


-Standard toolkit




Continued


Complete kit that also in-cludes operating manual.

3HAC15716-1Calibration Pendulum toolkit



Removal, tie rodThe procedure below details how to remove the tie rod from the robot.

NoteAction

DANGER

Turn off all electric power, hydraulic and pneumat-ic pressure supplies to the robot!

1

CAUTION

The robot upper arm weighs 23 kg without anyadditional equipment fitted.All lifting accessories used must be sized accord-ingly!

2

Shown in the figure Location of tierod on page 150.

Use a crane to secure the weight of the upperarm.

3


Remove the attachment screw from the upperand lower end.

4


Remove the locking washer from both ends.5

M8Insert a screw in the center of each end, to beused as support.

6

Use a puller to pull out the tie rod.7


Remove the bearings and seals.8

Refitting, tie rodThe procedure below details how to refit the tie rod to the robot.

NoteAction

DANGER


1

Use a crane!Make sure the weight of the upper arm isproperly secured.

2

Shown in the figure Location of tie rod onpage 150.

Fit the new spherical roller bearings to thetie rod using the press tool, parallel barbearing. Lubricate the bearings with bearinggrease.

3

Art. no. is specified in Required equip-ment on page 151.




Continued

NoteAction


Fit new bearing sealings to the shaft endsand lubricate the shaft ends with grease.

4



Refit the tie rod, using the mounting tool,parallel bar.

Note

Press by hand!

5

Fit new bearing sealings to the bearings.6


Refit the back up ring.7


Refit the locking washer.8

M8 x 16.Refit the attachment screw at both ends ofthe bar, using locking liquid.

9Loctite 243Shown in the figure Location of tie rod onpage 150.

Calibration is detailed in a separate calib-ration manual enclosed with the calibra-tion tools.


General calibration information is in-cluded in the sectionCalibration informa-tion on page 201.

DANGER

Make sure all safety requirements are metwhen performing the first test run. Theseare further detailed in the section DANGER- First test run may cause injury or damage!on page 46.

11



Continued

4.6 Frame and base

4.6.1 Replacement of SMB unit

Location of SMB unitThe SMB unit (SMB = serial measurement board) is located on the left hand sideof the base, as shown in the figure below.A more detailed view of the component and its position may be found in chapterSpare parts on page 227.Note that the robot is shown with the SMB cover already removed!

xx0200000451

Cable, battery/SMB boardA

Battery pack (2-pole battery contact)B

Serial measurement boardC

Lock nutsD



4 Repair4.6.1 Replacement of SMB unit

A B C

xx1300000289

SMB battery cableA

SMB battery RMU (3-pole battery contact)B

SMB unit RMU 101C

Required equipment

Note

There are different variants of SMB units and batteries. The variant with the3-pole battery contact has longer lifetime for the battery.It is important that the SMB unit uses the correct battery. Make sure to order thecorrect spare parts. Do not replace the battery contact!

NoteArt. no.Spare part no.Equipment

Must always be replaced!3HAB 5537-1Gasket, base cover




Continued


Contains serial measure-ment board 3HAC031851-001 and battery pack3HAC16831-1.

3HAC17396-1Serial measurement unit


3HAC046277-001Serial measurement unit


Standard toolkit


-Circuit Diagram


Other tools and proced-ures may be required. Seereferences to these proced-ures in the step-by-stepinstructions below.




Continued

SMB unit, layout

xx0600002645

Connector R2.SMB4-6A

Connector R2.SMB1-3B

Connector R2.SMB1-2 (external axis)C

Connector R2.SMBD

Connector R2.G (battery unit)E




Continued

A

B C D E

xx1300000310

Connector R2.SMB4-6A

Connector R2.SMB1-3B

Connector R2.SMB1-2 (external axis)C

Connector R2.SMBD

Connector R2.G (battery unit)E

Replacement, SMB unitThe procedure below details how to replace the SMB unit.

NoteAction

DANGER


1

xx0200000399

Remove the rear cover plate (A) from the baseby unscrewing the attachment screws (B).

2

Detailed in section Replacement, SMBbattery on page 99.

Remove the SMB battery.3




Continued

NoteAction

Remove the SMB cover by unscrewing its at-tachment screws.

4

Pull the battery cable through the hole in theSMB cover.

Remove the two locknuts and washers fromthe pins securing the board.

5

All connectors are shown in the figureSMB unit, layout on page 157.

Gently disconnect the connectors from theSMB unit when pulling the board out. Alsodisconnect the battery cable from the SMBunit.

6

All connectors are shown in the figureSMB unit, layout on page 157.

Gently connect the connectors to the newSMB unit and push the board in.

7

Refit the SMB cover using the attachment locknuts.

8

Pull the battery cable through the hole in theSMB cover.

Reassemble the two locknuts and washers tothe pins securing the board.

9

Refit the SMB battery.10

Always replace a removed gasket witha new!

Fit a new gasket to the cover and refit thecover with the attachment screws.

11


Detailed in the sectionUpdating revolu-tion counters on page 206.

Update the revolution counters!12



Continued

4.6.2 Replacement of brake release unit

Location of brake release unitThe brake release unit is located behind the flange plate at the robot base, asshown below.

xx0200000463

Brake release unit with buttonsA

Required equipment

NoteSpare part no.Equipment, etc.

3HAC16035-1BU w. buttons DSQC 563

The content is defined in the sec-tion Standard tools on page 223.

-Standard toolkit

These procedures include refer-ences to the tools required.


Replacement, brake release unitThe procedure below details how to replace the brake release unit from the robotbase.

Action

DANGER

If the robot normally works in an inverted position, it must be removed from this pos-ition and placed on the floor before the work detailed in this procedure may be carriedout!

1



4 Repair4.6.2 Replacement of brake release unit

Action

DANGER

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

2

Remove the cover at the rear of the base.3

Unscrew the six attachment screws of the brake release unit on the outside of thebase.

4

Disconnect the cable from the brake release unit and remove the unit from the base.5

Reconnect the cable to the new brake release unit and fit it to the base.6

Secure the unit with its six attachment screws on the outside of the base.7

Refit the cover to the rear of the base.8

DANGER

Make sure all safety requirements are met when performing the first test run. Theseare further detailed in the sectionDANGER - First test runmay cause injury or damage!on page 46.

9


4 Repair4.6.2 Replacement of brake release unit

Continued

4.6.3 Replacement of parallel arm

Location of parallel armThe parallel arm is located at the frame, as shown in the figure below.A more detailed view of the component and its position may be found in chapterSpare parts on page 227.

xx0200000444

Tie rodA

Parallel armB

Required equipment


3HAB3643-12Groove ball bearing

3HAB5515-1Sealing ring




4 Repair4.6.3 Replacement of parallel arm



Standard toolkit





Removal, parallel armThe procedure below details how to remove the parallel arm.

NoteAction

DANGER


1

Detailed in section Removal, tierod on page 152.


Remove the parallel arm by removing its eight at-tachment screws and washers.

3




Continued

Assembly, parallel armThe figure below shows the assembly of the parallel arm.

xx0200000450

Parallel armA

Sealing V- ring (2 pcs)B

Groove ball bearingC

Attachment screws and washers (8 pcs)D

Refitting, parallel armThe procedure below details how to refit the complete parallel arm to the robot.

NoteAction

DANGER


1

Shown in the figure Assembly, par-allel arm on page 164.

Fit one of the two V-rings to the parallel arm.2




Continued

NoteAction

Heat up the new bearing to 170º and fit it to theparallel arm.

3

Fit the second V-ring to the parallel arm.4

8 pcs; M10x60.Fit the complete parallel arm to the robot with theeight attachment screws and washers.

5Tightening torque: 72 Nm.

Detailed in section Refitting, tie rodon page 152.

Refit the tie rod.6

Calibration is detailed in a separatecalibration manual enclosed withthe calibration tools.



DANGER


8



Continued

4.7 Motors

4.7.1 Replacement of motor, axis 1

Location of motor, axis 1The motor, axis 1, is located on the left hand side of the robot as shown in thefigure below:A more detailed view of the component and its position may be found in chapterSpare parts on page 227.

xx0200000465

CoverA

Connection boxB

Attachment screws and washers, motor (4 pcs)C

Motor axis 1D

Correct orientation of holesE



4 Repair4.7.1 Replacement of motor, axis 1

Required equipmentNote! The different motors are not compatible. Make sure to replace with correctmodel!


IRB 2400 /L, /10, /16 (Elmo)3HAC4789-1Motor axis 1

IRB 2400 /Wall mounted(Elmo)

3HAC14271-1

IRB 2400 /L, /10, /16(Yaskawa)

3HAC021346-001

IRB 2400 /Wall mounted(Yaskawa)

3HAC021961-001

Always fit a new one!3HAB 3772-1O-ring

3HAB 3676-1Gasket

3HAB7887-1Measuring tool, motor

24 VDC, max. 1.5 A. Forreleasing the brakes.

-Power supply

The content is defined inthe section Special toolson page 224.

Standard toolkit





See the chapter Circuitdiagram on page 255.

Circuit Diagram

Removal, motor axis 1The procedure below details how to remove the motor, axis 1.


DANGER

Turn off all electric power, hydraulic and pneu-matic pressure supplies to the robot!

1

Shown in the figure Location ofmotor, axis 1 on page 166

Remove the cover of the connection box.2




Continued


xx0200000401

Disconnect the connectors R3.MP1 and R3.FB1.3

• A: R3.MP1• B: R3.FB1• C: Connection box

Shown in the figure Location ofmotor, axis 1 on page 166.

Remove the connection box by unscrewing itsthree attachment screws and plain washers.

4

xx0600002646

Use a marker pen to mark the position of themotor (A), if the same motor is to be refitted.

5

Shown in the figure Location ofmotor, axis 1 on page 166.

Unscrew the four attachment screws andwashers of the motor.

6

Gently lift the motor straight up, making surenot to damage the motor pinion.

7

Refitting, motor axis 1The procedure below details how to refit the motor, axis 1.


DANGER


1

Check that the assembly surfaces are clean andthe motor is unscratched.

2

Always fit a new one, see art. no. inRequired equipment on page 167.

Fit the new o-ring.3




Continued


Note the position of the motor! Usethe mark , made on the motor basebefore removal. See also orientationof the holes on top of the motor,shown in the figure Location of mo-tor, axis 1 on page 166.

Fit the motor by gently lowering it straight down.4

4 pcs. TIghtening torque: 2 Nm.Tighten the four attachment screws and washers.5

Connect power supply to connectorR3.MP1:

• + : pin 7• - : pin 8

In order to release the brakes, connect the 24VDC power supply to the motor.

6


Fit the measuring tool to the rear of the motor.7

Shown in the figure below.

Rotate the motor shaft several turns, using themeasuring tool.There must always be some backlash, meaningthat the shaft should go easy to rotate!

8

The tip of the dial indicator mustmeasure on a 50 mm radius fromthe center of the motor shaft.

xx0200000473

Place the tip of a dial indicator against the scribedmark on the measuring tool.

9

Measuring tool

Set the gear play to 0.02 mm, which correspondsto a reading on the dial indicator of 0.13 mm.

10

Pull gently in one direction. Note the reading.(The gear must not turn.)

11

Then gently knock on the tool in the other direc-tion and note the reading. The difference inreading = gear play. The gear play should be 0.02mm which corresponds to a reading on the dialindicator of 0.13 mm.

12

4 pcs. Tightening torque: 23 Nm.Tighten the motor attachment screws.13

Shown in the figure Location of mo-tor, axis 1 on page 166.

Refit the connection box with the three attach-ment screws and plain washers.Make sure the gasket is fitted properly!

14




Continued


xx0200000401

Reconnect the connectors R3.MP1 and R3.FB1.15



Refit the cover of the connection box.16




DANGER


18



Continued


Location of motor, axis 2The motor, axis 2, is located on the left hand side of the robot as shown in thefigure below:

xx0200000470

Attachment screws, cover (5 pcs)A

CoverB

Connection boxC

GasketD

Motor, axis 2E

Attachment screws, motor (4 pcs)F

O-ringG

Correct orientation of holes on top of motorH






(Elmo)3HAC4790-1Motor, axis 2

(Yaskawa)3HAC021350-001Motor, axis 2

Always fit a new one!3HAB3772-1O-ring

3HAB3676-1Gasket


24 VDC, max. 1.5 A. For re-leasing the brakes.

Power supply


Standard toolkit






Circuit Diagram



DANGER


1



xx0200000401

Disconnect the motor connectors R3.MP2 andR3.FB2.

3



4




Continued


Use a marker pen to mark out the position of themotor, if the same motor is to be refitted.

5

Secure the robot arms before un-screwing any of the attachmentscrews of the axis 2 motor.

xx0700000660

DANGER

Secure the weight of the lower arm properly beforereleasing the brakes of motor, axis 2!When releasing the holding brakes of the motor,the lower arm will be movable and may fall down!

6

WARNING

Oil will be running out of the motor attachmenthole when removing the motor! It may also be hot!Take any necessary measures to collect the oil.

7


Unscrew the four attachment screws and washersof the motor.

8

Remove the motor by gently lifting it straight out.9



DANGER


1

Check that the assembly surfaces are clean andthe motor is unscratched.

2

Always fit a new one, see art. no. inRequired equipment on page 172.

Fit the o-ring.3




Continued


Note the position of the motor! Usethe mark on the motor base, madebefore removing the motor. Also seethe orientation holes on the motorcover, shown in the figure Locationof motor, axis 2 on page 171.

Fit the motor by gently lifting it straight on.4

4 pcs. Tightening torque: 2 Nm.Fit the four attachment screws and tighten themslightly. Make the adjustments described belowbefore tightening the screws properly.

5

Connect to connector R3.MP2:• +: pin 7• -: pin 8


6

See the figure below.Fit the measuring tool to the rear of the motor.7Art. no. is specified in Requiredequipment on page 172.

Rotate the motor shaft several turns, using themeasuring tool.There must always be some backlash, meaningthat the shaft should go easy to rotate!

8

The tip of the dial indicator mustmeasure on a 50 mm radius from thecenter of the motor shaft.

xx0200000473

Place the tip of a dial indicator against thescribed mark on the measuring tool.

9

A Measuring tool

Set the gear play to 0.02 mm, which correspondsto a reading on the dial indicator of 0.13 mm.

10

See the figure above.Pull gently in one direction. Note the reading.(The gear must not turn.)

11

See the figure above.Then gently knock on the tool in the other direc-tion and note the reading. The difference inreading = gear play. The gear play should be0.02 mm which corresponds to a reading on thedial indicator of 0.13 mm.

12

4 pcs. Tightening torque: 23 Nm.Tighten the four attachment screws.13

Detailed in section Performing aleak-down test on page 114.

Perform a leak-down test.14




Continued


Where to find type of oil and totalamount is detailed in Type andamount of oil in gearboxes onpage 92.

Fill the gearbox with oil.15


Refit the connection box and secure with thethree attachment screws and plain washers.Make sure that the gasket is fitted properly!

16

xx0200000401

Reconnect connectors R3.MP2 and R3.FB2.17






General calibration information is in-cluded in the section Calibration in-formation on page 201.

DANGER


20



Continued


Location of motor, axis 3The motor, axis 3, is located on the right hand side of the robot, as shown in thefigure below:A more detailed view of the component and its position may be found in chapterSpare parts on page 227.

xx0200000471

Attachment screws, coverA

CoverB

Connection boxC

GasketD

Motor, axis 2E

Attachment screws, motor (4 pcs)F

O-ringG

Correct orientation of holes on top of motorH






(Elmo)3HAC4789-1Motor axis 3

(Yaskawa)3HAC021346-001

3HAB3676-1Gasket

Always fit a new one.3HAB3772-1O-ring



-Power supply


-Standard toolkit




Other tools and proced-ures may be required.See references to theseprocedures in the step-by-step instructions below.


-Circuit Diagram



DANGER


1



xx0200000401

Disconnect the motor connectors R3.MP3 andR3.FB3.

3




4




Continued


Use a marker pen to mark out the position of themotor, if the same motor is to be refitted.

5

Secure the upper arm beforeloosening any of the screws on themotor!

xx0700000660

DANGER

Secure the weight of the upper arm properly be-fore releasing the brakes of motor, axis 3.When releasing the holding brakes of the motor,the upper arm will be movable and may fall down!

6

WARNING

Oil will be running out of the motor attachmenthole when removing the motor! It may also behot! Take any necessary measures to collect theoil.

7


Unscrew the four attachment screws and plainwashers of the motor.

8

Remove the motor by gently lifting it straight out.9



DANGER


1

Check that the assembly surfaces are cleanand the motor is unscratched.

2

Always mount a new one, see art. no.in section Required equipment onpage 177.

Fit a new o-ring to the motor.3




Continued


Note the position of the motor! Use themark on the motor base, made beforeremoval. Also see the orientation holeson the motor cover, shown in the figureLocation of motor, axis 3 on page 176.

Fit the motor, by gently lifting it straight on.4

Tightening torque: 2 Nm.Tighten the four screws lightly.5

Connect to connector R3.MP3:• +: pin 7• -: pin 8


6

See the figure below.Fit themeasuring tool to the rear of the motor.7Art. no. is specified in Required equip-ment on page 177.

See the figure below.Rotate the motor shaft several turns, usingthe measuring tool.There must always be some backlash, mean-ing that the shaft should go easy to rotate!

8

The tip of the dial indicator mustmeasure on a 50 mm radius from thecenter of the motor shaft.

xx0200000473

Place the tip of a dial indicator against thescribed mark on the measuring tool.

9

A Measuring tool

Set the gear play to 0.02 mm, which corres-ponds to a reading on the dial indicator of 0.13mm.

10

See the figure above.Pull gently in one direction. Note the reading.(The gear must not turn.)

11

See the figure above.Then gently knock on the tool in the otherdirection and note the reading. The differencein reading = gear play. The gear play shouldbe 0.02 mm which corresponds to a readingon the dial indicator of 0.13 mm.

12

4 pcs. Tightening torque: 23 Nm.Tighten the four motor attachment screws.13

Detailed in section Performing a leak-down test on page 114.


Where to find type of oil and totalamount is detailed in Type and amountof oil in gearboxes on page 92.

Refill the gearbox with oil.15




Continued


Shown in the figure Location of motor,axis 3 on page 176.

Refit the connection boxwith the three attach-ment screws and plain washers.Make sure that the gasket is fitted properly!

16

xx0200000401

Reconnect the motor connectors R3.MP3 andR3.FB3.

17


Shown in the figure Location of motor,axis 3 on page 176.




General calibration information is in-cluded in the sectionCalibration inform-ation on page 201.

DANGER

Make sure all safety requirements are metwhen performing the first test run. These arefurther detailed in the section DANGER - Firsttest run may cause injury or damage! onpage 46.

20



Continued

4.7.4 Replacement of motors, axes 4-6, IRB 2400L

Location of motors axes 4-6The motor of axis 4 is located on the right hand side of the robot as shown in thefigure below:The motors of axes 5 and 6 are located on the back side of the robot as shown inthe figure below:A more detailed view of the component and its position may be found in chapterSpare parts on page 227.

xx0200000476

Torx screwA

CoverB

Connection boxC

ScrewD

Motor 6E

Motor 5F

Motor 4G

GearboxH



(Elmo)3HAC11864-1Motor unit axis 4

(Yaskawa)3HAC021740-001Motor unit axis 4

(Elmo)3HAC11865-1Motor unit axes 5-6

(Yaskawa)3HAC021741-001Motor unit axes 5-6

21522011-414O-ring

Loctite 2433HAB7116-1Locking liquid




4 Repair4.7.4 Replacement of motors, axes 4-6, IRB 2400L


30 ml11712016-604Lubricating oilFor the gearbox of axis 4.



-Power supply


Standard toolkit



See the chapterCircuit dia-gram on page 255.

Circuit Diagram

Removal, motor axes 5-6The procedure below details how to remove the motor, axes 5 and 6.


DANGER


1

Shown in the figure Location of motorsaxes 4-6 on page 181.


xx0300000063

Loosen connectors R3.MP5-6 and R3.FB5-6.3

Remove the connection box by unscrewingits three attachment screws and plain wash-ers.

4


Use a marker pen to mark out the position ofthe motors, if same motors are to be refitted.

5

Unscrew the attachment screws and plainwashers of the motors.

6




Continued



Remove the motors by gently lifting themstraight out (horizontal movement).

7



DANGER


1

Drain the oil from the axis 4 gearbox.2

xx0200000401



Disconnect the connectors R3.MP4 and R3.FB4.4


5

Use a marker pen to mark out the position of themotor.

6

Remove the motor by unscrewing its attachmentscrews and plain washers.

7

Remove the motor by gently lifting it straight out(horizontal movement).

8



DANGER


1

Check that the assembly surfaces are cleanand the motor unscratched

2


Fit a new o-ring on the motor.3


Lubricate the gear with bearing grease.4




Continued


xx0300000005

Fit the measuring tool at the rear of the mo-tor.

5

The motor’s fixing screws shall be fastened,but do not tighten them, to ensure that themotor will be able to move parallel to thegear when the adjustment is done

6

Connect to connector R3.MP4:• + : pin 7• - : pin 8

In order to release the brakes, connect the24 VDC power supply to the motor.

7

Start with a play in all positions and thenlocate the smallest play by turning the motorshaft six turns and thereby finding the areawith the smallest play within this range.

8

Use swift movements to avoid noticing themagnetic field, which makes the gears sticktogether.

Push or tap the motor in radial direction sothat the play becomes minimal within onemotor turn, without the gear “chewing”. Donot use force!

9

4.1 NmTighten the motor attachment screws andsecure them with locking fluid.

10Loctite 243

Detailed in section Performing a leak-down test on page 114.


Art. no. and amount is specified in Re-quired equipment on page 181.

Refill the axis 4 gearbox with lubricating oil.12

Detailed in section Refitting, cable har-ness, axes 4-6 on page 131.

Reconnect the cabling.13

Calibration is detailed in a separate calib-ration manual enclosed with the calibra-tion tools.


General calibration information is in-cluded in the section Calibration inform-ation on page 201.




Continued


DANGER

Make sure all safety requirements are metwhen performing the first test run. These arefurther detailed in the section DANGER -First test run may cause injury or damage!on page 46.

15


NoteAction

DANGER


1

Check that the assembly surfaces are clean andthe motor unscratched.

2

Spare part no. is specified in Re-quired equipment on page 181.


Look at the figure in the procedureRefitting, motor axis 4 on page 183.



The motor’s fixing screws shall be fastened, butdo not tighten them, to ensure that the motor willbe able to move parallel to the gear when theadjustment is done.

5

Connector to connector R3.MP5:• + : pin 7• - : pin 8


6

Locate the smallest play by turning the outgoingshaft for axis 4 in intervals of 90°, one full turn,and thereby finding the area where the play formotor 5 becomes smallest. Turn the motor foraxis 5 one full turn at a time for a total of fiveturns. Find where the smallest play is within thisarea.

7

Use swift movements to avoid noticing the mag-netic field, which makes the gears stick together.

Push or tap the motor in radial direction so thatthe play becomes minimal within one motor turn,without the gear “chewing”. Do not use force!

8

Tightening torque: 4.1 Nm.Tighten the motor attachment screws and securethem with locking fluid.

9Loctite 243

Described inRefitting, cable harness,axes 4-6 on page 131.





Continued

NoteAction




DANGER


12


NoteAction

DANGER


1

Check that the assembly surfaces are clean andthe motor unscratched

2


Fit an new o-ring on the motor.3

Look at the figure in the procedureRefitting, motor axis 4 on page 183.



The motor’s fixing screws shall be fastened, butdo not tighten them, to esure that the motor willbe able to move parallel to the gear when theadjustment is done

5



6

Find the smallest play by turning the outgoingshaft for axis 4 in intervals of 90°, totally onewhole turn, and thereby finding the area wherethe play for motor 6 becomes smallest.

7

Turn the motor for axis 5 one full turn at the time,totally five turns. Find the smallest play for axis6 within this area.Turn the motor for axis 6 one full turn at a timefor a time for a total of three turns. Find thesmallest play for axis 6 within this area.Use swift movements to avoid noticing themagnetic field, which makes the gears stick to-gether




Continued

NoteAction

Push or tap the motor in radial direction so thatthe play becomes minimal within one motor turn,without the gear “chewing”. Do not use force!

8


9Loctite 243

Described inRefitting, cable harness,axes 4-6 on page 131.





DANGER


12



Continued

4.7.5 Replacement of motors, axes 4-6, IRB 2400/10/16

Location of motors axis 4-6The motors axis 4-6 are located on the back of the upper arm as shown in the figurebelow:A more detailed view of the component and its position may be found in chapterSpare parts on page 227.

xx0300000108

Torx screwA

CoverB

Connection boxC

ScrewD

Motor axis 6E

Motor axis 5F

Motor axis 4G

GearboxH





IRB 2400/10 (Elmo)3HAC10600-1Motor unit axis 5

IRB 2400/16 (Elmo)3HAC10601-1Motor unit axis 5

IRB 2400/10/16 (Yaskawa)3HAC021722-001Motor unit axis 5



One piece for each motor.3HAB3772-12O-ring



4 Repair4.7.5 Replacement of motors, axes 4-6, IRB 2400/10/16


Loctite 2433HAB 7116-1Locking liquid

3HAB 3537-1Bearing grease

1,500 ml3HAC 0860-1Lubricating oilOptimol BM 100For the gearbox of axis 4.



-Power supply


Standard toolkit


Other tools and proced-ures may be required. Seereferences to these pro-cedures in the step-by-step instructions below.

Removal, motors axes 4-6 (10/16 kg)The procedure below details how to remove the motors of axes 4-6.


DANGER


1

Drain the oil from the axis 4 gearbox.2

Shown in the figure Location of motorsaxis 4-6 on page 188.





Continued


xx0200000406

Disconnect the connectors R3.MP4-6 andR3.FB4-6.

4

A R3.MP5B R3.MP6C R3.MP4D R3.FB5E R3.FB6F R3.FB4

Remove the connection box by unscrewingits three attachment screws and plainwashers.

5

Use a marker pen to mark out the positionof the motors, if same motors are to be re-fitted.

6

Remove the attachment screws and plainwashers from the motors.

7

Remove the motors by gently lifting themstraight out (horizontal movement).

8



DANGER


1

Check that the assembly surfaces are cleanand the motor unscratched.

2



Art. no. is specified inRequired equipmenton page 188.

Lubricate the gear with bearing grease.4




Continued


xx0300000005

Fit the measuring tool at the rear of themotor.

5

Art. no. is specified inRequired equipmenton page 188.

The motor’s fixing screws shall be fastened,but do not tighten them, to be sure that themotor will be able to move parallel to thegear when the adjustment is done

6


In order to release the brakes, connect the24 VDC power supply to the motor.

7

Start with a play in all positions and thenfind the smallest play by turning the motorshaft six turns and thereby finding the areawith the smallest play within this range.

8

Use swift movements to avoid noticing themagnetic field, which makes the gears sticktogether.

Push or tap the motor in radial direction sothat the play becomes minimal within onemotor turn, without the gear “chewing”. Donot use force!

9

Tightening torque: 4.1 Nm.Tighten the motor attachment screws andsecure them with locking fluid.

10Loctite 243

Art. no. and amount is specified in Re-quired equipment on page 188.

Refill the gearbox with oil.11

Described inRefitting, cable harness, axes4-6 on page 131.


Calibration is detailed in a separate calib-ration manual enclosed with the calibrationtools.

Recalibrate the robot.(When all service work is done, i.e. theother motors are also refitted.)

13

General calibration information is includedin the section Calibration information onpage 201.




Continued


DANGER

Make sure all safety requirements are metwhen performing the first test run. Theseare further detailed in the sectionDANGER- First test runmay cause injury or damage!on page 46.

14


NoteAction

DANGER


1

Check that the assembly surfaces are clean and themotor unscratched.

2

Spare part no. is specified inRequiredequipment onpage188.


See how to fit the tool in the fig-ure in the procedure Refitting,motor axis 4 on page 190.



The motor’s fixing screws shall be fastened, but donot tighten them, to be sure that the motor will beable to move parallel to the gear when the adjust-ment is done

5


In order to release the brakes, connect the 24 VDCpower supply to the motor.

6

Find the smallest play by turning the outgoing shaftfor axis 4 in intervals of 90°, one full turn, andthereby finding the area where the play for motor 5becomes smallest.

7

Turn the motor for axis 5 one full turn at a time for atotal of five turns. Find where the smallest play iswithin this area.Use swift movements to avoid noticing the magneticfield, which makes the gears stick together.

Push or tap the motor in radial direction so that theplay becomes minimal within one motor turn, withoutthe gear “chewing”. Do not use force!

8


9Loctite 243

Detailed in section Refitting,cable harness, axes 4-6 onpage 131.





Continued

NoteAction


Recalibrate the robot.(When all service work is done, i.e. the other motorsare also refitted.)

11

General calibration informationis included in the section Calib-ration information on page 201.

DANGER


12


NoteAction

DANGER


1

Check that the assembly surfaces are clean andthe motor unstructured.

2



See how to fit the tool in the figurein the procedure Refitting, motoraxis 4 on page 190.



The motor’s fixing screws shall be fastened, but donot tighten them, to be sure that the motor will beable to move parallel to the gear when the adjust-ment is done

5


In order to release the brakes, connect the 24 VDCpower supply to the motor.

6

Find the smallest play by turning the outgoing shaftfor axis 4 in intervals of 90°, one full turn, andthereby finding the area where the play for motor6 becomes smallest.

7

Turn the motor for axis 5 one full turn at the time,totally five turns. Find the smallest play for axis 6within this area.Turn the motor for axis 6 one full turn at a for a totalof three turns. Find the smallest play for axis 6within this area.Use swift movements to avoid noticing the magneticfield, which makes the gears stick together




Continued

NoteAction

Push or tap the motor in radial direction so that theplay becomes minimal within one motor turn,without the gear “chewing”. Do not use force!

8


9Loctite 243

Detailed in sectionRefitting, cableharness, axes 4-6 on page 131.



Recalibrate the robot.(When all service work is done, i.e. the other motorsare also refitted.)

11

General calibration information isincluded in the sectionCalibrationinformation on page 201.

DANGER


12



Continued

4.8 Gearboxes

4.8.1 Replacement of gearbox, axis 1-3

Location of gearbox, axis 1-3The axis 1 gearbox is located between the frame and base as shown in the figurebelow.Axis 1 gearbox is of the conventional type, manufactured with high precision.Together with the gearboxes for axes 2 and 3, it forms a complete unit.A more detailed view of the component and its position may be found in chapterSpare parts on page 227.Note! The gearbox is not normally serviced or adjusted.

xx0300000007

Attachment screws, gearbox unitA

Bottom plateB

Required equipment


3HAC025711-001Gearbox, axes 1-3


-Standard toolkit







4 Repair4.8.1 Replacement of gearbox, axis 1-3

Removal, gearbox axis 1-3The procedure below details how to remove the gearbox, axis 1-3.

NoteAction

DANGER


1

Detailed in sectionRemoval, cableunit, axes 1-3 on page 122.

Remove the cable unit, axes 1-3.2

Detailed in sectionRemoval, lowerarm on page 147.

Remove the complete lower arm.3

Detailed in sectionRemoval, motoraxis 1 on page 167.

Remove the motor, axis 1.4





CAUTION

The complete gearbox unit weighs 200 kg withoutthe base.All lifting accessories used must be sized accord-ingly!

7

Place the remaining parts of the robot upside-downon a table or similar surface and remove the bot-tom plate.

8

Undo the 12 attachment screws.9

Lift away the base from the gearbox unit.10

Refitting, gearbox axis 1-3The procedure below details how to refit the gearbox, axis 1-3.

NoteAction

DANGER


1

CAUTION

The complete gearbox unit weighs 200 kg withoutthe base.All lifting accessories used must be sized accord-ingly!

2

Place the gearbox unit upside-down on a tableor similar surface.

3

12 pcs; M12x50. Tightening torque:54 Nm.

Fit the base to the gearbox unit and secure withthe 12 screws and washers.

4




Continued

NoteAction

Refit the bottom plate to the base.5

Further detailed in sectionOrientingand securing the robot on page 67.

Turn the base and gearbox unit around and se-cure to the installation site.

6

Detailed in section Refitting, motoraxis 1 on page 168.

Refit the motor, axis 1.7





Detailed in section Refitting, lowerarm on page 149.

Refit the complete lower arm.10

Detailed in sectionRefitting, gearboxaxis 1-3 on page 196.

Refit the cable unit, axes 1-3.11


Calibrate the robot.12


DANGER


13



Continued

4.8.2 Replacement of drive shaft unit, IRB 2400L

Location, drive shaft unitThe drive shaft unit is defined as the gears and drive belts to axes 5 and 6. This isshown in the figure below.

xx0300000012

Required equipment


3HAC11804-1Drive shaft unit, axes 5-6

2 pcs3HAA2393-1Gear belt

3HAA7601-50Adjustment tool

-Lifting device, robot


Standard toolkit


Other tools and proced-ures may be required.See references to theseprocedures in the step-by-step instructions be-low.



4 Repair4.8.2 Replacement of drive shaft unit, IRB 2400L

Removal, drive shaft unitThe procedure below details how to remove the drive shaft unit from the robotupper arm.NOTE! ABB recommends its customers to carry out only the following servicingand repair work on the drive shaft unit.


DANGER


1

Detailed in section Removal, wrist uniton page 140.

Remove the wrist.2

Detailed in section Replacement of mo-tors, axes 4-6, IRB 2400L on page 181.

Loosen the connection box and disconnectthe connectors on the motors of axes 5 and6. Mark the motor number on the motors, tosimplify the reconnecting.

3

xx0300000021

Undo the screws.4

• A: Screws• B: Motor screws

Squeeze the drive shafts together at the tipof the tubular shaft, so they can passthrough the tube.

5

Pull out the complete drive mechanism ofaxes 5 and 6.

6

Detailed in section Replacement of mo-tors, axes 4-6, IRB 2400L on page 181.

Undo the screws and nuts, holding the mo-tors and remove both motors.

7

Undo the screws and remove the motorplate.

8

Remove the gear belts.9




Continued

Refitting, drive shaft unitThe procedure below details how to remove the drive shaft unit from the robotupper arm.NOTE! ABB recommends its customers to carry out only the following servicingand repair work on the drive shaft unit.


DANGER

Turn off all electric power, hydraulic andpneumatic pressure supplies to the ro-bot!

1

Install the belts.2

Note! Do not forget the nuts on the motors!Fit the plate using screws and washers.3

Fit the motors.4

Art. no. is specified in Required equipmenton page 198.

Push the motors sideways to tightenthe belts, using the tool. Place theround post of the adjustment tool intothe motor pulley and let the cam pressto the outer diameter of the large pulley.

5

Tighten screws B (shown in the illustrationbelow) to 4.1 Nm.

Rotate the drive shafts. Check the ten-sion on the belt.

6

Do not forget the rubber damper.Install the drive mechanism in the tubu-lar shaft.

7

xx0300000021

Tighten screws.8

• A: 8.3 Nm

Detailed in Replacement of motors, axes 4-6,IRB 2400L on page 181.

Install the cabling and fit the cover tothe motors axes 5 and 6.

9

Detailed in section Refitting, wrist unit onpage 141.

Refit the wrist.10

Calibration is detailed in a separate calibrationmanual enclosed with the calibration tools.

Calibrate the robot.11

General calibration information is included inthe section Calibration information onpage 201.

DANGER

Make sure all safety requirements aremet when performing the first test run.These are further detailed in the sectionDANGER - First test run may cause in-jury or damage! on page 46.

12



Continued

5 Calibration information5.1 Introduction

GeneralThis chapter includes general information about the different calibration methodsand also the detailed procedures that do not require specific calibration equipment.When the robot system must be recalibrated, it is done according to thedocumentation enclosed with the calibration tools.

When to calibrateThe system must be calibrated if any of the following situations occur.

The resolver values are changedIf resolver values are changed, the robot must be recalibrated using the calibrationmethods supplied by ABB. Calibrate the robot carefully with standard calibration.The different methods are briefly described in the section Calibration methods onpage 202 , and further detailed in separate calibration manuals.If the robot has absolute accuracy calibration, it is also recommended, but notalways necessary to calibrate for new absolute accuracy.The resolver values will change when parts affecting the calibration position arereplaced on the robot, for example motors or parts of the transmission.

The revolution counter memory is lostIf the revolution counter memory is lost, the counters must be updated. SeeUpdating revolution counters on page 206. This will occur when:

• The battery is discharged• A resolver error occurs• The signal between a resolver and measurement board is interrupted• A robot axis is moved with the control system disconnected

The revolution counters must also be updated after the robot and controller areconnected at the first installation.

The robot is rebuiltIf the robot is rebuilt, for example, after a crash or when the reach ability of a robotis changed, it needs to be recalibrated for new resolver values.If the robot has absolute accuracy calibration, it needs to be calibrated for newabsolute accuracy.


5 Calibration information5.1 Introduction

5.2 Calibration methods

OverviewThis section specifies the different types of calibration and the calibration methodsthat are supplied by ABB.

Types of calibration

Calibration methodDescriptionType ofcalibration

Calibration Pendulum(standard method)

The calibrated robot is positioned at homeposition, that is when the positions of the axes(angles) are set to 0º.

Standard calibration

orStandard calibration data is found on the SMB(serial measurement board) in the robot.

Levelmeter calibration(alternative method)

For robots with RobotWare 5.04 or older, thecalibration data is delivered in a file, calib.cfg,supplied with the robot at delivery. The fileidentifies the correct resolver/motor positioncorresponding to the robot home position.

CalibWareBased on standard calibration, and besidespositioning the robot at home position, theAbsolute accuracy calibration also com-pensates for:

• Mechanical tolerances in the robotstructure

• Deflection due to loadAbsolute accuracy calibration focuses on pos-itioning accuracy in the Cartesian coordinatesystem for the robot.

Absolute accuracycalibration (option-al)

Absolute accuracy calibration data is foundon the SMB (serial measurement board) in therobot.For robots with RobotWare 5.05 or older, theabsolute accuracy calibration data is deliveredin a file, absacc.cfg, supplied with the robot atdelivery. The file replaces the calib.cfg file andidentifies motor positions as well as absoluteaccuracy compensation parameters.A robot calibrated with absolute accuracy hasa sticker next to the identification plate of therobot.To regain 100% absolute accuracy perform-ance, the robot must be recalibrated for abso-lute accuracy!

xx0400001197



5 Calibration information5.2 Calibration methods

Calibration methodsEach calibration method is detailed in a separate manual. Following is a briefdescription of the methods available.

Calibration Pendulum - standard methodCalibration Pendulum is the standard method for calibration of all ABB robots(except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S) and is also the mostaccurate method for the standard type of calibration. It is the recommended methodin order to achieve proper performance.Two different routines are available for the Calibration Pendulum method:

• Calibration Pendulum II• Reference calibration

The calibration equipment for Calibration Pendulum is delivered as a completetoolkit, including the Operating manual - Calibration Pendulum, which describesthe method and the different routines further.

Levelmeter calibration - alternative methodLevelmeter calibration is referred to as the alternative method for calibration ofABB robots because of the less accurate values obtained during calibration. Themethod uses the same principles as Calibration Pendulum, but does not have asgood of mechanical tolerances to the toolkit parts as the standard method withCalibration Pendulum.This method may, after calibration, require modifications in the robot program andis therefore not recommended.The calibration equipment (Levelmeter 2000) for levelmeter calibration is orderedas separate parts for each robot, and includes the Operating manual - LevelmeterCalibration, which describes the method and the different routines further.

CalibWare - Absolute Accuracy calibrationTo achieve a good positioning in the Cartesian coordinate system, AbsoluteAccuracy calibration is used as a TCP calibration. The CalibWare tool guidesthrough the calibration process and calculates new compensation parameters.This is further detailed in the Application manual - CalibWare Field 5.0.If a service operation is done to a robot with the option Absolute Accuracy, a newabsolute accuracy calibration is required in order to establish full performance.For most cases after motor and transmission replacements that do not includetaking apart the robot structure, standard calibration is sufficient. Standardcalibration also supports wrist exchange.

ReferencesArticle numbers for the calibration tools are listed in the section Special tools onpage 224.The calibration equipment for Calibration Pendulum is delivered as a completetoolkit, including the Operating manual - Calibration Pendulum, which describesthe method and the different routines further.


5 Calibration information5.2 Calibration methods

Continued

5.3 Calibration scale and correct axis position

IntroductionThis section specifies the calibration scale positions and/or correct axis positionfor all robot models.

Calibration scales, IRB 2400The illustration below shows the calibration marks on all axes of the robot.

en0200000273


5 Calibration information5.3 Calibration scale and correct axis position

5.4 Calibration movement directions for all axes

OverviewWhen calibrating, the axis must consistently be run towards the calibration positionin the same direction in order to avoid position errors caused by backlash in gearsand so on. Positive directions are shown in the graphic below.This is normally handled by the robot calibration software.

Calibration movement directions, 6 axesNote! The graphic shows an IRB 7600. The positive direction is the same for all6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in theopposite direction!

xx0200000089


5 Calibration information5.4 Calibration movement directions for all axes

5.5 Updating revolution counters

IntroductionThis section describes how to do a rough calibration of each manipulator axis,which is updating the revolution counter value for each axis using the FlexPendant.

Step 1 - Manually running the manipulator to the calibration positionUse this procedure to manually run the manipulator to the calibration position.

NoteAction

Select axis-by-axis motion mode.1

See Calibration scale and correct axis po-sition on page 204.

Jog the manipulator to place the calibrationmarks within the tolerance zones.IRB 140, 1400, 2400, 4400, 6600ID/6650ID,6640ID: Axes 5 and 6 must be positionedtogether!

2

Step 2 - Storing the revolution countersettingwith theTPUonpage207 (BaseWare4.0).

When all axes are positioned, store the re-volution counter settings.

3

Step 2 - Storing the revolution countersetting with the FlexPendant on page 208.

Correct calibration position of axis 4 and 6When running the manipulator to calibration position, it is extremely important tomake sure that axes 4 and 6 of the following mentioned manipulators are positionedcorrectly. The axes can be calibrated at the wrong turn, resulting in an incorrectlycalibrated manipulator.Make sure the axes are positioned according to the correct calibration values, notonly according to the calibration marks. The correct values are found on a label,located either on the lower arm, underneath the flange plate on the base or on theframe.At delivery the manipulator is in the correct position, do NOT rotate axis 4 or 6 atpower up before the revolution counters are updated.If one of the following mentioned axes are rotated one or more turns from itscalibration position before updating the revolution counter, the correct calibrationposition will be lost due to uneven gear ratio. This affects the following manipulators:

Axis 6Axis 4Manipulator variant

NoNoIRB 2400

If the calibration marks seem to be wrong (even if the motor calibration data iscorrect), try to rotate the axis one turn, update the revolution counter and checkthe calibration marks again (try both directions, if needed).



5 Calibration information5.5 Updating revolution counters

Step 2 - Storing the revolution counter setting with the TPUUse this procedure to store the revolution counter setting with the TPU (BaseWare4.0).

NoteAction

Press the button Miscellaneous then ENTER to select the servicewindow.

xx0100000194

1

Select Calibration from the View menu.The Calibration window appears.If there is more than one unit connected to the manipulator, they willbe listed in the window.

xx0100000201

2

Select the desired unit and chooseRev Counter Update from theCalibmenu.The Revolution Counter Update window appears.

xx0100000202

3

Select the desired axis and press Incl to include it (it will be markedwith an x) or press All to select all axes.

4

Press OK when all axes that are to be updated are marked with an x.CANCEL returns to the Calibration window.

5

Press OK again to confirm and start the update.CANCEL returns to the Revolution Counter Update window.

6




Continued

NoteAction

Not required.At this point, it is recommended that the revolution counter values aresaved to a diskette.

7

CAUTION

If a revolution counter is incorrectly updated, it will cause incorrectmanipulator positioning, which in turn may cause damage or injury!Check the calibration position very carefully after each update.

8

How to perform the check is detailed in sectionChecking the calibrationposition on page 210.

Step 2 - Storing the revolution counter setting with the FlexPendantUse this procedure to store the revolution counter setting with the FlexPendant(IRC5).

Action

On the ABB menu, tap Calibration.1All mechanical units connected to the system are shown with their calibration status.

Tap the mechanical unit in question.2A screen is displayed, tap Rev. Counters.

en0400000771

Tap Update Revolution Counters....A dialog box is displayed warning that updating the revolution counters may changeprogrammed manipulator positions:

• Tap Yes to update the revolution counters.• Tap No to cancel updating the revolution counters.

Tapping Yes displays the axis selection window.

3




Continued

Action

Select the axis to have its revolution counter updated by:• Ticking in the box to the left• Tapping Select all to update all axes.

Then tap Update.

4

A dialog box is displayed warning that the updating operation cannot be undone:• Tap Update to proceed with updating the revolution counters.• Tap Cancel to cancel updating the revolution counters.

Tapping Update updates the ticked revolution counters and removes the tick from thelist of axes.

5

CAUTION

If a revolution counter is incorrectly updated, it will cause incorrect manipulator posi-tioning, which in turn may cause damage or injury!Check the calibration position very carefully after each update. See Checking thecalibration position on page 210.

6



Continued

5.6 Checking the calibration position

IntroductionCheck the calibration position before beginning any programming of the robotsystem. This may be done:

• Using a MoveAbsJ instruction with argument zero on all axes.• Using the Jogging window on the FlexPendant.

Using a MoveAbsJ instruction on the TPU, S4CplusUse this procedure to create a program that runs all the robot axes to their zeroposition

NoteAction

Create the following program:MoveAbsJ [[0,0,0,0,0,0], [9E9,

9E9,9E9,9E9,9E9,9E9]]\NoEOffs, v1000, z50, Tool0

1

Run the program in manual mode.2

See Calibration scale and correctaxis positiononpage204, andUpdat-ing revolution counters on page206.

Check that the calibration marks for the axes aligncorrectly. If they do not, update the revolutioncounters.

3

Using a MoveAbsJ instructionUse this procedure to create a program that runs all the robot axes to their zeroposition.

NoteAction

On ABB menu tap Program editor.1

Create a new program.2

Use MoveAbsJ in the Motion&Proc menu.3

Create the following program:MoveAbsJ [[0,0,0,0,0,0],

[9E9,9E9,9E9,9E9,9E9,9E9]]\NoEOffs, v1000, z50, Tool0

4

Run the program in manual mode.5

See Calibration scale and correctaxis position on page204, andUpdat-ing revolution counters on page206.

Check that the calibration marks for the axes aligncorrectly. If they do not, update the revolutioncounters.

6

Using the jogging window on the TPU, S4CplusUse this procedure to jog the robot to zero position of all axes.

Illustration/NoteAction

xx0100000195

Open the Jogging window.1



5 Calibration information5.6 Checking the calibration position

Illustration/NoteAction

xx0100000196

Select running axes-by-axes.2

Manually run the robot axes to a positionwhere the axis position value read on theTPU, is equal to zero.

3

See Calibration scale and correct axispositiononpage204, andUpdating revolu-tion counters on page 206.

Check that the calibration marks for the axesalign correctly. If they do not, update the re-volution counters.

4

Using the jogging windowUse this procedure to jog the robot to the zero position of all axes.

NoteAction

On the ABB menu, tap Jogging.1

Tap Motion mode to select group of axesto jog.

2

Tap to select the axis to jog, axis 1, 2, or3.

3

Manually run the robots axes to a positionwhere the axis position value read on theFlexPendant, is equal to zero.

4

SeeCalibration scale and correct axis pos-ition on page 204, and Updating revolutioncounters on page 206.

Check that the calibration marks for theaxes align correctly. If they do not, updatethe revolution counters!

5


5 Calibration information5.6 Checking the calibration position

Continued

6 Decommissioning6.1 Environmental information

Hazardous materialThe table specifies some of the materials in the product and their respective usethroughout the product.Dispose components properly to prevent health or environmental hazards.

Example applicationMaterial

Serial measurement boardBatteries, NiCad or Lithium

Cables, motorsCopper

Base, lower arm, upper armCast iron/nodular iron

Gears, screws, base-frame, and so on.Steel

Brakes, motorsNeodymium

Cables, connectors, drive belts, and so on.Plastic/rubber

GearboxesOil, grease

Covers, synchronization bracketsAluminium

Oil and greaseWhere possible, arrange for oil and grease to be recycled. Dispose of via anauthorized person/contractor in accordance with local regulations. Do not disposeof oil and grease near lakes, ponds, ditches, down drains, or onto soil. Incinerationmust be carried out under controlled conditions in accordance with local regulations.Also note that:

• Spills can form a film on water surfaces causing damage to organisms.Oxygen transfer could also be impaired.

• Spillage can penetrate the soil causing ground water contamination.


6 Decommissioning6.1 Environmental information

7 Reference information7.1 Introduction

GeneralThis chapter includes general information, complementing the more specificinformation in the different procedures in the manual.


7 Reference information7.1 Introduction

7.2 Applicable safety standards

Standards, EN ISOThe manipulator system is designed in accordance with the requirements of:

DescriptionStandard

Safety of machinery - Basic concepts, general principles fordesign - Part 1: Basic terminology, methodology

EN ISO 12100 -1

Safety of machinery - Basic concepts, general principles fordesign - Part 2: Technical principles

EN ISO 12100 -2

Safety of machinery, safety related parts of control systems -Part 1: General principles for design

EN ISO 13849-1

Safety of machinery - Emergency stop - Principles for designEN ISO 13850

Robots for industrial environments - Safety requirements -Part1 Robot

EN ISO 10218-1 i

Manipulating industrial robots, coordinate systems, and motionnomenclatures

EN ISO 9787

Manipulating industrial robots, performance criteria, and relatedtest methods

EN ISO 9283

Classification of air cleanlinessEN ISO 14644-1 ii

Ergonomics of the thermal environment - Part 1EN ISO 13732-1

EMC, Generic emissionEN IEC 61000-6-4(option 129-1)

EMC, Generic immunityEN IEC 61000-6-2

Arc welding equipment - Part 1: Welding power sourcesEN IEC 60974-1 iii

Arc welding equipment - Part 10: EMC requirementsEN IEC 60974-10 iii

Safety of machinery - Electrical equipment of machines - Part1 General requirements

EN IEC 60204-1

Degrees of protection provided by enclosures (IP code)IEC 60529i There is a deviation from paragraph 6.2 in that only worst case stop distances and stop times are

documented.ii Only robots with protection Clean Room.iii Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.

European standards

DescriptionStandard

Safety of machinery - Ergonomic design principles - Part 1:Terminology and general principles

EN 614-1

Safety of machinery - Two-hand control devices - Functionalaspects - Principles for design

EN 574

Safety of machinery - General requirements for the design andconstruction of fixed and movable guards

EN 953

Other standards

DescriptionStandard

Safety requirements for industrial robots and robot systemsANSI/RIA R15.06



7 Reference information7.2 Applicable safety standards

DescriptionStandard

Safety standard for robots and robotic equipmentANSI/UL 1740(option 429-1)

Industrial robots and robot Systems - General safety require-ments

CAN/CSA Z 434-03(option 429-1)


7 Reference information7.2 Applicable safety standards

Continued

7.3 Unit conversion

Converter tableUse the following table to convert units used in this manual.

UnitsQuantity

39.37 in3.28 ft.1 mLength

2.21 lb.1 kgWeight

0.035 ounces1 gWeight

14.5 psi100 kPa1 barPressure

0.225 lbf1 NForce

0.738 lbf-ft1 NmMoment

0.264 US gal1 LVolume


7 Reference information7.3 Unit conversion

7.4 Screw joints

GeneralThis section describes how to tighten the various types of screw joints on the IRB2400.The instructions and torque values are valid for screw joints comprised of metallicmaterials and do not apply to soft or brittle materials.

UNBRAKO screwsUNBRAKO is a special type of screw recommended by ABB for certain screw joints.It features special surface treatment (Gleitmo as described below) and is extremelyresistant to fatigue.Whenever used, this is specified in the instructions, and in such cases, no othertype of replacement screw is allowed. Using other types of screws will void anywarranty and may potentially cause serious damage or injury.

Gleitmo treated screwsGleitmo is a special surface treatment to reduce the friction when tightening thescrew joint. Screws treated with Gleitmo may be reused 3-4 times before the coatingdisappears. After this the screw must be discarded and replaced with a new one.When handling screws treated with Gleitmo, protective gloves of nitrile rubbertype should be used.

Screws lubricated in other waysScrews lubricated with Molycote 1000 should only be used when specified in therepair, maintenance or installation procedure descriptions.In such cases, proceed as follows:

1 Apply lubricant to the screw thread.2 Apply lubricant between the plain washer and screw head.3 Screw dimensions of M8 or larger must be tightened with a torque wrench.

Screw dimensions of M6 or smaller may be tightened without a torque wrenchif this is done by trained and qualified personnel.

Art. no.Lubricant

11712016-618Molycote 1000 (molybdenum disulphide grease)

Tightening torqueBefore tightening any screw, note the following:

• Determine whether a standard tightening torque or special torque is to beapplied. The standard torques are specified in the following tables. Anyspecial torques are specified in the repair, maintenance or installationprocedure descriptions.Any special torque specified overrides the standardtorque!

• Use the correct tightening torque for each type of screw joint.• Only use correctly calibrated torque keys.



7 Reference information7.4 Screw joints

• 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%!

Oil-lubricated screws with slotted or cross-recess head screwsThe following table specifies the recommended standard tightening torque foroil-lubricated screws with slotted or cross-recess head screws.

Tightening torque (Nm)Class 4.8, oil-lubricated

Dimension

0.25M2.5

0.5M3

1.2M4

2.5M5

5.0M6

Oil-lubricated screws with allen head screwsThe following table specifies the recommended standard tightening torque foroil-lubricated screws with allen head screws.

Tightening torque (Nm)Class 12.9, oil-lubric-ated

Tightening torque (Nm)Class 10.9, oil-lubric-ated

Tightening torque (Nm)Class 8.8, oil-lubricated

Dimension

--6M5

--10M6

403424M8

806747M10

14011582M12

340290200M16

670560400M20

1150960680M24

Lubricated screws (Molycote, Gleitmo or equivalent) with allen head screwsThe following table specifies the recommended standard tightening torque forscrews lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen headscrews.

Tightening torque (Nm)Class 12.9, lubricated i


Dimension

3528M8

7055M10

12096M12

280235M16

550460M20




Continued



Dimension

950790M24i Lubricated with Molycote 1000, Gleitmo 603 or equivalent

Water and air connectorsThe following table specifies the recommended standard tightening torque forwater and air connectors when one or both connectors are made of brass.

Tightening torque Nm -Max.

Tightening torque Nm -Min.

Tightening torque Nm -Nominal

Dimension

158121/8

2010151/4

2515203/8

5030401/2

9055703/4



Continued

7.5 Weight specifications

DefinitionIn installation, repair, and maintenance procedures, weights of the componentshandled are sometimes specified. All components exceeding 22 kg (50 lbs) arehighlighted in this way.To avoid injury, ABB recommends the use of a lifting accessory when handlingcomponents with a weight exceeding 22 kg. A wide range of lifting accessoriesand devices are available for each manipulator model.

ExampleFollowing is an example of a weight specification in a procedure:

NoteAction

CAUTION

The robot weighs 380 kg.All lifting accessories used must be sized accord-ingly!


7 Reference information7.5 Weight specifications

7.6 Standard tools

GeneralAll service (repairs, maintenance, and installation) procedures contains lists oftools required to perform the specified activity.All special tools required are listed directly in the procedures while all the toolsthat are considered standard are gathered in the standard toolkit and defined inthe following table.This way, the tools required are the sum of the standard toolkit and any tools listedin the instruction.

Contents, standard toolkit

ToolQty

Ring-open-end spanner 8-19 mm1

Socket head cap 2.5-17 mm1

Torx socket no: 20-601

Torque wrench 10-100 Nm1

Small screwdriver1

Plastic mallet1

Ratchet head for torque wrench 1/2"1

KM socket (KM10) (6369901-480)1

Socket head cap no: 5, socket 1/2" bit L 20 mm1



Small cutting plier1

T-handle with ball head1


7 Reference information7.6 Standard tools

7.7 Special tools

GeneralAll service instructions contain lists of tools required to perform the specifiedactivity. The required tools are a sum of standard tools, defined in the sectionStandard tools on page 223, and of special tools, listed directly in the instructionsand also gathered in this section.

Special toolsThe table below specifies the special tools required during the service procedures.The tools are also specified directly in the concerned procedures for repair.

NoteArt. no.Description

M8, length = 70 mm-Guide pinsUsed for guiding the wrist into place.

Used for measuring the gear play whenrefitting the motors.


Used for removing the shafts from the up-per arm.

3HAB9009-1Dismounting tool, shaft ends

3HAB6464-1Mounting tool, bearing

3HAA7601-50Adjustment tool

Calibration equipment, Levelmeter (alternative method)The table below specifies the calibration equipment required when calibrating therobot with the alternative method, Levelmeter Calibration.


68080011-LPAngle bracket

3HAC13908-9Calibration bracket

3HAC13908-4Calibration tool ax1

Includes one sensor.6369901-347Levelmeter 2000 kit

3HAC13908-5Measuring pin

68080011-GMSensor fixture

3HAC0392-1Sensor plate

3HAC13908-1Sync. adapter

3HAC68080011-GUTurn disk fixture

Calibration equipment, Calibration PendulumThe table below specifies the calibration equipment needed when calibrating therobot with the Calibration Pendulum method.


Complete kit that also includes operatingmanual.



7 Reference information7.7 Special tools

7.8 Lifting equipment and lifting instructions

GeneralMany repair and maintenance activities require different pieces of lifting equipment,which are specified in each procedure.The use of each piece of lifting equipment is not detailed in the activity procedure,but in the instruction delivered with each piece of lifting equipment.This implies that the instructions delivered with the lifting equipment should bestored for later reference.


7 Reference information7.8 Lifting equipment and lifting instructions

8 Spare parts8.1 Introduction

DefinitionsThis chapter specifies all spare parts and replacement articles of the robot.


8 Spare parts8.1 Introduction

8.2 Spare parts - base

Base, spare part listThe spare parts for the base are listed below and shown in the figure Base, sparepart view on page 229.

Note / DimensionSpare part no.DescriptionQtyItem

3HAC5945-1Base11

3HAC4795-1Gearbox axes 1-312

M12x50 8.8 Gleitmo 6103HAB3402-69Hex socket head cap screw123

13x24x2.59ADA312-9Plain washer124

IRB 2400 /L, /10, /16(Elmo)

3HAC4789-1Motor axis 1(Recommended spare part.Replacement is detailed insection Replacement ofmotor, axis 1 on page 166.)

15

IRB 2400 /Wall mounted(Elmo)

3HAC14271-1

IRB 2400 /L, /10, /16(Yaskawa)

3HAC021346-001

IRB 2400 /Wall mounted(Yaskawa)

3HAC021961-001

(Elmo)3HAC4789-1Motor axis 315(Recommended spare part.Replacement is detailed insection Replacement ofmotor, axis 3 on page 176.


109.5x321522012-434O-ring36

8.4x18x221542033-9Spring washer127





8 Spare parts8.2 Spare parts - base

Base, spare part view

xx0500001610


8 Spare parts8.2 Spare parts - base

Continued

8.3 Spare parts - lower arm

Lower arm, spare part list - Spare part view 1The lower arm spare parts listed below are shown in Spare part view 1 on page231.

Dimension/NoteSpare part no.DescriptionTotal Qty*Item

2400/10, /163HAC 4796-1Lower arm110

2400L3HAC 4797-1Lower arm1

3HAB 5512-1Damper axis 3115

M6x16 8c21212477-368Torx pan head tapp. screw416

3HAB 9394-1Parallel arm118

M8x129ADA 183-34Hex socket head cap screw226

3HAC 10088-4Bearing sealing132

SS 1914-043HAB 5523-1Locking washer133

M8x16 8.82121 2852-449Hex socket counters, head134

3HAC 10089-2Bearing sealing135

11712016-604Lubricating oil14,700 ml41

Loctite 2433HAB 7116-1Locking liquid1 ml43

3HAB 6687-1Stop, axis 1146

6.4x22x1.53HAA2356-13Washer SRKB648

3HAB 5522-1Sync. mark, axis 2150

Upper arm, axes 4-6151

M35x1.52126 2851-107Lock nut254

SS 1672-083HAB 5527-1Shaft end255

M12x60 12.9 Gle603+Geo500

3HAB3409-71Hex socket head cap screw256

VK 62x83HAA 2166-15VK-cover257

3HAB 8385-1Sync. mark, axis 3160

3HAA 1001-134Washer262

9ADA 629-43Torx pan head roll screw963

M6x16 8c21212477-368Torx pan head tappingscrew

15134

*Some of the articles and spare parts are used at different locations on the robotand therefor also listed in several tables, with identical information. The quantitygiven in the table is therefor the total quantity of the article, used for the completerobot! For more specified information about exact quantity, see the chapter Repairand the replacement procedure for the part involved!



8 Spare parts8.3 Spare parts - lower arm

Spare part view 1

xx1100000936


Dimension / NoteSpare part no.DescriptionTotal Qty*Item

2400/10, /163HAC 4796-1Lower arm110

2400L3HAC 4797-1Lower arm1

10.5x23x2.52154 2033-10Spring washer811

M10x40 12.93HAB3409-50Hex socket head cap screw1212

66x116x33HAC2205-1Spring tension plate113

3HAC2180-1Damper, standard axis 2114

M10x60 12.93HAB3409-57Hex socket head cap screw817

V-110-L 99x10.53HAB3732-13Sealing ring219




Continued


61822-2RS13HAB3643-12Groove ball bearing120

Acetal3HAB5515-1Sealing ring221

(Elmo)3HAC4790-1Motor, axis 2136(Recommended spare part.Replacement is detailed insection Replacement of mo-tor, axis 2 on page 171.)


Also shown inSpare part view 1on page 231

11712016-604Lubricating oil14,700 ml41

Also shown inSpare part view 2on page 233

3HAB3537-1Bearing grease1 g42

3HAC0447-1Friction washer149





Continued

Spare part view 2

xx1100000937




Continued


DimensionSpare part no.DescriptionTotal Qty*Item

Also shown in Spare partview 2 on page 233

3HAB3537-1Bearing grease1 g42



1100

Recommended spare part.Replacement is detailed insection Replacement ofcable unit, axes 1-3 onpage 121.

3HAC034712-001Cable unit axes 1-3,Cleanroom

1100

3HAC 2828-1Bottom plate1102

3HAC 4554-1Gasket1103

Standard3HAC 9368-1Cover1104

Foundry3HAC 9362-1

Wire feeder3HAC 7242-1

3HAC 3200-1Gasket1105

3HAC 4113-1Sealing1106

3HAB 5923-1Bracket1107

3HAB 3299-1Holder for cable guide2108

3HAB 5924-1Cable guide1109

3HAB 3662-1Spring1110

IRB 2400/10/163HAB 5928-1Cable guide upper arm1111

3HAC 4337-1Cover3112

M5x169ADA 629-45Torx pan head roll.screw

2116

M5 fzb Also in Spare partview 4 on page 238, Sparepart view 5 on page 241

9ADA 290-1Hexagon nut withflange

14118

L=208 mm2166 2055-3Cable straps, outdoor12119

3HAC7561-3Dust cap2132

3HAC 7561-4Dust cap1133

M8x12 8.89ADA 183-34Hex socket head panscrew

3135

M5x12. Also in Spare partview 4 on page 238, Sparepart view 5 on page 241

9ADA629-44Torx pan head rollscrew

63137

3HAB 3333-20Coupling1139

Loctite 5421269 0014-412Locking liquid140

D=11.4 - 132522 2101-8Protective hood2141





Continued


3HAB 7160-1Gasket1149

Loctite 57412340011-116Flange sealing150Also shown in Spare partview 4 on page 238

3HAC 3785-1Parallel pin1156



120 mm1866 1903-1Profile171





Continued

Spare part view 3

xx1100000938




Continued





1100

Recommended spare part.Replacement is detailed insection Replacement ofcable unit, axes 1-3 onpage 121.


1100


3HAC 4337-1Cover3112

M5 fzb9ADA 290-1Hexagon nut withflange

14118Also shown in Spare partview 3 on page 236 andSpare part view 5 onpage 241

L=208 mm21662055-3Cable straps, outdoor12119

Recommended spare part.3HAC0017-1Push button unit1121

21252052-198Distance bolt4122

3HAC2744-1Push button cover1123

Recommended spare part.3HAC7819-1Signal cable SMB1129

3HAC7561-3Dust cap2132

M4x12 Ext. conn.9ADA629-34Torx pan head rollscrew

8136

M5x12. Also in Spare partview 4 on page 238, Sparepart view 5 on page 241


63137

Also shown in Spare partview 3 on page 236, Sparepart view 5 on page 241



3147

Loctite 57412340011-116Flange sealing150Also shown in Spare partview 4 on page 238


3HAB7328-1Adaptor, customercabling

1157

3HAC6823-1Cover protection1157

3HAB2809-1Adaptor, powercabling

1158

Foundry3HAC7816-1Protection cover2159

Standard3HAB9040-1Gasket2169

3HAC0048-1Cover1170




Continued


Spare part view 4

xx1100000939




Continued



3HAC2589-1Instruction plate1114


3HAC17396-1Serial measurementunit

1115

Replacement is detailedin section Replacementof SMB unit on page 154.


3HAC046277-001Serial measurementunit

1115

Replacement is detailedin section Replacementof SMB unit on page 154.

DSQC 633A3HAC031851-001Serial measurementboard

1115

RMU 1013HAC044168-001Serial measurementboard

1155

Lithium battery3HAC16831-1Battery pack (2-polebattery contact)

111734x102x63Can only be used withSMB unit 3HAC17396-1containing SMB board3HAC031851-001.

Lithium battery 7.2V3.6Ah

3HAC044075-001Battery pack (3-polebattery contact)

1117

Can only be used withSMB unit 3HAC046277-001 containing SMBboard 3HAC044168-001.

Contains all parts neededif SMB unit 3HAC17396-1 shall be replaced withSMB unit 3HAC046277-001.

3HAC046686-001SMB replacement set1-

M5 fzb9ADA290-1Hexagon nut withflange

14118Also shown in Spare partview 3 on page 236 andSpare part view 4 onpage 238

21662055-7Cable straps, outdoor1125

M6x16 8.89ADA618-56Torx pan head screw15134

M5x12. Also in Spare partview 4 on page238,Sparepart view 5 on page 241


63137

Also shown in Spare partview 3 on page236,Sparepart view 5 on page 241

L=101 mm21662055-1Cable straps, outdoors6138




Continued


19x0.1811699198-301Adhesive tape151

3HAB5921-1Bracket1152

Suspended3HAC3189-1Protective hood1168

*Some of the articles and spare parts are used at different locations on the robotand therefore also listed in several tables, with identical information. The quantitygiven in the table is therefore the total quantity of the article, used for the completerobot! For more specified information about exact quantity, see the chapter Repairand the replacement procedure for the part involved!




Continued

Spare part view 5

xx1100000940



Continued

8.4 Spare parts - upper arm, IRB 2400/10/16

Upper arm, IRB 2400/10/16, spare part listThe spare parts for the upper arm, IRB 2400 version /10 and /16, are listed belowand shown in the Spare part view 6 on page244 and Spare part view 7 on page245.

Dimension/NoteSpare part no.DescriptionQtyItem

3HAC16672-1Upper arm withoutwrist and motors,Standard

11

3HAC034691-001Upper arm withoutwrist and motors,Cleanroom

11

67.5x50.5x0.73HAB3731-14Disk spring413

Recommended sparepart. Replacement is de-tailed in sectionReplace-ment of wrist IRB2400/10/16 on page135.

3HAB9398-1Wrist, Standard118

3HAC034720-001Wrist, Cleanroom118

Nitrile rubber 126x43HAB3772-12O-ring119

M8x30 8.8 Gleitmo 6103HAB3402-38Hex socket head capscrew

620

8.4x16x1.69ADA312-7Plain washer1521

IRB 2400/10 (Elmo)3HAC10600-1Motor unit axis 5125(Recommended sparepart. Replacement isdetailed in section Re-placement of motors,axes 4-6, IRB2400/10/16 onpage 188.)

IRB 2400/16 (Elmo)3HAC10601-1

IRB 2400/10/16(Yaskawa)

3HAC021722-001

(Elmo)3HAC10602-1Motor unit axis 4126Recommended sparepart. Replacement isdetailed in Replace-ment of motors, axes4-6, IRB 2400/10/16 onpage 188.)


Nitrile rubber 34.2x33HAB3772-18O-ring327

6.4x12x1.69ADA312-6Plain washer1228

M6x20 12.9 Steel 12.9Gle 603+Geo500

3HAB3409-25Hex socket head capscrew

1229

3HAB5544-1Damper axis 4130

M8x20 8.8 Gleitmo 6103HAB3402-36Hex socket head capscrew

432

3HAC0860-1Lubricating oil2425 ml33

G 1/4”3HAC037925-001Magnetic plug234

3HAC029646-001Sealing washer235



8 Spare parts8.4 Spare parts - upper arm, IRB 2400/10/16


3HAB3537-1Grease45 g39

Loctite 57412340011-116Flange sealing30 ml40

3HAC7877-2Sealing ring withoutdust lip

241

32007 X3HAA2103-15Taper roller bearing242

3HAC1564-1Parallel bar143

22206 CC3HAA2167-12Spherical roller bearing244

3HAC10089-2Sealing245

3HAB5511-1Damper axis 3146

3HAC0001-1Bracket147


M8x16 8.821212852-449Hex socket counters,head

149

SS 1914-043HAB5523-1Locking washer150

Loctite 2433HAB7116-1Locking liquid1 ml51


Recommended sparepart. Replacement is de-tailed in sectionReplace-ment of cable harness,axes 4-6 on page 127.

3HAC9328-1Cable unit axes 4-6Standard

153


153

M5x20 8.89ADA618-46Torx pan head screw954

2.5x10121662055-1Cable straps, outdoor955

500 mm, 19x0.1811699198-301Adhesive tape56

M5x123HAC2774-1Cover with lamp unit157

M6x109ADA629-44Torx pan head roll.screw

1058

M6x10 Steel 8.8-A2F9ADA183-22Hex socket head capscrew

1259

(Elmo)3HAC10602-2Motor unit axis 6160(Recommended sparepart. Replacement isdetailed in section Re-placement of motors,axes 4-6, IRB2400/10/16 onpage 188.)





Continued

Spare part view 6

xx1100000941




Continued

Spare part view 7

xx1100000942



Continued

8.5 Spare parts - upper arm, IRB 2400/L

Upper arm, IRB 2400/L, spare part listThe spare parts for the upper arm, IRB 2400 version L, are listed below and shownin the Spare part view 8 on page 248 and Spare part view 9 on page 249.


3HAC0235-1Tubular shaft11

3HAB6354-1Back-up ring12

99x10.5 V-110-L3HAB3732-13Sealing ring13

105x130x13 61821-2RSI2213253-12Ball bearing24

IRB 20002216264-14Cover plug25

3HAC0236-1Housing, axis 416

D=115/105, T=0.052159167-61Spacer27

D=115/105, T=0.12159167-62Spacer48

D=115/105, T=0.52159167-63Spacer19

3HAB3210-1Gear, axis 4, step 2110

3HAB6356-1Damper, axis 4111


6.4x12x1.6 A2F9ADA312-6Plain washer1013

M6x45 8.8, Gleitmo 6103HAB3402-30Hex socket head cap screw414

See section Spare parts -drive unit, IRB 2400/L onpage 250.

Drive unit axis 5-6115



M5x16 8.8, A2F9ADA183-14Hex socket head cap screw417

44.2x3, Nitrile rubber21522011-414O-ring118

3HAB3380-1Gear unit, axis 4123

8.4x16x1.6, A2F9ADA312-7Plain washer224

M8x30 8.8, A2F9ADA183-38Hex socket head cap screw225

3HAB6355-1Cover128

11712016-604Lubricating oil30 ml30

Loctite 2433HAB7116-1Locking liquid31

Loctite 63812690014-413Locking liquid32

Loctite 57412340011-116Flange sealing34

Shell Retinax MS3HAB3537-1Bearing grease35

Standard and Foundry.3HAC10814-1Wrist, 5 kg136Recommended sparepart. Replacement is de-tailed in section Replace-ment of wrist IRB 2400Lon page 139.



8 Spare parts8.5 Spare parts - upper arm, IRB 2400/L


M6x20 8.8, Gleitmo 6103HAB3402-25Hex socket head cap screw637

3HAB4350-1Cover138

Option3HAC2743-1Cover with lamp unit1

M5x12 89ADA629-44Torx pan head roll screw3939

3HAB4405-1Cover140

D=42/55 W=8 Nitrile rub-ber

3HAC7877-2Sealing ring (without dust lip)243

D=35/62 W=18 32007 X3HAA2103-15Taper roller bearing244

2.5x101 Polyamide 6.6black

21662055-1Cable straps, outdoors1045

D=621662018-8Clamp1465562-00-04

D=1121662018-2Clamp1475562-00-07

3HAB3230-1Bracket, axes 5-6148

M5x25 8 A2F9ADA629-47Torx pan head roll screw249

3HAC1563-1Parallel bar150

3HAB5511-1Damper, axis 3151

M6x10 8.8 A2F9ADA183-22Hex socket head cap screw252

D=30/62 W=20 22206 CCStandard

3HAA2167-12Spherical roller bearing253



9x35x33HAA2356-11Locking washer156


3HAB5927-1Cable bracket upper arm158

Recommended sparepart. Replacement is de-tailed in Replacement ofcable harness, axes 4-6on page 127.

3HAC9330-1Cable unit axes 4-6159

Wire feeder3HAC13052-1

3HAC4429-1Gasket360

21662055-3Cable straps, outdoors161




Continued

Spare part view 8

xx1100000943




Continued

Spare part view 9

xx1100000944



Continued

8.6 Spare parts - drive unit, IRB 2400/L

Drive unit, IRB 2400/L, spare part listThe spare parts for the drive unit, IRB 2400 /L, are listed below and shown in theSpare part view 10 on page 251.


Recommended spare part.Replacement is detailed insection Replacement ofdrive shaft unit, IRB 2400Lon page 198.

3HAC11804-1Drive shaft unit, axes 5-611

(Elmo)3HAC11865-1Motor unit axes 5-622(Recommended spare part.Replacement is detailed insection Replacement of mo-tors, axes 4-6, IRB 2400L onpage 181.)


3HAA2504-1Motor plate13

M5 8.A2F9ADA267-5Hexagon nut84


5.3x10x1. A2F9ADA312-5Plain washer106

Recommended spare part.Replacement is detailed inReplacement of drive shaftunit, IRB 2400L onpage 198.

3HAA2393-1Gear belt27



8 Spare parts8.6 Spare parts - drive unit, IRB 2400/L

Spare part view 10

xx1100000945


8 Spare parts8.6 Spare parts - drive unit, IRB 2400/L

Continued

8.7 Spare parts - customer cable, axis 4

Customer cable, axis 4, spare part listThe spare part of the customer cable, axis 4, is listed below and shown in thefollowing figure.

NoteSpare part no.DescriptionQty

Option 0433HAC8869-1Customer cable extension, axis 41

xx0300000409


8 Spare parts8.7 Spare parts - customer cable, axis 4

8.8 Spare parts - limit switch

Limit switch, spare part listThe spare parts for the limit switch are listed below.


Switches3

Holder ring21

M8x123HAC0596-31Hexagon screw, button head62

3HAB8086-1Cam, blank73

M6x129ADA618-55Torx pan head screw244

3HAC0982-1Attachment plate15

M6x169ADA618-56Torx pan head screw26

3HAC6447-1Position switch 107

3HAC6448-1Position switch 1-31

M4x169ADA183-5Hex socket head cap screw68

3HAB7478-1Shims-sheet99

M5x89ADA629-42Torx pan head roll. screw410

D=821662018-9Clamp611

4.8x20821662055-3Cable straps, outdoors112

Incl. in the delivery.3HAB8372-1Assembly instruction113

M6x30.9ADA618-59Torx pan head screw214


8 Spare parts8.8 Spare parts - limit switch

8.9 Spare parts - customer connection kits

Customer connection kits, spare part list

NoteSpare part no.Description

Standard protection.3HAC12558-1R1.CP/CS, Standard

Foundry protection.3HAC12558-2R1.CP/CS, Foundry

3HAC12557-1R1.LS1

3HAC12326-1R2.CP/R3.CP

3HAC12327-1R2.CS/R3.CS


8 Spare parts8.9 Spare parts - customer connection kits

9 Circuit diagram9.1 About circuit diagrams

OverviewThe circuit diagrams are not included in this manual, but delivered as separatedocuments on the documentation DVD. See the article numbers in the tables below.

Controllers

Article numbers for circuit diagramsProduct

3HAC024480-005Circuit diagram - IRC5 (drive system 09)

3HAC031403-003Circuit diagram - IRC 5 Compact

3HAC026871-006Circuit diagram - IRC5 Panel Mounted Con-troller

3HAC024120-004Circuit diagram - Euromap

Robots


3HAC031408-003Circuit diagram - IRB 120

3HAC6816-3Circuit diagram - IRB 140 type C







3HAC021351-003Circuit diagram - IRB 1600 type A




3HAC9821-1Circuit diagram - IRB 4400/4450S


3HAC8935-1Circuit diagram - IRB 6400RF

3HAC13347-1Circuit diagram - IRB 6600 type A3HAC025744-001

3HAC13347-1Circuit diagram - IRB 6600 type B3HAC025744-001


3HAC025090-001Circuit diagram - IRB 6620 / IRB 6620LX






3HAC13347-1Circuit diagram - IRB 6650S3HAC025744-001

3HAC025744-001Circuit diagram - IRB 66603HAC029940-001

3HAC13347-1Circuit diagram - IRB 76003HAC025744-001



Continued

IndexAAbsolute Accuracy, calibration, 203aluminum

disposal, 213attachment screws

securing robot, 67

Bbatteries

disposal, 213handling, 51

battery packreplacing, interval, 91

brake release unit, replacing, 160brakes

releasing manually, 65testing function, 32

Ccabling, robot, 87cabling axes 1-3, replacing, 121cabling axes 4-6, replacing, 127cabling between robot and controller, 87calibrating

roughly, 206calibration

Absolute Accuracy type, 202alternative method, 203Levelmeter calibration, 203rough, 206standard type, 202when to calibrate, 201

calibration, Absolute Accuracy, 203calibration manuals, 203calibration marks, 204calibration position, 206

checking, 210jogging to, 211jogging to, TPU, 210scales, 204

calibration scales, 204CalibWare, 202carbon dioxide extinguisher, 30cast iron

disposal, 213cleaning

robot, 101connecting the robot and controller, cabling, 87connection

external safety devices, 19connectors

on robot, figure, 86copper

disposal, 213customer connections, 86

Ddanger levels, 38direction of axes, 205drilling pattern, mechanical stop axis 1, 80drive shaft unit, replacing, 198

Eemergency stop

definition, 36devices, 37

enabling device, 34environmental information, 213ESD

damage elimination, 49sensitive equipment, 49wrist strap connection point, 49

Ffence dimensions, 29figures

connectors on robot, 86fire extinguishing, 30FlexPendant

jogging to calibration position, 211MoveAbsJ instruction, 210updating revolution counters, 208

foundationattachment screws, 67orienting and securing robot, 67requirements, 58

Ggearbox axes 1-3, replacing, 195Gravity Beta, 74grease

disposal, 213guide sleeves

securing robot, 69

Hhazardous material, 213hold-to-run, 34hole configuration

robot base, 68

Iillustrations

connectors on robot, 86installation

mechanical stop axis 1, 77mechanical stop axis 2, 83position switch axis 3, 85

intervalmaintenance, 91

inverted mounting, 74

Llabels

manipulator, 40Levelmeter calibration, 203lifting

upper arm, 144lifting accessory, 222Lithium

disposal, 213location of connectors, 86lower arm

replacing, 146securing, 148

Mmain power

switching off, 47


Index

main switchcontroller cabinet, 47control module, 48drive module, 48

maintenance intervals, 91maintenance schedule, 91manipulator

symbols, 40manually releasing the brakes, 65mechanical stop

axis 1, 77axis 2, 83

motion of axes, 60motor axis 1, replacing, 166motor axis 2, replacing, 171motor axis 3, replacing, 176motor axis 4-6 IRB 2400/10/16, replacing, 188motor axis 4-6 IRB 2400L, replacing, 181motor connectors, 86MoveAbsJ instruction, 210

TPU, 210

Nnegative directions, axes, 205neodymium

disposal, 213NiCad

disposal, 213nodular iron

disposal, 213

Ooil

disposal, 213oil change

gearbox axes 5-6 (wrist), 93safety risks, 52

orienting and securing robot, 67

Pparallel arm, replacing, 162parallel bar, replacing, 150plastic

disposal, 213position switch

axis 3, 85positive directions, axes, 205protection classes, 59protection standards, 216

RR1.MP connector, supplying power to, 66releasing brakes, 65replacing

brake release unit, 160cable unit axes 1-3, 121cabling axes 4-6, 127drive shaft unit, 198gearbox axes 1-3, 195lower arm, 146, 148motor axis 1, 166motor axis 2, 171motor axis 3, 176motor axis 4-6 IRB 2400/10/16, 188motor axis 4-6 IRB 2400L, 181parallel arm, 162parallel bar, 150

SMB battery, 96SMB unit, 154tie rod, 150upper arm, 142wrist, 135, 139

requirements on foundation, 58responsibility and validity, 19restricting

working range axis 1, 77working range axis 2, 83working range axis 3, 85

revolution countersstoring on FlexPendant, 208storing on TPU, 207updating, 206

risk of tipping, 63robot

cleaning, 101connectors, 86orienting and securing, 67protection class, 59symbols, 40

rubberdisposal, 213

Ssafety

brake testing, 32emergency stop, 36ESD, 49fence dimensions, 29fire extinguishing, 30FlexPendant, 34introduction, 17manipulator system, 19moving manipulators, 45reduced speed function, 33release manipulator arm, 31service, 19signals, 38signals in manual, 38symbols, 38symbols on manipulator, 40test run, 46working range, 35wrist strap, 49

safety equipmentmechanical stop axis 1, 77mechanical stop axis 2, 83position switch axis 3, 85

safety riskelectric parts, 27hot parts, 23hydraulic system, 25installation, 20oil change, 52operational disturbance, 26pneumatic system, 25service work, 20tools, 24voltage, 27work pieces, 24

safety signalsin manual, 38

safety standards, 216scales on robot, 204schedule for maintenance, 91


Index

signal connectors, 86signals

safety, 38SMB battery, replacing, 96SMB unit, replacing, 154special tools, 224stability, 63standards

ANSI, 216CAN, 216EN, 216EN IEC, 216EN ISO, 216protection, 216safety, 216

steeldisposal, 213

suspended mounting, 74symbols

safety, 38sync marks, 204system parameter

Gravity Beta, 74

Ttesting

brakes, 32tie rod, replacing, 150tightening torque

gearbox axes 1-3, 196lower arm, 149motor, axis 1, 169motor, axis 2, 174motor, axis 3, 179motor, axis 4, IRB 2400/10/16, 184, 192

motor, axis 4, IRB 2400L, 185motor, axis 5, IRB 2400/10/16, 185motor, axis 6, IRB 2400/10/16, 187, 194parallel arm, 165upper arm, 144wrist unit IRB 2400/10/16, 138wrist unit IRB 2400L, 141

toolscalibration equipment, Levelmeter, 224Calibration Pendulum equipment, 224for service, 224

TPUjogging to calibration position, 210MoveAbsJ instruction, 210updating revolution counters, 207

Uupdating revolution counters, 206upper arm, replacing, 142

Vvalidity and responsibility, 19

Wweight

gearbox unit, 196lower arm, 147robot, 149, 222upper arm, 152

working range, 60restricting axis 1, 77restricting axis 2, 83restricting axis 3, 85

wrist, replacing, 135, 139


Index

Contact us

ABB ABDiscrete Automation and MotionRoboticsS-721 68 VÄSTERÅS, SwedenTelephone +46 (0) 21 344 400

ABB AS, RoboticsDiscrete Automation and MotionBox 265N-4349 BRYNE, NorwayTelephone: +47 51489000

ABB Engineering (Shanghai) Ltd.5 Lane 369, ChuangYe RoadKangQiao Town, PuDong DistrictSHANGHAI 201319, ChinaTelephone: +86 21 6105 6666

ABB Inc.Discrete Automation and MotionRobotics1250 Brown RoadAuburn Hills, MI 48326USATelephone: +1 248 391 9000

www.abb.com/robotics

3HAC

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